The Challenge of Aging Production Assets Offshore in the Oil and Gas Industry: Navigating Increased Water Cut in Mature Oil Wells

By: Rune G. Nilssen, Co-Founder, Stauper Water Technologies AS

As oil fields mature, the production landscape changes significantly, presenting numerous challenges for operators. One of the most critical issues faced by the offshore oil and gas industry is managing aging production assets in the context of increasing water cut. The water cut—the ratio of water produced compared to the volume of oil produced—tends to rise as oil wells mature, necessitating upgrades to existing infrastructure. This article explores the complexities of this challenge and examines innovative solutions, including Stauper Water Technologies' Compact Flotation Units (CFUs) and retrofit approach, to handle increased water cut efficiently.

?????????????????????????? ?????? ?????????? ?????? ????????????????????

Water cut is an inevitable aspect of oil production that becomes more pronounced as wells age. Initially, oil reservoirs produce a high percentage of oil with minimal water. However, over time, the natural pressure within the reservoir diminishes, leading to an increase in the amount of water that is extracted along with the oil. This phenomenon necessitates efficient water separation and handling processes, which many aging platforms were not originally designed to manage.

???????????????????? ???????? ?????????? ????????????????????????????

Capacity Constraints

Older offshore platforms were constructed based on the production profiles anticipated at the time, with specific capacity limits for separators, pumps, and produced water processing equipment. As production profiles change and water cut increases, these systems can become overwhelmed. The inability to handle increased volumes of water can lead to operational inefficiencies, higher costs, and reduced oil recovery rates. Upgrading these systems or adding new equipment is often necessary, but space and weight limitations on platforms pose significant challenges.

Separation Efficiency

The effectiveness of separation systems is crucial in managing increased water cut. Older systems may struggle to separate water from oil efficiently, leading to higher operational costs and lower recovery rates. Enhanced separation technologies or additional treatment facilities might be required to manage the increased water cut effectively. These upgrades need to be integrated into the existing infrastructure without compromising safety or operational efficiency.

Environmental and Regulatory Compliance

Aging assets are often subject to stricter environmental and safety regulations. Compliance with these regulations can be challenging and may require significant investments in upgrades and retrofits. Operators must ensure that their facilities meet contemporary standards, which often means installing more advanced and efficient equipment.

???????????????????? ?????????????????? ?????? ???????????????????? ????????????????????

To address the challenges associated with increased water cut and aging production assets, operators in the oil and gas industry are exploring various innovative solutions.

Compact Flotation Units (CFUs)

One of the primary concerns with aging offshore platforms is the limited space available for new equipment. Compact Flotation Units (CFUs) developed by Stauper Water Technologies offer a viable solution. These systems are designed to have a small footprint, making them ideal for installation on platforms with space constraints. The CFUs utilize a patented coalescence process to enhance water separation efficiency. The design includes features such as co-current flotation, separate inlet chambers, and calm separation zones that maximize oil droplet and gas bubble interaction while minimizing turbulence and solids carryover.

Retrofitting Existing Equipment

Stauper Water Technologies also provides a retrofit approach that improves the efficiency of existing separation equipment. By installing their patented CFU internals into existing oil-water separation vessels, operators can enhance performance without extensive modifications. The retrofit includes the addition of gas mixers and coalescence chambers, which improve oil droplet and gas bubble collision frequency and prevent contamination of clean water discharge. This method allows for significant improvements in separation efficiency and processing capacity while utilizing existing infrastructure.

Digitalization and Automation

The integration of digital technologies and automation can also play a crucial role in managing increased water cut. Advanced monitoring and control systems, such as the oil and water online real data analyzer by Inov8 https://inov8s.com, can optimize separation processes, improve operational efficiency, and reduce costs. Real-time data analytics and predictive maintenance can help operators identify potential issues before they become critical, allowing for proactive management of aging assets.

Enhancing Safety and Environmental Performance

To ensure compliance with stricter environmental and safety regulations, operators must invest in upgrades that enhance the overall safety and environmental performance of their facilities. This includes the installation of advanced monitoring systems, improved water management practices, and the implementation of best practices for environmental protection.

???????? ?????????????? ?????? ???????????????? ????????????????

Case Study: Upgrading a North Sea Platform

A notable example of successful upgrades can be seen in the North Sea, where a platform underwent significant retrofitting. By installing compact produced water treatment systems and upgrading existing separation vessel, the operator was able to enhance water handling capacity. In the North Sea, over 50% of offshore platforms have exceeded their design life, emphasizing the need for such innovative solutions

Stauper Water Technologies: Retrofit Success in Brazil

Stauper Water Technologies' retrofit approach has been successfully implemented in various projects, including the upgrade of a separation vessel in Brazil. By installing Stauper's patented gas mixers and coalescence chambers into the existing vessel, the operator was able to increase the water handling capacity by 200% and achieve an oil in water outlet below 15 PPM. This approach allowed the platform to handle higher water cuts without extensive modifications, demonstrating the viability and effectiveness of retrofitting existing equipment.

???????????????? ??????????: ?????????????????? ????????, ???????? ???? ????????????, ?????? ?????????? ??????

In Southeast Asia, approximately 35% of offshore platforms are beyond their original design life, leading to increased maintenance needs and operational challenges. Similarly, in the Gulf of Mexico, around 40% of platforms have exceeded their design life. In the North Sea, over 50% of platforms have surpassed their design life. These aging infrastructures are becoming a significant issue, necessitating the adoption of advanced technologies and innovative solutions to manage these challenges efficiently.

???????????????? ???????????? ???? ???????? ?????????? ??????

High water cut can significantly reduce the economic viability of oil production, as separating and handling produced water increases operational costs. Water handling costs can constitute up to 30-40% of total operational expenses in high water cut fields. This economic burden highlights the importance of efficient water separation and handling technologies to maintain profitability.

???????????? ???????????????? ?????? ?????????????????? ????????????????????

Experts emphasize the importance of developing a clear late-life operator strategy to manage aging assets effectively. This includes planning ahead with brutally honest perspectives on the asset’s future potential, segmenting portfolios to identify late-life assets, and committing to the chosen operating strategy. A segmented portfolio allows operators to make deliberate choices on which assets to keep, divest, or decommission based on clear decision criteria. Implementing these strategies ensures that operators can maximize the value from productive asset wind-down and manage late-life assets differently from those in their more productive stages.

Furthermore, the management of asset integrity is critical for maintaining the safety and efficiency of offshore installations. Continuous development of Asset Integrity Management (AIM) practices helps address the challenges posed by fluctuating market conditions and ensures the safety and integrity of offshore facilities. This includes adopting a holistic approach that integrates various aspects of AIM to mitigate risks and enhance operational performance.

????????????????????

The challenge of aging production assets and increasing water cut in the offshore oil and gas industry is a complex issue that requires innovative and strategic solutions. By adopting advanced technologies, retrofitting existing equipment, and integrating digital tools, operators can enhance their water separation and handling capabilities. Stauper Water Technologies' Compact Flotation Units (CFUs) and retrofit solutions exemplify how innovative approaches can address these challenges effectively. Ensuring compliance with environmental and safety regulations is also critical, necessitating significant investments in upgrades and retrofits. Through careful planning and the implementation of innovative solutions, the industry can continue to operate efficiently and sustainably in the face of evolving production challenges.