Subsea Factory

Passion Creativity Innovation Initiative Intellect Dedication Compliance -
The
Competitive
Edge
The
Foundation
For Competing
Statoil’s Subsea Technology Strategy,
with selected technology challenges
Tor Willgohs Knudsen
Senior Advisor Subsea Technology & Operations, Statoil ASA
Subsea Innovation Day Bergen May 15’th 2015
Classification: Open
2013-11-20
Statoil’s technology strategy
Putting technology to work 1 Leading in seismic
2
2
imaging and
interpretation
Pushing reservoir
characterisation and
recovery to the next
level
Contribute to add quality
prospects in areas with
complex geology
Enable faster
maturation of resources
and reserves
Become a leading
exploration company
Contribute to add 1.5
bn boe to reserves by
2020
Classification: Open
2013-12-18
3 Step change in
4 Taking subsea
well-construction
efficiency
longer, deeper and
colder
30% reduction in well
construction time by
2020
15 % reduction in well
construction cost by
2020
Subsea gas
compression by 2015
Subsea factory by 2020
Subsea in Statoil: Half the production and
increasingly important
NCS: Subsea IMR in harsh
environment
Tyrihans: Subsea raw
seawater injection
Subsea large share of
production:
Significant yearly
subsea spend :
• 526 subsea wells
• 40% of Statoil operated
NCS prod
• 50% of equity prod
• New facility
development: xxxBNOK
• Operations and
aftermarket: ‘xxxBNOK
Crucial part of
development and IOR
projects
Statoil technology
frontrunner
• Norwegian Cont Shelf
• Globally
Troll and Tordis: Subsea
separation and boosting
3
Classification: Open
• Subsea one of four
technology priorities
• Longer, deeper, colder
Troll: World's largest
subsea development 122 subsea trees
Visund South: First fast
track project in production
Gullfaks & Åsgard: Gas
compression
2013-11-20
5
Classification: Open
2013-11-20
Technology an enabler for growth
Taking subsea longer, deeper, colder
2009 Tyrihans
Leading in seismic imaging and
interpretation – to increase
discovery and recovery
2007 Ormen Lange/Snøhvit
2015:
Gullfaks and Åsgard
Standardisation
subsea compression
Step change in well-construction
efficiency – to drill more costefficient wells
2007 Tordis
2005 Kristin
2000 Troll Pilot
1998-99 Åsgard Pushing reservoir
Gullfaks Satellites characterisation and recovery
1991 TOGI
1986 Gullfaks
6
2012-10-28
to the next level – to maximise
value
2020: Subsea factory
Troll Oil - Impossible made possible
Troll C
Troll B
1979
Discovery well
1990
Long term oil production test
1991
TOGI - Gas export to Oseberg
1995
Troll B
1996
Troll A
1999
Troll C
2000
Troll Pilot
• Largest oil producer on NCS 2013
Kollsnes
Troll A
5/15/2014
− Thin oil column (9 - 27 meter)
− 122 subsea well slots
− 2 100 million bbl reserve ambition
Gullfaks- has been still is an important field
to develop, prove and qualify new subsea technologies
Early production Gullfaks A 1986
using new subsea tech (6 wells)
Gullfaks Satellites (40 wells) came
in production from 1998 (to GFA)
and 2001 (to GFC) using new
qualified technologies (HOST, 7HXT,Smart wells, heated flowlines,
new flowline alloys, reeled pipe in
pipe, bundles)
The Gullfaks Sør Brent reservoir,
producing from the L and M
templates (7 wells) to GFC, is the
main source of gas from Tampen
fields towards Kårstø.
Subsea Compression :
The pressure has declined since
2001. In 2015, the wells will need
Subsea Compression to keep
production rates at todays level.
Hydrocarbon test loop at Fusa
Compressor
submerged under
qualification
9
Classification: external
2013-07-16
Project Drivers Gullfaks Subsea Compression
• “The development of subsea compression and processing is a central part of
Statoil’s technology strategy for long-term production growth” Margareth Øvrum
• Subsea compression at Gullfaks represents an important milestone in the efforts
to improve recovery from this and other gas fields.
• Without this technology 22 MBOE will be left behind.
• Statoil is the first energy company to utilize the Wet Gas Compression technology
• Start up gas compression Q4 2015
10
Application – Gullfaks (2012 design)
42m x 15m x 13m
1
Classification: Internal
2012-11-22
Åsgard Subsea Compression Project
• 2 x 11,5 MW subsea compressors
• 40 km step out
• Water depth 270 meters
• Production 21 Mill Sm3/d
Value creation
• Increased recovery from Midgard and Mikkel estimated to 282 Mboe
Technology step • Substantial recovery and lifetime increase for other technology users (gas fields)
Courageous decision • Pioneering work/complex development and important step towards a complete subsea factory
Process Flow Diagram
Subsea Templates
To Åsgard B
From Midgard X
Compression Station
Weight: 5100 tons
Size: 74x45x26 m
Manifold station
Weight: 910 tons
Size: 34x27x15 m
To Hot‐Tap on Y‐101
From Midgard Y
From Midgard Z & Mikkel A & B
Existing Subsea Processing Toolbox
Field closed
In operation
In operation
In operation
Lufeng
Troll
Tordis
Tyrihans
Multiphase pumping
Water Separation
Separation and boosting
Sea water injection
• Installed 2007
• Designed to increase oil
recovery from 49% to 55%
• Installed 2009
• Design: 10% increase
in total recovery
• Installed 1997
• 12 years in operation
• Enabler for FD
• Installed 1999
• Up to 10 000 add’nal bopd
Gullfaks
Åsgard
Compression
Compression
Subsea Factory
• DG3: May 2012
• Start up 2015
• Inc. recovery: 22 mill boe
Project execution
17
Classification: Open
2013-11-20
•
•
•
Realise by 2020
Towards 60% recovery
Improved CAPEX OPEX HSE
• DG3: Aug 2011
• Start up 2015
• Inc. recovery: 280 mill boe
Project execution
Subsea factory – description and benefits
The Subsea Factory
Processing to the necessary
transport quality
• Increased recovery
• Accelerated production
• Field development enabler
• Operational flexibility
• Reduced CAPEX
• Reduced OPEX
• HSE benefits
1
2012-10-28
Subsea Factory - Key Building Blocks
System
design
Monitoring
Installation,
intervention
&IMR
Controls
Boosting
Cooling
Gas
compression
Water
handling
Separation
Subsea
Prod.
System
Power
transmission
&distribution
Storage
Flow
Assurance
Supporting systems
Main processing systems
19
Classification: Open
2013-11-20
Structures
Pipelines &
Risers
Subsea
Field centre
technology
Gas
Treatment
Oil
Treatment
The Statoil Subsea Factory™
Oil export
Sea water injection
template with pumping
Produced water
injection template
Oil storage
Oil pump
Gas export
Power distribution
and control
Gas compression
Gas, oil, produced
water separation
Manifold
Produced water
injection pump
Production
template
Production
template
ROV
intervention
2
2012-10-28
Short term
Defining Subsea Factory
New / improved factory building blocks
SIMPLIFIED
BOOSTING
WATER
SEPARATION
& INJECTION
SIMPLIFIED
COMPRESSION
POWER
DISTRIBUTION
INTERVENTION
BROWNFIELD FACTORY
FOR INCREASED RECOVERY
SUBSEA FIELD
CENTRE
GAS TREATMENT
SEA WATER
INJECTION
SUBSEA-TO-HOST FACTORY
Medium term
FOR DE-BOTTLENECKING
LONG DISTANCE OIL
TRANSPORT
HIGH CAPACITY
BOOSTING
EXTENDED REACH FACTORY
FOR LONG TIE-BACKS
ARTIFICIAL LIFT
ESP & DUAL
BOOST
COMPACT
SEPARATION
DEEPER
INSTALLATION
& IMR
DEEP WATER FACTORY
TO ENABLE 3000m PRODUCTION
Long term
HIGH VISCOSITY
BOOSTING
21
HEAVY OIL FACTORY
TO ENABLE VISCOUS OIL TIE-BACK
OIL TREATMENT
ARCTIC FACTORY/
SUBSEA TO GAS MARKET
Classification: Open
2013-11-20
OIL STORAGE
& OFFLOADING
Potential subsea factory developments
22
Classification: Open
2013-11-20
Subsea Factory Menu – Vendor Strategy 1. Brown Field Factory
for increased recovery
Level1: System Integration vendors:
2. Subsea-to-Host Factory
for de-bottlenecking
Level 2: Vendors of Main Technology Elements:
Increasing
complexity
3. Extended Reach Factory
to enable long oil/gas tie-backs
Level 3: Vendors of Technology Components:
4. Deep Water Factory
to enable 3000 m
processing&production
5. Heavy oil Factory
to enable 50 km heavy oil tiebacks
• Objectives of Supplier Collaboration − Cost reduction
− Standardization
6. Arctic Factory
for stretch and extreme arctic
− Interchangeability
23 -
Statoil Subsea FactoryTM Supplier Collaboration
• Statoil would like to cooperate with Level 1, 2 and 3 vendors that
− Have the capability, competence and aspiration to develop, qualify and implement key «Subsea Factory» technology elements and total system integration
− Is looking for cost effective, fit‐for‐purpose subsea solutions
− Is pursuing (industry) standards to enable interchangeability of technology elements
− Will share the cost of the technology development
BROWNFIELD FACTORY
SUBSEA-TO-HOST FACTORY
EXTENDED REACH FACTORY
DEEP WATER FACTORY
ARCTIC FACTORY
HEAVY OIL FACTORY
Securi
ty
Classif
24
Clas
Summary
• Substantial Statoil subsea history and operational experience
• Realization of the Subsea Factory Menu is dependent on
− Cost effective solutions; more standardization and more effective life cycle operations is required
− Effective collaboration between operators and suppliers
• We invite you to be part of The Statoil Subsea FactoryTM: technology toolbox for cost‐ effective field development, increased recovery and accelerated production
Key Questions
BROWNFIELD FACTORY
• What are your thoughts on the Subsea Factory «menu» and how is it relevant for your company’s product range?
• What are the main challenges towards achieving profitable and fit‐for‐purpose subsea factories and how do we collaborate?
SUBSEA-TO-HOST FACTORY
EXTENDED REACH FACTORY
DEEP WATER FACTORY
• Why is broad implementation of existing subsea processing technology (e.g. subsea pumps) not taking place and what can we do to encourage this?
"Taking subsea longer, deeper and colder“
HEAVY OIL FACTORY
ARCTIC FACTORY
Conclusion Subsea Factory
• Subsea separation and boosting in operation at Troll and Tordis; raw
seawater injection at Tyrihans
• Åsgard and the Gullfaks subsea compression stations in operation in 2015
• The technology elements required for a subsea factory are in use or under
development
• "Brown field factories" for increased recovery from existing fields
• “Green field factories to host” for transport to existing infrastructure.
• Focusing on cost effective solutions; more standardization and more
effective life cycle operations
• Need continued effective collaboration between operators and suppliers
• The Statoil Subsea FactoryTM: technology toolbox for cost- effective field
development, increased recovery and accelerated production.
"Taking subsea longer, deeper and colder”
Installed equipment
Standardized and configurable
• System is configured to field spesific requirements
• Building blocks are standard – but configured as required to meet field requirements,
i.e reservoir conditions, seabed conditions and host platform characteristics
System configurations
Building blocks
Oil production
Oil production w/gas lift
Gas production
Gas injection
Water injection
4 slot templates
Single slot templates (satellites)
Wellhead
Tubing Hanger
Xmas Tree
Choke Module
Manifold
Production Control System
Tie-in tool (normally rented)
Combinations of above
32
33
From new technology to improved business
Smart Subsea manifoil
Why? How? Where? •
•
•
•
Utilize and combine technologies like subsea pumping, subsea water injection, subsea bulk separation and compression
•
•
•
•
Enable more tie‐in to exiting facilities
Reduce number of required risers/J‐tubes
Reduce topside scope, weight and space
Remove bottlenecks on FPSOs Johan Castberg
Oseberg field Center
Norne
Snorre
2. SPS Tooling – organized in toolpool
Multi Workover System (MWOS)
Enables use of Rig/UWOS across portfolio of
subsea systems from different vendors
Defines the interface between:
• Subsea Tree
• Workover System
Enabling independent contract processes for:
•
•
40
Subsea system including tree
Workover system
Classificati
on: Internal
2013 06 17
4. Next step: Standardized UTA (Umbilical Termination Assembly)
Defines the interface between:
• Template
• Umbilical
• Umbilical installation
Enabling independent contract processes for:
•
•
•
42
Template
Umbilical
Umbilical installation
Classificati
on: Internal
2013 06 17
Future standardization initiatives
• VXT
− Reduced fatigue risk , reduced life time cost
• DC/FO
− Utilize technology from communication industry
• Prepare ITS for pump installation
− Reduce cost of installing subsea pumps
• Smart Subsea manifold with processing capability
− Enable tie-in of subsea fields to host with limited riser and processing availability
• HPHT light ITS
− New step to standardize development for HPHT fields in NCS
• Deep water X-mas tree and SPS system
− International standard
• Tie-in tools ?
• …………………..Standarization of Interfaces
Towards The Subsea Factory:
Opportunities And Challenges
[email protected]
www.statoil.com
45
Classification: Open
2013-11-20

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