Missing the Potential Value of Subsea Processing Technology Produced Water Club Intro Talk Ian Ball, Technical Advisor INTECSEA UK Aberdeen, 10 th December 2014
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Outline What does new Subsea Processing include? SAPT building blocks Is it really new? Current Technology and Application Status INTECSEA 2014 Worldwide Survey Poster Why apply SAPT? What is the prize? When can specific project value be recognised? Where are the gaps & risks? Why is it still so under-utilised? Ian Ball Produced Water Club, Aberdeen, 10/12/14
What is SAPT? Subsea Active Production Technology Applications Subsea separation and conditioning Subsea pumping and gas compression Subsea water disposal and injection Allied supporting technologies Subsea big power transmission (or generation) and distribution Electrical flowline heating Integrated Control & Monitoring systems Subsea chemical injection Subsea hydraulic power units All electric systems Ian Ball Produced Water Club, Aberdeen, 10/12/14
Subsea Processing rewards Production can be accelerated and/or plateau prolonged Total hydrocarbon recovery can be increased Essential enabler for certain deepwater fields Marginal fields can become more economically viable Flow assurance risks can be mitigated Achievable tie-back distance can be increased potentially all the way to the beach Can potentially eliminate some in-field structures Subsea Processing offers a Compelling Value Proposition Ian Ball Produced Water Club, Aberdeen, 10/12/14
Why Such a Long Gestation? Discovered early that electricity doesn t like seawater Norway & Brazil established national subsea programmes One atmosphere chambers to house seabed equipment Allowed hands-on repair by specialists rather than divers Inductive electrical couplers replaced pin connectors Allowed surface insulation potting to keep seawater out Downside was high electrical losses requiring high power input Oil-filled wet-make electrical connectors Enabled return to efficient and reliable pin connectors This was the single most important technical breakthrough Gave confidence for planning deepwater frontier development Decades of Subsea Separation prototypes Ian Ball Produced Water Club, Aberdeen, 10/12/14
Subsea Separation New Technology?? These were all built before the Millennium: ZAKUM (1969-1972) operational pilot Exxon SPS (1969-1974) operational pilot BOET (1986-1989) operational pilot VASPS (2000) operational pilot Kvaerner Booster Station (Mid 80 s prototype tested) GASP (1986-1990 prototype tested) AESOP (1999-2000) prototype tested SUBSIS (2000 - operational pilot) Ian Ball Produced Water Club, Aberdeen, 10/12/14
Where are we now?
Where are we now?
The System: Pumping Multiphase Pumping proven reliable Incremental production justifies the investment. Recent installations of note: Petrobras Cascade/Chinook Chevron Jack & St. Malo ExxonMobil Julia 27 installations to date, 10 more planned API 17X Committee formed in 2013 Pump hydraulics Electrical systems Mechanical/structural Reliability and intervention Qualification and testing Image Courtesy INTECSEA/Offshore Magazine 2014 Worldwide Survey of Subsea Processing
The System: Separation, Injection Separation and pumping installations: Shell Perdido Total Pazflor Petrobras Marlim SSAO Pilot Ten to date, 3 more in manufacturing
The System: Separation, Injection Raw seawater treatment for injection Pressure maintenance above bubble point Waterflood capex reduction Three systems installed to date: CNR Columba E, (2007) Statoil Tyrihans (2013) Petrobras Albacora E. (2013) New system developed in JIP: Manufactured by Seabox AS Full scale pilot in 2009-2010 Integrated Subsea Raw Seawater Injection System Image Courtesy Seabox AS
The System: Compression, Disposal Full three+ phase separation Produced water injection Produced water discharge to sea Gas compression viewed as future need Longer term electric power studies underway Åsgard, Gulfaks, Ormen Lange - Early targets to watch Image Courtesy Man Diesel & Turbo
System Engineering is Key Early-Phase System Analysis Life-of-field IPM (eg MAXIMUS ) Through-life subsea power Production availability analysis (eg MAROS) Value Optimization Phasing of field developments Minimizing well counts Optimal hardware provisions Making sure it works Hardware and system reliability and integrity qualification (API 17N) Risk management of new vendor offerings - Qualification programmes Ian Ball Produced Water Club, Aberdeen, 10/12/14
What is round the corner? Emerging Subsea Active Production Technologies Liquids & Multiphase boosting proven Gas/liquid & Oil/water separation pilots performing well Produced & Seawater Injection pilots showing way forward Dry & Wet Gas Compression extensive land tests looking good Direct Electrically Heated flowlines proven Subsea water treatment that s what we are all here for! Subsea storage in development Electrical Power generation & distribution key constraint AUV intervention to reduce servicing costs and time New frontier regions especially Arctic/Ice areas Ian Ball Produced Water Club, Aberdeen, 10/12/14
What will the limiting factors be A few are less controllable, eg: Reservoir surprises particularly in new plays Environmental concerns that need to be addressed Mostly controllable factors that we don t control well: Resources throughout the supply & implementation chain Reliability issues arising as a result Learning to fast-track only where that makes real sense Ineffective industry experience exchange Too little holistic system thinking working in silos Integrated production modelling tool shortcomings Ian Ball Produced Water Club, Aberdeen, 10/12/14
Conclusions The Development Agenda is changing: Subsea technology has long been essential enabler for deepwater Energy adding technologies now emerging as game changers Inflated Oil price created a major investment driver (still?) Huge potential for recovery enhancement & prodn acceleration Often essential for deepwater feasibility But are we all aboard the change train? Often inadequate collaboration across silos Reluctance to tackle root causes of risk perceptions Reluctance to share operational experience Resource constraints will chip away at reliability Ian Ball Produced Water Club, Aberdeen, 10/12/14
Conclusions (2) So, can we act smarter to capture SAPT opportunities? Collaboration across discipline silos Experience sharing between Operators, System Designers and Vendors Collaboration & visibility on technology qualification Transparency by Vendors on performance data & costs Better use of integrated production modelling tools Use of objective independent specialist resources Management challenge has tended to be Why SAPT? Should soon change into Why Not SAPT? Ian Ball Produced Water Club, Aberdeen, 10/12/14
How will Operators build on success? To learn more, please visit INTECSEA on the web and download the 2014 Subsea Processing Poster www.intecsea.com http://www.intecsea.com/publications/posters