R&D - Technology Development November Conference RJ, 3-4 November by Innovation Norway Mika Tienhaara 04.11.2014 RJ
GENERAL ASPECTS 2
R&D CENTERS IN WINTERTHUR (DOWNSTREAM) & ARNHEM (UPSTREAM) 3
SINCE OCTOBER 1 2014 PART OF SULZER VESSEL BASED SEPARATION INLINE SEPARATION Industry leading design guidelines, based on extensive R&D and testing, involving operators and use of leading multiphase flowloop facilties 4
Complete Subsea separation toolbox Established through comprehensive testing (ExxonMobil) LARGE PROJECT - 8 fields generated design conditions input Qualification of all relevant separation equipment and system functionality The most comprehensive qualification programme done to date for processing equipment considered for subsea applications 5
Technology Qualification Multiphase Flowloop with Realistic conditions testing Fluids: Natural gas, Nitrogen Crude Oil Fresh water, salt water LARGEST FLOW RATE CAPACITY IN THE INDUSTRY Flowrates: 1200 Am3/hr natural gas 150 m3/hr Hydrocarbon liquid 22600 BPD 150 m3/hr Water 22600 BPD Design Conditions: Pressure: 90 barg 1305 psig Temperature: 0 120 C 248 F GVF: 0 100% Water cut: 0 100% Differential Pressure: 12 bar 174 psi Instrumentation: Gas and Liquid reference meters Temperature, Pressure and Differential Pressure transmitters Gas Volume Fraction Nucleonic Level Measurement Qualification of Processing Equipment and Systems the industry benchmark (ExxonMobil, Chevron, Total, Statoil, BP, FMC, Aker Solutions ++) 6
Technology Qualification steps For successful field implementation and to minimize risk Computer modeling/system design: (CFD simulations) of flow phenomena, forming the basis for understanding Inhouse of separation mechanism and design correlations Lab scale Real fluid tests: e.g. NTNU Ugelstad, UNIFEI Small scale Model Fluid tests: ProlabNL/CTAP Large scale Model Fluid tests: ProlabNL/CTAP Real scale tests: ProlabNL/CTAP In specific cases, such as with stable O/W emulsion, lab scale testing can be important to determine droplet-to-droplet interaction Measuring and visualizing physical flow phenomena (Hi Speed Video), in order to verify the validity above models In order to verify the validity of above design correlations to larger scale applications High pressure, realistic flowrates, full hydrocarbon tests, in order to verify the validity of design correlations and proper operation under field conditions Used by major IOCs and selected NOCs 7
Industry cooperation model NETHERLANDS Multiphase realistic conditions large scale facility MEXICO Large-scale facilities that can be used for qualification of processing (separation) equipement and system functionality tests for mature fields, subsea applications, multiphase flow meters (large scale) 50.000 BLPD / 80.000 MMSCFD / 65 barg Gas/Liquid Separation Oil/Water Separation Deoiling Solids Separation Gas Treatment Joint development / Qualification / Training 8
SUBSEA SPECIFIC 9
Subsea Solutions Use of known complex solutions OR novel simplified solutions Benefits of Subsea Separation Subsea Separation interesting for field life extension and increased recovery rates, as well as from robustness and CAPEX aspects Typical solutions Multiphase boosting Separation aided boosting Choice of solution impacts Topsides design Flow assurance aspects Seafloor design Topsides Reduction in complexity Less equipment / smaller module sizes Flow Assurance Minimize gas hydrates risk Absorbs transient flow condition Subsea Robust, static equipment High efficiency operations REMARK / All subsea separation projects have undergone a TQP / Tordis, Pazflor, Perdido, Marlim...Field specific! 10
Subsea Boosting Sulzer Boosting Solutions Flow Assurance Feed Multiphase Inlet Gas-Liquid Separation Multiphase Pump Compressor To Host Gas Gas hydrates? Need for hydrate inhibition? Dedicated risers for gas and liquids respectively? Slugs? Pumping capacity/energy? Pump Liquids Field economics? Qualification needs? 11
EXAMPLE - Spherical Vessel Separator Joint Industry Project for Deepwater Applications G/L O/W DEEPWATER JIP A spherical vessel type separator is beneficial from mechanical design and properties compared to a cylindrical vessel. Wall thickness can be significantly reduced. The Spherical Separator is developed as a Joint Industry Project Chevron ExxonMobil GE Oil&Gas Benefits of the sphere Reduced wall thickness Allows for deepwater deployments Tolerates slugs Compact Can be one of the key solutions for Gas/Liquid separation as well as more economic than PipeSeparator for O/W separation Field economics/feasibility Open for further participants from phase 2 Presented at Rio Oil&Gas, DOT, UTC etc PATENT PENDING 12
Subsea Separation Toolbox Qualified Equipment G/L Separation Gas Primary Separation and L/L Separation Slug Catcher, Desander, Coalescer Separator: inline, pipe, conventional, sphere Oil Reject handling/routing Desander Bulk deoiler Hydrocyclones Fines Removal Water Sand Removal & transport Solids 13
Conclusions Large scale realistic conditions testing required to minimize risks and to understand processing equipment behaviour and performance Further R&D required for the increased complexity of O&G fields Importance of cooperation between Oil Company / Integrator / Technology Provider AND Academia Ensure local content by involvement and training of local industry and academia High technology capabilities and enabler of local content initiatives 14
THANK YOU! OBRIGADO! TAKK! tienhaara@ascomsep.com // +31 6 2398 3676 15