Download - Cyclo Tech
-
8/13/2019 Cyclo Tech
1/27
1
Total Sand ManagementExperiences from primary
separation through to disposal
Malcolm Corsie, Cyclotech Norway
-
8/13/2019 Cyclo Tech
2/27
2 1/26/2010
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
-
8/13/2019 Cyclo Tech
3/27
3 1/26/2010
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
-
8/13/2019 Cyclo Tech
4/27
4 1/26/2010
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?
-
8/13/2019 Cyclo Tech
5/27
5 1/26/2010
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)
-
8/13/2019 Cyclo Tech
6/27
6 1/26/2010
Problems come in many sizes..
-
8/13/2019 Cyclo Tech
7/27
7 1/26/2010
Sand Accumulation in the ProcessSystem Potential Removal Points
=areas to be covered in this presentation
-
8/13/2019 Cyclo Tech
8/27
8 1/26/2010
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)
Wellhead (Multiphase) Desanding
-
8/13/2019 Cyclo Tech
9/27
9 1/26/2010
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
-
8/13/2019 Cyclo Tech
10/27
10 1/26/2010
Wellhead (Multiphase) Desanding
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
-
8/13/2019 Cyclo Tech
11/27
11 1/26/2010
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
-
8/13/2019 Cyclo Tech
12/27
12 1/26/2010
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
-
8/13/2019 Cyclo Tech
13/27
13 1/26/2010
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.
-
8/13/2019 Cyclo Tech
14/27
14 1/26/2010
Desanding Cyclone Comparison
-
8/13/2019 Cyclo Tech
15/27
15 1/26/2010
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!
-
8/13/2019 Cyclo Tech
16/27
16 1/26/2010
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
-
8/13/2019 Cyclo Tech
17/27
17 1/26/2010
Sand Receiving & Cleaning
Usually three modes
of operation: Sand Receiving
Sand Cleaning
Sand Discharge
-
8/13/2019 Cyclo Tech
18/27
18 1/26/2010
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
-
8/13/2019 Cyclo Tech
19/27
19 1/26/2010
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..
-
8/13/2019 Cyclo Tech
20/27
20 1/26/2010
Sand Cleaning Case StudyWoodside Vincent
6,000 BPD capacity
Duplex SS
300# Rating
Automated & equipped with Sand
Bagging System
Discharge Specs: Oil on Sand