ANSYS > Case Studies > Optimizing Offshore Oil Separation with IoT: A Case Study on Natco Group, Inc.

Optimizing Offshore Oil Separation with IoT: A Case Study on Natco Group, Inc.

Technology Category

Sensors - Gas Sensors
Sensors - Utility Meters

Applicable Industries

Chemicals
Oil & Gas

Applicable Functions

Product Research & Development
Quality Assurance

Use Cases

Intelligent Urban Water Supply Management
Leakage & Flood Monitoring

Services

System Integration
Testing & Certification

About The Customer

NATCO Group, Inc. is a leading provider of wellhead process equipment, systems, and services used in the production of oil and gas. With over 75 years of experience in designing and manufacturing production equipment, the company has established a strong presence both onshore and offshore in most major oil and gas producing regions of the world. Their commitment to innovation and efficiency is evident in their continuous efforts to optimize their services and products, such as the induced gas flotation (IGF) system, to meet the growing demands of the industry.

The Challenge

As the demand for offshore oil field services continues to rise, NATCO Group, Inc. was faced with the challenge of optimizing the performance of its induced gas flotation (IGF) system for customers producing oil on offshore platforms. The IGF system, which uses gas bubbles to trap oil and solids for separation from wastewater, was not as effective in vertical water treatment vessels due to their limited deck space and weight restrictions. These vertical systems often caused uneven distribution of gas bubbles, making the separation process less efficient. Furthermore, traditional physical testing methods to improve the system were costly, time-consuming, and lacked clear insight into why a design was or wasn't working.

The Solution

To overcome these challenges, NATCO's engineers turned to Fluent CFD software. This allowed them to simulate the performance of several initial design concepts before moving to the prototype stage, saving both time and resources. The software verified that the initial design required significant improvement, leading the team to evaluate a number of design variations. After modifying hardware designs for physical testing, they ultimately developed a new design based on the simulation results. This innovative approach not only improved the efficiency of the IGF system but also validated the accuracy of the ANSYS simulation results when the platforms and pumps successfully withstood the loading of mechanical equipment without excessive vibration at key locations during Category 2 Hurricane Gustav in 2008.

Operational Impact

The use of Fluent CFD software not only improved the efficiency of the IGF system but also provided valuable insights into the design process. This allowed NATCO to develop a more effective solution that could withstand the harsh conditions of offshore platforms, including the impact of a Category 2 hurricane. The new design also minimized the use of treating chemicals, reducing both operating costs and environmental impact. Furthermore, the success of this project validated the accuracy of the ANSYS simulation results, demonstrating the potential of such technology in optimizing oil and gas production processes.

Quantitative Benefit

The new design exceeded EPA standards by as much as 45 percent.
The use of simulation software reduced the costs associated with physical testing methods.
The optimized IGF system minimized the use of treating chemicals, reducing operating costs.