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TOTAL FLOW ASSURANCE MANAGEMENT FOR SUBSEA DEVELOPMENTS
– A CASE FOR REAL-TIME SOLUTION
Professor Babs Oyeneyin; C.Eng
School of Engineering
Robert Gordon University
Aberdeen
PRESENTATION OUTLINE
• Introduction
• Challenges of Deep Water Development - QUESTIONS
• OGI CHALLENGES
• Flow Assurance Challenges
• Need for Real-Time /Proactive Solutions
• Examples of RGU PE TEAM R&D Building Blocks – CO2 Sequestration for Heavy Oil Recovery
• CASE FOR COMBINATION OF CASED BASED REASONING + MACHINE LEARNING + MODELING
SUBSEA TIE-BACK
• Deep - Tier I – 500m – 1500m
• Very Deep Water Depths - Tier II – 1500- 3000meters
• Ultra Deepwater - Tier III – >3000meters
EXAMPLES OF DEEPWATER ENVIRON
KEY CHARACTERISTICS
• High Pressure : 20Kpsi – 30Kpsi[200MPa-300MPa]
• Low Pressure & High Temperature
• HP & LT/LP-HT/HP-HT
• Unconsolidated Reservoir:
– Sand Production
• Multiphase Fluid Production
– Gas, Condensate, Oil, Water [Formation Water vs Condensed Water], Solids[Sand, debris, hydrates, scale, etc]
• Long Subsea Tie Back
• 3-D Heat Transfer?
– High Temperature : >230oC
– Cold Sea Bed temperature < - 20oC
INTRODUCING RGU
RGU
FACULTIES
DESIGN & TECHNOLOGY
ENGINEERING COMPUTING
& INFORMATICS
SCOTT SUNDERLAND
BUSINESS SCHOOL
HEALTH & SOCIAL CARE
OIL & GAS INSTITUTE
SOE ACADEMIC PROGRAMMES • BSC - ME; MOE
• B.ENG – ME; MOE; EE
• M.ENG - ME; MOE; EE
• MSc – Oil & Gas
– Drilling & Wells
– Subsea Engineering
– Production Operations
– Renewable Energy
RGU SOE RESEARCH AREAS
R & D THEMES
OIL & GAS
PETROLEUM ENGINEERING CONDITION
MONITORING
FLUIDS & HEAT
TRANSFER
ENVIRONMENT & SUSTAINABILITY
SUSTAINABLE SYSTEMS
UNDERSTANDING SUSTAINABILITY RENEWABLE
ENERGY
MATERIAL & MANUFACTURING
ADVANCED MATERIALS
MEMBRANE & PROCESS CONTROL SYSTEMS
OGI CHALLENGES • Economic Downturn
• Demand vs Supply
• Unstable Regions
• High Lifting Cost
• Reactive Approach
• Human Factors – SITUATION AWARENESS
• NEED FOR OPERATIONAL EFFICIENCY = LOW $/BBL
– Proactive Approach to FEED & Management
– Real-Time Diagnosis & Solution
• ACCURATE AND RELIABLE MODELS/DATA
MULTIPHASE PRODUCTION CHARACTERISTICS
• OIL TIEBACKS
– OIL
– GAS
– FORMATION WATER
– CHEMICALS
• GAS TIEBACKS
– GAS
– CONDENSATE
– FORMATION WATER
– CONDENSED WATER
– CHEMICALS
FLOW ASSURANCE ISSUES • Hydrate Management
– MEG; KHI; AA[Anti Agglomerate]
– Flow Management
• Scale Management
– Scale Inhibitor
– Flow Management
• Alsphatenes/Wax
• Microbial
• Sand Management
– Sand Production Rate
– Sand Size Distribution
– Sand Transport
• Slugging
• Subsea Separation
• Produced Water Management [Separation, Treatment]
• UNCONVENTIONAL HEAVY OIL
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EXAMPLES OF FLOW ASSURANCE PROBLEMS
Hydrate Block Sand Production
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Typical Field Development Subsea Layout
AN EXAMPLE OF SUBSEA DEVELOPMENT
SUBSEA DEVELOPMENT CHALLENGES – TECHNOLOGY ENABLERS
• Front End Design Optimisation for Production control & Management
– Transient Multiphase Flow Phenomena
• Start-up & Blowdown effects VS WELL MANAGEMENT
• Precise Multiphase flow modelling – Coupled reaction kinetics?
- Produced water utilisation
• Multiphase Flow Metering?
– Salinity - SA
– Phase Fractions
– Phase Differentiation- Condensed Water vs Formation Water
• Precise Production Monitoring
• Cold Flow?
– Intelligent Condition Monitoring & Surveillance
– Precise Pressure & temperature Profiling
• Sand Production/Monitoring/Transport
• Produced Water Management
– Subsea Processing = In-line separation?[OSPAR Regulation QA/QC Standard]
ACTION POINTS
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HYDRATE PHASE BOUNDARY (MEG+KHI)
©MBO
INTEGRATED MODELLING TOOLS
RESERVOIR WELL INFLOW COMPLETION
SUBSEA PRODUCTION
SYSTEM
SUBSEA COMPRESSION
STATION
SUBSEA FLOW LINES
‘’TOPSIDE’’ SYSTEM UPSTREAM INLET SEPARATION
INLET
SEPARATION
TOPSIDE PRE-COMPRESSION
STATION
INTEGRATED/AUTOMATIC MODELLING DIFFICULT • Data Acquisition/Transmission in Deepwater • Data Quality • Model Quality
• Steady State/Transient Phenomena • E.g Temperature profile vs Gas expansion[Joules-Thomson Effect] • 3-D Heat Transfer
• Complex Environment
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SUBSEA HEALTH CARE
• Condition Monitoring
• Proactive Prediction/Diagnosis in Real-Time
– Integrated Modelling
• Complex Phenomena
• Loads of Uncertainties
• Quality Data
• ACCURACY /REPEATABILITY
– Case Based Reasoning + MODELLING + MACHINE LEARNING?
• Real-Time Process Optimisation
REAL-TIME PREDICTION AND AUTOMATED LOOKAHEAD SYSTEM
VIRTUAL SENSING
MODELLING
MACHINE LEARNING
CBR
PATTERN RECOGNITION
SENSOR
DATA
KEY REQUIREMENTS
• PRECISE AND ACCURATE DATA
• ACCURATE MODEL
• PRECISE MONITORING
• REAL-TIME PREDICTION
• LOOK AHEAD CAPABILITY
RESEARCH BUILDING BLOCK
HYBRID SOLUTION – R & D BUILDING BLOCKS • END-TO-END SOLUTION
• FLOW ASSURANCE SOLIDS DIFFERENTIATION AND QUANTIFICATION
• TRANSIENT MODELLING & VISUALISATION
– INTELLIGENT/VIRTUAL MONITORING
• NICHE HARDWARE SUPPORT & PROCESS SUPPORT
– NMR FOR SOLIDS MONITORING – NEW PROJECT
– COLD FLOW TECHNOLOGY
– SALINITYSCAN
• MULTIPHASE METERING
• ELECTROSTATIC COALESCENCE – MAIR’S TAIL
• CASE BASED REASONING FOR PROACTIVE PREDICTION
PETROLEUM ENGINEERING RESEARCH GROUP
PE RESEARCH
MULTIPHASE FLOW
ASSURANCE
DEEPWATER TECHNOLOGIES
INTEGRATED SAND MANAGEMENT
IMPROVED HEAVY
OIL RECOVERY
WELL ENGINEERING
UNCONVENTIONAL
RESERVOIR MNGMT
TRANSIENT MPF
MODELING
CBR +
MACHINE LEARNING
NMR SYSTEM
SALINITY SCAN
MARE’S TAIL
SAGD COLD FLOW
CO2 FOR
CHOR
HEAVY OIL
• What is Heavy Oil?
– High Density- above 0.92 specific gravity
– High Molecular weight
– High Viscosity- above 100 cP @ Reservoir
• Where and how much? Category °API
gravity
Down hole viscosity
(cP)
Light heavy oil 20-25 25-100
Heavy oil 10-20 100-10,000
Extra heavy oil <10 100-10,000
Tar
sands/Bitumen
<20 > 10,000
RECOVERY METHODS
• To fill the increasing gap between supply and demand
• Low mobility- Enhanced recovery techniques
• Cold
– Oil Mining, ESP, CHOPS (Solvent, CO2, water etc)
– Low Recovery
• Thermal
– Huff and Puff, In-situ combustion, SAGD
– SAGD is popular for high recovery- Steam reduces viscosity
– High recovery but require more investment
– Process risk assessment and planning is required
COLD FLOW?
• Useful & Effective Option
• To be backed up by Intelligent Condition Monitoring & Surveillance
• Total Insulation or Heating uneconomical
• Solids Transport with HECTOR Sub at strategic Points along Tie-Back
• Intelligent Pigs[Gel Pigs vs Mechanical Pigs]
• Hector Sub Positioning Critical
CRITICAL INDUSTRY CHALLENGES - OUR BUSINESS DRIVER
PRODUCTION/ INTEGRITY/ABANDONMENT
DRILLING/G&G
Losses
Inflow
Extended Reach Wel Problems Completion Material erosion - Sand
SAND MANAGEMENT
DEEPWATER DEVELOPMENT
Well Blowout 26
HYBRID SOLUTION • END-TO-END SOLUTION
– FOCUSSED RESEARCH THEMES
• SOLIDS DIFFERENTIATION & QUANTIFICATION – NMR SYSTEM FOR VOID FRACTIONS & DIFFERENTIATION
• TRANSIENT MODELLING & VISUALISATION
– INTELLIGENT/VIRTUAL MONITORING
• HEAVY OIL STUDIES
• NICHE HARDWARE SUPPORT & PROCESS SUPPORT
– HECTOR UNIT
– HYDRAFLOW/HYDRACHEK
– COLD FLOW TECHNOLOGY
– SALINITYSCAN
• MULTIPHASE METERING
• CASE BASED REASONING FOR PROACTIVE PREDICTION
STEP-CHANGE NODAL ANALYSIS FOR FLOW ASSURANCE
SCALE WINDOW
HYDRATE WINDOW
STRATEGIC SOLUTION PLAN • Establish Thorough Diagnosis Technique
• Improve Related Monitoring
• Drive to minimise impact of sand production & Flow Problems
• Condition Monitoring with Case Based Reasoning/SITUATION AWARENESS
– Unloading strategy
– Sand Sampling/Analysis
– Oil/Water Analysis
– Reservoir/Produced Water Management
– Topside Solids Management
• Competency Training
MULTIPHASE FLUID –NUCLEATED SOLID FLOW PATTERN COUPLING
CO2 SEQUESTRATION FOR IMPROVED HEAVY OIL RECOVERY
• CO2 needs to be at super critical pressure and temperature for it to be utilised for IHOR
• Improved recovery can effected by a combination of miscibility -immiscibility mechanism. - The CO2 at appropriate high pressure and temperature can be miscible with the heavy oil, and, once dissolved, it has two effects.
– First, it causes the oil to swell, thereby lowering the oil’s viscosity significantly and making it flow more easily in response to pressure gradients.
– Under the miscible conditions it reduces the interfacial (capillary) forces that cause the heavy oil to stick to the reservoir rock.
NEW RESEARCH
• Process of the interaction between CO2 and the rock matrix is not yet fully understood .
• There is evidence that, from formation chemistry aspect, there can be foaming phenomena that can dramatically affect the integrity of the rock matrix and its flow and petrophysical properties
• New follow-up research
• INDUSTRY COLLABORATION REQUIRED
REDUCING COST , INCREASING EFFICIENCY AND PRODUCTIVITY WITH
INTEGRATED MULTIPHASE MANAGEMENT SYSTEM +
PROACTIVE CONDITION MONITORING WITH
- CASE-BASED REASONING TECHNOLOGY APPLICATION TO REAL-TIME PROCESS DIAGNOSIS AND OPTIMISATION
SUBSEA HEALTH CARE
• Condition Monitoring
• Proactive Prediction/Diagnosis in Real-Time
– Integrated Modelling
• Complex Phenomena
• Loads of Uncertainties
• Quality Data
• ACCURACY /REPEATABILITY
– Case Based Reasoning + MODELLING + MACHINE LEARNING?
• Real-Time Process Optimisation
REAL-TIME PREDICTION AND AUTOMATED LOOKAHEAD SYSTEM
VIRTUAL SENSING
MODELLING
MACHINE LEARNING
CBR
PATTERN RECOGNITION
SENSOR
DATA
CASE BASED SITUATION AWARENESS COGNITIVE FRAMEWORK
CBSA MODEL
• SEVEN COMPONENTS
– User context,
– State of the environment,
– Case-base (situation library),
– Perception,
– Comprehension,
– Projection,
– Preserve experience.
CASE BASED SITUATION AWARENESS MODEL
HYBRID SOLUTION
VIRTUAL SENSING
REAL-TIME
SIMULATION
MODELLING
UPSCALING
CBR/PATTERN RECOGNITION
DATA ACQUISITION
MACHINE LEANING AUTOMATED
DATA MANAGEMENT VALIDATION
REAL-TIME PREDICTION AND AUTOMATED LOOKAHEAD SYSTEM
VIRTUAL SENSING
MODELLING
MACHINE LEARNING
CBR
PATTERN RECOGNITION
SENSOR
DATA
©MBO
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THANK YOU VERY MUCH FOR LISTENING
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