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PETROMAKS2-Stort program petroleum

ACS: Always-clean Cooling System

Alternative title: ACS: System for avkjøling av flerfasestrøm under temperatur for hydrat- og voksdannelse

Awarded: NOK 9.1 mill.

Project Manager:

Project Number:

269246

Project Period:

2017 - 2019

Organisation:

EMPIG AS has developed an always-clean cooling system (ACS). The ACS is a continuously producing subsea cooler that cools a multiphase flow below the temperature for hydrate and wax formation, without the risk of downstream deposition or agglomeration. A realization of this innovation will result in reduced costs for oil and gas production in existing fields, open fields farther from existing infrastructure and enable connection to existing tie-in hubs. ACS will also significantly reduce the environmental footprint from oil and gas production by replacing the energy intensive DEH method and large amounts of chemicals needed for subsea transportation. When the project started in 2017, we made a detailed plan for the test setup for testing the cooler. This involved calculations and simulations of pipe dimensions, cooling and heating needs needed. Work drawing drafts on the prototype were prepared including initial design on valves and pipes. Initial testing of the heating system to remove wax deposits was also conducted. During the first half of 2018 all equipment and parts for the test were ordered, and Kværner started the construction of the cooler. The cooler is mounted in a 40-foot container as the basin was transported to the SINTEF Multi-Phase Laboratory in October 2018 for further assembly of robotics and flow-loop currently. During first half 2019 the cooler was thoroughly tested in the established flow-loop. In all, three methods of removing wax and hydrates has been integrated in the Cooler system. The tests has shown good results, and through established sensors, we are able to show the built up of wax and hydrates and further the removal of these deposits by our established methods. The project has been successful, and The Always-clean Cooler System is feasible and we have shown that seeding with wax- and hydrate particles works. Through extensive testing we have shown that the downstream loop is clean showing that the ACS is a cold flow enabler, enabling long-distance transportation of hydrocarbons. Exisiting partners in this project is committed for next phase, targeting a full marinization and system test in 2021 and a field test in 2023.

Prosjektresultatene fra dette prosjektet har dannet grunnlag for en videreføring hvor man i løpet av 2020-21 skal teste og verifisere en fullt ut marinisert enhet (kjøler). Denne verifikasjonen vil igjen danne grunnlaget for en reell felttest/-installasjon. Ferdig utviklet vil dette prosjektet muliggjøre en svært energieffektiv og miljøvennlig langdistanse transport av hydrokarboner som også vil redusere utbyggingskostnader og muliggjøre utvikling av mer marginale felt og prosessering på land.

EMPIG, in cooperation with Kværner, will develop an always-clean cooling system (ACS). The ACS is a continuously producing subsea cooler that cools a multiphase flow below the temperature for hydrate and wax formation, without downstream deposition or agglomeration. Realisation of this innovation results in reduced costs for oil and gas production in existing fields. Additionally, it makes it possible to open fields far from land, connect to tie-in hubs subsea, reduce environmental impact from oil and gas production and create new jobs in domestic oil and gas industry. Transport of a multiphase flow at ambient sea temperature has the potential of large savings and will open up for new field opportunities. However, the technology to do this reliably has not been fully realized yet. EMPIG AS has developed and patented the "Always-clean Cooling System" (ACS) that will enable this. Hydrate and wax particles that form and deposit during the cooling process, are removed through a sequential heating process. The method operates without chemicals and can produce a multiphase flow without the risk of downstream plugging. The needs for pigging and thermal insulation of the pipe are therefore removed. The technology is currently at a Technology Readiness Level 2 (TRL 2) and patented by EMPIG AS. The methods for wax and hydrat management are already tested and verified isolated by EMPIG and SINTEF, but not tested long-term as a system with real hydrocarbon flow. Through multidisciplinary competence at SINTEF, and a close collaboration with Kværner, that will manufacture and assemble the main parts of the ACS prototype, the aim of the project is to take the ACS-concept to a higher TRL level through prototype testing.

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Funding scheme:

PETROMAKS2-Stort program petroleum