Data Driven Journey to Optimize Offshore Sand Management

Effective offshore sand management is crucial for the oil and gas industry as it impacts equipment reliability, containment prevention, operational efficiency, and sustainability. This work investigates data analytic approaches as well as design improvement to enhance the efficiency of surface desanding units. New data driven approaches have been developed. Lessons learned, and best practices are demonstrated through case studies in Thailand. Trial surface desander units were installed downstream of choke valves at a wellhead facility in the Gulf of Thailand, employing both filtration and hydrocyclone technologies. The performance of these units, particularly at a downstream central processing platform (CPP), was evaluated alongside the reliability of produced water injection pumps. Traditional hydraulic models, including those by Plitt and Stairmand, were reviewed and simplified to develop an innovative technique that integrates key operating parameters into a pseudo-performance coefficient. This approach proved valuable in monitoring desander performance, especially in the absence of sand sensor data, and was correlated with downstream equipment reliability metrics. A range of optimization strategies was explored, including adjusting the number of liners, redesigning holder plates, varying gas-to-liquid ratios, analyzing particle size distributions, managing flow regimes, and controlling differential pressure. The desander's efficiency is assessed by measuring the volume of sand drained while maintaining a controlled incoming flow rate under consistent conditions. Monitoring the pseudo-performance coefficient and vibration trends of downstream injection pumps serves as a cost-effective and efficient approach for locations lacking sand sensor data. Operating parameters are adjusted, and outcomes are recorded. For multiphase flow, the trial units consist of a filter type desander unit and a multi-cone hydrocyclone desander. The filter type demonstrates unsatisfactory performance, characterized by rapid plugging and significant pressure drop associated with the incoming gas phase flow rate over a short period of time. The hydrocyclone desander yields satisfactory results. The ratio of gas to liquid phase in well fluid and particle size characteristics significantly affects desander performance. For liquid-only flow, the operation of multi-cone hydrocyclone desanders is compared. Various operating parameters have been adjusted, and their performances are evaluated. The modifications include changing the throttling percentage of the underflow valve to the accumulator vessel, varying sand accumulator drain frequency, adjusting the PID control loop of the upstream valves for improved flow stability, and upgrading the liner holder plates and O-rings. Operational adjustments and new techniques demonstrate an effective way to maximize desander performance. This study demonstrates the effectiveness of data-driven approaches and design enhancements in optimizing desander performance for offshore sand management. Field tests and case studies in Thailand suggest the advantages of monitoring the pseudo-performance coefficient and implementing operational adjustments to improve equipment reliability. The findings highlight the necessity of adaptive sand management strategies for varying flow conditions, promoting enhanced operational efficiency and sustainability in oil and gas operations.