Subsea Separator Helix Segmented Fabrication

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Solution Overview

Problem

Conventional separator helix assemblies in subsea fields face challenges in maintaining fluid-tight connections to prevent remixing of gas and liquid phases, which is critical for effective separation, and existing fabrication methods are not straightforward, making ease of assembly difficult.

Innovation Solution

A helix assembly with fluid-tight connections between the helix and casings, achieved through weld seams and seal welds, and a method of fabrication using segmented components that are stacked and welded to form the helix and casings, ensuring secure and leak-proof assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional fabrication methods are used for helix assemblies, then the assembly process becomes complex and difficult, but fluid-tight connections can be maintained

Engineering Contradiction:

Improveease of helix assembly fabricationVSAvoidfluid tight connection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The helix assembly is divided into multiple modular segments that can be fabricated separately and then assembled. Each segment includes integrated connection features that simplify the assembly process while maintaining fluid-tight seals. The segmentation allows for easier fabrication of individual components without compromising the overall reliability of connections.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Specialized connection elements serve as intermediaries between the helix segments and casings. These intermediaries include integrated seals and coupling mechanisms that ensure fluid-tight connections while simplifying the assembly process. The intermediary components bridge the gap between fabrication ease and connection reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the helix connections to casings are made fluid-tight to prevent remixing, then separation effectiveness is improved, but the fabrication complexity increases

Engineering Contradiction:

Improveseparation effectivenessVSAvoidfabrication complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connection features for fluid-tight sealing are merged directly into the helix segment structures themselves. Rather than adding separate complex sealing systems, the seals are integrated into the segment design, allowing fluid-tight connections to prevent remixing while keeping fabrication relatively simple through unified component design.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If segmented components are used to simplify assembly, then ease of manufacture is improved, but the number of connections and potential leak points increases

Engineering Contradiction:

Improveease of assemblyVSAvoidpotential leak points

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The segmented design incorporates pre-integrated sealing features and tolerance compensation mechanisms in each connection interface. These beforehand provisions cushion against potential leakage by ensuring proper sealing alignment and contact during assembly, preventing leak points despite the increased number of connections.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 solution effectively prevents remixing of gas and liquid phases, enhancing the separation efficiency and simplifying the fabrication process by ensuring reliable and leak-proof connections between the helix and casings.

Implementation Method 1

A helix assembly with fluid-tight connections between the helix and casings, achieved through weld seams and seal welds

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

Due to gravity, the fluid is routed over and along the helix toward the lower end of the annulus. As the fluid travels, the liquid phase moves toward the lowest point of the helix at the wall of the inner casing due to its density. At the same time, the gas phase moves to the highest point of the annulus, also due to its density.

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentEP2629870B1Separator helix and method of fabricating a separator helix

Publication Date: 2018.05.23 ONESUBSEA IP UK LTD

Figure 1
Figure 2A~2B
Figure 3

AI summary

A separator with a helix assembly and methods for fabricating the helix assembly. In some embodiments, the helix assembly includes a plurality of segments disposed end to end and forming an intermediate casing. Each of the segments has a tubular portion with a first circumferential edge and a second circumferential edge and a helical portion extending from the second circumferential edge. The tubular portions of the segments form an intermediate casing, while the helical portions of the segments form a spiral helix. The helix assembly further includes an inner casing concentrically disposed within the intermediate casing and coupled to the spiral helix.