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Missing the Potential Value of
Subsea Processing Technology
Produced Water Club Intro Talk
Ian Ball, Technical Advisor – INTECSEA UK Aberdeen, 10th December 2014
DISCLAIMER
This presentation contains the professional and personal opinions of the presenter,
which are given in good faith. As such, opinions presented herein may not always
necessarily reflect the position of INTECSEA as a whole, its officers or executive.
Any forward-looking statements included in this presentation will involve subjective
judgment and analysis and are subject to uncertainties, risks and contingencies; many
of which are outside the control of, and may be unknown to, INTECSEA.
INTECSEA and all associated entities and representatives make no representation or
warranty as to the accuracy, reliability or completeness of information in this document
and do not take responsibility for updating any information or correcting any error or
omission that may become apparent after this document has been issued.
To the extent permitted by law, INTECSEA and its officers, employees, related bodies
and agents disclaim all liability [direct, indirect or consequential (and whether or not
arising out of the negligence, default or lack of care of INTECSEA and/or any of its
agents)] for any loss or damage suffered by a recipient or other persons arising out of,
or in connection with, any use or reliance on this presentation or information.
What does “new” Subsea Processing include? SAPT building blocks
Is it really new?
Current Technology and Application Status INTECSEA 2014 Worldwide Survey Poster
Why apply SAPT? What is the prize?
When can specific project value be recognised?
Where are the gaps & risks?
Why is it still so under-utilised?
Outline
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Subsea Active Production Technology
Applications Subsea separation and conditioning
Subsea pumping and gas compression
Subsea water disposal and injection
Allied supporting technologies Subsea “big power” transmission (or generation) and distribution
Electrical flowline heating
Integrated Control & Monitoring systems
Subsea chemical injection
Subsea hydraulic power units
All electric systems
What is SAPT?
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Production can be accelerated and/or plateau prolonged
Total hydrocarbon recovery can be increased
Essential enabler for certain deepwater fields
Marginal fields can become more economically viable
Flow assurance risks can be mitigated
Achievable tie-back distance can be increased – potentially
all the way to the beach
Can potentially eliminate some in-field structures
Subsea Processing offers a Compelling Value Proposition
Subsea Processing rewards
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Why Such a Long Gestation?
Discovered early that electricity doesn’t like seawater
Norway & Brazil established national subsea programmes
One atmosphere chambers to house seabed equipment Allowed hands-on repair by specialists rather than divers
Inductive electrical couplers replaced pin connectors Allowed surface insulation potting to keep seawater out
Downside was high electrical losses requiring high power input
Oil-filled wet-make electrical connectors Enabled return to efficient and reliable pin connectors
This was the single most important technical breakthrough
Gave confidence for planning deepwater frontier development
Decades of Subsea Separation prototypes
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Subsea Separation “New” Technology??
These were all built before the Millennium:
BOET (1986 -1989)
operational pilot
GASP
(1986 -1990 prototype tested)
Kvaerner Booster Station
(Mid 80’s prototype tested)
ZAKUM (1969 -1972)
operational pilot
SUBSIS
(2000 - operational pilot)
VASPS (2000)
operational pilot
AESOP (1999 -2000)
prototype tested
Exxon SPS (1969 -1974)
operational pilot
The System: Pumping
Multiphase Pumping proven reliable
Incremental production justifies the investment.
Recent installations of note:
Petrobras Cascade/Chinook
Chevron Jack & St. Malo
ExxonMobil Julia
27 installations to date, 10 more planned
API 17X Committee formed in 2013
Pump hydraulics
Electrical systems
Mechanical/structural
Reliability and intervention
Qualification and testing
Image Courtesy INTECSEA/Offshore Magazine 2014 Worldwide Survey of Subsea Processing
The System: Separation, Injection
Separation and pumping installations:
Shell Perdido
Total Pazflor
Petrobras Marlim SSAO Pilot
Ten to date, 3 more in manufacturing
The System: Separation, Injection
Raw seawater treatment for injection
Pressure maintenance above bubble point Waterflood capex reduction
Three systems installed to date: CNR Columba E, (2007) Statoil Tyrihans (2013) Petrobras Albacora E. (2013)
New system developed in JIP:
Manufactured by Seabox AS Full scale pilot in 2009-2010
Integrated Subsea Raw Seawater Injection System Image Courtesy Seabox AS
The System: Compression,
Disposal Full three+ phase separation
Produced water injection
Produced water discharge to sea
Gas compression viewed as future need Longer term electric power studies underway
Åsgard, Gulfaks, Ormen Lange
- Early targets to watch
Image Courtesy Man Diesel & Turbo
Early-Phase System Analysis
Life-of-field IPM (eg MAXIMUS™)
Through-life subsea power
Production availability analysis (eg MAROS)
Value Optimization
Phasing of field developments
Minimizing well counts
Optimal hardware provisions
Making sure it works
Hardware and system reliability and integrity qualification (API 17N)
Risk management of new vendor offerings - Qualification programmes
System Engineering is Key
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
What is round the corner?
Emerging Subsea Active Production Technologies Liquids & Multiphase boosting – proven
Gas/liquid & Oil/water separation – pilots performing well
Produced & Seawater Injection – pilots showing way forward
Dry & Wet Gas Compression – extensive land tests looking good
Direct Electrically Heated flowlines – proven
Subsea water treatment – that’s what we are all here for!
Subsea storage – in development
Electrical Power generation & distribution – key constraint
AUV intervention to reduce servicing costs and time
New frontier regions – especially Arctic/Ice areas
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
What will the limiting factors be
A few are less controllable, eg: Reservoir surprises particularly in new plays
Environmental concerns that need to be addressed
Mostly controllable factors that we don’t control well: Resources throughout the supply & implementation chain
Reliability issues arising as a result
Learning to fast-track only where that makes real sense
Ineffective industry experience exchange
Too little holistic system thinking – working in silos
Integrated production modelling tool shortcomings
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Conclusions
The Development Agenda is changing: Subsea technology has long been essential enabler for deepwater
Energy adding technologies now emerging as game changers
Inflated Oil price created a major investment driver (still?)
Huge potential for recovery enhancement & prodn acceleration
Often essential for deepwater feasibility
But are we all aboard the change train? Often inadequate collaboration across silos
Reluctance to tackle root causes of risk perceptions
Reluctance to share operational experience
Resource constraints will chip away at reliability
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
Conclusions (2)
So, can we act smarter to capture SAPT opportunities? Collaboration across discipline silos
Experience sharing between Operators, System Designers and Vendors
Collaboration & visibility on technology qualification
Transparency by Vendors on performance data & costs
Better use of integrated production modelling tools
Use of objective independent specialist resources
Management challenge has tended to be “Why SAPT?” Should soon change into “Why Not SAPT?”
Ian Ball – Produced Water Club, Aberdeen, 10/12/14
How will Operators build on success?
To learn more, please visit INTECSEA on the web and download the 2014 Subsea Processing Poster
http://www.intecsea.com/publications/posters
www.intecsea.com
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