Multiphase Pipe Separator for Deepwater Separation
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Solution Overview
Problem
Traditional subsea separation systems face challenges in deep water environments beyond 1500 meters due to increased hydrostatic pressure, making it impractical to use large diameter gravity separation vessels, which are heavy, costly, and difficult to maintain.
Innovation Solution
A multiphase separation system using a pipe separator configured to separate production fluids into oil, water, and gas phases, employing a pipe code design instead of vessel code, with a control volume for final phase separation and recycling of streams to manage phase interfaces and flow rates efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large diameter gravity separation vessels are used for subsea separation, then separation effectiveness is improved, but wall thickness and weight increase significantly at water depths greater than 1500 meters due to hydrostatic pressure
Solution Approach 1:
The separation system is divided into multiple functional sections within a single pipe: gas separation section, oil-water separation section, and polishing section. This segmentation allows each section to be optimized for its specific function while maintaining a compact overall structure that doesn't require thick walls to withstand deep water pressure.
Solution Approach 2:
The patent replaces the traditional mechanical gravity separation vessel with a pipe-based system that uses flow dynamics and phase separation principles. The pipe separator uses controlled flow paths and pressure differentials rather than relying on large vessel volume and gravity alone, enabling effective separation in a compact, pressure-resistant structure.
2Productivity
If large diameter gravity separation vessels are used, then separation capacity is improved, but fabrication difficulty and project cost increase
Solution Approach 1:
The pipe separator system uses standard pipe components and off-the-shelf equipment (pumps, valves, separators) rather than custom-fabricated large vessels. This approach reduces fabrication complexity and cost, making the system more economically viable for deep water applications where retrieval and replacement may be necessary.
Solution Approach 2:
Multiple separation functions are nested within the pipe structure - gas separators, oil-water separators, and polishing sections are arranged sequentially within the same pipe run. This nested arrangement provides high separation capacity in a compact footprint that is easier to manufacture and install than large diameter vessels.
3Reliability
If large diameter gravity separation vessels are used, then separation performance is improved, but retrievability for maintenance becomes difficult
Solution Approach 1:
The pipe separator system is designed with flexible connections and modular components that can be adjusted, removed, or replaced without requiring complete system shutdown or complex retrieval operations. The dynamic design allows for easier maintenance compared to rigid large-vessel systems.
Solution Approach 2:
The active separation components (pumps, valves, separators) are extracted as separate, removable units from the pipe structure. This allows individual components to be accessed, removed, and replaced independently, significantly improving ease of repair and maintenance compared to integrated large-vessel systems.
4Ease of operation
If multiphase pumps are used to handle production fluids, then flow control is improved, but energy consumption and operational complexity increase
Solution Approach 1:
The pipe separator system uses the natural flow dynamics and pressure differentials of the multiphase stream to drive separation processes. Phase separation occurs based on density differences and flow characteristics without requiring high-energy multiphase pumps, reducing energy consumption while maintaining operational control.
Solution Approach 2:
The system uses hydraulic principles to control flow distribution between different separation sections. Pressure differentials and flow rate control are achieved through valve regulation and pressure management rather than high-power pumping, reducing energy requirements while maintaining ease of operation.
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
Enables effective separation of oil and water phases, reducing the need for multiphase pumps, decreasing hydrostatic head, and lowering the risk of hydrates and corrosion, while allowing for efficient disposal or reuse of water and sand, thus enhancing reservoir drive and production efficiency.
Implementation Method 1
a pipe separator configured to separate production fluids into oil, water, and gas phases
Implementation Method 2
separate the liquid stream into an oil phase, an aqueous phase, and an oil/water emulsion phase
Implementation Method 3
a control volume for final phase separation and recycling of streams to manage phase interfaces and flow rates efficiently
Data Source
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AI summary
The current disclosure relates to multiphase fluid separation via a multiphase separation system. The multiphase separation system is configured to feed a multiphase fluid into feed lines within the multiphase separation system, wherein the feed lines consist of an upper line, a middle line, and a lower line. The upper line is configured to flow a first stream substantially including oil into an oil section of a control volume. The middle line is configured to flow a second stream substantially including an oil/water emulsion into an oil/water emulsion section of the control volume. The lower line is configured to flow a third stream substantially including water into a water section of the control volume. The control volume is configured to adjust fluid flow rate at an outlet, wherein the oil section, the water section, and the oil/water emulsion section each commingle at different heights of the control volume.