11 The Well Head Desander

The Wellhead Desander:
Separating Solids First
Hank Rawlins, PhD, P.E.

eProcess Technologies
September 24, 2014 - Stavanger, Norway
AUS | MAL | USA | UAE | UK
SPE and STTS

SPE Separations Technology Technical Section
Purpose
Share knowledge, experiences, and best practices

Identify major issues and technology areas
Promote awareness of separation-related issues and technologies
Enhance members technical competencies
Webinars
Three completed in 2014 and three in 2015
SPE ATCE Amsterdam
Unlocking Hidden Production Potential in Mature Fields,

special session, October 27, 2-5 PM
eProcess Technologies | Advancing Separation Solutions
AUS | MAL | USA | USA | UK
www.eprocess-tech.com
Company
eProcess Technologies
Innovative Process Separation Equipment Specialists

Facilities Sand Management
Produced Water Treating
Compact Separation Systems
Cyclonic Based Technologies

Falmouth
Houston
Dubai
Kuala Lumpur
Melbourne

Approach
Not simply a waste stream treatment exercise
It is a critical flow assurance issue
Increase / maximizing hydrocarbons production
While reducing / minimizing operating costs
Sand Management Options

All oil & gas wells produce sand
Exclusion Methodology
1. Production Limits
2. Downhole Equipment
Inclusion Methodology
3. Surface Facilities: Maintenance

4. Surface Facilities: Facilities Sand Management

1
Wellhead
Desanding
2
Wellstream
Desanding
Cyclonic
Solids Jetting
4
Produced
Water
Desanding
Solids Transport
& Handling
Multiphase Flow Desanding

Cyclonic
Solids Jetting
Solids Cleaning
& Disposal
2
Design Comparison
Insert Style (Single Cone)
Liner Style (Multi-Cone)
Multiphase applications
One insert per vessel
Smaller/lighter vessel
Change insert diameter
for high turndown (>3:1)
No fluid partitioning
Particles to 1-2
Concentration to 5 wt.%
Liquid applications
Many liners per vessel
Larger vessel
Change quantity of liners
for high turndown (>3:1)
Unequal fluid partitioning
Particles to 0.1-0.2
Concentration to 0.25 wt.%
Classification Performance
Graded Efficiency Curve
100
Y(x), Particle Recover (% to U/F)
90
80
Normalized Size vs. Recovery to U/F

Fits Yoshioka-Hotta curve (1955)
D98=Separation Size
70
1
() =
100
+ 2
60
50
40
= slope = separation sharpness
D50=Cut Size
30
=4 for silica particles

Plitt approximation;
2
= 2.96
= 1.54 0.47
0.15
1.58
20
10
0
0.0
0.5
1.0
1.5
2.0
2.5
Where Rf is flow split, L is internal length,

l is vortex finder length, Q is flow rate
D/D50c
WHD Development History

Jan.1994
Concept initiated as internal development project
Mar-Apr 1994
Laboratory testing using air-water-sand with 10 mining cyclone
Late 1994
JIP initiated for pilot-plant testing and mechanical design
Mid-1995
Late-1995
Detailed mechanical design for industrial unit

5K ASME design with single insert
1996
First commercial unit

Unit still in service
JIP pilot-plant test at (BP) Wytch Farm onshore gathering stations

ANSI 300# unit, 10 diameter desander
Sand injected into clean stream
Also tested with five sand monitoring devices
First Commercial
Wellhead Desander
Deployed in 1996
Shell/Expro Brent D
ASME 5K WHD Skid
Coiled-tubing well cleanout
Process Flow
Gas: 6.4-19.2 MMSCFD
Liquid: 16,000 BPD
Performance
<75 psid pressure drop
D98 = 20 micron
Sand w/ coal chunks

General Design and Operation

Pressure Retaining Vessel
ASME: 150# to 2500#
API-6A: 5/10/15 K rating
API at full shut-in pressure, no PSV
Small hold-up volume
Clean Well
Fluids
Wellhead
Solidsladen
Well Fluids
Wellhead
Desander
Cyclonic Insert
Performs separation duty
Contains erosion
Duplex SS/WC or SiC
4-10 replaceable inserts
Interchangeable size and materials
Installation/Operation
Upstream/downstream of choke
Service tool or production
5-75 psi P
Operate 0-100% GVF
10-25 micron separation
On-line batch sand discharge
Solids
Accumulator
Solids Discharge
Particle Travel
Inlet Transition
2nd Accumulator
Tangential transition
from pipe flow
Vortex finder prevents
particles short-circuit
Particles descend
by gravity
Sand displaces
water in vessel
No oil ingress
Cone-Cylinder-Apex
Heavy particles spin down inner wall

Light particles swept to overflow
Apex is concentration point
Multiphase Model
Flow regime determines model
Hydraulic model for liquid dominant

Pneumatic model for gas dominant
Model convergence/overlap
Use mixing rules for fluid properties

Calculate multiphase pressure drop
Ensure critical velocity regions stay within limits
Calculate separation size and collection efficiency
Rule-of-thumb: Wellhead desander will remove solids that settle
within a production separator
Particles collecting at oil-water interface or passing into oil phase

not captured
Hydraulic Capacity,
Turndown & Performance
Separation Size (D98)
Maximum P to balance
wear life.
(No shear maximum)
Avg. residence time is
1.3-4.2 seconds
Minimum P to maintain
vortex.
Pneumatic Capacity,
Turndown & Performance
Maximum P to balance
wear life.
Separation Size (D98)
Avg. residence time is

0.3-2.1 seconds
Minimum P to maintain
vortex.
Multiphase P & Capacity

Pressure Drop
Dependent on liquid and actual gas

volume flow
Power(liquid)-Polynomial(GVF) fit for P
relationship
For fixed P, increasing GVF decreases
liquid flow
10 Wellhead Desander
Constant Liquid (Water) Flow w/ Increasing GVF
Minimum P: 3-5 psid
Increasing GVF decreases minimum P

Velocity minimum to achieve proper
vortex flow
Maximum P: 25-75 psid
Increasing GVF decreases maximum P

Velocity maximum to minimize insert
wear
Operating Boundaries
Process: Fluids & Pressure
Pressure Drop
Minimum 3-5 psi based on GVF

Maximum set at 25-75 psi for wear life
Will impose back pressure on artificial lift wells
Flow Conditions
Operation from 0-100% GVF
Turndown:
Per insert 3:1 liquid only, 5:1 multiphase
Per vessel 20:1 by changing inserts
Slugging
Must stay within pressure drop range
Fluid Viscosity
Difficult to process heavy oil with high liquid

viscosity (>1000 cP), low watercut and low GVF
Operating Boundaries
Process: Solids Particles
Particle Size
Maximum 1/3 smallest opening on insert (inlet or apex)

WHD10: 21 mm
Particle Concentration
Static operation based on apex flux limits

Example: 150 micron sand in water
WH10: 10000 ppmw (1.0%)
Implementation of Apex Flux Balancing increases

limit by order of magnitude
Accumulator volume and rate of solation/discharge

will be limiting factory at high solids concentration
Application & Operations

Installation Location
Pre choke (API)

Post choke (ASME)
Subsea in development
Applications
Well testing, well cleanout, underbalanced drilling,

produced solids, proppant flow back
Utilities
Flush/fill accumulator (clean water any source at 50 psi)
Consumables
Insert replacement and o-rings
Process Connections
Five standard: inlet, clean fluid outlet, solids discharge,

accumulator-vent and accumulator-flush/fill
Mechanical Requirements
Footprint
Generally 1 m bare equipment and 1.5-2.0 m for skid with
basic valves/piping/instruments
Height
3-5 meters pending accumulator size
Orientation
Vertical standard, but WHD vessel can be operated horizontal
Weight
2,000-4,000 kg bare equipment, 10,000-25,000 kg full skid
Pressure Rating
ANSI: 150#-2500#
API: 5K, 10K, 15K
Materials of
Construction
Vessel: 4130 CS standard, Available: F22, UNS31803, UNS32760

Insert: Standard is UNS 31803 w/ HVOF-WC internal, alternate is thick RB-SiC
Operation
Instrumentation: Inlet-Overflow DPI, Inlet PI
Valves: Accumulator isolation, discharge, vent, and fill

Normally operated manual (valves) but can be automated
Wellhead Desander Vessel

Duty: 10,000 psi MAWP / 100 MMSCFD + 7,500 BLPD
Insert / API Calcs
Insert / API FEA
(Gen. 1)
(Gen. 2)
1918 mm
2189 mm
2599 mm
Multicone / ASME
Dry (kg)
11000
4173
1571
Oper. (kg)
11800
4525
1771
Vessel Custom Design

10,000 psi MAWP
100 MMSCFD + 7,500 BLPD
Insert: 10
Liners: 3
(Gen. 1)
Insert / API FEA
1918 mm
(Gen. 2)
5,000 psi MAWP

50 MMSCFD + 3,500 BLPD
Insert: 6
Insert / API Calcs

(Gen. 1)
Insert / API FEA

(Gen. 2)
662 mm
Insert / API Calcs
2189 mm
2599 mm
Multicone / ASME
Duty:
1293 mm
Duty:
Dry (kg)
11000
4173
1571
1251
315
Oper. (kg)
11800
4525
1771
1371
411
Malaysia Petronas Carigali

Operator
Petronas Carigali
Location
PMO Kerteh, Terengganu

Duyong Offshore Gas Complex
Fixed Platform 80 m water
Technology
API 5K Wellhead Desander Units

90 liter accumulator
Manual operation
Installation
2012
Operation
6 MMSCFD, trace liquids

WHFP 450 psig at 40C
P = 50 psi, 99% removal
Malaysia Murphy Oil

Operator
Murphy Sarawak Oil Co. Ltd.
Location
Kikeh Spar DTU 1300 m water
Technology
10-1500# Wellhead Desanders

Integrated into wellbay
Solids transport, dewatering,
bagging and cleaning system
Interim fix for failed completions
Operation
3300-6700 BPD
1.5-12 MMSCFD,
WHFP 1200 psig at 40C
P = 30-50 psi, D98=16-25 micron
>1000 BOPD increase per well
1-2 tons/day sand treated
Custom Installation
Murphy Kikeh Spur
1500# 10 Wellhead Desander Inlet off flexible jumper before choke
Malaysia Murphy Oil
Malaysia Murphy Oil
Saudi Arabia Halliburton

Operator
Halliburton Testing and Subsea
Location
Saudi Arabia
Onshore multiple locations
Technology
API 15K Wellhead Desander Skids

180 liter accumulator
PSL 3, P+X, DD-NL, 4130-75K
2.4 m W x 2.4 m L x 6.8 m H
Operation
15,000 BLPD, 200 MMSCFD

D98 = 20 microns
Solids Handling Summary

WELLHEAD
DESANDER
1. SEPARATE
SC OR MC
DESANDER
2. COLLECT
SAND JET
ACCUMULATE
CONCENTRATE
YES
CLEAN
DISPOSAL
METHOD
Overboard
To Caisson
Liquids to
Drain/Process
SAND WASH
Solids
NO
Injection to
Disposal Well
Collection
4. DEWATER
FILTER BIN
YES
DEWATER
Solids
YES
HAZARDOUS
CONTAINED
TRANSPORT
NO
DEWATER
NO
NO
CLOSED
COLLECTION
5. TRANSPORT
TANK
BOTTOMS
Dump / Purge
3. CLEAN
Liquids to
Closed Drain
or Process
VESSEL
SLOPS
YES
Liquids to
Drain
FILTER BAG
Solids
OPEN
COLLECTION
Land (Truck)
Offshore (Ship)
Pipeline
OPEN
TRANSPORT
Land (Truck)
Offshore (Ship)
Subsea Wellhead Desander

Process:
Gas-condensate well
120 MMSCFD, 2000 BPD
25 psid, 12 micron D98
Vessels:
FEA with DNV Certification

API 6A/17D
5K, PSL 3, P+X, F22
System:
Four tie-in points (TP)

8 inlet/outlet, 2 flush, 4 sand
Bypass piping
Automated operation
Sand discharge or container
WHD Key Items
All oil & gas wells produce sand
Facilities sand management is part of flow assurance
Separation of sand at the wellhead can restore

or increase hydrocarbon production
Sand removed at wellhead is easy to transport and handle
Wellhead desander operates at 0-100% GVF
Single insert design most appropriate for multiphase flow
Mechanical design available to API 15K
Tech Paper References

1. Rawlins, C.H., The Subsea Sand Management Challenge: What to do with the sand?, 6th European Sand Management Forum,
Aberdeen, UK, March 26-27, 2014.
2. Loong, Y., Rawlins, C.H., and Goo, D., Upgrade of Spar Topsides with Comprehensive Facilities Sand Management System,
paper 24705-MS, Offshore Technology Conference Asia, Kuala Lumpur, Malaysia, March 25-28, 2014.
3. Rawlins, C.H., Study on the Interaction of a Flooded Core Hydrocyclone (Desander) and Accumulation Chamber for Separation of Solids
from Produced Water, presented at the 2014 Produced Water Society annual seminar, January 14-16, Houston, TX.
4. Rawlins, C.H., Sand Management Methodologies for Sustained Facilities Operations, Oil & Gas Facilities,
Vol. 2, No. 5, October 2013, pp. 27-34.
5. Rawlins, C.H., Design of a Cyclonic Solids Jetting Device and Slurry Transport System for Production Systems, paper 166118-MS,
SPE Annual Technical Conference and Exhibition, New Orleans, LA, Sep 30-Oct 2, 2013.
6. Rawlins, C.H., Sand Management Methodologies for Sustained Facilities Operations, paper 164645-MS,
North Africa Technical Conference & Exhibition, Cairo, Egypt, Apr. 15-17, 2013.
7. Rawlins, C.H., and Hewett, T.J., A Comparison of Methodologies for Handling Produced Sand and Solids to Achieve
Sustainable Hydrocarbon Production, SPE European Formation Damage Conference, paper 107690, May 2007.
8. Rawlins, C.H. Application of Multiphase Desander Technology to Oil and Gas Production, BHR Group 3rd North American
Conference on Multiphase Technology, Banff, Alberta, Canada, Jun. 2002.
9. Rawlins, C.H., and Wang, I. I., Design and Installation of a Sand Separation and Handling System for a Gulf of Mexico Oil Production
Facility, SPE Production and Facilities, paper 72999, Vol. 16, No. 3, 2001, pp. 134-140.
10. Rawlins, C.H., Hazlip, S.E., and Wang, I.I., Design and Installation of a Sand Separation and Handling System for a Gulf of Mexico Oil
Production Facility, SPE Annual Technical Conference, paper 63041, Dallas, TX, Oct. 2000.
Contact
Presented by Hank Rawlins, PhD, P.E

Technical Director | USA
Telephone +1 713 586 8850
Mobile +1 406 565 2095
hrawlins@eprocess-tech.com

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The Wellhead Desander:

Separating Solids First

Hank Rawlins, PhD, P.E.

SPE and STTS

Share knowledge, experiences, and best practices

Three completed in 2014 and three in 2015

SPE ATCE Amsterdam

Unlocking Hidden Production Potential in Mature Fields,

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Innovative Process Separation Equipment Specialists

Cyclonic Based Technologies

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Facilities Sand Management

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Sand Management Options

3. Surface Facilities: Maintenance

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Facilities Sand Management

Multiphase Flow Desanding

Liner Style (Multi-Cone)

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Y(x), Particle Recover (% to U/F)

Normalized Size vs. Recovery to U/F

= slope = separation sharpness

=4 for silica particles

Where Rf is flow split, L is internal length,

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

WHD Development History

Concept initiated as internal development project

Laboratory testing using air-water-sand with 10 mining cyclone

JIP initiated for pilot-plant testing and mechanical design

Detailed mechanical design for industrial unit

First commercial unit

JIP pilot-plant test at (BP) Wytch Farm onshore gathering stations

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Sand w/ coal chunks

AUS | MAL | USA | USA | UK

General Design and Operation

AUS | MAL | USA | USA | UK

Heavy particles spin down inner wall

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Hydraulic model for liquid dominant

Use mixing rules for fluid properties

Particles collecting at oil-water interface or passing into oil phase

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Separation Size (D98)

Avg. residence time is

eProcess Technologies | Advancing Separation Solutions

AUS | MAL | USA | USA | UK

Multiphase P & Capacity

Dependent on liquid and actual gas

Constant Liquid (Water) Flow w/ Increasing GVF