Horizontal Liquid/Gas Separation Device and Separation Method, Intended in Particular for the Liquid and Gas Phases of Crude Oil

• US 20100212492A1
• Filed: 09/24/2008
• Published: 08/26/2010
• Est. Priority Date: 10/09/2007
• Status: Active Grant

• Current Assignee: Saipem SA (Saipem)
• Original Assignee: Saipem SA (Saipem)
• Inventors: Chiarotti, Massimo, Miotto, Giorgio
• Granted Patent: US 8,273,151 B2
• Time in Patent Office: Days
• US Class Current: 95/22
• CPC Class Codes: B01D 19/0036 Flash degasification the other groups take precedence
• CPC Class Codes: B01D 19/0042 modifying the liquid flow B01D19/0021 takes precedence
• CPC Class Codes: E21B 43/36 Underwater separating arrangements E21B43/38 takes precedence

Abstract

A liquid/gas separator device for separating liquid and gaseous phases of a fluid, in particular crude oil, the device comprising a network of first and second separator pipes disposed horizontally, said first and second separator pipes being connected together by vertical link third pipes. The first separator pipes are fed from and connected upstream to a horizontal cylindrical diffuser and are connected downstream to a first horizontal cylindrical manifold. The second separator pipes are connected upstream to the same diffuser and downstream to a second horizontal cylindrical manifold.

Claims

1-18. -18. (canceled)

19. An undersea liquid/gas separator device for separating liquid and gaseous phases of a fluid, in particular liquid and gaseous phases of crude oil, wherein the device comprises a structure resting on the sea bottom and supporting:

a) at least one and preferably a plurality of first separator pipes extending from a horizontally-extending cylindrical first tank of elongate shape and circular section, the first separator pipes being connected thereto at their upstream ends, said first tank preferably being of diameter greater than the diameter of said first separator pipes, said first separator pipes being inclined at an angle α

lying in the range 1°

to 5°

relative to the horizontal with a gentle downward slope from said first tank towards a substantially horizontal first cylindrical manifold to which said first pipes are connected downstream, said first diffuser tank being fed by at least one fluid feed pipe, and said first manifold being connected to a first liquid evacuation pipe of downward slope, and preferably including downstream an export pump suitable for drawing said degassed liquid from said first manifold;

b) at least one and preferably a plurality of second separator pipes disposed above said first pipes from and above said first tank with a gentle rising slope from said first tank towards a substantially horizontal second cylindrical manifold, said second separator pipes being inclined relative to the horizontal at an angle β

greater than α

, preferably less than 10°

, said second manifold preferably being of diameter greater than the diameter of said second pipes and smaller than the diameter of said first tank, said second manifold being connected to a first gas evacuation pipe;

c) a plurality of vertical link third pipes between each said first separator pipe and each said second separator pipe; and

d) a system of preferably hydraulic actuators enabling the inclination of said first and second separator pipes to be adjusted accurately and enabling said first tank and said first and second manifolds to be positioned horizontally.

20. The device according to claim 19, wherein said first gas evacuation pipe slopes upwards from said second manifold to the end of a second gas evacuation pipe, said first gas evacuation pipe being inclined at an angle γ

that is greater than α

, and preferably less than 10°

.

21. The device according to claim 19, wherein said second separator pipes are connected upstream to said first tank via a respective plurality of second link pipes of slope that is greater than the slope of said second separator pipes and that is preferably substantially vertical.

22. The device according to claim 19, wherein said first tank and said first and second manifolds are substantially parallel, and said first and second separator pipes extend substantially in the same direction that is substantially perpendicular to the longitudinal direction of said first tank and said first and second manifolds.

23. The device according to claim 19, including flow rate control devices downstream from said first tank at the upstream ends of said first separator pipes, said devices controlling the flow rate of fluid transfer by head loss, preferably being of the cyclone type having tangential inlets substantially perpendicular to the axial direction of said first separator pipes, and axial outlets substantially on the axis of said first pipes.

24. The device according to claim 19, wherein the device comprises a structure constituted by a frame of beams supporting said first and second pipes, said first tank, and said first and second manifolds, said structure comprising:

at least a first vertical pillar having a first frame at its bottom end, the first frame supporting portions of automatic connectors connected to said fluid feed pipe, to said first fluid evacuation pipe, and to said second gas evacuation pipe, said frame being suitable for co-operating in fastening with and on a first base anchored to the sea bottom; and

at least two second vertical pillars each fitted at its bottom end with a preferably hydraulic actuator, the at least two actuators being suitable for co-operating with second bases anchored to the sea bottom and supporting them, said second pillars being disposed in such a manner as to enable the inclination of said first and second separator pipes and of said first gas evacuation pipe to be adjusted and varied by actuating said actuators.

25. The device according to claim 19, that is installed at the sea bottom and includes a fluid delivery pipe providing a connection between at least one head of an oil well and said fluid feed pipe connected to said first tank at its other end, and including a pressure-reducer device and preferably a fluid flow rate control valve upstream from said delivery pipe for said fluid.

26. The device according to claim 24 that is installed at the sea bottom, that includes a fluid delivery pipe providing a connection between at least one head of an oil well and said fluid feed pipe connected to said first tank at its other end, and including a pressure-reducer device and preferably a fluid flow rate control valve upstream from said delivery pipe for said fluid, and that is connected to a first base anchored to the sea bottom, said first base preferably being anchored to the sea bottom by a first suction anchor, said first base supporting a series of male or female portions of automatic connectors respectively at the ends of said first fluid delivery pipe, of a second degassed liquid evacuation pipe, and of a third gas evacuation pipe, co-operating with the complementary female or male portions respectively of the automatic connectors connected to said second fluid feed pipe, to said first liquid evacuation pipe, and to said gas evacuation pipe.

27. The device according to claim 23, wherein said second fluid evacuation pipe co-operates with a said export pump inserted in a well buried in the sea bottom beside said suction anchor of said first base, said pump preferably being installed several meters below said first base, more preferably said well being secured to said suction anchor in order to be evacuated to the surface.

28. The device according to claim 19, wherein said first tank, said first and second manifolds, and said first, second, and third pipes are thermally insulated by a common rigid thermal-insulation enclosure filled with sea water and in communication with the sea via at least one communication orifice, preferably including a heater device for heating sea water inside the enclosure, said communication orifice and said heater device more preferably being situated in the bottom portion of the enclosure.

29. The device according to claim 19, comprising:

pluralities of 3 to 20 and preferably 4 to 12 of said first and second separator pipes and respectively of said link third telemeters, the number of said first separator pipes preferably being greater than or equal to the number of said second separator pipes; and

a single said fluid feed pipe, a single said first liquid evacuation pipe, and a single said first gas evacuation pipe.

34. The method according to claim 29, wherein said separator device is installed on the sea bottom at a depth lying in the range 100 m to 4000 m, and a pressure P2 lying in the range 10 bars to 50 bars, and preferably equal to 20 bars within said first tank and said first and second manifolds and said first and second separator pipes and said link third pipes by lowering the pressure by means of a pressure-reducer device co-operating with said crude fluid delivery pipe upstream from said first tank.

30. A method of separating liquid and gaseous phases of a fluid using a structure resting on the sea bottom and supporting

a) at least one and preferably a plurality of first separator pipes extending from a horizontally-extending cylindrical first tank of elongate shape and circular section, the first separator pipes being connected thereto at their upstream ends, said first tank preferably being of diameter greater than the diameter of said first separator pipes, said first separator pipes being inclined at an angle α

lying in the range 1°

to 5°

relative to the horizontal with a gentle downward slope from said first tank towards a substantially horizontal first cylindrical manifold to which said first pipes are connected downstream, said first diffuser tank being fed by at least one fluid feed pipe, and said first manifold being connected to a first liquid evacuation pipe of downward slope, and preferably including downstream an export pump suitable for drawing said degassed liquid from said first manifold;

b) at least one and preferably a plurality of second separator pipes disposed above said first pipes from and above said first tank with a gentle rising slope from said first tank towards a substantially horizontal second cylindrical manifold, said second separator pipes being inclined relative to the horizontal at an angle β

greater than α

, preferably less than 10°

, said second manifold preferably being of diameter greater than the diameter of said second pipes and smaller than the diameter of said first tank, said second manifold being connected to a first gas evacuation pipe;

c) a plurality of vertical link third pipes between each said first separator pipe and each said second separator pipe; and

d) a system of preferably hydraulic actuators enabling the inclination of said first and second separator pipes to be adjusted accurately and enabling said first tank and said first and second manifolds to be positioned horizontally;

wherein the following steps are performed;

1) sending the fluid, preferably crude oil, via a fluid feed pipe to said first tank;

2) allowing the at least partially degassed liquid to flow from said first tank via said first separator pipe in order to be further degassed and to move down towards said first manifold, and then to said first liquid evacuation pipe;

3) allowing the gaseous phase, possibly still containing liquid, to rise and flow via said second separator pipes towards said second manifold, and then towards said first gas evacuation pipe in order to allow additional separation of any residual liquid contained in the gaseous phase prior to being evacuated via said second evacuation pipe;

4) allowing the gas phase from the first separator pipe to rise through said vertical link third pipes and flow via said second separator pipes towards said second manifold and then towards said first and second gas evacuation pipes;

5) allowing the liquid coming from gas separation in said second separator pipes, said second manifold, and said first gas evacuation pipe to flow towards said first manifold, where appropriate by passing via said first tank or said vertical link third pipes prior to rejoining said first liquid evacuation pipe;

6) recovering the substantially degassed liquid phase from the bottom end of said first liquid evacuation pipe and taking it via a said second liquid evacuation pipe that is taken to the surface or sent to a liquid separator device in order to separate the different liquids possibly contained therein, preferably in order to separate the water and the oil of degassed oil, and where appropriate any remaining gas still present in imperfectly degassed crude oil; and

7) recovering the gas phase substantially separated from said liquid from the bottom end of said second gas evacuation pipe and preferably sending it to the surface or into a well for injecting gas into the sea bottom via a said third gas evacuation pipe.

31. The method according to claim 30, wherein said crude oil is sent at the bottom end of said first tank at a reduced pressure P1, less than the static pressure P2 at the sea bottom, preferably such that the pressure difference Δ

P=P1−

P0, where P0 is the pressure at the surface, is greater than the head losses in the second gas evacuation pipes from the sea bottom to the surface.

32. The method according to claim 30, wherein the liquid of the degassed fluid is exported from the sea bottom to the surface with the help of a said export pump.

33. The method according to claim 30, wherein the delivery flow rate of the crude fluid is controlled upstream from said first tank by said flow rate control valve, and/or the evacuation flow rate of the degassed fluid is controlled downstream from said first manifold by the speed of said export pump as a function of measurements from at least one device for monitoring the level of the fluid within at least said first manifold.

35. A method of placing a separator device on the sea bottom, the device for separating liquid and gaseous phases of a fluid, in particular liquid and gaseous phases of crude oil, wherein the device comprises a structure resting on the sea bottom and supporting:

a) at least one and preferably a plurality of first separator pipes extending from a horizontally-extending cylindrical first tank of elongate shape and circular section, the first separator pipes being connected thereto at their upstream ends, said first tank preferably being of diameter greater than the diameter of said first separator pipes, said first separator pipes being inclined at an angle α

lying in the range 1°

to 5°

relative to the horizontal with a gentle downward slope from said first tank towards a substantially horizontal first cylindrical manifold to which said first pipes are connected downstream, said first diffuser tank being fed by at least one fluid feed pipe, and said first manifold being connected to a first liquid evacuation pipe of downward slope, and preferably including downstream an export pump suitable for drawing said degassed liquid from said first manifold;

b) at least one and preferably a plurality of second separator pipes disposed above said first pipes from and above said first tank with a gentle rising slope from said first tank towards a substantially horizontal second cylindrical manifold, said second separator pipes being inclined relative to the horizontal at an angle β

greater than α

, preferably less than 10°

, said second manifold preferably being of diameter greater than the diameter of said second pipes and smaller than the diameter of said first tank, said second manifold being connected to a first gas evacuation pipe;

c) a plurality of vertical link third pipes between each said first separator pipe and each said second separator pipe; and

d) a system of preferably hydraulic actuators enabling the inclination of said first and second separator pipes to be adjusted accurately and enabling said first tank and said first and second manifolds to be positioned horizontally;

wherein the following steps are performed;

1) lowering a said separator device from the surface and placing it on the sea bottom; and

2) adjusting the horizontality of said first tank and of said first and second manifolds, and the inclination of said first and second separator pipes by actuating said system of actuators.

36. The method according to claim 35, wherein the device comprises a structure constituted by a frame of beams supporting said first and second pipes, said first tank, and said first and second manifolds, said structure comprising:

at least a first vertical pillar having a first frame at its bottom end, the first frame supporting portions of automatic connectors connected to said fluid feed pipe, to said first fluid evacuation pipe, and to said second gas evacuation pipe, said frame being suitable for co-operating in fastening with and on a first base anchored to the sea bottom; and

at least two second vertical pillars each fitted at its bottom end with a preferably hydraulic actuator, the at least two actuators being suitable for co-operating with second bases anchored to the sea bottom and supporting them, said second pillars being disposed in such a manner as to enable the inclination of said first and second separator pipes and of said first gas evacuation pipe to be adjusted and varied by actuating said actuators; and

wherein the following steps are performed;

a) said separator device is lowered from the surface and placed on three bases constituted by three suction anchors buried in the sea bottom;

then

b) the horizontality of the axes of said first diffuser tank and of said first and second manifolds are adjusted relative to the horizontal by actuating at least one of the actuators by means of an ROV; and

then

c) the inclinations of said first and second separator pipes are adjusted by actuating the rods of two actuators by the same amount in the same direction.