SealingProduced Water

complying with OSPAR &Environmental Legislation

Utilising USP technology

•Gib FitzGibbonSenior Applications EngineerJohn Crane Aberdeen

•Dr.Mike TurnerPrincipal TechnologistOil Plus

•Jim MalcolmGeneral ManagerJohn Crane North Sea Operations

Introductions

John Crane & Oil Plus are part of Smiths Group plc

Mike Turner

•PhD in Geochemistry and has worked in the oilindustry for 12 years

•Worked for Oil Plus for 8 years

•Has managed over 30 projects with Oil Plus andspecialises in flow assurance and management ofthe water cycle in the oil field

•Specific interests in scale management

Seal Selection Considerations

Safety - no risk to personnel

Environment - no harmful dischargesto atmosphere or sea

Technical - fit for purpose - reliable

Cost - acceptable value, taking intoaccount potential loss of production

COST OF CRUDE = $ 40 - $50 PER BARRELCOST OF DEFERRED OIL = $ 5 / £5 PER BARREL

COST OF WATER

COST OF INJECTED WATER = ?

COST OF LOSS OF P.W. INJECTIVITY = ?

SEAL SELECTION CRITICAL !

Potential cut back in production or possible shut down

Lost Production due to loss of PWI

No. of outages……………………………………………………………….8

Pump downtime per outage (days)………...……………………..11

Injection water lost (bbl/day)……….……………………….100,000

Total injection water lost (bbl)…………………………….8,800,000

Deferred oil (bbl)……………………………………………….5,866,667Based on a ratio of 1.5:1

Value of deferred oil (@ $4.60 per bbl)………….£18,792,943

ACTUAL CASE HISTORY

Seawater Safety Environment TechnicalTemperature 7-10 ºC

Pressures 5-15 barg

Clean, no solids

No hazardous substances

Water Injection

Single Seal usually OK

Water Injection

Produced Water Safety Environment TechnicalHot - up to 100 ºC

Pressures up to 45 bar g

Corrosive

Complex, unstable brines – Scale, Wax

Biologically ‘active’

Solids - µm to mm size

Pyrophoric when dried (FeS)

Toxic - added chemicals and naturalcomponents (heavy metals, radioactives)Characteristics may vary with time (newwells, injection water breakthrough)

OSPAR & Emission Management

“The prevention and reduction of produced water and oiland other substances contained therein, should be a priorityitem for continuous improvement in an operator'senvironmental management systems.”OSPAR Recommendation 2001/1 for the Management ofProduced Water from Offshore Installations• Total oil-in-water in 2006 reduced by 15% from 2000 level• Reduction from 40 to 30 mg/l by end 2006• BAT (best available technology) & BEP (best environmental practice)

to be applied

Other water (ballast, drainage) still limited to 40 ppmZero Emissions (corporate targets)

OSPAR & Emission Management

SME website - products required:•Products or services that improve safety or plant integrity•Products and services that will reduce customers costs

Consistent with their commitment to contribute to sustainable development, Shellcompanies have a systematic approach to health, safety and environmentalmanagement in order to achieve continuous performance improvement.

Our goals are simply stated - no accidents, no harm to people, and no damageto the environment.

Ensure all employees and others engaged on Canadian Natural’s behalf are awareof the need and informed of the requirements to protect the environment;Determine, evaluate and mitigate the environmental impacts of Canadian Natural’sbusiness during project planning, exploration, drilling, construction, operations anddecommissioning;Communicate with members of the public regarding Canadian Natural activities;Ensure that Canadian Natural operations comply with government regulations,industry guidelines and company policies and procedures concerning the protectionof the environment and public;Ensure appropriate waste and emission management programs are developed andimplementedUse energy and other resources efficiently at Canadian Natural operations.

Single SealSolids - Abrasion

Solids, Wax - Springs clogging

Solids, Wax - Hang up

VaporisationProduced Water

HC leak to environment

Corrosion of metal parts

Emulsions - unstable fluid film

Conventional Solution - the problems

A single seal is not suitableTechnically - not up to the job

Environmentally - HSE - OSPAR

Scaling

Conventional Solution - the problems

DRY TANDEM SEAL

HCemissions

Produced Water

Barrier Press. < Product

•Primary seal running on product - reduced life

•Leakage taken to drain

•Also pass through backup seal to atmosphere

•Emissions are managed and controlled

•But NOT ZERO

PI PT

DRAIN

WET TANDEM SEAL

Produced Water

HCemissions

Barrier Press. < Product

•Primary seal running on product - reduced life

•Leakage contained in vessel, drained offperiodically

•Emissions are managed and controlled

•But NOT ZERO

DOUBLE SEAL

Barrier Press. > Product

Product

Barrier fluid

Barrierfluid

Pressurised barrier systemBarrier pressure > productpressureBarrier leaks into pumpProduct cannot leak outZERO EMISSIONS

Summary

Single , Dry Tandem and Wet Tandem ALL have theirprimary seal in the product.

Tandem seals will control the emission of reservoir productsto some extent, but will still allow HC into the environment

The traditional safe, environmentally acceptable andtechnically reliable solution is a double seal. Guaranteed notto leak product to atmosphere.

However it can be expensive with high maintenance.

USP technology not only offers double seal integrity butsurpasses it in reliability, reduced maintenance and value.

Single SealSolids - Abrasion

Solids, Wax - Springs clogging

Solids, Wax - Hang up

VaporisationProduced Water

HC leak to environment

Corrosion of metal parts

Emulsions - unstable fluid film

Conventional Solution - the problems

A single seal is not suitableTechnically - not up to the job

Environmentally - HSE - OSPAR

Scaling

Produced Water Sealing Solutions

USP Technology

Rotation

Flow

Bar

rier f

luid

pre

ssur

e

Proc

ess

pres

sure

Max

imum

pres

sure

Produced Water Sealing Solutions USP Technology

Based on well-established dry gas seal technology

0 barseawater

40 barproduct

USP seal

Single seal

Plan 53 Seal System with Auto-top up tank

StoreCirculatePressuriseMonitorCondition

LTxVent

LG

PSV

PI

PSV

PI

PTx PTx PI

ACCUM

ULA

TOR

PTxPTxPI

AIRPUMP

AIRREG

‘Y’ TYPESTRAINER

DRIP TRAY

DRAIN1/2” NPT(F)

AIRPUMP

AIRREG

‘Y’ TYPESTRAINER

CROSS OVER VALVE

HIGH POINTVENTS

LOW POINTDRAINS

SEAL SEALPUMPSEAWATER SUPPLY &RETURN TO SEAL OILCOOLERS

FILL / INLINEFILTER BLOCK3/4” NPT (F)

LID

NRV

TRIP ALARM TRIPALARM

PLAN 53M

USP Seal for PW

Ultra reliableZero maintenanceSelf-recoveryGreatly reduced package costs 29% - 35%.Self-regulatingSelf-cleaningReduced heat generation & temperaturesSmall footprintSeal life: typically 3 years+