The Compact Separation Laboratory - Design and Engineering of Phase 2
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Increased oil and gas production over the past decades have claimed most of the easilyaccessible offshore reservoirs. Developing new reservoirs in remote environments andat large water depths are challenging for topside production facilities. This empathizesthe need for innovative subsea production and processing solutions. Aging reservoirs require methods to maintain the desired pressure during operation,often by re-injecting produced water back into the reservoir. As oil and gasfields become depleted, more water is required in order to extend the flow from thereservoir. The increasing rate of produced water, combined with large costs associatedwith treating water, provides an economic incentive to create innovative solutions. The SUBPRO (Subsea Production and Processing) Center of Innovation-DrivenResearch (SFI) cooperation have expressed interest in compact separator technology.The small size and reduced weight of a compact separator is favorable for installationat remote locations or at large water depths, compared to larger traditional separators.The disadvantage of compact separators is the decreased performance during flowirregularities when producing from a reservoir. To improve compact separation technology, SUBPRO has funded 3,000,000 NOKfor the development of a compact separation laboratory (CSL) at the NorwegianUniversity of Science and Technology, Department of Mechanical and Industrial Engineering.Development of the CSL is divided into three phases: Phase 1 consist ofthree hydrocyclones in series, Phase 2 introduces a compact flotation unit (CFU) anda gas-liquid cylindrical cyclone (GLCC) and Phase 3 concerns the pump and reservoirsystem for the lab. Experiments and research carried out on the different separatortechnologies will facilitate the development of advanced novel control algorithms. Thisenables autonomous solutions, required to realize the subsea factory concept, whereall production and processing equipment are placed on the seabed. This thesis describes the design and engineering of Phase 2. A literature study onCFU and GLCC has been conducted to acquire necessary knowledge for design andfunctional engineering. The result of the study and recommendations from industryspecialists, are the development of a complete design of the given separator vessels. A large number of manufacturers and suppliers have been consulted in order toengineer the process layout and select relevant process and instrumentation equipment.Arrangements for the construction of the three vessels have been establishedwith contractors, selected based on their experience with manufacturing similar units. As the project is limited by the available funds, a detailed budget has been createdto manage the project economy. The budget including all three phases of the CSLand the status of the economy have been discussed. The finalized design presented in this thesis has been engineered in order to initiatethe construction of Phase 2. All equipment are listed with model specifications.Respective suppliers and contractors are standing by, awaiting the initiation of theconstruction phase. All necessary documentation is provided to the supervisor, whois responsible for future planning and decisions regarding the CSL project. This thesis will determine if the design of Phase 2 fulfills the requirements withregards to quality, functionality and economy. If the design is found sufficient, theconstruction phase can be initiated.