Subsea compression. The big boost for subsea gas fields Knut Nyborg - VP Power & Process/Presented by Morten R Pedersen.

Transcription

1 part of Aker Subsea compression The big boost for subsea gas fields Knut Nyborg - VP Power & Process/Presented by Morten R Pedersen 2008 Aker Solutions

2 Topics Rationale of subsea processing and subsea compression The journey to industrialize subsea gas compression From Kvaerner Booster Statoil to Ormen Pilot Åsgard the first subsea gas compression system Compact wetgas compression system for smaller gas fields Åsgard SCS the movie to edit this text Slide 2

3 Summary Aker Solutions and its clients have industrialised subsea compression for long step-out, deep water (3000 ft) and large volumes (25 60 MW) The Ormen Pilot is the single largest development and qualification programme in the subsea industry and is now nearing its completion The Åsgard SCS will be the worlds first subsea compression system when it is installed in 2014 The business case for subsea compression looks promising for most large subsea gas fields Aker Solutions is now focusing on the development of a more compact and smaller subsea compression system for medium and small gas fields to edit this text Slide 3

4 Topics Rationale of subsea processing and subsea compression The journey to industrialize subsea gas compression From Kvaerner Booster Statoil to Ormen Pilot Åsgard the first subsea gas compression system Compact wetgas compression system for smaller gas fields Åsgard SCS the movie to edit this text Slide 4

5 Rate [bpd] Extend field life/ Increased oil recovery (IOR) Gap in recovery from subsea fields Gap 30-40% Reduce/overcome back pressure Single/multiphase boosting Subsea separation Gas compression Cost effective pressure support Seawater injection Platform fields Subsea fields Enhanced Production, Early Boosting Boosted Production Normal, Unboosted production Reduced OPEX Time [years] to edit this text Slide 5

6 Gas production and sale (e6 Sm3/day) Benefits of subsea StatoilHydro Ormen Lange Subsea Compression StatoilHydro Åsgard Subsea Compression GIIP=528e9 Sm3 w compression: +97e9Sm3 = 391e9 Sm3 Cost effective development solution (CAPEX and OPEX) Increased production Enhanced reservoir recovery Safer operation due to unmanned operation Avoid water accumulation in flowline by boosting flow wo compression: 294e9 Sm3 Calender year after startup (1 = Jan , 2 = Jan etc) Longer plateau and increased recovery at Ormen Lange (Courtesy of StatoilHydro) to edit this text Slide 7

7 Increased production and enhanced reservoir recovery Flowline (size and Step-out) Riser (size and Waterdepth) Well (size and depth) to edit this text Slide 9

8 Phase 1: Natural production (depletion) Riser (size and Waterdepth) Flowline (size and Step-out) Well (size and depth) to edit this text Slide 10

9 Phase 2, Alt 1: Topside compression m c Riser (size and Waterdepth) Flowline (size and Step-out) Well (size and depth) to edit this text Slide 11

10 Phase 2, Alt 2: Riserbase compression Flowline (size and Step-out) m c Riser (size and Waterdepth) Well (size and depth) to edit this text Slide 12

11 Phase 2, Alt 3: Subsea compression close to the wells Get close to wellhead by using subsea compressors! m c Flowline (size and Step-out) Riser (size and Waterdepth) Well (size and depth) to edit this text Slide 13

12 Topics Rationale of subsea processing and subsea compression The journey to industrialize subsea gas compression From Kvaerner Booster Statoil to Ormen Pilot Åsgard the first subsea gas compression system Compact wetgas compression system for smaller gas fields Åsgard SCS the movie to edit this text Slide 14

13 We started in the 80 s! 1987 Idea to Subsea compressor/pump station 1985 KBS 1993 to edit this text Slide 15

14 Subsea Compression roadmap History & possible future Possible Pilot testing Ormen Lange Subsea Compression Station Ormen Lange Subsea Compression Pilot Ormen Lange critical component qualification program Demo 2000 Project KBS Project to edit this text Slide 16

15 Ormen Lange Subsea Compression Pilot project Objective: Mature and qualify a viable subsea compression alternative to the base case platform Subsea Compression Pilot Identical to one of the 4 trains for OL subsea compression station 12,5 MW compressor unit 400 kw pump unit 2 year testing at Nyhamna Option: Subsea Compression Station 4 compression trains Tie-back 120 km Design water depth 900 m 70 MSm 3 /sd of gas production 58 MW total electrical power to edit this text Slide 17

16 Fabrication, assembly and testing at Aker Egersund Fabrication Integration work Module assembly to edit this text Slide 18

17 Integration of HV power equipment (Compressor VSD) to edit this text Slide 19

18 Completing system integration test (SIT) to edit this text Slide 20

19 Subsea modules and equipment Subsea control system Separator module Compressor module Pump module Cooler module VSD module Circuit breaker module UPS modules Main suppliers: Aker Solutions (Aberdeen, Tranby), Converteam, GE Oil&Gas, Aker Midsund, Poseidon, Ifokus, ConSepT, ABB, Deutsch, Tronic, Ifokus to edit this text Slide 21

20 Topics Rationale of subsea processing and subsea compression The journey to industrialize subsea gas compression From Kvaerner Booster Statoil to Ormen Pilot Åsgard the first subsea gas compression system Compact wetgas compression system for smaller gas fields Åsgard SCS the movie to edit this text Slide 22

21 Åsgard subsea compression system (SCS) Åsgard Subsea Compression System (SCS) comprises: Subsea compressor station (SCSt) Subsea compressor manifold station (SCMS) Subsea transformer station Topside power and control system Subsea compression station w/ 2 identical compression trains, each comprising: Multiphase gas coolers Separator / scrubber Compressor Subsea power and control units Pump to edit this text Slide 23

22 Åsgard Field Layout to edit this text Slide 24

23 Åsgard - Ormen Lange Comparison 25 Shut in pressure 220 bar High power 2 x 10 MW Flow rate 21 MSm3/d 2 compressors 50 km, 250 m water depth Topside frequency converter Shut in pressure 255 bar High power 4 x 12,5 MW Flow rate 60 MSm3/d 4 compressor 120 km, 850 m water depth Subsea frequency converter Smørbukk ~200 km ICELAND Smørbukk South Midgard PL208 Stjødal Trondhei Kristiansund m Molde Ålesund SCOTLAND DENMARK to edit this text Slide 25

24 Minimum Flow Remediation To maintain stable flow in a multiphase production system, the system needs to be operated in a way in that accumulation of liquids is not causing a dynamic problem, i.e. the flow velocity has to be maintained above a minimum. Gas velocity = f(pressure and flow rate) Gas velocity Time for minimum flow Lower limit for stable flow Corrective measures Year to edit this text Slide 26

25 Overall Schedule Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 DG2 DG3 PUD DG4 TQP Testing K-lab upgrade Pilot testing Topside Modification FEED EPC to edit this text Slide 27

26 Åsgard Subsea scope SCMS: Subsea Compression Station Manifold SCtS: Subsea Compression Station RTM: Riserbase Transformer Module to edit this text Slide 28

27 Scope of supply - Compressor system All electric compressor control system Topside Controller Topside Controller Topside PCS /PSD/CM system PCS PSD CM server segregated topside A A B B Topside Subsea PCS / PSD/CM system segregated (communication) SCM PCS /PSD/CM system segregated subsea PCS PSD CM (SEM) SEM SEM SEM A A B B Subsea compressor station spare compressor trains -Coolers (inlet and export) -Scrubber -Compressor -Pump -UPS -UTA w/step-down transformers PCS / PSD CM system segregated subsea (sensors) PT01 A PT01 B PZT01 A PZT01 B PT02 45 km HV power distribution system Topsides Subsea Platform Switchboard Step-down transformer Frequency Converter Sine filter Step-up transformer Earth switch cable splice Power umbilical Subsea Step-down transformer Subsea Compressors and pumps 11 kv 50 Hz Topside VSDs If required Transformer penetrator HV cable termination Transformer penetrator Compressor penetrator C M If required HV cable termination Wet mate connectors & Jumpers 12MW/6.6kV Compressor M P Combined in one umbilical Pump motor penetrator 500kW/2.8kV Liquid pump to edit this text Slide 29

28 2 + 1 spare Compressor trains Inlet & Antisurge Cooler Module (5x9x7m 75t) Separator Module ( 6x7x13m 175t) AS SCM AMB SCM Flexible Compressor Module (6x7x12m 175t) Train SCM Pump module (4x3x7m 30t) Export Cooler Module (5x10x5m 40t) to edit this text Slide 30

29 Significant synergies between Ormen Pilot and Åsgard SCS to edit this text Slide 31

30 2+1 Compressor modules + (1 pilot Compressor unit) Compressor unit ready tested from Compressor vendor including AMB electronic AMBCM assembled and tested from Aker Solutions HV Connection system, valves, actuators, instruments, jumpers etc. from qualified and nominated subvendors Integration, assebly, module FAT at Egersund -> ready for SIT Option: 1 compressor unit directly to testing in K-Lab ( Pilot unit ) Integration and assembly under controlled environment in new Hall to edit this text Slide 32

31 Topics Rationale of subsea processing and subsea compression The journey to industrialize subsea gas compression From Kvaerner Booster Statoil to Ormen Pilot Åsgard the first subsea gas compression system Compact wetgas compression system for smaller gas fields Åsgard SCS the movie to edit this text Slide 33

32 6 MW unit Compact Compression Aker Solutions Subsea GasBooster Minimised number of mechanical and electrical connections Separately retrievable control module and actuators Compact and low weight Footprint: 4 m x 4 m Height: 7 m Weight: 100 tonnes to edit this text Slide 34

33 Topics Rationale of subsea processing and subsea compression The journey to industrialize subsea gas compression From Kvaerner Booster Statoil to Ormen Pilot Åsgard the first subsea gas compression system Compact wetgas compression system for smaller gas fields Åsgard SCS the movie to edit this text Slide 35

34 Copyright Copyright of all published material including photographs, drawings and images in this document remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction. to edit this text Slide 36

35 Disclaimer This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Aker Solutions ASA and Aker Solutions ASA s (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as expects, believes, estimates or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Aker Solutions businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Aker Solutions ASA believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Aker Solutions ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Aker Solutions ASA nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use. Aker Solutions consists of many legally independent entities, constituting their own separate identities. Aker Solutions is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use Aker Solutions, we or us when we refer to Aker Solutions companies in general or where no useful purpose is served by identifying any particular Aker Solutions company. to edit this text Slide 37