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Topside Sand Handling Solutions

Tim Podger, Merpro

Second European Sand Management Forum


Aberdeen, March 2006

Topside sand handling solutions


Optimising separator performance Enhancing downstream PWT systems Protecting the integrity of produced water re-injection systems - through effective topside sand handling Provide information from four case studies

Topside sand handling solutions

Merpro has developed a range of products for sand handling Products incorporate Tore for sand/solids removal They can be provided

as individual products for specific applications or provided in combination to provide a complete topside sand handling solution

Tore - what it is

A solids fluidiser and hydrotransportation device high efficiency no moving parts no wear It is not a pump or jetting system

Tore - how it works


3 - Internal vessel pressure forces slurry into discharge pipe

1 - Tangential feed to swirl chamber

2 - Vortex generated fluidises solids

Tore - what it does

Moves slurries of up to 40% solids by volume 1" Tore transports up to 4 tonnes of sand per hour 2" Tore transports up to 16 tonnes of sand per hour Enables the removal of sand from vessels and the transportation of slurries through pipelines No moving parts = low maintenance

Tore sand handling applications

Sand removal from separators Sand cleaning Sand transportation De-sanding Filtration

Sand removal from separators

ToreManifold
Removes sand from separators and vessels on-line

ToreManifold what it is

Tores manifolded within base of vessel Fluid introduced to Tores Tore creates a vortex which fluidises sand Slurry exists through discharge pipe

AIOC, Azerbaijan

ToreManifold what it is

AIOC, Azerbaijan

ToreManifold what it is
AIOC, Azerbaijan

BP Alaska, Prudhoe Bay

ToreManifold demonstration

Click on the image to run the video clip

Case study 1 Apache Australia

Removal of sand from separators on-line

ToreManifold
Merpro acknowledges with thanks the permission of Apache to present this case study

Case study 1 the problem


Produced sand inside production separator before installation of ToreManifold

Apaches Stag Platform, Australia

Case study 1 - results

Removes sand from separator on-line whenever required. Apache activates them for half and hour every morning and evening remove up to 10 tonnes sand per week Eliminated unplanned shut downs to dig out sand previous practice was 4 day shut downs to dig out every 3 months In one year, eliminated 16 days of unplanned shut downs

Apache Stag, Australia

Case study 1 - results

Eliminated associated shut down/dig out costs and HSE issues Maintains vessel integrity Enables separator to operate continuously at design efficiency, maintaining well fluid throughput at maximum levels Maximises revenue generation
Apache Stag, Australia

Case study 2 Petronas Carigali

Removal of sand from separators on-line

ToreManifold
Merpro acknowledges with thanks the permission of Petronas Carigali to present this case study

Case study 2 the problem


Petronas Carigali Dulang B platform, Malaysia. Shut downs every 6 months to dig out sand Existing sand jetting system not working effectively due to Jet nozzles and piping clogged Drain line and valves eroded and clogged Sand carry over to produced water system Sand hardened and would not fluidise to flow through drain nozzles No means to monitor how much sand left or removed
Petronas Carigali Dulang B, Malaysia

Case study 2 the solution

Tore Manifold installed in HP separator Consists of 8 Tores in two banks of four Configured in single line 2 inch inlet header for water; 2 inch outlet header for slurry Modifications to existing facilities minimised Previous jetting system supports used to support Tore Manifold

Petronas Carigali Dulang B, Malaysia

Case study 2 the solution


Operating data Inlet pressure Outlet pressure Inlet flow rate Outlet flow rate Inlet fluid Outlet fluid : : : : : : 0.5 bar above vessel pressure Free discharge to atmosphere 16m3/hour circa 16m3/hour Treated water Slurry (sand and water)
Petronas Carigali Dulang B, Malaysia

Case study 2 results

809 litres of sand collected in first month after commissioning Annualised sand removal rate 9.7 kilolitres (15 tonnes) Some loss of fine sand Separator volume for oil and water separation is 92m3 (based on normal 60% liquid level) Accumulated sand would therefore result in loss of residence time of 10.5% More sand was removed by the B manifold closer to the fluids inlet nozzle then the A manifold
Petronas Carigali Dulang B, Malaysia

Case study 2 results


Petronas Carigalis conclusions

Tore Manifold was easy to install, utilising existing vessel nozzles It is simple to operate with minimum controls No problems in utilisation at a practical level It removes a significant volume of sand without causing any operational or process interruptions

Petronas Carigali Dulang B, Malaysia

Case study 2 results


Petronas Carigalis conclusions ctd

Eliminated shut downs to dig out sand Dulang B operations personnel have noticed better control over the produced water discharge due to less sand level interruption with the interface level reading

Petronas Carigali Dulang B, Malaysia

Case study 3 BP Schiehallion


Improving efficiency of produced water re-injection systems through effective topside sand handling the role played by Tore

Case study 3 BP Schiehallion


Merpro acknowledges with thanks the permission of the Schiehallion partners to present this case study:

BP Exploration Operating Company Ltd Shell UK Ltd Amerada Hess Ltd Murphy Petroleum Ltd OMV (UK) Ltd Statoil Exploration (UK) Ltd

Case study 3 the problem

Increasing produced water led to installation of PWRI system as part of reservoir pressure support strategy With increasing produced water came increasing sand Smaller than expected particle size resulted in increasing drop out from suspension later than expected in the process train Resulted in elevated solids loading within the treated produced water system In 2004, 13 tonnes of solids were removed from key process vessels
BP Schiehallion, UK

Case study 3 the problem

Key factors that set solids loading limit for the PWRI system well injectivity erosion limits for pumps, pipework, well bore and completion type Despite pipework integrity and sand removal/disposal methods in original design, increased solids loading within the produced water stream had several adverse effects including filter blockage accelerated pump erosion
BP Schiehallion, UK

Case study 3 the problem

Within 4 months water seals and pump casings began to fail within the water injection and produced water booster pumps. Wedge wire screen filters upstream of the water injection pump blocked Result the PWRI system was suspended one year after commissioning

BP Schiehallion, UK

Case study 3 the solution

Significant modifications made to the PWRI system - Tore important element in this Erosion and mechanical improvements sand erosion probes fitted to each production riser pumps changed out for high solids pumps desanding cyclone replaced wire screens

BP Schiehallion, UK

Case study 3 the solution


Sand removal and entrainment minimisation sand jetting system in the slug catcher and first stage separator - replaced with ToreManifold ToreManifold installed in the degasser to remove the finer grained sand settling out in the vessel to minimise re-entrainment into the produced water system nucleonic profiler for oil/water/sand interface measurement fitted to improve level control in the first stage separator

BP Schiehallion, UK

Case study 3 results

Initial teething problems amount of sand remaining in 1st stage separator higher than expected Merpro working with BP to resolve teething problems Tores remove the integrity risk of sand jetting process Slurry density better controlled Installation in degasser reduced erosion potential donwstream in pumps, filters and cyclones

BP Schiehallion, UK

Case study 3 results

Sand level control now managed Sand removed whenever required by ToreManifold No re-entrainment of sand into produced water system PWRI system to be re-commissioned shortly Same solution being implemented in Train B in 2006

BP Schiehallion, UK

Case study 3 lessons learned

Detailed understanding of sand production issues sand particle size distribution sand quantities sand drop out points within the process Equipment Specification sand removal and sand handling equipment pumps suitable for solids loading Review the correct point in the process to remove sand from produced water
BP Schiehallion, UK

Case study 4 Statoil Gullfaks C

Eliminating sand carry over problems into produced water outlet through effective topside sand handling
Merpro acknowledges with thanks the permission of Statoil to present this case study

Case study 4 the problem

Existing sparging system causing excessive sand in the produced water outlet Production restricted by additional jetting water introduced into the separator

Statoil, Gullfaks C, Norway

Case study 4 the solution

ToreManifold installed in production and produced water separators

Statoil, Gullfaks C, Norway

Case study 4 results


80 kgs of sand removed every 2 days from each separator Fluidising effect of each Tore is localised eliminated jetting system induced problems of solids in the produced water outlet, giving improved operational stability Feed water requirement reduced to 32m3/hour compared to previous 100m3/hour upstream and downstream equipment can be smaller

Statoil, Gullfaks C, Norway

Case study 4 results

Since Tores cause minimal turbulence at the liquid interface, and the feed water and slurry discharge rates are balanced, the separator interface level remains unaltered allows separation of liquids to continue unaffected while solids are removed Enabled Statoil to increase well fluid throughput by up to 30% - increasing oil production and revenues Supports field life extension

Statoil, Gullfaks C, Norway

Case Study 4 results

ToreManifold at annual shut down inspection after one year of operation No erosion in pipework or in vessel Statoil described vessel as clear of sand
Statoil Gullfaks C, Norway

Conclusions
Operator experience with ToreManifold has demonstrated it is an effective means of removing sand from separators

provides significant financial and operating benefits eliminates unplanned shut downs to dig out produced sand removes sand on-line, enabling separators to operate at design capacity on a continuous basis, maximising revenues protects downstream equipment from erosion e.g. PWRI systems

Conclusions

As more sand is expected from future production, the importance of effective topside sand handling increases Case studies have demonstrated Merpros Tore technology offers an effective solution for all levels of sand production It offers a life of field solution

Thank you for your attention Questions?