Internal Corrosion in Dry Gas Pipelines During Upsets L52079e
Optimize in-situ particle size distribution...
Transcript of Optimize in-situ particle size distribution...
Optimize in-situ particle size distribution management to maximize drilling efficiency
Benjamin SmithAnjan Pandey, PhD June 2012
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Energy Industry: In-Line Particles and Droplets
Energy Suppliers
Asphaltenes, Emulsions, Gas Hydrates, Drilling Fluids, Inorganic
Precipitation
Introduction to FBRM® and PVM®
Asphaltenes
Gas Hydrates
Emulsions
Inorganic Precipitation
Return on Investment
Drilling Mud
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Outline
Introduction to FBRM® Probe Technology
Case Studies
- Detecting Shaker Screen Failure
- Solids Control Management
Conclusions
Typical Installations
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Typical Installations
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In-Situ Particle Characterization Tools
FBRM® TechnologyFocused Beam Reflectance Measurement
PVM® TechnologyParticle Vision and Measurement
FBRM® TechnologyFocused Beam Reflectance Measurement
10 µm droplets
TemperatureG400 #/sec 0‐20µm
TimeChord Length (µm)
FBRM tracks the rate and degree of change to particles and particle structures as they naturally exist in process - Specifications and method of measurement available at - www.mt.com/fbrm
PVM visualizes how particles and particle structures are changing as they naturally exit in process - Specifications and method of measurement available at www.mt.com/pvm
What is PVM®?
Particle Vision and Measurement
Inline imaging of Particles and Droplets: - Real time visualization at full process concentration
without sampling or dilution
Rapid Understanding, Immediate Results- PVM® provides a detailed understanding of complex
particle systems faster than any other method
PVM® allows us to see and understand particles and particle structures as they naturally exist in process
ISO 9001 CE
High resolution under extreme conditions PVM® provides the high resolution ability to see particles
under extreme conditions:in extremely viscous or opaque materials, or at extremely low or very high temperatures and pressureswhere sampling is impractical or impossible.
Water in Crude Oil with PVM® RE Window
PVM® measuring gas hydrates in Crude Oil
PVM tracking solvent extration
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200 RPM
1000 RPM
PVM V825 Ex – Inline process microscope
Specification Details
Overall Length 886mm (35 inches) not including conduitBack End Diameter 61mm (2.4 inches)
Fits inside 2-1/2 inch Sch 40 pipeBack End Materials Stainless 316L and 304Wetted Probe Tip 303mm long x 25mm diameterWetted Materials Probe and tip—Alloy C-22, Window—Sapphire
O-ring seals—Kalrez Compound 7075
Operating Temperature, Probe Back End
Maximum +85° C
Operating Temperature, Probe Tip
–20° C to +120° C
Conduit Temperature –5° C to +130° CConduit Length 10 meters (32.8 ft)
Probe-based for easy installation
Robust design for process environment
ATEX rated probe and enclosure
PVM V819 – Inline particle microscope
Probe-based for easy installation and compact, lightweight design for laboratory use
Highest resolution images of particles and droplets as they actually exist in the process
Class 1M laser product
SystemComponent Specification
Environmental (Temperature and Humidity)
Unit temperature: 5 to 30ºC (41 to 86ºF)Unit Humidity: 15%-85% Operating Humidity Conduit temperature: -60 to 120ºC (-76 to 248ºF) Probe Housing temperature: 5 to 30ºC (41 to 86ºF)Probe Tip temperature: -80 to 120ºC (-112 to 248ºF)
Imaging Field of view (nominal): 1075mm x 825mmResolution: 2 μmFocus Adjustment: Manual
Pressure Standard: Vacuum to 150psi (10bar)Probe Head Length: 163mm
Diameter: 69mmProbe Body Length: 400mm
Diameter: 19mmMaterial: Standard Alloy C-22 wetted probe tip, sapphire window
Conduit Length: 5m
Summary: FBRM G600
Application Scale: See next slideMaterial of Construction:
Probe Tip: SS 316L (AlloyC-22 Optional)Probe Window: SapphireProbe O-rings: Kalrez (TM Optional)
Probe Pressure Rating:
10 bar(up to 300 bar)
Probe Temperature Rating:
-10°C – 120°C-80°C – 150°C (custom)
Conduit Length: 15mMounting: See options on next slideCertification: CE, Class 1 Division 1,
ATEX, IEC ExProduct Page: www.mt.com/FBRMG600Datasheet:
FBRMPVMPSC
Introduction to FBRM®
Focused Beam Reflectance Measurement (FBRM®)
FBRM® is a probe based measurement that tracks the rate and degree of change to particles and particle structures as the particles naturally exist in process
FBRM ® is the standard method for tracking changes in particles and droplets – in process and in real time
Measure particles in process without the need for sampling and off-line analysis
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The FBRM® Method of Measurement
FBRM® Probe TubeFBRM® Probe Tube
SapphireWindowSapphireWindow
Beam splitterBeam splitter
Rotating opticsRotating optics
FBRM® Probe TubeFBRM® Probe Tube
SapphireWindowSapphireWindow
Laser source fiberLaser source fiber
Beam splitterBeam splitter
Rotating opticsRotating optics
Focused beamFocused beamFBRM® Probe TubeFBRM® Probe Tube
SapphireWindowSapphireWindow
Detection fiberDetection fiberLaser source fiberLaser source fiber
Beam splitterBeam splitter
Rotating opticsRotating optics
Focused beamFocused beamFBRM® Probe TubeFBRM® Probe Tube
SapphireWindowSapphireWindow
Cutaway view of FBRM® In-process Probe
PVM® image illustrating the view from the FBRM® Probe Window
Probe installed in process stream
The FBRM® Method of MeasurementPVM® image illustrating the view from the FBRM® Probe WindowEnlarged view
Path of Focused Beam
Probe detects pulses of Backscattered light
And records measured Chord Lengths
The FBRM® Method of Measurement
Path of Focused Beam
Enlarged view
Thousands of Chord Lengths are measured each second to produce the FBRM® Chord Length Distribution :
Enlarged view
Path of Focused Beam
Tracking real-time changes with precision
0.5µm to 2000µm in a single unit without altering the system
Trended Statistics over time for specific user defined size ranges
No calibration necessary to measure fine and coarse particles
Unweighted Distribution
#/s <50 µm
#/s 50-1000 µm
Time (1 Measurement = 2 s)
FBRM comparison with Laser Diffraction
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Screensand
Separators
The Drilling Mud CycleClean drilling mud is pumped down the drill pipe to the bit
Clean mud from the separators is returned to the drill
The drilling mud lifts fresh cuttings up the annulus
The mixture of mud and cuttings enters a series of screens and separators
Screensand
Separators
FBRM in the Drilling Mud Cycle
Lubrication of drill bit is impacted by particle distribution
Formulation particle distribution impacts stabilization of well, ability to remove debris, and fluid losses into the formation
Separation efficiency can be improved by monitoring particle distribution
A broken screen can be identified by in situ monitoring of particle distribution in the recycle loop
Stability of mud is critical to optimize production rates
Introduction to FBRM® and PVM® Probe Technologies
FBRM/PVM Case Studies
- Detecting Shaker Screen Failure
- Solids Control Management
Conclusions
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Outline
MI SWACO Real-Time Fluids Monitoring
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FBRM® detects shaker screen tear/break without human monitoring.
Adding Cuttings to Drilling Mud
The mean particle dimension was monitored in situ and in real time
At key process time points large sand cuttings were added to simulate the production process upset of a screen break
FBRM® can quantitatively track the increase in particle dimension at these points
Laboratory
Unpublished results Francileide Gomes da Costa, Petrobras - CENPES
“Screen Break”Large particles
Stable Drilling Mud
“Screen Break”Large particles
Quantifying Changes During Cutting Additions
FBRM® distribution provides quantitative information about the particle distribution
As cuttings are added the distribution shifts to the right and the number of large particles counted increases
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Statistics Mean Sqr Wt <1006/22/2009
13:35 23.666/22/2009
13:44 26.196/22/2009
13:48 28.62
Increase in number of large particles
Increase in dimension
Unpublished results Francileide Gomes da Costa, Petrobras - CENPES
PVM® Images Validate FBRM® Distributions
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Increase in number of large particles
Increase in dimension
1:36:57
1:44:531:48:21
Unpublished results Francileide Gomes da Costa, Petrobras - CENPES
FBRM® Detects Screen Failures
185 ‐ 317µ
370 ‐ 632µ542 ‐ 1002µ
19 ‐ 63µ
54 ‐ 100µ
Example of screen failures causing increasing concentration of coarse particles
FBRM Off Shore Field Data Nov.2011
Introduction to FBRM® and PVM® Probe Technologies
FBRM/PVM Case Studies
- Detecting Shaker Screen Failure
- Solids Control Management
Conclusions
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Outline
FBRM enables users to achieve solids control management to maximize drilling efficiency and minimize upsets related to fluid losses or inefficient solids removal.
Use FBRM to target the correct particle distribution to plug formation (200-2000µm), lubricate and modify density (<75µm)
MI SWACO Real-Time Fluids Monitoring
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MI SWACO Real-Time Fluids Monitoring
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Drilling into depleted reservoirs is challenging as the fracture strength of the reservoir is reduced due to pressure depletion from production
Optimum particle blends and size distributions are designed based on expected fracture and formation pore size.
The objectives of the yard trial were threefold:
i) Test the functionality of the FBRM instrument and its suitability to the rig environment
ii) Establish procedures for using the instrument as a tool to help manage the particle loading of the drilling fluid.
iii) Implement FBRM in a field trial off-shore in the North Sea
MI-SWACO STUDY
SPE/IADC 125708
Drilling Fluid Measurement – Field TrialRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir
Ronaes et. al. SPE/IADC Conference, Bahrain, 2009
FBRM system ruggedized, C1/D1, IECEx, and ATEX –approved to withstand the harsh offshore rig environment.
FBRM probe directly installed in the flow loop (white arrow in the picture) to monitor circulating drilling fluid.
Offshore and onshore operators able to remotely monitor solid particulates while drilling depleted HTHP gas reservoir.
Drilling Fluid Measurement – Yard TrialRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir
Ronaes et. al. SPE/IADC Conference, Bahrain, 2009
Yard Trial Set Up
- Cesium/Potassium brine-based drilling fluid
- 15 liters of circulating fluid volume in the test loop
- LCM blend components (refer to the table) used in the field added separately starting with
the coarsest particles
Yard Trial ResultsRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir
Ronaes et. al. SPE/IADC Conference, Bahrain, 2009
Addition of CaCO3 (30)
Addition of CaCO3 (200)
Cou
nts/
s C
aCO
3 (2
00)
Cou
nts/
s C
aCO
3 (3
0)
Time (min)Time (min)
Cou
nts/
s C
aCO
3 (4
00)
Cou
nts/
s C
aCO
3 (1
000)
Addition of CaCO3 (400)
Addition of CaCO3 (1000)
FBRM® monitored addition and dispersion of variably sized particles in opaque drilling fluid.
FBRM® detected very small concentration of coarse particles which were difficult to measure with offline instruments.
Continuous measurement of particle size and successful detection of changes in size distribution confirm FBRM® effectiveness for good solids control management during drilling operation.
Field Trial ResultsRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir
Ronaes et. al. SPE/IADC Conference, Bahrain, 2009
FBRM® C90 is sensitive to the amount of coarse particles.
FBRM ® C90 increases when bottoms up circulation was performed at 19:30 due to removal of coarse well cuttings.
FBRM ® is sensitive to changes in solid particle size distribution, solids concentration, mechanical attrition of particles, and loss of solid particles during drilling fluid circulation.
Rapid detection of changes in solids enable operators to optimize drilling fluid particle distribution for wellbore strengthening and formation bridging.
Field Trial ResultsRemote Real-Time Monitoring of Particle Size Distribution in Drilling Fluids During Drilling of a Depleted HTHP Reservoir
Ronaes et. al. SPE/IADC Conference, Bahrain, 2009
Between 09:00 and 11:50 the drilling fluid returns were run across three shakers dressed with 33% 10-mesh, 33% 20-mesh and 33% 40-mesh screens, thus the major part of Graphite (233 – 683 μm) and CaCO3 (632 – 2,000 μm) were screened out
The reduction in particle size is well described by the FBRM C90 parameter in this period.
Rapid detection of changes in solids enable operators to optimize drilling fluid particle distribution for wellbore strengthening and formation bridging.
Introduction to FBRM® and PVM® Probe Technologies
FBRM/PVM Case Studies
- Detecting Shaker Screen Failure
- Solids Control Management
Conclusions
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Outline
Conclusions
FBRM® and PVM® enable scientists and engineers to understand, optimize and control particle droplet and particle distributions in complex multiphase pipeline flow.
The rate and degree of change to particles by size class can be quickly measured and downstream fluid losses can be minimized by adjusting upstream solid additions
A screen tear can be detected in real time improving the process consistency, safety, and reducing labor resource requirements.
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References
Gas HydratesEmmanuel Delle-Case, University of Tulsa. Greaves et al., Chemical Engineering Science 63 (2008) 4570 – 4579. Taylor, C. J. Master thesis, Colorado School of Mines, Golden, CO, 2006. Darbouret et al, Proc.Int.Conf. Gas Hydrates Vancouver, July 6-10, 2008. Hung, L. et. al., XII Congres de la Societe Francaise, France, 2009.Boxall, J. et. al., Proc. of the 6th Intl. Conf. on Gas Hydrates, Canada, 2008.Hung, L. et. al., Proc. of the 6th Intl. Conf. on Gas Hydrates, Canada, 2008Turner, D. et. al., Proc. of the 6th Intl. Conf. on Gas Hydrates, Canada, 2008
AsphaltenesCalles, J. et. al., Energy Fuels 22(2): 763-769 (2008).Marugan, J. et. al., Energy Fuels 23 : 1155-1161(2009).Dufour et. al. Energy Fuels, 2009, 23 (3), 1155-1161. Cajaiba et al, International Process Development Conference, Arosa, Switzerland, June 17 2009.
Oil-Water Emulsions
Boxall, J. et. al., Ind. Eng. Chem. Res. 2010 (Published Online).Westra, R.W. et al., International Petroleum Technology Conference 14917.
Partial List of FBRM® Users Petroleum Petrobras Exxon-Mobile Shell Chevron Conoco Phillips BP Total Statoil MI Swaco, Schlumberger Saudi Aramco
Mining Rio Tinto CSIRO Aughinish Alumina Alcoa Nalco
Government Agencies: Cogema (France) Oak Ridge National Laboratory (USA) Pacific Northwest National Labs (Battelle) Los Alamos National Labs (USA)
Specialty Chemical: Nalco Akzo-Nobel BASF Dow Chemical Dupont Exxon Mobil Monsanto Procter & Gamble
Research and Consulting Services:• Sintef (Norway)• IFP (France)• Southwest Research Institute • Eni-Technologie
Universities:• Universidade Federal do Rio de Janeiro• Universidade de Sao Paulo • University of Alberta• The University of Calgary• China University of Petroleum• Colorado School of Mines• Georgia Tech • University of Tulsa• MIT (Massachusetts Institute of Technology)• University College Dublin (Ireland)
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