This paper describes the design and operational performance of the 15 kpsi Shah Deniz Stage 2 completion clean-up surface process equipment which has been designed to ensure solid/debris-free gas/condensate production at first gas in 2018. This project demonstrates a genuine step change in the design and operation of well testing and clean-up systems. It takes process safety to a new level whilst simultaneously reducing the overall equipment footprint, compared to traditional well test systems.

The design brief for this project included a requirement to safely process and correctly dispose of all fluids produced from completed SD II production wells. This included formation hydrocarbons at elevated flow rates, completion fluids and residual drilling fluids. The surface package also had to fit within the rig well test deck and individual skid weights kept within the rigs crane capacity. As a result, the decision was made to design, engineer and manufacture a customized set of equipment. Additionally, an upgraded data acquisition system was required to process the increased volume of data as well as provide the required level of system monitoring and control. An enhanced process shut down system was also needed in order to implement the shut down philosophy demanded by the projects process safety policies.

The SD II completion installation schedule, in which twelve wells were completed back to back, called for a semi permanent installation of the surface process package. This provided the opportunity to implement many of the design upgrades described in this paper. As a result of these upgrades operations have been carried out in a safer, more controlled and efficient manner, whilst simultaneously maintaining full compliance with all industry and company specific regulations. The two central elements to this operational efficiency was due to the surface equipment operating well within its design envelope, even at high flow rates, and the data acquisition system enabling the entire process system to be fully monitored and controlled. This enhanced process control enabled emerging risks to be rapidly detected and mitigated prior to any detrimental escalation.

This paper discusses the various challenges posed by the project and the ways in which these were mitigated and overcome. Many of these design solutions can be applied to future high flow rate surface systems.

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