Separation Systems

Efficiency Improvement and Trouble-shooting

Separation problems can be

resolved by carefully analyzing

system performance and by

proposing improvements,

using our technology and

knowledge. In this way FMC

Technologies can eliminate

separation problems, provide

high quality products, reduce

environmental impact and

increase production.

Efficiency Improvement and Trouble-shooting

BenefitsImportant drivers to improve the efficiency of existing plant and for trouble-shooting include:

Improving the gas quality Improving the oil quality Maximizing gas production Maximizing oil production Optimizing the produced water quality Minimizing the environmental impact Reducing the impact of solids Minimizing foaming problems Minimizing operational issues Reducing maintenance costs

Separation Systems The separation company major oil companies go to

with their most challenging projects Maximum return on investment through extensive

experience and know-how The only separation company with a proven track

record with inline separation equipment. The leading company in subsea separation Develops out-of-the-box solutions for the separation

challenges of tomorrow

Crucial factors for the separation efficiency

Fluid properties (densities, surface tensions, viscosities, etc.)

Operating properties (pressure, temperature, etc.) Added chemicals (demulsifier, corrosion inhibitor, etc.) Side-effects of added chemicals (e.g. a corrosion

inhibitor prevents corrosion of the equipment but it can cause emulsions)

Plant and piping lay-out Separator design

Minimize problems, maximize production

Main reasons for efficiency improvement and trouble-shootingMinimize investmentsWith our technologies installations can be optimized and upgraded while the main existing infrastructure remains unchanged. Large vessels and pipes need not be changed; only the equipment that does the actual work inside the expensive pressure vessels is affected.

Maximize productionThe throughput of existing facilities will be increased. Thanks to the greater reliability of the system, production uptime will be increased.

Sustainable productionDue to the more efficient separation processes, the burden on the environment will be minimized. The oil content of produced water will be minimal, less gas needs to be flared and CO2 emissions will be reduced.

Size and weight reductionFor new-build applications the size and the weight of the separator can be reduced. This also has an effect on the total layout of the structure. If the weight of the topsides is less, the main structure can be reduced as well. This leads to reduced Capex, while the greater reliability reduces Opex.

Enhance production qualityA more efficient separation process improves the quality of the oil and gas. This results in higher revenue, more production and fewer problems.

Less maintenanceMore reliable equipment can reduce the maintenance interval, which results in more operational hours and thus more production. This also means that the cost of maintenance is reduced.

Easy to installOur solutions are easy to install. They are compact enough to pass through manholes and require no welding during installation (no re-certification of the existing vessels required). This also means that shutdown periods will be shorter and, once again, more time is available for production.

State-of-the-art inline solutions

With our inline equipment the efficiency of facilities can be improved even if there is no space for additional separators or when vessel entry is not possible or not permitted.

Computational Fluid Dynamics, knowledge and R&D

Our computational fluid dynamic modelling provides an accurate representation of the expected flow profiles which results in a precise prediction of system performance.

R&D is an integral part of our approach, which involves exploring new separation techniques. To ensure that our designs are as robust and efficient in practice as they are on paper, we conduct rigorous tests under operating conditions, in-house as well as on-site.

Tools for efficiency improvement and trouble-shootingState-of-the-art internals

Retrofit internals: our state-of-the-art internals provide maximum separation efficiency. Our internals are custom-made for each application, fabricated according to the highest quality standards, updated to the latest state of technology and they can always be installed without hot work at the pressure vessel.

For new-build applications these technologies can be com-bined in highly efficient, very compact separation systems. These systems can be installed topsides and subsea.

Subsea separation

We were the first company worldwide to install a subsea separation unit. This opens up unlimited opportunities for increasing oil recovery from brown fields. Today all such projects worldwide that include subsea separation use FMC technology.

Our approachWe first identify the needs and options for production improvement and undertake trouble-shooting and the required analyses and CFD studies. The resulting report contains recommendations and a proposal for the technology needed, including costs and expected installation time.

If the proposed solution is based on new technology, we can test it at the customers request, using our in-house test system. We usually run a full-scale test at high pressures and with actual process fluids.

The benefits of our efficiency improvement and trouble-shooting are considerable, as the cases on the right show.

System Layout

Debottlenecking (STATOIL Veslefrikk)

60 % gas capacity increase

Inline liquid separation (BP Etap)

45 $MM/yr production restored

Separator upgrade (SHELL Mars)

1.2 $MM/year chemical savings

System optimization (STATOIL Asgard)

1000 ton weight reduction

Vibration reduction (STATOIL Statfjord)

5 % production increasereduced CO2 discharge

1. Subsea processing

Locating separation equipment on the seabed can reduce operational problems such as slugging (caused by long pipes) and the formation of emulsions. The lifetime of a field can be improved because it can be operated at lower pressures. Subsea processing makes it possible to use the existing infrastructure for a new satellite. Remote fields in inacces-sible areas can suddenly become viable. Since less topsides

facilities are needed, the environment will benefit. And, finally, major savings can be made by re-injecting produced water at the seabed.

Statoil Tordis: three-phase separation and boosting in 220 m water depth, 12 km step-out. We were the first company worldwide to install subsea processing units for subsea separation. Right now all operating units in the world with subsea separation have been designed and delivered by us.

2

1 Subsea 2 Bulk liquid, gas or solids removal

3 Optimized internals and separator design

4 Gas polishing 5 Oil polishing 6 Produced water polishing

7 Desanding from sand slurry streams

To oil processing

To gas processing

To water treatment

To water treatment

Sand handling system

5

3

oilgaswaterSand

4

6

1

To oil processing7

2. Bulk Liquid, Gas or Solids Removal

One phase (solids, oil, water or gas) is separated upstream of the separator and will not flow through the vessel. This means that the existing vessel can be used to separate the other phases more efficiently.

No vessel entry is needed (less shutdown time, less risk for personnel).

Much less installation time needed than for retrofit internals (more production time).

Gas dehydration problems on BP Etap (North Sea): glycol losses 20 tonnes per month, frequent filter changes, production restriction of 30 MMSCFD, gas dewpoint -20 C. Solution: an InLine Deliquidiser was installed upstream of an existing scrubber. Results: gas dewpoint -52 C, glycol efficiency up from 26 % to 97 %, no significant glycol losses after the first month.

3. Optimized Internals and Separator design

More efficient separation More flow through existing equipment Design can be adjusted for new flow data

High Efficiency Internals

Inlet devices

We use Evenflow HE and Inlet cyclones.

Inlet devices are used to reduce incoming momentum and prevents the formation of small droplets.

High-pressure liquid-gas separation

We have found that the efficiency of a vane pack demister is substantially less at higher pressures. This why we only use Spiraflow cyclones as mist eliminators in medium to high-pressure conditions where high separation efficiency is required.

The cyclone mist eliminator Spiraflow is the most efficient device for separating liquid mist from gas.

Debottlenecking a vertical separator

Example of trouble-shooting a scrubber: the compressor was damaged by liquid in the feed gas. A CFD study identified the problem areas (inlet device, mist eliminator configuration and type of mist eliminator).

Proposed solution with Evenflow HE vane type inlet device, mesh agglomerator and Spiraflow cyclones. A CFD study showed efficiency improvements and production at the ConocoPhillips Hang Tuah platform was increased by a factor of three. Payback time for this investment was less than one week.

Spiraflow

Agglomerator

Evenflow HE

4. Gas polishing

Example of trouble shooting a scrubber without entering the vessel: the Evenflow HE inlet device can be installed through the inlet nozzle. The Spiraflow mist eliminating cyclones are placed in a small pipe spool outside the vessel.

Stop liquid carry-over Retrofit, but no manhole External mist-eliminating section Bayonet-type Evenflow

5. Oil Polishing

InLine DeWaterer Operating range 5 - 50 % WiO Removal efficiency 90 % Gas load up to 30 % GVF Low pressure drop

The InLine ElectroCoalescer enhance rate of droplets coalescence enhance separation performance breaks down emulsions

InLine tools used to remove water from the oil: InLine DeWaterer for oil continuous flows.

6. Produced water polishing

The regulations for the quality of the produced water that is discharged into the environment are getting more stringent. Alternatively the produced water can be re-injected into the well. In both cases, the oil content should be as low as possible, for economical and environmental reasons and for not plugging up the well.

InLine DeWaterer is designed for efficient separation of bulk oil from water which combines high efficiency with low pressure drop in a compact design.

The optimized HydroCyclone provides high separation efficiency with a low pressure drop. Worlds first subsea InLine HydroCyclone will be installed at the Petrobras Marlim Subsea Separation Project.

Improving produced water quality is very important both for environmental and for economic reasons.

7. Desanding

Sand and solids removal results in less damage to vessels, pipes and equipment. Theres less risk of plugging and less risk of filling up the vessel with solids and sand.

Removing solids results in less maintenance and shorter shutdown time.

Other solutions by Separation Systems

Production Improvements Compact Total Separation Systems Heavy Oil production Solids Handling Produced Water

The InLine- DeGasser, DeSander, PhaseSplitter, DeWaterer and DeLiquidiser are patented by Statoil and FMC have exclusive worldwide license to sell this technology.

www.fmctechnologies.com/separation

FMC Technologies

CDS Separation Systems

Delta 101

6825 MN Arnhem

The Netherlands

Phone: +31 (0)26 7999100

FMC Technologies

1777 Gears Road

Houston TX 77067

USA

Phone: +1 281 591 4000

Copyright February 2011 | FM

C Technologies