OPUS
Optimized Performance & Upgrade Solutions
An integrated systems approach to process optimization.
OPUS by NOV is our unique and innovative approach to resolving the process challenges of your production facility.
At NOV Process Systems, our analytical approach, deep understanding of fluids behavior, global network of technology experts, unique facilities,
and full project execution centers deliver the best technical, cost-effective, and sustainable solutions with a performance guarantee.
40+ years
of optimizing processes
3,000+
solutions delivered
Spanning from onshore to offshore, upstream to downstream, and fixed platforms to FPSOs.
Understand
Define and Verify
Deliver and Optimize
Sustain
Discover how it works
OPUS by NOV is a four-phased approach to production and processing facility optimization. We work as a specialist extension of your team to address the root cause of your capacity, performance, and reliability challenges.
We identify the source of the challenges through a detailed analysis
of the existing process system. Our team analyzes existing data
or—if necessary—conducts a site visit for a hands-on analysis of the
fluids and process system.
• Data collection
• Site assessment
• Fluids characterization
Case study
Case Study
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Three-phase separator retrofit
The operator needed to debottleneck its separation process to produce an additional tieback well. The original maximum capacity was 75,000 BOPD while the performance was 25% BS&W and 1,000 ppm OiW.
We conducted a detailed assessment of the current process, including the operating philosophy, levels, and chemical injection regime, and analyzed the chemistry of the process fluids.
Phase 1: Understand
Phase 2: Define and Verify
Our processing experts study the data to identify the bottlenecks and define the best options for optimization through a combination of theoretical and physical process modeling. We then test the proposed solutions to verify feasibility and performance at our advanced R&D and testing facilities in Flotta, UK.
• Root cause analysis
• Specialist process and detailed engineering
• Physical modeling
• Computational fluid dynamics
• Finite element analysis
Case study
Case Study
We completed a detailed process review of current and expected process rates and conditions, which led to the design and verification of a retrofit set of internals using CFD.
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Phase 3: Deliver and Optimize
We improve the existing process system, focusing on minimizing CAPEX and optimizing OPEX. If that is insufficient, we will retrofit/upgrade your equipment with advanced internals. New process packages are only considered if necessary. Our global project execution centers and fabrication footprint with large waterfronts ensure superior manufacturing, easy loadout, and timely delivery.
• Hardware fabrication and procurement
• Inspections, pre-commissioning checks
• Start-up and optimization
• On-spec performance
Case study
Case Study
We fabricated, delivered, installed, commissioned,
and optimized the internals.
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Phase 4: Sustain
Our specialists provide full life cycle support services.
• Operations and maintenance support
• Spare parts management
• Digitalization/remote support services
• Process studies for increased production
Case study
Case Study
We saved the operator more than $1 million by not installing a new separator vessel. The post-upgrade capacity increased to 120,000 BOPD while the performance improved to 2.5% BS&W and 200 ppm OiW.
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R&D and Testing Services
Our state-of-the-art R&D and testing facilities in Flotta, UK, provide unmatched, versatile once-through testing services that enable you to develop, optimize, and quantify process technologies under field conditions.
Environmental Services
Field Scale Testing
We can operate near field conditions to test, develop
and validate process technologies at realistic process conditions.
Technology Optimization
We can accurately control and vary all conditions
throughout testing.
Technology Validation
Independent and confidential services to demonstrate and verify the effectiveness of process equipment under controlled conditions.
Oilfield Chemistry Services
Our experienced chemists offer a range of oilfield chemistry services and consultancy.
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Our highly skilled team of scientists and consultants deliver reliable and independent ecotoxicology and environmental services from our laboratories in
Orkney, Scotland.
Environmental Services
We provide definitive support for managing ecological impacts and meeting ever-evolving regulations on issues such as chemical use and fluids discharge.
Environmental Impact
We offer discharge modeling services for oil and gas producing assets to assess the environmental risk using a risk-based approach. These include all wastewater discharges, including solids and chemicals.
Ecotoxicology Services
We supply a full range of aquatic and freshwater toxicity studies for the completion of HOCNF registration submissions to HMCS requirements. Our studies are in accordance with Good Laboratory Practice (GLP) accreditation to OSPAR, OECD, ISO, and ASTM.
Regulatory Support
Our wide-ranging knowledge of environmental legislation allows us to offer services for CHARM, HOCNF completion, REACH, and general ecotoxicology training.
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Crude dehydrator and desalter
An operator in the Middle East wanted to increase a refinery’s capacity by 30%. We visited the site to study the existing vessels, related equipment, and hydraulics. The implemented solution included activities such as CFD analysis, detailed engineering, supply of advanced desalter internals and site support during installation and commissioning. Our innovative approach enhanced performance with lower CAPEX and a reduced footprint.
Case study
Learn more
Separation and produced water treatment
Case study
An operator planned to handle an expected surge in produced water by installing either a bridge-linked platform or cantilever module offshore Malaysia. Our innovative approach revealed that the topsides had issues due to poor design and operation,
so we optimized the separation and water treatment process.
As a result, we improved performance, extended the platform's lifespan, and doubled its capacity without installing any new processing equipment.
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Discover how it works
OPUS by NOV is a four-phased approach to production and processing facility optimization. We work as a specialist extension of your team to address the root cause of your capacity, performance, and reliability challenges.
Click on each phase to learn more.
Sustain
Phase 1: Understand
• Identify root cause of challenges
• Detailed analysis of the existing process
• Site assessment if needed to gather data
• Careful assessment of fluids chemistry
Case study
Learn more
Data Collection
Site Assessment
Fluids Characterization
Phase 2: Define and Verify
Study
Modeling
Design
• Specialist process detailed engineering
• Performance models built on 30 years of process verification and optimization
• Physical modeling
• Computational fluid dynamics (CFD)
• Finite element analysis
Case study
Learn more
Phase 3: Deliver and Optimize
Optimization
Retrofit
Package
Supply
Solutions that minimize CAPEX and optimize OPEX.
In order of priority:
• Optimize the existing process
• Upgrade the existing process equipment
• Design and install new package
Lifecycle
Services
Case study
Phase 4: Sustain
Capacity
Performance
Reliability
• Operations and maintenance support
• Spare parts management
• Digitization/remote support services
• Process studies for increased production
Case study
Learn more
Case Studies
Click on each icon to learn more.
Increase your assets lifespan
Maximize your production
Enhance environmental performance
Separation and Produced Water Treatment
Case Studies
Click on each to learn more.
Production Chemistry
Gas Separation and Processing
Process Debottlenecking/
Optimization
MEG Recovery
FPSO Redeployment/
Life Extension
Harmonized Mandatory Conrol System
Harmonized Offshore Chemical Notification Format
Harmonized Offshore Chemical Notification Format
Chemical Hazard Assessment and Risk Management
Registration, Evaluation, Authorisation and Restriction of Chemicals
Equipment vendors (Phase 3 & 4)
Consultancies (Phase 1 & 2)
Phase 4
Sustain
Phase 3
Deliver & optimize
Phase 2
Define & verify
Phase 1
Understand
NOV expertise for every phase, every project.
Phase 4
Sustain
Phase 3
Deliver & optimize
Phase 2
Define & verify
Phase 1
Understand
OPUS Toolbox
OPUS Toolbox
OPUS Toolbox
OPUS Toolbox
