continuous production - fourphase · continuous production days on the gullfaks c, statoil. 174gk...
TRANSCRIPT
Continuous ProduCtion
Hundred_FourPhase1_RB.indd 1 20/02/2015 16:22
oiL
GAs
WAtEr
ProduCE MorE For LEss
FourPhase is revolutionizing the way produced solids are managed, enabling our clients to deliver a step change increase in production – while reducing the cost per barrel.
Our production solutions enable our customers to continuously remove solids from the well to significantly reduce the cost per barrel of production.
FourPhase plays an important role in the economic recovery of your oil and gas reserves.
iMProvinG FiELd EConoMiCs… rEduCinG ProduCtion Costs
Fact: we reduce production cost per barrel for solids producing wells.
Until now oil, gas and water have received the lion’s share of technical innovation. Effective solids management has too often been neglected despite its undeniable impact on production rates and well productivity.
No longer! We believe that continuous solids management holds the key. The efficient management of solids enables production engineers to tune well flow in real time.
We maximize solids-free production at a lower cost per barrel and enhance production performance. And we can prove it.
We are elevating produced solids to their rightful place as the fourth phase. In doing so we transform solids from a challenge to an opportunity. Continuous solids management reduces production costs, improves field economics and delivers more oil and gas from the reservoir to the refinery.
From the North Sea to the Middle East, as the solids control experts, FourPhase are transforming production performance and delivering increased revenues to operators.
in short, we know solids. soLids
Continuous Production / 3
Hundred_FourPhase1_RB.indd 2-3 20/02/2015 16:22
Continuous ProduCtion, soLid ProFits
Traditional approaches to solids control and flow management are often sporadic, costly and time-consuming.
Today, the risks associated with solids in the wellstream are controlled by choking back production to meet acceptable sand rates. Inevitably, this leads to solids build-up, well shut-ins and costly coiled tubing (CT) interventions.
All these factors have a significant impact on flow rates and, of course, the bottom line.
FourPhase ensure continuous solids removal and solids-free flow enabling operators to optimize production without costly and time-consuming well interventions, delivering increased production and solid profits. In the diagram below you can see the extra gains that can be achieved in a typical scenario where solids are present.
Continuous Production / 5 4 / Continuous Production
Photo: Harald Pettersen/Statoil
Photo: Statoil/ASA
Reinstating wellbore productivity in HPHT wellsKvitebjørn, StatoilSolids Removal System was successfully used in one of the most complex Snubbing Cleanout Operations ever done within Statoil.
Revenue
Loss
Expected
Production
Expected
Production
Disrupted
Production
FL
OW
RA
TE
FL
OW
RA
TE
TIME TIME
Expected
Production
Additional
Production
Expected
Production
Increased Total
Production
Choke Back
CT Intervention
Cleanup
Shut–in Shut–in
BeforeDisrupted Production
After – with FourPhaseContinuous Production
Continuous solids-free flow, ProduCtion uPLiFt
Maximize flow rates with continuous solids-free flow, minimize unplanned interventions and achieve significant production gains with FourPhase.
MEEtinG your oBjECtivEs
Continuous ProduCtionFourPhase ensure continuous solids removal and solid-free flow enabling operators to optimize production:■ Operate at maximized well flow■ Meet production objectives
inCrEAsE ProduCtionEnhancing the performance of underperforming wells, with interventionless clean-up: ■ Reinstate continuous production■ Gain more from less
rEstorE ProduCtionExtending the life of the well, protecting the reservoir, the wellbore and process equipment from solids build-up and long-term damage: ■ Optimize well performance■ Longer productivity and
improved economics
Hundred_FourPhase1_RB.indd 4-5 20/02/2015 16:23
We continuously measure and remove solids at the well, tune wellbore parameters and achieve optimal solids-free flow in process equipment to deliver all the economic benefits of maximized production performance.
oPtiMiZinG your WELL
Combining years of specialist solids control experience with engineering innovation, FourPhase continually advance the technical capabilities and possibilities of well production management.
Continuous sEPArAtionContinuously maintain optimum flow in the wellbore to prevent choking back production and to better manage solids; Continuously remove solids from the wellstream to ensure solids-free flow from the well.
Continuous MEAsurEMEntContinuously measuring, modeling and simulating wellbore and wellstream behavior using live and historic information, we track solids production, monitor trends and generate better decision-making information.
Continuous ProduCtionEnabling operators to continuously optimize well production at the maximum flow rate without the need to shut-in the well or undertake costly interventions.
Most operator’s objective is to produce as much as possible from the well without crossing acceptable sand rate (ASR) level. Typically, both well production and sand production increase. No longer a compromise with FourPhase, production increases while sand is held below the ASR level.
our uniquE APProACh
365 days27th of January 2014 marked a total of 365 continuous production days on the Gullfaks C, Statoil.
174 kgSolids Removal System has proved to be highly capable of separating heavy solids, including asphaltenes. A total of 174 kg of solids were separated throughout the operation in Ula, BP.
Continuous Production / 7 6 / Continuous Production
unCoMProMisEd ProduCtivity
FL
OW
RA
TE
TIME
Choke Back
Solids Production
Well Production
ASR
FL
OW
RA
TE
TIME
Choke Back
Solids Production
Well Production
ASR
With dualFlowWithout dualFlow
Hundred_FourPhase1_RB.indd 6-7 20/02/2015 16:23
soLids EXPErts
our soLids rEMovAL systEMs
Through our continuous collaboration with customers and fine-tuning of our system and through our flexibility in meeting changing real-world operator challenges, we provide a complete integrated production management solution.
Innovation, technology and smart production solutions have been the driving force behind the FourPhase ethos. Our engineers have designed, developed and improved technologies for solids removal systems for the oil and gas industry since 1997. Their technical expertise and exposure to the fourth phase challenges of operators worldwide has led to game-changing patents and repeat custom from the major players of today.
FourPhase’s Continuous Production System is an integral part of the surface production process that enables continuous solids removal and ensures solids-free flow.
CoMPACt And ModuLArA flexible, compact and modular system with:■ Small footprint■ Low weight■ Minimal logistical impactVital to today’s crowded rigs.
The compact, pressure-powered DualFlow units with:■ Built-in redundancy■ Flexible design■ No moving partsSafe and adaptable to all field conditions.
Whatever the operator’s specific solid control needs, FourPhase and our flexible, compact and modular solutions will meet them.
MEAsurE And ModEL Generates continuous, real-time, high resolution and direct measurements with innovative solid modeling and flow tuning for better production decisions.
BuiLt For ProduCtion■ Built to last production system that meets
the most demanding industry specifications■ Fast-track delivery, few modifications and speedy
installation – operational in a fraction of the time against traditional systems
Continuous Production / 9 8 / Continuous Production
Hundred_FourPhase1_RB.indd 8-9 20/02/2015 16:23
soLids rEMovAL systEMs
Continuous Production / 11 10 / Continuous Production
diMEnsions
Height 328 cm Width 200 cmDepth 200 cmWeight 8,500 kg
solids-free flow from the sAndFACE to thE ProCEss PLAnt
solids removal systemInterventionless clean-up
FourPhase’s Solids Removal System uses a unique patented and field proven technology to increase the performance of underperforming or shut-in wells with interventionless clean-up.
Our Solids Removal System is designed with focus on minimal logistical impact and with the greatest emphasis on safe and quick installation. The system lets you resolve the problem of solids production at the surface without the need for subsurface intervention. With space being a premium on many offshore installations our system is designed to be compact and easily installed, using a small footprint and requiring only occasional adaptations.
KiCK-start produCtion and inCrEAsE PErForMAnCE■ Eliminate the need for wellbore cleanout■ Avoid waiting for Coiled Tubing (CT) and hydraulic
workover equipment/campaigns■ Reduce downtime and extend life of the well■ Compact 2.0 x 2.0 meter footprint■ Meets and exceeds industry standards
Continuous Production systemIntegral part of the surface production process
FourPhase’s Continuous Production System is an integral part of the surface production process that enables continuous solids removal and ensures solids-free flow – enabling operators to optimize production without costly and time-consuming CT/HWO cleanouts. Our Continuous Production System is designed with focus on solids removal from multiple wells with remote access condition monitoring – providing operators with enhanced process monitoring and control.
The system integrates the measurement, modeling and removal of solids at the well and lets you optimize well production without interventions.
Continuous ProduCtion And MAXiMuM FLoW■ Measure, remove solids and tune the well to maximize
real-time production ■ Maximize well production■ Prevent solids build-up■ Eliminate need for wellbore cleanouts■ Online condition and performance monitoring■ Protect customer equipment ■ Reduce downtime ■ Reduce modifications■ Meets North Sea HSE standards
Over 21 tonsof solids removed in 14 wellbores with our DualFlow Unit – continuously (Gullfaks C, 2013)
diMEnsions
Height 120 cm Width 200 cmDepth 200 cmWeight 5,000 kg
Hundred_FourPhase1_RB.indd 10-11 20/02/2015 16:23
Continuous Production / 13 12 / Continuous Production
surface safety valve
X-Flow Choke Manifold X-Flow Choke Manifold More than just a manifold
■ Directional flow control■ Reversible flowpath■ Allows flowback from all manifold systems■ Integrated dual remote choke■ Process interlock system
singleFlow unit Solids removal in High pressure wells
■ 10kPSI unit designed for long-term production
■ Next generation hydrocyclone technology ■ For use in HPHT surface applications where
solids might be present during production or intervention clean-up applications
surface safety valve (ssv)Remote operation and multiple applications
■ Well testing■ Well clean-ups
jetting unit Minimal footprint – maximum efficiency
■ 2.0 x 2.0 meter footprint■ Efficient draining of solids from
production separators
MuLtiFunCtionAL systEM units
dualFlow unitMaking it possible to easily adjust the well flow in real time.
Our Continuous Production and Solids Removal Systems integrate the measurement, modeling and removal of solids at the well, enabling production engineers to fine tune the well flow in real time to deliver maximum solids-free production.
Our FourPhase experts have designed and built highly flexible and multifunctional systems to easily integrate with any offshore facility.
dualFlow unit Leading solids removal solution on the market
The DualFlow 5kPSI unit uses next generation hydrocyclone technology that was developed and engineered by FourPhase and is the leading solids removal solution on the market. The DualFlow is used in surface applications where solids might be present during production or intervention clean-up applications. The DualFlow design ensures continuous production because there are two vessels contained in one unit. One vessel can be isolated and flushed while production continues through the other vessel.
CoMPACt soLution WhErE sPACE is At A PrEMiuM■ Dynamic range 20 micron to 5 mm solids■ Inline solids flushing with no interruption to production■ Solids capacity 2 x 240 kg / 2 x 100 litre■ Online solids measurement and performance
monitoring■ 2.0 x 2.0 meter footprint■ Proven Efficiency 99.8%
real-time information for better quALity dECisionsInformation is monitored and logged locally, via control room or online.
Data logging system measures and records:■ Flow rate■ Pressure (six locations)■ Temperature■ Weight of solids removed■ Asset integrity of desander system
Valves are controlled and operated pneumatically for maximum safety and reliability.
Hundred_FourPhase1_RB.indd 12-13 20/02/2015 16:25
A FiELd ProvEn tEChnoLoGy
From the North Sea to the Middle East and beyond, FourPhase and its Continuous Production System are revolutionizing approaches to production, delivering increased production and revenues to operators.
14 / Continuous Production
statoilTurning The Tide on Solids Production Challenges on Gullfaks C
solutionA DualFlow unit containing two solids removal systems in one frame to meet space limitations on the Gullfaks C platform and to address years of solid production challenges in the field.
resultBenefits achieved ■ Operational - Less jetting work for operators - Reduced sand problems in process plant - Only one rigging needed■ Cost saving - Less need for CT sand clean out - More time for alternative CT operations■ Improved oil recovery - Higher flow rate (without exceeding ASR) - Optimized well performance
4000
01.Jan 21.Jan 10.feb 02.mar 22.mar 11.apr 01.mai 21.mai 10.jun 30.jun 20.jul 09.aug 29.aug 18.sep 08.okt
3500
3000
2500
2000
1500
1000
500
0
Oil
rate
s [S
m3 /d
]
CAsE study
saudi AramcoOptimal Production and Zero Flaring on the Hasbah Field
solutionOne FourPhase SingleFlow 10kPSI and three SingleFlow 5kPSI units for operation on Saudi Aramco’ Hasbah field. Saudi Aramco wished to stimulate wells for increased production while ensuring no well flowback after stimulation, and zero oil flaring. Previously, all well flowback effluent, consisting of gas, oil, water, oily solids and oil-water emulsions, had been flared leading to air and water pollution.
resultContinuous production at optimal flow rates for Saudi Aramco whilst achieving zero flaring and no reported HSE incidents. FourPhase are now a valuable, long-term partner to Saudi Aramco providing continuous production and solids removal management.
BP Removing 8.801kg of proppant on the Valhall IP Field
solutionA FourPhase solids removal system with a full flowback solution for the cleanout of Coiled Tubing and to address excessive amounts of solids and fracturing proppants. This was due to a plug slipping and blocked surface bleed lines on the flow line and surface equipment.
resultThe FourPhase solids removal system removed large amounts of solids – all separated efficiently and stored in appropriate slips – to enable fracturing operations to continue. 700 kg of proppants per hour were removed and a total of 8,801 kg. FourPhase will now supply two DualFlow units for future operations involving fracturing proppants with the goal of 1,400 kg removal per hour.
ConocoPhillipsTackling Emulsion and Chalk on Conoco’s Eldfisk Alpha Field
solutionFourPhase’s solid removal system, including the DualFlow 5kPSI desander and 15kPSI X-Flow Choke Manifold, was adopted to separate and remove solids and maintain wellbore parameters on Well 2/7. The well was a horizontal producer that had been producing formation solids and where chalk particles as small as 5 µm could be found.
resultFourPhase cleaned out emulsion in the tubing and the reservoir while also separating solids from the wellbore fluid. FourPhase also managed to separate chalk particles down to as little as 1 µm – unrivalled sensitivity. The A-22 is today producing with a stable well flow and – with emulsion and chalk particles no longer obstacles – has now been prioritized for production.
Increased production is indicated by yellow, purple, pink and red
Gimle scale squeeze C-33 w C-23 gas inj effect C-26 open after C-23 gas inj C-15 C – DHSV C-34 A CT C-32 CT C-3 sand cyclone C-19 – DHSV (*2) + sand cyclone C-2 sand cyclone C-27 – DHSV + sand cyclone “Do nothing”
5 μmRemoval of solids down to 5 μm – Alpha A22 ConocoPhillips
Reference: optimization of well performance by use of a semi-permanent dynamic desanderBy Asle Sandven / Ted Brueren MSc. SPE SMN European Sand Management Forum 26-27 March 2014
Continuous Production / 15
Hundred_FourPhase1_RB.indd 14-15 20/02/2015 16:25
FourPhaseFourPhase was founded in January 2012 and has offices in Aberdeen and Bergen. With a team averaging over 20 years experience in solids control, FourPhase is changing traditional approaches to oil & gas production, ensuring that solids and the control of them remains a key yet non-inhibiting element of the production process.
Above all, we remain the solid control experts, ensuring that the fourth phase receives as much focus as oil, gas and water and delivering improved field and well economics for all. As operators strive to demonstrate greater shareholder value and profitability through extending well life and optimizing production, FourPhase is leading the way.
Contact
AberdeenWellheads CrescentWellheads Ind. Est.DyceAberdeen AB21 7GA, UK
Saudi ArabiaIMSC Ltd. – PartnerP.O.Box-5169, Dammam 31422Khalidiya, Dammam
BergenHegglandsdalsvegen 2715200 OSNorway
Hundred_FourPhase1_RB.indd 16 20/02/2015 16:25