Deepwater Development

Deepwater Development
Flow / Thermal Management

and Subsea Production Concept
(an overall presentation)
by
T.M. Irfansyah
(Total E&P Indonesie)
Depok, 14 March 2009, Engineering Center FTUI
Subject
1. Introduction to Deepwater Development
2. Deepwater Flow Assurance (Hydraulic & Thermo Aspect)

Flow management
Thermal Management
Hydrate Management
3. Subsea Production Concept
4. Case Study & Discussion

Flowline Diameter & Thermal Insulation Sizing (Classical Loop)
2 - Depok, 14 March, Engineering Center FTUI
1
1. Introduction to Deepwater Development
Introduction to Deep Water Development
2
eline
press Pip
Neptune
Virgo
Canyon Ex
Marlin
Flowlines 2 x12”, 56 miles each

Ram-Powell
Water
Depth
2200m
King’s
Peak
Pipeline, daisy chain
Umbilical Camden
Hills
Subsea Well Aconcagua
Typical sea bed
Courtesy of TOTAL
3
Sea bed instability
Typical Sea Water Temperature Profile

Hydrographic Profile
water temperature (°C)

0 5 10 15 20 25
0
-200
-400
-600
Water depth (m)
-800
-1000
-1200
-1400
-1600
4
Deepwater - Typical Wellhead and Manifold
Manifold
X-tree
Flowline Jumper
Umbilical
Deepwater - Typical Manifold
5
Typical X-mas tree
Instability and Gas Hydrates
6
Basic Option Deepwater Permanent Production Platform (1)
Up to 450 m
~ 300 to 600 m
~ 1200 m
7
Basic Option Deepwater Permanent Production Platform (2)
~ 200 to 2300 m
~ 900 to 2300 m
~ 450 to 1700 m
SPAR Platform
Gulf of Mexico
Depth + 800 m
215 m long, 37m diameter
8
TLP (Tension Leg Platform)
Gulf Mexico
Depth + 900 m
Typical Mini-TLP and FPSO
9
FPSO (Floating Production Storage & Offloading)
Remotely Operated Vehicles (ROV)
10
Remotely Operated Vehicles (ROV)
ROV
ROV
Deepwater various Risers and Flowlines
11
SCR (Steel Catenary Riser)
Equipment Characteristic g
• Wet Insulation
• High load on facility
• U value > 2.5 W/m2 K
Flexible Riser
Integrated Production Bundle
12
Riser Tower
Riser Tower
2 risers injection 8”
ID
4 Gaslift
Lines
4 risers production 8”
ID
Core pipe
Cathodic
protection
Syntactic
foam
element
Services Lines
2”
Straps
Bundle Insulation (Typical)
13
Production Flowline
Wet insulation Pipe in Pipe insulation
Bundle insulation
14
2. Deepwater Flow Assurance
(Hydraulic and Thermo Aspect)
2.1. Flow management
2.2. Thermal Management
2.3. Hydrate Management
Deepwater is critical in term of Flow Assurance

Very low temperature ( 2-4 oC at sea bed)
High Pressure in production flowline and riser
Often long tie-back
Complex sub-sea architecture/design and installation
Severe environment
Involving remote control and power supply
Retrievable sub-sea pieces of equipment
Fairly new type of development
15
2.1. Flow Management
a. Production Line Design
b. Minimum Flow Rate Criteria
c. Artificial Lift
d. Hydrodynamic flow study

e. Slug Flow Mitigation means
a. Production Line Design

Line diameter determination, is based on many parameter, such us:
Fluid characteristic over field life: viscocity, density, water cut, Gas Oil Ratio,
Condensate Gas Ratio
Available pressure at well head along field life
Minimization of pressure drop at max rate and limitation of detrimental effect of a
possible diameter over-sizing
Flowline length and differential elevation between wells and process facilities.
Flowing velocity limitation (erosion velocity, ρv2 criteria)
Uniform line size is prefered for standarisation purpose.
If possible to avoid non standard pipe diameter, it could cause extra cost
Pipeline thickness, is based on mainly on:

Maximum Allowable Working Pressure
Max well shut-in pressure
Max gas lift injection pressure
Max chemical injection pressure
Collapse
16
General Pressure Profile in Deepwater
b. Minimum Flow Rate Criteria
Minimum expected stable in production line (and associated potential

liquid slud to be handled by receiving facilities)
Minimum flow rate related to steady state arrival temperature (SSAT)
Minimum flow rate related to required cool down time (CDT)

specification
17
c. Artificial Lift
Today gas lift injection at riser base is most generally implemented
Gas lift injection is to lighten the liquid column

Decreases back pressure on the wells
Boosting oil production
Mitigation action on severe slugging (during low flow)
Important during well restart
Subsea multiphase pumps

For wells with very low pressure
As consequence, strong emulsion may be created
d. Hydrodynamic flow study
To predict different flow regimes of production line, depending of the

anticipated operation condition (mainly gas and/or liquid flowrates,
water cut, gas lift injection rates and arrival topside pressure)
To determine safe operating envelope in term of flow stability
18
Historical two-phase flow regime maps
Horizontal (Mandhane-Gregory-Aziz) Vertical (Duns & Ross)
Two-phase flow regimes
19
Generic flow regime maps, MPFM handbook
Horizontal Vertical
Black oil Black oil

( GOR < 260 SM3/Sm3 ) o il 3 ) ( GOR < 260 SM3/Sm3 ) oil m3 )
ile /Sm tilem3/S
la t m 3 l a
Vo 0 S
Vo 0 S
3 3
<5 <5
OR OR
(G (G
Dead Dead
oil oil Gas-Condensate
Gas-Condensate
( GOR > 530 Sm3/Sm3 ) ( GOR > 530 Sm3/Sm3 )
Dry gas Dry gas
Gas-dominated flow : Gas-dominated flow :

Transitions : Strat Î Wavy Î Annular Î Mist Transitions : Bubble Î Slug Î Churn Î Annular
Oil-dominated flow: Oil-dominated flow:

All transitions possible depending on GOR All transitions possible depending on GOR
Riser gas lifting
Riser top choking
Combined between riser gas lifting and riser top chocking
Slug Suppression System
20
Riser-induced severe slugging
Liquid slug
reaches riser
top
Gas reaches
riser top
Flow stabilisation / activation by gas-lift
FPSO
Riser
Gas lift injection

1500m
Tod
a y's
Subsea wells Off Flowline
sets
: 0.
5-
15
km
Subsea wells
A
21
Riser-induced slugging
Slug control system
Principle
The opening of the slug control valve is automatically adjusted to maintain the
pressure at the riser base.
This pressure provides enough energy for the gas to lift the liquid as small slugs
and to prevent the formation of large liquid slugs filling the riser (severe slugs)
Rriser-induced slugging
Otter Slug Suppression System (S3)
Principle Control of
Liquid in line
the total
flowrate
Liquid holdup m3
Gas + Liquid
Slug 150 m3
SSD
no SSD
0 2 4 6 8
Time (hr)
Pressure at riser base

SSD
no SSD
Pressure bar a
8 bar
With S3
Without S3
0 2 4 6 8
Time (hr)
22
2.2. Thermal Management
a. Steady State Arrival Temperature (SSAT)
b. Cool down time after Production Shutdown
c. Operating procedure after shutdown (for Classical Loop)
d. Thermal insulation systems

a. Steady State Arrival Temperature (SSAT)
is the Temperature obtained at upstream of 1st separator
can be set by different factors, among them:

Hydrate temperature
Wax appearance temperature (WAT)
Topsite temperature requirement (to ensure efficient oil/water separation, etc)
23
General Temperature Profile in Deepwater
Fluid related issues (physico-chemistry)
ASPHALTENES
Depth
S E
HYDRAT
CP
7000 m
Pressure
WAX 2
0m
∆T
?
∆P
1
VISC
OSIT
Y
Temperature
FLOW PATH:
1: onshore oil well
Reservoir- bottom hole 2: deep offshore oil
Well tubing/ wellhead
Flowline
24
Hydrate
Hydrate &
& Wax
Wax Prevention
Prevention
Hydrate dissociation curves – Wax Appearance Temperature
350
300 Risk of
250 solid
Pressure, bar
200
deposition Safe
operating
150
domain
100
ProII
FHYD
50
0
0 5 10 15 20 25 30
Temterature, °C
b. Cool down time after production shutdown
Is the time taken for the fluid to cool down to minimum acceptable
temperature (generally the hydrate temperature)
Cool down is driven by heat capacitance of fluid / material
Gas cools down more rapidly than liquid
The insulation requirement will always be driven by gas filled section
The thicker inner pipe wall the longer cool down time
25
c. Operating Procedure After Shutdown
(Classical Loop)
Typical operation (preservation) sequence:

Shutdown Æ at time 0
Investigation (no touch) Æ typically 4 hours
Pressure equalization in network Æ typically 2 hours
MeOH injection in tubing, jumper, manifold well head and SPS Æ
typically 2 hours
Dead oil circulation in loop Æ 8 hours
Duration Elapsed Times (hours)

Operation
(hours) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Shutdown 0
No touch 4
Pressure Equalization 2
MeOH injection (WH, jumper, manifold) 2
Dead Oil Circulation 8
d. Thermal Insulation System
Three main technologies suitable for insulated flowline design:
Wet insulation
Bundle insulation
Pipe in Pipe insulation
26
Flowline
Thermal insulation : Wet Insulation
Flowline
Thermal insulation : Bundle Insulation
27
Flowline
Thermal insulation : Pipe in Pipe Insulation
PCM = Phase Change Material

EHTP = Electrically Heat Traced Flowline
Approach for Insulation Selection
28
2.3. Hydrate Management
HYDRATES …
29
HYDRATES
What are they?
Crystalline compounds that occur when water forms cage-like structures
around smaller “guest” molecules present in free water.
3 conditions have to be fulfilled for Hydrates to form :

the presence of water (“free”, dissolved or emulsified)
the presence of light hydrocarbons (from C1 to C4), or acid gas (CO2, H2S) or Nitrogen
meet the P, T conditions (depending on the nature & composition of gas)
Some heavier HC also form hydrates
Create operating problems because, at elevated pressures, they can exist at

higher temperatures than ice (e.g; 4°C @ 12bar or 20°C @ 100 bar)
Hydrates can be formed with or without presence of free (liquid) water
Also occur naturally underground, at & below seabed
HYDRATES
What are they?
Hydrocarbons (C1,C2,C3,iC4+nC4)
and / or H2S, N2, CO2
+
H20
+
(P, T)
------------------------------------------
=
HYDRATES
I II
30
Safety Hazards of Moving Hydrate Plugs
(Figure 1)
Safety Hazards of High Pressure Trapped by Hydrates

(Figure 2)
31
Avoiding Hydrate: three basic possibilities
P
Hydrates
Operational
Limits Dehydration
Dewpoint water
T
Inhibition
Control P-T domain

Typical oil field hydrate management
Might be performed with the topsite shutdown
No part of production subsea system is allowed to enter hydrate formation

domain
No continuous inhibition by chemical injection (on the contrary, for gas field
continuous chemical injection common / recommended)
Flowline/Riser thermal insulation requirement:

In Steady-state flowing condition: Arrival temperature target (SSAT) > Hydrate temperature & WAT Î insulation
designed on U-value (paraffinic fluid, high WAT)
In Shut-down conditions: Cool down time (CDT, typically 16-20hr)
Classical loop preservation procedure during shut-down:

No-touch time (4 hr)
Pressure equalization
MeOH injection at cold points (WH, jumpers, manifolds…)
Dead oil circulation
Remediation philosophy in case of hydrate plug:

Pipeline and riser depressurization
Chemical (methanol) injection
Coiled tubing operation
Combinations of these options
32
3. SUBSEA PRODUCTION CONCEPT
3. SUBSEA PRODUCTION CONCEPT
3.1. Classical (Conventional) Loop
3.2. Hybrid Loop
3.3. Subsea Separation
33
Classical Loop - General Principles:
is a subsea production system which consists of two production
flow lines working in parallel and linked together at the manifold
by a loop.
Water (and/or) gas injection lines system is installed using y

it
separate flow lines near the production loop.
ing Facil
Float
old
Manif
•Hydrate prevention strategy based on thermal
insulation, Methanol injection and dead oil
p
n Loo
circulation.
uctio
Prod
Wax strategy (thermal insulation + pigging)
ction
r Inje
Wate Injection
s
or Ga
Classical Loop
Courtesy of TOTAL
34
Typical subsea production system (classical loop)
Offloading Buoy
FPSO
Riser Towers
Injection Line
2 wellheads manifold
Production Loop
Production well
Umbilical
Injection Well
Courtesy of TOTAL
Hybrid Loop - General Principles :

A hybrid system consists of interconnected production and water injection line.
it y
ing Facil
Float ine
tion L
anif old oduc
FluidMreplacement after shut-down le Pr
Sing
Circulation with WI pumps
Pigging philosophy: From Subsea Pig
p
launcher n Loo
ro ductio
pressurePequalization between the WI and the
prod. Line
Warm-up before well restart

Hot water circulation with water injection
pumps from WI to Prod
Water injection to be slightly insulated
ction
r Inje
Field Layout Wate Injection
s
Subsea Pig Launcher (depending on pigging or Ga
philosophy)
Single production flowlines and in-line tees
• Hydrate prevention strategy based on thermal
insulation, Methanol injection and water circulation.
35
Typical Hybrid loop - Subsea Design
Hybrid loop – Operating sequence:

Production/Shutdown
Water Injection
Topsides
MeOH
Live Oil
Production
Injection
Wells
Wells
Subsea Pig
Launcher
36
Hybrid loop – Operating sequence:
Flushing/Pigging
Water Injection
Topsides
MeOH
Live Oil
Production
Injection
Wells
Wells
Subsea Pig
Launcher
Subsea gas / liquid separation

General Principles:
Gas/liquid separation at the mud line
Gas export by 1 or 2 dedicated risers
Liquid export by 1 riser thanks to a
boosting system Gas riser
Liquid riser
Different hydrate philosophy
Gas: depressurisation + inhibition flowline 2ϕ sep.
Liquid: operation outside hydrate zone
Multiphase: depressurisation
SSU location Riser

Riser
top XV
top XV
Close to WH: potential operational
issue for gas risers
Close to RB: natural drainage of Sep gas
multiphase flowline PC
XV
Advantages: LAH
23bar
Hydrate preservation philosophy PWV
RO
Sep
60°C LC
Sep
Choke inlet
based on depressurization
LAL
inlet XV Pump
valve
bypass outlet XV
XV
Thermal insulation PMV
Separator
ROV
liquid XV Pumps
Line number and length ROV
Potential gain of Production

37
Riser base gas/liquid separator
Single production flowlines and in-line tees
Gas-liquid separation at riser base and at lower pressure

(hydrate management by depressurization) Riser
top XV
Gas transferred through one (or more) dedicated riser Riser

top XV
Liquid transferred through one dedicated riser (pumping

required)
Sep gas
PC
XV
LAH
40/65bar
RO 55°C LC
PWV Sep
Sep
Choke inlet LAL
inlet XV Pump
valve
bypass outlet XV
PMV XV
Separator Pumps
ROV
liquid XV
ROV
ROV
Riser base gas/liquid separation
Flow management
Hydrate prevention by low pressure operation in flowline, allows
relaxing the thermal insulation of the flowline
Elimination of slugging in the liquid riser
Wax management ? Î Applicable to non – paraffinic or low WAT
effluent
Drawbacks
Increased friction in flowline
Manifolding at riser base
Additional riser for gas transfer
Management of start up
Management of flow instability in the riser (liquid carry-over)
38
Subsea Gas Liquid separation 0.00
-100.00
-200.00
-300.00
-400.00
-500.00
-600.00
Sea dep th (m )
-700.00
-800.00
-900.00
-1000.00
-1100.00
SSU @ WH
HydrateCurve
Hydrate curveof
of Field
Preowei
XYZwith
witha aSSU
SSUlocated close
located to the
close riser
to the bottom
riser bottom -1200.00 SSU @ Riser Base
-1300.00
bara
-1400.00
400 -1500.00
-1600.00
380
0 5000 10000 15000 20000 25000 30000
360 Horizontal distance (m )
340
320
300
280
Liquid // Pssu = 10 bara
260 Liquid // Pssu = 11 bara
240
220 Liquid // Pssu = 14 bara
200
180 Gas // Pssu = 10 bara
Reservoir fluid
160
140
120
100
80
60
40
20
0
-10 -5 0 5 10 15 20 25 °C
Flowline Diameter & Thermal Insulation Sizing

(Classical Loop)
39
Flowline Diameter & Thermal Insulation Sizing (Classical Loop)
Physical Properties Study

To get reservoir (fluid) data
To match the fluid model to the actual fluid (physical properties, fluid tuning)
Production Profile
To get production profile over field life (with the best forecast)
Hydraulic Study
Available Vs Required WHFP Profile
Determine ID of flowline with satisfy the production profile
Determine Gas Lift rate to ensure stability of flow
Thermal Study
Determine (adjust) the flowline and riser insulation to meet Cool Down Time
(hydrate curve) and Wax Appearance Temperature requirement
Flow Assurance Methodology (Simplified Scheme): Classical & Hybrid Loop
Reservoir
Process Process
Reservoir PVT.tab (by ProII) Hydraulic Study Thermal Study
Data
Pipeline profile
Flowline ID Flowline type/insulation
Gas Lift Riser type/insulation
Etc.
Production
Profile OLGA Hydraulic
(QL, GOR, WC) Simulations OLGA Thermal
P is fixed at top site
Qmin. Simulations
T is fixed at WH GL Req.
Available Required Hydrate Curves

WHFP Profile WHFP Profile WAT Curves
CDT Req.
AWHFP>
RWHFP?
No
& Flow Stable?
Meet CDT No
Yes Requirement ?
Flowline ID
Gas Lift No Yes
Flow
Stable?
Yes Finish
40
Physical Properties Study
Define PVT tab file for Simulation
Required Data for PVT Simulation

Components : C1-C10, Cn1, Cn2, N2, Component Mole Mw Tc Pc Omega Vc Sg
N2
CO2 CO2
C1
Percent mole C2
C3
Molecular Weight, MW iC4
nC4
Critical Temperature, Tc iC5
nC5
Critical Pressure, Pc C6
C7
Specific Volume, Vc C8
C9
Omega, ω
C10
Cn1
Cn2
Binary Coefficient, Kij
Compare physical properties: PVT Simulation

Parameter Unit PVT (lab)
Lab result Vs PVT simulation result value PVT gap (%)
Reservoir Pressure bara
Reservoir Temperature °C
3 3
Fluid Tuning GOR total

Tank density (@1 bara, 15°C)
Sm /Sm
kg/Sm
3
3
Density at reservoir condition kg/m
Bubble Point @ T reservoir bara
Viscosity @ 4°C, 1 bara cP
Viscosity @ Reservoir condition cP
Conventional loop: Field XYZ, ID selection, No Gas Lift

Field XYZ Liquid Production Profile
Liquid Production Flowrates and associated Water Cut
120
90
100 80
53 kSbpd 70
80
Scenario: Field XYZ, Classical Loop, No Gas Lift 60
Water Cut (%)
Available & Required Pressure @ WH

kSbpd
50
60
Back Pressure from FPSO = 25 bara 40
40
L=31043.8 km, H (riser)=1667.5 m, U-flow line=3 W/m2.K, U-riser=3.5 W/m2.K 30
320 20
20
300 10
280 0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
260 Tim e (years)
240 OIL RATE WAT RATE LIQ RATE
Liq. rate in ONE branch WC
220
200
WHFP (bara)
8” flowline ID
180
160
10” flowline ID
140 11” flowline ID
120
100 Available WHFP
80
60 Unstanble flows are notified
40
20
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Tim e (years)
8" ID min WHFP 8" ID max WHFP 10" ID min WHFP 10" ID max WHFP
11" ID min WHFP 11" ID max WHFP 12" ID min WHFP 12" ID max WHFP
14" ID min WHFP 14" ID max WHFP A vailable WHFP
41
Conventional loop: ID Selection, With Gas Lift
Scenario: Field XYZ, Classical Loop, ID=10", With Gas Lift
Back Pressure from FPSO = 25 bara
L=31043.8 km, H (riser)=1667.5 m, U-flow line=3 W/m2.K, U-riser=3.5 W/m2.K
200
180
increasing Gas Lift rate

160 Gas Lift 1000 kSm3/day
140
WHFP (bara)
120
100 Req WHFP is not always < Available WHFP
80
60
40
Required WHFP exceeds the available WHFP
20
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Tim e (years)
Qlift=0 kSm3/d min WHFP Qlift=0 kSm3/d max WHFP Qlif t=100 kSm3/d min WHFP
Qlift=100 kSm3/d max WHFP Qlift=200 kSm3/ d min WHFP Qlif t=200 kSm3/d max WHFP
Qlift=400 kSm3/ d min WHFP Qlift=400 kSm3/ d max WHFP Qlif t=600 kSm3/d min WHFP
Qlift=600 kSm3/ d max WHFP Qlift=800 kSm3/ d min WHFP Qlif t=800 kSm3/d max WHFP
Qlift=1000 kSm3/d min WHFP Qlift=1000 kSm3/d max WHFP Available WHFP
Scenario: Field XYZ, Classical Loop, ID=11", With Gas Lift

Back Pressure from FPSO = 25 bara
L=31043.8 km, H (riser)=1667.5 m, U-flow line=3 W/m2.K, U-riser=3.5 W/m2.K
200
180
11” flowline ID
160
140 increasing Gas Lift rate Gas Lift 800 kSm3/day
WHFP (bara)
120
100 Req WHFP is always < Available WHFP
80
60
40
20 Required WHFP exceeds the available WHFP
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Tim e (years)
Qlif t=0 kSm3/d min WHFP Qlift =0 kSm3/ d max WHFP Qlif t=100 kSm3/ d min WHFP
Qlif t=100 kSm3/ d max WHFP Qlift =200 kSm3/ d min WHFP Qlif t=200 kSm3/d max WHFP
Qlif t=400 kSm3/d min WHFP Qlift =400 kSm3/ d max WHFP Qlif t=600 kSm3/d min WHFP
Qlif t=600 kSm3/d max WHFP Qlift =800 kSm3/ d min WHFP Qlif t=800 kSm3/d max WHFP
83 - Depok, 14 March, Qlif
Engineering Center
t=1000 kSm3/ d min WHFP FTUI Qlift =1000 kSm3/d max WHFP Available WHFP
Conventional loop: 11” ID, flow stability, No Gas Lift

Scenario: Field XYZ, Classical Loop, No Gas Lift, ID=11''
Required Pres @WH Vs Liquid Prod Flow rate
Back Pres from FPSO=25 bara
L=31043.8 m, H(riser)=1667.6 m, U-flow line=3 W/m2.K, U-riser=3.5 W/m2.K
260
240
220
200
Required Pressure @ WH (bara)
stable flow
180
160
140
120
100 min WC = 0%
unstable flow 80
max WC = 0%
min WC = 30%
max WC = 30%
60 min WC = 50%
max WC = 50%
Preowei to Egina FPSO 40 min WC = 90%
Wellhead Manifold to FPSO max WC = 90%
20 Q design
-1100
0
-1150 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
-1200
Liquid Production Flow rate (kSbpd) / Branch
-1250
-1300
31 km
D epth (m)
-1350 400m
-1400
-1450
-1500
-1550
-1600
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Length (km)
42
Conventional loop: Field XYZ, 11” ID, WC 0%, Flow Stability,
Minimum Flow, Gas Lift Requirement
Scenario: Field XYZ, Classical Loop, GL 30°C, ID= 11'', WC=0%

Required Pres @WH Vs Gas Lift Flowrate
Back Pres from FPSO=25 bara, WHFT=46.7 °C
L=31043.8 m, H(riser)=1667.6 m, U-flow line=3 W/m2.K and U-riser=3.5 W/m2.K
340
320 Minimum Flow:
300
280
~ 15 to 25 k Sbpd
Required Pressure @ WH (bara)
260
240 11” flowline ID
220 Gas Lift for stabilisation
200
180
600 k Sm3/day
160
140
120
100 Increase GL to 800 kSm3/day
80
60 not significant to gain dP
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
Gas Lift Flow rate (kSm 3/d) / Branch
min, Q = 10 kbpd max, Q = 10 kbpd min, Q = 15 kbpd max, Q = 15 kbpd min, Q = 20 kbpd
max, Q = 20 kbpd min, Q = 25 kbpd max, Q = 25 kbpd min, Q = 30 kbpd max, Q = 30 kbpd
min, Q = 40 kbpd max, Q = 40 kbpd min, Q = 55 kbpd max, Q = 55 kbpd min, Q = 65 kbpd
max, Q = 65 kbpd min, Q = 75 kbpd max, Q = 75 kbpd min, Q = 90 kbpd max, Q = 90 kbpd
min, Q = 110 kbpd max, Q = 110 kbpd
Field XYZ hydrate curve

Hydrate Dissociation Curve of Field XYZ
450
0 g/l NaCl
10 g/l NaCl
400
33 g/l NaCl
350
300
Pressure (bara)
250
230 bara
(WHSIP)
200
150
100
50
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Temperature (°C)
T hydrate = 18.5°C + 3°C = 21.5°C

43
Thermal Study Scenario: Field XYZ, Classical Loop, ID=11",
Fluid tem perature during cool dow n,
GL=1 Million Sm3/day, Temp GL=30°C, L=31043 m, H(riser) = 1667 m,
U flow line PIP = 0.8 W/m2.K and U flexible riser = 2.5 W/m2.K
60 200
Initial Production flow rate @ FPSO = 20 kSbpd
55 WC = 0 % 0
50 Gas Lift @ Riser Base = 1 Million Sm3/day
-200
45 Steady state flow
Fluid temperature (°C)

-400
40 4 h shut dow n
Water detph (m)

35 8 h shut dow n -600
12 h shut dow n
30 -800
16 h shut dow n
25 20 h shut dow n -1000
24 h shut dow n
20
30 h shut dow n -1200
15 40 h shut dow n
-1400
10
5 -1600
0 -1800
0 5 10 15 20 25 30 35
Scenario:Distance
Field XYZ, Classical
from WH (km Loop,
) ID=11",
Steady state Fluid
flow tem perature
4 h shutduring
dow n cool dow n, 8 h shut dow n
12 h shut
GL=1 dow
Million n
Sm3/day, Temp16 h shut dow
GL=30°C, n
L=31043 20 h =
m, H(riser) shut dow
1667 m,n
24 h shut dow n 30 h shut dow n 40 h shut dow n
U flow line PIP = 0.8 W/m2.K and U flexible riser = 2.5 W/m2.K
Elevation
7 1.1
1
6
0.9
0.8
Liquid Holdup (m2/m2)

5
0.7
Pressure (Mpa)
4 0.6
0.5
3 0.4
0.3
2 Initial Production flow rate @ FPSO = 20 kSbpd
WC = 0 % 0.2
Gas Lift @ Riser Base = 1 Million Sm3/day 0.1
1
0
0 -0.1
0 5 10 15 20 25 30 35
Distance from WH (km )
P(Steady st ate f low) P(8 h shut down)
P(30 h shut down) Holdup(Steady stat e flow)
Holdup(8 h shut down) Holdup(30 h shut down)
Thermal Study – Cool Down

Basis of Design: Base case
Tie-back: 27 km and Thyd = 18.6°C PiP aerogel: 0.8 W/m2°C
8” ID + TD rate = 15 kbopd/branch (25%) Riser tower: 1.5 W/m2°C
NO WAT Flexible jumper: 3.4 W/m2°C
CDT: 19 hr
Design with conventional philosophy
bara PREOWEI Reference design 0g/l NaCl

Designing spot P&T envelop 33g/l NaCl + 1°C
250
33g/l NaCl + 2.7°C
1st Flexible
1st Riser
1st Flow line
2nd Flow line
200 2nd Riser
2nd Flexible
Thydrate (pure w ater) + 3°C of margin
150
100
50
[°C]
0
0 5 10 15 20 25 30 35 40 45 50
44
Field XYZ dynamic
Field XYZ
END
&
THANK YOU
45
BACK UP
Conventional loop: Filed XYZ, 11 ID, WC 0%, Flow Stability,

Q=30kbbld - GL=700kSm3/d (6.14kg/s)

@ Wellhead @ RT bottom @ Topside
Max DP variation = 0.3bara

Max DP variation = 0.15bara
46
Conventional loop: Field YZ, 11” ID, WC 0%, Flow Stability,
@ Well Head
Max DP variation = 0 bara
@ Riser Tower Bottom

Max DP variation = 0 bara
Conventional loop: Field YZ , 11” ID, WC 0%, Flow Stability,


Max DP variation = 3.5bara Max DP variation = 12bara Max DP variation = bara

Max DP variation = bara Max DP variation = bara Max DP variation = bara
47
Definitions
Two-phase flow
Flow in which two phases are present; a gas phase and a hydrocarbon liquid phase
Multi-phase flow
Flow in which several phases are present; gas, hydrocarbon liquid, free water (with
chemical additives) and sometimes solids
Unlike in single-phase flow:
The fluid is not homogeneous
A segregation of the gas and the liquid phases occurs in the pipeline
Flow pattern or flow regime

The manner in which the gas and the liquid phases are distributed in a pipeline
section
48
Effect of GOR and gravity on flow pattern
(steady-state two-phase flow)
ρG Decreases with pressure drop Consequence

Consequence
ρL Remains practically constant A
A multiphase
multiphase pipeline
pipeline can
can be
be seen
seen as
as
vG , actual gas velocity, increases Single-phase pipeline

Multiphase pipeline ~
with pressure drop, along the line +
Liquid storage tank
vL , actual liquid velocity, remains
practically constant, along the line
The
The flow
flow pattern
pattern in
in aa pipeline
pipeline is
is function
function
of:
of:
Slippage between gas and liquid phases GOR
GOR
Slip velocity: vslip = vG - vL Flowrate
Flowrate
Pipe
Pipe slope
slope
Flow direction
and
and may
may change
change along
along thethe pipe
pipe length
length
i le
p rof
ity
loc
Ve
Experimental flow pattern maps
Show
Show the
the effect
effect of
of GOR
GOR and
and Flow
Flow maps
maps are
are usually
usually functions
functions of:
of:
flowrate
flowrate on
on flow
flow pattern
pattern Superficial
Superficial gas
gas velocity
velocity
Based
Based onon experimental
experimental results
results vvSG = q G// SS
SG = qG
usually
usually obtained
obtained onon laboratory
laboratory test
test
loops Superficial
Superficial liquid
liquid velocity
velocity
loops (short
(short length,
length, small
small diameter
diameter
lines vvSL =q /S
SL = qLL/ S
lines handling
handling air/water
air/water mixtures
mixtures atat
near
near atmospheric
atmospheric pressure).
pressure). with:
with:
Flow
Flow patterns
patterns are
are discriminated
discriminated byby qqGG Gas
Gas volumetric
volumetric flowrate
flowrate
visual
visual observation.
observation. qqLL Liquid
Liquid volumetric
volumetric flowrate
flowrate
SS Pipeline
Pipeline cross-section
cross-section
THERE
THERE IS
IS ONE
ONE FLOW
FLOW MAP
MAP PER
PER PIPE
PIPE
SLOPE AND EACH FLOW
SLOPE AND EACH FLOW MAP MAP
DEPENDS
DEPENDS ON ON THE
THE AUTHOR
AUTHOR ’s’s
EXPERIMENTAL
EXPERIMENTAL RESULTS
RESULTS
49
Pressure gradient in two-phase flow
For a mass unit of fluid: Momentum balance:
dl S -dP/dl = d(ρ v2/2)/ dl + ρ g sinθ + fD ρ v2/2
P+dP
v
S dz acceleration gravity friction
P
With:
Inclined pipe, constant cross-section fD = fD ( Re, ε/D )

S, no mechanical energy exchanged
For a gas/liquid flow element: Hold-up definition :

(volumetric
(volumetric fraction)
fraction)
Due to the non-homogeneity of
the phase distribution: Liquid volume in a section of pipe
HL =
The gas and the liquid do not flow Volume of this section of pipe
at the same velocity
HG = Gas volume in a section of pipe
There is slippage between the Volume of this section of pipe
phases
HG
It is necessary to know the liquid HL + HG = 1
hold-up HL (or αL)of the pipe HL
element to determine the actual
gas and liquid velocities: HL HL
VG= VSG/(1-HL), VL= VSL/HL Uphill Downhill section
section
A rigorous momentum balance

can be written for each of the
Flow Flow
gas and liquid phases
50
For a gas/liquid flow element:
Gravity term:
(dP/dl)gravity = [ ρG + (ρL - ρG)HL ] g sinθ

Friction term:
Gas friction against pipewall

(dP/dl)friction = Fonction of Gas/liquid interfacial friction
Liquid friction against pipewall
Acceleration term:
Sometimes discarded as it is negligible compared to the others
Pressure gradient multiphase vs single phase
Unlike
Unlike single
single phase
phase flow,
flow, in
in multiphase
multiphase flow
flow the
the pressure
pressure
gradient
gradient goes
goes through
through aa minimum
minimum with
with increasing
increasing flowrate
flowrate
uphill slope downhill slope

single-phase flow TWO-PHASE FLOW single-phase flow two-phase flow
Dp/Dl Dp/Dl
Dp/Dl Dp/Dl
total
total
friction
gravity
flowrate flowrate
gravity
friction
flowrate flowrate
dP/dL
dP/dL is
is gravity-dominated
gravity-dominated at
at low
low flowrate,
flowrate, friction-dominated
friction-dominated at
at high
high flowrate
flowrate
51
Problems related to slugging
Different types of « slugging » Main concerns

Hydrodynamic Slugging = Slug flow The steady operation of the
regime downstream facilities
Natural hydrodynamic phenomenon The design of the slugcatcher to be
The mechanisms of slug formation installed at the outlet of the pipeline
and evolution still not well known nor
modelled
Different types of slugcatchers
Additional capacity in inlet vessel
Slug volume
Terrain and riser induced slugging

between NLL and LAH Î Crude oil
(severe slugging) system (generally)
SC volume
Vessel-type Gas/Condensate
Operational Slugs :
Finger-type system, onshore
due to depressurisation
due to variations of operating
conditions (flow ramping) Two-phase or Three-phase
due to pigging
Terrain or riser-induced severe slugging
Severe slugging
Intermittent flow which may
occur at low points of a
multiphase pipeline, due to
coupling effects between uphill
and downhill sections
Typically encountered in upward

risers
52
Wax management
Risk
Risk assessment:
assessment:
Lab
Lab analysis
analysis of
of fluid
fluid samples
samples to
to quantify
quantify paraffin
paraffin content
content and
and WAT
WAT (Wax
(Wax
Appearance
Appearance Temperature)
Temperature)
Assessment
Assessment ofof wax
wax deposition
deposition quantities
quantities vs
vs sample
sample information.
information.
Design:
Design:
Find
Find best
best compromise
compromise ::
Thermal
Thermal insulation
insulation toto maintain
maintain the
the pipe
pipe inner
inner wall
wall temperature
temperature above
above the
the WAT
WAT
Inhibition
Inhibition by
by chemical
chemical injection
injection (ppd
(ppd paraffin
paraffin dispersant)
dispersant)
Pigging:
Pigging: to
to routinely
routinely scrape
scrape the
the paraffin
paraffin deposit.
deposit.
Simulate
Simulate &
& monitor
monitor thickness
thickness &
& nature
nature of
of deposit
deposit
Operation:
Operation:
Adjust
Adjust frequency
frequency of
of pigging
pigging operation
operation
Two-phase flow regimes
Horizontal Vertical
53

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Deepwater Development

Flow / Thermal Management

(an overall presentation)

Depok, 14 March 2009, Engineering Center FTUI

1. Introduction to Deepwater Development

2. Deepwater Flow Assurance (Hydraulic & Thermo Aspect)

3. Subsea Production Concept

4. Case Study & Discussion

2 - Depok, 14 March, Engineering Center FTUI

3 - Depok, 14 March, Engineering Center FTUI

Introduction to Deep Water Development

4 - Depok, 14 March, Engineering Center FTUI

Flowlines 2 x12”, 56 miles each

5 - Depok, 14 March, Engineering Center FTUI

Typical sea bed

6 - Depok, 14 March, Engineering Center FTUI

7 - Depok, 14 March, Engineering Center FTUI

Typical Sea Water Temperature Profile

water temperature (°C)

8 - Depok, 14 March, Engineering Center FTUI

9 - Depok, 14 March, Engineering Center FTUI

Deepwater - Typical Manifold

10 - Depok, 14 March, Engineering Center FTUI

11 - Depok, 14 March, Engineering Center FTUI

Instability and Gas Hydrates

12 - Depok, 14 March, Engineering Center FTUI

Basic Option Deepwater Permanent Production Platform (1)

14 - Depok, 14 March, Engineering Center FTUI

15 - Depok, 14 March, Engineering Center FTUI

16 - Depok, 14 March, Engineering Center FTUI

17 - Depok, 14 March, Engineering Center FTUI

Typical Mini-TLP and FPSO

18 - Depok, 14 March, Engineering Center FTUI

19 - Depok, 14 March, Engineering Center FTUI

Remotely Operated Vehicles (ROV)

20 - Depok, 14 March, Engineering Center FTUI

21 - Depok, 14 March, Engineering Center FTUI

Deepwater various Risers and Flowlines

22 - Depok, 14 March, Engineering Center FTUI

23 - Depok, 14 March, Engineering Center FTUI

Integrated Production Bundle

24 - Depok, 14 March, Engineering Center FTUI

25 - Depok, 14 March, Engineering Center FTUI

Bundle Insulation (Typical)

26 - Depok, 14 March, Engineering Center FTUI

Wet insulation Pipe in Pipe insulation

27 - Depok, 14 March, Engineering Center FTUI

28 - Depok, 14 March, Engineering Center FTUI

29 - Depok, 14 March, Engineering Center FTUI

Deepwater is critical in term of Flow Assurance

High Pressure in production flowline and riser

Often long tie-back

Complex sub-sea architecture/design and installation

Involving remote control and power supply

Retrievable sub-sea pieces of equipment

Fairly new type of development

30 - Depok, 14 March, Engineering Center FTUI

d. Hydrodynamic flow study

31 - Depok, 14 March, Engineering Center FTUI

a. Production Line Design

Pipeline thickness, is based on mainly on:

32 - Depok, 14 March, Engineering Center FTUI

33 - Depok, 14 March, Engineering Center FTUI

b. Minimum Flow Rate Criteria