1 - 5 Opus Maxim

Bulk Separation The first stage of produced
water treatment
Produced Water Best Management Practices
Conference, Kuala Lumpur
20-21 November 2013
OPUS Maxim Limited 2013
Objectives of this Presentation
The Traditional Approach:

Our industry divides Bulk Separation and Produced Water
Treatment as two separate processes dealt with by different
departments and vendors
> Bulk Separation

The objective is to remove as much water and gas from
the oil for product quality
> Produced Water Treatment
The objective is to remove as much oil and solids as
possible to meet discharge consents and remove any
residual gas
The objective of this presentation is to demonstrate why we do
not segregate the two processes and consider the bulk separation
stage as the first stage of produced water treatment.
About Opus
T EC H N O LO G Y
E N V I R O N M E N TA L
A UNIQUE BLEND OF
TECHNOLOGIES
MARINE & FRESH WATER
EXPERTISE & RESOURCES
DEVELOPED TO MEET THE
TOXICITY TESTING,
GROWING LEGISLATIVE
BIOACCUMULATION &
REQUIREMENTS OF THE
BIODEGRADATION
ENERGY SECTOR
ANALYSES
C O N S U LTA N C Y
C O N S U LTANC Y
The challenges
Some common factors that contribute to PW quality challenges:

>
>
>
>
Increasing water rates

>
Aging wells
>
New tie-backs
>
EOR
Ageing process equipment

>
Hydrocyclones
>
IGF
>
Erosion of internals, control valves etc
Operational methods / changes

>
Recycles,
>
Fluids incompatibilities (inc EOR)
>
Chemical treatment e.g. corrosion inhibitor
Tightening regulations/targets
C O N S U LTANC Y
Overview of the Separation Process
Oil Removed
Majority Free Oil
Some Dispersed
Oil
Majority Dispersed Oil
Some Dissolved Oil
Incoming Fluids
(Oil Content)
>10%
1,000 - 10,000ppm
100 - 500ppm
10 - 50ppm
Treated Fluids
(Oil Content)
1,000 - 10,000ppm
100 - 500ppm
10 - 50ppm
< 5ppm
Natural Mean Oil Droplet

Size (exit)
100 - 500 Microns
20 - 100 Microns
5 - 20 Microns
<5 Microns
Relative Separation
Difficulty
Easy
Medium
Difficult
Very Difficult
C O N S U LTANC Y
Process Modelling
>
The objective is to identify non ideal

fluids behaviour and adapt a theoretical
design to achieve optimal hydraulic
efficiency
>
Physical Modelling and Computational

Fluid Dynamics (CFD) are
complementary tools
>
Results of modelling validate upgrade

design and support for investment
decisions
>
Apply the strengths of both techniques

to develop optimal solutions
C O N S U LTANC Y
Physical Modelling of Separators
>
Physical modelling is a scaled modelling

technique that successfully illustrates the
fluids behaviour
>
Identifies excessive turbulence, gas carry

under and recirculation
>
Can replicate conditions such as slugging,

surging and sloshing
>
Provides a realistic, visual and dynamic

means of assessing fluids behaviour
within the vessel
C O N S U LTANC Y
Computational Fluid Dynamics (CFD)
>
Mathematically simulates multiphase

flows in a process vessel of system at
full scale
>
Simulates actual process conditions e.g.

mass flow rate, temperature, pressure,
and other physical properties
>
Helps to verify results from process

evaluation and feed directly into detail
design, reducing time and costs
>
Used to verify and fine tune a design

alongside the results from physical
modelling, on a scale up basis
C O N S U LTANC Y
Sloshing Analysis and Design

CFD and Physical Modelling
>
Physical modelling and CFD can be applied

independently, but the strength lies in
applying both simultaneously to verify results
from process evaluation
>
Results fed into detailed design - reducing

time, costs and improving process and
mechanical robustness of hardware
>
Correct interpretation of the results from

either technique is key to their success
>
Understanding the effects of geometry and

flow scaling on results obtained from physical
modelling is also important
>
Quality of CFD results are dependant on the

process understanding of the CFD Engineer
Correlation of Physical and Computational

modelling of sloshing
T EC H N O LO GY
Good Practice for Separator Design
Objectives of Multi-phase Separator Optimisation:

>
>
>
Inlet/Transition Zones:
>
Preserve stratified fluids
>
Achieve early gas release
>
Achieve effective dissipation of energy
>
Minimise droplet shear
Liquid/Gas Interface and Liquid Level:

>
Optimise the fluid residence times
>
Identify and correct any undesirable fluid

behaviour
>
Channelling & Recirculation
>
Gas carry-under
Gas Outlet:
>
Remove Liquid Droplets

T EC H N O LO GY
Inlet Zone
Challenges:
>
Flow bias due to upstream pipework leads
>
Leads to shortcutting and reduced residence

time
Solutions:
>
Pipe diameter changed to achieve plug flow
>
CFD Image of a Biased Inlet Pipe

Flow
Offset inlet vanes
T EC H N O LO GY
Inlet Zone
Challenges:
>
Poor inlet device design leading to:
>
>
>
>
>
>
>
Droplet shear/shatter
Emulsion & Foam creation
Gas entrainment
Poor distribution
Clogging
Mechanical failure
Unsuitable for slugging
Physical modelling of
a bare vane inlet
Physical modelling of
an optimised vane inlet
Solutions:
>
Bespoke inlet device design
>
One size does not fit all

Physical modelling example of poor inlet zone leading to
shortcutting and reduced RT
T EC H N O LO GY
Transitional & Quiescent Zone

Challenges:
>
Poor baffle design, leading to:
>
Poor distribution of fluids
>
Can lead to shortcutting and reduced RT
>
Increased velocity due to higher water rates
>
Droplet shear
>
Clogging/Scaling
Examples of blocked Perforated Plates
Fluid flow jets through small

orifices and penetrates further
downstream than is necessary
Solutions:
>
Bespoke baffle design considering:
>
Fluids chemistry
>
Solids/scale
>
Future rates
Recirculation behind
solid sections of plate
Shear layer between jetting
fluids increasing droplet shear
Pathlines coloured by velocity (m/s-1)
T EC H N O LO GY
Outlet Zone
Challenges:
>
Poor water outlet design including:
>
>
Poorly positioned leading to reduced RT
>
Formation of vortices leading to oil pad

drawdown
>
High velocities due to undersized nozzles
Weir design
>
Poorly placed leading to reduced RT
>
Inappropriate bucket or V-notch designs

leading to poor skimming efficiency
Solutions:
>
Bespoke designs for individual applications
>
Optimised skimming
>
Future rates considered
Example of a Correctly
Designed Vortex Breaker
Example of a through-weir
nozzle cross-over
Original outlet location
Optimised outlet location

RESOURCES
TECHNOLOGY CASE STUDIES
Case Study 1:
Mrsk Olie Og Gas A/S HP Separator on Gorm Platform
Case Study 2:
Talisman Malaysia Ltd Separator, Hydrocyclone and Degasser Debottlenecking
Case Study 3:
Hess Ltd HP Separator on Triton FPSO
Opus Maxim Limited 2013
RESOURCES

Mrsk Gorm HP Separator
Driver for the upgrade
>
>
Fluids study for end of pipe package

design information
High oil in water concentration, small
droplet emulsion
Original Design & Performance

>
>
>
Original internals arrangement
Vessel Internals Comprised of:> Basic deflector plates Inlet

> Perforated Plate Distribution Baffles
> Two Vane Packs
> Gas Outlet Droplet Separator
> Adjustable Weir
> Sand Jetting System
Oil in Water Performance ~1000 mg/l for
an inlet flowrate of 600 700 m3/hr
Small oil droplet emulsion
RESOURCES

Review Phase
The requirement was to identify the operational
limitations of throughput through the HP Separator.
Physical modelling of Gorm Separator
Methods Adopted:> Theoretical Process Review

> Physical Modelling
> Finite Element Analysis of Existing Supports
Findings:> The inlet device created significant turbulence
> Flow is seen to exit the inlet zone over the first
distribution baffle
> Low open area baffle design is very restrictive
> The water outlet nozzle was found to be
undersized
> Sand system, Droplet Separator & Weir height
acceptable
RESOURCES

Upgrade Modifications
>
Removal of Existing Inlet, Perforated Baffles

and Vane Packs
>
Internals Supplied for Upgrade:-
Upgraded internals arrangement
Client confirmed results
Outlet
Pre-upgrade
Outlet Post
Upgrade
~1000ppm
<100ppm
>
>
Inlet Vane Device with Diffuser Baffle
>
Horizontal Gate Baffle with Top Gas

Baffle (Inlet Zone)
>
Horizontal Gate Baffle (Distribution

Baffle)
>
Vertical Gate Baffle (Calming Baffle)
>
Vortex Breaker (New Water Outlet)
The water outlet nozzle was replaced for a

larger nozzle
RESOURCES

Talisman Malaysia Ltd Bunga Raya
Debottlenecking
Driver for the upgrade
>
>
New wells require water handling increase

from 35MBD to 70, then 100MBD
Overboard discharge target <25ppm

>
>
>
Process designed for 35 MBD

Consists of 2 stages of Bulk Separation,
Hydrocyclones and a Degasser
Overboard discharge: 40 80ppm
RESOURCES

Debottlenecking
Review Phase
>
>
>
>
>
>
>
>
Full fluids characterisation and detailed process

review
Multi vendor Hydrocyclone trial
Small vessels
Separator internals consisted of:
> Rear Facing Vane Type Inlet Device
> 2 x Perforated Plate Baffles
> Weir & water outlet ~4m from Tan
Separator performing reasonably well at current
flows but small droplet size exiting vessel
Large diameter hydrocyclone liners giving ~15
40% oil removal
Degasser internals consisted of:
> Deflector inlet device
> Non-porous baffles
> Flow under weir bucket
> Spill over water weir
No oil removal from Degasser
RESOURCES

Debottlenecking
Blowby CFD
>
>
>
>
>
>
>
Initially proposed internals

Liquid pool is pushed straight up into the gas
outlet
Substantial back pressure exceeding MAWP
Final proposed internals (as built)

Existing box is sealed and a new pipe
manifold fitted, which extends the gas outlet
A shroud is attached to the manifold nozzle
to deflect liquid away from the gas outlet
Dissipation baffle installed above the inlet
device to dissipate the momentum of the
blowby gas downstream
RESOURCES

Debottlenecking
>
>
>
>
>
Install Opus peripheral Diffuser Baffle around

the existing Vane type inlet
Replace perforated plate baffles plate/slotted
distribution baffles
New vortex breakers
Replace weir and relocate further downstream
Install internal piping to extend water outlet
>
Upgrade Hydrocyclones with high capacity high

efficiency liners
>
>
Remove all existing internals

Internals supplied for upgrade:> Opus inlet device
> Slotted baffles
> Notched spillover weir
> Crossover pipework for Oil & Water
outlets
RESOURCES

Talisman Malaysia Ltd Bunga Raya Debottlenecking
The Achievements
>
>
>
>
>
Offshore fluids characterisation and process optimisation identified specific areas for improvement
Detailed process review of the vessels identified where the best gains could be had
Opus supplied all vessel internals including 3rd party Hydrocyclones (single process guarantee)
Supervised installation with local contractors
Currently operating within discharge specification at design flow, with study underway to push
that to 100,000 BPD
>
Client confirmed performance:-
Original discharge
(35,000 BPD)
Current discharge
(70,000 BPD)
40-50ppm
<25ppm
RESOURCES

Hess Triton HP Separator
>
>
>
>
Split Flow Vessel Situated on FPSO

Vessel Internals Comprised of:> Inlet Diverter Assembly
> Perforated Plate Baffles
> Perforated Plate Over Weirs
Oil in Water Performance 300-1500ppm
Objective was to increase throughput by
~70% whilst maintaining performance
RESOURCES

Review Phase
>
>
>
>
Process review carried out

Physical Modelling undertaken with some CFD
Comparative analysis performed
Improved internals arrangement determined
Physical modelling of Triton Separator
>
>
CFD modelling of Triton Separator

Remove all existing internals

Internals supplied for upgrade:> Vane type inlet device with distribution baffle
> Slotted baffles
> Plate pack coalescer
RESOURCES

The Achievements
>
>
>
New internals fabricated and supplied on schedule

Opus supervised installation
Tie-in fluids added shortly after start-up
>
Client confirmed performance:-
Original Internals
Upgraded Internals
(with 70% additional flowrate)
300 - 1,500ppm
100 - 600ppm
Conclusions
>
Bulk separation and Produced Water Treatment processes are inextricably linked and
should be considered as a single process during design and optimisation projects
>
The quality of separation obtained in the first stage of bulk separation has a direct
impact on the performance of the downstream produced water treatment process
>
The root cause of a lot of Produced Water Treatment challenges is often the result of
poor 1st stage separator design
>
Oil in water levels entering the produced water treatment process can be improved
by orders of magnitude, leading to much less pressure on the rest of the process to
perform, leading to the following key benefits:
> Increased production through existing process vessels
> Optimised/Focussed CAPEX and OPEX
> More flexibility in the process with reduced impact from transient flows and
process upsets
> Better environmental performance
Opus Maxim Limited - 2013
Thank You
Opus
Flotta
Stromness
Brooklea
Compton
Orkney
United Kingdom
KW16 3NP
Guildford
United Kingdom
GU3 1HU
Glen McLellan
E-mail: glen.mclellan@opus-results.com
Web: www.opus-results.com
Telephone: +44 (0)1856 702000
Opus are a part of Aker Solutions

Opus Maxim Limited - 2013

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Bulk Separation The first stage of produced

OPUS Maxim Limited 2013

Objectives of this Presentation

The Traditional Approach:

> Bulk Separation

OPUS Maxim Limited 2013

MARINE & FRESH WATER

EXPERTISE & RESOURCES

DEVELOPED TO MEET THE

OPUS Maxim Limited 2013

Some common factors that contribute to PW quality challenges:

Increasing water rates

Ageing process equipment

Erosion of internals, control valves etc

Operational methods / changes

Fluids incompatibilities (inc EOR)

Chemical treatment e.g. corrosion inhibitor

OPUS Maxim Limited 2013

Overview of the Separation Process

Majority Free Oil

Majority Dispersed Oil

Some Dissolved Oil

Natural Mean Oil Droplet

100 - 500 Microns

The objective is to identify non ideal

Physical Modelling and Computational

Results of modelling validate upgrade

Apply the strengths of both techniques

OPUS Maxim Limited 2013

Physical Modelling of Separators

Physical modelling is a scaled modelling

Identifies excessive turbulence, gas carry

Can replicate conditions such as slugging,

Provides a realistic, visual and dynamic

OPUS Maxim Limited 2013

Computational Fluid Dynamics (CFD)

Mathematically simulates multiphase

Simulates actual process conditions e.g.

Helps to verify results from process

Used to verify and fine tune a design

OPUS Maxim Limited 2013

Sloshing Analysis and Design

Physical modelling and CFD can be applied

Results fed into detailed design - reducing

Correct interpretation of the results from

Understanding the effects of geometry and

Quality of CFD results are dependant on the

Correlation of Physical and Computational

OPUS Maxim Limited 2013

Good Practice for Separator Design

Objectives of Multi-phase Separator Optimisation:

Preserve stratified fluids

Achieve early gas release

Achieve effective dissipation of energy

Minimise droplet shear

Liquid/Gas Interface and Liquid Level:

Optimise the fluid residence times

Identify and correct any undesirable fluid

Channelling & Recirculation

Remove Liquid Droplets

Good Practice for Separator Design

Leads to shortcutting and reduced residence

CFD Image of a Biased Inlet Pipe