First Full-Electric Shared-Actuation Control for Subsea Manifolds in Brazilian Ultra-Deep Waters: A Discussion of the Technological Development up to Field Commissioning

2021 ◽  
Author(s):  
Alexandre Rabello ◽  
Dorival Natal Neto ◽  
Eduardo Coelho ◽  
Estevan Seraco ◽  
Wagner Destro ◽  
...  
Keyword(s):  
Control Systems ◽  
Technological Development ◽  
Lessons Learned ◽  
Control Solution ◽  
Offshore Production ◽  
Deep Waters ◽  
Water Alternating Gas ◽  
Technical Specifications ◽  
Performance Results ◽  
Robotic Tool

Abstract In projects to develop offshore production in Brazilian pre-salt fields, an innovative model of subsea manifolds is being used, based on shared-actuation control (SAC) for the remote operation of valves. The control solution, which comprises the first full-electric robotic tool designed to operate in ultra-deep waters, has achieved an important mark in 2020, with the commissioning and start-of-operation of the first fabricated unit. In this article, we present lessons learned and discuss relevant specifications and programs of the technological development that contributed for the results obtained so far. Considering aspects on conception, technology, and environment of application, the pre-salt SAC required the adoption of new solutions on several disciplines of subsea engineering. As a typical case of technological development, the design process comprised decisions on engineering requirements and the establishment of a comprehensive qualification program. Now, after the first robot completing critical stages at field, such as subsea deployment, functional testing, and integration with the subsea system, we obtain a set of performance results that serve us to evaluate e.g. how effective were the selected technical specifications and testing routines, used throughout the engineering program. This discussion also provides possible adjustments in the overall development plan, considering its application as new generations of SAC arise. The commissioning in 2020 of the first robot resulted in its full integration with the subsea manifold and the correspondent production system, contributing to water-alternating-gas injection in the pre-salt field Tupi Extremo Sul. A second subsea system featuring the same model of robotic tool, for manifold control, is in advanced schedule in 2021 for integration in Búzios II, another pre-salt field in Brazil. Confirming the advantages that we could expect with the adoption of SAC in subsea equipment, the pre-salt SAC allowed a series of optimizations on design of the robot-controlled manifold. The robot tool replaced all the hydraulic actuators that traditional control systems, based on electric-hydraulic multiplexing, would require to implement remote controlling of the manifold valves. This led to a significant reduction on sizes and weight of the manifold structure.

Malaysia's First Successful Implementation of Sand Consolidation Technology as a Primary Sand Control Method Executed during the Drilling Phase: Success Story and Lessons Learned

2021 ◽  
Author(s):  
Nadiah Kamaruddin ◽  
Nurfuzaini A Karim ◽  
M Ariff Naufal Hasmin ◽  
Sunanda Magna Bela ◽  
Latief Riyanto ◽  
...  
Keyword(s):  
Control Method ◽  
Movement Control ◽  
Lessons Learned ◽  
Successful Implementation ◽  
Success Story ◽  
Control Solution ◽  
Consolidation Process ◽  
Execution Plan ◽  
Well Completion ◽  
Sand Control

Abstract Field A is a mature hydrocarbon-producing field located in eastern Malaysia that began producing in 1968. Comprised of multistacked reservoirs at heights ranging from 4,000 to 8,000 ft, they are predominantly unconsolidated, requiring sand exclusion from the start. Most wells in this field were completed using internal gravel packing (IGP) of the main reservoir, and particularly in shallower reservoirs. With these shallower reservoirs continuously targeted as good potential candidates, identifying a sustainable sand control solution is essential. Conventional sand control methods, namely IGP, are normally a primary choice for completion; however, this method can be costly, which requires justification during challenging economic times. To combat these challenges, a sand consolidation system using resin was selected as a primary completion method, opposed to a conventional IGP system. Chemical sand consolidation treatments provide in situ sand influx control by treating the incompetent formation around the wellbore itself. The initial plan was to perform sand consolidation followed by a screenless fracturing treatment; however, upon drilling the targeted zone and observing its proximity to a water zone, fracturing was stopped. With three of eight zones in this well requiring sand control, a pinpoint solution was delivered in stages by means of a pump through with a packer system [retrievable test treat squeeze (RTTS)] at the highest possible accuracy, thus ensuring treatment placement efficiency. The zones were also distanced from one another, requiring zonal isolation (i.e., mechanical isolation, such as bridge plugs, was not an option) as treatments were deployed. While there was a major challenge in terms of mobilization planning to complete this well during the peak of a movement control order (MCO) in Malaysia, optimal operations lead to a long-term sand control solution. Well unloading and test results upon well completion provided excellent results, highlighting good production rates with zero sand production. The groundwork processes of candidate identification down to the execution of sand consolidation and temporary isolation between zones are discussed. Technology is compared in terms of resin fluid system types. Laboratory testing on the core samples illustrates how the chemical consolidation process physically manifests. This is used to substantiate the field designs, execution plan, initial results, follow-up, lessons learned, and best practices used to maximize the life of a sand-free producer well. This success story illustrates potential opportunity in using sand consolidation as a primary method in the future.

The Development of a Pressure Actuated Isolation Nozzle Assembly and its Application as Flow Control Device in Extended Reach Water-Alternating-Gas Pilot Wells

2021 ◽  
Author(s):  
Zhihua Wang ◽  
Aqib Qureshi ◽  
Tarik A Abdelfattah ◽  
Joshua R Snitkoff
Keyword(s):  
Flow Control ◽  
Drilling Fluid ◽  
Applied Pressure ◽  
Control Device ◽  
Lessons Learned ◽  
Production Performance ◽  
Dissolution Time ◽  
Enhanced Production ◽  
Water Alternating Gas ◽  
Flow Control Device

Abstract The re-development of a giant offshore field in the United Arab Emirates (UAE) consists predominantly of four artificial islands requiring in most cases extremely long horizontal laterals to reach the reservoir targets. Earlier SPE technical papers (1,2) have introduced the development, testing, qualification, and deployment of the plugged liner technology using the dissolvable plugged nozzles (DPNs). The use of DPN plugged liner technology has resulted in CAPEX savings and enhanced production performance. The benefits of DPN technology are its simplicity along with its cost effectiveness. However, the dissolvable material has some limitations, such as pressure rating and dissolution time, which are fluid chemistry dependent. To overcome these limits, a new Pressure Actuated Isolation Nozzle Assembly (PAINA) was developed as an alternative to the plugged liner tool for applications where a higher pressure rating is required, as well as on demand opening. Furthermore, the new PAINA also functions as a flow control device during injection and production, enhancing acid jetting effects during bullhead stimulation and reducing brine losses during liner installation. Liners with PAINAs can be run to TD similar to blank pipe: fluids can be circulated through the inside of the liner without the need for a wash pipe. Once on bottom, non-aqueous drilling fluid is displaced to brine without actuating the isolation mechanism. When the well is ready for production or injection, pressure is applied and the isolation mechanism is activated to establish communication between well and reservoir. These tools were successfully run as flow control devices in water-alternating-gas (WAG) pilot wells. The planning and execution of the initial application will be discussed, along with the tool development, qualification testing, and lessons learned. The key advantage of this technology is in extending plugged liner applications to cases where other pressure-operated tools are included as part of the liner lower completion. Pressure can be applied to the well multiple times without activating the isolation mechanism as long as the applied pressure is below the actuation pressure.

Experience with Chemical Injection and Umbilicals in Pre-Salt Fields

2021 ◽  
Author(s):  
Sidnei Guerreiro Da Silva ◽  
Andre Athayde Gonçalves ◽  
William Albuquerque Da Silva ◽  
Rafael Di Lorenzo Filho
Keyword(s):  
Control Systems ◽  
Deep Water ◽  
Production Systems ◽  
Poor Performance ◽  
Lessons Learned ◽  
Operational Experience ◽  
The Poor ◽  
Design Requirements ◽  
Chemical Products ◽  
Wax Deposits

Abstract The characteristics of Pre-Salt carbonate reservoirs demand downhole chemical injection to prevent scale, asphaltene, and wax deposits, besides the need of H2S scavenger, and MEG, normally injected at Xmas tree (WCT). The poor performance of injection systems installed in Santos Basin, together with production risks associated to the lack of chemical injection, led the project team to re-evaluate design requirements, such as chemical products characteristics, production systems equipments, umbilicals, and chemical injection valves. In addition, umbilical failures are being observed in other deep-water fields, related to subsea control systems functions. This paper focuses on Company operational experience and lessons learned related to umbilicals and downhole chemical injection.

Requirements Management for Data Driven Requisitions

2021 ◽  
Author(s):  
Duncan James McLachlan ◽  
Changlih Ee ◽  
Jeroen Veen ◽  
Fabien Cochet ◽  
Daniele Tomassi ◽  
...  
Keyword(s):  
Systems Engineering ◽  
Task Force ◽  
International Association ◽  
Substantial Reduction ◽  
Lessons Learned ◽  
Data Driven ◽  
Requirements Management ◽  
Technical Specifications ◽  
Equipment Supplier

Objectives/Scope Systems engineering techniques, particularly requirements management, are critical to realizing the value of digital transformation to improve capital project delivery. Drawing on the results of a case study, this paper will demonstrate the value of using digital requirements management to exchange information through a project lifecycle, specifically showing benefits in the integrity of data transfer; more efficient procurement lifecycle; more robust deviation management; and bidirectional traceability of requirements, including full visibility and end to end verification and validation. Methods, Procedures, Process A requirement is a capability to which a project outcome (product or service) should conform, and the purpose of requirements management is to ensure that an organization documents, verifies and validates these capabilities. In this case study the operator provides their technical specifications in the form of requirements. These requirements are then imported into the EPC's PLM platform, where they are supplemented with additional information from the EPC's engineers to create a requirements-based requisition package. This is then transmitted to the equipment supplier, where it is reviewed and, for the purposes of the case study, reviewed for completeness. To test the ability to identify changes and deviations, the EPC engineer modified the requirements and the file was transferred to both the operator and equipment supplier to ensure the changes were transferred and were identifiable. The case study also demonstrates how verification activities (testing, commissioning, etc.) can be linked to requirements; passed through the supply chain and be modified to capture changes to the status of the activity (such as test results). Results, Observations, Conclusions The case studies described show how requirements can be exchanged between operator, EPC and equipment supplier without any loss of data. It will also show how this approach allows a data driven approach, as opposed to a document driven approach, to be deployed in the requisitioning process, which could facilitate substantial reduction in the procurement lifecycle. This is achieved by removing extraneous information exchanged between the companies; the removal of swivel chair solutions, where data is extracted from one system and transferred to another; and expediting the bid evaluation stage. Finally, the case study will demonstrate how this approach could be extended beyond the purchase order to provide a direct link between specific requirements and testing (FATs) or commissioning activities, which facilitates a more efficient process for verification as well as ensuring a digital record of the entire lifecycle of a package. The case study highlighted the importance of aligning data model and developing workflows, these findings are captured in the lessons learned section and have been shared with the International Association of Oil and Gas Producers (IOGP) Requirements Digitalization Task Force (RDTF). Novel/Additive Information The paper will also include a vision of requirements models can be used to establish a holistic requirements model of a project, including the interdependencies of different system components. The case study will also demonstrate how the adoption of a common data standard for requirements allows a software agnostic solution that can be adopted by all.

A Model Repository for Automotive Embedded Control Systems Design

2003 ◽  
Author(s):  
Kenneth R. Butts ◽  
Ravi Rangan ◽  
Mark Jennings ◽  
Gail Cheng
Keyword(s):  
Product Development ◽  
Control Systems ◽  
Data Model ◽  
Configuration Management ◽  
Systems Design ◽  
Lessons Learned ◽  
Embedded Control ◽  
Embedded Control Systems ◽  
Model Repository ◽  
Control Systems Design

Model-based product development methodologies are becoming more widely used by developers of automotive embedded control systems. This paper presents a model repository intended to provide configuration management, reuse, and sharing infrastructure in support of this trend. An initial set of repository requirements is presented and then augmented with lessons-learned from a pilot realization of the system. This pilot realization is discussed with respect to implementation and application. A repository data model is also described.

Anomaly Criteria for General Visual Inspection of Subsea Flexible Pipes

2020 ◽  
Author(s):  
Damir Tadjiev
Keyword(s):  
Visual Inspection ◽  
Service Failure ◽  
Lessons Learned ◽  
Inspection Method ◽  
Deep Waters ◽  
Flexible Pipes ◽  
Increased Risk ◽  
Competent Person ◽  
Routine Basis ◽  
Areas Of Concern

Abstract For flexible pipes in subsea applications, General Visual Inspection (GVI) by Remotely Operated Vehicles (ROV) remains the most common inspection method that is used on a routine basis. It enables verification of pipe configuration or layout and also helps to identify any areas of concern indicative of an increased risk of in-service failure. The success of ROV GVI chiefly relies on the anomaly criteria used, these help inspectors to identify any areas of concern, which can then be assessed by a competent person to ensure any threat to the integrity of an inspected component is identified and addressed. Currently there are no commonly accepted anomaly criteria for ROV GVI of flexible pipes. As a result there is no consistent approach between different operators and experience shows that the inspection approach and anomaly criteria are often adopted from what has traditionally been used for rigid pipes. Since flexible pipes have different design and associated failure threats and mechanisms to rigid pipe, use of this approach may result in under or over inspection of flexible pipes. This paper presents a set of anomaly criteria for ROV GVI of flexible pipes. The criteria were developed using the experience and lessons learned from a population of approximately 350 flexible pipes from two different manufactures operating in deep waters of the UKCS for over a period of 20 years. The criteria cover dynamic flexible risers and associated ancillary equipment, seabed flexible flowlines and jumpers. The applicability of the proposed anomaly criteria to other systems, the benefits of having commonly accepted anomaly criteria, the anomaly detection capability of ROV GVI and the reporting of anomalies are also discussed.

35 Years of Incineration in Studsvik: Lessons Learned and Recent Modifications and Improvements

2011 ◽  
Author(s):  
Maria Lindberg ◽  
Joakim Lo¨vstrand ◽  
Karin von Kronhelm
Keyword(s):  
Radioactive Waste ◽  
Control Systems ◽  
Lessons Learned ◽  
Nuclear Industry ◽  
Academic Institutions ◽  
Waste Streams ◽  
Gas Treatment

Since the incinerator in Studsvik was taken into operation in 1976 it has been operating at a level of 350–500 tonnes per year. The incinerator treats waste from both the nuclear industry and from other sectors generating radioactive waste such as hospitals, research companies/facilities and academic institutions. The incineration facility has been upgraded several times during its lifetime. The upgrades includes, change of off gas treatment as well as new control systems and currently the commissioning of a sister pyrolysis plant. Several new waste streams have also been approved for treatment in the last few years.

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