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Opus case studies - March2012

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Summary of Opus case studies for Consultancy and Technology business platforms.

Summary of Opus case studies for Consultancy and Technology business platforms.

Published in: Business, Technology

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  • 1. RESOURCESC O N S U LTA N C Y TECHNOLOGY E N V I R O N M E N TA LPROCESS STUDIES PRODUCED WATER TREATMENT MARINE ECOTOXICOLOGYCOMPUTATIONAL FLUID DYNAMICS - CFU FRESHWATER ECOTOXICOLOGYPHYSICAL MODELLING - Mare’s Tail WHOLE EFFLUENT ANALYSISSLOSHING ANALYSIS & DESIGN - Hydrocyclones BAT/BEPFLUIDS CHARACTERISATION PROCESS UPGRADE ENVIRONMENTAL SERVICESTEST FACILITIES PROCESS NEW BUILDOILFIELD CHEMISTRY SERVICES PROCESS INTERNALSBAT/BEP SAND MANAGEMENT IMPLEMENTATION RESEARCH & DEVELOPMENTCASE STUDIES CASE STUDIES CASE STUDIES NOTE: PLEASE CLICK ON THE GREY TAB BELOW ON ANY SLIDE TO RETURN TO THIS MENU
  • 2. RESOURCESTECHNOLOGY – CASE STUDIES CFU - Triton CFU – Gorm Platform CFU – Heather Platform CFU – Peregrino FPSO CFU – Field Test Unit MARE’S TAIL - Video NEW BUILD Condensate Separator NEW BUILD Production Separator PROCESS UPGRADE – HP Separator PROCESS UPGRADE – Degasser PROCESS UPGRADE – HP Separator on FPSO
  • 3. RESOURCESC O N S U LTA N C Y – C A S E S T U D I E S Process Optimisation – Review and Upgrades. PM3 BRA/BRD Hydrocyclone Optimisation – BAT/BEP
  • 4. RESOURCESC O N S U LTA N C Y – C A S E S T U D I E S Talisman Energy (Malaysia) Ltd – Bunga Raya Complex Scope of Work: > Process Review, Offshore Fluids Characterisation, > Hydrocyclone Trials > Vessel Upgrades Method > Comprehensive review of Produced Water Treatment and Operating Philosophy > Conduct Offshore Fluids Characterisation and evaluation of two hydrocyclone vendors > Identify Bottlenecks and Prioritise Improvements Upgrades > Replacement hydrocyclone liners > 1st stage separator and degasser internals Result > Capacity increased from 35,000 to 70,000 BWPD.
  • 5. RESOURCESC O N S U LTA N C Y – C A S E S T U D I E S Shell (now Talisman) Auk – Hydrocyclone Optimisation Background: > Not meeting discharge consent > Hydrocyclones operating very inefficiently > Multi-vendor trial to ascertain best option for upgrade Findings > Platform HC’s operating at ~50% removal > Identified best vendor liner > Platform HC’s PDR set at 1.2 – 1.3 due to reject bottleneck > With raised PDR, achieved improved efficiency Conclusion > The existing platform hydrocyclones would be capable of meeting the efficiency targets if operated at the correct PDR > A reject piping cross-over was recommended to achieve PDR > No need to upgrade the hydrocyclones > Considerable CAPEX savings
  • 6. RESOURCESTECHNOLOGY – CASE STUDIES BP Andrew Mare’s Tail® Scope of supply > Mechanical and process design, fabrication, testing, inspect ion, certification and delivery ex- works of an 18” Mare’s Tail > Design to pressure vessel specification > Complete with spare media cartridge and revised cartridge handling systems (for aid in removal and insertion of media cartridges) Process Specifications > 18” unit > Max design flow: 440m3/hr, > Normal flow: 191m3/hr > Predicted inlet process conditions; 100-1000mg/l oil at 10-20 µm
  • 7. RESOURCESTECHNOLOGY – CASE STUDIES Mare’s Tail® Demonstration Video
  • 8. RESOURCESTECHNOLOGY – CASE STUDIES Hess / Wood Group: Triton FPSO > Design PW flowrate per CFU train – 430 m3/hr > Oil inlet concentration 100 ppm with 10 – 15 ppm at the outlet > Package comprises 2 x trains of 2 CFU’s > with interstage Mares Tail® > Approx package dimensions 5m x 6m x 6.5m high – dry weight 30.0 te > Vessels, pipework and valves in Duplex 31803 > Structural steel etc carbon steel > Instrumentation – impulse tubing all wiring terminated at skid edge JB’s > Package successfully commissioned
  • 9. RESOURCESTECHNOLOGY – CASE STUDIES Lundin / Petrofac: Heather Platform > PW flow rate – 331 m3/hr > Oil inlet concentration 1500 ppm with 10 ppm at the outlet > Package comprises 1 x train of 2 CFU’s with Mares Tail and Reject package added to take reject stream > Approximate dimensions 11m x 8m x 7m high – dry weight 50.0 te > Vessels, pipework and valves in lined / painted carbon steel > Structures - carbon steel > Instrumentation – impulse tubing all wiring terminated at skid edge JB’s > Package being installed and being commissioned
  • 10. RESOURCESTECHNOLOGY – CASE STUDIES Maersk Olie og Gas, Esbjerg: Gorm Platform > Design PW flow rate– 400 - 500 m3/hr > Oil inlet concentration 500 ppm with < 15 ppm at the outlet > Package comprises 1 x train of 2 CFU’s. > Approx package dimensions 5m x 5.5m x 6m high – dry weight 20.0 te. > Vessels, pipework and valves in Super Duplex 32760. > Structure carbon steel > Instrumentation – capillary’s with all wiring terminated at skid edge JB’s > Package commissioning completed Nov 2008
  • 11. RESOURCESTECHNOLOGY – CASE STUDIES Maersk / McDermott: Peregrino FPSO > PW flowrate– 357 m3/hr Heavy Crude > Oil inlet concentration 100 ppm with 29 ppm at the outlet > Package comprises 1 x train of 1 CFU > Approximate dimensions 2.5m x 4.3m x 6.5m high – dry weight 11.5 te > Vessels, pipework & valves in Duplex 31803 > Structural steel etc carbon steel > Commissioned > Exceeding contractual performance with higher inlet oil loading and transient conditions > Client is very pleased with robust operation and reliable operation
  • 12. RESOURCESTECHNOLOGY – CASE STUDIES Compact Flotation Test Rig > Design Basis: > Suitable for side stream flowrates between 5.0 – 15 m3/hr > Vessel designed to PD5500 in SS316L. > Unit provided with all piping, instrumentation, motive water pump etc > Tie-in points 1.5 – 2” NB
  • 13. RESOURCESTECHNOLOGY – CASE STUDIES Rambol Denmark, South Arne Degasser > Vessel process / mechanical design and supply of internals. > Opus also took responsibility for the supply, installation and commissioning including nucleonic instrumentation. Process specifications > PW Flowrate 100,000 bpd > 6.8m T/T > 2.8m ID > Inlet 400ppm OIW > Outlet 20ppm OIW
  • 14. RESOURCESTECHNOLOGY – CASE STUDIES BP Andrew Kinnoull Separator Scope of supply > Process design and supply of process internals, including VIEC (electrostatic coalescer). > CFD modelling analysis includes: multiple flow cases, slugging behaviour. > Project management of design, new build vessel interfaces and internals installation > Overall process responsibility for the separator
  • 15. RESOURCESTECHNOLOGY – CASE STUDIES BP Andrew Kinnoull Separator
  • 16. RESOURCESTECHNOLOGY – CASE STUDIES Mærsk Gorm HP Separator 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
  • 17. RESOURCESTECHNOLOGY – 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 > 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
  • 18. RESOURCESTECHNOLOGY – CASE STUDIES Mærsk Gorm HP Separator Upgrade Modifications > Removal of Existing Inlet, Perforated Baffles and Vane Packs > Internals Supplied for Upgrade:- > Inlet Vane Device with Diffuser Baffle > Horizontal Gate Baffle with Top Gas Confirmed results Baffle (Inlet Zone) Outlet Outlet Post > Horizontal Gate Baffle (Distribution Pre-upgrade Upgrade Baffle) ~1000ppm 50 - 90ppm > Vertical Gate Baffle (Calming Baffle) > Vortex Breaker (New Water Outlet) > The water outlet nozzle was replaced for a larger nozzle
  • 19. RESOURCESTECHNOLOGY – CASE STUDIES Mærsk Halfdan Degasser Original Design & Performance > Vessel Internals Comprised of:- > Open Pipe Inlet > Perforated Plate > Longitudinal Notched Weirs Oil in Water Performance – 15-30ppm for an inlet concentration of 50-200ppm.
  • 20. RESOURCESTECHNOLOGY – CASE STUDIES Mærsk Halfdan Degasser Review Phase > Perforated plates fouled > Solids > Scale > Behaving more like weirs > Notched weirs not effective > Vessel levels difficult to control > Lack of inlet device causing poor flow distribution
  • 21. RESOURCESTECHNOLOGY – CASE STUDIES Mærsk Halfdan Degasser Upgrade Modifications > Remove all existing internals > Internals supplied for upgrade:- > ZSQ inlet device > Slotted baffles > Conventional notched weir
  • 22. RESOURCESTECHNOLOGY – CASE STUDIES Mærsk Halfdan Degasser Upgrade Modifications > Remove all existing internals > Internals supplied for upgrade:- > ZSQ inlet device > Slotted baffles > Conventional notched weir
  • 23. RESOURCESTECHNOLOGY – CASE STUDIESMærsk Halfdan DegasserThe Achievements> New internals fabricated and supplied on schedule> Opus supervised installation> Client confirmed performance:- Original Internals Revamped Internals Inlet Outlet Inlet Outlet 50-200ppm 15-30ppm 50-200ppm 5-10ppm
  • 24. RESOURCESTECHNOLOGY – 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
  • 25. RESOURCESTECHNOLOGY – 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
  • 26. RESOURCESTECHNOLOGY – CASE STUDIES HP SEPARATOR ON FPSO Upgrade Modifications > Remove all existing internals > Internals supplied for upgrade:- > Vane type inlet device with distribution baffle > Slotted baffles > Plate pack coalescer
  • 27. RESOURCESTECHNOLOGY – CASE STUDIESHess Triton HP SeparatorThe Achievements> New internals fabricated and supplied on schedule> Opus supervised installation> Tie-in fluids added shortly after start-up> Client confirmed performance:- Original Internals Revamped Internals (with 70% additional flowrate) 300 - 1,500ppm 100 - 600ppm