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water treatment
C O N S U LTA N C Y T EC H N O LO G Y E N V I R O N M E N TA L
The challenges
> 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
Some Dispersed
Oil Removed Majority Free Oil Majority Dispersed Oil Some Dissolved Oil
Oil
Incoming Fluids
>10% 1,000 - 10,000ppm 100 - 500ppm 10 - 50ppm
(Oil Content)
Treated Fluids
1,000 - 10,000ppm 100 - 500ppm 10 - 50ppm < 5ppm
(Oil Content)
Natural Mean Oil Droplet
100 - 500 Microns 20 - 100 Microns 5 - 20 Microns <5 Microns
Size (exit)
Relative Separation
Easy Medium Difficult Very Difficult
Difficulty
Process Modelling
> Correct interpretation of the results from Correlation of Physical and Computational
modelling of sloshing
either technique is key to their success
Inlet Zone
Challenges:
> Flow bias due to upstream pipework leads
> Leads to shortcutting and reduced residence
time
CFD Image of a Biased Inlet Pipe
Flow
Solutions:
> Pipe diameter changed to achieve plug flow
> Offset inlet vanes
Inlet Zone
Challenges:
> Poor inlet device design leading to:
> Droplet shear/shatter
> Emulsion & Foam creation
> Gas entrainment Physical modelling of Physical modelling of
an optimised vane inlet
> Poor distribution a bare vane inlet
> Clogging
> Mechanical failure
> Unsuitable for slugging
Solutions:
> Bespoke inlet device design
> One size does not fit all
Physical modelling example of poor inlet zone leading to
shortcutting and reduced RT
Challenges:
> Poor baffle design, leading to:
> Poor distribution of fluids
> Can lead to shortcutting and reduced RT Examples of blocked Perforated Plates
> Increased velocity due to higher water rates
> Droplet shear Fluid flow jets through small
orifices and penetrates further
> Clogging/Scaling downstream than is necessary
Solutions:
> Bespoke baffle design considering:
> Fluids chemistry
> Solids/scale Recirculation behind
solid sections of plate
> Future rates
Shear layer between jetting
fluids increasing droplet shear
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
Example of a Correctly Example of a through-weir
> Weir design Designed Vortex Breaker nozzle cross-over
Case Study 2: Talisman Malaysia Ltd – Separator, Hydrocyclone and Degasser Debottlenecking
Review Phase
Methods Adopted:-
> Theoretical Process Review
> Physical Modelling
> Finite Element Analysis of Existing Supports
Findings:-
> The inlet device created significant turbulence
Physical modelling of Gorm Separator
> 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
Upgrade Modifications
Review Phase
Blowby CFD
Upgrade Modifications
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
Review Phase
The Achievements
> 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
Flotta Brooklea
Stromness Compton
Orkney Guildford
United Kingdom United Kingdom
KW16 3NP GU3 1HU
Glen McLellan
E-mail: glen.mclellan@opus-results.com
Web: www.opus-results.com
Telephone: +44 (0)1856 702000