ADVANCED FLOW ASSURANCE TOOLS TO MINIMIZE

PIGGING RISKS IN CHALLENGING LINES

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020
CONTENTS
1. Introduction
2. Pigging Feasibility
3. Operational Feasibility (Flow Assurance)
4. Need to Combine Pigging Feasibility and Flow Modelling
5. Pigging Feasibility and Flow Modelling – Applications
6. Case Study
7. Summary
8. Q&A

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 2
INTRODUCTION
INTEGRITY SERVICES
Working across all assets with all the key disciplines covered in-house
• Pipelines, Flowlines, Flexibles & Risers
• Offshore Structures
• Production Facilities
• Upstream Pipelines
• Tank & Terminal Facilities
• Onshore Distribution
• Gas Networks
• Renewables

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020
Slide 3
This document is the property of ROSEN Swiss AG who will safeguard its rights according to the civil and penal provisions of law. No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN.
INTRODUCTION
INTEGRITY SERVICES
Risk and Flow
Reliability Assurance

Geotechnics

Stress Analysis,
Fracture and Fatigue

Structures

Materials and Laboratory Pigging Feasibility

Corrosion Welding Flexibles
Services and Optimization
Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020
Slide 4
This document is the property of ROSEN Swiss AG who will safeguard its rights according to the civil and penal provisions of law. No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN.
Pigging Feasibility
PIGGING FEASIBILITY
RISKS
• All pigging operations contain an element of risk: Requirement
for
No
production
o Stuck or stalled pig inspection
history
deferment

o Blocked pipeline Incomplete or

incompatible
launch / receive
o Damaged pig facilities

o Damaged infrastructure Challenging

pipeline
operating
conditions
• Run success is not guaranteed:
Challenging
o Sensor lift-off Unknown
pipeline
geometry
o Damaged cleaning / ILI tool solids / liquid
deposition in Limitations of
process
o Speed excursions pipeline
infrastructure

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 6
PIGGING FEASIBILITY
CHALLENGES
Operational pigging employed for cleaning operations and management of – liquid, hydrates, solid deposits
and corrosion

WHY?
• Minimize liquid holdup to reduce ΔP losses
• Clean sand / wax / scales / debris / hydrates
• Reduce corrosion (under deposit, MIC etc.)
• Effective application of chemical treatment
• Pre-inspection cleaning service
Loss of
Throughput
OUTCOMES
• Increase pipeline operational efficiency
• Pipeline integrity – extend life of pipeline
• Minimize production deferment / trips / stoppages
• Minimize sensor lift-off of the ILI tool
Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 7
PIGGING FEASBILITY
CHALLENGES
‘Achieving ILI run success requires close collaboration between the Client and Contractor teams,
where adequate planning and preparation are important factors.’ – POF 2018

Operational Causes of Failed ILI Runs

22

41 Pipeline Cleanliness
Pipeline Restriction
Speed Excursions

37

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 8
PIGGING FEASIBILITY
CHALLENGES
Wye
Deep Water
Check Valves
Multi-diameter
CRA Cladding
Pipe-in-pipe
Operating Conditions

Challenging Very Challenging Heavy wall thickness

No pigging infrastructure
Multiphase Flow
Mitre bends Low pressure
Production deferment
Wax deposition
Proficient Challenging

Pipeline Construction

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 9
PIGGING FEASIBILITY
SOLUTION Define
Cleaning
Technology
Options

Asset Data
Pipeline
Threat /
Optimization Loop
Define
Operational Inspection
Drivers Technology BEST
Specify Options PRACTICEDEFI
Cost /
Campaign NED
Data Review Benefit /
Performance Risk
Requirements Analysis

Define Define
Infrastructure Infrastructure
Constraints • Technology Selection
Configuration
Options • Campaign Sequencing
• Infrastructure Set-up
• Developmental Work
Site Survey
• Contingency Options
Define
Operating
Conditions
Flow
Assurance

INPUT PROCESS OUTPUT

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 10
Operational Feasibility
(Flow Assurance)
FLOW ASSURANCE
INTRODUCTION
Assure transportation fluids from source to facility in a safe and economical manner over the life of the
asset

• Process conditions
• Hydraulic calculations
• Corrosion, erosion
• Severe slugging
• Solids: sand, slurry, dust etc.
• Gas hydrates, wax and asphaltenes
• Liquid management during pigging
• Production deliverability
• Pressure surge analysis

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 12
FLOW ASSURANCE
CHALLENGES DURING PIGGING
• Operating conditions
o Pressure, temperature, flowrate limits
• Liquids
o Rate of accumulation
o Pig generated liquid slug could flood the receiving equipment
• Solids
o Rate of accumulation and location
o Avoid “stuck pig” scenario
• Maintaining production
o Minimize deferment
o Maximize throughput
• First pass success
o Pig velocity control within recommended limits
Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 13
FLOW MODELLING
APPLICATION IN PIGGING OPERATIONS

• Estimate solids / liquid inventory

o Blockages due to deposit build-up
o Motive pressure for propulsion

• Tool behaviour due to hydraulics

o Pig wall frictional factors to simulate pig behavior
o Bypass port sizing to maximize production flow
without flooding the slugcatcher

• Pigging optimization
o Process conditions for optimum tool velocity
o Pigging frequency

• Pigging diagnostics for flow model validation

o Data, data and more data!

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 14
Need to Combine Pigging
Feasibility and Flow
Modelling
FLOW ASSURANCE & PIPELINE PIGGABILITY
OPERATING LIMITS

Process Operating Envelope Pigging Operating Window

Objective:
• Optimized process conditions for economical “off-the-shelf” pigging solutions
• Assured piggability of the system

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 16
FLOW ASSURANCE & PIGGING FEASIBILITY
SERVICES
Cleaning
• Pigging frequency for sand / wax / liquid management
CLEANING
• Liquid holdup estimation and surge calculations
• Pig velocity tracking and validation
• Pigging feasibility & configuration e.g. standard / bypass pig, challenging tool

Inspection
INSPECTION
• Pig velocity tracking
• Optimization of pigging operation in single & multiphase flow

Corrosion
• Corrosion models integrated with flow calculations, e.g. DeWaard, Norsok, TOLC IFE
• Support NACE ICDA for un-piggable lines
• ILI data validation CORROSION
• Inspection location prioritization
• Optimize inhibitor injection rates & performance

Integrity
• Risk studies: Water hammer / pressure surge analysis, blowdown modelling etc.
INTEGRITY
• Black powder: root cause analysis and mitigation
• Erosion in slurry / sand transporting lines: root cause analysis and mitigation
Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 17
Case Study –
Condensate line cleaning & ILI
CASE STUDY – CONDENSATE LINE CLEANING & ILI
OVERVIEW

System
Dual flow line system in deep water (~1500m)
Topside Liquid
• 22” diameter Handling ~50m3

• Each ~80 km long

• Flow line 1 produces multiphase fluids
• Flow line 2 supplies dry gas 1500m

Production Wells

Pigging Loop PLEM

Recycle Valve

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 19
CASE STUDY – CONDENSATE LINE CLEANING & ILI
CHALLENGES

• Client preferred “online” pigging at maximized production:

o The asset produced most of the client’s revenue.

• Multiphase in deep water  Large liquid holdup (>1500 m3):

o Limited liquid handling capacity of 50 m3

• Large hydrostatic head

o Insufficient driving pressure for pigging
o Well close to backing out

• Different service fluids

o Compressible gas in one and multiphase fluid in other.

• Maintaining pig velocity challenging in multiphase line

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 20
CASE STUDY – CONDENSATE LINE CLEANING & ILI
SCOPE OF WORK

The scope of work consisted of the following:

• Data Review
• Site Visit INPUT

• Mechanical Feasibility Study

• Identify Requirements for Cleaning and Baseline Inspection
• Flow Assurance for In-Service Progressive Pigs and ILI PROCESS

• Develop In-Service Progressive and ILI Procedures

• Emergency Response Procedure
• Pig Tracking Procedure
OUTPUT
• Pig Stuck Emergency Rescue Plan
• Supervise Pigging Operation

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 21
CASE STUDY – CONDENSATE LINE CLEANING & ILI
METHODOLOGY

• OLGA multiphase hydraulic simulator employed to

estimate the liquid inventory in the flow lines
• Bypass pig calculations
• Critical pig wall frictional factors to model pig behavior
• Various configurations considered:
o Gas wells, increased gas velocity, standard pigs,
passive and active bypass pigs etc.

Optimized cleaning pigging (Configuration 4):

• Sweep the line with gas at high flowrates
• Passive or “fixed” bypass pigging at reduced production

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 22
CASE STUDY – CONDENSATE LINE CLEANING & ILI
STANDARD PIG

Liquid Holdup (Standard pig)

Production Line (Flowline 1)

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 23
CASE STUDY – CONDENSATE LINE CLEANING & ILI
THE SOLUTION

A standard pig would:

• Cause the wells to back out
• Overwhelm the receive facilities causing a trip / shutdown
Therefore a solution was sought…

Solution
High velocity sweep of the pipeline to remove excess liquid holdup
Cleaning pigs with 3% bypass – Pigging needed to be continuous as liquids were replenished within 24 hours

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 24
CASE STUDY – CONDENSATE LINE CLEANING & ILI
BYPASS PIG

Liquid Holdup (3% bypass pig)

Production Line (Flowline 1)

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 25
CASE STUDY – CONDENSATE LINE CLEANING & ILI
CONCLUSIONS

Overall Results:

Recycle Line Production Line

KEY BENEFITS
• Reliable and cost effective solution for an “online” pigging specification
• An acceptable level of production could be maintained

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 26
Conclusions
FLOW ASSURANCE & PIGGING FEASIBILITY
CONCLUSIONS
Flow assurance is key for ensuring operational feasibility:

• OLGA Multiphase simulator for solid / liquid estimates

• Pig frictional factors for predicting bypass pig behavior

• Access to PDL diagnostics and inspection data for validation

Combining flow assurance into pigging feasibility studies is beneficial for:

• Assurance of a pigging solution

• Management of risks in complex challenging assets

• Profitable, safe and efficient running of a pipeline asset

Advanced Flow Assurance Tools to Minimize Pigging Risks in Challenging Lines · Ashwin Pinto & Paul Westwood · © ROSEN Group · 18/11/2020 Slide 28
Questions…?
THANK YOU FOR JOINING
THIS PRESENTATION.

www.rosen-group.com