Otc 24297 Ms

OTC 24297
Ormen Lange Flow Assurance System (FAS) - Online Flow Assurance

Monitoring and Advice
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K. Holmås, G. G. Lunde, G. Setyadi, FMC Technologies; P. Angelo, G. Rudrum, Shell
Copyright 2013, Offshore Technology Conference
This paper was prepared for presentation at the Offshore Technology Conference Brasil held in Rio de Janeiro, Brazil, 29–31 October 2013.
This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of OTC copyright.
Abstract
A Flow Assurance System (FAS) is installed on Ormen Lange in order to give information about the multiphase flow through
the entire subsea production and pipeline system and onshore slug catchers to support the operation of the field. The FAS
includes the following modules:
• Virtual Flow Metering System (VFMS):
Model calculated values of flow rates as backup to physical multiphase meters.
• Pipeline Monitoring System (PMS):
Model calculated values of pipeline flowing conditions and onshore receiving facilities.
• Leakage and Blockage Detection (LDS):
Combining information from measurements and model calculated values of pressures and flow rates along with
statistical process control methods.
In 2011 the FAS was upgraded with the transient multiphase flow simulator FlowManager™ Dynamic, replacing the
previous simulator. In this paper, it is shown that the new simulator gives accurate model predictions, which is essential for
all the modules in the FAS.
The flow assurance challenges of the Ormen Lange field are significant. Due to sub-zero temperatures at the sea bed, there is
a risk of hydrate and ice formation. However, the FAS reduces the risk of hydrate and ice formation. The transient simulator
calculates pressure, temperature, water content and MEG concentration through the entire subsea system, giving the margin
to the hydrate formation curve for actual operation conditions.
Another flow assurance challenge is liquid surges. The long transport (120 km) of unprocessed fluids in a hilly seabed terrain
induces liquid surges in the pipelines due to liquid accumulation at low rates. In this paper it is shown that the new transient
simulator is able to accurately predict the liquid surges including arrival time and liquid level in the slug catchers. Thus, the
operators and flow assurance engineers have a tool to optimize the ramp-up speed avoiding flooding of the slug catchers.
The FAS gives full overview of current operation conditions and predicted changes in the subsea system and slug catchers
the next hours. All operations (e.g. shut-in, restart or ramp-up) can be simulated in advance. This ensures safe and optimized
operation of the complex Ormen Lange production systems.
2 OTC 24297
1 INTRODUCTION
The Ormen Lange field is located 120 km off the north-west coast of Norway, in the Møre Basin, and is developed as a
subsea tie-back to shore. The field was developed by Norsk Hydro and came in production in September 2007. In November
2007 the field operation was handed over to A/S Norske Shell. The licensees are A/S Norske Shell (17.04 %), DONG E&P
Norge AS (10.34 %), ExxonMobil Exploration & Production Norway AS (7.23 %), Petoro AS (36.48 %), Statoil ASA (10.84
%) and Statoil Petroleum AS (18.07 %).
The field was discovered in 1997 and approval for development was given in April 2004 by the Norwegian parliament. The

development of the Ormen Lange field in the Norwegian Sea is one of the largest and most demanding industrial projects
ever carried out in Norway. Ormen Lange is a gas and condensate field and it will be recovered initially by depletion and
later by gas compression. Subsea gas compression is being evaluated as an alternative. The field will be developed with up to
32 wells from up to four subsea templates, in sea depths between 800 and 1 100 meters. Figure 1 shows the field layout.
Template A and B started producing in September 2007, template D started producing in July 2011 while template C started
producing in December 2012. The well fluids are transported 120 km to the onshore processing plant at Nyhamna through
two 30” multiphase pipelines. After being processed, the gas is exported to England via the 1200 km long Langeled pipeline,
providing up to 20% of the total gas consumed in England at peak production.
The Ormen Lange field has some very critical flow assurance issues due to its 120 km long tie-back to shore, the bathymetry
of the flowlines as well as low seabed temperatures. Figure 2 shows the depth profile of the flowlines, indicating the very
steep and long underwater Storegga landslide. Due to sub-zero temperatures at the sea bed there is always a risk of hydrate
and ice formation. Formation water will increase the risk further. Hence, it is necessary to inhibit the fluid by injecting MEG
continuously. MEG is injected at each wellhead through 2 MEG pipelines from shore to subsea. The MEG is regenerated
onshore and reused. Being able to calculate the required amount of MEG to be injected is essential as well as accurately
metering the amount actually injected and the production flow rates.
The long transport of unprocessed fluids in a very demanding subsea terrain with a hilly seabed (up to 35 degree incline)
induces liquid surges in the pipelines due to liquid accumulation, especially at low rates. In the worst case the result can be
flooding of slug catchers. Because of the holdup reduction in the pipelines during production ramp-up, this limits the ramp-up
speed. Also, there are slow dynamics and long time delays in the pipelines due to the very long distances. Slug catcher
pressure is controlled by the gas rates from the wells and the export rate. Gas export according to nominated gas rate is of
high importance.
These flow assurance issues are the main motivation for the Ormen Lange Flow Assurance System (FAS). To help coping
with them, the following features in FAS are emphasized:
• Robust and reliable metering.
• Detailed real time production insight, especially conditions in the pipelines.
• Hydrate monitoring.
• Monitor MEG-injection.
• Slug catcher monitoring – pressure & liquid level.
• Production and well ramp-up management.
• Efficient planning and simulation tool.
The Ormen Lange FAS serves several purposes. It is an online monitoring and guidance tool for central control room (CCR)
operators, and an analysis tool and offline simulation tool for production planning and for testing and verification of different
production scenarios for operations support and flow assurance engineers.
The Ormen Lange FAS was originally delivered in 2007. The original FAS is described by Lunde et al. (1). In 2011 a new
version of the FAS was delivered by FMC Technologies. This paper describes the new version of the Ormen Lange FAS,
which is based on FlowManager™ technology only.
OTC 24297 3

Figure 1: Illustration of the Ormen Lange field layout shown with the FAS overview page.
Figure 2: Subsea profile of Ormen Lange pipelines to shore. Pipeline inlet to the left.
2 ORMEN LANGE FLOW ASSURANCE SYSTEM (FAS)
the entire subsea production and pipeline system and onshore slug catchers to support the operation of the field. The FAS
includes the following modules:
• Virtual Flow Metering System (VFMS):
The VFMS is used to calculate individual well production rates in parallel with the multiphase meters. The flow rate
of each fluid phase for every well is calculated.
• Pipeline Monitoring System (PMS):
The PMS calculates and presents information regarding the fluid transport in the Ormen Lange production system.
The PMS includes models for the well, templates, production pipelines and on-shore slug catchers.
• Leakage and Blockage Detection System (LDS):
The LDS combines information from measurements and model calculated values of pressures and flow rates along
with statistical process control methods.
4 OTC 24297
2.1 Virtual Flow Metering System (VFMS)
The VFMS includes models for each of the 17 wells (that are currently producing) from reservoir to wellhead with sub-
surface wellhead equipment. Since the dynamics in the wells typically are fast, it is chosen to model the wells using the
steady-state multiphase flow model (see Figure 5). The flow rate of each fluid phase for every well is calculated based on
sensor readings along the flow path. Pressure and temperature sensors in the well bore and at the wellhead, and pressure drop
across the choke are the most important sensors. Figure 3 shows the operating principles of the VFMS. The model makes an
initial guess of the well rates and calculates the equivalent sensor (e.g. pressure and temperature) responses. The discrepancy
between the measured and the calculated well responses are quantified through the object function and evaluated. The

procedure is repeated iteratively using multivariable optimization until the value of the object function reaches one of a set of
cut off criteria.
The VFMS incorporates all measurements throughout the well flow path; hence is does not depend on single sensors and it
serves as a robust backup for the multiphase meters. The VFMS also calculates pressure and temperature along the flow path
including downhole and reservoir pressures. By comparing measured and calculated values, the sensors are also kept under
surveillance.
The Ormen Lange field does not allow testing of individual wells towards onshore facilities. Therefore, it was decided to
calibrate the VFMS model towards gas rate measured by the multiphase meter. Each well was calibrated individually using
multivariable optimization. Data from a ramp-up period was selected for the tuning, and the tuned model was verified by
comparing the flow rates from several other ramp-up periods. Results from such a comparison are presented in Figure 4. The
calculated gas flow rate shows very good accuracy (better than ± 2 %). The excellent agreement with the measured flow rates
are a result of accurate field proven multiphase models (used on more than 35 fields and 600 wells since 1995) and the
multivariable optimization which adjusts the models instantaneously according to measurements. The VFMS calculated gas
rates are transferred to the SAS system in real time and are available for CCR operators as an alternative to the multiphase
meter. In periods where the multiphase meters fail or if the production rates exceed the multiphase meter
calibration/operational range, the VFMS is used as the official well rate measurement.
Initiate
Valve
@ P1,T1
Position
P,T
Guess phase rates
Simulate P,T
Search
Well or System
Performance for new rates
Calculate object function
Yes No
Accept?
P,T
Store
Q
oil
Qgas
Q water
Figure 3: Operating principles of the VFMS.

OTC 24297 5
Gas flow rate in a well

Time
Figure 4: Comparison of calculated (blue line) and measured (red line) gas flow rate for a well. The well is ramped up from zero to
full production.
2.2 Pipeline Management System (PMS)
2.2.1 PMS Model Scope

The PMS calculates and presents information regarding the fluid (gas, condensate, water and MEG) transport in the Ormen
Lange production system. The model scope is split into the following four sub-models, all modelled in FlowManager™:
1. Well models representing the wells from reservoir to wellhead with the possibility to route the well to any of the two
production pipelines.
2. Production pipeline model representing four infield pipelines and the two production pipelines to shore.
3. Onshore production model representing the slug catchers.
4. MEG distribution model consisting of injection pipelines and the subsea MEG injection equipment on the templates and
wellheads.
Wells model
The PMS uses the same well models as the VFMS (described in section 3.1). All the producing wells are included to allow
tuning of responses to reflect the individual well behaviour.
Production pipeline model

The production pipeline model includes the subsea crossover at the Pipeline End Termination (PLET), the two main
multiphase pipelines (A and B) from the subsea PLET to onshore upstream of the onshore pipeline crossover. In addition, the
four infield pipelines from template C and D are included. The pipelines are modelled using the dynamic multiphase flow
model (see Figure 5) (Holmås and Løvli (2))). The model is a 1-D drift flux model with algebraic slip and friction relations
for all flow regimes. All friction and slip relations, and the transitions between flow regimes, are continuous and smooth for
robustness, easy tuning and optimization. The equations are solved numerically using the Strongly Implicit Mixture Flux
(SIMF) method developed by Evje and Flåtten (3). SIMF is a fast and robust numerical method that ensures accurate
resolution of liquid slugs and surges.
Onshore model
The onshore system is modelled using the dynamic process models (see Figure 5) and includes the two slug catchers, each
consisting of two units. All components are solved using the multivariable optimization solver. The pressures in the slug
catchers and in the main separator are taken to be the measured sensor values. Thus, the flow rate of each fluid phase at the
outlet of the slug catchers is calculated based on the pressure drop across the outlet valves. All controllers in the model are set
up so that the controller parameters from the real plant can be applied directly into the model.
MEG distribution model

The MEG distribution model scope includes MEG injection pipelines network and subsea MEG injection equipment. The
MEG injection pipelines network is modelled using the steady-state model. The well MEG rates are calculated based on the
pressure drop across the MEG Dosing Valves (MDV) using multivariable optimization, as backup for the MEG flow meters.
As continuous and sufficient MEG injection is required to prevent hydrate and ice formation, accurate and reliable MEG
rates are essential.
6 OTC 24297

Figure 5: The wells are modelled using the steady-state model, while the flowlines and slug catchers are modelled using the
dynamic model. Pressure and temperature measurements are included in the calculations.
2.2.2 Applications of the PMS model

Important applications for the PMS are; 1) well ramp-up advice, 2) liquid holdup and surge wave monitoring and 3) MEG
and hydrate monitoring. Examples of output from the PMS related to the conditions in pipelines and slug catchers are:
• Liquid holdup in production pipelines
• Pressures and temperatures in production pipelines
• MEG concentration in production pipelines
• Hydrate inhibition margin
• Liquid level in slug catchers
Figure 6 shows a screen shot of the GUI page for a pipeline. This page gives the PMS main output for a pipeline. Similar
pages for all wells, templates, infield pipelines, onshore process and MEG distribution are showing the main output for the
rest of the models. Figure 7, 8 and 9 show examples of profile plots from the PMS, a pipeline profile plot of MEG
concentration and liquid (condensate and water) holdup (figure 7), profile plot of pressure and temperature (figure 8) and
profile plot of hydrate formation margin with respect to pressure and temperature in the pipeline (figure 9). All profile plots
show typical values in the pipeline at fairly steady state conditions.
Figure 6: Screen shot of the GUI page for an Ormen Lange pipeline.
OTC 24297 7

Figure 7: Profile plot of MEG concentration (green), liquid holdup (red), condensate holdup (cyan) and water holdup (blue). The
black line is the pipeline trajectory.
Figure 8: Profile plot of pressure (green) and temperature (blue). The red line is the pipeline trajectory.
Figure 9: Profile plot of hydrate formation margin with respect to temperature (green) and pressure (blue). The red line is the
pipeline trajectory.
8 OTC 24297
2.2.3 Execution modes
The PMS can be run in different execution modes, to meet the different needs.
The Real Time (RT) mode runs in parallel with the real process. It reads sensor values and control parameters from the
process control system, and automatically adapts the models to the real process. In this way the FAS users have a
continuously updated metering, monitoring and surveillance system.
Look-Ahead (LAH) mode continuously simulates the predicted process behaviour for the next 4-8 hours, Figure 10. It

always starts the prediction from current process conditions and runs two different simulations in parallel:
1. What will happen if the process is produced without changing any operator input (LAH)
2. What will happen if the wells continue to be ramped up as planned (RUP: Ramp-up Look-Ahead)
The intention is thus to look into the future and give the user an early warning if the current control parameters will lead to
hazardous operations (e.g. flooding of slug catchers or hydrate formation).
The What If (WI) mode is a simulator used for training, analyzing or planning purposes. The WI mode can start from
current process state, a historical state or from a predefined state. The aim of using the WI mode is to run scenarios and
analyze the consequences of changing system set points, prior to making changes. It can also be used to analyze flow
assurance situations that have occurred, or are suspected. Also, the WI mode can be used to improve the operational
procedures and improve the regularity; e.g. improve start-up and ramp-up procedures.
Figure 10: The results of the Look-Ahead simulations (both LAH and RUP) are shown together with the Real Time monitoring.
2.3 Leakage and Blockage Detection (LDS)
The LDS combines information from physical measurements and model predictions of pressures and flow rates along with
statistical control methods. A gas leakage results in an unexpected decrease in pressure drop in addition to a decrease in outlet
flow rate. However, the changes in the pressure drop and outlet flow rate may be slow and much smaller than the noise in the
measurements. To be able to detect trends in a noisy signal that could represent a leakage, statistical methods like Shewhart
control chart and cumulative sum (CUSUM) detection are continuously applied. The two methods have different advantages.
The control chart method rapidly detects larger leakages while smaller leakages are ‘hidden’ in the measurement noise.
CUSUM on the other hand detects smaller leakages by integrating the leakage information over time. Both detection methods
are combined to give an overall probability for leakage. The objective of the LDS is to detect, as soon as possible and as
accurately as possible, a leakage (or blockage) in the production pipelines or the MEG distribution pipelines (se Figure 11). It
is an early warning tool for the operators.
OTC 24297 9

Figure 11: Screen shot of the GUI page for Ormen Lange leakage detection.
3 PREDICTION OF LIQUID SURGE WAVES
The main flow assurance challenge of the Ormen Lange field is liquid surge waves. Liquid accumulation in the flowline is a
function of gas flow rate. The ramp-up rate is limited by the capacity of the receiving slug catchers. Too fast ramp-ups can
lead to unplanned shutdowns at the receiving facility. Thus, it is important to accurately predict the arrival time and volume
of liquid surge waves.
The upgraded PMS gives accurate predictions of the liquid surge waves in the pipelines and the liquid level in the slug
catchers. Figure 12 shows a series of liquid holdup profiles in pipeline A together with the corresponding calculated and
measured liquid level trends in the slug catcher. The first liquid holdup profile (00:00:00 28.08.2012) shows liquid
accumulation in the pipeline after shut-in of all wells. The wells at template A are ramped up and the accumulated liquid is
propagated through the pipeline. First the level in the slug catcher increases due to several small surge waves from the last
part of the pipeline. All liquid accumulated in the Storegga hill propagates through the pipeline as a large surge wave. After
about 18 hours the large surge wave arrives in the slug catcher, and the liquid level in the slug catcher increases significantly.
As seen in the figure, the predicted time of arrival of the large surge wave compares very well with the measured field data.
Figure 13 shows trends of pressure drop in the pipeline and liquid level in the slug catcher for two other shut-in and ramp-up
periods in 2011. The predicted pressure drop in the pipeline shows very good accuracy (better than ± 5 % for most of the
time). As seen in the liquid level trends, the periods have five surge waves each. All the surge waves are accurately predicted
and the predicted liquid level shows very good accuracy (better than ± 5 % for most of the time).
The upgraded PMS with FlowManager™ is able to accurately predict the liquid surges in the pipelines, liquid surge arrival in
the slug catchers and the liquid level in the slug catchers. Thus, the operators and flow assurance engineers have a tool to
optimize the ramp-up speed avoiding flooding of the slug catchers.
OTC 24297
28.08.2012 06:00
10
11
Figure 12: Liquid holdup profiles in pipeline A and liquid level trends in the slug catcher.
OTC 24297
12 OTC 24297

Figure 13: Comparison of calculated (blue line) and measured (red line) pressure drop in pipeline and liquid level in slug catcher.
4 CONCLUSION
the entire subsea production and pipeline system and onshore slug catchers to support the operation of the field.
In 2011 the Ormen Lange FAS was upgraded with the new transient multiphase flow simulator FlowManager™ Dynamic,
replacing the previous transient simulator. The new simulator has proven to give accurate predictions of pressure,
temperature and flow rates of gas, condensate and water/MEG in the wells, templates, flowlines and slug catchers.
The flow assurance challenges of the Ormen Lange field are significant. Due to sub-zero temperatures at the sea bed, there is
a risk of hydrate and ice formation. However, the FAS reduces the risk of hydrate and ice formation. The transient simulator
calculates pressure, temperature, water content and MEG concentration through the entire subsea system, giving the margin
to the hydrate formation curve for actual operation conditions.
Another flow assurance challenge is liquid surges. The long transport (120 km) of unprocessed fluids in a hilly seabed terrain
induces liquid surges in the pipelines due to liquid accumulation at low rates. In the worst case, the result can be flooding of
slug catchers. In this paper it has been shown that the upgraded simulator is able to accurately predict the liquid surges in the
pipelines, liquid surge arrival in the slug catcher and the liquid level in the slug catchers. Thus, the operators and flow
assurance engineers have a tool to optimize the ramp-up speed avoiding flooding of the slug catchers.
The FAS gives full overview of current operation conditions and predicted changes in the subsea system and slug catchers
the next hours. All operations (e.g. shut-in, restart or ramp-up) can be simulated in advance. This ensures safe and optimized
operation of the complex Ormen Lange production systems.
OTC 24297 13
5 BIBLIOGRAPHY
(1) G. G. Lunde, K. Vannes, O.T. McClimans, C. Burns, K. Wittmeyer; “Advanced Flow Assurance System for the Ormen Lange Subsea
Gas Development”, OTC, Houston, 2009.
(2) K. Holmås and A. Løvli; “FlowManagerTM Dynamic: A multiphase flow simulator for online surveillance, optimization and prediction
of subsea oil and gas production”, 15th International Conference of Multiphase Production Technology, Cannes, 2011.
(3) S. Evje, and T. Flåtten; “CFL-Violating Numerical Schemes for a Two-Fluid Model”, J. of Scientific Computing, 29 (1), 83-114, 2006.

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OTC 24297

Ormen Lange Flow Assurance System (FAS) - Online Flow Assurance

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Copyright 2013, Offshore Technology Conference

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2 ORMEN LANGE FLOW ASSURANCE SYSTEM (FAS)

2.1 Virtual Flow Metering System (VFMS)

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Calculate object function

Figure 3: Operating principles of the VFMS.

Gas flow rate in a well

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2.2 Pipeline Management System (PMS)

2.2.1 PMS Model Scope

Production pipeline model

MEG distribution model

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2.2.2 Applications of the PMS model

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2.2.3 Execution modes

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2.3 Leakage and Blockage Detection (LDS)

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3 PREDICTION OF LIQUID SURGE WAVES

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