new technology application - lbcg · pdf filenew technology application cost reduction while...
TRANSCRIPT
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9/10/2015
New Technology Application Cost Reduction while Increasing Operational Efficiency
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Slide 2
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The Double-Edged Sword of Technology
Petroleum: Shale Production vs. Rig Count
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Cost Saving Innovations
44%
44%
More Efficient Operations Get more out of existing assets Optimize exiting production Recover more oil
Sustainable Cost Reductions Technology innovations Reduce capital project costs Reduce operating costs
Tanks Compact Separation
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Technology Application - Onshore Facilities Cost Saving Opportunities
¾ New Facilities
9 CAPEX reduction
9 Separation challenges
¾ Debottlenecking Existing Infrastructure
9 Increased production or new
well tie-ins
9 Gain in incremental revenue
with residual oil recovery
9 Special solutions
9 Retrofit applications
9 Heavy oil
9 Chemical EOR
9 Downhole separation
¾ Water Reuse
9 Produced Water
9 Flowback Water
Special Separation Solutions
Oil
Water
Sand & Solids
Separator Internals
Gas
Secondary Separation
InLine Technologies
Cyclonic Separation
High Efficiency Gas Scrubbing
1
2
3
Bulk- Oil Water Separation
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6
Compact cyclonic separation
• Stokes
d
dcss
gdv
PUU
18*2 �
ͻ Swirling flow Î enhanced gravity
gaG
Conventional vessel separation
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Sand production • Flow line clogging • Erosion of production choke and
upstream facilities • Accumulation in separator vessels • Continuous monitoring and safety
supervision • Intervention & maintenance
Flowback and Production Sands
1 Oil
Water
Sand & Solids
Gas
Cyclonic Separation 1
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Cyclonic Sand Separation – Wellhead Desander
Gravity base Cyclonic
Inlet Single/Multi phase flow + sand
Sand outlet Concentrated slurry, to accumulation vessel
Liquid outlet
Cyclonic technology proven and applied in the most demanding environments
Conventional Sand-trap
Cyclonic Sand Separation
dF
gF
Inlet
Inlet
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9 Drill-out, Flowback & Production operations
9 >95% Sand removal
9 Compare conventional with cyclonic separation
9 Controlled test criteria
9 Measure/Sample solids
Application at unconventional shale
Wellhead Desander
Conventional Cyclonic
Sand volume/mass measurement
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Solids removal - Wellhead Desander (10K psi)
Operator’s benefit ͻ Avoids costly repairs & throwaways to downstream
equipment due to erosion ͻ Eliminates solids carryover in water & oil streams
after separator ͻ Accelerates the move to a Productions stage ͻ Avoids operational slowdowns and increases safety
Karnes County, Eagleford TX
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ͻ Desander unit is connected directly to the wellhead - sole sand separation unit ͻ Samples are constantly taken every hour, at upstream and downstream locations
of the unit to monitor its performance
Wellhead Desander Performance – Permian Lea County, Permian TX
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12 9/10/2015
Before and after Desander application Wellhead Desander Performance
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13 9/10/2015
ͻ Current practice of using two Sand-Traps per operation ͻ Cost savings show, removal of one Sand-Trap and use of the Desander along with the eliminated
costs it brings by efficient separation ͻ Single well, Desanding related, approximately 10 days in durations
Value provided Case 1 : Dual Sand trap Scenario Permian Basin
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14 9/10/2015
Gonzales County, TX Wellhead Desander Performance – Eagleford
Gonzales County, Case History - II
Sand Separation Efficiency >99%
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Bulk Oil Water Separation 2 InLine Liquid-Liquid Separation
Size reduction ~50 times
Size comparison, gravity vs. cyclonic liquid-liquid separation
Conventional gravity separator
Inline DeWaterer
ͻ Removes oil from water ͻ Compact and Mobile – “Facility on a Skid” ͻ High separation efficiency, >90% reduction
in the hydrocarbon content ͻ Proven cyclonic technology powered by
the operating flow (<50 PSI) ͻ Small footprint, easy to install; once setup,
it operates with minimal maintenance
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16 9/10/2015
Production DeWaterer – Applications Production – Recover More Oil
SWD – Accommodate More Water SWD – Facility on a SKID
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17 9/10/2015
Production Facility - EOR Case History - Central Texas, 110Kbbls/day
Annual Savings $2.4M
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18 9/10/2015
Production/Disposal Facility Pilot Case History – Delaware Permian Basin , 4Kbbls/day
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19 9/10/2015
Cost Savings - Dewaterer
*50K bbls/day Facility & $55/bbl Oil Price
Advantages
Higher oil recovery
Compact Capex and Opex Savings
No Moving Parts
No Solids Accumulation
Maintenance Free
(%)
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Produced and Flowback Water Reuse Understanding the water lifecycle economics and the end use is critical to technology selection
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ͻ Recover residual oil ͻ Compact mechanical
separation ͻ Significant reduction in
Bacteria ͻ Cost savings on Biocide ͻ Reduced load on
subsequent unit processes
Uinta Basin
Oil and Grease Effect on Bacteria
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Total Suspended Solids
Particle Size Effect
> 1/3 Pore Throat Bridge Instantly
1/3 to 1/7 Pore Throat Deeper Invasion
<1/7 Pore Throat Non- Damaging
Courtesy : www.bakerhughes.com
ͻ Solids in oilfield water: ͻ Suspended Solids ͻ Sand, Silt, Clays, Humic Acid, Fulvic
Acid, Microorganisms ͻ Colloidal Particles ͻ Microorganism, Sand, Clays ͻ Dissolved Substances ͻ Cations, Anions, Organic Matter,
Gases
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Inline Compact Desilting Technologies > 95% Solid removal (>10Microns size)
Total Suspended Solids
SPE : 165085
Cyclonic for Solids Removal
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Why Cross-Link?
Low cost Ease of use High viscosity Fluid recovery
Why Treat
Interference with CXL Premature viscosity Fluid Degradation
Frac
Flu
id S
tabi
lity
Boron Levels
30 2010
2013 60
• Boron in produced water
• Concentration Range
• 10-200mg/ltr
• Difficult to remove
Paradigm Shift
Boron – A Critical Component
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Removal of special constituents
Stages in the water treatment process
Boron – A Critical Component
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High Efficiency : NF and RO
26
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Conclusion
• New technology : Adapting will only make them more efficient and dynamic
• Near-term impact – Low hanging fruit – Immediate impact on CAPEX/OPEX
• Innovation in the sector is increasing • Risk Averse • Few early adaptors
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Thanks