The Wellhead Desander: Separating Solids First

Transcription

The Wellhead Desander:
Separating Solids First
Hank Rawlins, PhD, P.E.
eProcess Technologies
September 24, 2014 - Stavanger, Norway
AUS | MAL | USA | UAE | UK
SPE and STTS
SPE Separations Technology Technical Section
• Purpose
–
–
–
–
Share knowledge, experiences, and best practices
Identify major issues and technology areas
Promote awareness of separation-related issues and technologies
Enhance members technical competencies
• Webinars
– Three completed in 2014 and three in 2015
• SPE ATCE Amsterdam
– “Unlocking Hidden Production Potential in Mature Fields”,
special session, October 27, 2-5 PM
eProcess Technologies | Advancing Separation Solutions
AUS | MAL | USA | USA | UK
www.eprocess-tech.com
Company
eProcess Technologies
• Innovative Process Separation Equipment Specialists
– Facilities Sand Management
– Produced Water Treating
– Compact Separation Systems
• Cyclonic Based Technologies
Falmouth
Houston
Dubai
Kuala Lumpur
Melbourne
Facilities Sand Management
Approach
•  Not simply a waste stream treatment exercise
•  It is a critical flow assurance issue
•  Increase / maximizing hydrocarbons production
•  While reducing / minimizing operating costs
Sand Management Options
All oil & gas wells produce sand
Exclusion Methodology
1. Production Limits
2. Downhole Equipment
Inclusion Methodology
3. Surface Facilities: Maintenance
4. Surface Facilities: Facilities Sand Management
Facilities Sand Management
1
Wellhead
Desanding
2
Wellstream
Desanding
Cyclonic
Solids Jetting
3
4
Produced
Water
Desanding
Solids Transport
& Handling
Multiphase Flow Desanding
1
Cyclonic
Solids Jetting
Solids Cleaning
& Disposal
2
Design Comparison
Insert Style (Single Cone)
Liner Style (Multi-Cone)
•
•
•
•
•
•
•
•
Multiphase applications
One insert per vessel
Smaller/lighter vessel
Change insert diameter
for high turndown (>3:1)
• No fluid partitioning
• Particles to 1”-2”
• Concentration to 5 wt.%
Liquid applications
Many liners per vessel
Larger vessel
Change quantity of liners
for high turndown (>3:1)
• Unequal fluid partitioning
• Particles to 0.1”-0.2”
• Concentration to 0.25 wt.%
Classification Performance
Graded Efficiency Curve
100
•
•
Y(x), Particle Recover (% to U/F)
90
80
Normalized Size vs. Recovery to U/F
Fits Yoshioka-Hotta curve (1955)
D98=Separation Size
70
𝑒 𝛼𝑥 − 1
𝑌(𝑥) = 𝛼𝑥
× 100
𝑒 + 𝑒𝛼 − 2
60
•
50
40
 = slope = separation sharpness
•
•
D50=Cut Size
30
=4 for silica particles
Plitt approximation;
𝐷2 𝐿 − 𝑙
𝑚 = 2.96𝑒
𝑄
𝛼 = 1.54𝑚 − 0.47
0.15
−1.58𝑅𝑓
20
10
0
0.0
0.5
1.0
1.5
2.0
2.5
•
•
Where Rf is flow split, L is internal length,
l is vortex finder length, Q is flow rate
D/D50c
WHD Development History
Jan.1994
• Concept initiated as internal development project
Mar-Apr 1994
• Laboratory testing using air-water-sand with 10” mining cyclone
Late 1994
• JIP initiated for pilot-plant testing and mechanical design
Mid-1995
•
•
•
•
Late-1995
• Detailed mechanical design for industrial unit
• 5K ASME design with single insert
1996
• First commercial unit
• Unit still in service
JIP pilot-plant test at (BP) Wytch Farm onshore gathering stations
ANSI 300# unit, 10” diameter desander
Sand injected into clean stream
Also tested with five sand monitoring devices
First Commercial
Wellhead Desander
Deployed in 1996
• Shell/Expro – Brent D
• ASME 5K WHD Skid
• Coiled-tubing well cleanout
Process Flow
• Gas: 6.4-19.2 MMSCFD
• Liquid: 16,000 BPD
Performance
• <75 psid pressure drop
• D98 = 20 micron
Sand w/ coal “chunks”
General Design and Operation
Pressure Retaining Vessel
• ASME: 150# to 2500#
• API-6A: 5/10/15 K rating
• API at full shut-in pressure, no PSV
• Small hold-up volume
Clean Well
Fluids
Wellhead
Solidsladen
Well Fluids
Wellhead
Desander
Cyclonic Insert
• Performs separation duty
• Contains erosion
• Duplex SS/WC or SiC
• 4”-10” replaceable inserts
• Interchangeable size and materials
Installation/Operation
• Upstream/downstream of choke
• Service tool or production
• 5-75 psi ΔP
• Operate 0-100% GVF
• 10-25 micron separation
• On-line batch sand discharge
Solids
Accumulator
Solids Discharge
Particle Travel
Inlet Transition
2nd Accumulator
•
•
Tangential transition
from pipe flow
Vortex finder prevents
particles short-circuit
•
•
•
Particles descend
by gravity
Sand displaces
water in vessel
No oil ingress
Cone-Cylinder-Apex
•
•
•
Heavy particles spin down inner wall
Light particles swept to overflow
Apex is concentration point
Multiphase Model
• Flow regime determines model
• Hydraulic model for liquid dominant
• Pneumatic model for gas dominant
• Model convergence/overlap
• Use mixing rules for fluid properties
• Calculate multiphase pressure drop
• Ensure critical velocity regions stay within limits
• Calculate separation size and collection efficiency
Rule-of-thumb: Wellhead desander will remove solids that settle
within a production separator
•
Particles collecting at oil-water interface or passing into oil phase
not captured
Hydraulic Capacity,
Turndown & Performance
Separation Size (D98)
Maximum ΔP to balance
wear life.
(No shear maximum)
Avg. residence time is
1.3-4.2 seconds
Minimum ΔP to maintain
vortex.
Pneumatic Capacity,
Turndown & Performance
Maximum ΔP to balance
wear life.
Separation Size (D98)
Avg. residence time is
0.3-2.1 seconds
Minimum ΔP to maintain
vortex.
Multiphase ΔP & Capacity
Pressure Drop
•
•
•
Dependent on liquid and actual gas
volume flow
Power(liquid)-Polynomial(GVF) fit for ΔP
relationship
For fixed ΔP, increasing GVF decreases
liquid flow
10” Wellhead Desander
Constant Liquid (Water) Flow w/ Increasing GVF
Minimum ΔP: 3-5 psid
•
•
Increasing GVF decreases minimum ΔP
Velocity minimum to achieve proper
vortex flow
Maximum ΔP: 25-75 psid
•
•
Increasing GVF decreases maximum ΔP
Velocity maximum to minimize insert
wear
Operating Boundaries
Process: Fluids & Pressure
Pressure Drop
•
•
•
Minimum 3-5 psi based on GVF
Maximum set at 25-75 psi for wear life
Will impose back pressure on artificial lift wells
Flow Conditions
•
Operation from 0-100% GVF
•
Turndown:
– Per insert 3:1 liquid only, 5:1 multiphase
– Per vessel 20:1 by changing inserts
Slugging
•
Must stay within pressure drop range
Fluid Viscosity
•
Difficult to process heavy oil with high liquid
viscosity (>1000 cP), low watercut and low GVF
Operating Boundaries
Process: Solids Particles
Particle Size
•
Maximum 1/3 smallest opening on insert (inlet or apex)
– WHD10: 21 mm
Particle Concentration
•
Static operation based on apex flux limits
– Example: 150 micron sand in water
– WH10: 10000 ppmw (1.0%)
•
Implementation of Apex Flux Balancing increases
limit by order of magnitude
•
Accumulator volume and rate of solation/discharge
will be limiting factory at high solids concentration
Application & Operations
Installation Location
•
•
•
Pre choke (API)
Post choke (ASME)
Subsea – in development
Applications
•
Well testing, well cleanout, underbalanced drilling,
produced solids, proppant flow back
Utilities
•
Flush/fill accumulator (clean water any source at 50 psi)
Consumables
•
Insert replacement and o-rings
Process Connections
•
Five standard: inlet, clean fluid outlet, solids discharge,
accumulator-vent and accumulator-flush/fill
Mechanical Requirements
Footprint
•
Generally 1 m² bare equipment and 1.5-2.0 m² for skid with
basic valves/piping/instruments
Height
•
3-5 meters pending accumulator size
Orientation
•
Vertical standard, but WHD vessel can be operated horizontal
Weight
•
2,000-4,000 kg bare equipment, 10,000-25,000 kg full skid
Pressure Rating
•
ANSI: 150#-2500#
•
API: 5K, 10K, 15K
Materials of
Construction
•
•
Vessel: 4130 CS standard, Available: F22, UNS31803, UNS32760
Insert: Standard is UNS 31803 w/ HVOF-WC internal, alternate is thick RB-SiC
Operation
•
Instrumentation: Inlet-Overflow DPI, Inlet PI
•
•
Valves: Accumulator isolation, discharge, vent, and fill
Normally operated manual (valves) but can be automated
Wellhead Desander Vessel
Duty: 10,000 psi MAWP / 100 MMSCFD + 7,500 BLPD
Insert / API Calcs
Insert / API FEA
(Gen. 1)
(Gen. 2)
1918 mm
2189 mm
2599 mm
Multicone / ASME
Dry (kg)
11000
4173
1571
Oper. (kg)
11800
4525
1771
Vessel Custom Design
10,000 psi MAWP
100 MMSCFD + 7,500 BLPD
Insert: 10”
Liners: 3”
(Gen. 1)
Insert / API FEA
1918 mm
(Gen. 2)
5,000 psi MAWP
50 MMSCFD + 3,500 BLPD
Insert: 6”
Insert / API Calcs
(Gen. 1)
Insert / API FEA
(Gen. 2)
662 mm
Insert / API Calcs
2189 mm
2599 mm
Multicone / ASME
Duty:
1293 mm
Duty:
Dry (kg)
11000
4173
1571
1251
315
Oper. (kg)
11800
4525
1771
1371
411
Malaysia Petronas Carigali
Operator
• Petronas Carigali
Location
• PMO Kerteh, Terengganu
• Duyong Offshore Gas Complex
• Fixed Platform – 80 m water
Technology
• API 5K Wellhead Desander Units
• 90 liter accumulator
• Manual operation
Installation
• 2012
Operation
• 6 MMSCFD, trace liquids
• WHFP 450 psig at 40°C
• ΔP = 50 psi, 99% removal
Malaysia Murphy Oil
Operator
• Murphy Sarawak Oil Co. Ltd.
Location
• Kikeh Spar DTU – 1300 m water
Technology
• 10-1500# Wellhead Desanders
• Integrated into wellbay
• Solids transport, dewatering,
bagging and cleaning system
• Interim fix for failed completions
Operation
• 3300-6700 BPD
•
•
•
•
•
1.5-12 MMSCFD,
WHFP 1200 psig at 40°C
ΔP = 30-50 psi, D98=16-25 micron
>1000 BOPD increase per well
1-2 tons/day sand treated
Custom Installation
Murphy Kikeh Spur
1500# 10” Wellhead Desander Inlet off flexible jumper before choke
Malaysia Murphy Oil
Malaysia Murphy Oil
Saudi Arabia Halliburton
Operator
• Halliburton Testing and Subsea
Location
• Saudi Arabia
• Onshore – multiple locations
Technology
• API 15K Wellhead Desander Skids
• 180 liter accumulator
• PSL 3, P+X, DD-NL, 4130-75K
• 2.4 m W x 2.4 m L x 6.8 m H
Operation
• 15,000 BLPD, 200 MMSCFD
• D98 = 20 microns
Solids Handling Summary
WELLHEAD
DESANDER
1. SEPARATE
SC OR MC
DESANDER
2. COLLECT
SAND JET
ACCUMULATE
CONCENTRATE
YES
CLEAN
DISPOSAL
METHOD
Overboard
To Caisson
Liquids to
Drain/Process
SAND WASH
Solids
NO
Injection to
Disposal Well
Collection
4. DEWATER
FILTER BIN
YES
DEWATER
Solids
YES
HAZARDOUS
CONTAINED
TRANSPORT
NO
DEWATER
NO
NO
CLOSED
COLLECTION
5. TRANSPORT
TANK
BOTTOMS
Dump / Purge
3. CLEAN
Liquids to
Closed Drain
or Process
VESSEL
SLOPS
YES
Liquids to
Drain
FILTER BAG
Solids
OPEN
COLLECTION
Land (Truck)
Offshore (Ship)
Pipeline
OPEN
TRANSPORT
Land (Truck)
Offshore (Ship)
Subsea Wellhead Desander
Process:
• Gas-condensate well
• 120 MMSCFD, 2000 BPD
• 25 psid, 12 micron D98
Vessels:
• FEA with DNV Certification
• API 6A/17D
• 5K, PSL 3, P+X, F22
System:
•
•
•
•
•
Four tie-in points (TP)
8” inlet/outlet, 2” flush, 4” sand
Bypass piping
Automated operation
Sand discharge or container
WHD Key Items
•
All oil & gas wells produce sand
•
Facilities sand management is part of flow assurance
•
Separation of sand at the wellhead can restore
or increase hydrocarbon production
•
Sand removed at wellhead is easy to transport and handle
•
Wellhead desander operates at 0-100% GVF
•
Single insert design most appropriate for multiphase flow
•
Mechanical design available to API 15K
Tech Paper References
1. Rawlins, C.H., “The Subsea Sand Management Challenge: What to do with the sand?”, 6th European Sand Management Forum,
Aberdeen, UK, March 26-27, 2014.
2. Loong, Y., Rawlins, C.H., and Goo, D., “Upgrade of Spar Topsides with Comprehensive Facilities Sand Management System”,
paper 24705-MS, Offshore Technology Conference Asia, Kuala Lumpur, Malaysia, March 25-28, 2014.
3. Rawlins, C.H., “Study on the Interaction of a Flooded Core Hydrocyclone (Desander) and Accumulation Chamber for Separation of Solids
from Produced Water”, presented at the 2014 Produced Water Society annual seminar, January 14-16, Houston, TX.
4. Rawlins, C.H., “Sand Management Methodologies for Sustained Facilities Operations”, Oil & Gas Facilities,
Vol. 2, No. 5, October 2013, pp. 27-34.
5. Rawlins, C.H., “Design of a Cyclonic Solids Jetting Device and Slurry Transport System for Production Systems,” paper 166118-MS,
SPE Annual Technical Conference and Exhibition, New Orleans, LA, Sep 30-Oct 2, 2013.
6. Rawlins, C.H., “Sand Management Methodologies for Sustained Facilities Operations,” paper 164645-MS,
North Africa Technical Conference & Exhibition, Cairo, Egypt, Apr. 15-17, 2013.
7. Rawlins, C.H., and Hewett, T.J., “A Comparison of Methodologies for Handling Produced Sand and Solids to Achieve
Sustainable Hydrocarbon Production,” SPE European Formation Damage Conference, paper 107690, May 2007.
8. Rawlins, C.H. “Application of Multiphase Desander Technology to Oil and Gas Production,” BHR Group 3rd North American
Conference on Multiphase Technology, Banff, Alberta, Canada, Jun. 2002.
9. Rawlins, C.H., and Wang, I. I., “Design and Installation of a Sand Separation and Handling System for a Gulf of Mexico Oil Production
Facility,” SPE Production and Facilities, paper 72999, Vol. 16, No. 3, 2001, pp. 134-140.
10. Rawlins, C.H., Hazlip, S.E., and Wang, I.I., “Design and Installation of a Sand Separation and Handling System for a Gulf of Mexico Oil
Production Facility,” SPE Annual Technical Conference, paper 63041, Dallas, TX, Oct. 2000.
Contact
Presented by Hank Rawlins, PhD, P.E
Technical Director | USA
Telephone +1 713 586 8850
Mobile +1 406 565 2095
[email protected]

The Wellhead Desander: Separating Solids First

Transcription

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