Photo (Statfjord A): Statoil, O

yvind Hagen

Produced WaterSeparation Systems

Produced WaterProduced water handling is a key challenge at most production facilities. It can be a crucial factor limiting the production of oil and gas. If the discharge requirements are not met, there may be a significant environmental and economic impact. Furthermore, produced water can take up valuable space in the oil transport lines, reducing the amount of oil that can be produced and transported.

Produced Water SolutionsThe produced water solutions include all technologies required to separate water from the well-stream and to deliver clean water that can either be discharged to sea or re-injected back to the reservoir:

� Separator vessel internals � InLine separation � Sand handling � Hydrocyclones � Compact Floatation Units � Chemical treatment technologies � Absorption technologies

FMC’s Separation Systems

� Innovative separation solutions for oil and gas production

� Proven technology with successful operational experience

� Only company with proven InLine separation track record

� Subsea experience from the industry’s most challenging projects

The need to handle produced water efficiently

� Oil cannot be produced without the capability to handle produced water

� Oil which has not been separated from produced water equals oil not produced

� Water re-injection may be needed for reservoir pressure maintenance, in order to maintain or increase production

� Excessive oil or sand concentrations in re-injected water may lead to well damage

� Environmental regulations and fines are imposed if the permitted oil concentration in water discharged overboard is exceeded

Oil PPM

Water TreatmentBulk Separation

Separator Internals & InLine Separation

Sand Jetting SystemInLine DeSander InLine HydroCyclone

Sand Handling

Bulk Separation

Separation Internals

Our high performance internals maximize the capacity and increase the efficiency of a separator vessel to make it perform at its best. Troubleshooting and debottlenecking of separation processes by use of these internals increase the throughput and efficiency of existing production trains. New built vessels can be reduced in size compared to conventional separators. The results are performance improvement, problem-free operation, reduction in capital and operational expenditure, and increase in profits. We have provided solutions for more than 1400 separators world-wide.

Inlet devices

CDS Inlet Cyclone™Evenflow HE

Gravity separation

CDS Drained Meshpad Agglomerator™Distribution BafflesPlate Pack Coalescers

Sand Removal

Sand Jetting System

Demisting devices

Mesh Pad Demister Vane Pack CDS Spiraflow™CDS Gasunie™ Cyclone Scrubber

Separation Internals Portfolio

Gas-liquid InLine DeGasserInLine DeLiquidiserInLine DeMisterInLine PhaseSplitter

Liquid-liquid InLine DeWatererInLine ElectroCoalescerInline HydroCyclone

Solids InLine DeSander

Controls InLine Controls

InLine Technology Portfolio

InLine Technology

We have developed a line of highly efficient compact separation equipment based on cyclonic and electrostatic technologies that covers all aspects of primary separation. Together they allow operators to achieve complete phase separation by using pipe segments. The equipment can be combined to suit all conditions and separation requirements.

down to <1 ppm oil in water

Chemical Treatment CFU Polishing

Sorbsep™ SorbPol®Sorbfloc®

Sand HandlingOur sand handling technologies can be applied in various locations through the process plant and are in some cases key components of the produced water treatment systems. Both technologies have undergone successful qualification programs for topside as well as subsea applications:

Sand jetting and removal technology is an efficient way of removing solids from production separators:

� Combines sand fluidization and sand transportation

� Robust system – free of clogging � Operates with minimum water

InLine DeSander allows for highly-efficient separation of small solid particles, as well as bulk separation of coarse solid particles.

� Can be used for multiphase, water and gas streams

� Protects of process equipment against erosion � Prepares produced water to re-injection criteria

The InLine DeSander is the first of its kind in the world to be installed subsea, at the Petrobras Marlim Subsea Separation System.

Retrofit the existing separator. Install an InLine DeLiquidiser upstream. Our solution increased oil production capacity by 10 per cent.

Compact three phase separation system based on use of InLine technology

InLine HPPhaseSplitter

CyclonicL/L Separator

Slug CatcherGravity Separator

InLine LPPhase-Splitter

Conventional gravity separator

InLine DeWaterer

Size comparison, gravity vs. cyclonic liquid-liquid separation

Application Examples - Bulk Separation

By combining InLine and vessel separation solutions we achieve a compact integrated system with all features of a three phase separation train.

The InLine DeWaterer allows for more compact new build systems and can also easily be retrofitted in existing facilities to increase the water handling capacity.

InLine DeSander

InLine HydroCylone

The InLine HydroCyclone is a solution for produced water applications based on a unique axial flow design:

� High separation efficiency � Low pressure-drop � Low differential pressure-drop ratio � Erosion resistant � Resistant to clogging � Suitable for installation in existing

hydrocyclone vessels.

A successful performance optimization project that was completed in 2009, delivered a significant performance enhancement compared to conventional hydrocyclone technology offered in the market. This resulted in a novel design that can be fitted into standard vessels as used by most operators.

Approximately 50% outlet OiW concentration reduction compared to previous designs. Performance was improved at all droplet sizes and under all inlet conditions.

Erosion test: A view inside the InLine HydroCyclone liner after 2.5 years of simulated field wear reveals no impact of wear.

Sand Tolerance Qualification Project

Erosion of produced water handling equipment is always an important issue. Cyclonic technology requires high velocities which could potentially lead to erosion by sand and failure of the produced water treatment system. When FMC Technologies started the qualification program of the water treatment system for the Marlim Subsea Separation System, special means were taken to ensure long term safe operation without risk of failure due to erosion. A successful qualification program was carried out to demonstrate sand handling tolerance and to ensure that this technology is fit for the purpose of this challenging application. The tests demonstrated that the water treatment system had excellent sand tolerance, and this technology is now being manufactured.

Performance Optimization > Significant performance enhancement

The world’s first subsea application of an InLine HydroCyclone, will be at the Petrobras Marlim field.

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Increased shear applied on oil droplets

Fixed inlet OiW

Industry sta

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New design

Marlim Subsea Separation System

The Petrobras Marlim Project is the world’s first system for deepwater subsea separation of heavy oil and water that includes water reinjection to boost production in a mature field development.

Marlim is the most complex subsea processing project carried out to date. The water is separated from the well-stream and re-injected back to the reservoir. This is the first application where the produced water is used for pressure maintenance of the reservoir as part of the subsea separation operation and it is also the first subsea heavy oil application. The system includes a PipeSeparator, separating the water from the well stream and a water treatment system using InLine HydroCyclones. The sand handling system includes a multiphase InLine

DeSander at the inlet of the separation system to protect the downstream equipment and avoid sand accumulation. It also contains a dual redundant Sand Jetting System in the outlet section of the PipeSeparator, and an InLine DeSander for removing the smallest particles in the water stream from the separator to protect the re-injection well and reservoir. The separated sand is taken with the oil to the topside facility.All the separation and sand handling equipment has been tested as part of the technology qualification program and was installed in Q4 2011.

Tordis Subsea Separation Boosting and InjectionTordis is recognized as one of the most important breakthrough technology milestones for subsea in recent years.

The vessel includes a sand removal system operated by high-pressure water from the water injection pump. The removed sand is conveyed in batches to a desander and sand accumulator vessel. The accumulated sand is pressurized and goes to the discharge side of the water injection pump to protect the pump from erosion. All the separated sand is injected with the water, avoiding sand handling requirements at the topside facility.The Tordis system was qualified through a Subsea Separation and Sand Handling System Qualification Program at FMC’s facilities in The Netherlands.

FMC Technologies delivered a subsea separation boosting and injection system for the Tordis field in the North Sea in 2007. The system was installed to enhance oil recovery from the field and to enable increased production. The subsea processing system solved both water and sand handling capacity problems at the topside platform. The Tordis system combines water and sand separation with a re-injection system. The water and sand are separated from the well-stream in a patented semi-compact separator vessel, where the sand separates and accumulates at the bottom.

Darkfield micrograph of oil droplets captured by Sorbfloc®

SorbFloc® – Green technology for clean water to even the most challenging applications

Produced water consists of very small droplets of oil that are difficult to separate. Consequently, many production processes suffer from unacceptably high oil content in the discharged water.

Sorbfloc® is a product made from alginate and seaweed. It is completely green, even used in food products. The chemical enables any particles to be collected and agglomerated such that the droplets and particles easily can be separated from the produced water.

The Sorbfloc® is added to the produced water upstream of an oil removal separator such as a Compact Floatation Unit, hydrocyclone or other water treatment equipment. The technology enables separation of submicron oil droplets and other particles from produced water.

Our water treatment solutions are based on in-house technologies as well as technology offered through a partnership with Sorbwater AS. Together, FMC Technologies and Sorbwater have a combined product portfolio that can solve any produced water challenge.

Final Stage Water Treatment Technologies

Injecting Sorbfloc® into the water stream brings the hydrocolloid chains in physical contact with oil droplets or suspended solids. Then, larger flocculates are formed that can be easily separated. Reaction time is just a few seconds.

ZERODischarge Solutions

SorbSep™ – Second Generation Compact Floatation Unit

Compact Floatation Units (CFU) are high-efficiency produced water treatment technologies well known for the capability to separate oil droplets from water, easy operability and high robustness.

Sorbsep™ is a combined flotation cyclone, stripping and coalescing device utilizing all these effects to separate hydrocarbons from water. Unlike similar devices, Sorbsep™ is designed especially to capture the smallest droplets which normally avoid such separation. This is a new, but proven technology that has successfully been tested at several offshore fields that are known for their challenging chemical characteristics.

SorbSep™ installed on a platform

SorbPol®– Meeting requirements below 1 ppm oil in water

Some substances are extremely difficult to remove from water. When very strict oil-in-water content is required or when the water chemistry is extreme, a highly-efficient solution is required.

SorbPol® is a polishing reactor where hydrocarbons are absorbed on the surface of the SorbPol® vessel such that all pollutants in the water phase are removed, meeting one hundred per cent zero-discharge requirements.

OFFSHOREInnovation

GREENWater Technology

Statoil qualification of the InLine DeWaterer

3-Phase compact separation skid Al Huwaisah (PDO)

� Compact remote produced water separation and reinjection skid

� Increase oil production by reducing water in transport line to gathering station

� Capacity 70,000 bbl/day of water � Water injection quality < 80 ppm oiw

Our skid replaced an installation in the desert of 135 T. and 12x20x10 m. (LxWxH). It weighs 24 T. and measures 5x6x10 meters.

Integrated InLine System Shell PDO Al-Huwaisah, Oman

InLine DeGasser

InLine DeWaterer

Booster pump

InLine DeWaterer

The InLine DeWaterer has been tested over several periods at Statoil’s advanced High Pressure, Live Hydrocarbon test loop in Porsgrunn, Norway and through offshore field testing at the Gullfaks platform in the North Sea. The results of these qualification tests demonstrated that Statoil’s performance requirements were met and even exceeded. FMC is continuously working with Statoil to develop this solution to meet their compact oil-water needs for various applications.

Photo (Gullfaks C): Statoil,O

yvind Hagen

InLine three-phase separation

The Integrated InLine System for the Brazilian national oil company Petrobras is a skid for complete three phase oil, gas and water separation. The system consists of, a CDS Gasunie™, InLine DeWaterer and improved InLine HydroCyclones. The system has been tested with very successful results in Brazil demonstrating the capability of both the individual separation components and the total system. It will be used further at various fields in operation in Brazil to identify how use of InLine technologies can increase effectiveness of the production process.Design conditions:

� Heavy Oil (°API 19) � Liquid: Max. 6,000 bbl/day � Gas: 5,000 Sm3/hr � Outlet OiW < 200 ppm

Other Separation Systems Solutions

� Production Improvements � Compact Total Separation Systems � Heavy Oil production � Efficiency Improvement and

Troubleshooting � Solids Handling

Test skids for produced water handling

Defining solutions for produced water handling challenges requires predictions of how certain technologies will perform on the installation. An indication of the suitability of a certain technology can be obtained from laboratory tests, but often it will be required to test at the actual field to verify the performance at real operating conditions.

For that reason we provide test skids that can be connected to a slipstream of the produced water stream that needs to be treated. In this way we be obtain an accurate indication of the efficiency that our technical solution will have in the production plant which again ensures that the equipment will work successfully when it is finally installed.

We have the following test skids available:

� InLine DeWaterer � InLine DeSander � InLine HydroCyclone � Sorbsep™ Compact Floatation Unit � Sorbfloc® Chemical Injection � SorbPol® Water Polishing Unit

The InLine- DeGasser, DeSander, PhaseSplitter, DeWaterer and DeLiquidiser are patented by Statoil and FMC has exclusive worldwide license to sell this technology.

Three-phase separation test skid made for Petrobras

www.fmctechnologies.com/separation

FMC TechnologiesSeparation SystemsDelta 1016825 MN ArnhemThe NetherlandsPhone: +31 (0)26 7999100

FMC Technologies1777 Gears RoadHouston TX 77067USAPhone: +1 281 591 4000

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C Technologies