The present disclosure relates to pumping systems. Specifically, the present disclosure relates to systems and methods for subsea pumping and boosting to increase oil and gas production.
Throughout the life of an oil and gas producing well or during initial production operations, formation pressures or recovery rates may drop or be less than desirable, which often leads to expensive and time consuming well intervention techniques. These techniques may include mechanical techniques, such as adding boosters or pumps into the wellbore, or chemical techniques to stimulate additional flow. However, these techniques may not be suitable for all wells, for example, where some reservoirs may provide a fluid composition that is richer in light hydrocarbons and carbon dioxide (CO2), which generate large volumes of gas as pressure drops along the fluid transportation system. These scenarios may be even more challenging with offshore wells, which may factor in water production as well as operating in more extreme pressure and temperature scenarios.
Applicant recognized the problems noted herein and conceived and developed embodiments of systems and methods, according to the present disclosure, for subsea pumping and boosting systems.
In an embodiment, a system includes a pumping unit and a base unit. The pumping unit includes a plurality of tubulars, the plurality of tubulars directing flow from a first end to a second end. The pumping unit also includes two or more electric submersible pumps (ESP) positioned within at least two or more tubulars of the plurality of tubulars, the two or more ESPs receiving production fluid and increasing a pressure of the production fluid. The pumping unit further includes a plurality of valves associated with the plurality of tubulars, the plurality of valves each independently moveable between respective open positions and closed positions, wherein respective positions of groups of valves corresponding to operational configurations selected to adjust operation of the two or more ESPs. The base unit is adapted to receive the pumping unit, the base unit being positioned at a subsea location to support the pumping unit, and includes a subsea connector, arranged in a horizontal configuration, for receiving a production line and directing production fluid toward the pumping unit. The base unit also includes an isolation valve, upstream of the subsea connector, to block production fluid.
In an embodiment, a system includes a pumping unit with a plurality of tubulars, the plurality of tubulars directing flow from a first end to a second end, two or more electric submersible pumps (ESPs) positioned within at least two or more tubulars of the plurality of tubulars, the two or more ESPs receiving production fluid and increasing a pressure of the production fluid, and a plurality of valves associated with the plurality of tubulars, the plurality of valves each independently moveable between respective open positions and closed positions, wherein respective positions of groups of valves correspond to operational configurations selected to adjust operation of the two or more ESPs. The system also includes a base unit, adapted to receive the pumping unit, the base unit being positioned at a subsea location to support the pumping unit, where the base unit includes a subsea connector for receiving a production line and directing production fluid toward the pumping unit and an isolation valve, upstream of the subsea connector, to block production fluid.
In an embodiment, a system includes a pumping unit with a plurality of tubulars, the plurality of tubulars directing flow from a first end to a second end, two or more electric submersible pumps (ESPs) positioned within at least one tubular of the plurality of tubulars, the two or more ESPs receiving fluid and increasing a pressure of the fluid, and a plurality of valves associated with the plurality of tubulars, the plurality of valves each independently moveable between respective open positions and closed positions, wherein a plurality of valve configurations correspond to a plurality of operational modes for the two or more ESPs. The system also includes a base unit, adapted to receive the pumping unit. The base unit includes a connector for receiving a fluid line and an isolation valve, upstream of the connector.
The present technology will be better understood on reading the following detailed description of non-limiting embodiments thereof, and on examining the accompanying drawings, in which:
The foregoing aspects, features, and advantages of the present disclosure will be further appreciated when considered with reference to the following description of embodiments and accompanying drawings. In describing the embodiments of the disclosure illustrated in the appended drawings, specific terminology will be used for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms used, and it is to be understood that each specific term includes equivalents that operate in a similar manner to accomplish a similar purpose.
When introducing elements of various embodiments of the present disclosure, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment”, “an embodiment”, “certain embodiments”, or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms such as “above”, “below”, “upper”, “lower”, “side”, “front”, “back”, or other terms regarding orientation or direction are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. It should also be appreciated that dimensions, angles, and other components may be referred to as being substantially within a range of approximately plus or minus 10 percent.
Embodiments of the present disclosure are directed toward systems and methods for boosting or increasing a pressure in an underground formation. Embodiments may be utilized in a subsea environment, but it should be appreciated that other environments may also be used. Various embodiments include one or more pumps, which may be submersible pumps, to increase a pressure within the formation. These pumps may be part of a modular systems that includes one or more removable pumping units and one or more base units. The pumping units may include features to facilitate coupling to the base units and the base units may include one or more connections to couple to associated equipment, such as production trees. In various embodiments, specific valve configurations may determine different operational modes of the pumps, which may include, but are not limited to, series operation, parallel operation, re-circulating, standby, and bypass. Furthermore, embodiments may enable multiple banks of pumping units to be coupled together in a variety of different configurations. Accordingly, systems and methods may enable well production and pressure stimulation without intervention into the wellbore itself by providing an external, skid-mounted, retrievable pumping system.
In one or more embodiments, systems and methods of the present disclosure may be utilized in order to enhance recovery and/or provide fluids for boosting production. That is, an inlet of the system may receive a fluid and then increase the pressure of the fluid to transport the fluid to another location. Additionally, in embodiments, the inlet of the system may receive a fluid for injection or use with a wellbore. Accordingly, systems and methods of the present disclosure may be described with reference to well intervention or production recovery, but such descriptions are for illustrative purposes only and are not intended to limit the scope of the present disclosure. In one or more embodiments, fluids utilized with the system may include hydrocarbons, water, solids-laden fluids, muds, and the like. Accordingly, various embodiments may be used with a variety of operations. Furthermore, it should be appreciated that subsea operations are also described by way of example, and other configurations and uses may be suitable for systems of the present disclosure. For example, embodiments may include surface-mounted systems that send and/or receive fluids from offshore facilities or other surface facilities. Furthermore, embodiments may include rig-mounted or ship-mounted systems that are utilized with subsea wells. Accordingly, systems and methods may be utilized to allow pump production fluid from well to subsea, well to topside, well to shore, well to well, topside to well, topside to subsea and topside to shore, among various other configurations.
Various embodiments of the present disclosure provide a system for increasing oil and gas production flow. In at least one embodiment, an electrical submersible pump (ESP) is utilized in a skid-mounted pumping module positioned external to a wellbore. In at least one embodiment, the ESP may be arranged at mudline, associated with a manifold, or any other reasonable subsea location. The ESP may then be used to increase pressure and/or flow with a wellbore, reducing the impacts of low reservoir pressures, flow drop in various flow lines, or other potential elements that may impact flow and recovery rates. As will be appreciated, flow and pressure drop may be experienced in mature wells, wells where paraphine and other elements have reduced flow rates, or fields where pressure management has resulted in a decrease in formation pressures. Accordingly, systems and methods may be utilized without well intervention (e.g., adding equipment within the wellbore) to increase recovery rates, postpone various well intervention operations (e.g., mechanical and/or chemical), and reduce operating expenses.
Systems and methods are directed to overcome challenges and drawbacks with boosting or stimulating production with wellbores, and in various embodiments, may be particularly suited for subsea applications. Accordingly, systems and methods may be directed to increasing efficiency and reducing costs. Design limitations as gas fraction, pump serialization and pumps arrangement, directly affect production efficiencies. Prior art solutions do not provide a versatile design sufficient to overcome the problems currently faced in the industry. By way of example, U.S. Pat. No. 7,516,795 introduces a system that cannot function as a combination of single pump operations, pumps in series, and pumps in parallel without retrieving the system and installing a new configuration. Additionally, some reservoirs may provide a fluid composition that is richer in lighter hydrocarbons and CO2 (carbon dioxide), for instance, generating large volumes of gas as pressure drops along fluid transportation systems (flowlines, risers. valves, etc.). Systems and methods now need capabilities to accommodate more than 60% of gas fraction in the production flow. However, U.S. Pat. No. 7,516,795 is limited up to 60%. Furthermore, methods directed toward building a dummy well in U.S. Pat. No. 7,314,084 do not overcome the problems, as this dummy well still has problems with accessibility and maintains a high cost for pump replacement and/or maintenance.
Systems and methods may be utilized in offshore recovery operations, which a platform or floating production, storage, and offloading vessel (FPSO) are utilized. As a result, such systems are operational to accommodate the inclusion of both gas and water, among other fluids, with oil production. In various embodiments, systems may include exportation flow paths for gas. In various embodiments, artificial lift technologies, such as ESPs, are utilized to increase hydrocarbon recovery. In at least one embodiment, a modular subsea system is utilized, which may include a base and a modular pumping system. The modular pumping system may include one or more artificial lift devices to increase the hydrocarbon production pressure to improve recovery rates and/or extend well life. Moreover, various systems and methods may reduce operating costs due to ease of access with the modular pumping system as opposed to well interventions, which may utilize additional equipment and take more time.
Embodiments of the pressure disclosure may also enable serialization, where different pumping modules may be coupled together, and in some embodiments, may utilize a common base. Furthermore, various embodiments may be a scalable solution that enables different installation configurations to vary an amount of boost provided. In at least one embodiment, systems and methods may include one or more ESPs, arranged in a horizontal position, positioned within one or more tubulars associated with the modular pumping unit. Additionally, mechanical connectors may be arranged at an inlet and an outlet, and in certain embodiments the connectors may also be positioned in a horizontal configuration. Furthermore, systems and methods may include a plurality of configurable valves to enable a variety of pumping configurations. In at least one embodiment, the valves may be positioned between open and closed positions to enable operation of the pumps in series or parallel. Additionally, the valves may be positioned between open and closed positions to enable operation of the pumps in a serialized manner, in a bypass configuration, or in a flushing configuration. The serialized connections may be enabled through one or more connections, for example at a top of the pumping unit, to receive an additional pumping unit. In at least one embodiment, controllers may be utilized to send and receive instructions for valve and/or pump operations, for example via a wired or wireless communication system. This communication system may enable start and stop of the pumping operations, changes in valve position, communication of operating parameters, and the like. Various embodiments may also include a base frame that receives the modular pumping unit, where the base frame includes flowline connections at the seabed for coupling to a wellbore. Furthermore, a modular skid frame may be incorporated for landing and to protect the base and/or pumping unit.
In one or more embodiments, the system may be referred to as a scalable modular smart pumping and boost system. Additionally, individual components may be referred to as a base portion and as a pumping unit. In at least one embodiment, a booster pump is utilized, which may be an ESP. The scalable smart pumping and boost system may additionally include an inlet manifold to promote a production flow bypass. In embodiments, the scalable modular smart pumping and boost system is capable of pumping the fluid production flow with gas volume fractions between 0% in minimum and 80% of gas volume fraction. Various embodiments may also include a heat exchange feature and/or injection points to heat fluid or chemicals inside the module to further alleviate blockages or plugging, for example due to hydrates or paraffin. Additionally, the system may include mechanical valves coupled in the retrievable module or in the fixed base frame accommodated in the seabed. Furthermore, the system may include isolation valves blocks coupled in the retrievable module or in the fixed base frame accommodated in the seabed.
One efficient way to start drilling a wellbore 106 is through use of a suction pile 134. Such a procedure is accomplished by attaching the wellhead housing 108 to the top of the suction pile 134 and lowering the suction pile 134 to a sea floor 136. As interior chambers in the suction pile 134 are evacuated, the suction pile 134 is driven into the sea floor 136, as shown in
It should be appreciated that while
The base unit 302 includes a bottom portion 310 for supporting the base unit 302 on the sea floor. It should be appreciated that various reinforcement fittings and the like may be incorporated to accommodate the subsea environment. Further illustrated are subsea connectors 312, which in this example are arranged in a substantially horizontal configuration. Subsea connectors 312 may include mechanical, hydraulic, or other types of connections. It should be appreciated that this is for illustrative purposes only and that the subsea connectors 312 may be in a vertical configuration or at an angled configuration, among other options. As used herein, horizontal is with reference to an axis 328 extending along the base unit 302 (e.g., an axis parallel to the bottom portion 310). The subsea connectors 312 may be used to couple to production flow lines 314, such as the lines 206 shown in
The illustrated pumping unit 300 includes a frame portion 318 and a plurality of tubulars 320, which may be pipe segments. The frame portion 318 may include a variety of beams, cross bars, posts, and the like in order to provide a structure frame for various components of the pumping unit 300, such as the tubulars 320. It should be appreciated that various aspects of the frame portion 318 may be particularly selected based on intended operating conditions, with longer pumping units 300 having more posts and cross bars, and shorter pumping units 300 have fewer. Furthermore, widths or thicknesses of the components may also vary based on expected operating conditions. The tubulars 320 may include electrical submersible pumps (ESPs) 322 for boosting a formation pressure. In one or more embodiments, the ESPs 322 may be arranged in a substantially horizontal configuration, however, this is by way of example only and the ESPs 322 may be in a vertical configuration and/or an angled configuration. Furthermore, ESPs 322 may not have the same configuration, for example a first ESP may be horizontal and a second ESP may be vertical. Accordingly, ESPs 322 may be at a variety of different angles and configurations. Additionally, in embodiments where there are multiple ESPs, it should be appreciated that each ESP may be operated independently, such that different ESPs may operate together or not at all during various stages of the operations. For example, one ESP may serve as a backup or provide redundancy to another. In operation, fluids may be directed toward the tubulars 320 and the ESPs 322 may add energy (e.g., pressure) to the fluid for injection into the wellbore. In this example, the pumping unit 300 includes a series of valves 324, which as will be described below, may be particularly configured to enable a variety of different operating modes for the pumping unit 300. By way of example, the valves may be moved between open and closed positions to enable parallel flow, series flow, re-circulating flow, and/or bypass flow. Furthermore, in one or more embodiments, serialization connectors 326 may be utilized to add additional pumping units 300, which may also be positioned on the base unit 302, or on a separate base unit 302.
In operation, one or more control signals may be utilized to adjust positions of the various valves 324 to begin a certain operating mode. Additional control signals may be used to adjust or otherwise change valve configurations. Furthermore, it should be appreciated that other control methods may be used, such as using ROVs to adjust valve positions without additional control signals. Moreover, in at least one embodiment, additional pumping systems may be added. In one or more embodiments, the configuration shown in
Embodiments of the present disclosure may utilize ESPs, but external to the well, to enable improved interventional operations while also enabling better access to the ESPs, for example, during maintenance. Accordingly, access may be provided without production shutdown, compared to operations where the ESPs are placed within the well. For example, one or more valves may be moved to a closed position such that the pumping unit 300 can be accessed without affecting operation of the wellbore.
Various embodiments of the present disclosure include a main module or system that may be divided into one or more sub-components, such as the pumping unit 300 and the base unit 302. In operation, the base unit 302 is installed prior to installation of the pumping unit 300. In this example, the production line 314 is coupled to the subsea connector 312, which is in the horizontal configuration in this example. Such a configuration may provide various benefits, such as easing access by personnel or ROVs as well as reducing bends or changes in direction due to the configuration of the tubulars 320. It should be appreciated that various embodiments may modify this positioning based on operating conditions or specifications.
The pumping unit 300 may be lowered or sunk to the base unit 302, for example via cables and/or ROVs. Each of the pumping unit 300 and/or the base unit 302 may include one or more components to facilitate landing and/or coupling of the components, as will be described herein. By way of example, the posts 306 may be used to direct the pumping unit 300 to the recess 304, and various features of the pumping unit 300, such as a positioning support, may facilitate the connection. After coupling the units together, various valves may be moved into desired positions to permit fluid flow, where the production fluid flow coming from the well passes through the system 204 gaining energy in the form of pressure increase, making its way to the surface facilitated. As a result, an increase of hydrocarbons volume produced is realized compared with a well in a similar condition without the aid of this disclosure.
While not shown in
The illustrated pumping unit 300 further includes deployment features 510, which in this embodiment include eyelets or mounting members that may receive one or more cables in order to raise and/or lower the pumping unit 300 into position. Any reasonable number of deployment features 510 may be utilized and the four illustrated herein are for illustrative purposes only.
In this example, the sets of valves 324 are arranged at the first and second ends 500, 502 and one or more of the tubulars 320 may include one or more ESPs 322 arranged within the tubular 320. In various embodiments, flow controllers 506 (e.g., valve blocks) are positioned at the ends 500, 502 and may include the valves 324. The flow controllers 506 may provide a centralized location for the valves 324, which may be associated with an electronic control system for controlling a valve position. Furthermore, grouping the valves 324 together may enable easier access by an ROV.
The illustrated embodiment includes 3 tubulars 320, but it should be appreciated that more or fewer may be included. Furthermore, a bypass line 508, which is also a tubular, is illustrated with the pumping unit 300. It should be appreciated that this may be the same or different bypass described above. For example, in one embodiment the bypass line 508 may be associated with the pumping unit 300, while in another embodiment the bypass line may be associated with the base unit 302. Furthermore, as noted above, various embodiments may also include a bypass cap. It should be appreciated that each component may also have a distinct and separate bypass line. That is, the pumping 300 may include a bypass line and the base unit 302 may include a bypass line. In operation, the flow controllers 506 may be coupled to the subsea connectors 312 to regulate flow through the pumping unit 300, where different configurations may permit or block flow to different tubulars and/or ESPs to adjust the operating mode of the pumping unit 300. While the illustrated embodiment includes singular valves 324, it should be appreciated that there may be multiple valves 324 arranged in series to provide double blocking capabilities and or provide redundancy.
It should be appreciated that additional systems and methods may be included, such as one or more heat exchangers and/or injection points coupled in the pumping unit 300 and/or the base unit 302. These systems may be used to avoid hydrates and/or paraffin blockage. By way of example, one or more heat changers may be positioned at inlet or outlet points, or be incorporated into the tubulars 302. Furthermore, it should be appreciated that alternative configurations may be used, such as installing the horizontal mechanical connections as associated with the pumping unit 30. Moreover, various valves shown as being associated with the base unit 302 may also be incorporated into the flow controller 506.
Turning to the schematic diagram of
The illustrated flow configuration includes the valves 324, 604, 606 in the configuration shown in Table 1 to permit series flow. As a result, fluid may travel through the valves 324A, 324D, 324E, 324F, 604, through the ESPs 322A, 322B, and exit the outlet 608.
Returning to
Turning to the schematic diagram of
The illustrated flow configuration includes the valves 324, 604, 606 in the configuration shown in Table 2 to permit parallel flow. As a result, fluid may travel through the valves 324A, 324B, 324C, 324E, 324F, 604, through the ESPs 322A, 322B, and exit the outlet 608.
Turning to the schematic diagram of
The illustrated flow configuration includes the valves 324, 604, 606 in the configuration shown in Table 3 to permit re-circulation flow. As a result, fluid may travel through the valves 324A, 324D, 324E, 324F, 606 for recirculation or to flush out the pumping unit 300.
Turning to the schematic diagram of
Different from the other configurations shown herein, the serialization connections 326 are utilized to add an additional pumping unit 300. In this example, additional serialization valves 902 permit flow and also facilitate return flow. It should also be appreciated that this configuration may also be used during re-circulation, as illustrated by the arrows.
The illustrated flow configuration includes the valves 324, 604, 606, 902 in the configuration shown in Table 4 to permit serialized flow. As a result, fluid may travel through the valves 324A, 324D, 324E, 324G, 324J, 324K, 324L, 902, 604, 606, through the ESPs 322A, 322B, 322C, 322D, and exit the outlet 608.
Turning to the schematic diagram of
In this example, the serialization connections 326 are utilized to add an additional pumping unit 300. Moreover, additional serialization valves 902 permit flow and then also facilitate return flow. It should also be appreciated that this configuration may also be used during re-circulation, as illustrated by the arrows.
The illustrated flow configuration includes the valves 324, 604, 606, 902 in the configuration shown in Table 5 to permit serialized flow with pumps in a parallel configuration.
Turning to the schematic diagram of
The illustrated flow configuration includes the valves 324, 606 in the configuration shown in Table 6 to permit bypass flow.
Turning to the schematic diagram of
The illustrated flow configuration includes the valves 324, 604, 606 in the configuration shown in Table 7 to permit flow of a single ESP while maintaining an ESP as a backup and/or for redundancy. As a result, fluid may travel through the valves 324A, 324C, 604, through the ESP 322A and exit the outlet 608. However, in this configuration, the ESP 322B may not be operational and/or may be maintained for later operation
Turning to the schematic diagram of
The illustrated flow configuration includes the valves 324, 604, 606 in the configuration shown in Table 8 to permit flow of a single ESP while maintaining an ESP as a backup and/or for redundancy. As a result, fluid may travel through the valves 324B, 324E, 324F, 604, through the ESP 322B and exit the outlet 608. However, in this configuration, the ESP 322A may not be operational and/or may be maintained for later operation
Turning to the schematic diagram of
The illustrated flow configuration includes the valve 606 in the configuration shown in Table 9 to permit bypass flow.
It should be appreciated that various components, such as support systems, electrical systems, control systems, injection systems, and the like may also be incorporated into the embodiments described herein. By way of example only, one or more injection systems may be utilized to enable chemical or other injection into the pumping system 204. For example, the injection system may be upstream and/or downstream of one or more ESPs 322 and may include a separate pump or the like to provide sufficient pressure to enter the system. In one or more embodiments, the injection systems may include an injection point that extends into the tubulars 320 and/or at various other locations associated with the system, for example at the subsea connectors 312 and/or at various other locations. In various embodiments, chemical and/or fluid injection may assist in the flow assurance and improve lifting performance. Examples of issues to be treated are hydrate, paraffin's, emulsion, and scale, among others. Additionally, systems may also utilize one or more heat exchangers in order to control or assist with flow. For example, one or more heater systems may include heat exchangers or other heaters to control a system temperature, which may facilitate flow. Moreover, in one or more embodiments, the ESPs 322 themselves may be used as heating elements.
Various embodiments may be described with reference to operation of two or more EPSs 322, but it should be appreciated that one or more ESPs 322 may operate independently and/or without the use of the other ESPs 322 within the system. As an example, one ESP 322 may be taken offline for maintenance while the other ESP 322 continues to run. Furthermore, in various embodiments, lifting requirements may permit operation of only a single ESP 322 within the system.
As noted above, various support systems and the like have not been shown for convenience. One such example includes various block valves, drains, vents, and the like. For example, one or more drains (e.g., low point drains) may be provided to facilitate clearing or otherwise flushing of the system before and/or after the system is placed into use. In one example, at the surface, the drains and/or vents may be used to clear the system prior to installation. Furthermore, the system may be drained, either subsea or at the surface, prior to or after retrieval. Drains may be utilized for removal or liquid and/or gases. Additionally, these systems, or other support systems, may enable pressure compensation during subsea deployment and/or retrieval.
It should be appreciated that various control and monitoring systems may also be associated with embodiments of the present disclosure, either as a separately deployable skid, integrated system, surface system, or a combination thereof. For example, instrumentation may be incorporated to enable ESP performance monitoring, such as monitoring a speed, pressure, flow rate, and/or the like. Moreover, individual ESP current measurement may be incorporated by direct and/or indirect methodologies. System monitoring may be incorporated with one or more motors utilized to drive the ESPs 322, which may be any suitable type of motor, such as induction or permanent magnet motors, among other options. Accordingly, systems and methods may be provided to monitor operation of the ESPs 322. In certain embodiments, these systems may provide control of the system to facilitate operation at approximately 1200 rpm. Additionally, the system may facilitate operation up to 10,000 rpms. These operational ranges of the ESPs should be understood as example ranges and are not intended to limit the scope of the present disclosure.
The foregoing disclosure and description of the disclosed embodiments is illustrative and explanatory of the embodiments of the disclosure. Various changes in the details of the illustrated embodiments can be made within the scope of the appended claims without departing from the true spirit of the disclosure. The embodiments of the present disclosure should only be limited by the following claims and their legal equivalents.
This application claims priority to and the benefit of co-pending U.S. Provisional Patent Application No. 63/161,248, filed Mar. 15, 2021 and titled “SUBSEA PUMPING AND BOOSTER SYSTEM,” the full disclosure of which is hereby incorporated in its entirety for all purposes.
Number | Date | Country | |
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63161248 | Mar 2021 | US |