Fluid Separator Unit with Nested Centrifugal Zones

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Solution Overview

Problem

The petroleum industry faces challenges in fluid processing, particularly in subsea and topside applications, where equipment reliability is critical due to harsh environments and demanding fluid conditions, leading to frequent service needs and limited service life of rotating equipment like ESPs.

Innovation Solution

A fluid separator unit with an elongate body and circular internal cross-section, featuring multiple centrifugal separation zones and fluid paths to effectively separate fluids into light and heavy fractions, minimizing the recycling of solids and gases, thereby enhancing equipment performance and operational life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If rotating equipment like ESPs is used for fluid processing, then pumping capability is achieved, but service life is limited and frequent service is required

Engineering Contradiction:

Improvepumping capabilityVSAvoidservice life

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent replaces rotating mechanical equipment (ESPs) with a static pumping system that uses a progressive cavity pump. This substitution eliminates the reliability issues associated with rotating equipment while maintaining pumping capability, as the static pump has no moving parts that wear out or require frequent maintenance in harsh subsea environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If fluid processing equipment operates in harsh subsea environments, then remote field exploitation is enabled, but equipment reliability deteriorates

Engineering Contradiction:

Improveremote field exploitation capabilityVSAvoidequipment reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent incorporates a fluid separator unit with centrifugal separation zones that automatically separate solids and gases from the fluid stream. This self-service mechanism prevents accumulation of harmful substances that would otherwise degrade equipment performance in remote subsea locations where manual intervention is difficult or impossible.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts potentially harmful solids and gases in the fluid stream into beneficial separated phases. By using centrifugal force to separate these components, the system prevents them from causing equipment damage while utilizing the separation to improve overall system reliability in harsh environments.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If multiple centrifugal separation zones are implemented, then fluid separation efficiency is improved, but device complexity increases

Engineering Contradiction:

Improvefluid separation efficiencyVSAvoidseparator structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements nested centrifugal separation zones where a second separation zone is positioned within the first zone. This nesting arrangement achieves multiple separation stages in a compact configuration, improving fluid separation efficiency without proportionally increasing device complexity or occupying excessive space.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

The fluid separator unit improves fluid processing by efficiently separating fluids, reducing the risk of equipment damage from solids and gas accumulation, and optimizing fluid composition for recycling, thus enhancing the reliability and performance of subsea and topside operations.

Implementation Method 1

an inlet configured to direct a flow of a fluid into the body in a rotational flow pattern around the longitudinal axis of the body

Methodology Applied

Scientific EffectRotational flow: Vortex Ring

Implementation Method 2

a first centrifugal separation zone arranged within the body, a second centrifugal separation zone arranged within the body

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Data Source

PatentUS11071930B2System and method for fluid processing

Publication Date: 2021.07.27 ONESUBSEA AS

AI summary

A fluid separator unit includes an elongate body having a circular internal cross-section and a longitudinal axis, an inlet which directs a fluid flow into the body in a rotational flow pattern around the longitudinal axis, a first outlet, a second outlet, a first centrifugal separation zone arranged within the body, a second centrifugal separation zone arranged within the body, a first fluid path from a central part of the first centrifugal separation zone to the first outlet, a second fluid path from an outer periphery of the second centrifugal separation zone to the first outlet, and a third fluid path from the second centrifugal separation zone to the second outlet. A diameter of the second centrifugal separation zone is smaller than a diameter of the first centrifugal separation zone.