SPE 71536 Deployment of Multiphase Pumps on a North Sea Field

Emile Leporcher, SPE, TOTALFINAELF Exploration Norge, Alain Delaytermoz, SPE, Jean-Franois Renault, Alain Gerbier, TOTALFINAELF, Olivier Burger, TOTALFINAELF Exploration UK.
Copyright 2001, Society of Petroleum Engineers Inc. This paper was prepared for presentation at the 2001 SPE Annual Technical Conference and Exhibition held in New Orleans, Louisiana, 30 September3 October 2001. This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members. Papers presented at SPE meetings are subject to publication review by Editorial Committees of the Society of Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

ABSTRACT During the past years, the Oil and Gas industry has invested a lot of resources in the development of the multiphase technology (flow modelling, multiphase production equipment, fluid-related effects). The POSEIDON programme aimed at developing multiphase pumping based on the rotodynamic helico-axial design. This technology has been qualified with two tests on onshore fields. After an extensive comparison with conventional alternatives involving separation, compression, pumping, additional pipeline, it has been decided to install a multiphase boosting station on the offshore DUNBAR field in the North Sea. This paper will present a summary of the qualification tests, the Dunbar field case, the comparison between several export alternatives, the reasons for the selection, the export system over 22 km, the multiphase boosting station (two 4.5MW units) and installation related issues. Field experience after more than a year of operation will be discussed. INTRODUCTION For a period of time, multiphase technology focused only on flow modelling. Later, it was deemed likely that multiphase transport capabilities could be extended if technology could be developed to increase the transportation distances (horizontal as vertical as well). It was also estimated that such a scheme would be more reliable and easier to operate if the fluidrelated effects (such as hydrates, waxes, mineral deposits, etc) could be better controlled. In the frame of this vision, as early as mid-85, TOTALFINAELF has undertaken an extensive programme of development of multiphase technology components such as multiphase pumping and multiphase metering. Several twin-screw pumps were tested in

different fields with encouraging results. But the extension of the capabilities in terms of flow rate immediately demanded a new concept. By mid 85, TOTALFINAELF in association with IFP (Institut Franais du Ptrole) and Statoil launched the POSEIDON programme. This initiative aimed at developing the rotodynamic helico-axial pumping concept. This concept has been qualified, it is presently deployed in onshore or topsides applications as well as in deep offshore conditions. The largest individual capacity per pumping unit is in operation on the North Sea Offshore field of Dunbar. This paper delivers a summary of the qualification campaign which took place on several operated fields, and presents the case of DUNBAR operated in a higher pressure and flowrates domain as compared to the initially anticipated applications. The POSEIDON research and development programme received the financial support from the EU in the frame of the THERMIE Programme. SOME LESSONS FROM THE PAST FIELD TESTS A first prototype has been tested onshore in Tunisia. This first prototype had the following main mechanical features and design specifications. Main mechanical features: - Casing design pressure: 5000psi - Isostatic and subcritical shaft including 13 impellers (8X250 mm and 5X232 mm ) - Bearings: hydrodynamic and thrust bearing - Mechanical seals: single and compensated - Lubrication: incorporated and autonomous - Buffer tank of 4.5 m3 Main design specifications: - Suction total (gas+liquid) flowrates: 200m3/h - Suction pressure: 40 bar - Differential pressure: 40 bar - Suction GLR: 10 - Speed: from 3000 to 6000 rpm - Electrical driver power: 500 KW On the field, the pump was tested in the following conditions: - Suction total flowrates: 140-260 m3/h - Suction pressure: 8-15 bar - Differential pressure. 5-15 bar (max: 23 bar)

E. LEPORCHER, A DELAYTERMOZ, J.F. RENAULT, A. GERBIER, O. BURGER

SPE 71536

Power consumption in operations: 300 KW Speed: 3000-6000 rpm

static reservoir pressure. This second phase would require additional facilities on the wellhead platform to maintain fluid flow rates at a lower export pressure (see fig 4). Production principles In the HP mode, Dunbar and subsea satellite (Ellon and Grant) oil and gas productions are commingled and exported to the Alwyn North processing platform via the 16-inch multiphase pipeline. The average oil and gas flowrates are about 50000 blpd and 3 to 5 mmscmd with a low water content. The pressure at the central processing facilities is 70 bar. This set point requires about 125 bar at the inlet of the 16 line. According to the initial flow predictions, the wells could sustain the nominal flowrates until the end of 1999 (WHFP above 125 bar). Beyond this natural flow period, the production system would have to be adapted for exporting of Low Pressure (LP) flowing wells. Additional facilities for the transportation of the LP production from Dunbar to the central processing facilities were scheduled. This phase was originally defined as the installation of a new HP separator on the Dunbar platform, HP gas would be exported to the central facilities via a new 16 inch pipeline, HP liquids would be mixed with the LP wells fluids to be exported via the existing 16 inch multiphase pipeline operated at a lower pressure (arrival pressure of 30 bar). This concept would have generated the following major problems : - extensive and consequently expensive debottlenecking of the LP system on the central facilities because of the increase of LP process requirements, - unstable LP operation of the existing multiphase pipeline due to the changes of phase distribution and mass flowrates (slugging) with safety concern with respect to flaring and detrimental impact on process stability. - lack of flexibility to export increasing LP production. - complex operation of two multiphase pipelines in parallel with specific flow conditions (pressure and flowrates). New alternatives This analysis motivated investigations to suggest other alternatives restricted to Dunbar rather than extensive modifications on the central facilities and additional facilities on the Dunbar platform. Fig 5 shows two possible alternatives which would allow the multiphase export from Dunbar with the existing pipeline without modification of the facilities and/or of the operating conditions of the process system (processed gas kept at 70 bar); the boosting of the LP fluids could be contemplated on the Dunbar Wellhead platform as follows: - conventional approach : using a separator operated at low pressure, with liquids pumping and gas compression to export the LP wells fluids via the

A set of performance curves was established for several actual suction GLR from 5 to 10 v/v and for different suction pressures. The pump operated for more than 5000 hours, out of the initially-specified process domain, in low pressure conditions with slugging flows from gas-lifted wells. The technical feasibility of the concept was demonstrated. The comparison of the initial specifications with the domain of field tests put in evidence the efficiency and the high operational flexibility of the boosting device (see table 1). Before contemplating field installation, a further qualification test was performed over a long period of time on another onshore field in the South of France (Pecorade field) with a new prototype. This prototype was specified according to operational parameters which anticipated the tranfer of multiphase fluids over distances of 15-25 km in a relatively low pressure domain (see table 2 and fig 1). In addition, the lubricating system used process water as lubricant. The pump performed a programme of tests within specifications, in extreme conditions (see table 3) and a long-term endurance test. The campaign was successful to such an extent that the machine was maintained in operation till the end of 2000, nearly 6 years of operation. DUNBAR : The North sea field case General The Dunbar field is located 120 km North East of the Shetland Islands and 440 km from Aberdeen in 145 m of water depth. It is operated as a satellite of the Alwyn North Field located 22 km to the North East. The field consists of hydrocarbon reservoirs lying in Quadrant 3 of the UKCS (see fig 2). These fields are 100% owned and operated by TOTALFINAELF UK. The production started in December 1994. The Dunbar platform was initially designed as a wellhead platform and operated as a satellite facility from the Alwyn North central complex (see fig 3). Oil and gas treatment, oil export to Sullom Voe via the Brent pipeline system, gas export to St Fergus via the Frigg Transportation System are handled on ALWYN (NAB platform). The Alwyn North complex provides DUNBAR with electrical power via two 22 KV cables and with injection water via a 10 inch diameter pipeline. The initial development plan envisaged two main phases of production: a first period of natural flow (HP: High Pressure production mode) would deliver the fluids at sufficient pressure to be exported towards the central complex via a 16 inch multiphase pipeline, a second phase would involve a Low Pressure (LP) production mode when wells would lose their productivity because of watercut increase and loss of

SPE 71536

DEPLOYMENT OF MULTIPHASE ON A NORTH SEA FIELD

existing multiphase pipeline, keeping one multiphase pipeline in operation within the range of initial flow conditions, innovative alternative : using multiphase pumps to boost the LP wells directly into the multiphase pipeline.

Suction Pressure: between 50 and 70 bar in a first phase (possibly down to 20 bar at the end of the production) Discharge pressure: 125 bar

The WHFP profiles, the available flowrates versus the WHFP raised the question of the arrangement of the pumping station. Several arrangements were contemplated to achieve the export duty over the operational lifetime (See Fig 7: multiphase pumps arrangement). The deployment of a boosting device means that all the wells will flow at the pressure set point of the separator, wasting a large amount of valuable energy at the well head on the most productive wells. The second sketch shows an arrangement where the multiphase pumps are operated in a parallel mode. For these both alternatives, the manifolding is quite simple, but all wells are operated at low pressure downstream their choke. The final sketch shows a segregated operation of the wells according to their available FWHP. This alternative allows the use of the natural energy of the wells as long as possible, saving energy consumption on the multiphase pumps. This final segregated scheme proposal was eventually selected. Multiphase pumps can cope with a wide range of gas and liquid flowrates, of GVF and differential pressures. In addition, their design enables a fast change of their compression rotor ( full cartridge pull-out type) on the platform. This capability allows an easy matching of the design of the pump to the flow conditions. In order to minimize the electrical power consumption, a segregated arrangement was selected including 3 independent pumping units. Each pump would have its own domain of operation. Low pressure wells will be boosted from 70 barg to 125 barg for instance, while the lower LP wells would be boosted from 50 to 125 barg. Later a serial/parallel arrangement could be implemented for really low pressure wells (30barg assumption). The main specifications of the different components of the pumping station are shown on table 5. The presently deployed pumping station includes two pumping modules in parallel. Each one includes one process cooler, one buffer tank at the suction of each multiphase pump, one boosting unit (multiphase pump, gear box, electrical driver, frequency converter, lub and seal oil system, step-down transformer, anti-harmonic filters). Compression ratios and total suction flowrates were selected to fit with the distribution of the expected FHWP. Therefore the first unit was designed to boost 1071 m3/h of total fluid with an actual GLR of 3.35 from 50 to 125 barg, while the second unit was

These options were evaluated and compared to the initial phase 2 development in terms of weight and location of additional facilities, power consumption, investments. Table 4 presents the results of this comparison. The cost estimates are given in relation to the less expensive one. It appeared that the multiphase pump alternative was the most competitive in terms of investments and easiness of operation. The main concern of the management was the level of confidence in such a new technology. A detailed analysis of the results, learning curve of previously-performed fields tests, and analysis of the publicly known experience from other operators convinced the decision makers to select the multiphase pumps alternative to maintain the production plateau of Dunbar area. The first consequence of this decision was that no modifications of installations would be undertaken on the central complex, as no additional pipeline would be built. The development would thus focus on the selection and installation of the multiphase pumps on the wellhead platform. Specifications of the multiphase pumping station The field includes 5 individual reservoirs, which produce from two main geological layers (Statfjord and Brent). The reservoir depths are between 3430 and 3620m. Fluids were encountered between 554 and 575 bar at a temperature of 129133 C. The saturation pressure is 361 bar at 128 C. The GOR is 470 v/v at the saturation pressure. The stock tank oil density is 821 kg/m3, while the gas specific gravity is 0.82. Though fluids are produced from different reservoirs, they are quite similar. About 20 wells are producing (among them 3 are subsea completions). Their productivity ranges from 1000 to 10000 bopd with an average low watercut. During the natural flow plateau period, the wells were producing with an initial FWHP (Flowing Well Head Pressure) from 300 bar down to 125 bar (minimum pressure to export through the 16 inch pipeline). The WHFP general trend is presented on Fig 6. Fluid flow predictions and expected FWHP have determined the process specifications of the pumping station as follows : - Liquid flowrate: 12 000 m3/d (75000blpd) - Gas flowrate: 2 000 000 SCMD (70 mmscftd)

E. LEPORCHER, A DELAYTERMOZ, J.F. RENAULT, A. GERBIER, O. BURGER

SPE 71536

designed for a total suction fluid flowrate of 780 m3/h to be boosted from 70 to 125 barg. Fig 8 shows the operating envelope of an 8 stage multiphase pump. The two suction cooler units lower the temperature of the fluids from 100 C (FWHT: flowing wellhead temperature) down to 50C. This process decreases the suction GLR and reduces the compression power demand. The buffer tank is designed to damp the quick variations of the suction GLR. The electrical driver for each pump is a 4500KW induction motor. On the Dunbar platform, transformers reduce the voltage from 22 KV to 3.3KV. A frequency converter adjusts the motor speed according to the process and export requirements. Installation The pumps were installed during summer 99 (see fig 9a: module on the platform and fig 9b: components of the Multiphase pump module). Taking into account the weight constraints, this module was installed in cantilever, vertical arrangement of the pumps was selected for to reduce offset. After commissioning during fall 99, the pumps were started up in December 99. Lessons from two years of operation a.- Production Table 6 provides the forecasts of production for boosting over five years. The predictions have been established with the specific water cut increase of each well. Therefore, we observe that the percentage of boosted oil production increase from 20% to 84%. Such predictions require some operational flexibility. The working mode is presented on fig 10a, 10b and 10c for three different production situations: 1999-2000, 2000-2001, and 2001-2002. The pumps were started end of 1999 when only a few wells were reaching the natural flow limit. During this period, 7 wells were boosted on one pump only, the differential pressure requirement was low, the pump was run at its lower limit of stability, consuming 800-900KW, the suction was lowered at 90 bars on wells which still had 105 bar at the wellhead. This status shows that the pumps were installed just in time to maintain the flowrate according to the FWHP predictions. After 6 months of transition, each pump was operated alternatively with the full stream of the initial LP wells with a suction pressure of 70 bars. Since August 2000, both pumps were run in parallel at two different suction pressures. The first group of wells that was produced at 70 bars in 2000 is presently produced in the LLP header at 50

bars, a second group of wells is boosted via the second multiphase pump from 70 to 125 bar. In case of unavailability of one pump, the upstream manifolding of the pumps enables routing a maximum of flowrate through the available pump to maximize the oil production. Updated well production parameters are stored in a model. They are used for simulation purposes. The simulation of the routing of different wells through the pump allows maximizing the hydrocarbons export through the available production system. Multiphase pumps can be operated following different modes. The operator can set the speed to get a requested flowrate and subsequent suction pressure within the operating envelope of the pump (power limitation, overflow or low differential pressure through the pump). The pump can be torquecontrolled, in this case the speed is self-adjusted to keep a constant torque within the speed and power ranges (when the GLR rises, the speed increases and vice versa). The discharge pressure of the pump is governed by the pressure drop in the multiphase pipeline and the operating pressure of the receiving vessel at the outlet of the pipeline. During the startup, the suction pressure decreases when the speed of the pump ramps up, this pressure decrease will generate additional production from the wells and will be the main component of the differential pressure. The last modification will take place next summer when the second unit will receive a rotor with 12 impellers. In the future according to the behaviour of the wells, a third unit will be installed to operate in series with one existing unit to lower the suction pressure down to 20 bars. The expected behaviour of the wells and of the reservoir, the high initial GOR do not require any artificial-lift in the wells. In addition to this experience, it has to be outlined that the application of a temporary increased drawdown on the reservoir has accelerated the recovery of the nominal flowrate of wells after a long shutdown or work-over. b.- Technology During the commissioning some adjustments were performed on the ancillaries. The initial capacity of the seal oil system was under designed. Three accumulators were installed in more appropriate locations to maintain a full protection. The heat exchange capacity of the seal oil cooler located on the seal oil return line was initially under designed. For a while, the pump was operated at a lower velocity (5000rpm) till the replacement of the seal oil cooler. Some interferences were observed on the accelerometer of the gearbox. A more appropriate location of the accelerometer with additional frequency filters remedied this situation.

SPE 71536

DEPLOYMENT OF MULTIPHASE ON A NORTH SEA FIELD

During the first year, the operation of the multiphase pumps has been disrupted by the following problems: - After 800 hours of operation, a blistering phenomenon was observed on the carbon seal. After their replacement by resin impregnated carbon seals, no more problems was observed. - After six months of operation, the seal oil pumps failed very frequently because of fatigue. New pumps from a new supplier more familiar with the handling of low viscosity lub oil and high diferential pressures were deployed with success. These two units were the most powerful built at that date. From a process point of view, the machines met the specifications in accordance with the performance diagrams. The high speed pump, the gearbox, the electrical driver have operated with a good reliability, after the remediation of the previous described failures. The thermodynamic parameters of the fluids are quite modified during the boosting process: increase of pressure and of temperature. Under these conditions and because of the mixing of incompatible water upstream the pump, sulfate deposits took place both in the pump and in the downstream piping as well. One pump rotor had to be changed, a spare being available, the operation was performed in a minimum period of time. The pump shafts are vertical. The stabilizing of the shaft required the installation of a throttle bushing pressurized with an important flowrate of lubricating fluid. Some water has been encountered in the seal oil tank, due to unexpected condensation, a continuous blanketing with air instrument has been implemented to avoid this problem. CONCLUSIONS As a general conclusion from these different field experiences (onshore field tests, Dunbar field operation, etc), multiphase pumping is definitely an export system that can be deployed in several operational configurations. The first unit in Tunisia was designed for a differential pressure from 40 to 80 bar for GVF up to 10. It was successfully operated in a lower pressure domain with much higher GVF and very harsh flow conditions. The second unit was dedicated to a lower operational domain (7.5 - 22 bar), it included three bearings lubricated with water from the separation process. When the validation tests were terminated, the field operator maintained the prototype in operation to ease the gas export of the field. Dunbar case is quite specific because multiphase pumps are deployed in high pressure domain on gas-dominated system. But if we compare the Pecorade and the Dunbar thermodynamic conditions of operation, we observe that suction GVF are similar. It means that multiphase pumping can be deployed in a wide spectrum of operational conditions.

Compared to other alternatives of the initial complementary development, export systems deploying multiphase pumping stations are very competitive in terms of investments and operating costs. This technology has demonstrated its ability to replace export process systems using separators, pumps, compressors, flaring network, safety devices in relation with operation of pressurized vessels,etc In the Dunbar case, we may draw the more specific following conclusions: A multiphase boosting station including two pumping units of 4.5 MW each has been installed with success on a minimum manned platform in the North Sea. The wide range of operability of the machines has allowed their use as soon as maintaining the productivity of the wells has been required. A temporary use with excess of required differential pressure avoided the use of a recirculating device. The interchangeability of the compression rotor offers flexibility to adjust the process specifications to the operational needs. If upstream manifolding is designed to face expected and unexpected behaviour of the wells, multiphase boosting offers a mean to maintain the production plateau for a very long period of time. Usually, multiphase pumps are recommended to transfer multiphase fluids from artificial-lifted wells (gaslift for instance) to overcome the flow resistance of a transportation system to a central processing facility. In the case of Dunbar, the multiphase pumps have been deployed in a relatively high pressure operational domain. The specific flow and fluid conditions of this field show a case where multiphase pumping is the appropriate technology to maintain the production plateau. The overall hydraulic efficiency has been confirmed. In terms of costs, the previous general statement of cost competitiveness of the multiphase pumping alternative has been confirmed. For the Dunbar case, the modifications on the central complex have been avoided. Nomenclature blpd : barrel of liquid per day bopd : barrel of oil per day BSW : basic sediment and water CC : Central Complex HP : high pressure GOR : gas-oil ratio GLR : gas-liquid ratio GVF : gas volume fraction LP : low pressure LPP : lower low pressure MPP : multiphase pump(mpp) PF : Platform RPM : rotation per minute SCMD : standard cubic meter per day MSCMD : thousand of standard cubic meter per day

E. LEPORCHER, A DELAYTERMOZ, J.F. RENAULT, A. GERBIER, O. BURGER

SPE 71536

MMSCFTD : million of standard cubic feet per day UKCS : United Kingdom Continental Shelf WC : watercut WHFP : flowing wellhead pressure WHFT : flowing wellhead temperature Subscripts gas liquid oil Total water

= = = = =

gas phase liquid phase oil phase total water phase

ACKNOWLEDGEMENTS The authors thank TOTALFINAELF for permission to publish this paper. In addition specific thanks are addressed to Arnaud BREUILLAC and Eric FANOUILLAIRE from TOTALFINAELF Exploration UK who have delivered a huge amount of operational feedback that was impossible to report in totality in the present paper. SI Metric Conversion Factors bar 1.013 25* psi 6.894 757 bbl 1.589 873 B/D 6.624 471 cuft 2.831 685 cfd 1.179 869
*Conversion factor is exact.

E+05 = Pa E+00 = kPa E01 = m3 E03 = m3/h E02 = m3 E03 = m3/h

REFERENCES (1) J. Falcimaigne, P. Durando, M. Loupias, R. Vilagines : "Multiphase rotodynamic pumps extend their capabilities" paper SPE n 28882 presented at the 1994 European Petroleum Conference (Europec 1994 - London, october, 25-27, 1994). (2) P. Buvat: POSEIDON MULTIPHASE PUMP, Sidi El Itayem field tests, Tunisia, October 1992. (3) E. Leporcher Elf-Aquitaine, SPE, and S. Taiani, ElfAquitaine: Multiphase Pumping : The Lessons of LongTerm Field Testing SPE 30661 (4) P. Gie, P. Buvat, C. Bratu, P. Durando, Total Inst. Franais du Ptrole. Poseidon multiphase pump: Field tests results. 24th annu SPE et al offshore technol conf (Houston, 5/4-7/92) 1992 (OTC-7037; 7 refs) (5) A. Lafaille. CIE francaise des Ptroles. Poseidon: The multiphase boosting and transportation technology now reaching the pre-industrial stage. 7th SPE middle east oil show conf (SPE-20974). (6) M.P. Arnaudeau. Inst Franais du Ptrole. Development of a two-phase oil pumping system for evacuating subsea production without processing over a long distrance: Poseidon project. 20th annual SPE offshore technol. Conf. (OTC-88). (7) J. De Salis, C De Marolles, J. Falcimaigne, P. Durando. Sulzer Pumps: Inst. Franais du Ptrole. Multiphase pumping Operation & control. Annual SPE tech conf. (SPE-36591). (8) C. Bratu. Inst. Francais du Petrole. Two-phase pump transient behaviour. Annual SPE tech conf. SPE-30660 (9) J. Falcimaigne, P. Durando, M. Loupias, R. Vilagines. Inst. Francais du Petrole. Multiphase rotodynamic pumps extend their operation capabilities. SPE Europe Petrol conf. SPE-28882. (10) C. Bratu. Inst. Francais du Petrole. Rotodynamic twophase pump performances. 69th annu SPE tech. conf. SPE28516.

Suction Pressure (bar) Differential Pressure (bar) Total suction flowrate (m3/h) Suction GLR (v/v) Speed (rpm) Electrical motor power (kw)

Design 40 40 200 10 3000-6000 500

Tested 8-15 5-15 (max: 23) 140-260 5-20 3000-6000 300

Table 1: Comparison of design specifications with field tested domain of the P300 prototype

SPE 71536

DEPLOYMENT OF MULTIPHASE ON A NORTH SEA FIELD

Design Point Suction pressure (bar) Discharge pressure (bar) GVF (at suction condition) Total suction flowrate (m3/h) Speed (rpm) Hydraulic power (KW) 8,5 26 0,86 175 to 265 4600 5500 230-300

Working domain 6 to 16 to 35 0,66 to 0,91 100 to 365 3000 to 660 100 to 500

Table 2 : P302 design specifications (Pecorade field)

Suction pressure (bar ) Discharge pressure (bar) GVF (at suction condition) Total suction flowrate (m3/h) Speed (rpm) Shaft power (Kw)

Minimum 2 18 50 50 1800 50

Maximum 23 45 100 350 6600 600

Table 3: P302 testing domain at Pecorade Initial concept separator on Dunbar new line Dunbar-CC LP mod. on NAB 393 ton on CC 444 ton on Dunbar 25 km pipeline Dunbar PF CC weatherdeck X2.15 6+(9) MW CC HP flare, receiving facilities New concept 2+1 mpp 700 ton Dunbar cantilever X1 14 MW New concept separator 2 compressors 1 pump 1300 ton Dunbar cantilever X1.5 15 MW Dunbar flare, diverter line ? -

New equipment weight Location Capex comparison Power demand from CC Other upgrade(s) & modification(s) Dunbar demanning Phasing & flexibility

+ +

Table 4: Comparison of initial and new alternatives

E. LEPORCHER, A DELAYTERMOZ, J.F. RENAULT, A. GERBIER, O. BURGER

SPE 71536

Specifications of a 12 stage multiphase pump Type of Pump/Stages MPP 8/12 Total Suction fluid flow rate 1071m3/hr (37,000 BOPD) (at rated duty) Liquid/Gas Flow rate 246/825 m3/hr @ 3.35 GLR Suction Pressure 50 barg Discharge Pressure 125 barg Operating Speed Range 3500 to 6000 rpm Nominal Speed Range 5000-5200 rpm

Dunbar oil prod. Year 2000 2001 2002 2003 2004 26000 22000 11500 8500 2000

Dunbar boosted oil prod. 8000 12000 15000 14000 20000

Satellites oil prod. Bopd p >125 bar 6000 4000 3500 2500 2000

Tot. Oil prod. Av. Bopd 40000 38000 30000 25000 24000

Boosted Oil prod. P<125 bar 20% 31% 50% 55% 84%

Specifications of a 8 stage multiphase pump Type of Pump/Stages MPP 8/8 Total Suction flow (at rated 780m3/hr (27,000 BOPD) duty) Liquid/Gas Flow rate @ 2.07 254/526 m3/hr GLR Suction Pressure 70 barg Discharge Pressure 125 barg (WHFP) Operating Speed Range 3500 to 6000 rpm Nominal Speed Range 4500-4700 rpm

Table 6: 5-year predictions of boosting requirements

Specifications of the electrical motor Rated Output 4500 kW @ 1785 rpm Voltage 3.3 kV Frequency 50 hZ Nominal Speed 1504 rpm Motor weight (cooler incl.) 15.7 ton (dry)

Specifications of the step-down transformer Type KTAP/S 24 NA 6000 Rated Output 6000/1500/1500/1500/1500 Voltage ration 2000/1725/1725/1725/1725 Frequency 60 Hz Temperature Rise: Oil / 69 C /74 C Windings Weight (with Oil) 13.6 ton Cooling Oil Silicone Oil Table 5: Specifications of the main equipments of the Dunbar boosting station

SPE 71536

DEPLOYMENT OF MULTIPHASE ON A NORTH SEA FIELD

P(bar)
35

25

300k w

15 200kw 5 Working domain 100kw 10 20 30 40 50 60 Liqu id flow rate (m3 / h) 50 350 Total suction flow rate (m3 / h) 150 250 450

Fig 3: Alwyn-Dunbar infrastructure

Fig 1: Operating envelope of Pecorade pump

DUNBAR
Multi 16

Central Complex HP system 71b C111 LP system

HP wells Phase 1

HP wells LP wells Phase 2 (initial concept)

New 16 gas Multi 16

71b 31b C111

HP system

LP system

Fig 4: Initial development phasing

DUNBAR
Multi16

Central Complex HP system 71b C111 LP system

HP wells LP wells

Fig 2: Location of Dunbar field

HP wells LP wells

Multi 16

HP system 71b C111 LP system

Fig 5: Dunbar new alternatives

10

E. LEPORCHER, A DELAYTERMOZ, J.F. RENAULT, A. GERBIER, O. BURGER

SPE 71536

WHFP bar wellhead flowing pressure

126 106 70 50

range

1999
Fig 6: WHFP predictions
Conventional concept HP wells
16

2000

2003

Time

*Parallel* scheme HP wells

16

*Segregated* scheme HP wells

16

LP wells 1

LP wells 1

LP wells 1

LP wells 2

LP wells 2

LP wells 2

LP wells 3

LP wells 3

LP wells 3

Fig 7: Multiphase pumps arrangements

P (bar)
140 130 120 110 100 90 80 70 60 50 40 30 20 10 0 100 200 Liquid quid Flow Rate ( m3 / h )
5 00 70 0 9 00 1 10 0 1 30 0 1 5 00

5500 rpm 6100 kW 5700 kW 5000 rpm 5300 kW 4900 kW 4500 rpm 4500 kW 4100 kW 4000 rpm 3700 kW 3300 kW 2300 kW 2700 kW

1100 kW

1500 kW

1900 kW

300

360

Liquid and Gas Flow Rate at Suction ( m3 / h )

Fig 8: Operating envelope of Dunbar MPP 8 stages

SPE 71536

DEPLOYMENT OF MULTIPHASE ON A NORTH SEA FIELD

11

MPP module

Fig 9a: Platform layout with MPP module

mpp station

mpp, piping, electrical equipment

Piping

Complete module
Fig 9b: Multiphase pump module

12

E. LEPORCHER, A DELAYTERMOZ, J.F. RENAULT, A. GERBIER, O. BURGER

SPE 71536

HP header 130 bar Other wells Grant LP header 70 bar 3 wells (4500bopd+560mscmd)

8 stages GLR >10, 1300 m3/hr

mpp A mpp B

Test header

Test sep

12 stages GLR >10, 1300 m3/hr

16 export

Fig 10a: 1999-2000 operating configuration

HP header 130 bar Other wells

Grant 8 stages GLR >10, 1300 m3/hr

LP header ( 70 bar) 8wells:12500blpd+1375mscmd LLP header ( 50 bar) 8wells: 21700blpd+1400mscmd Test header
ELLON

mpp A mpp B
12 stages GLR >10, 1300 m3/hr

Test sep

16 export

Fig 10b: 2000-2001 operating configuration

HP header (~120 bar) 2 wells D5, Grant

12stages GLR >10, 1300 m3/hr

LP header (~ 75 bar) 11wells: 17000blpd+2600mscmd LLP header (~ 50 bar) 11 wells:27000blpd+1800mscmd

Test header ELLON

m pp A

m pp B
12 stages GLR ~6, 1300 m3/hr

Test sep 16 export

Fig 10c: 2001-2002 operating configuration