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