Patent Grant
10549325
The invention relates to an apparatus and a method that removes deposits on the inside and/or outside walls of pipes as set out in the introduction to the independent claims.
Pipelines that are used to transport products such as petroleum, gas or other fluids can become blocked or inefficient through the build up of deposits on the pipe walls. The deposits can be foreign material, detritus, or natural waste products such as, for example, paraffin, calcium, wax, hydrates, scaling, naftenat and asphaltenes. In order to remove these undesired deposits pipes and pipelines in general require cleaning, testing or gauging. A well known technique to obtain such removal is to use a so-called “pig” (Pipe Inspection Gauge). The pig is designed to fit closely within the pipe and is caused to travel along the pipe by admitting fluid under pressure behind the pig. During the travel the deposits are removed from the inner surface by scraping or brushing, or simply by pushing the deposits ahead of it as it travels to a point where it can be removed along with the released deposits. Such mono-directional pigs, which are transported along with the fluid flow, may become stuck when it encounters large amounts of pipe wall deposits, and thus form a permanent plug in the pipeline. Examples of traditional mono-directional pigs may be found in GB 2,141,201 A or FR 2,630,934 A1. Very recently bi-directional pigs have been demonstrated suitable for removing deposits within subsea hydrocarbon production flowlines, see WO 2012/093079 A2.
Removal of deposits is particularly important in the oil and gas industry. Severe problems often occur when hydrocarbon fluids are transported in long subsea pipelines at large depths and in cold waters. Such problems may include the formation of obstructions in the pipeline, in the form of hydrates or other deposits such as ice, wax and debris (e.g. asphaltenes, sand). The initially warm well fluid is cooled down by cold seawater, thereby inducing condensation, precipitation and hydrate and wax formation/crystallization. Below is a non-exhausting number of known methods disclosed that often are employed for removing the undesired wax and hydrate formation, or preventing the formation of such:
Several disadvantages have been associated the use of pigs. A pigging system typically comprises a pig launching station and a retrieving station, each comprising an assembly of isolation valves, a trap barrel, an entry hatch and a bypass valve, enabling an operator to launch a pig (by support of a vessel) into the pipeline safely and to retrieve it at the other end. The trap barrels are generally closed at one end and situated outside the main pipeline. The system tends to take up a large volume and is heavy. Pigs are also launched from a top side facility (platform or land) and two costly production pipes are thus needed (pig loop) instead of just one. Also, the well stream production must in many cases be reduced in order not to impose too high pressure on the pig. As mentioned above it has recently been published a bi-directional pig apparatus that overcome these shortcomings. This pig apparatus disclosed in WO 2012/093079 A2 comprises a pig arranged for movement inside a pipe and includes a tubular body having a longitudinal axis coinciding with the central axis of the pipe and a through-going opening allowing fluids in the pipe to flow through the body. The pig apparatus also comprises propulsion means arranged and configured for imparting a motive force to the pig to allow the pig to move inside the pipe portion independently of the fluid flow. However, this system still necessitates a movable pig inside the pipe and propulsion means to impart the required pig movements, setting a complexity level that may prove costly and cumbersome. Even with the novel bi-directional plug operations based on plugging will face the risk of operational challenges such as pig obstruction due to excessive deposit formation.
With the exception of the pig apparatus disclosed in WO 2012/093079 A2 the measures taken to prevent formation or hydrate and wax deposits today have clear limits when it comes to transportation distance. The longer the pipe, the higher the cost.
A simple and reliable system for ensuring subsea transport of hydrocarbons over long distances is to allow so-called “cold flow”. If the well stream fluids, pipeline wall and the ambient seawater all are at the same or similar temperature, wax deposits do not form on the interior pipe wall surface, but are transported together with the well fluid without problems. Cold flow is normally achieved by allowing the well stream to be cooled to ambient seawater temperature simply by heat exchange through the pipeline wall. However, severe hydrate and wax formation will take place in the pipeline section where cooling takes place. This relatively short cooling section, typically 1000 m or less, will therefore have to go through deposit removing operations on a more frequently basis, for example by using the above mentioned pigs as disclosed in WO 2012/093079 A2 or by statically exposing the relevant section to heating for short period of time as disclosed in WO 2009/051495.
It is therefore a need for an apparatus and a method that removes deposits, particularly on the inside walls of pipe sections, in areas with excessive amount of deposits, for example around the cooling sections in case of the “cold-flow” process, and which overcome shortcomings of the prior art and obtains further advantages.
The invention is set forth and characterized in the main claims, while the dependent claims describe other characteristics of the invention.
In particular, the invention concerns a fluid flow processing plant and a method for pig-free removal of wax and hydrate deposits in hydrocarbon production flowlines or pipes/pipelines. The plant comprises at least one cooling flowline and cooling means arranged to cool the fluid in the cooling flowline(s) over a cooling section until the fluid reaches a temperature at or near the cooling flowline's surrounding/ambient temperature, thereby significantly reducing or eliminating the possibility of the deposits to stick to the inner walls of the flowlines. The plant further comprises at least one vehicle arranged on at least one of the at least one cooling flowline, where each vehicle, or some of the vehicles, comprise(s) at least one sleeve/segment configured to at least partly surround the outer circumference of the cooling flowline, deposit removing means at or near the outer circumference of the cooling flowline, the deposit removing means being configured to remove deposits situated on the inner wall of the cooling flowline, and a propulsion unit configured to drive the vehicle bi-directionally on the cooling flowline. The cooling section is defined as the area of the cooling flowline(s) in which the through passing fluid experiences a cooling due to the imposed cooling mechanism as will be explained in more details below.
The inventive plant should be suitable for subsea hydrocarbon production, but may advantageously also be suitable for top-side or onshore production.
At least one of the at least one vehicle is preferably retrievable, for example by use of a ROV in case of subsea production, for example by connecting the respective vehicle to the outer circumference of the respective cooling flowline by a hinged clamp-on technique, by magnets, etc.
Further, the deposit removing means may comprise heating means configured to heat the inner walls of the cooling flowline, thereby allowing heat induced removal of deposits. The heating means may advantageously be configured to heat the inner wall by heat pulses of finite time durations in order to avoid melting of the deposits to be released. The duration of the heat pulses is preferably set to be long enough to remove a major part of the deposit from the inner wall within the cooling section. At the same time the duration is preferably short enough, and/or the intensity is preferably low enough, to avoid any substantial melting of a major part of the deposit within the cooling section. Alternatively, or in addition to heating means, the deposit removing means may comprise vibration means configured to cause vibrations of the inner wall of the cooling flowline, thereby allowing vibration induced removal of deposits. In the latter case the frequencies of a major part of the vibrations set off by the vibration means lie preferably within the ultrasonic range. The formulation “a major part” signifies in this application a part constituting more than 50% of the total frequency range.
The induced release of deposits may also be achieved by allowing at least one of the at least one vehicle to traverse the relevant part(s) of the cooling flowline with a predetermined speed and a predetermined setting of the heating and/or vibration. For example, in order to obtain favourable heat exposure the vehicle(s) is/are set with a continuous heating effect and a constant speed, or with a continuous heating effect and a variable speed. The latter parameter may also function as a replacement or an addition to any setting/adjustment of the heat pulse time durations under an optimization procedure.
In an alternative embodiment of the invention the propulsion unit is self-sustained, for example by means of one or more dedicated batteries connected to mechanical systems based on pitch rack between flowlines, winch systems, dedicated wheels on the vehicles, etc. The propulsion system may also be a magnetic force generated within the vehicle by a dedicated magnetic system. Such a propulsion unit may comprise thrusters, for example thrusters normally used in ROV.
In yet a preferred embodiment of the invention the plant further comprises dedicated charging means for the vehicle(s), for example by means of umbilicals and/or dedicated station(s) distributed close to or on the cooling flowlines, that may provide inter alia power and communication signals.
In yet a preferred embodiment of the invention the plant comprises several vehicles on each of the at least one cooling flowlines, each operating in dedicated section(s) of its respective cooling flowline.
In yet a preferred embodiment of the invention the plant further comprises a feed flowline fluidly connectable to a fluid reservoir and an export flowline, wherein the at least one cooling flowline is fluidly connecting the feed flowline with the export flowline.
The cooling flowline(s) constituting the cooling section may be configured in various manners such as in parallel, helical/spiral, elevated or a combination thereof. In a preferred embodiment of the invention the plant comprises a plurality of cooling flowlines, for example arranged substantially parallel with each other and/or stacked vertically. The plurality of cooling flowlines may be connected to the feed flowline and the export flowline via an inlet manifold and an outlet manifold, respectively, where each one of the plurality of cooling flowlines comprises the vehicle or vehicles.
In yet a preferred embodiment of the invention the plant is, during use, supported on the seabed below a body of water and connected in fluid communication with one or more subterranean fluid reservoirs producing a hydrocarbon containing flow having a temperature which is higher than the ambient seawater temperature. The plant may be situated directly on the seabed or be lifted above the seabed by a frame structure or a combination thereof.
In yet a preferred embodiment of the invention the plant further comprises a return line used for example to boost production and/or to feed seed particles therethrough. The return line is in this embodiment fluidly connected between the export flowline and the feed flowline adjacent to the inlet of the cooling flowline(s). The return line may advantageously also comprise pumping means and valve means, whereby a portion of the flow in the export flowline may be fed into the flow upstream of the at least one cooling flowline. In this way the colder fluid in the export flowline exiting the cooling flowline(s) will act as a cooling agent for the warmer fluid in the feed flowline entering the cooling flowline(s). A beneficial effect of feeding a fraction of the cooled fluids into the warm well stream in the feed flowline before it enters the cooling flowline(s) is obtained by introducing comparably dry hydrate seed particles into the flow. These dry particles are in effect condensations seed particles for gas hydrates forming kernels for the further particle growth. Thus, inert and dry hydrate particles are suspended in the liquid phase as the well stream enters the cooling section, yielding less deposit in the cooling flowline(s). Dry hydrates are not as problematic as adhesive hydrate slurry or wet hydrate formed on water molecules. The return line may optionally be furnished with an inside situated pig in accordance with prior art, for example as disclosed in WO 2012/093079. In case of subsea hydrocarbon production the ideal fluid temperature within the cooling flowline(s) (i.e. in order to obtain the above mentioned beneficial effect) is within 1-3° C. higher than ambient temperature, the latter being typically 4° C. (standard seabed temperature). However, note that the temperature can be more or less than 4° C. in certain areas.
In yet a preferred embodiment of the invention at least one of the above mentioned vehicles is/are used to operate/run one or more pumps within the cooling section and/or within the return line.
In yet a preferred embodiment of the invention the vehicle(s) further comprise(s) one or more wall-cleaning means arranged in contact with the outer circumference of its or their respective cooling flowline.
As mentioned above the invention also concerns a method for pig-free removal of wax and hydrate deposits in subsea hydrocarbon production flowlines. The method comprises the following steps:
The movement of the vehicle may be performed by an integrated propulsion unit, externally operated propulsion unit or a combination thereof. The vehicle is preferably retrievable and the deposit removing means may comprise heating means allowing heating of the inner walls of the cooling flowline and/or vibration means allowing vibrations exerted on the inner wall of the cooling flowline. In the latter case the frequencies of a major part of the vibrations set off by the vibration means preferably lie within the ultrasonic range. Furthermore, any heating of the inner wall by the at least one heating element may advantageously be performed by heating pulses of finite time durations in order to avoid melting of the deposits to be released. Note that heating element is defined as any means capable of heating a nearby object, for example by means of resistive heating or inductive heating.
The method may use any other features and combination of features specified in connection with the above disclosed plant.
By means of the invention may wax and hydrate deposits, etc., in hydrocarbon production flowlines be removed in an efficient manner, in particular for subsea production. The plant uses rapid cooling of the flow in the cooling section to assure long distance export of hydrocarbons below Wax Appearance Temperature (WAT) and at the same time ensures that deposits are continuously or frequently removed along the cooling sections.
The invention is applicable to any hydrocarbon flow, such as multiphase, oil, gas and condensate where deposits such as wax and hydrate might be a problem, and to other types of flow or production in pipes where deposits, debris or material sticking on the interior pipe walls may occur. Examples of such other fluid flows are water, coolants, fuels or sewage. The deposits may in principle be any dry or fatty particulates that are removable by means such as heating or vibration. Removal of deposits from fish feed pellets in distribution pipes is an example of alternative deposits.
In the cooling section, cooling may be further improved by actively forcing water (or air if on land) over the cooling pipes, by e.g. propellers, fans, etc. Circulation around the cooling pipes is enhanced by natural convection, and the cooling pipes may be arranged in an inclined configuration in order to further utilize this effect. Natural ocean currents may also be useful in the cooling process, e.g. by arranging the pipes transversely with respect to the currents. The pipes in the cooling section may also comprise a pipe-in-pipe arrangement where the well fluids flow in an inner pipe and cooling fluids flow in the annulus between the inner pipe and the outer pipe, preferably in the opposite direction of the well fluids. The length of the cooling section will depend on production volume and flow rates, as well as the contents and temperature of the fluid. The greater the number of parallel intermediate pipes is, the shorter the length of the cooling section may be.
If the vehicle is retrievable it may easily be replaced if malfunction occurs. The vehicle(s) may contain any kind of propulsion systems, wired and/or wireless. Electro magnets in the vehicle can be used for inductive heating in order to achieve the desired melting of hydrate or wax deposits formed on the pipe's inside walls. Plugs that clog the pipe entirely can also be melted, if they occur. In case of wired connection may power be provided via umbilical/tether from an adjacent unit, via cables on the sea floor or on reels, or via electricity passed through the pipes or rails on the pipes. The vehicle(s) may be rechargeable via docking/recharging stations at one or both ends of the cooling section, or distributed along the pipes, as an alternative to said direct or indirect powering by suitable umbilicals/tether cables.
The vehicle can be used as a platform for inspection of the pipelines and surrounding structures. Devices such as cameras, ultrasonic sensors, acoustic microphones, eddy current probes, temperature meters, distance meters, current and voltmeters might be mounted on the vehicle. In addition lights, lasers, position transponders and/or any communication system can be mounted. One or more ROV manipulator arms might also be mounted for better inspection and/or intervention work. A small ROV, mainly for inspection, might also be fitted for more inspection range. The ultrasonic sensors (or any other vibrational or optical sensors) may for example be used as a mean to measure wall thickness and other characteristics of deposit layers.
Moreover, the vehicle can be used to pull at least one internal object inside the pipe by locking to the internal object magnetically. The magnetic force can be provided through inductive spools or permanent magnets clamped on the outside or close to the outside of the pipe. In one embodiment the at least one internal object is a pump piston that can be used to boost production and/or to feed particles through the aforementioned return line. In a more preferred embodiment the plant comprises at least two internal objects such as pump pistons. The latter configuration may achieve a more even/steady flow since two or more objects/pistons allow an almost non-interrupting pumping performance by at least one of the pistons. In contrast, the operation of only one pump object/piston causes the fluid to flow more in gusts. The object(s)/piston(s) is/are preferably hollow in order to let fluid flow pass. Further, to ensure flow in one direction only, at least one one-way valve such as a flapper valve, ball valve or similar may be arranged at one or both ends of each object/pump, thereby improving production through pumping/pushing when the object(s)/piston(s) is/are moved in the flow direction, preferably with a speed significantly higher than the flow velocity. The valve(s) might be locked in an open or locked position if necessary. In the particular embodiment comprising multiple internal objects with one-way valves the objects may be allowed to pump sequentially, i.e. during the pumping of one object/pump, others are “charged” by being guided back to theirs (former or new) initial pumping position by means of the spools or permanent magnets mentioned above. The internal object(s) may be relocated to a parking position outside the cooling flowline(s), allowing maintenance and/or receiving/launching of other internal objects. The vehicle can be used as the retrievable magnetic spool/clamp to be placed on or by the pipe at any point. This magnetic clamp may act as an inductive pipe heater or (as indicated above) a magnetic field generator that propels the (magnetic) internal object within the pipe. Several magnetic clamps or vehicles can be mounted in series on a non-magnetic pipe and drive the internal object for longer distance inside the pipe. In the case that the internal object is a pump piston, the retrievable magnetic spools/clamps will work as a modular linear actuator or pump acting through the pipe wall. The stroke of the pump might be long or short, and, as explained above, two or more pump pistons can be moved in the same system to increase the pump effect. However, permanent inductive spools mounted on the pipe can do the same as the magnetic clamp described above. In both cases one or more magnetic spools might be placed around, parallel, arrayed, radially or axially to the pipe. The vehicle/clamp may also be a stationary, yet retrievable, spool comprising heat means and/or electromagnetic means for moving the at least one internal object.
The invention provides an efficient tool for removing ice from a pipe, both on the inside wall (by e.g. heating) and optionally on the outside wall (by any cleaning elements on the trolley). During normal operation the vehicle used in the inventive plant has limited or no use of support from external sources such as a support vessel or ROVs. Further the vehicle may be operated fully automatic with its own propulsion system, the latter being either self-driven, remotely controlled or a combination thereof. Finally, the operation may be either discretely or continuously.
These and other characteristics of the invention will be clear from the following description of preferential forms of embodiment, given as non-restrictive examples, with reference to the attached schematic drawings wherein:
The return line 3 is equipped with a valve 4 and a pump 5 in order to control the fraction of the fluid flow. The transition from the feed flowline 16 to the multiple cooling flowlines 2, and the transition from the multiple cooling flowlines 2 to the export flowline 17, is controlled by an inflow manifold 6 and an outflow manifold 7, respectively. Comparably warm well fluids 19 are fed from subterranean reservoirs into the cooling flowlines 2. Here, heat exchange with the ambient seawater 18 takes place by thermal convention through the walls of the flowlines. When the fluids reach the outflow manifold 7, the temperature of the well fluids is ideally on the same level as the temperature of the seawater (Tsea), and the cooler well fluids 24 are fed into the export flowline 17. The efficiency of the heat exchange will increase with the number of the cooling flowlines 2 and its individual dimensions. The cooling flowlines 2 are in
An example of a vehicle 9 that may be used with the inventive plant 1 is illustrated in
The wheels 13 are in the illustrated embodiment driven by an electric motor which may be powered by on-board batteries or from an external source via an umbilical 15. The wheels 13 may be rubber wheels, rolling directly on the pipe outer wall. The wheels 13 may also be gear wheels, rolling in a pitch rack 14 in a rack-and-pinion configuration. Other propulsion units may for example be based on various winch and/or thruster configurations.
Schematic presentations of the above mentioned first or second vehicle 9 during operation are shown in
Other embodiments of the vehicle 9 may be found in the publication WO 2012/093079 which is hereby included by reference.
In the preceding description, various aspects of the apparatus according to the invention have been described with reference to the illustrative embodiment. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the apparatus and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the apparatus, which are apparent to persons skilled in the art to which the disclosed subject matter pertains, are deemed to lie within the scope of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 20131438 | Oct 2013 | NO | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2014/072286 | 10/17/2014 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2015/062878 | 5/7/2015 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 3843409 | Ice | Oct 1974 | A |
| 6939082 | Baugh | Sep 2005 | B1 |
| 8424608 | Lugo | Apr 2013 | B1 |
| 8555978 | Ganelin | Oct 2013 | B2 |
| 9327810 | Zediker | May 2016 | B2 |
| 9605916 | Stickling | Mar 2017 | B2 |
| 10018432 | Stickling | Jul 2018 | B2 |
| 20030217422 | Tsai | Nov 2003 | A1 |
| 20050061512 | Reid | Mar 2005 | A1 |
| 20100300486 | Hoffman | Dec 2010 | A1 |
| 20120073823 | McClanahan | Mar 2012 | A1 |
| 20130233350 | Tomkins | Sep 2013 | A1 |
| 20130298937 | O'Donnell | Nov 2013 | A1 |
| 20150367387 | Alcuri | Dec 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| 2 630 934 | Nov 1989 | FR |
| 2 141 201 | Dec 1984 | GB |
| 2009051495 | Apr 2009 | WO |
| 2010087724 | Aug 2010 | WO |
| 2012093079 | Jul 2012 | WO |
| Entry |
|---|
| International Search Report issued in corresponding application No. PCT/EP2014/072286 dated Dec. 2, 2014 (3 pages). |
| Written Opinion issued in corresponding application No. PCT/EP2014/072286 dated Dec. 2, 2014 (6 pages). |
| Norwegian Search Report issued in application No. 20131438 dated May 21, 2014 (2 pages). |
| Number | Date | Country | |
|---|---|---|---|
| 20160279684 A1 | Sep 2016 | US |
