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Hank Rawlins

Society of Petroleum Engineers
Society of Petroleum Engineers
Society of Petroleum Engineers Communications Specialist - Social Media

Enhanced Production Through Surface Facilities Sand Management

Hank Rawlins

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Primary funding is provided by
The SPE Foundation through member donations
and a contribution from Offshore Europe
The Society is grateful to those companies that allow their
professionals to serve as lecturers
Additional support provided by AIME
Society of Petroleum Engineers
Distinguished Lecturer Program
www.spe.org/dl
Society of Petroleum Engineers
Distinguished Lecturer Program
www.spe.org/dl
Dr. Hank Rawlins
Technical Director
Enhanced Production Through
Surface Facilities Sand Management
Hank Rawlins
hrawlins@eprocess-tech.com
Metallurgical Engineer (PhD, P.E.)
26 years experience
• Facilities Sand Management
• Produced Water Treatment
• Compact Separation Systems
Former Chair SPE Separations Tech Section (STTS)
Fifty-Seven Published Articles
Adjunct at Montana Tech University (Butte, MT)
Luxuriant Facial Hair Club for Scientists (2016)
3
Greetings from Butte, MT, USA
4
Pop: 33,500
Elev: 1700 m
Weather:
• Jan: -40º C
• Jul: 30º C
Montana: 380,800 km²
1.03 million pop.
Road Map
Sand Management Options
Facilities Sand Management
Five-Steps of Sand Management
1. Separation
2. Collection
3. Cleaning
4. Dewatering
5. Transport
The One Slide to Stay Awake For
Tech Paper References…
5
Training Module Outline
Two-Day SPE Course
6
Module Title
FSM-M1 Introduction to Facilities Sand Management
FSM-M2 The Nature of Solids
FSM-M3 Solids Handling
FSM-M4 Liquid Desander
FSM-M5 Multiphase Desander
FSM-M6 Wellhead Screen-Filters
FSM-M7 Separator Solids Removal and Cyclonic Jetting
FSM-M8 Sand Cleaning
FSM-M9 Solids Dewatering, Transport, and Disposal
FSM-M10 Subsea Sand Management
FSM-M11 Heavy Oil Sand Management

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Hank Rawlins

  • 1. Primary funding is provided by The SPE Foundation through member donations and a contribution from Offshore Europe The Society is grateful to those companies that allow their professionals to serve as lecturers Additional support provided by AIME Society of Petroleum Engineers Distinguished Lecturer Program www.spe.org/dl
  • 2. Society of Petroleum Engineers Distinguished Lecturer Program www.spe.org/dl Dr. Hank Rawlins Technical Director Enhanced Production Through Surface Facilities Sand Management
  • 3. Hank Rawlins hrawlins@eprocess-tech.com Metallurgical Engineer (PhD, P.E.) 26 years experience • Facilities Sand Management • Produced Water Treatment • Compact Separation Systems Former Chair SPE Separations Tech Section (STTS) Fifty-Seven Published Articles Adjunct at Montana Tech University (Butte, MT) Luxuriant Facial Hair Club for Scientists (2016) 3
  • 4. Greetings from Butte, MT, USA 4 Pop: 33,500 Elev: 1700 m Weather: • Jan: -40º C • Jul: 30º C Montana: 380,800 km² 1.03 million pop.
  • 5. Road Map Sand Management Options Facilities Sand Management Five-Steps of Sand Management 1. Separation 2. Collection 3. Cleaning 4. Dewatering 5. Transport The One Slide to Stay Awake For Tech Paper References… 5
  • 6. Training Module Outline Two-Day SPE Course 6 Module Title FSM-M1 Introduction to Facilities Sand Management FSM-M2 The Nature of Solids FSM-M3 Solids Handling FSM-M4 Liquid Desander FSM-M5 Multiphase Desander FSM-M6 Wellhead Screen-Filters FSM-M7 Separator Solids Removal and Cyclonic Jetting FSM-M8 Sand Cleaning FSM-M9 Solids Dewatering, Transport, and Disposal FSM-M10 Subsea Sand Management FSM-M11 Heavy Oil Sand Management
  • 7. Solids Production All oil & gas wells produce sand. • Now or at some point in future • Especially with water breakthrough • Small or large amounts and sizes 7 Sand Clay Water Oil Deepwater South China Sea North Sea Danish Sector Onshore Egypt Know what comes out of your well.
  • 8. What are Produced Solids? Inorganic, Insoluble Particulate Material • Not asphaltene, paraffin, wax, hydrate, or resin (organic) • Not precipitates (soluble) or scale (non-particulate) • Natural solids: from reservoir material • Artificial solids: corrosion debris, proppant, junk, etc. Primarily “sand” by classification • ISO/Wentworth “sand” from 63-2000 microns • Practical separation limit is 10 microns Solid particles separable in facilities equipment 8
  • 9. Sand Management Options 9 ProductionRate Cost (CAPEX + OPEX) Low High Low High Inclusionary Exclusionary Production Limits “moving target” Completions “not complete” Maintenance “not a shovel” Facilities Sand Management Don’t minimize production. 4 3 21
  • 10. Facilities Sand Management Facilities: Surface/subsea equipment for separation and energy addition Sand: Tiny loose pieces of rock Management: Handle with a degree of skill Not a waste stream exercise… … but a critical Flow Assurance issue 10
  • 11. Effects on Facilties Erosion • High velocity zones • Chokes, pipe, valves, deoilers, etc. Collection/Filling • Low velocity zones • Vessels, tanks, separators, float cells, etc. • Creates corrosion zones where solids collect Interference • Instruments plugged, valve range of motion, seals, swivels, any small orifices or gaps Oil-in-Water (OIW) Content • Increases OIW concentration • Stabilizes emulsions 11 Define what problem sand causes. Erosion Filling Plugging OIW
  • 12. Where to Remove Sand? 12 Solve the right problem. Wellhead Desanding Solids Jetting Produced Water Desanding Cleaning, Dewatering & Transport Wellstream Desanding . . Node 1 Node 2 Node 3 Node 4
  • 13. Five-Steps of Sand Management 13 Follow all the steps. Remove particles from fluid stream Centralize and remove from process Remove oil from sand Remove free liquids Bring to disposal SEPARATE COLLECT CLEAN DEWATER TRANSPORT
  • 14. Step 1: Separate Remove particles from fluid stream • Dilute, dispersed particles in fluid (oil + water + gas) • Solids must be separable • Continuous flow process Low Velocity Zones (Gravity) • Bottom of production separator Enhanced Separation • Cyclonic: Multiphase (Wellhead) or Produced Water Desander • Impact w/ Retention: Filters or Screens • Flotation: Attached to oil droplets Sand separation equipment is the smallest… • …compared to oil-water-gas separation 14 Focus on the methodology – not a piece of equipment.
  • 15. Unit Process: Separation 15 Sand Filter API 10K Australia 2013 Wellhead Desander API 5K Malaysia 2012 PW Desander ASME 150# US GoM 1999
  • 16. Step 2: Collect Gather separated solids to central location • Isolate from pressure and flow • Minimize letdown points • Remove from process without interrupting production Minimize volume of fluids with solids • Desander accumulator minimizes hydrocarbon ingress • Jetting systems: large amounts of process fluids Any vessel/tank - isolated, vented, and flushed • Batch process • Fill with clean water to aid cleaning and prevent packing/plugging 16
  • 17. Unit Process: Collection 17 Wellhead Desander Acc. ASME 1500#, 600 liter Malaysia 2011 Wellstream Desander Acc. ASME 900#, 108 liter Turkmenistan 2011 PW Desander Acc. (integral) ASME 150#, 65 liter (Graphic)
  • 18. Step 3: Clean Remove adsorbed oil from surface of particle • Not H2S, pyrophoric material, heavy metals, or NORM Clean to meet offshore discharge • <1 weight% oil-on-dry solids (OSPAR spec) • Offshore cleaning systems use batch cyclone-recirculation loop • Specialized systems use chemicals, heat, and/or biological agents Integrate cleaning action in all areas • Separation, collection, and transport • May eliminate need for specific cleaning station Cleaned sand is easer to dewater and transport 18
  • 19. Unit Process: Cleaning 19 Attrition Scrubbing System Floating Barge Venezuela 1997 Attrition Scrubbing System Deepwater Spar Malaysia 2014 Attrition Scrubbing System Fixed Platform Malaysia 2015
  • 20. Step 4: Dewater Removing free liquids associated with sand • Minimizes disposal volume • Up to 90% reduction in volume Open (non-hazardous) dewatering • Liquids to open drain, sand/vapors open to atmosphere • Hanging dewatering bag Closed (hazardous) dewatering • Liquids captured to closed drain, vapors captured to vent system, and solids not exposed to atmosphere or personnel • Screen-lined bin Dewatering bag/bin also transport device • Combined step with transport 20
  • 21. Unit Process: Dewatering Two-Stage System (Open) Desilter & Dewatering Bag Malaysia 2011 Enclosure System (Open) Dewatering Bin Austria 2006 DNV Transport (Closed) Dewatering Bin Saudi Arabia 2013 21
  • 22. Step 5: Transport Disposal site determines route & method Overboard discharge: • Transported by pipe as a slurry to caisson Landfill disposal: • Transported in dewatering bag or bin to landfill Slurry injection: • Transported by pipe as a slurry to injection pump Unique methods: • Add sand to road surface mix • Add sand to existing drill cuttings disposal • Grind smaller size prior to injection disposal • Bioremediation 22 Know where to put the sand.
  • 23. Unit Process: Transport 23 Slurry Injection Disposal Sand from PW System Australia 2007 Dewatering Bag to Skip Transport Wellhead Desander System Malaysia 2011 Dewatering Bin Transport Sand Jetting System Malaysia 2015
  • 24. Putting it all Together (OTC-24705) 24 Wellhead Desander, 1500# Solids D98 = 16 micron 600 liter Accumulator 10 Wellhead Desanders Retrofit into Well bay of Spar Three-year Re-completion Work Piping header from Accumulators Transport Slurry to Dewatering Or to Cleaning Station Collapsed Expandable Screens Completion and FSM Approach Separation Collection
  • 25. Continued (OTC-24705) 25 Four-Place Layout Desilter – Bulk Removal Dewater Bag – Final Removal Recirculation Scrubbing Design: 32 tons/day <1 wt. % oil on sand Piping header from Accumulators Transport Slurry to Dewatering Or to Cleaning Station Cleaning Dewatering Transport
  • 26. 26 Do You Know Sand Production? START HERE NO • Sample Flow Stream • Physical Analysis Remove Sand upstream of choke? YES Remove Sand before separator? Remove Sand in separator? Remove Sand from Produced Water? Wellhead Desander Wellstream Desander Cyclonic Jetting Produced Water Desander NO NO NO NO Use Other Means YES YES YES YES Accumulator Slurry Dewatering Disposal: • Overboard • Landfill • Injection • Other Sand Cleaning (Optional)
  • 27. The One Slide to Stay Awake For All oil and gas wells produce sand. 1. Know what comes out of your well. 2. Don’t minimize production. 3. Define what problem sand causes. 4. Solve the right problem. 5. Follow all the steps. 6. Focus on the methodology – not a piece of equipment. 7. Know where to put the sand! Facilities Sand Management into initial system • Add taps and blinds (and space) for future equipment • Add place for sand to go – don’t choke system • Ensure parts can have material upgrade in future • Spares management can be a philosophy but not the best 27
  • 28. Technical Paper References… (OnePetro papers in yellow) 1. SPE-27797: “Fluid Production Enhancement by Exploiting Sand Production” 2. SPE-63235: “How Can Sand Production Yield a Several-Fold Increase in Productivity: Experimental and Field Data” 3. SPE-28815: “The Separation of Solids and Liquids With Hydrocyclone-Based Technology for Water Treatment and Crude Processing” 4. SPE-185658: “Separating Solids First – Design and Operation of the Multiphase Desander” 5. Priestman et al., Trans IChemE: “The Design and Operation of Oil-Gas Production Separator Desanding Systems” 6. Lohne, Trans IChemE: “Separation of Solids From Produced Water Using Hydrocyclone Technology” 7. SPE-166118: “Design of a Cyclonic Solids Jetting Device and Slurry Transport System for Production Systems” 8. SPE-72999: “Design and Installation of a Sand Separation and Handling System for a Gulf of Mexico Oil Production Facility” 9. OTC-24705: “Upgrade of Spar Topsides with Comprehensive Facilities Sand Management System” 10.SPE-56812: “Generalization of API RP 14E for Erosive Service in Multiphase Production” 11.SPE-66577: “E&P Waste Management in the Orinoco Delta” 12.Jones et al., IPEC: “Discharge Practices and Standards for Offshore Operations around the World” 28
  • 29. Where to get more info? Connect on LinkedIn • FSM article each week on Tuesday (85 so far) • Material taken directly from FSM training course Get articles from OnePetro (www.onepetro.org) Take Facilities Sand Management two-day training course Future: SPE DL Webinar on FSM 29
  • 30. Society of Petroleum Engineers Distinguished Lecturer Program www.spe.org/dl 30 Your Feedback is Important Enter your section in the DL Evaluation Contest by completing the evaluation form for this presentation Visit SPE.org/dl #SPEDL