WO2014031728A1 - System and method for separating fluid produced from a wellbore - Google Patents

System and method for separating fluid produced from a wellbore Download PDF

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Publication number
WO2014031728A1
WO2014031728A1 PCT/US2013/055957 US2013055957W WO2014031728A1 WO 2014031728 A1 WO2014031728 A1 WO 2014031728A1 US 2013055957 W US2013055957 W US 2013055957W WO 2014031728 A1 WO2014031728 A1 WO 2014031728A1
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WO
WIPO (PCT)
Prior art keywords
flowline
liquid
fluid
separator
manifold
Prior art date
Application number
PCT/US2013/055957
Other languages
French (fr)
Inventor
James Raymond Hale
Original Assignee
Shell Oil Company
Shell Internationale Research Maatschappij B.V.
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Filing date
Publication date
Application filed by Shell Oil Company, Shell Internationale Research Maatschappij B.V. filed Critical Shell Oil Company
Publication of WO2014031728A1 publication Critical patent/WO2014031728A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH OR ROCK DRILLING; MINING
    • E21BEARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/34Arrangements for separating materials produced by the well
    • E21B43/36Underwater separating arrangements

Definitions

  • the present disclosure relates generally to the production of fluid from a wellbore. More specifically, the present disclosure relates to techniques for separating fluid, such as gas and hydrocarbons, from produced fluids.
  • Wellbores are drilled into the earth to locate and produce valuable hydrocarbons.
  • Land or water based rigs are positioned about the wellbores to retrieve downhole fluid from subsurface reservoirs.
  • Various devices such as casing, downhole tubing, pumps, manifolds, valves and other fluid control devices, may be positioned about a wellsite and/or deployed into the wellbore to facilitate production of downhole fluids.
  • fluids such as water, oil, gases and other downhole fluids, may be produced from the wellbores.
  • subsea tubing is extended from a surface platform to a subsea wellbore for transporting fluids produced from the wellbore to the surface.
  • Various devices such as pigs, pumps, etc., may be positioned along the tubing to facilitate the flow of fluids to the surface. Examples of equipment that may be used are provided in US Patent Nos. 4844165 and 6926504.
  • separators may be positioned along the tubing and/or fluidly connected to fluid control devices at the wellbore to separate components of the produced fluids. Examples of separators are provided US Patent No. 4139352. Some separation techniques involve the use of separate flowlines for separate fluids. Examples of flowline separation techniques are shown in PCT Patent Application No. 2011/073203. Despite the advances in fluid separation techniques, there remains a need to provide advanced techniques for separating fluid.
  • the disclosure relates to a separation assembly for separating fluids produced from a wellbore.
  • the produced fluids pass from the wellbore and into a manifold fluidly coupled thereto.
  • the manifold is fluidly coupled to a surface platform via fluid flowlines for passage of the produced fluid thereto.
  • the fluid flowlines include a gas flowline and a liquid flowline.
  • the separation assembly includes a separator fluidly coupled to the manifold and the fluid flowlines.
  • the separator includes a vessel separating the produced fluid into gas and liquid.
  • the separator receives the produced fluid from the manifold and selectively passes the gas to the gas flowline and the liquid to the liquid flowline.
  • the pump is positionable about the liquid flowline and pumps the separated liquid therethrough.
  • the pump is selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of the separated liquid is adjustable.
  • the disclosure relates to a system for separating fluids produced from a wellbore.
  • the system includes a manifold fluidly coupled to the wellbore and receiving the produced fluid therefrom, a surface platform, fluid flowlines and a separator assembly.
  • the fluid flowlines fluidly couple the manifold to the surface platform for passing fluids therebetween.
  • the fluid flowlines include a gas flowline and a liquid flowline.
  • the separator assembly includes a separator and a pump.
  • the separator is fluidly coupled to the manifold and the fluid flowlines.
  • the separator includes a vessel separating the produced fluid into gas and liquid.
  • the separator receives the produced fluid from the manifold and selectively passes the gas to the gas flowline and the liquid to the liquid flowline.
  • the pump is positionable about the liquid flowline and pumps the separated liquid therethrough.
  • the pump is selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of the separated liquid is adjustable.
  • the disclosure relates to a method for separating fluids produced from a wellbore.
  • the produced fluids pass from the wellbore and into a manifold fluidly coupled thereto.
  • the manifold fluidly couples to a surface platform via fluid flowlines for passage of the produced fluid thereto.
  • the fluid flowlines include a gas flowline and a liquid flowline.
  • the method involves passing the produced fluid from the manifold to a separation assembly, separating the produced fluid into gas and liquid with the separator, selectively diverting the separated gas to the gas flowline and the separated liquid to the liquid flowline, pumping the separated liquid through the liquid flowline, and adjusting flow of the separated liquid through the liquid flowline by selectively actuating the pump in response to changes in fluid flow through the liquid flowline.
  • Figure 1 is a schematic diagram, partially in cross-section, depicting an offshore wellsite having a system for separating fluids produced from a wellbore in accordance with the present disclosure
  • Figure 2 is a schematic diagram of a system for separating produced fluids in accordance with the present disclosure
  • Figure 3 is a schematic diagram of another system for separating produced fluids in accordance with the present disclosure.
  • Figures 4.1-4.3 are schematic diagrams depicting various configurations of a pump in accordance with the present disclosure.
  • Figure 5 is a schematic diagram depicting a fluid separator in accordance with the present disclosure.
  • Figure 6 is a flow chart depicting a method of separating fluids produced from a wellbore in accordance with the present disclosure.
  • the disclosure relates to techniques for separating fluids produced from a wellbore.
  • the techniques provide a system incorporated into existing production equipment for selectively passing gas and liquid into separate flowlines for transport to a surface platform.
  • the system is provided with a pump (e.g., a seabed or an electric submersible pump) to boost fluid flow and enhance recovery of separated liquids.
  • the separation system may retrofit existing, multi-flowline, subsea tie-backs, manifolds, flowlines and existing subsea controls with subsea separation, pumping and/or boosting capabilities. Pigging, bypass, separation and other capabilities may also be provided.
  • Figure 1 illustrates a subsea wellsite system 100 for separating fluids produced from one or more wellbores 102.
  • the wellsite system 100 includes a production portion 104 at seabed 109, a surface portion 106 at a surface location, and a fluid transport portion 108 therebetween. Fluid is produced from the production portion 104, is passed through the fluid transport portion 108, and is drawn to the surface portion 106.
  • the production portion 104 includes a wellhead 110 for each of the wellbores
  • Subsurface multiphase fluids may be produced from the subsurface reservoir and transported up through the wellheads 110 via the tubing 112.
  • Well chokes 115 may be provided to adjust flow from the wellbores 102.
  • Additional equipment may be provided about the wellheads 110, such as tree assemblies 116.
  • a subsea manifold 118 is fluidly connected to each of the wellheads 110 and tree assemblies 116 for controlled passage of fluid therethrough.
  • the surface portion 106 includes a platform 120 with various surface equipment thereon. Surface equipment may be used to facilitate production of fluids and/or to operate equipment at the wellsite 100. As shown, the surface equipment includes subsea master control station 122, a pump control variable frequency drive 124, a fluid treatment source 125, production processing facilities 126, gas & liquid inlet separators 128, and pig launcher/receiver 129.
  • the master control station 122 is a computer interface with access to subsea controls for operating valves and chokes remotely, and for reading subsea gauges, such as pressure and temperature gauges.
  • the pump control variable frequency drive 124 is a device that converts power in a desired format (e.g., voltage and frequency) for use by the pumps, for example, to control pump speed.
  • the fluid treatment source 125 contains various chemicals that may be deployed to subsea locations to treat produced fluids in the system.
  • the production processing facilities 126 receive the fluids at the surface and further separate, degas and treat the collected fluids for discharge and/or transport.
  • the gas & liquid inlet separators 128 are a part of the processing facilities used to further separate and degas the collected fluids.
  • the pig launcher/receiver 129 may be used to deploy and control a pig into the flowlines. These and other components may be provided at the platform 120 or at other locations about the wellsite system 100.
  • the fluid transport portion 108 fluidly connects the production portion 104 to the surface portion 106.
  • the fluid transport portion 108 includes fluid assemblies 131a,b, umbilical termination & distribution modules (modules) 132a,b,c, riser touchdowns 134a,b,c, and flowlines 139a,b,c.
  • the fluid assemblies 131a,b each include a fluid separator 130a,b and a pump
  • the fluid assemblies 131a,b are configured to separate fluid as it passes from the subsea manifold 118 to the platform 120 and/or to facilitate the flow of such fluid.
  • the fluid separators 130a,b are fluidly connected to the subsea manifold 118 for receiving the produced fluids therefrom.
  • the fluid separators 130a,b may include a separator vessel capable of separating the produced fluids into gas and liquid components as will be described more fully herein.
  • the fluid separators 130a,b are also fluidly connected to the platform 120 by flowlines 139.
  • the flowlines 139 include gas flowline 139a, fluid flowline 139b and a gas & injection flowline (or umbilical) 139c.
  • Modules 132a,b,c and riser touchdowns 134a,b,c are positioned along the gas, fluid and injection flowlines 139a,b,c, respectively.
  • the fluid flowline 130a passes liquids from manifold 118 and to the platform
  • the gas flowline 130b passes gases from the manifold 118 and to the platform 120.
  • the injection flowline 139c may be an umbilical for passing fluids, such as control & chemical injection, from the platform 120 to the manifold 118.
  • the fluid treatment source 125 may pass chemicals through the injection flowline 139c for treatment of fluid passing through the wellsite system 100.
  • the fluid separators 130a,b are fluidly connected to the gas and liquid flowlines 130a,b along a horizontal portion thereof.
  • the fluid separator 130a is positioned in a downstream portion of the fluid transport portion 108 between the manifold 118 and the modules 132a,b,c.
  • the fluid separator 130b is positioned in an upstream portion of the transport portion 108 between the modules 132a,b,c and the riser touchdowns 134a,b,c.
  • the fluid separators 130a,b may be used alone or in combination to separate fluids passing therethrough.
  • An example of a fluid separator usable as the fluid separators 130a,b is shown in Figure 5 and will be described further herein.
  • the fluid separators 130a,b work in combination with one or more of the pumps 140a,b,c.
  • Pump 140a is shown positioned along liquid flowline 139a between the fluid separator 130a and the module 132a.
  • Pump 140b is positioned between fluid separator 130b and the liquid flowline 139a.
  • Pump 140c is positioned along the liquid flowline 139a between the fluid separator 130b and the riser touchdown 134a.
  • the fluid separators 130a,b may be used with the pump (e.g., an electrical submersible pump (ESP) or seabed pump) 140a,b,c for facilitating the flow of liquid through the flowline 139a, for example, by boosting such flow.
  • the pump 140a,b,c are shown positioned in specific locations about the wellsite, one or more pumps may be located in other configurations as will be described further herein.
  • a pig 141 may be deployed from surface platform 120 via pigging control unit
  • the pig 141 may be a conventional pig deployable into the flowline and used, for example, to clean up solids or other obstructions in the flowline.
  • the pig 141 may also be used to monitor the integrity of the walls of the flowlines.
  • FIGS 2 and 3 depict various configurations of separation systems 242a,b that may be used with the wellsite 100.
  • the separation systems 242a,b include a subsea separator 130a,b retrofitted between the existing manifold 118 and existing flowlines 139a,b.
  • the separation systems 242a,b also include pumps 140a,b,c positioned about the separator systems 242a,b. While specific examples of separation systems 242a,b are provided in existing fluid transport systems available at existing wellsites, separator systems 242a,b may be positioned about a wellsite together with new flowlines and/or manifolds for attachment between production and surface portions of a wellsite system.
  • Figure 2 is a schematic diagram depicting an example configuration of a separation system 242a. As shown in this version, subsea tree 116 is fluidly connected to the subsea manifold 118. While only one subsea tree is depicted for descriptive purposes, one or more wellbores, wellheads and/or subsea trees 116 may be used as shown, for example, in Fig. 1.
  • the subsea manifold 118 is fluidly connected to the fluid separator 130a by a pair of manifold flowlines (or jumpers) 244a,b.
  • a pigging loop 245 couples the manifold flowlines 244a,b to permit passage of fluid therebetween. In this manner, the fluid is permitted to recycle between the subsea manifold 118 and the separator 130a.
  • existing manifold flowlines may be removed, and/or new flowlines (or jumpers) 250a,b fabricated and installed between the manifold 118 and the separator 130a. Additional separator flowlines (or jumpers) 250c-d may be provided between the separator 130a and flowlines 139a,b.
  • the separator 130a may be installed between the manifold 118 and the flowlines 139a,b by attaching the separator 130a via the separator flowlines 250a-d.
  • the pump 140a is positioned along liquid flowline 139a to form the separation assembly 131a.
  • the pump 140a may be positioned in the flowline 139a for pumping separated liquid from the fluid separator 130a.
  • the pump 140a is depicted as being positioned between the module 132a and the platform 120, but may be at any location along flowline 139a. While the pump 140a is shown in the liquid flowline 139a upstream of module 132a, one or more pumps may be positioned in various locations about the separation system 242a as will be described further herein.
  • the pump 140a is schematically depicted as being deployed into flowline 139a via a coiled tubing 243, but may be installed using a variety of techniques.
  • Figure 4A schematically depicts the deployment of pump 140a through the liquid flow line 139a for cooperative operation with fluid separator 130a.
  • the pump 140a may be deployed through the liquid riser (e.g., 134a of Fig. 1) into liquid flowline 139b using coiled tubing 243 (or other deployment means).
  • Figure 3 is a schematic diagram depicting another example configuration of a separation system 242b.
  • one or more subsea trees 116 of one or more wellbores e.g., 102 of Fig. 1
  • the subsea manifold 118 is fluidly connected to the fluid separator 130b by manifold flowlines 244a,b.
  • the fluid separator 130b is also fluidly connected to the platform 120 by the liquid and gas flowlines 139a,b.
  • Separator flowlines 250a,b may fluidly couple the fluid separator 130b and the manifold flowlines 244a,b.
  • Separator flowlines 250c,d may fluidly couple the fluid separator 130b to the liquid and gas flowlines 139a,b, respectively.
  • a liquid bypass 352a may link the manifold flowline 244a to the liquid flowline 139a.
  • a gas bypass 352b may link the manifold flowline 244b to the gas flowline 139b.
  • Valves, such as pigging valves 354a,b may be positioned in the liquid bypass 352a and the gas bypass 352b, respectively, to selectively bypass fluid therethrough.
  • the pumps 140b,c may be positioned for fluid communication with liquid flowline 139a for cooperative operation with the fluid separator 130a.
  • Pump 140b is schematically depicted as being positioned in a bypass flowline 356.
  • Bypass flowline 356 is in selective fluid communication with liquid flowline 139a.
  • Valves 354c,d are provided along bypass flowline 356 to allow selective bypass of some or all of the fluid flowing through flowline 139a, and for receiving a boost from pump 140b.
  • Pump 140c is schematically depicted as being positioned in separator flowline 250d between separator 130b and flowline 139a.
  • pump 140b is depicted as being fixedly positioned in bypass flowline 356.
  • Pump 140c is schematically depicted as being deployed via wireline 343 into separator flowline 350c.
  • the pump 140c may be deployed, for example, through the liquid riser touchdown (e.g., 134a of Fig. 1), through liquid flowline 139a, and into separator flowline 350d using a wireline 343 (or other deployment means).
  • An electrical conduit 357 is also positioned along the liquid flowline 130a and the separator flowline 350c for electrical coupling between the platform (e.g., 120 of Fig. 1) and the pump 140c.
  • An electrical connector 359 is also provided for electrically coupling the electrical conduit 357 to the pump 140c and receiving power therefrom.
  • the pumps may be positioned in various locations about the wellsite system 100, such as in liquid flowline 139a and/or separator flowline 250d.
  • the pumps may be run deep into the flowline(s) from the host platform using existing coiled-tubing or wireline techniques.
  • the top of the riser touchdown may have direct vertical access for a coiled-tubing or wireline unit to provide for deployment of the pump.
  • a "dry-tree" type assembly with electric penetrations (not shown) may be provided for the tubing or wireline.
  • the pumps 140a-c are shown in the liquid flowline 139a and the separator flowline 350c, one or more pumps may be positioned in various locations about the separation system 242a.
  • the pump(s) may be positioned in a vertical riser section, in a flowline downstream from a riser touchdown, near the wellbores, etc. Pumps may be located such that curvature of the flowline is small. Separation levels of fluids passing through the separation system may be controlled by pump responses.
  • the pump(s) may respond based on in- well control methods with or without additional subsea controls. Such controls may be based on, for example, amp responses of the pump(s).
  • the pumps 140a-c may be provided with various features.
  • a power supply 470 and controller 472 may be installed on the pump as shown in Figure 4B. If available, power and/or control signals may be sent to the pump(s) from existing topside power generators at the surface platform 120, such as from the pump control variable frequency drive 124 via electrical cable 357 as shown in Fig. 4C. Power generation may also be installed into the pump(s).
  • a variable frequency drive (VFD) 474 may be provided to give the pump motor soft start and stop capability, allow continuous voltage and current monitoring, and allow pump speed control as shown in Figure 4A. The VFD may be used for separator level monitoring and control.
  • the pump(s) 140a-c may be configured for operation with the separator(s)
  • the pump may be used to estimate liquid level and gas ingress into the liquid line, thereby controlling the level in the separator without subsea control or level measurement.
  • FIG. 5 is a detailed view of an example separator 530 usable as the separator
  • the separator may be a conventional separator, such as a gas/liquid cylindrical cyclone separator.
  • the separator may use any known separation technique, such as gravity and centrifugal forces.
  • the separator 530 may be a vertical separator with a separator vessel 563 positionable in a suction pile 565 secured in the seabed 109.
  • the vessel 563 may have a diameter of, for example from about 3 feet (0.91 m) to about 10 feet (3.05 m).
  • the vessel 563 may be installed from an anchor handler vessel (not shown).
  • the separator 530 also includes inlets 564a,b for fluid connection to the manifold flowlines (e.g., 244a,b of Fig. 3) and outlets 566a,b for fluid connection to the liquid and gas flowlines (e.g., 139a,b of Fig. 3),
  • the separator vessel 563 receives fluid from the manifold (e.g., 118 of Figure
  • the liquid outlet 566a is located at a bottom end of the vessel 563 to access the liquid 567 at the bottom therein for passage to liquid flowline 139a.
  • the gas outlet 566b is located at a top end of the vessel 563 to access the gas 568 at the top end therein for passage to gas flowline 139b.
  • the produced fluid flows through manifold flowlines 244a,b and to the separator 130a,b where gas and liquids are separated.
  • Gas may flow freely from the separator 130a,b and through the gas flowline 139b.
  • Liquids may flow freely from the outlet 566a and into the liquid flowline 139a where they are pumped to the platform 120 using one or more pumps 140a,b,c.
  • Fluid parameters such as flow rates of fluids and/or levels in the separator 130a,b, may be maintained by monitoring pump performance and selectively adjusting fluid operations. Levels in the separator may be maintained regardless of pump location by balancing pressure. Levels may be kept at a desired level to prevent gas underflow or liquid carry over. For example, the pump speed and/or production rates at the wellbores 102 may be adjusted (e.g., using well choke(s) 115 in the wellbore(s) 102).
  • liquids may be diverted back to the separator 130a,b via the pigging loop 245 and/or the separator flowlines 250a-d (using e.g., pigging valves 354a,b).
  • pigging valves 354a,b e.g., pigging valves 354a,b.
  • amperage of the pump(s) 140a-c may become erratic, and the pump speed may be reduced and/or well chokes 115 adjusted appropriately.
  • Additional adjustments may be made to facilitate fluid flow, such as performing pigging using a displacement pig 141 to clean the liquid flowline 139a and/or using pigging valves 354a,b,c,d and/or pigging loop 245 to adjust flow as needed (e.g., due to terrain).
  • Figure 6 depicts a method 600 of separating fluid produced from a wellbore, such as the wellbores 102 of Figure 1.
  • the method 600 may be used with the fluid separators and/or separation systems as depicted herein.
  • the method 600 involves 680 - passing the produced fluid from the manifold to a separation assembly (the separation assembly including a separator and a pump), 682 - separating the produced fluid into gas and liquid with the separator, 684 - selectively diverting the separated gas to the gas flowline and the separated liquid to the liquid flowline, 686 - pumping the separated liquid through the liquid flowline, and 688 - adjusting flow of the separated liquid through the liquid flowline by selectively actuating the pump in response to changes in fluid flow through the liquid flowline.
  • a separation assembly the separation assembly including a separator and a pump
  • the method may also involve other operations, such as 690 - deploying the pump through the liquid flowline, 692 - selectively diverting the separated fluid to the gas and liquid flowlines, 694 - selectively bypassing fluid, 696 - pigging the flowlines, and/or 698 - treating the produced fluid.
  • the method may be repeated as desired and performed in any order.
  • one or more separators, pumps, flowlines, valves and/or other fluid components may be positioned along the wellsite system to separate and flow fluid produced from the wellbore.

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Abstract

Techniques for separating fluids produced from a wellbore are provided. The produced fluid passes from the wellbore and into a manifold. The manifold is fluidly coupled to the wellbore, and to a surface platform via fluid flowlines for passage of the produced fluid thereto. The fluid flowlines include gas and liquid flowlines. The separation assembly includes a separator and a pump. The separation assembly is fluidly coupled to the manifold and the fluid flowlines, and includes a vessel separating the produced fluid into gas and liquid. The separator receives the produced fluid from the manifold and selectively passes the gas to the gas flowline and the liquid to the liquid flowline. The pump is positionable about the liquid flowline and pumps the separated liquid therethrough. The pump is selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of separated liquid is adjustable.

Description

SYSTEM AND METHOD FOR SEPARATING FLUID PRODUCED FROM A
WELLBORE
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 61/692,420, filed August 23, 2012, which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates generally to the production of fluid from a wellbore. More specifically, the present disclosure relates to techniques for separating fluid, such as gas and hydrocarbons, from produced fluids.
[0003] Wellbores are drilled into the earth to locate and produce valuable hydrocarbons. Land or water based rigs are positioned about the wellbores to retrieve downhole fluid from subsurface reservoirs. Various devices, such as casing, downhole tubing, pumps, manifolds, valves and other fluid control devices, may be positioned about a wellsite and/or deployed into the wellbore to facilitate production of downhole fluids. During production, fluids, such as water, oil, gases and other downhole fluids, may be produced from the wellbores.
[0004] For subsea applications, subsea tubing is extended from a surface platform to a subsea wellbore for transporting fluids produced from the wellbore to the surface. Various devices, such as pigs, pumps, etc., may be positioned along the tubing to facilitate the flow of fluids to the surface. Examples of equipment that may be used are provided in US Patent Nos. 4844165 and 6926504.
[0005] In some cases, it may be desirable to separate the fluids produced from the wellbore. For example, separators may be positioned along the tubing and/or fluidly connected to fluid control devices at the wellbore to separate components of the produced fluids. Examples of separators are provided US Patent No. 4139352. Some separation techniques involve the use of separate flowlines for separate fluids. Examples of flowline separation techniques are shown in PCT Patent Application No. 2011/073203. Despite the advances in fluid separation techniques, there remains a need to provide advanced techniques for separating fluid.
SUMMARY [0006] In at least one aspect, the disclosure relates to a separation assembly for separating fluids produced from a wellbore. The produced fluids pass from the wellbore and into a manifold fluidly coupled thereto. The manifold is fluidly coupled to a surface platform via fluid flowlines for passage of the produced fluid thereto. The fluid flowlines include a gas flowline and a liquid flowline. The separation assembly includes a separator fluidly coupled to the manifold and the fluid flowlines. The separator includes a vessel separating the produced fluid into gas and liquid. The separator receives the produced fluid from the manifold and selectively passes the gas to the gas flowline and the liquid to the liquid flowline. The pump is positionable about the liquid flowline and pumps the separated liquid therethrough. The pump is selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of the separated liquid is adjustable.
[0007] In another aspect, the disclosure relates to a system for separating fluids produced from a wellbore. The system includes a manifold fluidly coupled to the wellbore and receiving the produced fluid therefrom, a surface platform, fluid flowlines and a separator assembly. The fluid flowlines fluidly couple the manifold to the surface platform for passing fluids therebetween. The fluid flowlines include a gas flowline and a liquid flowline. The separator assembly includes a separator and a pump. The separator is fluidly coupled to the manifold and the fluid flowlines. The separator includes a vessel separating the produced fluid into gas and liquid. The separator receives the produced fluid from the manifold and selectively passes the gas to the gas flowline and the liquid to the liquid flowline. The pump is positionable about the liquid flowline and pumps the separated liquid therethrough. The pump is selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of the separated liquid is adjustable.
[0008] Finally, in another aspect, the disclosure relates to a method for separating fluids produced from a wellbore. The produced fluids pass from the wellbore and into a manifold fluidly coupled thereto. The manifold fluidly couples to a surface platform via fluid flowlines for passage of the produced fluid thereto. The fluid flowlines include a gas flowline and a liquid flowline. The method involves passing the produced fluid from the manifold to a separation assembly, separating the produced fluid into gas and liquid with the separator, selectively diverting the separated gas to the gas flowline and the separated liquid to the liquid flowline, pumping the separated liquid through the liquid flowline, and adjusting flow of the separated liquid through the liquid flowline by selectively actuating the pump in response to changes in fluid flow through the liquid flowline. BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the above recited features and advantages of the disclosure may be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are, therefore, not to be considered limiting of its scope. The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[00010] Figure 1 is a schematic diagram, partially in cross-section, depicting an offshore wellsite having a system for separating fluids produced from a wellbore in accordance with the present disclosure;
[00011] Figure 2 is a schematic diagram of a system for separating produced fluids in accordance with the present disclosure;
[00012] Figure 3 is a schematic diagram of another system for separating produced fluids in accordance with the present disclosure;
[00013] Figures 4.1-4.3 are schematic diagrams depicting various configurations of a pump in accordance with the present disclosure;
[00014] Figure 5 is a schematic diagram depicting a fluid separator in accordance with the present disclosure; and
[00015] Figure 6 is a flow chart depicting a method of separating fluids produced from a wellbore in accordance with the present disclosure.
DETAILED DESCRIPTION
[00016] The description that follows includes exemplary apparatuses, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
[00017] The disclosure relates to techniques for separating fluids produced from a wellbore. The techniques provide a system incorporated into existing production equipment for selectively passing gas and liquid into separate flowlines for transport to a surface platform. The system is provided with a pump (e.g., a seabed or an electric submersible pump) to boost fluid flow and enhance recovery of separated liquids. The separation system may retrofit existing, multi-flowline, subsea tie-backs, manifolds, flowlines and existing subsea controls with subsea separation, pumping and/or boosting capabilities. Pigging, bypass, separation and other capabilities may also be provided.
[00018] Figure 1 illustrates a subsea wellsite system 100 for separating fluids produced from one or more wellbores 102. The wellsite system 100 includes a production portion 104 at seabed 109, a surface portion 106 at a surface location, and a fluid transport portion 108 therebetween. Fluid is produced from the production portion 104, is passed through the fluid transport portion 108, and is drawn to the surface portion 106.
[00019] The production portion 104 includes a wellhead 110 for each of the wellbores
102 and tubing 112 extending from the wellheads 110 into the wellbores 102 for receiving fluid from subsurface reservoir. Subsurface multiphase fluids may be produced from the subsurface reservoir and transported up through the wellheads 110 via the tubing 112. Well chokes 115 may be provided to adjust flow from the wellbores 102. Additional equipment may be provided about the wellheads 110, such as tree assemblies 116. A subsea manifold 118 is fluidly connected to each of the wellheads 110 and tree assemblies 116 for controlled passage of fluid therethrough.
[00020] The surface portion 106 includes a platform 120 with various surface equipment thereon. Surface equipment may be used to facilitate production of fluids and/or to operate equipment at the wellsite 100. As shown, the surface equipment includes subsea master control station 122, a pump control variable frequency drive 124, a fluid treatment source 125, production processing facilities 126, gas & liquid inlet separators 128, and pig launcher/receiver 129. The master control station 122 is a computer interface with access to subsea controls for operating valves and chokes remotely, and for reading subsea gauges, such as pressure and temperature gauges. The pump control variable frequency drive 124 is a device that converts power in a desired format (e.g., voltage and frequency) for use by the pumps, for example, to control pump speed. The fluid treatment source 125 contains various chemicals that may be deployed to subsea locations to treat produced fluids in the system. The production processing facilities 126 receive the fluids at the surface and further separate, degas and treat the collected fluids for discharge and/or transport. The gas & liquid inlet separators 128 are a part of the processing facilities used to further separate and degas the collected fluids. The pig launcher/receiver 129 may be used to deploy and control a pig into the flowlines. These and other components may be provided at the platform 120 or at other locations about the wellsite system 100.
[00021] The fluid transport portion 108 fluidly connects the production portion 104 to the surface portion 106. The fluid transport portion 108 includes fluid assemblies 131a,b, umbilical termination & distribution modules (modules) 132a,b,c, riser touchdowns 134a,b,c, and flowlines 139a,b,c.
[00022] The fluid assemblies 131a,b each include a fluid separator 130a,b and a pump
140a,b,c. The fluid assemblies 131a,b are configured to separate fluid as it passes from the subsea manifold 118 to the platform 120 and/or to facilitate the flow of such fluid. The fluid separators 130a,b are fluidly connected to the subsea manifold 118 for receiving the produced fluids therefrom. The fluid separators 130a,b may include a separator vessel capable of separating the produced fluids into gas and liquid components as will be described more fully herein.
[00023] The fluid separators 130a,b are also fluidly connected to the platform 120 by flowlines 139. The flowlines 139 include gas flowline 139a, fluid flowline 139b and a gas & injection flowline (or umbilical) 139c. Modules 132a,b,c and riser touchdowns 134a,b,c are positioned along the gas, fluid and injection flowlines 139a,b,c, respectively.
[00024] The fluid flowline 130a passes liquids from manifold 118 and to the platform
120. The gas flowline 130b passes gases from the manifold 118 and to the platform 120. The injection flowline 139c may be an umbilical for passing fluids, such as control & chemical injection, from the platform 120 to the manifold 118. The fluid treatment source 125 may pass chemicals through the injection flowline 139c for treatment of fluid passing through the wellsite system 100.
[00025] The fluid separators 130a,b are fluidly connected to the gas and liquid flowlines 130a,b along a horizontal portion thereof. The fluid separator 130a is positioned in a downstream portion of the fluid transport portion 108 between the manifold 118 and the modules 132a,b,c. The fluid separator 130b is positioned in an upstream portion of the transport portion 108 between the modules 132a,b,c and the riser touchdowns 134a,b,c. The fluid separators 130a,b may be used alone or in combination to separate fluids passing therethrough. An example of a fluid separator usable as the fluid separators 130a,b is shown in Figure 5 and will be described further herein.
[00026] The fluid separators 130a,b work in combination with one or more of the pumps 140a,b,c. Pump 140a is shown positioned along liquid flowline 139a between the fluid separator 130a and the module 132a. Pump 140b is positioned between fluid separator 130b and the liquid flowline 139a. Pump 140c is positioned along the liquid flowline 139a between the fluid separator 130b and the riser touchdown 134a.
[00027] The fluid separators 130a,b may be used with the pump (e.g., an electrical submersible pump (ESP) or seabed pump) 140a,b,c for facilitating the flow of liquid through the flowline 139a, for example, by boosting such flow. While the pumps 140a,b,c are shown positioned in specific locations about the wellsite, one or more pumps may be located in other configurations as will be described further herein.
[00028] A pig 141 may be deployed from surface platform 120 via pigging control unit
129 and positioned along flowline 139a. The pig 141 may be a conventional pig deployable into the flowline and used, for example, to clean up solids or other obstructions in the flowline. The pig 141 may also be used to monitor the integrity of the walls of the flowlines.
[00029] Figures 2 and 3 depict various configurations of separation systems 242a,b that may be used with the wellsite 100. The separation systems 242a,b include a subsea separator 130a,b retrofitted between the existing manifold 118 and existing flowlines 139a,b. The separation systems 242a,b also include pumps 140a,b,c positioned about the separator systems 242a,b. While specific examples of separation systems 242a,b are provided in existing fluid transport systems available at existing wellsites, separator systems 242a,b may be positioned about a wellsite together with new flowlines and/or manifolds for attachment between production and surface portions of a wellsite system.
[00030] Figure 2 is a schematic diagram depicting an example configuration of a separation system 242a. As shown in this version, subsea tree 116 is fluidly connected to the subsea manifold 118. While only one subsea tree is depicted for descriptive purposes, one or more wellbores, wellheads and/or subsea trees 116 may be used as shown, for example, in Fig. 1.
[00031] The subsea manifold 118 is fluidly connected to the fluid separator 130a by a pair of manifold flowlines (or jumpers) 244a,b. A pigging loop 245 couples the manifold flowlines 244a,b to permit passage of fluid therebetween. In this manner, the fluid is permitted to recycle between the subsea manifold 118 and the separator 130a. In some cases, existing manifold flowlines may be removed, and/or new flowlines (or jumpers) 250a,b fabricated and installed between the manifold 118 and the separator 130a. Additional separator flowlines (or jumpers) 250c-d may be provided between the separator 130a and flowlines 139a,b. The separator 130a may be installed between the manifold 118 and the flowlines 139a,b by attaching the separator 130a via the separator flowlines 250a-d.
[00032] The pump 140a is positioned along liquid flowline 139a to form the separation assembly 131a. In this configuration, the pump 140a may be positioned in the flowline 139a for pumping separated liquid from the fluid separator 130a. The pump 140a is depicted as being positioned between the module 132a and the platform 120, but may be at any location along flowline 139a. While the pump 140a is shown in the liquid flowline 139a upstream of module 132a, one or more pumps may be positioned in various locations about the separation system 242a as will be described further herein.
[00033] The pump 140a is schematically depicted as being deployed into flowline 139a via a coiled tubing 243, but may be installed using a variety of techniques. Figure 4A schematically depicts the deployment of pump 140a through the liquid flow line 139a for cooperative operation with fluid separator 130a. By way of example, the pump 140a may be deployed through the liquid riser (e.g., 134a of Fig. 1) into liquid flowline 139b using coiled tubing 243 (or other deployment means).
[00034] Figure 3 is a schematic diagram depicting another example configuration of a separation system 242b. As shown in this version, one or more subsea trees 116 of one or more wellbores (e.g., 102 of Fig. 1) are fluidly connected to the subsea manifold 118. The subsea manifold 118 is fluidly connected to the fluid separator 130b by manifold flowlines 244a,b. The fluid separator 130b is also fluidly connected to the platform 120 by the liquid and gas flowlines 139a,b. Separator flowlines 250a,b may fluidly couple the fluid separator 130b and the manifold flowlines 244a,b. Separator flowlines 250c,d may fluidly couple the fluid separator 130b to the liquid and gas flowlines 139a,b, respectively.
[00035] A liquid bypass 352a may link the manifold flowline 244a to the liquid flowline 139a. A gas bypass 352b may link the manifold flowline 244b to the gas flowline 139b. Valves, such as pigging valves 354a,b may be positioned in the liquid bypass 352a and the gas bypass 352b, respectively, to selectively bypass fluid therethrough.
[00036] The pumps 140b,c may be positioned for fluid communication with liquid flowline 139a for cooperative operation with the fluid separator 130a. Pump 140b is schematically depicted as being positioned in a bypass flowline 356. Bypass flowline 356 is in selective fluid communication with liquid flowline 139a. Valves 354c,d are provided along bypass flowline 356 to allow selective bypass of some or all of the fluid flowing through flowline 139a, and for receiving a boost from pump 140b. Pump 140c is schematically depicted as being positioned in separator flowline 250d between separator 130b and flowline 139a.
[00037] As shown in Figures 3 and 4, pump 140b is depicted as being fixedly positioned in bypass flowline 356. Pump 140c is schematically depicted as being deployed via wireline 343 into separator flowline 350c. The pump 140c may be deployed, for example, through the liquid riser touchdown (e.g., 134a of Fig. 1), through liquid flowline 139a, and into separator flowline 350d using a wireline 343 (or other deployment means). An electrical conduit 357 is also positioned along the liquid flowline 130a and the separator flowline 350c for electrical coupling between the platform (e.g., 120 of Fig. 1) and the pump 140c. An electrical connector 359 is also provided for electrically coupling the electrical conduit 357 to the pump 140c and receiving power therefrom.
[00038] As shown in Figures 1-4C, the pumps may be positioned in various locations about the wellsite system 100, such as in liquid flowline 139a and/or separator flowline 250d. In the examples of Figures 4A and 4B, the pumps may be run deep into the flowline(s) from the host platform using existing coiled-tubing or wireline techniques. For example, the top of the riser touchdown may have direct vertical access for a coiled-tubing or wireline unit to provide for deployment of the pump. A "dry-tree" type assembly with electric penetrations (not shown) may be provided for the tubing or wireline.
[00039] While the pumps 140a-c are shown in the liquid flowline 139a and the separator flowline 350c, one or more pumps may be positioned in various locations about the separation system 242a. For example, the pump(s) may be positioned in a vertical riser section, in a flowline downstream from a riser touchdown, near the wellbores, etc. Pumps may be located such that curvature of the flowline is small. Separation levels of fluids passing through the separation system may be controlled by pump responses. In other words, the pump(s) may respond based on in- well control methods with or without additional subsea controls. Such controls may be based on, for example, amp responses of the pump(s).
[00040] Referring to Figures 4A-4C, the pumps 140a-c may be provided with various features. A power supply 470 and controller 472 may be installed on the pump as shown in Figure 4B. If available, power and/or control signals may be sent to the pump(s) from existing topside power generators at the surface platform 120, such as from the pump control variable frequency drive 124 via electrical cable 357 as shown in Fig. 4C. Power generation may also be installed into the pump(s). For example, a variable frequency drive (VFD) 474 may be provided to give the pump motor soft start and stop capability, allow continuous voltage and current monitoring, and allow pump speed control as shown in Figure 4A. The VFD may be used for separator level monitoring and control.
[00041] The pump(s) 140a-c may be configured for operation with the separator(s)
130a,b for dependent or independent control of fluids during separation. While subsea control or level measurement may be provided, the pump may be used to estimate liquid level and gas ingress into the liquid line, thereby controlling the level in the separator without subsea control or level measurement.
[00042] Figure 5 is a detailed view of an example separator 530 usable as the separator
130a,b described herein. The separator may be a conventional separator, such as a gas/liquid cylindrical cyclone separator. The separator may use any known separation technique, such as gravity and centrifugal forces.
[00043] The separator 530 may be a vertical separator with a separator vessel 563 positionable in a suction pile 565 secured in the seabed 109. The vessel 563 may have a diameter of, for example from about 3 feet (0.91 m) to about 10 feet (3.05 m). The vessel 563 may be installed from an anchor handler vessel (not shown). The separator 530 also includes inlets 564a,b for fluid connection to the manifold flowlines (e.g., 244a,b of Fig. 3) and outlets 566a,b for fluid connection to the liquid and gas flowlines (e.g., 139a,b of Fig. 3),
respectively.
[00044] The separator vessel 563 receives fluid from the manifold (e.g., 118 of Figure
1) and separates the fluid therein. The fluid is separated such that liquid 567 settles to the bottom of the separator vessel 563 and gas 568 rises to a top portion of the vessel 563. The liquid outlet 566a is located at a bottom end of the vessel 563 to access the liquid 567 at the bottom therein for passage to liquid flowline 139a. The gas outlet 566b is located at a top end of the vessel 563 to access the gas 568 at the top end therein for passage to gas flowline 139b.
[00045] Referring to Figs. 1-3, in operation, well fluids are produced from the wellbore
102 and into the manifold 118. The produced fluid flows through manifold flowlines 244a,b and to the separator 130a,b where gas and liquids are separated. Gas may flow freely from the separator 130a,b and through the gas flowline 139b. Liquids may flow freely from the outlet 566a and into the liquid flowline 139a where they are pumped to the platform 120 using one or more pumps 140a,b,c.
[00046] Flow through the fluid transport portion 108 may be managed using the fluid assemblies 131a and/or 131b. Fluid parameters, such as flow rates of fluids and/or levels in the separator 130a,b, may be maintained by monitoring pump performance and selectively adjusting fluid operations. Levels in the separator may be maintained regardless of pump location by balancing pressure. Levels may be kept at a desired level to prevent gas underflow or liquid carry over. For example, the pump speed and/or production rates at the wellbores 102 may be adjusted (e.g., using well choke(s) 115 in the wellbore(s) 102).
[00047] If the flow of fluid needs adjustment, for example if the gas flowline loads with liquids and begins slugging, liquids may be diverted back to the separator 130a,b via the pigging loop 245 and/or the separator flowlines 250a-d (using e.g., pigging valves 354a,b). In another example, if gas begins to be produced into the liquid line 139a, amperage of the pump(s) 140a-c may become erratic, and the pump speed may be reduced and/or well chokes 115 adjusted appropriately. Additional adjustments may be made to facilitate fluid flow, such as performing pigging using a displacement pig 141 to clean the liquid flowline 139a and/or using pigging valves 354a,b,c,d and/or pigging loop 245 to adjust flow as needed (e.g., due to terrain).
[00048] Figure 6 depicts a method 600 of separating fluid produced from a wellbore, such as the wellbores 102 of Figure 1. The method 600 may be used with the fluid separators and/or separation systems as depicted herein. The method 600 involves 680 - passing the produced fluid from the manifold to a separation assembly (the separation assembly including a separator and a pump), 682 - separating the produced fluid into gas and liquid with the separator, 684 - selectively diverting the separated gas to the gas flowline and the separated liquid to the liquid flowline, 686 - pumping the separated liquid through the liquid flowline, and 688 - adjusting flow of the separated liquid through the liquid flowline by selectively actuating the pump in response to changes in fluid flow through the liquid flowline.
[00049] The method may also involve other operations, such as 690 - deploying the pump through the liquid flowline, 692 - selectively diverting the separated fluid to the gas and liquid flowlines, 694 - selectively bypassing fluid, 696 - pigging the flowlines, and/or 698 - treating the produced fluid. The method may be repeated as desired and performed in any order.
[00050] While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible. For example, one or more separators, pumps, flowlines, valves and/or other fluid components may be positioned along the wellsite system to separate and flow fluid produced from the wellbore.
[00051] Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.

Claims

C L A I M S
1. A separation assembly for separating fluids produced from a wellbore, the produced fluids passing from the wellbore and into a manifold fluidly coupled thereto, the manifold fluidly coupled to a surface platform via fluid flowlines for passage of the produced fluid thereto, the fluid flowlines comprising a gas flowline and a liquid flowline, the separation assembly comprising: a separator fluidly coupled to the manifold and the fluid flowlines, the separator comprising a vessel separating the produced fluid into gas and liquid, the separator receiving the produced fluid from the manifold and selectively passing the gas to the gas flowline and the liquid to the liquid flowline; and a pump positionable about the liquid flowline and pumping the separated liquid
therethrough, the pump being selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of the separated liquid is adjustable.
2. The separation assembly of Claim 1, further comprising manifold flowlines fluidly coupling the manifold to the separator.
3. The separation assembly of Claim 2, wherein the manifold flowlines are fluidly coupled by a pigging loop.
4. The separation assembly of Claim 2, further comprising bypass flowlines in selective communication with the manifold flowlines and the fluid flowlines and providing selective fluid communication therebetween.
5. The separation assembly of Claim 1, further comprising a liquid separator flowline fluidly coupling the separator to the liquid flowline and a gas separator flowline fluidly coupling the separator to the gas flowline.
6. The separation assembly of Claim 5, wherein the pump is positioned in the liquid separator flowline.
7. The separation assembly of Claim 1, further comprising a bypass flowline selectively fluidly coupled to the liquid flowline.
8. The separation assembly of Claim 7, wherein the pump is positioned in the bypass flowline.
9. The separation assembly of Claim 1, wherein the pump is deployed into the liquid flowline.
10. The separation assembly of Claim 1, wherein the pump is one of an electrical submersible pump and a sub sea pump.
11. A system for separating fluids produced from a wellbore, comprising: a manifold fluidly coupled to the wellbore and receiving the produced fluid therefrom; a surface platform;
fluid flowlines fluidly coupling the manifold to the surface platform for passing fluids therebetween, the fluid flowlines comprising a gas flowline and a liquid flowline;
a separator assembly, comprising:
a separator fluidly coupled to the manifold and the fluid flowlines, the
separator comprising a vessel separating the produced fluid into gas and liquid, the separator receiving the produced fluid from the manifold and selectively passing the gas to the gas flowline and the liquid to the liquid flowline; and
a pump positionable about the liquid flowline and pumping the separated liquid therethrough, the pump being selectively actuatable in response to changes in fluid flow through the liquid flowline whereby the flow of the separated liquid is adjustable.
12. The system of Claim 11, further comprising an injection umbilical fluidly coupling the platform to the manifold for passing fluids thereto.
13. The system of Claim 11, further comprising a pig deployable through the liquid flowline.
14. A method for separating fluids produced from a wellbore, the produced fluids passing from the wellbore and into a manifold fluidly coupled thereto, the manifold fluidly coupled to a surface platform via fluid flowlines for passage of the produced fluid thereto, the fluid flowlines comprising a gas flowline and a liquid flowline, the method comprising: passing the produced fluid from the manifold to a separation assembly, the separation assembly comprising a separator and a pump, the separator fluidly coupled to the manifold and the fluid flowline, the pump positionable about the liquid flowline;
separating the produced fluid into gas and liquid with the separator;
selectively diverting the separated gas to the gas flowline and the separated liquid to the liquid flowline;
pumping the separated liquid through the liquid flowline; and
adjusting flow of the separated liquid through the liquid flowline by selectively
actuating the pump in response to changes in fluid flow through the liquid flowline.
15. The method of Claim 14, further comprising deploying the pump through the liquid flowline.
16. The method of Claim 14, further comprising selectively diverting the separated fluid into the gas flowline and the liquid flowline.
PCT/US2013/055957 2012-08-23 2013-08-21 System and method for separating fluid produced from a wellbore WO2014031728A1 (en)

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