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

1. RESOURCES
C O N S U LTA N C Y TECHNOLOGY E N V I R O N M E N TA L
PROCESS STUDIES PRODUCED WATER TREATMENT MARINE ECOTOXICOLOGY
COMPUTATIONAL FLUID DYNAMICS - CFU FRESHWATER ECOTOXICOLOGY
PHYSICAL MODELLING - Mare’s Tail WHOLE EFFLUENT ANALYSIS
SLOSHING ANALYSIS & DESIGN - Hydrocyclones BAT/BEP
FLUIDS CHARACTERISATION PROCESS UPGRADE ENVIRONMENTAL SERVICES
TEST FACILITIES PROCESS NEW BUILD
OILFIELD CHEMISTRY SERVICES PROCESS INTERNALS
BAT/BEP SAND MANAGEMENT
IMPLEMENTATION
RESEARCH & DEVELOPMENT
CASE STUDIES CASE STUDIES CASE STUDIES
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2. RESOURCES
TECHNOLOGY – 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. RESOURCES
C 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. RESOURCES
C 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. RESOURCES
C 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – CASE STUDIES
Mare’s Tail® Demonstration Video

8. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – CASE STUDIES
BP Andrew Kinnoull Separator

16. RESOURCES
TECHNOLOGY – 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. 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
> 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – 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. RESOURCES
TECHNOLOGY – CASE STUDIES
Mærsk Halfdan Degasser
Upgrade Modifications
> Remove all existing internals
> Internals supplied for upgrade:-
> ZSQ inlet device
> Slotted baffles
> Conventional notched weir

22. RESOURCES
TECHNOLOGY – CASE STUDIES
Mærsk Halfdan Degasser
Upgrade Modifications
> Remove all existing internals
> Internals supplied for upgrade:-
> ZSQ inlet device
> Slotted baffles
> Conventional notched weir

23. RESOURCES
TECHNOLOGY – CASE STUDIES
Mærsk Halfdan Degasser
The 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. 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

25. 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

26. RESOURCES
TECHNOLOGY – 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. 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 Revamped Internals
(with 70% additional flowrate)
300 - 1,500ppm 100 - 600ppm