Compact Electrostatic Separator for FPSO Space Reduction
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Solution Overview
Problem
Conventional topside oil separation trains on FPSO installations are large, heavy, and space-intensive due to their three-phase separation requirements, which exceed the space and weight limitations of FPSO installations.
Innovation Solution
Implementing a compact electrostatic separator that converts early stages of separation to two-phase processes, allowing for vertical positioning of vessels and reducing overall footprint and weight by minimizing equipment types and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional three-phase separators are used for oil-water-gas separation, then separation effectiveness is maintained, but space requirements and equipment weight increase significantly
Solution Approach 1:
The patent extracts the gas separation function from the traditional three-phase separator, creating a dedicated gas separator that handles gas-liquid separation independently. This allows the remaining oil-water separation to use compact electrostatic separation technology, significantly reducing the overall space requirements while maintaining separation effectiveness.
Solution Approach 2:
The patent replaces traditional mechanical gravity-based three-phase separation with electrostatic separation technology. The electrostatic separator uses electrical fields rather than mechanical gravity settling, enabling much more compact equipment design while achieving the same or better separation effectiveness.
2Reliability
If conventional three-phase separators are used for oil-water-gas separation, then separation effectiveness is maintained, but equipment weight increases significantly
Solution Approach 1:
The patent extracts the gas separation function from the traditional three-phase separator, creating a dedicated gas separator that handles gas-liquid separation independently. This allows the remaining oil-water separation to use compact electrostatic separation technology, significantly reducing the overall space requirements while maintaining separation effectiveness.
Solution Approach 2:
The patent replaces traditional mechanical gravity-based three-phase separation with electrostatic separation technology. The electrostatic separator uses electrical fields rather than mechanical gravity settling, enabling much more compact equipment design while achieving the same or better separation effectiveness.
3Reliability
If multiple three-phase separators are used in the process train, then treatment performance is maintained, but device complexity increases
Solution Approach 1:
The patent creates a multi-functional integrated separation system where the electrostatic separator performs both oil-water separation and contributes to gas-liquid separation. This universal approach reduces the number of dedicated equipment pieces needed while maintaining comprehensive treatment performance across all phases.
Solution Approach 2:
The patent extracts the gas separation function from the traditional three-phase separator, creating a dedicated gas separator that handles gas-liquid separation independently. This allows the remaining oil-water separation to use compact electrostatic separation technology, significantly reducing the overall space requirements while maintaining separation effectiveness.
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 approach results in a 37% reduction in space requirements and a 50% reduction in dry weight, maintaining treatment performance while optimizing space and weight constraints on FPSO installations.
Implementation Method 1
a compact electrostatic separator pre-treater arranged downstream of the low pressure degasser
Data Source
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AI summary
A system and method for dehydrating crude oil on a floating production storage and offloading installation include a separator vessel (20) to receive an incoming produced water stream (15), followed by a flash vessel (30), a treatment block, a crude oil storage tank (60), and an electrostatic treater (70). The treatment block includes a low pressure degasser (40) followed by a compact electrostatic separator pre-treater (50) or a compact electrostatic separator pre- treater (50) followed by a low pressure degasser (40). The flash vessel (30) and/or the low pressure degasser (40) may employ an inlet cyclonic distributor and demisting cyclones, while the electrostatic treater may employ DUAL FREQUENCY® technology. The separator vessel (20) may be a single horizontal two-phase separator/degasser or two vertical two-phase separator/degassers that operate in parallel with each receiving approximately 50 percent of the incoming produced water stream. The final outlet stream preferably contains no more than 0.5 BS&W and 285 milligrams per liter salt.