Active Heating Potential Benefits to Field Development

Transcription

1 Active Heating Potential Benefits to Field Development Journées Annuelles du Pétrole 12/13 Octobre Paris Atelier Champs Matures et Satellites Technip Subsea Innovation Management (T-SIM)

2 Contents 1. INTRODUCTION TO ETH-PIP TECHNOLOGY 1. New PiP Generation and Key Principles 2. ETH-PiP Qualification & Industrialisation Status 3. ETH-PiP as Tool of a Global Active Heating Solution for FDP Strategy 4. Combination of Active Heating and Subsea Separation 2. ACTIVE HEATING APPLICATIONS 1. In-Field Flowlines and Architectures 2. Satellite Fields and Tie-Backs 3. Operations 4. Potential Contribution to Improved Oil Recovery (IOR) 3. ETH-PIP TECHNOLOGY POTENTIAL COST BENEFITS 4. TOTAL ISLAY PROJECT 1. Main Features 2. Construction 5. CONCLUSIONS 2

3 ETH-PIP Technology a New Pipe-in-Pipe Generation Standard PiP Electrically Heated PIP (EH-PiP) 3

4 ETH-PiP Technology Key Principles Heating Principle : Joule Effect in tracing cables laid in PiP annulus (closed & controlled electrical paths) in direct contact with inner flowline hence underneath the thermal insulation => 99 % electrical power used for heating conveyed fluid Main Advantages ETH-PIP = Combination of qualified components Low OHTC = low heating power high efficiency Typical heated tie-back length = 10 to 20 km Heating power adjusted to meet project requirements Built-in temperature monitoring based on fibre optics technologies Reel-lay compatible = min. nb. of in-line connections 4

5 ETH-PIP Technology Qualification & Industrialisation Status Technip Internal Qualification Tests Programme completed from 2000 to 2004 Additional Qualification Tests Performed for TOTAL for two Projects in North Sea from 2008 to 2010 : According to TOTAL TEQP = Technology Evaluation Qualification Process which is a structured & comprehensive method aimed at giving Full & Fair Opportunity to New Technologies for Application to Projects Successfully applied to ETH-PiP prior to selection for Islay (+ Kessog) To be applied to other TOTAL projects in In 2011, 1st EPCI Project in North Sea 6 km long, 6 x12 ETH-PiP line Pre-fabrication at Technip Evanton spool-base (Scotland) Line installation in October 2011 by Apache II 5

6 ETH-PIP Technology Tool of a Global Active Heating Solution for Field Development Planning Strategy Combination of ETH-PiP Technology and EH-Flexible Pipe / Risers 6 ETH-PiP will allow long range tie-backs in cost effective way ETH-Flexible Pipe will allow continuous flexible + riser installation Reliable and proven active heating will potentially allow simplification of lay-out e.g. reduction of loops and more efficient flow assurance throughout project production cycle including additional recovery

7 Combination of Active Heating and Subsea Separation Potential Applications Santos Basin Pre-Sal Fields Challenging flow assurance requirements : Severe Wax High fluid viscosity Preliminary Results are Confirming : Possible Options : Full IPB option : flowlines + risers Combination of EtH-PiP for flowlines + IPB for risers Current IPB technology not necessarily the most cost effective option ETH-PiP would definitely bring cost and efficiency benefits to flowlines Multiphase Flow In addition, a simple liquid/gas separation at each W/H (e.g. Perdido, BC-10) would greatly improve overall flow assurance scheme FPSO 100% Gas Liquid + Residual Gas Gas/Liquid Separator Multiphase Pump 7

8 Active Heating Applications In-Field Flowlines and Architectures (1/3) In-Field Flowlines Design Flexibility for definition of thermal insulation requirements and CAPEX trade-off between U (OHTC) value requirements : at beginning of production : high energy fluid at flowline inlet {p, T, Q} at end of field production : low energy fluid {p, T, Q} + WOR increase hence more severe hydrate issues which, in turn, require much more methanol / MEG injection Permanent heating : CAPEX vs. OPEX possible trade-off More Insulation CAPEX Less Heating OPEX Vs. Less Insulation CAPEX More Heating OPEX Less safety margin on thermal insulation requirements to guarantee a minimum arrival temperature on topsides in order to avoid any risk of appearance of hydrate and/or wax For viscous oils and limited GOR, active heating contributes to reducing pressure drop => potential diameter optimisation 8

9 Active Heating Applications : In-Field Flowlines and Architectures (2/3) Comparison Results p, T, cp Profiles along Distance 30-km Flowline Including Passive Insulation (U= 1 W/m2. K) 30-km EH-PiP Flowline Including Passive Insulation (U= 1 W/m2. K) + 30W/m Active Heating 9

10 Active Heating Applications : In-Field Flowlines and Architectures (3/3) Single Line Based Field Lay-Out vs. Conventional Loops Less total flowlines length (procurement, installation) Less risers Loop with Conv. PiP Single Line ETH- PiP Umbilical Subsea Manifold FPSO ETH In-Line Tee FPSO Umbilical Subsea Manifold 10

11 Active Heating Applications Complex Reservoirs and Satellite Fields Access to Complex / Spread-out Reservoir Structures Access to low temperature / low pressure / heavy oil reservoir structures Access to complex reservoir structures : fractionation vs. communication issues different types of reservoirs : depths, different fluid compositions, pressure & temperature, production profiles Access to hydrocarbon fields which are prone to major hydrate and / or wax management issues Access to Remote Satellite Fields by Long Subsea Tie-Backs No need for additional surface support infrastructure Long subsea tie-backs by single line only i.e. without need for loops 11

12 Active Heating Applications Operations Operations Flexibility and Reliability Steady state regime : less needs for continuous chemical injection => savings on chemicals and umbilicals sizing Preservation : no need for dead-oil circulation, no time limitation => no need for re-circulation loop => minimum operations Restart : much easier in particular with high viscosity oil Wax management : no need for frequent pigging 12

13 Active Heating Applications Potential Contribution to Improved Oil Recovery (IOR) Main Flow Assurance Issues at End of Field Life : Low flowrates Reservoir pressure reduction Fluid temperature variation at wellhead outlet Water cut increase GOR variation All above factors contribute to increase flow assurance risks, hence to shorten production period of wellhead to remain within envelope of operating conditions manageable by conventional flowlines & riser system including passive insulation Active Heating Can Then Help Compensate for : Low temperature profile along the flowline and therefore mitigate hydrates and wax associated risks for all operating modes (steady state, transient, preservation) Fluid viscosity increase and, in turn, increase of counter-pressure downstream wellhead 13

14 ETH-PiP Technology Potential Cost Benefits In-House Case Study Flowline : 10 ID / U = 1 W/m2. C / 30 W/m for ETH-PiP Option Water depth : 1,300 m Distance of wellheads cluster + manifold to FPSO : 10 km Wellhead flowing pressure : 150 bar (WH outlet, Plateau) / 30 bar (topsides) Temperature range : 50 C (WH outlet) / 25 C (min. arrival at topsides) Three options : Conventional loop : 2 x [10 x16 ] Optimised loop : 2 x [8 x14 ] Single ETH-PiP : 1 x [10 x16 ] Preliminary Results CAPEX (EPC basis) : ETH-PiP solution is significantly lower than that of any loop option i.e. about 25 % saving OPEX (NPV basis) : power requirements and associated costs for ETH-PiP used in continuous heating mode are negligible 14

15 TOTAL Islay Project Main Features Field Lay-Out Flowline Data x ETH-PiP line 6.2 km length Aerogel insulation (Cabot) 3 heat tracing cables (Heat Trace Ltd.) Fibre optics system in annular space for temperature monitoring 15

16 TOTAL Islay Project Construction Flowline Components and Construction Methods CAM + HPF Arrangement Cabot Pack Cables Centraliser CAM Slotted Centraliser Chambers Welding On End Termination Bulkhead Apache II Ready for Spooling at Evanton End Termination Assembly 16

17 Conclusions ETH-PIP can already bring Significant Benefits to Today s Projects : Flow assurance : Long subsea tie-backs i.e. distance > 10 km Viscous / waxy fluids low temperature and/or low pressure reservoirs Field lay-out : single lines can replace conventional loops However, new specific robust preservation strategies need to be qualified Over the full project life cycle : Operations : new approach for hydrates and wax management FA issues at field end life and impact on wellhead production time (IOR) More generally, Active Heating can bring New Options for the Architecture of Future Subsea Field Development Projects : Extended fields Remote fields Including combination with Subsea Processing 17