Patent Application
20180328541
Aspects of the disclosure are directed to flow of multiphase fluids in a conduit, and more particularly, to methods and systems to maintain the flow of such multiphase fluids at ambient temperatures conducive for the formation of clathrates and or wax in the conduit.
Clathrate hydrates (commonly called hydrates) are composites formed from a water matrix and a guest molecule, such as methane or carbon dioxide, among others. The presence of water in hydrocarbon production fluids may cause problems while transporting hydrocarbon fluids because of the formation of clathrate hydrates with hydrocarbon gases.
Various expensive techniques have been used to lower or reduce the ability for hydrates to form or cause plugging or fouling. These techniques include pipeline insulation, dehydration of the hydrocarbon-containing fluids, and adding hydrate inhibitors such as thermodynamic hydrate inhibitors ((THIs) and low dosage hydrate inhibitors (LDHIs). Examples of LHDIs include kinetic hydrate inhibitors (KHIs) and anti-agglomerates (AAs).
The hydrate-stability phase envelope includes the region on a temperature versus pressure diagram wherein hydrates may form because temperatures are sufficiently low, or pressures are sufficiently high, or both. Hydrates may form, for example, at the high pressures and low temperatures that may be found in pipelines and other hydrocarbon transportation equipment. After forming, hydrates can agglomerate, leading to plugging or fouling of the equipment. Hydrates can plug flow lines or other conduits by either forming large aggregates that plug the conduit, by film growth that constricts the conduit creating increased pressure drop, or a combination of these effects. Additionally, hydrate agglomeration can combine with other typical problems in conduit systems (for example, wax build-up) to create more difficult plugging issues.
When an effective level of kinetic hydrate inhibitors is in use, the conduit is generally free of hydrates both on the conduit wall as well as in the bulk flowing fluids. However, if the level of hydrate inhibitor is slightly low or during upset conditions a hydrate film can form on the wall of a conduit. This hydrate film along the wall can seed hydrate formation in the bulk flowing fluid. Further, when a hydrate film forms on the wall of a conduit, that hydrate film can seed hydrate formation in the bulk flowing fluid even when the bulk flowing fluid is treated with a KHI.
In contrast to KHIs, AAs allow hydrates to form, but the hydrates formed in the bulk liquid are generally limited in size and do not stick/adhere to each other. Besides hydrate formation in the bulk liquid, water film that forms on the conduit wall can form hydrates. Some AAs can slow hydrate film growth on conduit walls, but fail to altogether prevent hydrate film growth, which can ultimately lead to long term remediation efforts.
Still another technique is known as hydrate cold flow in which hydrates are permitted to form in the hydrocarbon fluid but are prevented from becoming attached to a conduit wall using various strategies. A common problem with hydrate cold flow is that while hydrates do not stick to the wall from the bulk phase, water films do form on the pipe wall and are then converted in situ to hydrate films. In many instances these water films form faster than systems using AAs. These hydrate films then grow slowly as additional water coats them and converts to hydrates. The process of hydrate film growth on the conduit wall is similar in end result to ice frost formation. Similarly, wax deposits may form the same way but by paraffin components in the crude oil that continually build up.
One method of preventing hydrate film growth is suggested in U.S. Patent Application Publication No. 2015/0260348, the disclosure of which is incorporated by reference herein in its entirety. The '348 application teaches that hydrate film growth may be prevented by using an additive that adheres to the conduit walls and inhibits hydrate growth only on the wall. The formation of hydrates in the bulk fluids continues, resulting in a fluid comprised of flowable hydrate particles carried along by the liquid fluids, including oil and water that has not been converted into hydrates. The fluid flow remains unrestricted because hydrates neither adhere to nor form on the pipe wall. However, the use of additives may require extra equipment for the injection, filtering, and/or recycling of the additive, thereby adding extra cost to a pipeline project.
Another method of preventing formation of hydrates may be to heat the pipeline. Conventional pipeline heating systems are designed to conserve the temperature of a pipeline fluid to prevent solids formation, especially wax and hydrates. In principle, conventional pipeline heating systems can be used at much higher power levels to melt hydrates and wax in a fluid. But conventional pipeline heating systems are not as suited for remediation of solids after their formation as it is for prevention of their formation. The reason is that the heat of fusion required to melt solids (the energy to effect a phase change) is much larger than the heat required to hold a fluid at constant temperature.
Traditionally, conventional pipeline heating systems are applied over the entire pipe length to maintain a fluid temperature above the hydrate or wax equilibrium temperatures, which takes a lot of power over long pipelines. What is needed is a way to prevent the formation of hydrate films within a pipeline that does not require large volumes/transport of expensive additives or traditional power-intensive pipeline heating systems.
The invention provides a method of transporting a mixed phase fluid in a conduit. A hydrate and/or wax film is permitted to deposit on an inner wall of the conduit in a conversion zone, the conversion zone being less than a length of the conduit. A quantity of heat is applied to the conduit in the conversion zone until the hydrate and/or wax deposited on the inner wall in the conversion zone separates therefrom, thereby inhibiting the continual formation of hydrates and/or wax on the inner wall. The separated hydrates and/or wax are flowed in the mixed phase fluid.
The invention also provides a system for heating a conduit. The conduit has a length and an inner wall and is configured to transport a mixed phase fluid. A heating element is positioned only in a conversion zone of the conduit, the conversion zone being defined as a portion of the conduit between a first location where a temperature of the inner wall is at a temperature at which hydrates and/or wax form in the mixed phase fluid, and a second location where a temperature of the inner wall is equal to an ambient temperature. The heating element is configured to be actuated to heat the conduit within the conversion zone until hydrates and/or wax deposited on the inner wall in the conversion zone separate therefrom and flow in the mixed phase fluid, thereby inhibiting continual formation of hydrates and/or wax on the inner wall.
Various specific aspects and versions of the present disclosure will now be described, including preferred aspects and definitions that are adopted herein. While the following detailed description gives specific preferred aspects, those skilled in the art will appreciate that these aspects are exemplary only, and that the present invention can be practiced in other ways. Any reference to the “invention” may refer to one or more, but not necessarily all, of the aspects defined by the claims. The use of headings is for purposes of convenience only and does not limit the scope of the present invention. For purposes of clarity and brevity, similar reference numbers in the several Figures represent similar items, steps, or structures and may not be described in detail in every Figure.
All numerical values within the detailed description and the claims herein are modified by “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
As used herein, “clathrate” is a composite made of a host compound that forms a basic framework and a guest compound that is held in the host framework by inter-molecular interaction, such as hydrogen bonding, Van der Waals forces, and the like. Clathrates may also be called host-guest complexes, inclusion compounds, and adducts.
As used herein, “clathrate hydrate” and “hydrate” are interchangeable terms used to indicate a clathrate having a basic framework made from water as the host compound. A hydrate is a crystalline solid which looks like ice, and forms when water molecules form a cage-like structure around a “hydrate-forming constituent.”
A “hydrate-forming constituent” refers to a compound or molecule in petroleum fluids, including natural gas, which forms a hydrate at elevated pressures, reduced temperatures, or both. Illustrative hydrate-forming constituents include, but are not limited to, hydrocarbons such as methane, ethane, propane, butane, neopentane, ethylene, propylene, isobutylene, cyclopropane, cyclobutane, cyclopentane, cyclohexane, and benzene, among others. Hydrate-forming constituents can also include non-hydrocarbons, such as oxygen, nitrogen, hydrogen sulfide, carbon dioxide, sulfur dioxide, and chlorine, among others.
“Exemplary” is used exclusively herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not to be construed as preferred or advantageous over other embodiments.
A “conduit” as used herein is an enclosed flow space such as flow lines, pipelines, flexibles, flexible risers, and other types of enclosed flow spaces. A conduit is not restricted to flow spaces with a cylindrical shape (i.e., with a generally circular axial cross-section), but is instead intended to encompass enclosed flow spaces of any desired cross-sectional shape, such as rectangular, oval, annular, non-symmetrical, etc. In addition, the term “conduit” contemplates enclosed flow spaces whose cross-sectional shape or size varies along its length.
A “mixed phase fluid” as used herein is a fluid containing constituents at two or more phases of matter. For example, a liquid-solid mixed phase fluid contains liquid matter and solid particulate matter flowing within the liquid. Two immiscible liquids may form so-called liquid-liquid mixed phase fluids. A gas and liquid dispersion is a gas-liquid mixed phase fluid containing a liquid and dispersed gas bubbles within the flowable fluid mixture.
A “facility” as used herein is a representation of a tangible piece of physical equipment through which hydrocarbon fluids are either produced from a reservoir or injected into a reservoir. In its broadest sense, the term facility is applied to any equipment that may be present along the flow path between a reservoir and the destination for a hydrocarbon product. Facilities may include production wells, injection wells, well conduits, wellhead equipment, gathering lines, manifolds, pumps, compressors, separators, surface flow lines and delivery outlets. In some instances, the term “surface facility” is used to distinguish those facilities other than wells. A “facility network” is the complete collection of facilities that are present in the model, which would include all wells and the surface facilities between the wellheads and the delivery outlets.
The term “FSO” refers to a Floating Storage and Offloading vessel. A floating storage device, usually for oil, is commonly used where it is not possible or efficient to lay a pipe-line to the shore. A production platform can transfer hydrocarbons to the FSO where they can be stored until a tanker arrives and connects to the FSO to offload it. A FSO may include a liquefied natural gas (LNG) production platform such as a floating LNG (FLNG) platform. The concept of a FSO may also include a floating production storage and offloading (FPSO) unit or any other floating facility designed to process and store a hydrocarbon prior to shipping.
A “formation” is any finite subsurface region. The formation may contain one or more hydrocarbon-containing layers, one or more non-hydrocarbon containing layers, an overburden, and/or an underburden of any subsurface geologic formation. An “overburden” and/or an “underburden” is geological material above or below the formation of interest.
The term “gas” is used interchangeably with “vapor,” and means a substance or mixture of substances in the gaseous state as distinguished from the liquid or solid state. Likewise, the term “liquid” means a substance or mixture of substances in the liquid state as distinguished from the gas or solid state. As used herein, “fluid” is a generic term that may include either a gas or vapor.
A “hydrocarbon” is an organic compound that primarily includes the elements hydrogen and carbon although nitrogen, sulfur, oxygen, metals, or any number of other elements may be present in small amounts. As used herein, hydrocarbons generally refer to organic materials that are transported by pipeline, such as any form of natural gas or oil. A “hydrocarbon stream” is a stream enriched in hydrocarbons by the removal of other materials such as water and/or any additive.
The term “cold flow” refers to a process that utilizes mostly mechanical means, e.g., static mixers, to achieve low viscosity hydrate slurry formation. The cold flow hydrate slurry may be analytically indistinguishable from the anti-agglomerant hydrate slurry, but its formation process is distinguishable.
“Pressure” is the force exerted per unit area by the gas on the walls of the volume. Pressure can be shown as pounds per square inch (psi). “Atmospheric pressure” refers to the local pressure of the air. “Absolute pressure” (psia) refers to the sum of the atmospheric pressure (14.7 psia at standard conditions) plus the gauge pressure (psig). “Gauge pressure” (psig) refers to the pressure measured by a gauge, which indicates only the pressure exceeding the local atmospheric pressure (i.e., a gauge pressure of 0 psig corresponds to an absolute pressure of 14.7 psia). The term “vapor pressure” has the usual thermodynamic meaning. For a pure component in an enclosed system at a given pressure, the component vapor pressure is essentially equal to the total pressure in the system.
“Production fluid” refers to a liquid and/or gaseous stream removed from a subsurface formation, such as an organic-rich rock formation. Produced fluids may include both hydrocarbon fluids and non-hydrocarbon fluids. For example, production fluids may include but are not limited to oil, natural gas, and water.
“Substantial” when used in reference to a quantity or amount of a material, or a specific characteristic thereof, refers to an amount that is sufficient to provide an effect that the material or characteristic was intended to provide. The exact degree of deviation allowable may in some cases depend on the specific context.
“Well” or “wellbore” refers to a hole in the subsurface made by drilling or insertion of a conduit into the subsurface. The terms are interchangeable when referring to an opening in the formation. A well may have a substantially circular cross section, or other cross-sectional shapes (for example, circles, ovals, squares, rectangles, triangles, slits, or other regular or irregular shapes). Wells may be cased, cased and cemented, or open-hole well, and may be any type, including, but not limited to a producing well, an experimental well, an exploratory well, or the like. A well may be vertical, horizontal, or any angle between vertical and horizontal (a deviated well), for example a vertical well may include a non-vertical component.
The term “natural gas” refers to a multi-component gas obtained from a crude oil well (associated gas) or from a subterranean gas-bearing formation (non-associated gas). The composition and pressure of natural gas can vary significantly. A typical natural gas stream contains methane (C1) as a significant component. Raw natural gas will also typically contain ethane (C2), higher molecular weight hydrocarbons, one or more acid gases (such as carbon dioxide, hydrogen sulfide, carbonyl sulfide, carbon disulfide, and mercaptans), and minor amounts of contaminants such as water, nitrogen, iron sulfide, wax, and crude oil.
Certain aspects and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
All patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
As previously explained, it has been proposed in the past to design flow lines and other conduits to prevent hydrate formation using insulation and electric heating (also known as heat tracing) along its entire length. However, it has been discovered that heating the entire length of a conduit is not necessary to prevent hydrate or wax films from depositing on the inner wall of the conduit. Described herein are methods and processes to heat only part of a conduit, known as limited flux heating (LFH), which allows the fluids to cool and only applies the limited heating until the fluids reach or are colder than the surrounding ambient temperatures. Such limited and intermittent heating to selected portions of a conduit significantly reduces the amount of heating components and operating power necessary to keep hydrocarbons flowing through a flow line or other conduit. Specific aspects of the disclosure include those set forth in the following paragraphs as described with reference to the Figures. While some features are described with particular reference to only one Figure, they may be equally applicable to the other Figures and may be used in combination with the other Figures or the foregoing discussion.
A flexible line 114 may couple the central pipeline 108 to a collection platform 116 at the ocean surface 118. The collection platform 116 may, for example, be a floating processing station, such as a floating storage and offloading unit (or FSO), that is anchored to the sea floor 106 by a number of tethers 120. The collection platform 116 may have equipment for dehydration, purification, and other processing, such as liquefaction equipment to form purified hydrocarbons for storage in vessels 122. The collection platform 116 may transport the processed gas to shore facilities by pipeline (not shown). Alternatively, flexible line 114 may transport hydrocarbons directly to shore-based processing facilities.
Heating elements associated with the disclosed heating system may completely or partially extend around an external and/or internal surface of the conduit.
In another aspect, the inner wall surface of the portion of a conduit in the above described hydrate forming region may be modified to prevent and/or destabilize adhesion of the hydrate and/or wax deposit thereto. Such modification may be accomplished by making the inner wall surface substantially smooth so that no hydrates and/or wax can adhere thereto. In other words, any protrusions on the inner wall surface are smoothed to a point where it is difficult or impossible for hydrates and/or wax to adhere to the wall. In effect, a fine layer of molecules, and particularly protruding molecules, is removed from the internal wall surface to obtain an internal wall surface that is smooth, and in some cases, the surface may have a nearly mirror-like finish. Non-limiting examples of the disclosed wall modification include (a) removing portions of the internal wall surface to obtain a substantially smooth surface, and (b) modifying the internal wall surface to include a coating surface.
Removing portions of the internal wall surface may include any method that can obtain a substantially smooth surface, such as mechanically and/or electrically removing material from the internal wall surface. Mechanically removing material from the internal wall surface may, for example, include sanding, grinding, sandblasting, and/or mechanically polishing the internal wall surface. Electrically removing material from the internal wall surface may, for example, include electropolishing the internal wall surface and/or laser ablating the internal wall surface. When the internal wall surface is electro-polished, an electrically-conductive solution may be held against the internal wall surface while electric current passes through the electrically-conductive solution. The electro-polishing may remove microscopic peaks of internal wall surface. Electrically removing the material may be preferred to mechanically removing the material because it may be easier to obtain a substantially smooth and homogenous surface.
Alternatively, the internal wall may be coated with any coating that can withstand the expected temperatures and pressures inside the conduit, and that provides non-stick characteristics. For example, the coating may be polytetrafluoroethylene (PTFE), which is considered to be low energy and can be made very smooth. Specifically, PTFE is not easily attracted to other components, so other components have difficulty adhering to PTFE. The coating may be any suitable thickness. For example, the coating thickness may be 100 microns to 300 microns, or about 100 microns to about 300 microns. Alternatively, the coating thickness may be 100 microns to 1 mm or about 100 microns to about 1 mm.
The electric heating system 612 shown in
The disclosed aspects have especial applicability to cold flow technologies, which as previously described are designed to permit hydrates and/or wax to form in a conduit and flow along with the transported hydrocarbons. Reducing or eliminating hydrate deposits and/or wax deposits on the inside wall of the conduit maintains flow within the conduit even under low-temperature conditions.
The disclosed aspects provide a method of preventing hydrate and/or wax formation by electric heating of only a portion of a conduit. An advantage is a significant reduction in cost when compared to conventional heating systems. Especially for very long tiebacks or conduits, the disclosed LFH process requires a significantly shorter area to be equipped with electric heating components by allowing the fluids to cool and only applying LFH until the fluids reach or are colder than the surrounding ambient temperatures. In the case of a 200 km tieback this may reduce the needed electric heating system to only 6-10 km depending on the transported fluids. It is also envisioned that this process can be more fully optimized with the coupling to wellhead separation techniques.
Another advantage is that the disclosed aspects can be used advantageously with cold flow technologies and strategies, and that there would be no need to inject inhibition chemicals (e.g., methanol, AA, KHI, and the like) into the conduit. Still another advantage is that with an effective cold flow empowered by the disclosed aspects, dual pipeline systems required for pigging would not be needed. Yet another advantage is that the predictable formation of hydrate and/or wax deposits—as a function of temperature—enables an easily operable system to periodically slough off the deposits.
Aspects of the disclosure may be modified in many ways while keeping with the spirit of the invention. For example, the disclosed aspects have been described as principally used to eliminate hydrate deposits, but the disclosed aspects may be equally useful for the elimination of wax deposits, which exhibit similar temperature-based deposition behavior. Of course, the temperature(s) at which wax may be deposited on an inner wall of a conduit may be different from the hydrate deposition temperature(s), and therefore the locations and lengths of the electric heating components may differ. Additionally, the required frequency of actuation of the electric heating components may also differ for wax deposits. As a non-limiting example, one of the sub-portions 906b of portion 906 (
Aspects of the disclosure may include any combinations of the methods and systems shown in the following numbered paragraphs. This is not to be considered a complete listing of all possible aspects, as any number of variations can be envisioned from the description above.
1. A method of transporting a mixed phase fluid in a conduit, comprising:
2. The method of paragraph 1, further comprising:
3. The method of paragraph 1 or paragraph 2, wherein the cold flow process includes:
4. The method of any of paragraphs 1-3, further comprising:
5. The method of any of paragraphs 1-4, further comprising defining the conversion zone as beginning at the first location and ending at the second location.
6. The method of any of paragraphs 1-5, further comprising:
7. The method of any of paragraphs 4-6, wherein the conversion zone is further defined by one or more of
8. The method of any of paragraphs 1-7, further comprising:
9. The method of any of paragraphs 1-8, further comprising:
10. The method of paragraph 9, wherein the plurality of sub-zones comprises a first sub-zone and a second sub-zone, and wherein more hydrates and/or wax form within the first sub-zone than in the second sub-zone, the method further comprising:
11. The method of any of paragraphs 1-10, wherein the quantity of heat is applied in an intermittent operation.
12. The method of any of paragraphs 1-11, wherein the conduit is uninsulated at least in the conversion zone.
13. The method of any of paragraphs 1-12, further comprising sanding, grinding, sandblasting, mechanically polishing, or electropolishing the inner wall of the conduit in the conversion zone.
14. The method of any of paragraphs 1-13, further comprising coating the inner wall of the conduit with a non-stick coating in the conversion zone.
15. The method of any of paragraphs 1-14, wherein the conversion zone is a hydrate conversion zone in which hydrates are permitted to deposit on the inner wall, and wherein the quantity of heat is a first quantity of heat, the method further comprising:
16. The method of paragraph 15, further comprising:
17. A system for heating a conduit, the conduit having a length and an inner wall, the conduit configured to transport a mixed phase fluid, the system comprising:
18. The system of paragraph 17, further comprising a temperature sensor located along the conduit.
19. The system of paragraph 17 or paragraph 18, wherein the conversion zone is divided into a first sub-zone and a second sub-zone such that more hydrates and/or wax form within the first sub-zone than in the second sub-zone, and wherein the heating element is actuated to provide more heat to the first sub-zone than to the second sub-zone.
20. The system of any of paragraphs 17-19, further comprising a non-stick coating applied to the inner wall of the conduit in the conversion zone.
21. The system of any of paragraphs 17-19, wherein the inner wall has been treated in the conversion zone using one of sanding, grinding, sandblasting, mechanically polishing, or electropolishing.
While the foregoing is directed to aspects of the present disclosure, other and further aspects of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
This application claims the benefit of U.S. Provisional Patent Application 62/505,411 filed May 12, 2017 entitled HEATING SYSTEMS FOR FILM GROWTH INHIBITION FOR COLD FLOW, the entirety of which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 62505411 | May 2017 | US |
