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Heimdal Brae De-Waxing Operation
Arild Fahre-Skau, Statoil
Aidan O’Donoghue, Pipeline Research Limited
Hans Petter Rønningsen, Statoil
Ketil Rongved, Statoil
PPSA Seminar 20th november 2013
2012-09-28Classification: Open
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Heimdal Brae Wax Removal Summary
Removing large accumulations of wax using an aggressive high-friction pig
with bypass
2012-09-282 Classification: Open
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Presentation contents
• Part 1:
− System & History
2012-09-283 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
2012-09-284 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
− Pigging operation
2012-09-285 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
− Pigging operation
2012-09-286 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
− Pigging operation
• Part 2:
− Pig design
2012-09-287 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
− Pigging operation
• Part 2:
− Pig design
− Pigging dynamics
2012-09-288 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
− Pigging operation
• Part 2:
− Pig design
− Pigging dynamics
− Observations
2012-09-289 Classification: Open
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Presentation contents
• Part 1:
− System & History
− Pipeline conditions
− Pigging operation
• Part 2:
− Pig design
− Pigging dynamics
− Observations
2012-09-2810 Classification: Open
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System
2012-09-2811 Classification: Open
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System
2012-09-2812 Classification: Open
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Total Wax Volume = 350 m3 (ca)
0
5
10
15
20
25
30
0 20000 40000 60000 80000 100000 120000
2012-09-2813 Classification: Open
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From Heimdal to Kinneil
116 km
ID = 197 mm (8’’)
Turbulent
117 km
ID = 710 mm (28’’)
Laminar
169 km
ID = 860 mm (34’’)
Turbulent
Heimdal
Brae Alpha
Forties Charlie Kinneil
2012-09-2814 Classification: Open
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Introduction of Vale fluids in 2002
2012-09-2815 Classification: Open
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Introduction of Vale fluids in 2002
- Build up of line differential pressure was insignificant until 2004
Before 2002, no wax and no pigging performed. Then Vale field started up with
high wax content.
0
10
20
30
40
50
60
70
80
19.4.01 5.11.01 24.5.02 10.12.02 28.6.03 14.1.04 1.8.04
No
rmal
ize
d p
ress
ure
dro
p, b
ar
Start-up waxy cond.
2012-09-2816 Classification: Open
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Pigging started early 2004 using foam pigs
First stuck foam pig April 2004
2012-09-2817 Classification: Open
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2004 - 2008
- Foam pigging
program
- Stuck pigs
2008- Fill and soak operation
- Chemical dissolvant
- Very good effect in laboratory
- Only minor effect in field
2008 - 2010
- Foam pigging
- Stuck pigs
2012-09-2818 Classification: Open
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2010: Aggressive pigging!
Two Alternatives for consideration:
1. Hydraulically Activated Power Pig (HAPP)
• Limited experience
• Assumed best for downstream facilities
Why change strategy?
1. The pipeline NEEDS to become wax free due to inspection requirements
2. Progressive approach with foam pigs does not work
2. High Friction Jetting Pig (HFJP)
• Well proven technology
• New application
Overall risk was evaluated together with our downstream
partners, and the HAPP was chosen
2012-09-2819 Classification: Open
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HAPP pigging operation January 2012Markland tests before and after
Estimated wax removed by HAPP = 80 m3
Remaining wax in pipeline = approx 350 m3Pig stopped 15.01.12 at 8357 m
2012-09-2820 Classification: Open
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Decide to go for High FrictionJetting Pig
2012-09-2821 Classification: Open
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Basis of design
Qbypass > Qwax
Qwax > Qbypass
2012-09-2822 Classification: Open
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Continuity Principle (5 bar HF Pig, 18 mm port)
Continuity
DP if stalled
Expected %bypass
2012-09-2823 Classification: Open
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Pig Design
Slotted guide
Bypass port
Sealing discsTracking
Magnets
Shuttle valve Transmitter
Bypass flow /
Pigging direction
2012-09-2824 Classification: Open
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Final pig ready for deployment
2012-09-2825 Classification: Open
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Testing and Validation
2012-09-2826 Classification: Open
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Other assurance
• Piggability studies (Negotiation of line components);
• Slurry study (transportation of wax particles);
• Risk assessments / Hazops;
• CFD work on bypass and forces on the pig;
• FMECA;
• Pig assembly checks / pig build quality.
2012-09-2827 Classification: Open
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HFJP Operation – Launch January 2013
500m
zone
HeimdalBrae- 1 pig launched from Heimdal using condensate
- Pig tracked through topsides down to riser hang-off
- Pigging speed: ca 0,3 m/s
1
2PS 1&2
2012-09-2828 Classification: Open
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500m
zone
HeimdalBrae- When pig arrives at the 500m zone, confirm pig
passage
Haug shipping
HFJP Operation – Riser Base
1
2PS 1&2
3
PS 3
2012-09-2829 Classification: Open
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500m
zone
Heimdal
Brae
Haug shipping
HFJP Operation – flowline
KP7
- When pig arrives at kp’s 7, 10, 20, 30, 40, 50 and 60
confirm pig passage
- Pig speed in waxy zone: > 0,1m/s
To FPS
KP10KP20KP30
4567
9
1
0
PS 9&101
2PS 1&2
.
KP…..
2012-09-2830 Classification: Open
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Procedures – monitoring of pressures and flowScenario
1
Scenario
2
Scenario
3
Scenario
4
Scenario
5
Scenario
6
Scenario
7
Flow Steady Steady IncreaseRising /
fallingDropping Steady
Goes to
zero
Line Inlet
Pressure
Falling
slowlySteady
Falling
slowlyErratic Rising
Rises to
180bars
max
Rises to
180bars
max
Line DPFalling
SlowlySteady
Falling
SlowlyErratic Rising
Rises
124bar
max
Rises
124bar
max
ActionIdeal, no
action
Monitor,
no action
Monitor,
no action
Expected
behaviour
Reduce
Inlet
Pressure,
20bar DP
increase
maximum
Reduce
flow and
monitor
closely.
Plan to
continue
Stop flow.
Reverse
2012-09-2831 Classification: Open
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Initial Pig run
Pig stalled topside due to
mislaunch through the
eccentric reducer
2012-09-2832 Classification: Open
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Modified Pig Design
2012-09-2833 Classification: Open
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Line DP during the run
DP
Wax thickness
2012-09-2834 Classification: Open
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Pig Location against time
2012-09-2835 Classification: Open
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Pig Velocity against distance
Flow velocity
Pig Velocity
%Bypass by
flow
2012-09-2836 Classification: Open
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Lessons and observations
• Isotopes would be better for location of pig topside;
• Magnetic signaller worked very well subsea;
• Monitoring of flows and pressures / pig location fed
in well to the analysis of the pig run in real time;
• Understanding of the flow rate ranges and
controllability of the flows is key to the operation;
• Control of outlet pressures and conditions would be
good but not always possible (complex system);
• Shuttle valve for reversal was useful during initial
mis-launch.
2012-09-2837 Classification: Open
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Final Markland test
2012-09-2838 Classification: Open
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After the HFJP
• Winter / Spring 2013: 4 operational pigs for wax control, similar design to HFJP
• June 2013: 1 pre-inspection scraper pig + 1 operational pig
• June 2013: Inspection pig from Rosen
Pipeline approved!!
X 4 +
2012-09-2839 Classification: Open
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Cake!
2012-09-2840 Classification: Open
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Presentation title
Presenters name
Presenters title
E-mail address ……@statoil.com
Tel: +4700000000
www.statoil.com
2012-09-2841 Classification: Open