The upstream offshore multi-phase well-pipeline-riser installations are facing huge challenges related to slugging flow: An unstable flow regime where the flow rates, pressures and temperatures oscillate in the multi-phase pipelines. One typical severe slug is induced by vertical wells or risers causing the pressure to build up and hence originates the oscillating pressure and flow. There exist many negative consequences related to the severe slugging flow and thus lots of investments and effort have been put into reducing or completely eliminating the severe slug. This paper reviews in detail the state-of-the-art related to analysis, detection, dynamical modeling and elimination of the slug within the offshore oil & gas Exploration and Production (E&P) processes. Modeling of slugging flow has been used to investigate the slug characteristics and for design of anti-slug control as well, however most models require specific facility and operating data which, unfortunately, often is not available from most offshore installations. Anti-slug control has been investigated for several decades in the oil & gas industry, but many of these existing methods suffer the consequent risk of simultaneously reducing the oil & gas production. This paper concludes that slug is a well defined phenomenon, but even though it has been investigated for several decades the current anti-slug control methods still have problems related to robustness. It is predicted that slug-induced challenges will be even more severe as a consequence of the longer vertical risers caused by deep-water E&P in the future.
An increasing water to oil ration in the North Sea oil and gas production motivates for an optimization of the current deoiling facilities. Current facilities are operated on matured methodologies, which in most cases fulfill the government regulations. However, it has also observed that these solutions could be further improved. In order to more precisely monitor the deoiling operations, this study investigated the real-time monitoring of the deoiling efficiency of the hydrocyclone facilities which are commonly used in offshore oil and gas production. Fluorescence based monitors were applied to measure hydrocyclone inlet's and underflow's Oil-in-Water (OiW) concentrations in real-time. Image-based microscopy was used to analyze the oil droplet size distribution at inlet and underflow to investigate the droplets' influence on hydrocyclone's efficiency. Performance experiments were carried out to identify how pressure difference ratio (PDR) and the droplet's sizes affect the deoiling efficiency. The performance of the deoiling hydrocyclone was significantly influenced by the inlet flow rate, while less or marginally dependent on the PDR. The droplet size distribution experiment proved that large droplets have a high probability to be separated by the hydrocyclone. The findings suggest that the coupled separator tank and hydrocyclone system can be further improved upon by deploying coordinated control as the two systems are strongly interdependent.
The severe slugging flow is always challenging in oil & gas production, especially for the current offshore based production. The slugging flow can cause a lot of potential problems, such as those relevant to production safety, fatigue as well as capability. As one typical phenomenon in multi-phase flow dynamics, the slug can be avoided or eliminated by proper facility design and control of operational conditions. Based on a testing facility which can emulate a pipeline-riser or a gas-lifted production well in a scaled-down manner, this paper experimentally studies the correlations of key operational parameters with severe slugging flows. These correlations are reflected through an obtained stable surface in the parameter space, which is a natural extension of the bifurcation plot. The maximal production opportunity without compromising the stability is also studied. Relevant studies have already showed that the capability, performance and efficiency of anti-slug control can be dramatically improved if these stable surfaces can be experimentally determined beforehand.
From the process control point of view, any reliable and online Oil-in-Water (OiW) measurement could provoke a brand new control paradigm for produced water treatment. However, the real-time OiW monitoring is still an open and ad-hoc situation in recent decades. The fundamental issue, ie, the OiW measurement is methodology dependent, leads to numerous challenges, such as (i) how to verify the reliability and accuracy of a specific methodology/instrument; (ii) how to handle and interpret the measured data in a most objective manner; and (iii) how to keep a cost-effective on-site calibration and maintenance under the harsh offshore conditions etc. The paper reports our latest achievements and observations in usage of fluorescence- and microscopybased OiW monitoring technologies for advanced Produced Water Treatment (PWT) control and evaluation, particularly by focusing on the de-oiling hydrocyclone installations.
The current offshore oil & gas multi-phase production and transportation installations have big challenges related to the slugging flow: An unstable multi-phase flow regime where the flow rates, pressures and temperatures oscillate in the considered processes. Slug can be caused by different operating conditions and installation structures. The most severe slugs are often induced in long vertical risers or production wells, where liquid blocks gas at the riser/well base and correspondingly it causes the pressure to accumulate and hence originates the oscillating performance. There are many severe consequences to the production processes because of the slugging flow. This paper reviews some observed latest status and key challenges about slug detection, dynamical modeling and elimination of slugging flows. Mathematical modeling of slug has been used to investigate the slug mechanism and anti-slug control. Most of available models are based on mass-balance formulations, which often require sufficient data for reliable parameter tuning/identification. Slug elimination and control have been investigated for many years and there exist many solutions to eliminate the slug, but some of these methods can simultaneously reduce the oil & gas production, which is a very big concern as the production rate is the key evaluation parameter for offshore production. We conclude that the slugging flow is a well-defined phenomenon, even though this subject has been extensively investigated in the past decades, the cost-effective and optimal slug modeling and control are still open topics with many related challenges.