Lys Ark Yang 2012
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Transcript of Lys Ark Yang 2012
1 - Classification: Internal 2010-09-23
Challenges in offshore multiphase
viscous oil transport
Zhilin Yang
Guest lecture at NTNU, March 26, 2012
2 - Classification: Internal 2010-09-23
Outline
• Introduction
• Challenges for multiphase viscous oil transport
• Experimental programme and modeling of viscous oil-water flow
• Summary
Classification of viscous (heavy) oils
• American Petroleum Institute (API) gravity:
− Specific Gravity:
− At 60 ºF (15.5 ºC):
• Classification of viscous oils
3 - Classification: Internal 2010-09-23
oil
water
SG
141.5 131.5API gravity
SG
Light crude Medium oil Heavy crude Extra heavy crude
>31.1 ºAPI
(<870 kg/m3)
22.3 – 31.1 ºAPI
(870 – 920 kg/m3)
22.3 – 10 ºAPI
(920 – 1000 kg/m3)
<10 ºAPI
(> 1000 kg/m3)
Remaining World Oil Resources
4 - Classification: Internal 2010-09-23
Source: IEA
World Energy Outlook
5 - Classification: Internal 2010-09-23
0.0
50.0
100.0
150.0
200.0
250.0
300.0
350.0
400.0
2000 2010 2020 2030 2040 2050 2060 2070 2080 2090 2100
Years
Mill
bo
e/d
ay
Alternative Energy (mmboe/d)
Gas (mmboe/d)
Conv Oil (mmboe/d)
Heavy Oil (mmboe/d)
Coal (mmboe/d)
World Heavy Oil Basins
6 - Classification: Internal 2010-09-23
Statoil Heavy Oil areas
Heavy and Extra Heavy Oil Portfolio
7 - Classification: Internal 2010-09-23
API density scale
40o 30o 10o
Mariner
Oseberg
Grane
Alba
PetroCedeño
NAOSC
Peregrino
Bressay
HO / EHO
Statfjord
22 11 14 6+ 8.5
Troll
Viscosity (cp)* <1 10 1000 100000+
* Depending on temperature
Dalia
20o
19
Source HO definition: American Petroleum Institute
Light crude Medium oil Heavy crude Extra heavy crude
>31.1 ºAPI
(870 kg/m3)
22.3 – 31.1 ºAPI
(870 – 920 kg/m3)
22.3 – 10 ºAPI
(920 – 1000 kg/m3)
<10 ºAPI
(> 1000 kg/m3)
Statoil’s ambition for offshore multiphase
transport
8 - Classification: Internal 2010-09-23
Long distance transport ambitionFluid viscosity
0.1
1
10
100
1000
10000
100000
0 50 100 150 200 250 300 350 400 450 500 550 600
Transport distance [km]
Vis
co
sit
y@
20
C [
cP
]
50 km heavy oil
200 km oil
500 km gas-condensate
2009
2016+
Peregrino
Tyrihans
Snøhvit
Mikkel
Midgard
Troll
Kvitebjørn
Huldra
TOGI
Svale
Sygna
Vega
Peregrino
9 - Classification: Internal 2010-09-23
Brazil
BM-C-7
Brazil
BM-C-7
Rio de Janeiro
• Peregrino (BM-C-7) is located in the Southern
Campos Basin area, approximately 85 km
southeast of the nearest coastline (Cabo Frio).
• Water depth in Block BM-C-7 range from 95 to 135
meters.
• In the areas of planned field facilities, the water
depths will average 98 to 122 meters.
• Oil: 14 API
Peregrino Project • Statoil: Operator with 60% share
• Phase I: 1st oil in 29th of March, 2011
• Ambition for Phase II
− 20 km Tie-back
10 - Classification: Internal 2010-09-23
Technologies for long distance transport of
viscous oil
11 - Classification: Internal 2010-09-23
Pre-heating
0
5 000
10 000
15 000
20 000
25 000
0 20 40 60 80 100
Vis
cosity [
mP
a.s
]
Water Cut [%]
Water
continuous flow
Core annular
flow
Dilution: reduction of
oil viscosity
Major issues for water continuous flow
transport in offshore production pipeline
• Inversion point identification:
− Complex function of surface chemistry,
compositions of the crude and the way to
generate emulsion
• Emulsion viscosity
− Water-in-oil emulsion
− Oil-in-water emulsion
• Emulsion stability
− dP/dx for ST >> dP/dx (cw) for large oil
viscosity
• Shut-in and restart process
12 - Classification: Internal 2010-09-23
0
5
10
15
20
25
0 10 20 30 40 50 60 70
Water cut (%)
Rel.
vis
c.(
-)
No chemicals
With chemical
Pal&Rhodes model
PHASE
INVERSION
0
5
10
15
20
25
30
35
0 0.1 0.2 0.3 0.4 0.5
dP/
dx,
Pa/
m
Oil viscosity, Pa.s
90% WC - ST
90% WC -water continuous flow
95% WC - ST
95% WC -water continuous flow
Challenges from laboratory study to industrial
application - Inversion
13 - Classification: Internal 2010-09-23
• Three generally accepted mechanisms
− Normal to abnormal - Tightly packed
emulsion which spontaneously inverts at
the critical concentration
− Abnormal to normal – through the
formation of multiple emulsions
− Normal to abnormal – Through the
formation of a bicontinuous phase
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
0 % 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
Pre
ssu
re g
rad
ien
t re
lati
ve to
sin
gle
ph
ase
mo
del o
il [
-]
Watercut
Model oil - water
Crude oil - waterDW
DWDW
DW
ST
DW
DWDW
DO
STST
DWDW
STSTST
DODO
STSTST
DO
DO
DO
Challenges from laboratory study to industrial
applications - Emulsion
14 - Classification: Internal 2010-09-23
Different
emulsions
Lubrication of
unstable
emulsions
Emulsion
viscosity
variation
Challenges from laboratory study to industrial
application - Emulsion
• Emulsion viscosity for laminar flow
− Well predicted if WC <30%
− Complicated for WC >30%
15 - Classification: Internal 2010-09-23
0
1
2
3
4
5
6
7
0 10 20 30 40 50 60 70 80
Water cut (%)
Re
lative
vis
cosity (
-)
Rheometer data, 16800 1/s
Rheometer data, 1000 1/s
Data multiphase flow loop
(approx 900 1/s)
Inversion water cut
from DCR experiments
• Emulsion viscosity for turbulent flow
− Valle (2000)
− Brinkmann (1956)
− Importance for relative viscosity?
• Water viscosity uncertainty?
• Umix=1, D=0.3m: Re>105
• May not be an issue for large
pipe flow
16 - Classification: Internal 2010-09-23
2.5
1rel d
Challenges from laboratory study to industrial
application - Emulsion
Challenges from laboratory study to industrial
application - Emulsion
• Emulsion stability under flowing condition:
− Water continuous flow normally generated by ESP
− Droplet formation due to ESP
• Droplet size and its distribution
− Droplet coalescence in turbulent flow condition
• Time and length scale
• From lab scale to real pipeline (D and L)
− Identification of flow stratification
• From lab to real pipe system
• Critical condition; miminal Umix
for dispersed flow
17 - Classification: Internal 2010-09-23
0
5
10
15
20
25
30
35
0 0.1 0.2 0.3 0.4 0.5
dP/
dx,
Pa/
m
Oil viscosity, Pa.s
90% WC - ST
90% WC -water continuous flow
95% WC - ST
95% WC -water continuous flow
Challenges from laboratory study to industrial
application – shut-in and restart
• During the shut-in period
− Phase separation for unstable
emulsion
− Cooling process
− Status of fluid in pipeline before the
restart
• Phase distribution along pipe
• T distribution along pipe and
across the pipe section
18 - Classification: Internal 2010-09-23
Challenges from laboratory study to industrial
application – shut-in and restart
• Restart process by flushing with hot water
or oil
− Initial condition
− Front velocity
− Thermal non-equilibrium
• Natural convection in large
diameter pipe
19 - Classification: Internal 2010-09-23
Challenges from laboratory study to industrial
application – shut-in and restart
• CFD simulation of hot fluid propagation process:
20 - Classification: Internal 2010-09-23
How is this handled by classical 1D model?
Statoil’s response to these challenges
• Experimental study of different scales
− Systematic study of oil characterization – physical properties
− Small scale experiment: understanding emulsion and inversion
behavior:
• both model and crude oils
− Large scale experiment to mimic real production scenario
• Modeling of multiphase viscous flow
− CFD and classical 1D model
− From lab observations to field application - scaling
• Field tests
− Verification and validation
21 - Classification: Internal 2010-09-23
Statoil’s response to these challenges
• Current research activities - 2012
− Large scale experiment at Porsgrunn – real crude oils
• ESP, transport and separation
− Field tests at Peregrino-I
− Internal modeling work
− Experiment at SINTEF – model oil
− Cold shut-in and restart – TNO
− Modeling and experiment of multiphase viscous oil – Post-Doc and PhD at NTNU
− Viscous vertical flow –PhD at Nottingham University via TMF
− FACE program
− Summer internship, project work and Master Thesis work at NTNU
22 - Classification: Internal 2010-09-23
Large scale
experimental program
at Statoil
23 - Classification: Internal 2010-09-23
a
b
c
j
fd
e
h i
g
gas
oil
water
mixture
Baker Hughes 84-P75SXD Centurion
Centrifugal pump with 84 stages
Specifications of the experimental facility
24 - Classification: Internal 2010-09-23
Number of phases 3 (gas, oil, water)
Water flow rate 0-10 m3/h
Oil flow rate 0-15 m3/h
Liquid flow rate 0-25 m3/h
Gas flow rate Normal: GOR = 25
High: GOR = 100
Maximum pressure (except
ESP)
100 bar
Maximum pressure ESP 175 bar
Temperature range 4-110 ºC
Maximum temperature high
temp separation
170 ºC
Material Duplex Stainless steel 22Cr ( S31803)
Total liquid volume Ca 8.3 m3 (this test configuration)
Pipe internal diameter 0.05248 or 0.079m
Pipe length of test section 200 m
Pipe inclination -/+ 5 degrees
Main issues for modeling long distance
multiphase viscous oil flow • Emulsion formation
− Emulsion formation due to ESP: droplet size and its distribution
• Is the Hinze type of correlation applicable?
• Emulsion transportation (for unstable emulsion)
− Distance or time to reach fully-developed flow
• Droplet coalescence
− Flow regime transition – evolution
• Shut-in-and restart process
− What needs to be done?
• Classical 1D modeling
25 - Classification: Internal 2010-09-23
Summary
• The biggest challenge is:
− To find right people, to work on right problem, and to get right solution
• The key to solve this challenge is:
− Educate the people
• Welcome to work with Statoil
− Internship, Project, Master Thesis, PhD program, Post-Doc, and professional
career
26 - Classification: Internal 2010-09-23
27 - Classification: Internal 2011-08-17
Presentation title
Presenters name
Presenters title
E-mail address, tel: +00 00 00 00
www.statoil.com
Thank you