Will subsea production make topside obsolete

“Will subsea production make topside obsolete”
Floating Production 2010
Ove Jahnsen
Manager – Early Phase and Market
[email protected]
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Content
• Subsea market development
• Subsea Processing
• New enabling subsea technology breaking boundaries
• Subsea Today's and Future solutions
• Major Projects
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FMC Offshore Capabilities
Light Well
Intervention
Metering & Control
Systems
Surface Well
Systems
Subsea Drilling
Systems
Standard Subsea
Trees
Subsea Processing
Subsea Manifold
Smart Well
Control Systems
Subsea Template
Systems
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Guidelineless
Deepwater Trees
ROV Tie-In Systems
Subsea Development last 10 years
• Number of wells per year since 2000 (x-mas trees)
1,200
# of Subsea Trees
1,000
800
600
400
200
0
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009e
2010e
2011e
2012e
2013e
Award Year
Tree Orders (High)
Tree Orders (Mean)
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Tree Orders (Base)
©2009 Quest Offshore Resources, Inc.
Supply growth from offshore
Global production of oil, condensate and gas - Thousand boe/d
120000
100000
Onshore wells
80000
60000
Subsea wells
40000
Topside wells offshore
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
2024
2026
2028
2030
20000
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Will subsea wells be preferred –
Yes, driven by deeper waters..
02.01.1980
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100
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02.01.1990
03.01.2000
03.01.2010
Zakum
Gullfaks
Troll
Gas
Troll
Oil
Åsga
rd
Shah
Deniz
Zafiro
Girassol
Dry Trees
Partly subsea wells
Only subsea wells
Most deepwater fields
with subsea wells
Ormen
Dalia
Roncador
(however compliant towers,
TLPs, spars have dry trees to
530, 1500 and 1700m
respectively)
Marlim
Sul
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Moving into Deeper Waters
Strong subsea track record
World record water depths
achieved by FMC Technologies
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Subsea vs Topside
• Most floating production system would required a subsea production
system.
• Most of subsea production systems have a host, majority of these
are floating production units.
• “Subsea to the beach” is a fairly new term, but not widely applied
today. The few examples are Snøhvit and Ormen Lange in the
Norwegian North Sea, both gas fields.
– Snøhvit approx 150 km tie back
– Ormen Lange approx 120 km tie back
• The trend is that an increased number of marginal satellite fields are
tied into already existing topside, i.e. utilize topside to its optimum
capacity to avoid to build new and expensive platforms.
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Ormen Lange – Subsea to the beach
• Supplied by FMC
• Tie back distance 120 km
• Water Depth 900 -1100 m
• Start production 2007
• Gas filed with condensate
• Depleting pressure - Gas compression
required
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Subsea Scope Expansion
Expanding subsea solutions strategy
Core Products
New Products
•
•
•
•
•
•
•
• Subsea Processing
− Separation
− Boosting
− Gas Compression
Light Well Intervention
Trees
Manifolds
Control Systems
Template Systems
Flowline Connection Systems
Umbilicals & Flowlines
Workover systems
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Subsea Processing
Enhancing brownfield oil recovery and enabling
greenfield development
•
Brownfield challenges:
−
−
−
•
Greenfield challenges:
−
−
−
•
Declining oil & gas production
Increasing water production
Constrained topside facilities
Heavy oil
Low reservoir pressure
Hydrate formation
Subsea processing solutions:
−
−
−
−
−
−
−
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3 phase separation
Gas & Liquid Separation
Sand Removal
Water removal and reinjection
Gas removal and reinjection
Single and Multiphase Boosting
Gas compression
Raw Seawater Injection
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SUBSEA PROCESSING
“Subsea Processing – Todays and future solutions”
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Subsea Processing Evolution
Subsea to Market
Subsea Compression
Compact Separation
Raw Seawater Injection
Gravity Separation
Boosting
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Why Subsea Processing
• Increased recovery
• Accelerate production
• Reduced Capital Expenditure
• Makes it possible to:
–
connect satellite fields to existing infrastructure
–
exploit fields that are normally inaccessible
–
exploit costly infrastructure fully throughout the systems
operational period
–
depressurize system as a hydrate strategy
• Influence on the environment will
decrease
• Reduces water disposal to sea
• Enhances flow management
What influence selection of separation
technology?
• Drivers for subsea processing station
–
System considerations, not only component considerations
–
Flexibility over the life of field, need to cover changes in conditions and uncertainties
• Fluid properties
–
Density, viscosity, mixed viscosity, inversion point etc at operational conditions, asphaltenes,
”schmoo”, creation of foam, emulsions etc.
• Production profile
–
Water cut (WC), gas volume fraction (GVF) as function of time
–
Pressure, temperature profile as function of time
• Sand production
–
During ”normal” conditions and ”worst case” conditions (e.g. screen failure)
• Field layout
–
Field layout of wells/drilling centers/existing infrastructure
–
Sizes of pipelines
–
Location of processing station compared to wells
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Future Solutions
• Moving from bulk gravity separation ……
Tordis oil/water separator
Pazflor gas/liquid separator
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……to slimmer and more compact
solutions……
Caisson separator cluster in deep water
PipeSeparator
Caisson separator in GoM
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……to inline, ultra-compact solutions
• Proven topside technology
• Ongoing qualification for subsea use
CDS Inline deliquilizer
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Subsea pumping
•Multi Phase pump - Helicoaxial or Twin Screw
•Single phase pump - Centrifugal
•Hybrid pump - Helicoaxial + Centrifugal
•Seabed ESP – Horizontal or Vertical
•Applications:
•Single Phase Oil/water
•Single Phase Water Injection
•Single phase Raw Seawater injection
•Multiphase Oil/Water/gas
Sulzer/FMC
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Subsea compression
- What are the drivers
• IOR
–
Accelerated production
–
Reservoir depletion – Maintain production
–
Utilize existing infrastructure and extend the
field life time
• Flow assurance
–
Maintain gas velocity to avoid liquid
accumulation in multiphase flow.
• Subsea to beach
–
Compensating pressure drop in transport
system
–
Avoid surface installations
–
Environmental issues as harsh conditions
• CAPEX / OPEX considerations
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FMC’s Subsea Processing Major Projects
Activity in every major deepwater basin
Tordis
• Brownfield
• Gas/Oil/Water/Sand Separation
• Boosting/Water Injection
• Installed 2007
Cascade
• Greenfield
• Boosting
• To be Installed 2010
Pazflor
• Greenfield
• Gas/Liquid Separation
• Boosting
• First oil 2011
Perdido
• Greenfield
• Gas/Liquid Separation
• Boosting
• Installed 1Q 2010
Marlim
• Brownfield
• Gas/Oil/Water/Sand Separation
• Water Injection
• First oil 2011
Greenfield
BC-10
• Greenfield
• Gas/Liquid Separation
• Boosting
• Installed 3Q 2009
Brownfield
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Statoil Tordis
LANDMARK: FIRST SEMI-COMPACT
SEPARATOR WITH SAND MANAGMENT
Project Overview
Contract Award:
Water Depth:
Step Out:
Design Pressure:
2005
220 meter
12 km
3,000 psi
Project Scope of Supply
Subsea Separation, Injection & Boosting Station
Process Capacity:
220 000 bbl/day
MultiPhase Pump:
Helico-Axial to 68% GVF
1.8 MW 450 psid
Water Injection Pump : Single Phase
2.3 MW 1100 psid
Sand Removal System
Tordis Project
Challenges:
• Increasing water production
• Declining pressure in wells
• Limited topside water handling capacity
• Sand production
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StatoilHydro – Tordis Project
Enhancing Brownfield Oil Recovery
• First full-scale subsea separation
system
• Gas/Oil/Water/Sand Separation
• Increase recovery from 49% to 55%
• Potential to recover additional 35
million barrels of oil
Project Partners:
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Project Status
• Tordis Subsea Separation has been running more that 2000 hours
with success.
• Problem during start up solved and normal operation achieved.
• Experience so far is very positive.
• Experienced problems with disposal reservoir shut down in 3Q 2008
• Phased restart of system in 3Q 2009
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Shell Perdido
LANDMARK: FIRST GoM FULL FIELD
SEPARATION & BOOSTING SYSTEM
Project Overview
Contract Award:
Water Depth:
Step Out:
Design Pressure:
2007
2.800 meter
0 mi
4,500 psi
Project Scope of Supply
5 Gas-Liquid Separator DVA Caissons Systems
Process Capacity :
25,000 bopd and
1600 MSm3/d
Gas Tolerant ESP:
ESP to 15% GVF
25,000 bopd pump systems
Centrifugal gas inlet and large slug handling capacity
Shell design subsea
boosting system
Total Pazflor
LANDMARK: FIRST WEST AFRICAN
GAS-LIQUID GRAVITY SEPARATION SYSTEM
Project Overview
Contract Award:
Water Depth:
Step Out:
Design Pressure:
2007
900 meter
14 Km
2,750 psi
Project Scope of Supply
3 Gas-Liquid Separation Systems
Process Capacity :
110,000 bopd and
1.0 MMSm3/d
Gas Tolerant Pump:
Hybrid to 18% GVF
2 x 55,000 bopd pump systems
Hybrid pump system with subsea barrier fluid control
Pazflor Project
3 Gas-Liquid Separator Stations in 800m water depth, 2-4 km step-out
»
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Client:
Total
Location: Angola,W.Africa
Delivery: 2011
»
Challenges:
•
•
•
•
•
•
Deliveries: 3 Gas-Liquid Separator Stations
6 hybrid pump modules (+ 2 spares)
Combined Power and service umbilicals
Vertical separator with CDS inlet and internals
3 G/L separation station as part of
Green Field development
Low
energy reservoir
Highlights
Deep water ~ 800m
High
viscosity
and
stable emulsion
» First
Seabed
Gas-Liquid
Gravity
Separation system
» Enabling Technology for oil production
Large
pressure
drop in flowlines
» Enabling
Technology
for hydrate
andstrategy
risers using simplified field
architecture
High
water production from year 4
» Size: 21 x 21 x 19 meters
Large amounts of methanol needed
for hydrate prevention
FREE FLOW NOT POSSIBLE
Power Control Module
Separator tank
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Separation Unit
The Solution: Subsea Processing
•
Gas / Liquid Separation and Liquid
Boosting:
–
Gas flows freely to the FPSO
•
•
–
Liquid out of separator with relative low GVF
•
–
Hydrate preventions of flowlines by means of
depressurization is possible
Reduced cost due to elimination of circular
flow line
Efficient pumps with high ∆P can be used
Ô
Increased recovery
Boosting of liquid
•
Stabilized flow regime in risers
Ô
Reduced slugging
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Petrobras Marlim
LANDMARK: FIRST BRAZILIAN FULL FIELD
SEPARATION & INJECTION SYSTEM
Project Overview
Contract Award:
Water Depth:
Step Out:
Design Pressure:
2009
900 meter
5 Km
5,000 psi
Project Scope of Supply
Subsea separation station with water processing
Process Capacity :
Pipe Separator
22,000 bpd, 67% water-cut
Water Injection Pump: 20,000 bwpd/system
1.9 MW Motor, DP 3000 psi
Compact Separators for de-oiling and de-sanding
Petrobras – Marlim project
Enhancing brownfield oil recovery
• First deepwater subsea oil/water separation system
• Mature field (brownfield) with heavy oil and
increasing water production
• Gas/oil/water/sand separation at 3,000 ft. depth
• Water reinjected into reservoir to boost production
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Challenges:
Project Operator:
• Increasing water production
• Limited topside water handling
capacity
• Sand production
Brazil
Why FMC?
Uniquely Positioned to Deliver Results
•
Extensive Global Processing Experience and Project Track Record
Providing subsea processing solutions since 1992
•
Experienced Organization
Dedicated Team of Discipline Engineers for SSP
•
Technology Building Blocks
FMC owns separation, meters, subsea motor, fiber optic controls technology etc.
•
Technology Development and Qualification
Qualified numerous subsea processing systems / sub-systems
•
Front End Engineering Capabilities
Feasibility, concept selection, FEED, project execution, installation and operation, flow
assurance
•
Life of Field Services
Condition and Performance Monitoring; installation, operation and maintenance support
Future?
Subsea Production and Subsea Processing
will not make topside obsolete.
Thank You!
www.fmctechnologies.com
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