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.

© OPUS Maxim Limited 2013

About Opus

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

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

© OPUS Maxim Limited 2013

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

© OPUS Maxim Limited 2013

C O N S U LTANC Y

Overview of the Separation Process

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

© OPUS Maxim Limited 2013

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

© OPUS Maxim Limited 2013

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

© OPUS Maxim Limited 2013

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

© OPUS Maxim Limited 2013

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 Correlation of Physical and Computational
modelling of sloshing
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

© OPUS Maxim Limited 2013

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

© OPUS Maxim Limited 2013

T EC H N O LO GY

Good Practice for Separator Design

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

© OPUS Maxim Limited 2013

T EC H N O LO GY

Good Practice for Separator Design

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

© OPUS Maxim Limited 2013

T EC H N O LO GY

Good Practice for Separator Design

Transitional & Quiescent Zone

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

Pathlines coloured by velocity (m/s-1)

© OPUS Maxim Limited 2013
T EC H N O LO GY

Good Practice for Separator Design

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

> Poorly placed leading to reduced RT

> Inappropriate bucket or V-notch designs
leading to poor skimming efficiency
Solutions:
> Bespoke designs for individual applications Original outlet location

> Optimised skimming

> Future rates considered

Optimised outlet location

© OPUS Maxim Limited 2013
RESOURCES

TECHNOLOGY – CASE STUDIES

Case Study 1: Mærsk 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

TECHNOLOGY – CASE STUDIES

Mærsk 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

> 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

Original internals arrangement

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Mærsk Gorm HP Separator

Review Phase

The requirement was to identify the operational

limitations of throughput through the HP Separator.

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

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Mærsk Gorm HP Separator

Upgrade Modifications

> Removal of Existing Inlet, Perforated Baffles

and Vane Packs
> Internals Supplied for Upgrade:-
Original internals arrangement
> 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)
Upgraded internals arrangement
> Vortex Breaker (New Water Outlet)
Client confirmed results > The water outlet nozzle was replaced for a
Outlet Outlet Post larger nozzle
Pre-upgrade Upgrade
~1000ppm <100ppm

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

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

Original Design & Performance

> Process designed for 35 MBD

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

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Talisman Malaysia Ltd – Bunga Raya

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

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Talisman Malaysia Ltd – Bunga Raya

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

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Talisman Malaysia Ltd – Bunga Raya

Debottlenecking

Upgrade Modifications

> 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

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

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 Current discharge

(35,000 BPD) (70,000 BPD)
40-50ppm <25ppm

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Hess Triton HP Separator

Original Design & Performance

> 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

Original internals arrangement

© Opus Maxim Limited 2013

RESOURCES

TECHNOLOGY – CASE STUDIES

Hess Triton HP Separator

Review Phase

> Process review carried out

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

> Remove all existing internals

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

CFD modelling of Triton Separator

© Opus Maxim Limited 2013
RESOURCES

TECHNOLOGY – CASE STUDIES

Hess Triton HP Separator

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

© Opus Maxim Limited 2013

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 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

Opus are a part of Aker Solutions

© Opus Maxim Limited - 2013