cyclo tech

8/13/2019 Cyclo Tech

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Total Sand ManagementExperiences from primary

separation through to disposal

Malcolm Corsie, Cyclotech Norway


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Items to be covered during this presentation:

Cyclotech Company Update

What is Sand and why is it a problem?

Sand Accumulation in Process and Produced Water Systems

Sand Removal Options

Wellhead (Multiphase) Desanding

Produced Water Desanding

Sand Cleaning

Sand Disposal

Cyclotech R&D Focus on Sand

Topics


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In November 2009 Cyclotech Group of Companies was

purchased by MI SWACO

Cyclotech now part of MI SWACOs Production Technologies Group

Cyclotech now work alongside Epcon technology within the ProductionTechnologies Group

Business as usual!

Cyclotech company update


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Sand generally means ALL types of production solids

Proppant:

D98 ~ 400 - 1200 microns, hard ceramic beads, s.g. 2.6

Sand:

D98 > 100 microns, hard silica, angular shapes, s.g. 2.6

Chalk:

D98 > 5 microns, absorbent, amorphous, soft, almost neutrally buoyant

Scale:

similar to chalk but wide range of sizes

Corrosion Products: wide range of sizes, hard, angular, s.g. 4.0

Abnormal:

Casing fragments, Drill cuttings , spanners, gloves etc, range of sizes

What is sand?


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Why is sand a problem?

Solids Production can block and erode equipment and

pipework Can be a major contributor to production OPEX

Downhole Solids exclusion not always possible and can fail

Impacts Process Availability

Compromises System Integrity

Safety

Environmental (not forgetting carry-over of oil-wetted solids)


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Problems come in many sizes..


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Sand Accumulation in the ProcessSystem Potential Removal Points

=areas to be covered in this presentation


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Definition

Desanding a Multiphase Flow Stream

Upstream of Choke - High Pressure

Ratings (up to 15k psi)

Production / Test manifold - Lower

Pressure, Higher Capacity

Applications

Well Operations Drilling, Well

workover, proppant flowback

Production Choke Protection(upstream of choke), Manifold

(downstream of choke)



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Principle of Operation

Solids separated by spinning flow

within cyclone insert

Separated solids collect in lower

solids accumulator

Desanded multiphase flow exits

through upper overflow nozzle

Solids accumulator periodically

purged: isolate, vent, flush, re-

pressurise, de-isolate

Cyclone operation independent ofsolids accumulator purge process

Wellhead (Multiphase) Desanding - Cont


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The Pros

Effective removal of problematic solids at earliest point of process

Minimises equipment damage and downstream solids accumulation

Removed sand is generally still water-wetted and in some cases can bedischarged straight to sea

Effective solids removal performance with d98 removal generally below 80

microns and in some cases as low as 10 microns Use of advanced ceramics to ensure solids stream never encounters pressure

vessel wall

The Cons

Tall

Heavy and expensive, if used to treat total production rate, so generally bestsuited to single (problematical) well application

High design pressures


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Design conditions 120MMSCD gas, 1000 BPD liquid

Design pressure 15k psi rated

WDC-200 (8) cyclone insert

Manual Operation Well work overoperations

Performance: 20 mic to 25mm @Pressure Drop = 3 bar

Wellhead Desanding Case StudyShell Shearwater


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Equipment Protection

Blockage of heat exchangers etc.

Erosion of Deoiling Hydrocyclones,

pipework, control valves, pumps etc.

Oil or produced water

Large Diameter MC or UC Desanding

cyclone

Produced Water and PWRI

Sustain injectivity

Cut size sub-10 to 25+ microns Produced water, aquifer water,

seawater

10, 25, 50 & 100mm diameter MC

cyclones

Produced Water DesandingHydrocyclones


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Different Cyclones for DifferentSolids

MC-10F : ULTRA FINE Solids removal (3 -5 mic)

Duty: ultra fine particulate removal

MC-25F : Fine Solids removal (5 -10 mic)

Duty: Fines (silt) removal

MC-25 : Fine Solids Removal (10 - 20 mic)

Duty: Water Polishing, Intensive Sand CleaningMC-50 : Standard Sand Removal (20 - 40 mic)

Duty: PW Desanding, PWRI, Sand Cleaning

MC-100 : Coarse Sand Removal (40+ mic)

Duty: Equipment Protection

BUT.


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Desanding Cyclone Comparison


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Desanding HydrocyclonesConsiderations

Care should be taken when selecting required solids cutsize

for any given system Smaller cyclones require larger pressure vessels and therefore larger system

Balance between cutsize and system robustness shouldalways be evaluated

Maximum expected particle size and maximum solids loading should also be

taken into account not just solids d50 size

Focus should always be on removal of problematic solids

Often smaller fines will pass right through system

Solids which drop out in main production separator are generally large and arethe ones that cause downstream erosion

Finally remember once solids have been removed, youhave to do something with them!


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Desanding Cyclone Case StudyBP Schiehallion

Design conditions 220,000

BPD liquid Design pressure 300#

Replaced Duty/Standby Filters

Performance: d98 15 microns at 2.5bar DP


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Sand Receiving & Cleaning

Usually three modes

of operation: Sand Receiving

Sand Cleaning

Sand Discharge


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Sand Receiving & Cleaning

Generally uses a combined Desanding / Accumulator

Vessel;

Same equipment used to receive separator jetting waterand for sand cleaning proposes;

Uses erosion resistant materials (ceramic) in high wearareas (ie cyclones and SandScape ejector);

System designed to be robust to deal with elevated sandlevels during initial jetting operations (if traditional

jetting system used);

Solids cleaned to a level suitable for onward disposal

(usually less than 1%w

/w oil-on-solids).

BUT


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Sand Cleaning Considerations

Cleaning loop will require similar pressure drop to removal

loop to ensure solids are held within system

Critical that clean water is always taken in and dirty (oily)water always removed from loop

Sand cleaning requires clean water input..


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Sand Cleaning Case StudyWoodside Vincent

6,000 BPD capacity

Duplex SS

300# Rating

Automated & equipped with Sand

Bagging System

Discharge Specs: Oil on Sand

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