Electrostatic Internals for Crude Oil Dehydration in FPSO Tanks
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Solution Overview
Problem
Conventional FPSO installations face challenges in dehydration of crude oil within storage tanks, as existing electrostatic separators can only handle up to 30% water content, necessitating large and heavy processing equipment, and require a separate electrostatic pressure vessel.
Innovation Solution
A system comprising parallel separator vessels, a flash vessel, a degasser vessel, and an electrostatic treater within the crude oil storage tank, utilizing electrostatic internals to increase water handling capacity up to 80% without a pre-treater, reducing topside equipment requirements and incorporating DUAL FREQUENCY technology for enhanced dehydration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrostatic separators are used in FPSO installations, then dehydration of crude oil can be achieved, but the water cut is limited to only about 30% and large horizontal pressure vessels are required
Solution Approach 1:
The patent combines the electrostatic separator functionality with the crude oil storage tank by installing electrostatic internals directly within the tank. This integration eliminates the need for a separate electrostatic pressure vessel and enables the storage tank to handle water cuts up to 80%, significantly improving adaptability while maintaining dehydration capability.
2Reliability
If conventional electrostatic separators are used, then dehydration can be performed, but large horizontal pressure vessels take up space and add weight
Solution Approach 1:
The electrostatic separator is merged with the storage tank by installing electrostatic internals within the tank structure. This eliminates the need for separate horizontal pressure vessels, reducing the space occupied by equipment while maintaining the dehydration function.
Solution Approach 2:
The patent transitions from horizontal pressure vessels to vertical vessel configuration for the electrostatic separator. This dimensional change allows the equipment to be more space-efficient and integrate better with the storage tank structure, reducing overall footprint.
3Reliability
If conventional electrostatic separators are used, then dehydration is achieved, but the equipment weight is significant
Solution Approach 1:
The electrostatic separator is integrated into the storage tank structure, combining two functions into one piece of equipment. This eliminates the weight of the separate electrostatic pressure vessel while maintaining dehydration performance.
4Reliability
If a separate electrostatic pressure vessel is used, then dehydration can be performed, but it requires additional equipment in the process train
Solution Approach 1:
The electrostatic separator and storage tank are merged into a single integrated system. This reduces the number of equipment components in the process train by eliminating the separate electrostatic pressure vessel, thereby reducing device complexity while maintaining dehydration capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces the size and weight of FPSO process trains, achieving higher water cut efficiency and meeting BS&W requirements while accommodating higher water volumes, with a 72% reduction in space and 76% reduction in weight compared to prior art.
Implementation Method 1
The electrostatic separator section of the tank houses at least one set of electrostatic (high velocity) internals
Implementation Method 2
a flash vessel arranged downstream of the first and second separator vessels to receive an outlet stream of the first and second separator vessels
Implementation Method 3
a degasser vessel arranged downstream of the flash vessel to receive an outlet stream of the flash vessel
Data Source
AI summary
A process train for a floating production storage and offloading installation includes a crude oil storage tank equipped with at least one set of electrostatic internals. The set of electrostatic internals are arranged to provide a treatment flow path within the crude oil storage tank oblique to a longitudinal centerline of the crude oil storage tank and through an electric field provided by the set of electrostatic internals. Employing these electrostatic internals within the tank permits an allowable inlet water content into the tank of up to 80%, significantly reducing the required topside processing equipment. The process and system also includes, upstream of the tank, two separator vessels arranged in parallel so each receives a portion of an incoming oil-and-water stream, a flash vessel arranged downstream of the two separator vessels, and a degasser vessel. Downstream of the crude oil storage tank is an electrostatic treater.