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11/19/2013

Flow Assurance - Managing Flow


Dynamics and Production Chemistry

Abul Jamaluddin, Ph.D.


Production Technology Advisor
Business Manager – North America
NExT – Oil & Gas Training and Career Development

What is the primary operating focus


of your team?

Acknowledgement

• SPE for organizing this Webinar


• All clients who contributed to some of the field examples
• Schlumberger to allow me to participate and thanks to the
following sub segments for providing the contents -
– Schlumberger Research
– Reservoir Sampling and Analysis sub segment
– Flow Assurance Consulting group of OneSubsea
– NExT – Oil and Gas Training and Competency Development
of Petrotechnical Services

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11/19/2013

Presentation Outline

Deepwater & flow assurance


Flow hindrance elements
A holistic flow assurance workflow
Field examples with key technology applications
• Waxy crude production management (SPE 132615)

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Deepwater Flow Assurance Challenges

– Colder temperatures
– Greater hydrostatic head
– Longer tiebacks, and hence complex thermo-hydraulic fluid
behaviour
– Gas condensate production Commingling of
Incompatible fluids
– Organic/Inorganic solids precipitations
– Commingled production – complex fluid systems
– Reservoir Large pressure drops
Complexity - shallow reservoir, HPHT,
Cold deep water
facilitates deposition facilitates deposition
compartmentalised, …
– Reduce uncertainties and minimize risks CAPEX versus
OPEX
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Flow Assurance

“Maintain flow from pore to


process”

Corrosion Surveillance
Integrated Liquid- PVT & Fluid- Operability
Asphaltenes Hydrates Wax Scale & &
Solutions Management Behaviour Assessment
Erosion Operation

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Flow Hindrance Elements –


Especially Critical in Offshore Arena
Fluid Properties - PVT
Fluid Flow & Heat
Transfer
Asphaltene
Wax
Hydrate
Naphthanates - Soaps
Oilfield Scales
Emulsions/ Foams
Corrosions/Erosions/Sand
Heavy Oils
Understanding the fundamentals of these elements are the
key to design management strategy
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Flow Assurance Domains

Production Chemistry Production Engineering Production Surveillance

Characterization, prediction of Thermal-hydraulic design and Production optimization and


flow stoppage elements assessment of subsea early detection of flow stoppages
multiphase flow systems

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What is your primary area of


expertise/interest?

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Holistic Flow Assurance Workflow

Downhole Laboratory Modeling Integration, Field


Characteriza Measureme Interpretatio Implementat
tion & nts n and ion
Single- • Thermod Design
Phase ynamic –
Sampling • PVT • Steady & • Implement
• Asphalten Transient a
e State technically
Modeling sound,
• Wax cost
• Hydrate effective
and
environme
ntal sound
solution

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Feedback Loop
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Pressure & Liquid Management

Subsea Gas Lift

Liquid Management
Subsea Natural Lift
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Sampling and analysis

Production Chemistry
Fluid sampling, analysis, characterisation, prediction of
challenges
Development of Asphaltene Deposition Model

Perform asphaltene characterization


Calculate asphaltene-liquid (SL) flash
Implement the particle deposition mechanism which includes particle formation,
transportation and adsorption
Single and two phase flow models

(1) Particles
Form (2) Particle
Transport
Scale Precipitation Results
(3) Particles
Adsorb
6.00E-04
BaSO4 Cal.
SrSO4 Cal.
5.00E-04
BaSO4 Exp.
Value of Data

Solid Mas s Fra ction

SrSO4 Exp.
4.00E-04

3.00E-04

2.00E-04

1.00E-04

0.00E+00
0 0.2 0.4 0.6 0.8 1
Mass Fraction of Formation Water

20 45
1 month
Samples Analysis

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Model calibration

6 months 40
1 year
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Fluid Sampling

Deposit thickness (mm)

14
30
Fluid Modeling

Temperature (C )

12
25
Interpretation

10
20
8
Temperature profiles 15
6

4 10

2 5

0 0
0 3000 6000 9000 12000 15000 18000
Distance (m)

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Time

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Production Engineering
Importance of Dynamics from Reservoir to Process Facilities
Slug Catcher

Steady State Outcomes


Peak production rates
Completions design
Pipeline sizing
Equipment sizing
Process Facilities

Reservoir Dynamic Outcomes


Production profiles
Well clean-up / start-up procedures
Cooldown / insulation requirements
Liquid surge management / slug catcher

ECLIPSE

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Production Operations
Production surveillance and optimization, operational well and pipeline remediation,
prevention and mitigation techniques in order to optimize production

Monitor Distributed temperature


Production Intervention
sensors DTS
Sensors and MP meters
Data acquisition
Data validation and storage
Process Facilities

Reservoir
Alarm
Optimise
Multiphase
meter
Integrated asset management
Well intervention
Flowline remediation
ECLIPSE

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Asphaltenes in the Reservoir

Reservoir Architecture – Aerial Compositional Grading


Compartments, sealing barriers, baffles
Different Fault Blocks
Different GOR (colors)

Hibernia
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Courtesy of OC Mullins Areal Map
11/19/2013

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Impact Completions
Vertical Compositional Grading (Heavy Ends ! )
Reservoir Fluids are often highly graded and often
NOT in equilibrium
May have compatibility issues

Column
One Oil

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Production Chemistry
Mercury

Athabasca Asphaltene
Bitumen ρ>1
Wax

Diamondoids
Gas
Hydrate
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Organic Scale

Asphaltenes
Asphaltenes
Operationally defined as a portion of crude oil insoluble in n-
S
alkanes such as heptane but soluble in aromatics such as
toluene or dichloromethane. Source specific.
They are the heaviest and the most polar components in
crude oil composed of :
• Polyaromatics carrying aliphatic rings or chains N
• H/C atomic ratio = 1.0-1.2 H
• Heteroatoms: nitrogen, oxygen, sulfur
• Metals: nickel, vanadium, iron.

Causes of Asphaltene Precipitation


Change in Oil Composition
Pressure Depletion Above Psat
Change in Temperature
Others (pH, Water Cut, Electro-kinetic Effects etc…)

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Key properties of waxy crudes


Waxes are high molecular weight saturated carbons (>C20) mainly from
normal paraffins CnH2n+2
Tend to precipitate when temperatures are reduced.
Precipitates as crystalline waxy solids.
Viscosity

Highly Non- Mildly Non-Newtonian Newtonian


Newtonian

15-25 oC

Pour Point Cloud Point


Wax Appearance
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11/19/2013 Temperature Temperature (WAT)

Hydrates – Ice That Burns

Crystalline solid consisting of gas molecules each surrounded by a cage of


water molecules.
Hydrate usually forms at high P & low T
One volume hydrate can carry 160-180 volumes of methane
Hydrate Formers:
C1 C2 C3 i-C4
n-C4 N2 CO2 H2S
O2 Ar cyclo-C3
others

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Common Inorganic Scales


• Calcite (CaCO3) – acid soluble
carbonates
– Formed due to the presence of calcium ions
and bicarbonate ions in the produced water
– Pressure changes may cause precipitation
• Barite (BaSO4) – acid insoluble
sulphates
– Generally formed when there is co-
production of formation water (Ba2+) and
injection water (SO4-)

Barite

Anhydrite

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What is your major flow


assurance concern?

Field Example: Waxy Crude Management in


Deepwater from South East Asia
SPE 132615

Field Situation
Dual 5-km deepwater subsea line capability with pigging operations
Half buried no insulation
High pour point waxy crude production at subsea temperature of 4°C
No wax deposition in early life

Challenge
Concerned with wax gelling during unplanned shut down.

Recommendation by Chemical Vendor


Continuous chemical (PAO82004) injection at 300 ppm

Operating Company Perspective


Independent verification of gelling characteristics & chemical
requirements
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Waxy Crude Flowline Unplanned Shutdown/Re-


Start Evaluation Workflow
Fluid Sampling • Representative Sampling
Thermodynamic Modeling

• Standard PVT analysis


Phase Behavior
Transient Modeling

• (Define phase boundaries)

Thermodynamic Characteristics
• Compositions C90+
• Wax Content
• Cloud Point/WAT @ Ambient/Line
Wax Condition

Characterization Transport Characteristics @


Ambient/Line Condition
• Gel-Strength
• Rheology

Deposition Measurements (not done


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Compositions & Wax Content


Recombine separator gas and oil samples at producing GOR to make reservoir fluid sample
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Recombined fluid 100000
10
10000

Concentration (ppm)
8
1000
wt%

6
100
4
10
2
1
0
0
CO2
N2
C2
i-C4
i-C5
C6

C7

C10
C12
C14
C16
C18
C20
C22
C24
C26
C28
C30+
Toluene

o-Xylene
Benzene

C2-Benzene

0 10 20 30 40 50 60 70 80
n-alkane carbon #

GOR = 1058 scf/sbl UOP wax content ~ 4.3 wt% at -31oF/-35°C


API = 37.9 HTGC wax content (n-C18+) ~ 11.16 wt%
MW = 182.6 g/mol
Psat ~ 3660 psia @169.5oF/76.4°C
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Schematic Diagram of Cross Polar Microscope


(CPM) Measurement of WAT of Stock Tank Oil

CC
D
Hot Stage

Analyzer Top View

4 50
25

Hot Stage
360o Rotatable Stage Cooling
Polarizer Gas

IR Filter
Light Source
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High Pressure Cross Polar Microscope


(HPCPM) – Wax Precipitation Assessment (20,000 psi &
200oC; Resolution ~ 4 micron)

HPCPM HPCPM

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Live oil WAT at 4000 psia ~ 20°C

1.4E-04

GOR = 1058 scf/stb


1.2E-04 SDS WAT ~ 20°C

1.0E-04
Power (W)

8.0E-05
HPCPM WAT
~ 15°C
6.0E-05

4.0E-05

2.0E-05

0.0E+00
0 10 20 30 40 50 60 70 80
Temperature (°C)

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Wax Appearance Temperature/Cloud Points


Characteristic Value/Observation
STO WAT (°C) 26.8
Live oil WAT at 4000 psia
(°C) 20
Live oil WAT at 2200 psia
(°C) 20
WAT (Exp) Pb (Exp) Hyd WAT (Sim) Pb

5000
PX02 Reservoir
4500 Conditions

4000

3500
Minimum seabed
Temperature
3000
P (psia)

2500
Wellhead
2000 Conditions

1500

1000
FPSO Arrival
500

0
-100 0 100 200
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T (C)
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Gel-Strengtgh Measuremeht using Model


Pipeline Test (MPT)
N2 Pressure
For Ungelling
HP Circulation Pump
Back-Pressure
Regulator
Heated Lines

Test Coils (2)


Fluid • 7.0 mm ID
Sample • 7.64 m long
Cylinder • 3,000 psi (35 Mpa)
• 170oF (75oC)

Temperature Applications:
Controlled Bath • Measure Yield Strength
• Evaluate Effectiveness Of Flow
Improvers

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Gel Strength Measurement


Results
90 30
Yield pressure
80 = 80.6 psi
Untreated STO 25 Yield pressure
= 24.3 psi
70 Untreated live oil
60 20
DP (psi)

DP (psi)
50
15
40
30 10
20
5
10
0 0
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160
Time (min) Time (min)

Test # Oil Type PY(psi) τ (Pa)


τ = PYD/4L = 1.988 PY 1 STO 80.6 160.3
PY = ungelling or yield pressure
2 Live Fluid at 2200 psia 24.3 48.3
D = coil inner diameter
L = coil length 3 STO + 300ppm chemical --- No gel

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Rheometer – Viscosity Measurements

3.0
STO at 40°C
2.5
Shear Rate Sweep
• STO @ 40oC ~ 1.5 cP slightly non-linear
Viscosity (cp)

2.0
• STO @ 4oC – highly non-linear (highly viscous)
1.5 • Live Oil @ 4oC - Highly non-linear (less viscous)
1.0

0.5

0.0
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Shear rate (1/s)

Viscosity Modeling
Test # Oil Type PY(psi) τ (Pa)
1 STO 80.6 160.3

2 Live Fluid at 2200 psia 24.3 48.3

3 STO + 300ppm chemical --- No gel

The plastic viscosities for the STO and live oil @ 2200 psia line
pressure were obtained from gradients of the shear stress vs shear
rate plots

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Rheology Model Selection in OLGA


based on Experimental Validation

• The non-Newtonian behavior of the fluid (gel)


was approximated by the Bingham plastic
model, with the plastic viscosity and the yield
stress obtained from the rheological and gel
strength measurements.

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Shut-Down and Re-Start Modelling -


Transient Simulation using OLGA
Liquid filled

Flowline / Riser Geometry Arrival pressure of 628 psig


0

-200

-400

-600
Elevation (m)

-800

-1,000

-1,200 Seabed temperature of 4oC

-1,400 Constant mass source


of12,000 bpd @ 68.3oC
-1,600
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
Flowline / Riser Length (m)

Gas filled

– Only flowline/riser considered. The production tubing was not


included.
– Flow-line assumed to be half buried in soil.
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11/19/2013 – Recombined reservoir fluid composition was used in simulations.

Live Oil Shut-in Pressure & Temperature –


Gas Dissolution Effect

STO Condition Live Oil @2200 psia

WAT = 26C
WAT = 20C

16 hrs 24 hrs

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Re-Starts - STO
~ 2500 psi ~ 2500 psi

2-hour restart 6-hour restart

– Blow down after unplanned shut-in, pressures required to initiate


flow in the pipeline is around 2500 psi for both ramp-ups.

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Restarts – Live oil @ 2200psia


~ 2200 psia ~ 2200 psia

2-hour restart 6-hour restart

– For live fluid with solution gas, pressures required to initiate flow in
the pipeline is 2200 psia for both ramp-ups, respectively.

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Summary Results

τ = Py D /4 L
Case OLGA predicted pressure (psia) Calculated from force
balances (psia) using gel-
2-hour restart 6-hour restart strength data
STO 2500 2500 2100
Live oil @ 2200psia 2200 2200 600

Force balance calculations with an assumption of a continuous


liquid gel at the pipeline inlet provides conservative numbers

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Field Study Conclusions


– As expected, solution gas at line condition provided lower WAT, Gel-Strength
and viscosity values.
– Transient simulation of shut-down scenarios with experimental validation and the
choice of right viscosity model provided longer shut-in time to reach WAT of 20
deg C at line condition 24 hrs as oppose to 16 hrs design shut-in time.
– Continuous chemical injection provided no gelling at subsea temperature of 4
deg C
– Transient simulation predicted re-start pressures of ~2500 psi for STO & 2200
psi for live fluid after a prolonged shut-in period. Are these pressures
bigger/smaller than theFlowing Wellhead Pressure ~ 2200 psia
SIWHPs?
Shut-in Wellhead Pressure = 2600 psia
Contingency is the pig-launching pump at subsea

– Continuous chemical injection is not a requirement with current shut-in subsea


wellhead conditions.
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Integration & Interpretation


WAT (Exp) Pb (Exp) Hyd WAT (Sim) Pb

5000
PX02 Reservoir
4500 Conditions

4000

3500
Minimum seabed
Temperature
3000
P (psia)

2500
Wellhead
2000 Conditions

1500

1000
FPSO Arrival
500
Predicted FPSO Arrival
0
-100 0 100 200

T (C)

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Concluding Remarks

• Understanding the fundamental flow assurance issues


are key to successful field development & production,
especially, in deepwater subsea environment.
• Application of appropriate technology and a customized
workflow process is critical.
• Based on fundamental understanding, optimized
operating strategies can be designed.

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Fluid Watcher Dashboard


Reservoir
P&T
Pressure

Hydrate Curve

Facility

43 AJ Temperature *Same number for Scale


11/19/2013

Flow Assurance - Managing Flow


Dynamics and Production Chemistry

Thank You
Any Questions?
Abul Jamaluddin, Ph.D.
Production Technology Advisor
Business Manager – North America
NExT – Oil & Gas Training and Career Development

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