ASCOM

ADVANCED SEPARATION COMPANY

INTRODUCTION TO
COMPACT SEPARATION SOLUTIONS

Danny Thierens (General Manager Business Development)

thierens@ascomsep.com

September 2013
CONTENT

ASCOM PRODUCTS CASE

OVERVIEW AND STUDIES
SERVICES

2
 ASCOM
OVERVIEW

3
Renaissance Group structure

Advanced, compact
Production boosting and Industry leading
separation technologies
debottlenecking solutions hydrocarbon test facilities
Onshore - Topsides – Subsea
Innovative business models 50.000 BLPD 2400 Am3/hr
Separator internals / compact
Marginal field EOR expertise 90 barg, 100 oC
inline

Independently operating private companies with main offices/facilities in Arnhem, the Netherlands
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ADVANCED SEPARATION COMPANY
the future of technology today
• Main office in Arnhem, NL
• Engineering hub for Process & Mechanical in KL, Malaysia
• JV´s Malaysia, Brazil, Oman, Korea, Nigeria, partners in China, India,
Mexico
• High in-country value through
• Process Design, Engineering
• Fabrication
• Technology development/R&D

• ISO 9001:2008 certified, FPAL, ACHILLES registered

• Prequalified and approved vendor with several OILCO and EPC
companies
• Technical solutions using high performance technologies with verified
designs
• Subsea processing
• Newbuilt facilities
• Mature fields rejuvenation
• Heavy Oil solutions
• A company by separation specialists
• Dynamic and high level of customer drive
• ASCOM proprietary technology and IP rights
• Verified industry leading design rules
GAS/LIQUID SEPARATION – LIQ/LIQ SEPARATION - SAND MANAGEMENT - GAS TREATMENT - PR WATER TREATMENT 5
Client Benefits

Increased or
prolongued
production and
revenues

Experienced staff
High
in technology
performance,
development,
reliability and
testing, site
robustness, lower
installations, EPC
operational costs
projects, studies,
(OPEX)
CFD

Compact
Dynamic execution equipment,
models, local smaller modules,
content reduced capital
costs (CAPEX)
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 Local Partnering of ASCOM

Malaysia
Process Design
JOINT VENTURES BY ASCOM

R&D
Fabrication
Engineering
Korea
Fabrication

Oman KUANTAN FABRICATION SHOP AND RESEARCH LAB

R&D
Fabrication Additional fabrication partners in Europe,
Nigeria, China, India.

Brazil ASCOM business model to build up strong

Process Design regional hubs capable of technology
R&D development, process design, engineering
Fabrication and fabrication, with training and support
Engineering from ASCOM NL
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Client References
ASCOM has established superior client relations with major international /
national oil companies, EPC/engineering companies and vessel fabricators
Anadarko – USA Pearl (Mubadala) - Thailand
AQP – Egypt PDO - Oman
Chevron – Bangladesh, Thailand Pemex - Mexico
CNOOC - China Petrofac - Malaysia
ConocoPhillips - Canada Petronas Carigali – Malaysia
Eni - Egypt, Nigeria PTTEP - Thailand
ExxonMobil - Malaysia, Nigeria, USA, Russia RWE Dea - Egypt
E.ON Ruhrgas – UK Santos - Indonesia
Foxtrot – Ivory Coast Saudi Aramco - Saudi Arabia
Framo - Norway SCOP - Iraq
Gasunie - the Netherlands Shell - Nigeria, USA
GdF Suez – Germany Statoil - Norway, Brazil
Ithaca Energy - UK Total - France, Nigeria, Congo, UAE, Gabon,
KOC - Kuwait Italy
Marathon - USA Trans Thai Malaysia - Thailand
MLNG – Malaysia WAPEC / CNPC – Iraq 8
Murphy - Malaysia Wingas – Germany
Newfield – Malaysia
ASCOM in the value chain

Field Development Challenges

Feasible Solutions / Alternatives

Realisation / Project Execution

JIPs
Operations
Testing
Simulations
CONCEPTUAL EPC SITE
R&D FEED
DESIGN SEP PACKAGE SERVICES

OIL COMPANY

EPC/Engineering Company

Vessel Fabricator

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Focus Area

ASCOM technology Gas

Compression
Gas
Dehydration
Gas Export

Gas/Liquid

covers 85-100% of all vessel-based Separation

Oil
Oil Export
Stabilisation
process equipment of a typical
Oil/Water
Desanding
upstream process system Separation

Produced Water Water

Treatment Disposal

Well Test Gas

Separation Export
Pipeline

1st Stage 3-Ph

Separation 1st Stage 2nd Stage 3rd Stage
Mercury Removal Dehydration Export Compression
Compression Compression Compression

2nd Stage 3-Ph

Separation

Vapour Recovery Fuel Gas Treatment

3rd Stage 2-Ph

Separation

Electrostatic
Coalescence
Oil Storage
Conventional
or Central Processing
Oil Export
Produced Water Treatment Pipeline Facilities Layout
Overboard
or
Produced Water
Reinjection

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Conventional versus
compact separation facilities
Conventional solution Well Test
Separation
Gas
Export
Pipeline

• ”practical” 1st Stage 3-Ph

• References
Separation 1st Stage 2nd Stage 3rd Stage
Mercury Removal Dehydration Export Compression
Compression Compression Compression

• Experience 2nd Stage 3-Ph

Separation

BUT – Vapour Recovery Fuel Gas Treatment

• Complex, big, heavy

3rd Stage 2-Ph
Separation

• Lack of data
Electrostatic
Coalescence
Oil Storage
Conventional
or Central Processing

•
Oil Export
Facilities Layout
Need for large design margins Produced Water Treatment

Overboard
Pipeline

• Use of 40 year old designs

or
Produced Water
Reinjection

• Limited performance mapping

• Mostly low/medium performance

ASCOM COMPACT SOLUTION

enabled through verified realistic conditions testing Advanced Separation
Technologies:
and performance mapping •
•
Cyclonic Liquid Removers
Cyclonic Degassers
Reduced no. equipment

•
Reduced carryover

Cyclonic (Bulk) Deoilers

Reduced size Reduced ID

Compact ASCOM solution

Reduced bed dP
Reduced catalyst fouling
Well Test Reduced ID

•
Metering Reduced ID
Reduced carryover
Cyclonic Dewaterers
• Simplified solution
Reduced carryover
~ Reduced no. compressor trips
Reduced compressor trips Gas
Export
Pipeline
• Cyclonic Desanders
• Complete performance mapping
Reduced size

1st Stage 2-Ph

Separation • Cyclonic DGF
• Verified design rules
1st Stage 2nd Stage 3rd Stage
Mercury Removal Dehydration Export Compression
Compression Compression Compression

Reduced size Reduced carryover Reduced carryover

• Compact technologies 2nd Stage 3-Ph

• Pressure Recovery Systems
•
Reduced sand carryover Separation

Sand Removal Systems

• Reduced weight and footprint
Reduced sand erosion
Reduced size Vapour Recovery Fuel Gas Treatment
Reduced size

Reduced gas entrainment 3rd Stage 2-Ph

• Improved robustness and

Reduced cavitation Separation
Reduced oil carryunder
Improved liquid level control

Services:
performance
Electrostatic
Optimised
•
Coalescence
Oil Storage
or
Oil Export
Central Processing Computational Fluid Dynamics
• Need for heavy, viscuous crude
Facilities Layout
•
Produced Water Treatment Pipeline

Overboard
Conceptual Design / Facility
performance mapping
or
Produced Water
Reinjection
Review Studies
• Installation Supervision
• Testing

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 SOLUTIONS & SERVICES

Vessel-based Compact Studies &

Separation Separation Testing
Internals Technologies

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ASCOM Vessel-based Internals
From the supplier’s viewpoint:
Vessel performance optimization = f(system behaviour)
...and the system behaviour
Gas
depends on performance
Processing
individual vessels!

Demisting
Oil
Treatment

Separation
Gravity
Optimization
Flow
Conditioning

Upstream
Inlet

conditions
Produced
Water
Treatment
Sand
Management

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ASCOM Vessel-based
Internals

Inlet Devices: Demisters:

• Vane inlet devices • Mesh mist eliminators
• Inlet cyclones • Vane mist eliminators
• Cyclone mist eliminators

Mechanical Baffles:
Coalescers/Agglomerators : • Perforated distributing baffles
• Mesh agglomerators • Wave dampening baffles
• Vane pack agglomerators
• Plate pack coalescers

Solids Handling: Produced Water Treatment

• Sandjetting systems • MixedFlow hydrocyclones
• Sand removing cyclones • Single and 2-Stage
• Topsides/Subsea

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ADVANCES in Vessel-based Internals
Examples

HiPer Cyclone Mist Eliminators

HiPer Sand Removal Cyclones

HiPer MixedFlow Hydrocyclones

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HiPer Cyclone Mist Eliminator

• Performance tested and design verification up to 180 bar

in full HC system
• High speed videos from 40 bar HC testing
• Increased liquid handling capability
• Reduced pressure drop
• Design correlates extremely well to real performance

15 bar-15 l/h

ASCOM HiPer Demisting Cyclone 40 bar-15 l/h

1-8-15-40 bar tests with Natural gas and air
40 bar- 50 l/h

15 bar-100 l/h
100.00
40 bar-100 l/h

15 bar-200 l/h

40 bar-200 l/h
98.00
15 bar-400 l/h

40 bar-400 l/h
Separation efficiency in %

8-bar-50 l/h
96.00
40 bar -670 l/h

atm+100 l/h
water
atm+200 l/h
water
94.00 atm+300 l/h
water
atm+400 l/h
water
atm+670 l/h
water
atm+100 l/h
92.00
Diesel
atm+300 l/h
Diesel
atm+400 l/h
Diesel
atm+670 l/h
90.00 Diesel
8 bar-50 l/h new
box
8 bar-200 l/h
new box
8 bar-400 l/h
new box
88.00 40 bar-100 l/h
0.00 10.00 20.00 30.00 40.00 50.00 60.00 new box
27 bar-100 l/h
Cyclone k-value [m/s] new box
27 bar-460 l/h
new box
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HiPer Sand Removal Cyclones

12m see-through separator

for liq-liq sep and sand
handling

• Reduced water consumption compared to HiPer Sand Jetting System

(combination possible), resulting in low impact on oil/water separation
• Pro-active and efficient approach to sand removal
• Reduced pressure drop
• Tolerant to fouling/plugging

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HiPer MixedFlow Hydrocyclones

Unique swirl design maximizing energy

utilization for centrifugal forces
generation

Flow is guided through vanes → low dP (25-30% < axial)

Multiple inlets assure symmetric flow pattern → minimal

reject core oscillation

Outlet Concentration (PPM)

Boundary layer and oil core stabilization

Tangential
Pre-separation in swirl
Axial
Avoidance of preferential flow path → no severe erosion

Removable swirl section → easy cleaning and inspection

ASCOM Mixed
Flow
Field tests resulting in 12-16 ppm OiW Feed Concentration (PPM)

• Produced Water Community 4th Annual 2011 Global Produced Water Management, Istanbul, Turkey, 24-28 October 2011
• Tekna Produced Water Management Conference, Stavanger, Norway , 28-29 January 2012 18
 SOLUTIONS & SERVICES

Vessel-based Compact Studies &

Separation Separation Testing
Internals Technologies

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ASCOM Compact
Technologies
COMPACT TOPSIDES – SUBSEA PROCESSING – DEBOTTLENECKING – PRODUCTION BOOSTING

Cyclone Type Cyclone Type

Liquid Separation Degassing

Cyclone Type Spherical Type

Deoiling & Dewatering Separator JIP
2013

Cyclone Type Cyclone Type

Desanding Dissolved Gas Floatation
JIP
2013
• OTC , 21617-PP, De-bottlenecking of mature field production through the use of very compact and efficient separation
equipment, topside or subseaHouston, USA, 4-11 May 2011
• IBC Energy Offshore Heavy Oil Conference, London, 24-25 November 2011
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ASCOM Inline Gas-Liquid Separation
Technology application map

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TwinLine Compact Gas/Liquid Separator

1st 2nd

Typically 20-30% liquid in

gas stream 2nd stage remaining liquid Separation efficiency
1st stage ~90% liquid removal 98-99%
removal

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TwinLine Compact Gas/Liquid Separator

* actual LVF only approx2%, can

treat up to 10% with same sep. Each component easily
efficiency exchangeable

LP test unit ExxonMobil/SWRI Santos Wortel Anadarko Hadrian-

HP Qualification unit (Indonesia) Lucius (GoM)

< 8 barg, 1000 180 barg 65 barg / 60 250 barg / 300

Am3/hr, 70 m3/hr Liq MMSCFD, 400 BLPD* MMSCFD, 4000 BLPD
Used as test unit at Used as qualification Operational since Delivery Q2 2013
ProlabNL unit at Southwest Aug 2012, good Start-up 2014
Research Institute performance,
2nd unit ordered 24
TwinLine Compact Degasser
Liquid levels displayed

Robust inline 2-stage

degasser
Up to 60% GVF
Further testing under
real conditions, HP

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MonoLine Compact Desander (HiGVF)

Real multiphase inline desanding

Ongoing multi-phase development and
qualification at full range of gas
volume fractions (up to 98% GVF)

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Compact Applications & Solutions

SUBSEA PROCESSING

RETROFITS AND DEBOTTLENECKING

COMPACT TOPSIDES SKIDS 27

 SOLUTIONS & SERVICES

Vessel-based Compact Studies &

Separation Separation Testing
Internals Technologies

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ASCOM Conceptual Solutions

• Inlet separator design for heavy oil facility FPSO

• Produced water treatment facilities and testing
Concept/FEED for heavy oil FPSO
• Compact 3 phase separation unit for well testing
• Compact subsea processing systems

• UltraCompact skid for extension of operational

Debottlenecking window FPSO
and production • FWKO and separation facilities analysis and site
boosting survey
• TVP vessel
Case studies will give details...

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 ASCOM Testing Partner Facilities

Natural
Gas

Crude
Oil

Water

Sand Fast access to test and verify performance of ASCOM technology in world class
test facilities.
90 barg, 100 deg.C, 13 API crude and lighter
22,600 BOPD + 22,600 BWPD – 2,400 Am3/hr (natural gas)
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 CASE
STUDIES
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Case Studies

EXXONMOBIL/Malaysia – separation internals for HP vessels

EXXONMOBIL/USA – HP testing of TwinLine gas/liquid separator

STATOIL/Norway – Flare KO drum design including CFD verification

PETROFAC/Malaysia – Performance verification for FPSO-based

separator internals

SAUDI ARAMCO/Saudi Arabia – Performance field trial for HiPer

MixedFlow Hydrocyclones in produced water treatment upgrade

Total/Congo – Glycol Contactor Inlet Scrubber revamp

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Case Studies / ExxonMobil - 1

• Tapis EOR & Rejuvenation Project (Malaysia) : design and supply of

separation internals for HP scrubbers and separators

• Internals include :
• HiPer Vane Diffuser
• HiPer Vane Pack Mist Eliminator
• HiPer Cyclone Mist Eliminator
• HiPer Distribution Baffles 35
Case Studies / ExxonMobil - 2

• HP testing and qualification of TwinLine Gas/Liquid Separator

• 2-stage design for added robustness
• Increased slug handling capability
• Tested and qualified up to 180 bar,
including subsea application

SCRUBBER

• High liquid rate removal and separation efficiency even during turn-down operations
• Design being considered on upcoming projects
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Case Studies / Statoil

• Gudrun (Norway) : HP Flare KO Drum design (1/2)

• Piping routing results in severe gas mal distribution to one side

• Division plate forces gas flow to split evenly
• High gas velocities at the wall, liquid surface protection needed
• 400 micron droplets to be separated

Inlet piping to N14

Inlet piping to N1

N2

Liquid Surface
HiPer Vane
Diffusers

HiPer Liquid Surface Protection Baffles

37
Case Studies / Statoil

• Gudrun (Norway) : HP Flare KO Drum design (2/2)

Without (L) and With (R) Splitter Plate

400 micron particles settling: N1 (L) and N14 (R) 38

Case Studies / Petrofac Production

Performance verification for FPSO-based separators

• Design and supply of separator and
scrubber internals, both for new and
existing vessels (retrofit) for FPSO
• CFD verification of wave dampening
• Mechanical stress verification
• Similar work ongoing for several other
FPSOs (retrofits)

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Case Studies / Saudi Aramco

Performance field trial for HiPer MixedFlow Hydrocyclones in produced

water treatment upgrade
Existing client solution
• >160 ppm OiW in gravity settling
• Long residence time

ASCOM Solution:
• < 20 ppm oil-in-water achieved
• Design qualified for major PWT upgrade
projects in planning (> 600.OOO BWPD)
• Replace settling tanks
• OR
• Downstream treatment 40
Case Studies / Total

• Nkossa (Congo) : Glycol Contactor Inlet Scrubber revamp (1/2)

• Existing internals (4-bank vane pack, inlet

baffle) not providing sufficient HC liquid
removal, resulting in poor performance of
downstream glycol contactor not meeting dew
point + additional knock-on effects
• Challenging operating conditions :
• High pressure (> 80 bar)
• High liquid loading

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Case Studies / Total

• Nkossa (Congo) : Glycol Contactor Inlet Scrubber revamp (2/2)

ASCOM retrofit design with HiPer separation internals
for performance upgrade

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Thank you for your attention.

Q&A?

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