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7/27/2019 Al Cook - Harnessing Technology to Develop Shah Deniz Al Cook
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Harnessing Technology to Develop Shah DenizAl Cook, Vice President Shah Deniz Development
Caspian Oil and Gas Conference, Baku
6 June 2013
Harnessing Technology to DevelopShah DenizAl CookVice President, Shah Deniz Development
Goodmorning,
Itsarealpleasuretobespeakingatthisconferencetoday.Thisimportanteventhasbeen
takingplaceinBakufor20yearsnow.AlmostexactlythesameamountoftimethatBPhasbeenworkinginAzerbaijan.
For20yearsthisconferencehasbeenanexcellentopportunitytodiscusstheprogressof
theoilandgasindustryinthiscountry.Andtheachievementsoverthepasttwodecades
havebeenremarkable.
TodayintheCaspianSea,BPoperatessomeofthelargestoilandgasfieldsintheworld.
Azerbaijanisamajorexporterofoiltointernationalmarketsandnowitisemergingasone
oftheworldsgreatnaturalgasproducers.
ThekeytounlockingtheCaspiansgaspotentialisthegiantShahDenizfield,withover1
trillioncubicmetresofgasreservesinplace.ItrepresentsthelargestgasdiscoveryinBPs
100yearhistoryandremainsoneofthelargestoilandgasfieldsintheworld.
Despitethecomplexitiesofdrillingthewells,buildingaplatform,constructinganonshore
terminaland layingthe700 kmSouthCaucasuspipeline fromAzerbaijantoTurkey,Shah
DenizStage1wasdevelopedinonlysevenyears.Sinceitstartedproductionin2006,Shah
DenizhasprovedasecureandreliablesupplierofgastoAzerbaijan,GeorgiaandTurkey.
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WearecurrentlydevelopingthesecondstageofShahDenizwhichwilldeliveranadditional
16billioncubicmetersperyear(orbcma)ofgas.Theprojectwillinvolvedrilling26wells,
constructingnewoffshorefacilities,expandingSangachalterminalandbuildinga4000km
pipelinechaintoexportCaspiangastoEuropeforthefirsttimeinhistory.
Projectsofsuchscale comewiththeir challenges. These challenges canbecommercial,
regulatoryandevenpolitical.Buttoday,Iwouldliketospeakaboutsomeofthetechnical
challengesweface,andhowweplantoovercomethem.
WebelievethatexpandingAzerbaijansengineeringcapabilitiesanddeployingcutting-edge
technologieshereinBakuarethekeystothefuturedevelopmentoftheoilandgasindustry
ofthiscountry.Webelievethatbybringingintechnologicalexpertiseandexpertsfrom
around theworldwithcan unlock the potential of the Caspian.And ShahDeniz Stage2
providesanopportunitytodemonstratethebenefitsthatthesetechnologiescanbring.
Illstartwithabriefoverviewoffiveofourkeytechnicalchallengesandthenwilldiscuss
howweplantoaddresseachoneofthem.
Challenges
High pressure gas
Giant geographical
spread Tough drilling
environment
500 m water depth
4000 km to gasmarkets
Challenges
ThemainShahDenizreservoirsareatadepthofabout6000mbelowsealevel.Atthese
depthsweseesomeofthehighestreservoirpressuresinanyfieldoperationintheworld.
Thesepressuresofupto14,000poundspersquareinchcreatethefirstofthechallenges
thatIwilldiscusstoday.
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OursecondchallengeisthesizeofthefieldaboutthesameasManhattanIsland.How
canwesafelyandeconomicallyextractgasfromeachandeverypartofthefield?
Thirdly, many of youwill be aware that the southern Caspian Sea is one of themost
demandingdrillingenvironmentsintheworld.Ontheseabed,geo-hazardslikeactivemud
volcanoesandsoftsoilmakeoperationsdifficult.Andbeneaththeseabed,theenvironment
iseventougher.Indeed,weareunabletodrillwellsverticallyintothereservoir.Alargearea
ofthefieldrightabovethereservoirisanodrillzone.Thegeologyofthispartofthefield
is such that applying any additional pressure to drill the wellswouldcause the rock to
fracture.Wethereforeneedtoplacethewellsontheperipheryofthereservoiranddrillat
anangletoundercutthenodrillzone.
Our penultimate challenge isthewaterdepth,as deepas500metres.Atthisdepth the
pressuresarehighandthewateriscold:around5degreescentigrade.Thiscouldcausethe
fluidsinourpipelinestosolidifyandcauseblockages.
Andthen,evenwhenweveovercomethesefourchallengesandbroughtthegastoshore,wearefacedwithafinalchallengethegasmarketsareupto4000kmaway.Howdowe
getthegastherereliablywhilstmitigatingourenvironmentalimpact?
Managing high pressure gas safely
HIPPS
High Integrity Pressure
Protection System (HIPPS)
HIPPS
Letmestartwiththepressurechallenge.Whatis14,000psilike,andwhatisHIPPS?
Thepressureswegetdeepinsidethereservoirsarealmost1000timesashighasthose
thatweseeinthisconferencecentrehereinBakuImaginebalancingtheEiffelTowerin
Parisontheroofofacar.Thatswhat14,000psiislike.Sohowdoweprotectourpeople
andequipmentfromthis?
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AkeytechnologyisHIPPS,aHighIntegrityPressureProtectionvalve.Thiswillbeafirstfor
theCaspianSea.Andthisvalveisenormous:itweighs18tonnesandstands4mhigh.
The HIPPS valve will be capable of shutting in just 15 seconds if the pressure in the
manifoldincreasesaboveapre-definedlevel.Thevalvethereforeprovidesprotectiontothe
pipelines and to other subsea equipment from possible damage. Most importantly, it
providesprotectiontothepeopleontheShahDenizplatform.Weareplanningtoinstalltwo
autonomousvalvesoneachofoursubseamanifolds.
BPhasextensiveexperienceofmanagingHIPPSsystemsworldwide,includingintheNorth
SeaandEgypt.WebelievethatHIPPSrepresentsasignificantstepforwardandallowsus
toachievetheveryhighsafetystandards.
Increasing production rates
Tubing HangerTubing Hanger
Tubing Hanger
Thisbringsmeontooursecondchallenge thehugegeographicalspreadofShahDeniz.
How dowedraina field the size ofManhattan Islandwith the fewest number ofwells
possible? The clue lies inour successon ShahDeniz Stage 1,whereourwellsproduce
morethan200mmscfd,over50mboed.Thismakesthemsomeofthebiggestmostprolific
wellsanywhereintheworld:onshoreoroffshore.
ToincreasetheflowrateonShahDenizStage2,weuseanotherpieceoftechnologythis
timemuch smaller in size.Whereas the HIPPS valve is 4mhigh, this technology the
tubinghangerisonly7inchesindiameter.
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Thisdevicesitsontopofthewellandconnectsthepipesinthewelltothesubseasystem,
asyoucanseeonthescreen.
Aconventionaltubinghangerinonly5.5wide.Werecognisedearlyonthata7tubing
hangerwouldoffersubstantialvalueasitreducesthepressurelossasgastravelsfroma
wellintothesubseasystem.Byreducingpressurelosseswecanboostflowrates.
A1.5increaseindiametermightnotsoundlikeverymuchbutinengineeringtermsitis
verydifficulttodesignlargerequipmentwiththesamepressurerating.Wereproudofthis
achievement.
Asaresult,weestimatethatwewillbeabletoincreaseproductionbyupto50%.Itgives
usthatextrabitofconfidencethatwecanmeetoursalescommitmentstoourcustomers
inAzerbaijan,Georgia,TurkeyandinEurope.
Addressing drilling challenges
SolidExpandableTubulars
NormalTubulars
Solid Expandable Tubulars
ThethirdchallengeIdliketohighlightisthedrillingenvironment.Thenatureofthepressure
regimeinShahDenizmeansthatwecannotdrillvertically,sowehavetodrilllongwells
fromtheperipheryofthefield.Inaddition,thepressureofdifferentzonesinthewellvaries:
some zones have been depletedthroughpriorgas production and someremain at their
originalhighpressure.
Thisallmeansthatthewellswedrillarecostlyeachonemeasuredinhundredsofmillions
ofdollarsandwehavetofindwaysofdrillingthemefficientlywhilstholdingourselvesto
industry-leadingsafetystandards.
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Onewaywedo this isbyusing thesolidexpandable tubulars.Thenamegives thisone
away. The tubulars are pipes used for casing the wells. Normally, tubulars have to get
smaller,thedeeperyougo,asshownontheleft.Thiscanbecomeaproblemwhenyoure
drilling6000metresbelowtheseabed:youreleftwithaverynarrowwell.
Soweusetheexpandabletubularsyoucanseeontheright.Theexpansionofthetubulars
is achieved by driving a solid cone through them either by using hydraulic pressure or
mechanicalforce.Thespecialmetallurgicalcompositionofthesesolidexpandabletubulars
allowsthemtoexpandwithinthewell,whilstmaintainingtheirstrength.
Expandable tubulars have already been successfully deployed on Shah Deniz, enabling
deeperholesectionstobedrilledandcasedinalargersizethanwouldotherwisehavebeen
possible.We have alsomanaged touse them to isolate higher pressure layers, like the
Sabunchi,fromlowerpressurelayersliketheSurakhany,preservingwellintegrity.Thisway,
justaswiththetubinghangers,wecanachievehigherlevelsofintegrity,higherproduction
ratesandhighergasrecovery.
Maintaining gas flow at 500m water depth
Direct Electrical Heating
Direct Electrical Heating
Direct Electrical Heating
Oncetheoilandgascomesuptotheseabed,thechallengescontinue.Atwaterdepthsof
500m,itscoldanddark.AndonShahDeniz2therewillliterallybehundredsofkilometers
ofpipelinesdeepontheseabed,bringingtheoilandgastotheplatformsinthenorth-west
ofthefield.Ifthefluidscooldown,waxandlumpsoficecalledhydrateswouldquicklybuild
up,blockingthelines.
Atypicalhydrateandwaxmanagementsystemwouldinvolveinjectingchemicalinhibitors
intothe flowstreamtopreventformationofblockages.Howeverthisoptionwouldhave
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involvedvastquantitiesoffluidsbeingtransportedoffshore.Instead,wehaveoptedfora
betteroption:OpenLoopDirectElectricalHeating. This isa systemwhichwe have just
deployedonourSkarvfieldinNorway.
DirectElectricalHeatinginvolvesattachinghighlyconductivewireoutsidetheflowlineand
thentransferringelectricitythroughthepipeworkitself.Thepipeheatsupwhenacurrentis
passed through itpreventing theformation ofhydratesandwaxdeposits.Tocreate this
current,weareplanningtoinstall25MW ofpowergenerationcapacityonthenewShahDenizplatforms.AswithsomuchonShahDenizStage2,thescaleofpowergeneration
andthenumberofflowlineswillsetarecord:makingthisthelargestDEHdeploymentin
theworld.
Reducing emissions at Sangachal Terminal
Waste HeatRecovery Units
Waste Heat Recovery at Sangachal Terminal
So,wevemanagedthepressurechallengessafelyusingHIPPS.
Andwevereducedthenumberofwellsbyemploying7tubinghangers.
Weveusedsolidexpandabletubularstoaddressthedrillingchallenges.
And weve overcome the cold waters at the bottom of the Caspian Sea with Direct
ElectricalHeating.
Butthatonlygetsthegastotheshoreofthesea.Wenowhavetopumpit4000kmto
Europe,overmountains,underriversandacrosswholecountries.Andwewanttodoitina
waythatminimisestheuseoffuelgas,andreducescarbondioxideemissions.
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ThefinalexampleoftechnologythatIdliketoprovideyouwithtodayisattheSangachal
terminal.Thisterminalisalreadyoneofthebiggestintheworld.ButtoprepareSangachal
for the additional oil and gas coming from Shah Deniz Stage 2 we will expand it
considerably, installing two new gas processing trains and three new compressors. The
compressorsareusedforpushingthegasthroughtheSouthCaucasusPipelineforthestart
ofitslongjourneytoEurope.
And an important component of the terminal expansion plan are the energy efficiency
measures.OneoftheseisWasteHeatRecovery.
The Waste Heat Recovery Units are physically attached to the gas turbines of the
compressors. They take the exhaust from the gas turbine and use it to provide heat
throughouttheterminal.Theseheatexchangersalonewill reduceouremissionsbyabout
70,000tonnesofCO2peryear.Thatisaboutasmuchastheplanethatfliesdailybetween
LondonandBakuuseseveryyear.
Conclusion
Asyoucansee the scale ofShahDeniz isquiteexceptional.Aninvestment ofover $40
billionwillbeneededtodelivertheproject.Andthechallengesareexceptionaltoo.
But it isBPs trackrecord ofdeliveringprojects like this, intheCaspian and around the
world,thatgivesustheconfidencetomoveforward.
AndIhopeIhavebeenabletogiveyouan ideaofsomeofthenewtechnologiesthatwill
bedeployedonShahDeniztoaddressthetechnicalchallenges.
Thesetechnologiesare illustrative ofwhatwedobestinBP.Wecontinue tooperatein
mostchallengingenvironments.Wesetindustryrecordsforthescaleanddepthofournew
developments.Andwecontinueto invest in researchanddevelopmentof rangeofnew
technologies.
These technologies not only enable Shah Deniz Stage 2 but are crucial for unlocking
Azerbaijansgaspotentialinthefuture.Enhancingourcapabilitiesindeepwaterandhigh
pressure environmentswill allow us to develop ACG Deep, Shah Deniz Deep, Shafag-
Asimanandothergasfieldsinthefuture.
Sodespiteitsscale,despiteitschallengesanddespiteitsrewards,ShahDenizisjustthe
beginningofthedevelopmentofAzerbaijansnaturalgasresources.
Thankyou.
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