Over the last 60 years, Costacurta has gained high level expertise in the optimisation of separation processes, thanks to its experience in the design and manufacturing of gas-liquid and liquid-liquid separation internals. Costacurta’s Separation Technologies Department offers this expertise to its clients by providing Engineering Services during the design of new plants or the operation of existing ones.
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CFD simulations
Within the context of separation technologies, Costacurta, using Computational Fluid Dynamics, can support its clients in controlling the behaviour of the internals previously chosen or identify the best separation solution in terms of internals and positioning inside the vessel, based on the specific operating conditions or on the fluid dynamic behaviour of the gas and liquid phases in the vessel.
Feasibility studies
Costacurta’s Separation Technologies department can carry out feasibility studies during the design stage of new plants or during the revamping of existing equipment, when it is necessary to study specifications that guarantee the required performances, adapting to any imposed restrictions.
Typically, Costacurta, bearing in mind the operating conditions and layout of the plant, and using its design tools, identifies the best combination of internals able to optimise both the separation performances and the overall size of the vessel, supported, if necessary, also by fluid-dynamics controls using CFD. Mechanical engineering, where necessary, is controlled by means of finite elements analysis (FEA).
Troubleshooting
During normal plant operations bottlenecks or malfunctions may occur that reduce the efficiency of the various processes, limiting the overall productivity of the plant. Using its experience and tools, as well as CFD simulations, Costacurta’s Separation Technologies department can analyse the specific separation problems and propose suitable solutions. Bearing in mind the operating conditions and layout of the internals in the existing separator, Costacurta is able to identify the best combination of internals to prevent bottlenecks or increase the flow rates that can be managed by the separator, maintaining the required performance levels.
Moreover, when the internals are subject to high mechanical stress or have complex geometries, Costacurta can verify the mechanical engineering using finite elements analysis (FEM or FEA).
On field assistance
Costacurta’s experienced engineers, qualified to work on oil rigs, can offer its clients on field assistance.
During surveys, both onshore and offshore, our specialists can identify the actual operating conditions of the plant and the cause of any malfunctioning of separators, gathering the information needed to be able to propose solutions to specific problems and, where necessary, supporting the operators in the analysis of the data and the performance of activities to solve problems on the plant.
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