DRAUGEN SUBSEA BOOSTER PUMP

DRAUGEN SUBSEA BOOSTER PUMP

Challenges, Technology and Way of the Future

Richard Tong Technology Coordinator/ Senior Subsea Processing Engineer

1 25 March 2014

Use this area for cover image (height 6.5cm, width 8cm)

AGENDA

•1.0 Draugen

•2.0 Draugen Subsea Booster Pump

•3.0 Project Challenges

•4.0 Shell & Subsea Boosting

•5.0 Future

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Courtesy of: Heine Schjølberg

History and Introduction to Draugen

DRAUGEN 1.0

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DRAUGEN

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Haltenbanken area, 140km North of Kristiansund

Discovered in 1984 and production start 19.10.1993

Partners: A/S Norske Shell (Operator, 44.56%),

Petoro AS (47.88%), Chevron Norge AS (7.56%)

Water Depth ~ 250-280 m

Peak Production 225 000 bbl/day

Continuous project activity and investments underway to make Draugen a high integrity mature producer

Robust and sustainable design; fit-for-purpose for potential future 3rd party Tie- ins

Scope & Technology, 2 Booster Pump Installations (1993, current)

DRAUGEN SUBSEA BOOSTER PUMP 2.0

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HELICO-AXIAL PUMPS

The first subsea helico-axial pump installation was at the North Sea Draugen field by Norske Shell in 1993.

More than twenty helico-axial pumps are in operation worldwide, with more than 1,200,000 hours of run time.

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WORLD’S FIRST MULTIPHASE SUBSEA PUMP (1993)

Contract Award: 1990 Sales: FMC Kongsberg, Norway Fabrication Pump: Framo, Norway Pump integration: FMC Kongsberg, Norway Host Type: Platform Contract Type: EPC Water Depth: 280 m (920 ft) The Draugen Subsea Well Facilities Contract was the largest subsea EPC contract in Norway at the time. All subsea installations were designed for diverless installation, operation and maintenance. The seabed pumps (i.e. system integration of FRAMO pumps) were the world’s first commercial multi-phase pump installation. The pump was installed in 1993. It ran sucessfully for 12 months (1000 operating hours) and was decomissioned and abandoned due to change in water injection strategy.

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DRAUGEN INFILL PROJECT

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Booster Pump Location

DRAUGEN INFILL PROJECT PUMPING SYSTEM

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• Reduces back pressure “seen” by wells = increased oil recovery

• Accelerated end-of-field life production

• Avoid continuous gas lift, reduces hydrate formation risk

• Offers metering of new wells coming on stream & expansion flexibility

• Tie-back distance (To Draugen): ~4 km (12” flexible)

• Ambient Temperature (seawater): 6 – 8 °C

• Design temperature (flowlines): 75 °C

• Design pressure: 220 bar

• Number of Pumps: 2

• Motor Rating: 2300 kW

• Maximum dP: 50 bar

PUMPING SYSTEM SCOPE OF SUPPLY

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Process Control Module Topside Umbilical Termination Unit

Subsea Umbilical Termination Assembly

DRAUGEN SUBSEA PUMP: PROCESS CONTROL MODULE

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DRAUGEN SUBSEA PUMP: PUMP

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DRAUGEN SUBSEA PUMP: PUMP STATION

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PROJECT CHALLENGES 3.0

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3 Major Challenges Encountered by the Project and Industry

CHALLENGE 1 - STANDARDS

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Description Focus

•Subsea Processing is novel. •>100 specifications (APIs, NORSOK, Draugen Platform Specifications & Shell Standards) •Topside specifications used on subsea processing equipment

•Active engagement with Technical Matter Experts •Early identification of deviations •Standards interpretation (how standards are read)

CHALLENGE 2 - QUALITY

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Description Focus

•Limited production capacity of suppliers and subsuppliers •Rework required (value adding?)

•Inspection and Test Plans for major and medium risk components •Define expectation & definition of quality •Focus on finding the right balance in inspection

CHALLENGE 3 - COST

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Description Focus

•Large number of specifications and standards are time consuming Stringent requirements for documentation and inspection

Focus on Integrity, Safety, Enviromnent Separate ”must have” from ”nice to have” Cost benefit analysis

SHELL GLOBAL & SUBSEA BOOSTING 4.0

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Shell’s Groups Engagement with Subsea Boosting

Single Phase Pump

0

50

100

150

200

250

0 10 20 30 40 50 60 70 80 90 100

GVF [%]

Diffe

rential P

ressu

re [b

ar]

Hybrid pump

300

350

400

WGC

0

725

1,450

2,175

2,900

3,625

4,350

5,075

Diffe

rential P

ressu

re [p

si]

Multi Phase Pump

SUBSEA BOOSTING ENGAGEMENT

1992 2006 2013 2016 2020

SMUBS

FRAMO HIGH BOOST

FLOWSERVE

FRAMO HPHT 15 PSI

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FUTURE 5.0

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What Does the Future Hold?

22

OneSubsea Design Pressure Milestones

1990 2000 2010 2005 1995

0

5,000

10,000

15,000

1997, Lufeng 2003, Ceiba 2006, Columba E

2015

2013, JSM

2014

1998, Troll

Des

ign

Pre

ssur

e <

psi>

23

OneSubsea motor shaft power mile stones

1990 2000 2010 2005 1995

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

1997, Lufeng

1998, Troll

2007, Tordis

2013, JSM

2010, Gullfaks WGC

2009, Pazflor

2006, Columba E

1999, Topacio

0

2015

3400

3200

3600

3800

Q4-2013

Sha

ft po

wer

<kW

>

24

OneSubsea Water Depth Milestones

1990 2000 2010 2005 1995

1000 m

500 m

0 m

1500 m

2000 m

2500 m

3000 m

JSM

Azurite

Ceiba

Topacio

Troll Lufeng SMUBS

2015

Des

ign

dep

th <

m>

Julia

SUBSEA BOOSTING INITIATIVES

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•Active screening of portfolio of assets (green and brownfield)

•Standardisation and replication initiative

•Cost optimisation (execution, scope)

•Technology Qualification Standardisation (API 17N)

•Subsea Boosting in Deepwater (15psi, high temp, high boost)

•Development of Subsea Processing Skillpool

•Establishment of Deepwater Centres of Excellence in Stavanger

STAVANGER CENTRE OF EXCELLENCE EXECUTION

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Strategic Location

• Contractors Expertise (Oslo, Stavanger, Bergen) • One Subsea Offices & Assembly

Yards (Bergen) • Shell Technology Norway (Oslo)

Project Execution

• Support Field Screening

• Technology Qualification (when required)

• Draugen Infill Execution

• Global Subsea Pumping Execution

Q & A

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Have a Safe Day

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