qualification of weatherford’s red eye near infrared water cut...

Qualification of Weatherford’s Red Eye near infrared Water Cut ProbeAlexander Quayle (BP), Babajide Adejuyigbe (BP), Andrew Hall (BP)

John Lievois (Weatherford)

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Subsea RedEye Water Cut Meter

• Infrared Sensor for water detection and measurement

• Water Cut (Multiphase)

− 0-100% WC

− 0-99.5% GVF

− Salinity independent

• Water Detection (Wet Gas)

− <1.0 bbl H2O/MMSCF

• Water-Hydrate Inhibitor measurement

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Red Eye: How it works

OH H

OH H

HC

3

Starting Point 2009

• Topsides unit available 2005

− Joint Testing Programme to confirm capability 2007/09

− BP, BHP, Shell, Chevron, Total, Conoco-Phillips

• Weatherford specification:

• 800 surface installations in 2009

• Simple and robust design

• Potential Subsea Applications− Detection of water onset− Verification of water cut− Production allocation− Flow assurance

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Subsea Qualification

• Hardware Qualification

− Compliance with codes and standards

− Equipment lifetime (25 years+)

− Pressure integrity (13,000 psi / 900 bar)

− Robustness to external environment

• Reliability

− Retrieval not considered possible

− Electronics to ISO 13628-6 with additional BP requirements

• Performance

− Achieve optimal hardware subsea design

− Maintain accuracy of measurement

TRL Number

Development Stage Completed

0 ConceptBasic R&D, paper concept

1Proven ConceptPaper study or R&D experimentation

2

Validated ConceptExperimental proof of concept using physical models withfunctional testing

3Prototype tested System function, performance and reliability tested. Major milestone.

4Environment TestedPre-production system environment tested, e.g. production fluid testing

5 System TestedProduction system interface tested

6 System InstalledProduction system installed

7Field ProvenTypically 3 years or more w/o failure

API 17N Table B.19

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Component Hardware

• Process side

− Dual Barriers

− Intrusive Probe Material (Hastelloy 276)

− Sensor Window (Sapphire)

− Sealing Penetrator

− API Subsea Flange

• Housing

− Electrical connection

− Connection to flange

− 1atm electronics housing

Component 2008 TRLProbe 2Housing 3Electronics 2

Component 2013 TRLProbe 4Housing 4Electronics 4

• Electronics

− NIR Optical source

− Optoelectronics

− Data processing

− Communications

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Example Qualification – Sapphire Window

• Primary fluid barrier, non-metallic

− Pre check critical dimensions

− Initial leak tightness

− Hydrostatic pressure test to 2.5x RWP

− Post test critical dimension check

• Acceptance Criteria

− Pressure test to a factor of 2.5x maximum allowable working pressure

− No failure!

− Dimensions within tolerances after test7

Functional Qualification

• Vibration testing

− Low frequency testing (5-25Hz, ±2mm)

− Higher frequency (25-150Hz, 5g accel.)

− 2hrs random spectrum with applied notches, 20 – 2,000 Hz, 6 grmscomposite excitation level

• Criteria

− No damage

− Optical input channels within ±0.1 a.u.

− Internal voltages ±5%, ripple ±10%

− Comms > 99% for 30 mins

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Performance Testing

Technology Readiness

2008 20102009 2011 2012 2013

TRL 2 [Concept Validation]Subsea Design

TRL 2/3 testing of new probe

TRL 3Refinements to design (SWRI & CEESI)

SWRI

Fluids Natural Gas, Texas Regal (26°), Water

GVF 0-100%

Press 53 bar (800psi)

CEESI Wet Gas

Fluids Natural Gas, Condensate, Water

GVF 98-100%

Press 1000 bar

Prolab NL

Fluids Crude OilSaline WaterNatural Gas

GVF 0 – 99%

Press 45 bar

TRL 4Qualification

CEESI Wet Gas

Fluids Natural Gas, Kerosene, Water

GVF 94-100%

Press 53 bar (800psi)

CEESI

Fluids Natural Gas, Kerosine, Water

GVF 96-100%

Press 53 bar (800psi)

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Condensate Testing – CEESI 2013

MEG

HC liq

H2O

Test Setup• BP Condensate• Once thru design

(liquid)• 1000psi, 40°C• Gas recirculated,

flowrate 30-60ft/s

• XLM <<0.3

New installation• New 4”

Hydrocarbon Circulation System

• Additional flow metering

• Thermal control building (Fluid WAT 35°C)

• Additional pumps

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Condensate Testing – CEESI 2013

Test Setup• BP Condensate• Once thru design

(liquid)• 1000psi, 40°C• Gas recirculated,

flowrate 30-60ft/s

• XLM <<0.3

New installation• New 4”

Hydrocarbon Circulation System

• Additional flow metering

• Thermal control building (Fluid WAT 35°C)

• Additional pumps

Test objectives met:

Detected water onset at lower than 1bbl / mmscf gas

Tracked changes < 0.5bbl/mmscf gas

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Qualification Complete

• TRL level 4 achieved

• Can now be specified as part of a BP major project, subject to:

• Weatherford guidance on positioning in the flow

• Minimum velocities need to be observed

• TRL 5+ occurs with Site Installation Testing

• TRL 6 on successful startup

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Conclusions

• RedEye water cut measurements have significant value for an operator in:− Detection of water onset− Verification of water cut− Production allocation− Flow assurance

• Qualification of the probe for Subsea use is a significant step for this product:

− Extensive focus on Integrity, Reliability and Performance

− Completed over a 4/5 year timescale

− Verified performance with actual operating fluids

• Now ready for installation Subsea

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THANKS FOR LISTENING!

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Qualification of Weatherford’s Red Eye near infrared Water Cut Probe