Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Explotación en aguas
profundas
Ricardo Rodríguez Canney
Ingeniero en minas, School of Mines of Colorado, Maestro
en Administración de Empresas por la Universidad de
Chicago.
Actualmente es Director de Inversiones en Tecnología
de Shell, USA.
Agradecemos la colaboración del Ing. Antonio Acuña
Rosado.
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Explotación en aguas profundas
Sistemas rígidos
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Plataformas de concreto
Sistemas flexibles
Torres atirantadas
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Explotación en aguas profundas
Torres articuladas
Sistemas flotantes
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Plataforma semisumergible
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Tuberías de conducción
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Explotación en aguas profundas
Torre Gamma
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Explotación en aguas profundas
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EL RETO FUTURO
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SHELL DEEPWATER
Las aguas profundas son un sitio para pioneros. Es un reto física, ambien-
tal y tecnológicamente. No hay luz, es frío y la presión es intensa. En la
superficie los fuertes vientos, las olas de más de 20 m y las fuertes co-
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Su visión y conocimiento de este universo hace que casi todas las ba-
rreras naturales produzcan un triunfo
La diferencia de Shell
Respeto cultural
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Explotación en aguas profundas
Innovaciones tecnológicas
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Explotación en aguas profundas
Experiencia tecnológica
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Impuso un récord al instalar las líneas de flujo más largas, desde el siste-
ma de producción submarino Mensa hasta la plataforma anfitriona a 108 km.
Moldear el futuro de las aguas profundas requiere una compañía que esté
a la vanguardia de la tecnología, que utilice efectivamente la fuerza de su
propia diversidad cultural y se comprometa a relacionarse exitosamente
con todos sus empleados.
Shell Deepwater sabe que en el futuro la demanda de hidrocarburos
continuará creciendo y que, además, es más grande el potencial de descu-
brimientos en aguas profundas comparado con aquellos en aguas poco
profundas. Con lo mejor en tecnología y el manejo más eficiente del pro-
yecto, los costos de desarrollarlo continuarán reduciéndose, de manera
que continuará incursionando en aguas cada vez más profundas.
1989, BULLWINKLE
412 metros,
Golfo de México, Estados Unidos,
instalación de la plataforma de acero más larga del mundo.
1993, DRAGUEN
275 metros,
Noruega,
estación elevadora de potencia multifase de Shell: mejoró el flujo
del pozo en un 50%.
1994, AUGER
872 metros,
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1994, TAHOE
4557 metros,
Golfo de México, Estados Unidos,
primer desarrollo submarino en el Golfo de México,
1995, ROCKY
544 metros,
Golfo de México, Estados Unidos (desarrollo submarino).
1996, TROLL
270 metros,
Noruega,
la estructura más grande movida a través de la faz de la Tierra.
Consiguió el récord mundial por el arreglo submarino más largo:
30 millas.
540 metros,
Golfo de México, Estados Unidos,
consiguió el record de producción de gas del Golfo de México.
1996, MARS
896 metros,
Golfo de México, Estados Unidos,
consiguió el récord mundial de producción en aguas profundas
(TLP).
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1996, POPEYE
610 metros,
Golfo de México, Estados Unidos,
logró 20 avances tecnológicos (desarrollo submarino).
1997, FOINAVEN
500 metros,
oeste de Shetland, UK (desarrollo submarino).
980 metros,
Golfo de México, Estados Unidos,
consiguió el récord mundial por producción en aguas profundas
(TLP).
1997, MENSA
1 615 metros,
Golfo de México, Estados Unidos,
consiguió el récord mundial por el arreglo submarino más largo.
1997, TROIKA
823 metros,
Golfo de México, Estados Unidos,
desarrollo submarino.
1998, SCHIEHALLION
400 metros,
oeste de Shetland, Reino Unido,
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1999, URSA
1 220 metros,
Golfo de México, Estados Unidos,
consiguió el récord mundial de producción en aguas profundas
desde un TLP.
1999, ANGUS
610 metros,
Golfo de México, Estados Unidos (desarrollo submarino).
1999, MACARONI
1 128 metros,
Golfo de México, Estados Unidos (desarrollo submarino).
1999, MARLIN
988 metros,
Golfo de México, Estados Unidos,
plataforma de piernas tensionadas.
2000, EUROPA
1 189 metros,
Golfo de México, Estados Unidos,
primer desarrollo de arreglo submarino a Mars TLP.
2001, BONGA
1 000 metros,
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2002, MALAMPAYA
850 metros,
Filipinas,
consiguió el récord mundial por el oleoducto más largo: 510 km
(desarrollo submarino).
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The advantages of a seabed oil processing system are many, the most
notable of which are as follows: When the oil pressure falls below its bubble
point, gas will break out. Pressure losses then increase and slugs formed
in the pipeline undulations can overload or even damage downstream
equipment. Downhole or multiphase pumping will prevent gas breakout
but seabed separation with single phase pumping is simpler, more reli-
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able, requires less power and does not require the well to be shut-in for
maintenance. Gas flows in a separate flowline under its own head. Pump-
ing the separated liquid overcomes the static back-pressure due to the
riser height and also flowline friction. The absence of the need to over-
come the head of seawater is an advantage as it significantly improves
drawdown from the reservoir and results in higher production rates and
extended field life. Increased step-out distances (50 km or more) and/or
greater working depths (1 000 m or more) are thus made practicable by
separating the gas from the liquid products on the seabed. CAPEX sav-
ings can therefore be made because seabed oil processing now makes it
possible to exploit deepwater fields without the need for additional plat-
forms. It is also feasible to extend the life of existing platforms by tying-in
satellite fields. Yet another benefit is the freeing of topside space.
The liquid products may be further separated within the seabed sys-
tem to re-injectproduced water back into the well from the seabed. Seabed
separation and re-injection of produced water increases oil line capacity,
alleviates hydrate formation problems, obviates the need for extensive water
treatment at the mother or host platform (thus freeing up more topsides
capacity for oil processing) and reduces overall power demand. In addi-
tion, the seabed injection of seawater, by means of booster pumps within
the separator module, is possible.
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lic methods of power and control need multiple interfaces, electrical sys-
tems are able to perform the same or even more tasks with the minimum
number of interfaces for power and only one for control. The cost of elec-
trical umbilicals is therefore much lower than for hydraulic umbilicals.
As with the oil processing system, the control system can be adapted to
suit the characteristics of a particular field and would typically have two
data processing units, the more powerful one within the module and the
other one on the platform so as to minimise data traffic between them.
Several alternative sensor systems are provided, with a control voting sys-
tem to increase reliability. Electrically powered systems were in use as
long ago as the early 1970s. At that time, Mr Alan Webb (who is now the
subsea electrical power consultant to Alpha Thames) worked on the Zakum
field (off Das Island) in the Persian Gulf. Although the electrical hydrocar-
bon processing equipment operated successfully underwater, the system
operation was compromised owing to the unreliability of the connectors
available in those days. Subsequently, Alan Webb invented the connector
which bears his name: The Hydro Webb Connector which has been devel-
oped by Alpha Thames Engineering Ltd and their licence partners,
HydroBond Engineering Ltd. This connector is highly reliable because it
eliminates the degradation of the filling oil due to the ingress of water
molecules induced by the high voltage which form tree-like formations of
conductive material. These "trees" grow progressively and ultimately lead
to electrical failure. In the Hydro Webb Connector, the connection cham-
ber is filled with oil that is pressure balanced to maintain it at the same
pressure as the ambient seawater. On making the connection, however,
the oil is replaced by air at atmospheric pressure. The three-phase con-
tacts then function in air and reliability is assured. The Hydro Webb Con-
nector was successfully tested by GEC Alsthom Engineering Systems Ltd
as part of their SPEED (Subsea Power Electrical Equipment Demon-
stration) trials. The connector operated at 11kV and 80% of its 1MVA load
capacity (this being the maximum available power from the trial equip-
ment) continuously for a period of five weeks.
The reliability of the system as a whole is underpinned by the ability
to retrieve the module to the surface and carry out maintenance on it in
factory conditions ashore.
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Support Structure.
Service Installation Equipment.
Docking Manifold.
Pipeline Connection System.
Retrievable Autonomous Modules.
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is also used to install any electrical cable and connectors that may be
required.
The Docking Manifold contains only static pipework and the lower
half of the Module Isolation Connector (MATE) which in turn only con-
tains static valves. These valves are actuated from the Processing Module
when it is installed.
The Pipeline Connection System connects the Docking Manifold to
the previously pulled in flowlines. This system is based on the proven CUSP
Connection System.
The recommended retrievable autonomous module is the ÆSOP (All-
Electric Seabed Oil Processing) module, configured to suit particular field
characteristics. All rotating/serviceable equipment is retrieved with the
module leaving only static equipment on the seabed.
A typical ÆSOP module has a footprint of up to 9 m by 4 m and is
approximately 6.2 m high. However, wherever field characteristics allow,
smaller modules are used e.g. 5 m by 4 m by 6 m. An ÆSOP module has
the following features:
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Ongoing Development
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Webb Connector has the potential to be developed for subsea use at higher
voltages and power ratings and it is to be uprated from its present 11kV.
The configuration of the prototype ÆSOP module has been adapted
to suit a particular oil field; the project programme provides for installa-
tion during 1999.
Comparisons
Examples 1 and 2
Examples 3 and 4
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Examples 5 and 6
Data
Actual field data has been used, taken from fields studied in the past, and
includes the production profiles expected as water cuts increase. For con-
fidentiality these data have been adjusted slightly, and applied to some-
what different field scenarios than those from which they originated.
The data are from typical fields. The same reservoir analysis has been
used throughout, which gave a GOR of around 300 SCF/BBL - a typical
North Sea value. The original field had a productivity index of 10 BPD/psi
and this value has been maintained throughout.
The same reservoir depth, pressure and temperature have also been
used throughout to ensure the production profile used is applicable to
all examples. Water depths and distances to shore and/or platforms are
those typical of some of the previous studies done for Clients by Alpha
Thames.
So, essentially, all that has been done is to take a typical North Sea
field, abstract its data, and apply it to three different field scenarios.
Methodology
The HYSYS program has been used in all examples. The latest version
has the facility to use pipeline segments that fairly well describe the parts
of the production system such as tubing, flowlines and risers. Using the
spreadsheet facility in HYSYS, it is easy to model constant productivity
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indices, vary water cuts, and adjust upstream variables, such as flowrates,
to deliver desired downstream values, such as pressures at the inlet to
production separators on land or on platforms. In all cases the downstream
pressures were kept to about 150 psia, recognising that to go any lower
would be undesirable from several points of view - recompression of
associated gas, recovery levels of oil and onward transmission pump power.
Process flow diagrams are shown for each of the six examples.
Despite the considerable power of the HYSYS program, it required a
considerable time for each of the many runs to converge. Each example
was run for water cuts ranging from zero to 90% by volume. The con-
verged run results were then captured by the "data recorder" facility and
transferred to a spreadsheet, from which the final curves were calcu-
lated.
The time taken to set up the overall model is well spent, since it is
now possible to test any Client’s field production scenarios with and with-
out subsea separation, overcoming the inevitable question of "how much
good will this new system do for me?".
Results
The ÆSOP subsea separation system uses a relatively simple canned electric
centrifugal pump to increase the pressure in the oil to drive it as far as is
necessary. There is obviously a trade off between the cost of the pump
and its power usage and the cost of the oil line in terms of its diameter. In
this study only a rudimentary optimisation has been done, but its results
generally show significant advantages for the subsea system.
Gas has to flow under its own head to the downstream facility and the
gas pipeline diameter often controls the total flowrate into the separator.
Attempts to pass further flow through the gas pipeline will cause choking.
The static head lost by the liquid from the seabed to the downstream
facility is often a significant fraction of the available flowing wellhead pres-
sure. By removing the greater part of this static back-pressure by means
of the subsea pump we can lower the flowing wellhead pressure by a sig-
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nificant amount. The reservoir can then be drawn down to a lower pres-
sure, thus producing more oil over the field life. Furthermore, in many
cases where the choke is fully open at the start of field life, the flowrate
can be increased by use of the subsea separator pump, which can improve
the field economics significantly.
Frictional pressure loss can also be serious in the case of long flowlines,
such as in Examples 5 and 6. By placing the subsea separator and pump
close to the wellheads the frictional losses due to multiphase flow in long
flowlines can be reduced.
Table 1 shows the effect of improved production rates and yield for
each of the three scenarios. The fraction increase in yield ranging from
19% for the extended reach case through 43% for the floater to 75% for
the distant field case.
Charts 1, 2 and 3 compare each pair of examples and show graphi-
cally the improvements made possible by subsea production.
The flow regime for multiphase is not always benign; slugging can occur
and hydrates can form. The single-phase flows resulting from subsea sepa-
ration largely overcome these obstacles.
Although the gas line must by nature contain some gas condensate
and liquid water, and, as the line temperature falls below the gas dewpoint
along the pipeline, wet hydrocarbon liquids will form and there will be a
risk of hydrates forming. But the amount of hydrate inhibitor that might
be required is considerably less than if the entire wet oil/gas flow had to be
treated. Also, in these examples (see Table 1), the hydrate formation tem-
peratures are rather low, partly due to the low pressure of subsea separa-
tion and partly due to the fluid composition; in the subsea separation ex-
amples, the hydrate formation temperatures are so close to that of the sea
that it might not prove necessary to use inhibitor at all, except possibly at
extended shutdown if the line is to be left pressurised.
The Phase Envelope for feed to Subsea Separator, taken from Ex-
ample 6, shows the hydrate curve for the multiphase subsea flow. Any
operating point above or to the left of the hydrate line risks the formation
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at all, could be supplied by a small umbilical laid with the pump power
cable.
The liquid line from the subsea separator contains negligible quanti-
ties of the lighter hydrocarbon gases most readily identified with hydrate
formation, so hydrates are not likely to be a problem in the liquid pipeline.
Thus, for hydrate control, the subsea separator is a better system
than any using multiphase delivery over long distances. Gas is separated
from the liquid close to the wellheads, where the flow temperature is still
well above the hydrate point.
Even were there to be hydrates formed, or wax deposited, the provi-
sion of two pipelines of similar diameter, for gas and liquids, make it pos-
sible to install "round-trip" pigging.
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Conclusions
The 3 scenarios presented are all real. Alpha Thames have at one time or
another been asked to consider each of them. Previously it has not been
possible to demonstrate how much extra yield can be obtained by using
subsea separation, although the capital and operating cost savings had
been appreciated.
Using a typical North Sea type oil with typical reservoir characteris-
tics, it has been possible to demonstrate, in each of three widely differing
scenarios, that subsea separation makes a significant improvement to field
economics. Other field types, reservoir characteristics and associated fa-
cilities are expected to show similar benefits.
The principles of the "AlphaPRIME" technology could also be applied
to multiphase systems and multiplexed systems. However, it is evident
that the need for all-electric systems has increased. Exploration in vari-
ous parts of the world has led to installations in deeper water and in sites
which are well away from existing platform facilities. Diverless, subsea
processing systems such as ÆSOP which are electrically powered and
controlled, and which have the advantages of an electrical rather than
hydraulic umbilical, therefore offer an attractive solution to the problems
which such sites present. Although at the forefront of technology, they are
less expensive to install and operate and are environmentally friendly be-
cause, at the end of field life, all components are retrievable for re-use or
recycling. Finally, subsea processing systems are also visually friendly from
coastal viewpoints.
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Acknowledgements
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