CONTINUOUS PRODUCTION

Transcription

1 CONTINUOUS PRODUCTION

2 Continuous / 3 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. OIL WATER 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. 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. GAS SOLIDS 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. 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. 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.

3 4 / Continuous Continuous / 5 CONTINUOUS PRODUCTION, SOLID PROFITS MEETING YOUR OBJECTIVES 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. Photo: Statoil/ASA 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 FourPhase ensure continuous solids removal and solid-free flow enabling operators to optimize production: Operate at maximized well flow Meet production objectives INCREASE PRODUCTION Enhancing the performance of underperforming wells, with interventionless clean-up: Reinstate continuous production Gain more from less RESTORE PRODUCTION Extending 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 CONTINUOUS SOLIDS-FREE FLOW, PRODUCTION UPLIFT Maximize flow rates with continuous solids-free flow, minimize unplanned interventions and achieve significant production gains with FourPhase. FLOW RATE Before Disrupted Choke Back CT Intervention Cleanup Shut in Shut in After with FourPhase Continuous FLOW RATE Reinstating wellbore productivity in HPHT wells Kvitebjørn, Statoil Solids Removal System was successfully used in one of the most complex Snubbing Cleanout Operations ever done within Statoil. TIME TIME Expected Revenue Loss Expected Expected Additional Expected Disrupted Increased Total Photo: Harald Pettersen/Statoil

4 6 / Continuous Continuous / 7 OPTIMIZING YOUR WELL UNCOMPROMISED PRODUCTIVITY Combining years of specialist solids control experience with engineering innovation, FourPhase continually advance the technical capabilities and possibilities of well production management. We continuously measure and remove solids from the well, tune wellbore parameters and achieve optimal solidsfree flow in process equipment to deliver all the economic benefits of maximized production performance. FLOW RATE Most operator s objective is to produce as much as possible from the well without exceeding 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. Without DualFlow Unit Choke Back Solids Well With DualFlow Unit ASR TIME OUR UNIQUE APPROACH CONTINUOUS SEPARATION Continuously 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. REAL TIME MEASUREMENT Real time continuous solids measurement using online sand weighing technology with 0,1kg accuracy. CONTINUOUS PRODUCTION Enabling operators to continuously optimize well production at the maximum flow rate without the need to shut-in the well or undertake costly interventions. 365 days 27th of January 2014 marked a total of 365 continuous production days on the Gullfaks C, Statoil kg Daily solids production on the Gullfaks C, Statoil where Continuous production system with DualFlow unit is used.

5 8 / Continuous Continuous / 9 SOLIDS EXPERTS OUR SOLIDS REMOVAL SYSTEMS FourPhase s Continuous System is an integral part of the surface production process that enables continuous solids removal and ensures solids-free flow. 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 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. 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 COMPACT AND MODULAR A flexible, compact and modular system with: Small footprint Low weight Minimal logistical impact Vital to today s crowded rigs. The compact, pressure-powered DualFlow units with: Built-in redundancy Flexible design No moving parts Safe 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.

6 10 / Continuous Continuous / 11 SOLIDS REMOVAL SYSTEMS Continuous System Integral part of the surface production process SOLIDS-FREE FLOW FROM THE SANDFACE TO THE PROCESS PLANT Over 21 tons of solids removed in 14 wellbores with our DualFlow Unit continuously (Gullfaks C, 2013) FourPhase s Continuous System is an integral part of the surface production process that enables continuous solids removal and ensures solidsfree flow enabling operators to optimize production without costly and time-consuming CT/HWO cleanouts. Our Continuous 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 DIMENSIONS Height Width Depth Weight DIMENSIONS Height Width Depth Weight 328 cm 200 cm 200 cm 8,500 kg 120 cm 200 cm 200 cm 5,000 kg Solids Removal System Interventionless 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

7 12 / Continuous Continuous / 13 MULTIFUNCTIONAL SYSTEM UNITS Making it possible to easily adjust the well flow in real time. Our Continuous 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 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 cleanup 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 DECISIONS Information 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. X-Flow Choke Manifold X-Flow Choke Manifold More than just a manifold Surface Safety Valve (SSV) Remote operation and multiple applications Directional flow control Reversible flowpath Allows flowback from all manifold systems Integrated dual remote choke Process interlock system Well testing Well clean-ups Surface Safety Valve SingleFlow Unit Solids removal in High pressure wells Jetting Unit Minimal footprint maximum efficiency 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 2.0 x 2.0 meter footprint Efficient draining of solids from production separators

8 14 / Continuous Continuous / 15 A FIELD PROVEN TECHNOLOGY From the North Sea to the Middle East and beyond, FourPhase and its Continuous System are revolutionizing approaches to production, delivering increased production and revenues to operators. 5 μm Removal of solids down to 5 μm Alpha A22 ConocoPhillips Saudi Aramco Optimal and Zero Flaring on the Hasbah Field Solution One 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. Result Continuous production at optimal flow rates for Saudi Aramco whilst achieving zero flaring and no reported HSE incidents. FourPhase are now a valuable, longterm partner to Saudi Aramco providing continuous production and solids removal management. Operator in the North Sea Solids Removal from Oil Based Mud Solution Solution was found to perform a wellbore cleanout using Coiled Tubing, accompanied by a FourPhase 5K DualFlow unit, allowing separation of particles such as drilled solids, calcium carbonate, commercial clay, Micromax and Barite from the oil based mud. Result The wellbore cleanout and separation of solids from Oil Based Mud was a great operational success. The DualFlow unit showed good capacity and separation abilities on oil based mud. A total of 1074 kg of solids was separated throughout the operation. ConocoPhillips Tackling Emulsion and Chalk on Conoco s Eldfisk Alpha Field Solution FourPhase 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. Result FourPhase 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. CASE STUDY Statoil Turning The Tide on Solids Challenges on Gullfaks C Solution A 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. Result Benefits 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 Increased production is indicated by yellow, purple, pink and red Oil rates [Sm 3 /d] 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 0 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 Reference: Optimization of well performance by use of a semi-permanent dynamic desander By Asle Sandven / Ted Brueren MSc. SPE SMN European Sand Management Forum March 2014

9 FourPhase FourPhase 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 Aberdeen Wellheads Crescent Wellheads Ind. Est. Dyce Aberdeen AB21 7GA, UK Saudi Arabia IMSC Ltd. Partner P.O.Box-5169, Dammam Khalidiya, Dammam Bergen Hegglandsdalsvegen OS Norway mail@fourphase.com