Subsea Separation Station Modular Design
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Solution Overview
Problem
Current subsea fluid separation systems are bulky, costly, and require significant space and resources for expansion, leading to inefficiencies in oil production and increased operational costs due to inaccurate production curve estimates and high equipment weight, which complicates maintenance and intervention.
Innovation Solution
An integrated compact subsea separation and pumping system with modular design, featuring a separation module with cyclonic devices and a pumping module, reducing weight and size through the integration of components and use of robotic arms for actuation, allowing for flexible capacity adjustments and localized intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large modules with complete equipment, piping, sensors and structures are designed for surface facilities to process each phase produced by oil tank, then all necessary functions for individual processing are included, but the system occupies significant space, requires high investment for expansion, and processing plant must stop for suitability adjustments
Solution Approach 1:
The system is divided into separate functional modules: a subsea separation module for initial fluid separation, and surface treatment modules for specific phase processing. This segmentation allows the surface facilities to be smaller while maintaining processing capability through modular expansion.
Solution Approach 2:
The invention moves the separation function to the subsea dimension, freeing up surface space. By performing separation at the source (subsea) rather than consolidating all processing at surface facilities, the system reduces the area required for surface equipment while maintaining or enhancing processing adaptability.
2Weight of stationary object
If subsea separation systems are implemented to reduce space and operational costs, then water reinjection capacity is improved and surface space is freed, but equipment weight is reduced which may compromise structural integrity and maintenance capabilities
Solution Approach 1:
The system employs a robotic arm with dynamic positioning and actuation capabilities that can adapt to different maintenance scenarios. The robotic arm provides on-demand intervention capability, maintaining system reliability without requiring permanent heavy-duty manual access infrastructure.
Solution Approach 2:
The system incorporates self-monitoring sensors and automated control systems that detect and respond to operational anomalies without human intervention. This self-service capability maintains reliability while reducing the weight associated with manual maintenance infrastructure.
3Ease of manufacture
If production curve estimates are used to size treatment equipment, then initial system design is simplified, but actual production volumes may exceed equipment capacity leading to water quality loss and increased operational costs
Solution Approach 1:
The system incorporates dynamically adjustable treatment capacity through modular surface modules that can be activated or deactivated based on actual production volumes. This allows the system to start with a simpler design based on estimates but expand capacity as needed without requiring over-design from the outset.
Solution Approach 2:
The system uses sensors and monitoring systems to provide real-time feedback on actual production volumes and water quality parameters. This feedback loop enables the control system to adjust operational parameters and activate additional treatment capacity when production exceeds initial estimates, preventing water quality degradation.
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 compact system achieves efficient fluid separation and pumping with reduced operational costs, improved maintenance capabilities, and a better cost-benefit ratio by minimizing equipment weight and space requirements, enabling more effective oil recovery and environmental compliance.
Implementation Method 1
separation module (10) comprising a set of cyclonic devices (15)
Implementation Method 2
a gravitational separator of gas and liquid phases (19)
Implementation Method 3
The removal of residual oil is carried out by bank of hydrocyclones (15)
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to an integrated compact station of subsea separation and pumping systems of fluids, which is suitable for use in any subsea system that has as objective the separation of fluids and/or solids. The compact integrated station according to the invention comprises a first separation module (10) and a second pumping module of reinjection water (40), a harp as gas-liquid gravitational separator (19) and, optionally, a robotic arm (16) installed on a cover (17) involving said separation module (10) and a liquid-liquid gravitational tubular separator module (30). The integrated compact station may be applied to any subsea system of separation of fluids connected to the well of oil and gas production, or alternatively, installed directly connected to the production manifold.