2) United States Patent Hopper SUBSEA PROCESS AS EMBLY Inventor: Hans Paul Hopper, Aberdeen (GB) Cameron International Corporation, Houston, TX (US) Assignee Notice: Subject to any disclaimer, the tem ofthis patent is extended of adjusted under 35 USC. 154(b) by 0 days. an Appl. Nos 101510,825 (22) PCT Filed: Mar. 24, 2003 (86) PCTNo: — PCTIGBAS/01254 $371 (eX!) 2), (4) Date: Oct. 7, 2004 (87) PCT Pub. Nos WOO3/87535 PCT Pub Date: Oct. 23, 2003 6s) Prior Publication Data US 2005/0145388 A1 Jul. 7, 2005 jon Priority Data (02282503 G0) Ape 8, 2002 » Foreign Applic ey "Cl E21 2912 (2) USC 2006.01) 166(387; 166/351: 210/110 (G8) Fleld of Classiieation Seareh 1660357, 166/351; 210110, See application file for complete search history. 36) References Cited USS. PATENT DOCUMENTS. 4asgo2 4248305 8 * 1979. Wissman DIVE Scarbrough 166305. USOT '52682B2 (10) Patent No. (4s) Date of Patent: US 7,152,682 B2 Dec. 26, 2006 4300375 A$ VIS. Wiseman 200 AaR707 A$ 41984 Scie eal “oo R ore922 26 71987 Leininger oust 48287 A #4198) Goldsbeny 369 4829,196 8 ¢ S198) Bronick eta “ost ASIST A$ 71989 Bencre 166335 848475 7198) Dean ta 90048 421990 Deane a 517908 61992. Holmann 6197005 BL* 32001 Dita. 9524s Toms.cst BL* 82006 Olsen 166.357 ousiooes94 A1* 43004 Olsens 166.357 2on40009422 AL* 92004 Lush otal 166357 POREIGN PATENT DOCUMENTS an 499 024 woot 20128 1939 32001 (OTHER PUBLICATIONS Interatonl Search Repot for Appl. No. PCT/GHO3I012S4dated 4.9, 2003 (pp 3), {Cit Rowling eal: Design and Analysis of «Multiphase Turbine for Compact Gas-LigidSeparaion, SPE Production & Fults eb. 2002 (pp 47-52). * cited by examiner Primary Examiner Thomas A Beach (74) Atorney, Agent, or Firm Conley Rose, PC. on ABSTRACT A subsea process assembly fo separating a multiphase flow, the assembly comprising: an inet for a multiphase medium: ‘ pressure reducing means for reducing the pressure of the ‘multiphase ow from the inlet and creating @ source of ‘energy multiphase separator for separating the multiphase input into individual phases: and a pumping system for, ia ‘use, pumping at last one ofthe desired individval phases t0 ‘delivery point by utilizing atleast some of the energy Irom the source of energy 23 Claims, 12 Drawing Sheets 710U.S. Patent Dee. 26,2006 Sheet 1 of 12 US 7,152,682 B2 2 14 12 10 15 17 18 16 AL 26 2 23 Fig 1 (rior Art) 20 21 HI ttt 22 25 19U.S. Patent Dec. 26, 2006 Sheet 2 of 12 US 7,152,682 B2 27:32 «15 «18 16 12 33° «28 Fig2 Prior ArpU.S. Patent Dec. 26, 2006 Sheet 3 of 12 US 7,152,682 B2 ‘ig 14 16 18 iL Fig 3 22U.S. Patent Dec. 26, 2006 Sheet 4 of 12 US 7,152,682 B2US 7,152,682 B2 Sheet 5 of 12 Dec. 26, 2006 U.S. Patent ¢ Bry 6E . LL SLI LE OL iL SEU.S. Patent Dec. 26, 2006 Sheet 6 of 12 US 7,152,682 B2 Fig 6U.S. Patent Dee. 26,2006 Sheet 7 of 12 US 7,152,682 B2 \U.S. Patent Dee. 26, 2006 Sheet 8 of 12 US 7,152,682 B2 Fig 8U.S. Patent Dec. 26, 2006 Sheet 9 of 12 US 7,152,682 B2 Fig 9US 7,152,682 B2 Sheet 10 of 12 Dec. 26, 2006 U.S. Patent Fig 10U.S. Patent Dec. 26, 2006 Sheet 11 of 12 US 7,152,682 B2 Fig 11U.S. Patent Dec. 26, 2006 Sheet 12 of 12 US 7,152,682 B2 z = = oe oc a 1] g gS ee (ene ; : Es | ll |). i 53: 2US 7,152,682 B2 1 SUBSEA PROCESS ASSEMBLY CROSS-REFERENCE TO RELATED APPLICATION, ‘This application is a National Phase entry of PCT Appli= cation No. PCT/GBO301254 filed Mar. 24, 2003 which ‘laims priority wo EP Application No, 02252508 4 filed Apr 8, 2002, both of which are incorporated herein by elerence. BACKGROUND OF THE INVENTION ‘The invention relates fo a subsea process assembly whieh ‘can be used when extracting materials such as hydrocarbons from subsea environments and, in particular, to an assembly ‘which separates a multiphase flow into individval compo: nent flows for further sippy to specific locations. ‘In general, the current practice lor development of subsea hydrocarbon fields is om 4 macro field approach which uses ‘2 plurality of subsea wells connected trough subsea jnfastructure, pipelines and risers to a surface process Joely, such as. floating production vessel ora platform. In many locations, especially in remote areas, the proportion of as and water within the fluid produced by the well is igniflcant and is generally a surplus product, when com- pared to the cil which i is svally desired to retrieve. The ‘22s and water has to be safely and cleanly disposed of in 3 ‘manner which does not damage the environment. ‘A solution for such a system is that gas and water which have boon taken out ofthe well and which are separated at the surface can be pumped buck to the seabed to be rein- jected at the seabed into subsea wells. This reinjection reduces the rte of decline of the reservoir pressure allowing the fleld to produce longer, To inerease the rate of produc- tion, energy must be supplied tothe production steam using citer downhole of seabed! methods Overall, the current approach requires @ complex feld production system which has numerous pipelines, thus ‘incurring « high feld capital expenditure sad operational ‘expenditure. This high expenditure reduces the commercial ‘cing at which the Feld ca be operated viably. As the eld matures and prodction declines, level is reached at which ‘considerable resources are left in place but at which itis no longer commercially viable to operate the wel ‘Conventionally, the flow whichis achieved from a subsea eli directed toa surface production vessel. Back pressure ‘on the well reduces the production rate and brings on an ‘early decline of the wells Mowing life as the reservoir pressure at the bottom of the well mast overcome the hydrostatic head and the pressure caused by fiction. There- {ore the well depth the distance slong the seahed and the water depth ae al coneibuting factors aginst the reservoir pressure. At a certain stage, the well ceases to produce Useable flow when 2 significant proportion of the desired fluid remains in the reservoir area drained by the wel. Energy ean be ade to the production steam, either down- hole, at the wellhead or in the riser. The input of enorgy increases the eostof the Well, thereby reducing the eom- ‘mercial viability of the well ad, in some eases, the entire field In deep water or for wells a considerable distance, such as overa number of kilometres fm the surface production vessel, the production rte deetine or the energy input causes the commercial value of a field to be reduced. The early non-viability of the field means considerable valuable resources sich as the non recovered natural resources are Jeft in situ, Accordingly, and especially in deep water, the o 2 Jimited produetion rates, the early decline and the higher costs rvul ian increaved investment requirement with a lower rae of return This ensures tat small and medinm sized folds eannot be exploited fully, iat all using eurent practices ‘When wells are at » considerable horizontal distance ‘long the seabed from the surface production vessel, a ‘number of significant problems such as shigging, yrs, ‘waxing and an inereased back pressure are eaused by the distance tht the production fuid must travel. In addition using gas artificial tin the well can exacerbate these prablems causing pipelines to require higher speifieations And larger diameters, thereby increasing the eost Tn order to maximise the production capability ofa well well operators are considering solutions which are based on the macro field approach and these include downhole gas lit ‘or pumping, seabed drive, multiphase pumping, gasliguid separation, hydrocarbon/water separation, individual well ss/lguid separation and three phase separation. ‘As the pressure in the reservoir declines and at different, rates in different pars of the fel, the volume produce rom the wells wil also decline, Ths also applies in reverse wo the injection wells. To maintain an effective predaction rte will require the addition of artifical lift in the wells that will ‘increase the seabed wellhead flowing presse. This means that, in pumped wells, considerable amount of was will tl be in solution atthe wellhead Downhole pumping typically uses either electric sub- mersible pumps or hydraulic submersible pumps which have ‘o be installed in all commingled wells. The reasons for this is that unpressursed wells cannot flow into pamped pressurised commingled system, Therefore, totally pumped fel! approach has to be taken and poping has to be installed in some wells that could flow naturally or they ced their own pipeline which is very costly. Accordingly, ‘energy and therefore costs are spent on wells whieh did not require them, These pumps are effective because they are preferably set in the well below the gas bubble point and therefore only have to pump a liquid. Also, the same subsea infasteueture, pipelines and riser systems are still roquite Accordingly the pumping requirements add t the conven ‘ional field capital expenditure and also increase the oper tional expenditure of the field In a macro field approach, the wells produce owing up to the subsea twee along to a manifold for commingling ‘where the flow from individual wells is commingled and then the multiphase Mud flows to the surface via pipelines and risers. For commingling to occur, higher and medium pressured wells need to be choked ‘ick to the lowest pressure of a commingled wel, thereby losing energy from the Hlow stream, To redice the back pressure caused by the pipelines, methods for providing energy tothe Now stream downstream ofthe manifold, such as additonal pumps, may be used. As the fid fos up the well the gas wll come ot ‘of solution once tis above the bubble point, thereby causing ‘1 gallquid flow atthe wellhead, However, such mlkphase ‘pumps require addtional enerpy Which increases the cost of {his approach. The requirements for pumping ths free gas fare very diferent and, in many cases, apposite (0 those required for pumping liquid and therefore there is design conlliet and, at best, only a poor compromise can be achieved. Therefore itis referable to separate the fui into ‘888 and liquid whieh can be directed to suitable gas pumps And liquid pumps. As friction losses along a pipeline reduce the pressure, more and more gas comes out of the liguid solution, possibly forming 50 to 100 metre shigs of gos. It should Be considered that this gas does not need pumpingUS 7,152,682 B2 3 ‘due to the Jow ga fiction factor and low gas hydrostatic head, and can ficely travel along its own pipeline. Its the Tiguid slugs dat have to be pushed along by the compressed ‘gas. Accordingly, the energy used by a muitiphase pump t0| ‘compress the gas to achieve a pressurised multiphase flow is tunnocessiry if a separate gas flow fine is use ubsea gas/liquid separation and pomping pstially takes advantage of the wellhead at the scabed and water depth. The gas is separated at a lower pressure than the lowest pressure point in the pumped liquid pipeline, Such a system Js deseribed in US. Pat, No, 4.900.433 and this uses drilling practices and a conventional subsea conductor asa separator housing. Due tothe conductor size, a maximum theovghput ‘of about 30,000 barrels per day is what can be expected rom such system. The system shown in US. Pat. No. 490,433 follows conventional practices in fowing toa surface instal- Jation but now requires two small pipelines, one for gas and ‘one for liquid, instead of one large multiphase production, Pipeline "An alternative separation approach is hydrocarbon! ‘water separation system, The reason for separating the water from the hydrocarbon is tha, when the wells are produced ino the system, surface installations need not handle the increased volume of Mui, in particular, caused by the water By reducing the water atthe seabed, the surface installation ‘can operate on a greater number of wells. Oilwater sepa ‘ators are usually gravity separators and require sufiient Sanding time forthe hydeocarbons o float up and the water to sink down, ‘The water is then pumped into a water injection well withthe unassisted hydrocarbons owing in a Pipeline tothe surface vessel. The gravity multiphase sepa- rator does not provide enemzy tothe well steam, except by the effect of later allowing th elimination ofthe hydrostatic head caused by the removal ofthe partial presse exerted by the water in the multiphase Buid. This approach is solution to solve a specific field symptom such as a production uid train bottleneck caused by a standart macro fild system approach. To inerease the procicton rate the multiphase byrocarbon Bow can he pimped Tree phase separation has beca attempted and this has ben hase om a macro field approach with the objective of using horizontal gravity separators, similar fo those used on the surface but now on the seabed ‘An alternative approach is covered in US, Pat. No. 4.848.475. A production and process method is described ‘which nilises Single units from U.S. Pat. No, 4.900.433 for ‘each well prior tothe few from the well entering respective as ant Tiguid pipelines. The individnal units allow wells 10 flow at their maximum production rate with the separator ‘operating pressure being dropped to the allowable pressure to deliver the gas, and the pumped liquid to the surface where further separation on the surface vessel can occur. Avvordingly, the deeper the water in which the well is located, the more eifective this systom is at reducing the individual back pressure on a well. This ean delay the need for arifcial lif, such as gas fit or downhole pumping, and reduces the reliability isues due to the reduction in the downhole complexity. However, the disadvantage of such 3 system is that the capital expenditure is extremely high and the complexity of operating such a system are significant. ‘This foam of operation has only been considered on a macro approach and therefore considerable energy will ned to be ‘supplied to each unit to deliver the Fguidl back to the surFace and on the surface for reinjecton. “Toachieve separation of gases and liquids, several param- ‘ters must be met. Typically in oil wells, some gas will Be jn solution in the water and oil mixture and the amount of 0 o 4 sz in solution is dependent on the pressure of the fui frder to Separate the gas from the liquid, the pressure must be reduced, chereby lowering the bubble point and allowing _288 bubbles to form, The pressure level wil set the amount ‘ofthe gas which is released from the solution and no further ‘28s will be given up until the pressare of the liguid is reduced further. Once gas has been released, itis slow to be reabsorbed into the guide and theretore repressuring the sas and injecting it into the fguid line will not prevent Separate two phase How and the fonning of slug hws, nce the gas bubbles have formed, the difference in density of the ga to the liquid is significant and this means ‘that dhe gas wil separate readily from a liquid which can be achieved under gravity in approximately a number of see- fonds for a small volume. Again this time increases as the volume is inereased, thereby requiring a large and costly system. ‘The fiction in a horizontal pipeline will cause the pres- sure inthe uid flow along the pipline’s length to decrease ‘and therefore, even if all of the fre gas is removed at the ‘tar of the pipeline, futher release of gas will occur along the pipeline due to the pressure drop and this will eollet and orm a slug, especially in the upper part of an undulation in ‘pipeline. Each upper part of an undulation will cause @ pressure drop in its own righ, thereby resting in a higher pressure beng required atthe head of the pipeline to move {he vid. To prevent this fom occurring, the pressure ofthe ‘uid a the wellhead is preferably reduced beyoad the lowest pressure point in the pipeline. Altematively, if cersin amount of gas is required atthe surface Lily, then the pressure at the head ofthe pipeline need not be as lowe but ‘against the penalty of having a higher wellhead fowing pressure, Tn. riser, the pressure change or drop is considerable due to the hydrostatic gradient, Gas breakout in the riser or just prior othe riser base will race the density ofthe Fi and ‘ofthe hydrostatic head and wil therefore cause gas lif inthe riser This is acceptable if the gs is required atthe surface ‘eilty but, if not, then top side separation Lilies, pump- ing equipment, « gas re-injection riser and a gas pipeline back to the wellhead site are also required, For separation of liquids, it aot possible wo use der. ences in presse changes as this has itl elfet on the iguid ‘density. Accordingly, the ability of molecules to move freely ‘Sepends on the diference in mas, the viscosity of the prime Tiquid andthe surfice tension, By increasing the droplet size and its ability to coalesce, a greater mass force is available ‘oovercome ihe restraining forces, thereby helping the fluids to separate. The ability to allow a Muid to coalesce and collect on wetted surfaces, walls or plates also improves separation, “To achieve separation of @ multiphase flo, a fst step must be to ercate a low pressure physical state by fist dropping the pressure atthe seabed to the surfce delivery point requirement. Turbulent flow will continue the mixing ‘and therefore a large volume is required into whieh the flows passes to allow the fui flow to stabilise and fem a uniform profile, A low velocity and a steady Hlow encourages such a profile. As mentioned above, separation is typically depen- ‘dent on mass. A simple technique therefore isto use a sealed settling tank’ in which gas is quickly given up but, for erent Fiquids, the velocity of the flow has to be reduced drastically to allow effective gravitational separation, This therefore results in large tanks ora very sma throughput of separated ids, The has serio listing factors subsea due to collapse and burst requirements,US 7,152,682 B2 5 However, if @ fhid is rotated or allowed to rotate by tangentially entering a circular container, the gravitational Jorce can be signilicanly inerwased from normal earths _grvityto approximately ten fold or higher i.e, 100 or 1000, By inereasing. the foree, the separation process can be speed! up and this ensures that small Mid containers can be used. Cyclones oF a id vortex ereated ina eylinder are cllective methods and these reduce the time required for separation but these can only handle a small volume of fa and at specific parameters At high gravitational forces, typically above 20 G, shear forces are created in a moving fuid compared f a rotating stationary uid in #eentrifuge. These do not effet solids in the liguid but wll break down the size of iguid droplets, and possibly create an emulsion. Reduced droplet sizes will ‘considerable extend the time required to achieve separation, ‘Therefore, creating a very high gravity free is effective for removing solids. For liquids, elicient separation ofthe flow stream occurs between 10 and 20 G. Inthe macro fiek concept, the producing wells are choked down to allow commingling with the How froin the lowest pressured well. The commingled multiphase low to a plat- form then enters a surface installation field separator to separate off the gas and to allow liquid pumps to pessurise Celliciently the respective uid phases tallow for production ‘or re-injection. The pressure in gas re-injection line oe & Water-einjection line supplied by the surface installation as to be suficiently high 1 meet the injection peossuees of the highest pressurised injection well. This therefore requires ‘’chokes on the reinjction wells that have a lovee injection, pressure, This shows that in the macro field well stream system, energy is Test that thon has to be replaced by Pumping, and energy bas to be provided to pump up the Fe-injetion phases with a considerable amount being lest on the low pressured injetion wells ‘Currently the tendeney isto ow all the produced ids to the surface installation because of the magnitude of the ‘cost and the ability to operate and control # macro subsea field separation system, BRIEF SUMMARY OF THE PREFERRED EMBODIMENTS, to overcome the problems ‘According to the present invention, there is provided 2 subsea process assembly for separating a multiphase How, the assembly comprising ‘an inlet for @ multiphase medivas; pressure reducing mean for redcing the pressure of the "nultipiase flow from the ilet snd creating a source of cenerys ‘multiphase separator for separating the multiphase input ‘nto incvidual phases; 4 pumping system for, in use, pumping atleast one ofthe desired individual phases toa delivery point by utls- ing at least some of the energy fom the source of nergy: ‘The pumping may be powered by utilising a variable ‘controllable amount of the energy from the source of energy. Preferably, the pressure reducing means is eoupled 10 2 hydraulic power drive or alternatively to an electric power ‘drive ora flow controller, such asa choke, depending on the ‘optimum method wither hydraulic, electrical or pneumatic §s used for distributing the power 0 o 6 Preferably, the assembly further comprises @ control pro- cess module for contolling the pressure reducing means and the pumping system, Preferably, the process assembly also inckades a power rive unit that generates hydraulic power from an extemal fenergy source. The extemal energy source may be cither electrical oF fd energy. The power deve unit andlor the Pressure reducing means may be driven by 2 Mid which provides energy in te form of Tiquid or gas. The wellstream energy may be achieved by creating a pressure differential in ‘the multiphase flow between the inlet and the separator, for example by reducing the pressure of the multiphase medium. The module may further comprise a drive fluid inlet, the drive fluid being pumped to the module from an extemal point The pressure reducing means may also com prise a means for ereating a pressure differential in the drive uid, for example by reducing the pressure ofthe drive hid, thereby creating a further source of energy. The drive fil ‘may be water from a water injection supply. If an extemal clecizical supply is available instead of using drive Mui. then this con be used directly to supplement the electrical power obiined from the well stream elecrial power drive. “This description describes an approach were energy from the well stream and the second energy source are converted into hydraulic power for distributing the power to the various power consuming modules. Altemative power istibution methods can be considered being electric or ‘neumstes, Ia eran locations there is no need to support fhe reservoir pressure by injecting water, and therefore t0 supply the supplementary power ean be provided more ficiently using preferably clectric energy but pressurised {dead erude or gas could be considered. An electric secondary tenergy’ source cou be wed directly ifthe power distribu tion on the module is eletrc or the electric energy coud rive an clecric hydraulic power unit if Use power distrib sion is hydrauli Preferably, the pressure of the multiphase fluid supplied to the separator is reduced to a level specified by tho surface installation of below the lowest pressure in a pipeline to the elivery point, The pressure of the multiphase low may be reduced to helow 25 atmospheres. The separator may be one of the following: # centrifugal container. a vortex tube, a cyclone, helix container or auger, ‘gravity vertical or horizontal tank, silo, «conductor pile housing, toridal ring, a toroidal sprial combination or @ spiral. A suitable toroidal separator is deseribed in our co-pending Furopean patent application, entitled “Separi- tor” and filed on the same day (agents's ref: MJBO7104EP) Dreferably the separator is arranged to separate the mul- ‘iphase fuid into solids, gs, oil and water although it may be arranged to separste « multiphase fd into two or more ‘ofthese, infact, o remove, for example only gas from the remaining phases. Preferably, the assembly also comprises an individ! pump for each phase. The pumps may be driven using energy created in the assembly. ‘The assembly preferably further comprises a means for.in 2, reinjcting surplus gas and water and possibly the solids slumy which have been separated either back into the reservoir or to a specified delivery point “The assembly preferably also comprises template, a piping mat and a retrievable subsen process module. The retrievable subsea process module may comprise a retiev- able base mode and retievable mini modules Additionally, the subsea process assembly may comprise solids removal module for removing solids, sich as sand rior o separation of the Mids inthe form ofa solids slurry.US 7,152,682 B2 7 The present invention also provides a subsea hydrocarbo recovery system comprising: 1 subsea well for supplying 2 multiphase Suid; a subsea process assembly according © any one of the preceding claims, wherein the inlet the assembly is in fluid communication with the well and delivery point for receiving the recovered Ihydrocarbon(3) from the subsea process assembly. ‘The system preferably further comprises a well nto which surplas products ofthe separator, such as wate, sas or the solids slurry can be renjected ‘The system preferably comprises a plurality of subsea ‘wells, cich well or set of wells having an associated subsea process assembly using «process module which supplies the recovered hydrocarbon(s) 10 the same delivery point for farer supply to a delivery poi ‘The delivery point is preferably one of a pipeline for removing the product from the field, a water injection wel as injection well or a producing well to achieve artical it ‘This invention describes a system that can achieve three phase scpation on the seabed down to the same degree oF Tower than a surface fist stage separator and which is tailored to suit the production ofan individual subsea well, ‘withthe ability to supply each phase ata separate pressure suitable for ctr exportation tothe topside whether nea oF Jar, oF for re-injetion tailored to suit local r-iajection well rexjirements, and all with a minimum of energy consuimp- tion from an extemal souree, Therefore a process assembly that can be connected to 3 well or set of compatible wells and that can simulate atop side surface separator will, effectively, have eliminated the celfecs of water depth and any downstream back pressure handicaps. This can now allow the wel to flows at surface ‘conditions hut onthe seabed, In water depth from, 1000-3000 m this difference allows a considerable increase Jn produetion and the reeoverable hydrocarbons. Being able to vary the input pressure into the process ‘assembly will allow each well 10 be treated individually. increasing the effcieney of production and the reservoir ‘management of the area drained by the wel “The fest step, snd alo at later suitable opportunites inthe system, is the emoval of harmful solids which can cause sever damage andor blockage to values, choke, separators, pumps, pipelines and risers. In addition there i the ability 10 ‘monitor individual sources and then to take suitable action. ‘The next step isto process the fuid. To allow an indi= vidual well or set of similar wells to produce at theit ‘optimam level requires an individual process assembly ‘capable of accepting a certain volume atthe required pres> sure, This can vary according to the top side resiremionts ‘and on the changing effects in the reservoir, To achieve ‘cparation levels equivalent toa lopside itt stage separator, the process assembly operates down ( surface separator pressures, Tiss to ensure that a maximum level of gas and water are capable of being removed fom the oil An ‘individual process assembly, in the form of a process mod- ule, maxioises the poteatial ofthis pressure difference hy harmessing the maxinim amount of energy between the ‘wellhead flow system and the inlet 10 the separation system, “The operating pressure of the process module is depen- ‘dent on the level of gas separation required. The ability t0 separate the flow int distinet phases allows each phase to be monitored and measured (ie. velocity and density) which eliminates the nee fora tes line fom the field tothe surface installation 0 o 8 The process module has the capability to r-pressurise each phase separately to suit the delivery point, Pump modules for a phase can be assembled in series to achieve high pressures, or in parallel if there are two different elivery points for an individual phase. Ths allows the gas andlor water to be r-injcted into local injection wells at their optimum injection pressure instead of into a higher pressure common field injetion fine. This ability to ind Vidnally Select the pressure also allows the use of either pressurised gas to gas Tift the producing well or to use pressure oi or water asthe deve Fguid to operate the turbine cof a hydraulic submersible pump in the producing wel The capability to reinjoct the gas oF water oF both removes the expanding problems caused by gas andor the volume of water inthe pipeline back to the riser base ofthe surface installation, Also the removal of water from the pipeline means the partial differential back pressure eased by water in the riser is eliminated. The removal of eier pas fo water or both results in a considerable rediction in the size of the resulting production pipeline and riser, and the eed not to install any downhole or seabed pumping require ‘ments and its associated energy consumption, the topside process facility, r-njection pump equipment and its ass0- ciated enemy consumption, and the re-injetion pipelines land risers. This sal n addition to the elimination of the test Tine. To achieve these benefits, enemy is required by the process module. The priority is to obtain available energy ‘rom the well stam, but hen to back this up where need Where a reservoir rogues water injection, the water injec ‘ion pipeline is operated at higher pressure with the process ‘moxdile using this pressure difference, This is small change tat does not require any additional operations and may be already within the water pipeline specification range ‘The process module will require additonal power if there is a insuficent wellhead flow pressure due to reservoir characteristics ln addition when a closed in well ix being Drought on, the pump modules will require power before the well steam has developed. Its possible tht if. well and its process module are in fll production, ith the capability ‘of producing & quantity of surplus povser This then could be cascaded to another well loeation to being ether wells on ‘without requiring the need to use an extemal energy supply. Ia process module has sullicient power fo its requirements ‘whieh is not using all Uae wel stream power, then when fall capacity is reached, the chokes on the various inlet units ‘would be used to contro the flaw pressure, In addition the process assembly may consider tempers ture contol ofthe fluid in respect to insulation and a heat ‘eansfer system. When gas is de-pressurised, cooling will ‘cur and when compressed, a temperature rise will occu, ‘Maintaining 2 minimum temperature is important to prevent ‘waxing, asphatines and hydrates forming in the system. Also, downstream of pump, the enemzy used will have been converted into waste heat. Beside insulation on the find ‘ontinaent hardware, hea transfer system from the pump rmodlules to especially the power drive units is recom- mended. “The process module processes the well steam wo meet the constantly changing parameters of the field due t0 the surface installation requirements, and it optimises is dliv~ feny based on the well flowing characteristics. This requires fast active contol system that ean process te information from various sources and manage the process system by ‘operating the flow control meckanisms, Now selectionUS 7,152,682 B2 9 ‘devices and pressure barriers. This includes self digunostes, and emergency shutdown management of itself and the wel BRIBE DESCRIPTION OF THE DRAWINGS For example the present invention will now be described With reference to the accompanying drasvings. in which FIG. 1 shows a schematic arrangement of a conventional subsea production system: TIG. 2 shows a schematic cross scctional view of 3 ‘conventional subsea commingled separation operation sys TFIG, 3 shows a schematic cross sectional view through 3 system acoonding to the present invention; FIG, 4 shows a schematic plan view of part of a field, using the present invention FIG, is a schematic cross soctional view through 9 process module according to the present invention: TIG, 6s a schematic plan view of the mode of FIG. 5: x FIG. Tis a schematic cross sectional view through a sand removal module which could be used in the module of FIG. 5 FIG. 8 is a schematic cross sectional view showing one {orm of separator which could be used inthe module of FIG. 5 FIG. 9 is a schematic cross soctional view throwgh 3 asiiguid divider for use in the module of FIG. 5: IG. 10 is a schematic cross sectional view through 3 toroidal separator for use in the module of FIG. 8; and TIG, 11 is a schematic cross sectional view through a ‘column separstor which can 25 be used in the module of FIG. § FIG. 12 is a schematic cross sectional view through process module using dual power drive modules accordingly to the present invention DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows 8 conventional subsea production approach in which a relatively stationary produetion installation 10 is provided on the surface inthe sea Hl. The installation 10 is ‘connected tothe seabed 12 by means of tes 13 to anehor it in positon. A series of Bow risers connect the instalation 10 to a riser base 14, Pipelines are provided forthe flow of gas 18 for reinjection, water 16 for the injection, a test ow line 17 and a prodnetion line 18 forthe supply ofthe produced product from the wells lo the surface installation. ‘On the seabed 12, a number of typical field wells 19, 20, ‘and 21 have boon installed. For example, well 19 is 4 805 injection well and well 20 is a water injection well. Fach of these ae used to reinject gas and water respectively sepa rated out om the surface installation 1. Gas injection well 19 is connected to a gas injetion line 22, the water injection wells connected to.a water injection fine 23 and a typical gas lifted production well 21 is ‘connected to a proicton fine 24 and toa gas lift line 25, ‘The two sets of ow lines 15, 16, 17, 18 and 22, 23,24, 25, are connected respectively via a manifold 26 located on a template 28 positioned on the seabed 12, ‘Although not shown in FIG. 1, a plurality of production ‘wells 21, water injection wells 20nd gas injection wells 19, ‘woul be connected via a single manifold 26, Accordingly, the pipelines 18, 16 and 18, and the corresposding portions running from the riser base 14 tothe installation 10, need be siunificantly lager than those running from the manifold o 10 to the individual wells, As all the wells are individually choked and connected io the manifold where they are selectively valved and connected to the respective common Pipeline, ths is known as a macro fild system. Tn FIG. 2, a subsea three phase separation system is shown in which a multiphase separator 27 is provided between ‘manifold 26 andthe flow ine 18. The remaining features are similar to those in the system of FIG. 1 and like reference ‘numerals ate used. The manifold 26 and the separator 27 are ‘mounted on a template 28 through which a number of the flow fines pass, such thatthe manifold and the separator ca be ireated as separate modules which ean be replaced ‘without he need for replacing the entire subsea structure, An electri power supply 31 is provided to drive the multiphase pump 32 and water pumps 33 as roquited. a this example, the separator isa simple gravity separa tor, although more complex separators could be vied. ‘A choke 29 is provided between the output from the production well 21 and the inlet w the manifold 26 so that the Now through the manifolds atthe lowest common field pressure from the various production wells in the field. The choke 29 reduces the pressure where necessary and this leads to a loss of power in the low and therefore a lass of energy. This energy cannot be recovered. Chokes $4 and $8 fare also provided on the gas injection wells 19 and on the ater injection wells 20 respectively. Again the pressures in the gas injection pipeline 22 and the water injection pipeline are sulliciently high to meet the needs of all the wells tonnected t0 it. choke 56 is also provided on the gas lift Tine 25 othe gas lifted produetion well 21, Again, for some wells, the supply pressure is above the requirement whichis lost afer itis choked down, This follows the macro field approach, FIG. 3 is directed o a production system which utilises a preferred subsea process assembly according tothe present Jnvention. Like reference mumerals have been used for ccommon features between the present invention and the embodiments described in FIGS. 1 and 2 "The subsea process mocile 30 isa self contained, stand ‘alone unit that can be positioned at a point between the ‘pat of a well and the export ol line 18. Several prod tion wells 21 can supply the same process mole 30 bi cach well 21 is preferably provided with ts own individval racess module 30, This individual well system could be falled the micro Held approach As canbe seen from FIG. 4, each template 28 may include 1 plurality of process modules 30 connected to individual production wells 21, A single gas injection well 19 and a Single water injection well 20 can he used for more than one production well 21. Individual templates 28 can be con- fected together such that they supply a single pipeline bundle to the surfave and possibly a set of flow fines for individual template low communication, FIGS, § and 6 show the schematic layout of one of the process modules 30.As ean be seen in FIG. 8, the individual Subsea process module 30 is hased on a two-part module ‘configuration tht connects to the necessary pipe armnge- ‘meats inthe template 28. In this way, the process modules ‘0 can be disconnected fom the template 28, for example to replace if worn, corroded. or damaged” or for cleaning, ‘without the need to move al ofthe subsea structures to the surface. Basic ROV (Remote Operated Vehicle) or diver ‘manna, isolation valves are in the piping mat ofthe template 28 to allow prime isolation with the Now Fines. The loseer part of the process module 30 consists af the static equip: ‘ent for separation and the interconnecting pipework, f= ing fil closed isolation valves. All the active componenUS 7,152,682 B2 u ‘and moving machinery will be housed in mini modules to allow simple replacement from a service vessel. Within the ‘mini modules, individual units will also be reievable 10 ‘enable simple replacement. The basie configuration consists ‘ofa set of mini modules as follows: a solids removal module 38, a well flow hydraulic power drive unit 37, a drive fluid hydraulic power drive unit 36, a series of pumps 39, 40,41 for pumping the individual separated phases and a solids slurry pomp 42. contol process module 43, shown in FIG. 6. is provided to control the active operation ofthe subsea process module 30, The contol module 43 receives infor ‘mation from the surface so that it can manage independently the subsea process modules and he treo which the madule ‘dO isconnected. A water injection hydraulic power dive unit 6 s provided to obiain energy from a water injection supply 53. These units 38, 36, 37. 39; 40.41, 42 and 43 can be ‘lasso a6 mink modules The solids removal module 38 takes in the multiphase flow at the wellhead pressure so that solids, in particular sand, ean be removed prior to separation of the multiphase production low. The solids removal module 35 takes in the wellhead pressure multiphase flow through pipeline 24 “The subsea process module 30 is mounted abowe a piping ‘mat 48 in which the, main gas, oil and water pipelines are supported within the template 28. The process module ‘consists ofa base module 46 az the mini modules, The base module 46 is provided with a number of connection points Jor connection tothe respective water $0, oil SL, gas 82 and ive fhid 83 pipelines in the piping mat 48. When the drive fluid is seawater, it s important to keep the drive fui line 53 separate fm the waterline $0 to prevent the ereation of undesirable salts, However, should the drive fhuid. be recycled water from line 50, tis permitted forthe to lines to be mixed ‘he individual mini modules 38, 36,37, 39, 40,41 and 42 ‘are located above the base module 46, and in. Mud connec tion therowith, for easy removal incase of damage or service requirements "As can be seen from FIG. 6, the multiphase inlet line 24 feeds into the solids remaval module 38 and from there on to the well stream hydraulic power drive unit 37. The well stream hydraulic power deive unit 37 is connected to the ulti stage separator 38 and also to the hydraulic power system 47 which leeds, for example, single gas 39, oil 0 ‘and water 41 pumps. The mulisage separator system 38 has thro separate outlet feeds 48, 49 and 80 which connect 10 the gas, ol and water pumps respectively. water hydraulic power drive nit 36 s also connected tothe hydraulic poser system 47 for supplying complementary power t the ind Vidal pumps and i fed by the water drive Tine 83 and has fn outlet through the water injection line 50 which aso receives an input from the water pump 41. A contol process module 43, which may receive instructions from a surfce installation or maybe pre-programmed, is provided to con- tro the subsea process module 30, Not shown isthe chemi- ‘eal injection system for injecting chemicals at different points inthe process module 30 for corrosion inhibitor anti oaming, hydrate reducer, wax inhibiter or retin reducer The solids removal moviole 38 shown in FIG. 7 is a retrievable module consisting of a passive vertical housing 60 with a well flow control choke 70-dovn stream of the solids removal process and a small solids choke 62. The housing has generally vertical, cylindrical ses with the ower part tapering down into a conical par 63 having @ single exit 64 for the solids. The multiphase flow enters the howsing 60 tangentially st the upper end 68 of the housing, a a distance below the upper surface 66 of the housing o 12 The multiphase flow line 67 exits the top ofthe housing 60 substantially along the exis ofthe housing 60. The end 68 ofthe flow line 67 inthe housing 60 is below the entry point {65 of the tangential flow, but above the top of the tapersd ‘conical section 63 and is provided with a vortex breaker 79. ‘Malkphase flow tangentially enters a gas zone 69 at high speed atthe top ofthe housing where centrifugal separation ‘occurs. This forces the solids to the outer portion of the ‘housing 60 ad. asthe velocity drops the solids move dawa towards the solids exit line 64, A solisiiguid sensor (not shown) allows a controlled escape of solids in a liguid Solution ina shuy ratio nto and through the solids choke 62 predetermined at least at a minimum so as 10 prevent a blockage. ‘The multiphase flow Hine 67 is provided with a choke 70 and, 10 maximise the energy from the well stream, itis preferable that this choke is filly open but i utilised on tart up, elose down and to contr a peak flow prior o entering the well steam power drive unit 37, ‘The fhid power drive units 36, 37 as shown in FIG. 5 consists of isolation valves 71, a means of converting the energy of the fluid into mechanical power 72 which could be in a hydraulic power drive unit, to create a high pressure hydraulic drive lid supply and a How contro! mechan (Choke) 73, 74, respectively. The objective of the well steam power drive unit 37 is to maximize the available ‘energy i the uid stream and to cause «pressure drop to the required separator operating pressure. When this isthe case, the choke 74s fully open but at certain periods where Timited amount of power is required, the choke will be required to control the How partially. In the well stream power drive unit 37, the fow through the unit mast mest filly the maximum throwgh-put of the process systems, To achieve this, a by-pass path 78 is Provided with a valve 76 and choke 77 which will be ‘operated in elose conjuction with the other functions in the power drive, ‘The fluid poser drive unit 36 provides any additional power to the process module and the Aovr of fuid trough the drive unit ean be controlled by its choke 73 ‘In FIGS. 7 to 12 the gas liquid phase divider 80 is provided with a vortex mantel 89 and a voriex breaker 79. ‘The column separator 82 is provided witha vortex ring 83 ‘nd a number of vortex plates or shrouds 84 (funnels 122, 126, 131 in FIG. 11). The purpose of each ofthese items is to prevent coning occurring ora vortex from being formes This oceurs when a fluid has separated into two clear phases, either into different layers in a “standing” or plug flow environment or into eylindrical or conical boundries in @ ‘lating environment. In this ease, there is tendency when ‘one phase is drawn off for a low pressure are to be esate As this pressure differential inereases, the houndary layer between the two phases is drawn down oF up and a break ‘through is likely to occur and such an occurrence i unde- sirable In FIG. &, one example of a multistage separator can be seen and, in this embodiment, itis a the stage separator having a first stage comprising a gas/iguid phase divider 80 second stage comprising toroidal separator 81 and a third stage comprising a column separator 82, all of which can ‘maximise the Hlow rate and meet the burst and collapse pressure requirements All three stages have the ability to remove resid solids, As can be seen in FIG. 9, the gasligquid divider 80 is also arerievable mode fod by a passive vertical housing 8S having a Wet gos exit line 86, coaxial with the housing andUS 7,152,682 B2 13 ‘a the upper end thereof, and bottom central multiphase liguid line 87, surrounded by a lower outer annulus solids exit 38, ‘The multiphase input flow enters the housing 80 at 2 tangential entry por 92 from the solids removal module 38. ‘As with the solids removal module 38, the multiphase ‘entry port is below the top of the housing, but above the bottom of the top exit fine, thereby allowing a gas void or ‘cap 93 to form around the parallel wall section (vortex ‘mantel) 89. This configuration encourages liquid contifugal ‘ction on the wall and, therefor, further gas separation, One form of toroidal separator is shown in FIG. 10 and it is divided into three interlinking sress, an upper gas section 100, a central multiphase liquid section 101 and @ lower water section 102, ‘We gos from the top of the gas/liguid divider 80 enters the bottom portion ofthe gas forbidal 103 and travels upwards through the gas section 100 to a gas outlet pipe 104. The Tiguid within the wet pas i foreed onto the outer wall and collects. t certain points inthe outer wall, liquid taps 105, ‘and comesponding piping 106 are provided such dit any Tiquid flows down to the central section 101 ‘The multiphase liquid with entrapped gas from the bottom. ‘ofthe gasliguid device 80 enters through Mow Tine 113 into the central section 101. The large bore toroidal 107 allows partial separation of the multiphase How into standing Iayers. The remaining gas comes out of solution, forming & Void on the inside top area of the bore 107. vent line 108 from this region allows the gas to be forced up to combine with the wet gas in 103, ‘As the liguid spirals dow and through the central section 101, the oi forms in the top inside bore area and the water in the lower outside bore area. Exit lines 110 are provided from the top inside area ofthe bore to allow ol to escape to ‘common lise IM which feeds the thnd stage separator 82, "AL the lower end of the Toroidal separator, a solids removal pipe or pipes 113 are provided to remove any ‘additional solids which has entered the toroidal separator. “The lower end of the toroidal separtor should now ‘contain water which can be directly piped off along a water Pipe line 112 FIG, 11 shows the use of cohumn separator 82 as the third stage of the separation process. ‘The use of a column separator isto remove any residual ‘entrapped gas or water from the ol. A vertical housing 120 js provided into which the il line 121 from the second stage (lomidal) separator enters the housing. tangentially just below the gasol level, thereby eausing a centrifugal flow on the wall ofthe housing, “This encoumges any remaining gas to collet inthe centre ‘and this removed from the ol through a vertical yas axial funnel 122, which then redirects the gas centrifugally into the gas void 123 to the upper wall 124 of the housing such thatthe gas exits through gas ine 128 and joins the main gas ‘outlet line 104 feom the second stage separator Te combined gas flow now flows through a demister unit 183.0 remove any condensate. The condensate is drained off Jno the liquid section ofthe toroidal separator bore 107, “The liquid in the housing 120 rotates centrifugally in the ‘central section to allow water droplets tobe driven out ofthe cil towards the wall of the housing. The oil collects under 3 ‘downwardly facing funnel 126 which funnels any remaining trapped gas up ito the gs void below the gas axial funnel in. “The oil under the Funnel 126 is forced to move centifir- ally into the centre ofthe housing, thereby providing final 0 o 14 separation before exiting the separator through the cil line 128, the upper end 129 of whic is located just beneath the sunset 126. Water 130 collects heneath the oil zone and another downwardly facing funnel 131 is provided such that any small oil droplets which ae in the Water 130 are guided up into the oil zone. The water exits the lower end of the housing 120 through a central annular opening 132 whieh surrounds the oil line 128. A further annular opening sur rounds the water outlet 132 so that any aldtional solids ea be taken away: The ext from the water fine 132 feds into the waterline 112 from the second stage separator. Two Tevel sensors 140 and 180 are provided to aid contol othe subsea process modules 30 in order that acceptable levels of the individual phase of gas, oil and water can be achieved throughout the process module 30, The level sensors 140, 180 cifer a simple dual level sensing method, as the indi- vidual vertical measuring tubes 140, 180 have ther top end connected 1 the exiting gas line, elear ofthe separator. The tubes are fe from the respective ol and water exit ines 112, 128 such that sample Fiquids are captured via feed lines 141 and 151 ‘The oil tube feed line 141 tangentially enters the ube 140 ‘below the low/low design level and exits tthe bottom ofthe ‘ube 140 using a retum line 142 into the oil ext line 128, using a venturi discharge 143, This therefore ensures ‘uniform centrifugal fow down through the tube 140 10 prevent any droplets of water collecting ax these would affect the density of the oil column. For dual monitoring, iti proposed that a foat 144 on 2 tnuvel sensor 148 will register the gasoil level 180. This will aive a continuous read out of the particular level. To back {his up its proposed tht high/high 146, high 147, low 148 ‘and lowilow 149 fixed sensors arc provided. This will provide across reference check on the float reading. ‘A similar tube 150 is provided forthe water feed except that the feed pipe 181 enters the tube 150 tangentially atthe lower end and exits through a exit Hine 152, the upper end of ‘whieh is positioned above the entry point to ensue that any oil is removed by a vortex setion resting ina pure water column, This measures the gas/water level 182 from whieh the oilivater level I81 can be evaluated ‘The approach described covers multiphase inlet low Whiet is predominately guid with a high proportion of water. Fora system witha high gas content, itis preferable to move the gas liquid divider upstream of the wel stream hydraulic power drive module and instead have a separate flow-stream power drive module to handle the gas and nother forthe liguid. This ie to improve the effcieney to ‘obtain power from the well steam de tothe different and conllicting operating parameters between gas and liquids Such a system is shown ia FIG, 12 with the multiphase fvid {om the solids removal module 38 Rowing into @gaslignid vider 80, The gas trom the gasTiquid divider 80 flows into ‘gas hydraulic power deive module 200 and the oil Rows into a liquid hydraulic power drive module 201, The exits rom gas and Tiguid hydraulic power drive modules now ‘orm the inlets to the second stage separator as por 109 and 106 respectively. “The invention claimed is 1A subse process assembly for separating a multiphase flow, the assembly comprising: an inet for dhe multiphase flow; a pressure reducing means for ecg the pressure ofthe multiphase flow from the inlet and ereating a source of cenersy:US 7,152,682 B2 15 Itiphase separator for separating the multiphase flow into individual phases; ‘4 pumping system for in use, pumping at least one ofthe ‘desired individual phases to a delivery point, and ‘power supply’system that uses the source af enerzy fom. s the pressure reducing means to selectively supply power to the pumping system 2.'A subsea process assembly according 10 claim 1 ‘wherein the pressure reducing means is one of 2 hydraulic power device, electric power drive and a flow controller 3.Asubsea process assembly according to claim 1, further ‘comprising a control process module for controlling the pressure redueing means and the pumping system, 4.4 subsea process assembly according to claim 1 ‘wherein the power supply system comprises a power drive ‘unit that generates hydraulic power from an external energy 'S. A subsea process assembly according to claim 4 wherein the externa energy source is either inthe form of ‘uid or cletrcal ener. 6. A stibsen process assembly according to claim §, wherein the power drive unit is driven hy a fluid that provides energy in the form of liquid or gas 7. 4 subsea process assembly acconiing 10 claim 6, ‘wherein the source of energy is achieved by creating 3 pressure differential in the multiphase flow between the ilet and the multiphase separator. 8, A subsea process assembly according to elaim 1, further ‘comprising drive fii inlet, the drive fuid being pumped to the module from an extemal point 9. subsea process assembly according to claim wherein the pressure reducing means further comprises rans for creating a pressure differential in the drive fs ‘and thereby creating a further source of energy 10. A subsea process assembly according to claim wherein the drive Mid is water from s water injection supply. ILA subsea process assembly according to claim 1, ‘wherein the pressure of the multiphase flaw is reduced 10 below 25 atmospheres. 12. A subsea process assembly according to claim 1 ‘wherein the multistage separator can be formed by at least ‘one ofthe following: a centrifugal container, a vortex tube, 4 cyclone, helix container or auger, a gravity vertieal oF horizontal nk, a silo, a conductor pile housing, toroidal ring, a toroidal spiral combination or a spiral TBA subsea process assembly according to claim 1 ‘wherein the separating process can separate the multiphase Aid into at Teast tWo of the following: a solids shir, gas, oil and water. 14, A subsea process assembly according to claim 1 further compesing an individual pump for each phase 0 16 15, A subsea process assembly according 10 claim 14, ‘wherein the individual phase pumps are driven by the energy created in the assembly. 16, A subsea process assembly according to claim 1 further comprising of a solids removal unit for removing a solids slurry prior to separation, 17. A subsea process assembly according to claim 1 further comprising a means for, in use, injecting exhaust water into a wel 18, A subsea process assembly. according t lim 1, ‘further comprising a template, 2 piping mat and a retrievable subsea process module. 19, A subsea process assembly according to claim 18, ‘wherein the retrievable subsea process module comprises retrievable base module and retrievable mini modules. 20. A subsea hydrocarbon recovery system comprising: a subsea well for supplying a multiphase fow comprising 's hydrocarbon: a subsea process assembly comprising ‘an inlet for the multiphase flow: ‘a pressure reducing meuns for reducing the pressure of | the multiphase flow from the inlet and creating a source of energy: ‘8 muliphase separitor for separating the multiphase flow into individual phases, and ‘8 pumping system for, in use, pumping atleast one of | the desired individual phases 10 a delivery point, ‘wherein the inlet tothe assembly is in id comma nication withthe well; 1 power supply system that uses the source of enerpy om the presture reducing means to selectively supply power tothe pumping system: and a delivery point for reeeiving the recovered hydrocar- Tbon(s) from the subsea process assembly, 21. A subsea hydrocarbon recovery system according to claim 20, further comprising a well into whieh, surplus products of the separation ean be reinjested 22. A subsea hydrocarbon recovery system according to claim 20, further comprising a plurality of subsea wells ‘ach having an associated subsea process module which supplies the recovered hyerocarbon(s) tothe same delivery point 23. A subsea hydrocarbon recovery system acconding 10 claim 20, wherein the delivery point is one of pipeline for removing the product flour the field, «wate injection well, 4 gas injection well ar @ producing wel to achieve artificial ik