5.2 Production Facilities PDF

5.
2 Production Facilities
1 Copyright ©2012 NExT. All rights reserved

GENERAL DIAGRAM OF
SURFACE PROCESS
Gas injector Gas Manifold
Well
DRY GAS
C
GAS FOR ARTIFICIAL LIFT
DRY GAS U
Producing RICH GAS LNG
S
Well
Gas Plant
T
OIL + WATER + GAS
Flow O
Station
M
Water injector OIL
Well STEAM WATER OIL E
R
WATER
Water Treatment S
Gathering Separation Treatment Storage Transportation

SURFACE PROCESSES
GATHERING
SEPARATION
TREATMENT

SURFACE PROCESSES
GATHERING
SEPARATION
TREATMENT

Gathering
From the wellhead to the separator

Gathering
To General
Flowline Separator
Wellhead TT
PT
Flow Station

Test line
 To Test Separator, Tank
or MFM

TT
PT
Wells
Gathering System
CONVENTIONAL PRODUCTION MANIFOLD

Surface Gathering System
Manifold-center gathering system (radial
gathering system)
Wells
Gathering Center
& Flow Station
Production
Manifold
Trunk-line gathering system (axial
gathering system) Gathering Center
Wells & Flow Station
Main trunk line
Well trunk line

Pipelines in series Parallel pipelines

LA LB LC A
B
A B C C
Looped
pipelines
LA LC
A
C
B
Gathering System
NON CONVENTIONAL PRODUCTION MANIFOLD
MULTIPHASE
METER
MULTIPORT
VALVE
PIPELINES

GATHERING SYSTEM
NON CONVENTIONAL PRODUCTION MANIFOLD WITH A

MULTIPORT VALVE
• Easy to maintain
• Inexpensive
• Simplify automation

GATHERING SYSTEM
NON CONVENTIONAL PRODUCTION MANIFOLD WITH A

MULTIPORT VALVE

GATHERING SYSTEM
GATHERING SYSTEM ENDS AT THE FLOW STATION

Phase Separation

Two-phase Oil and Gas Separation
INTRODUCTION
 The produced fluids from the wellhead are a

complex mixture of different compounds of
hydrogen and carbon, generally in presence of
water and solids
 The physical separation of these phases is one of
the basic operations in the processing, and
treatment of oil and gas
 Separator as classified as
Vertical
- Two-phase Horizontal
- Three-phase Vertical
Horizontal

FACTORS AFFECTING SEPARATION
Characteristics of the flow stream will greatly affect the design and operation of a
separator. The following factors must be determined before separator design.
 Gas and liquid flow rates (minimum, average, and peak)
 Operating and design pressure and temperature
 Surging or slugging tendencies of the feed stream
 Physical properties of the fluids such as density and compressibility
 Designed degree of separation (e.g., removing 100% of particles greater than
10 microns)
 Presence of impurities (paraffin, sand, scale, etc.)
 Foaming tendencies of the liquids or gas
 Corrosive tendencies of the liquids or gas

EQUIPMENT DESCRIPTION
Horizontal Separators
PRESSURE CONTROL VALVE
MIST EXTRACTOR
GAS OUT
INLET GRAVITY SETTLING SECTION
GAS-LIQUID INTERFACE
LIQUID COLLECTION SECTION
INLET DIVERTER LIQUID OUT
LEVEL CONTROL VALVE

TWO-PHASE OIL AND GAS
SEPARATION
A. INLET C. DIVERTER E. MIST EXTRACTOR G. DRAINAGE
B. IMPACT ANGLE D. WAVE BREAKER F. GAS OUTLET H. LIQUID OUTLET

SEPARATION
PRESSURE CONTROL VALVE
Vertical Separators
MIST GAS OUT
EXTRACTOR
GRAVITY SETTLING
SECTION
LIQUID-GAS
INLET INTERFACE
INLET DIVERTER
LEVEL CONTROL
VALVE
LIQUID COLLECTION LIQUID OUT

SECTION

SEPARATION
VERTICAL SEPARATORS
STANDARD Mist Extractor
• Removes smallest particles of liquid
• Utilizes collision forces
Primary Separation Section
• Removes the main volume of liquid
INLET • Brakes oil batches and
minimizes
Gravitational Separation Section
turbulencesmall particles of liquid
• Removes
• Efficiency depends on gas-liquid
properties and turbulence.
Liquid Settle Section
• Receives and disposes liquid
• Minimizes turbulence
SEPARATION
VERTICAL VS. HORIZONTAL SELECTION
Uses: Uses:
• Sand, paraffin, or wax production • Large volume of liquid
• Plot space is limited • High-to- medium GOR streams
• Ease of level control is desired • Foaming crudes
• Small flow rates • Three-phase separation
• Very low or very high GOR streams
Advantages:
Advantages: • Cheap than vertical
• More versatile than horizontal • Less diameter for a same gas capacity
• Liquid level control is not critical • Skid mounting and shipping
• Good bottom-drain and clean-out facilities • No counter flow (gas flow does not
• Can handle more sand, mud, paraffin, wax oppose drainage of mist extractor
without plugging • Large liquid surface area for foam
• Less tendency to re-entrainment dispersion generally reduces turbulence
• Full diameter for gas flow at top and oil flow • Large surge volume capacity
at bottom
• Occupies smaller area
SEPARATION
VERTICAL VS. HORIZONTAL SELECTION
Disadvantages: Disadvantages:
• More expensive than horizontal • Only part of shell available for

• Require larger diameter for a pasage of gas
• Given gas capacity, therefore, more • Occupy more space unless “stack”
• Competitive for very low GOR or mounted
• Very high GOR o scrubber application • Lquid-level control is more critical
• More difficult to skid mount and ship • More difficult to clean produced
• More difficult to reach and service sand, mud, wax, paraffin, etc
• Top-mounted instruments and safety
devices

SEPARATION
VESSEL INTERNALS
1) Inlet Diverters
A. Baffle plates
Tangential Baffle
Diverter Baffle
Cone Baffle
SEPARATION
VESSEL INTERNALS
1) Inlet Diverters
B. Centrifugal diverters

SEPARATION
VESSEL INTERNALS
1) Inlet Diverters
B. Centrifugal
diverters

SEPARATION
VESSEL INTERNALS
2) Wave Breakers
Wave
Breakers

SEPARATION
VESSEL INTERNALS
3) Defoaming Plates
Foam at the interface may occur when gas bubbles are liberated
from the liquid. This foam can be stabilized with the addition of
chemicals at the inlet. Many times a more effective solution is to
force the foam to pass through a series of inclined parallel plates
or tubes so as to aid in coalescence of the foam bubbles.

SEPARATION
VESSEL INTERNALS
4) Vortex Breaker

SEPARATION
VESSEL INTERNALS
5) Mist Extractor
Momentum change throws liquid Gas

to outside
Velocity decreased on inside

Gas/Liquid Inlet Coalesced Liquid fall
of turn

SEPARATION
VESSEL INTERNALS
5) Mist Extractor

SEPARATION
VESSEL INTERNALS
5) Mist Extractor

SEPARATION
VESSEL INTERNALS
5) Mist Extractor

TWO-PHASE OIL AND GAS SEPARATION
VESSEL INTERNALS
5) Mist Extractor

CYCLONIC

TWO-PHASE OIL AND GAS SEPARATOR OPERATION

THREE-PHASE OIL AND GAS SEPARATOR OPERATION

THREE-STAGE SEPARATION SCHEME
G
A
2000 PSIA S
HIGH PRESSURE
SEPARATOR
MIDDLE PRESSURE
W 1000 PSIA
SEPARATION
E SEDIMENTS
L
LOW PRESSURE
L SEPARATION
500 PSIA
S
SEDIMENTS 100 PSIA
OIL
SEDIMENTS
WATER

RUTINARY OPERATION OF SEPARATORS
• Check pressure and level control instruments as much as possible.

• Actuated control valves must be frequently checked to assure that
they can open and close .
• Liquid in glass sights must be drained from time to time.
Safety Flare
valve Gas
outlet
Inlet
Liquid
outlet
Drainage

SHUTDOWN OF PHASE SEPARATORS
4. Check that the flare valve

is open 3. Close the gas outlet valve
Safety Flare
valve Gas
outlet
2a. If vessel will be drained, adjust the
control level to drain the separator.
1. Close the inlet
valve
Inlet
Liquid
outlet
2b. If it is not necessary to drain the

Drainage separator, proceed to close the
liquid outlet valve.

STARTING UP OF PHASE SEPARATORS
2. Set operating pressure in the

pressure control
Safety Flare
valve Gas
outlet
6. Adjust the pressure and level controls
until operation is stabilized
Inlet
4. Open the inlet
valve slowly
Liquid outlet
1. Check that the liquid outlet

Drainage valve is closed
3. Deactivate control of low level if
liquid level is below that point 5. When operating level is normal, open the outlet
liquid valve and re-activate the low level control.

POTENTIAL OPERATING PROBLEMS

1) Foamy Crudes
- Mechanical control of liquid is aggravated
- Foam has a large volume-to-weight ratio
- Uncontrolled foam bank
2) Paraffin
- Plugging of coalescing plates and mesh pad mist extractors
2) Sand
- Cutout of valve trim
- Plugging of separator internals
- Accumulation in the bottom of the separator
4) Liquid carryover and Gas Blowy
‐ Free liquid escapes with the gas phase: high liquid level, damage to
vessel internals, foam, improper design, plugged liquid outlets, or higher
flow rates that exceeds the vessel’s design rate
‐ Free gas escapes with the liquid phase: low liquid level, vortexing, or
level control failure

OIL - WATER
SEPARATION

OIL AND WATER SEPARATION
INTRODUCTION
Growth of water layer with

time
% Water in sample
ho
Oil
hw/h
he
Emulsion
h
hw
Water
Time

Horizontal Three Phase PRESSURE CONTROL VALVE
Separator
MIST EXTRACTOR
GAS OUT
INLET
GRAVITY SETTLING SECTION
INLET DIVERTER OIL AND EMULSION
WATER
WATER OUT OIL OUT
LEVEL CONTROL VALVE LEVEL CONTROL VALVE

Horizontal Three Phase Separator: Bucket and Weir
design

Horizontal Three Phase Separator: Bucket and weir design
h = ho [ 1 – (o/  w)]
Where: h = distance below the oil weir, in.
ho = desired oil pad height, in.
 o,  w = oil and water densities, lbm/ft3

Horizontal Three Phase Separator: Free – water
knockout (FWKO)

Horizontal Three Phase Separator:
Operation

Vertical Separators

OIL WEIR
Vertical Separators
LC LC
OIL OIL
OUT OUT
OIL
OIL OIL
LC LC
WATER
WATER WATER WATER
OUT OUT
INTERFACE LEVEL CONTROL

INTERFACE LEVEL CONTROL WITH OIL CHAMBER
Liquid level control schems

EQUIPMENT DESCRIPTION GAS EQUALIZING LINE
Vertical Separators
LC ADJUSTABLE
HEIGHT
OIL
OUT
OIL
LC
WATER
WATER
WATER
OUT
WATER LEG WITH OR WITHOUT OIL CHAMBER
Liquid level control schems

Horizontal vs. Vertical Selection
Process related aspects:
1. Horizontal separators are not as good as vertical separators in
handling solids
2. Horizontal vessels required more plan area to perform the same
separation as vertical vessels
3. Smaller, horizontal vessels can have less liquid surge capacity than
vertical vessels sized for the same steady-state flow rate
Non-process related aspects:
1. The relief valve and some of the controls may be difficult to service
without special ladders and platforms
2. The vessels may have to be removed from a skid for trucking due
to height restrictions

VESSEL INTERNALS
• Most of the vessel internals were discussed. Two common internals not
discussed are coalescing plate and sand jets. It is possible to use
various plate or pipe coalescer designs to aid in the coalescing of oil
droplets in the water and water droplets in the oil
1) Plate Coalescers
Are skim tanks or vessels that use internal plates to improve the gravity
separation process
a) Parallel Plate Interceptor (PPI)
b) Corrugated Plate Interceptor (CPI)
2) Sand Jets and Drains

VESSEL INTERNALS
1) Plate Coalescers
a) Parallel Plate Interceptor (PPI)
Section A-A
Large Droplet Rise to Oil

Collection Surface
Water
Oil Sheet
Coalescing Plate Velocity
Oil
u
Oil Out
o Oil Droplet
 Inlet Water
Water
Out
A

VESSEL INTERNALS
Gas
Out
Gas Out
Adjustable
Oil Out
Adjustable Oil Weir
Water Weir Oil
Flow Distribution
Baffle
Inlet
Water
Out
Drain
Drain

VESSEL INTERNALS

OIL & WATER TREATMENT

CRUDE OIL TREATING SYSTEMS
Removing water from crude oil often requires additional processing

beyond gravitational separation. In selecting a treating system, several
aspect should be considered:
1. Tightness of the emulsion.

2. Specific gravity of the oil and produced water.
3. Corrosiveness of the produced crude oil, water and gas.
4. Scaling tendencies of the produced water.
5. Total volume of fluid to be treated and water percent in the fluid.
6. Paraffin-forming tendencies of the crude oil.
7. Desirable operating pressure for equipment.
Other factors or design considerations:
- Temperature, time, viscosity and vessels’ dimensions

- Laboratory analysis and field experience

EMULSION TREATING THEORY

Forming Emulsions
Two mutually immiscible liquids
An emulsifying agent
Sufficient mechanical energy (agitation)
The difficulty of separating the emulsified water from oil depends on
the stability of the emulsion. The stability of the emulsion depends
on several factors:
1) The difference in density between the water and oil phases.
2) The size of dispersed water particles.
3) Viscosity
4) Interfacial tension
5) The presence and concentration of emulsifying agents
Forming Emulsions
Photomicrograph of normal emulsion Photomicrograph of emulsifying agent Photomicrograph of emulsifying agent

sorrounding a water droplet preventing two droplets from coalescing

Emulsifying Agent
- Preference for the oil
- Preference for the water
An emulsifier tends to be insoluble in one of the liquid phases. The

emulsifying agent’s action can be visualized as one or more of the
following:
1) It decreases the interfacial tension of the water droplet
2) It forms a viscous coating on the droplets that keeps them from
coalescing into larger droplets when they collide
3) They may be polar molecules, which align themselves in such a
manner as to cause an electrical charge on the surface of the
droplets.

Emulsifying Agent Solid stabilizer agent
Emulsified
Water
Droplet
Molecules stabilizer agent


Demulsifiers
There are four important actions required of a demulsifier:
1. Strong attraction to the oil-water interface
2. Flocculation
3. Coalescence
4. Solid wetting
It would be unusual if one chemical structure could produce

all four desirable actions. In selecting a demulsifiers one
should keep in mind:
- Process system
- Bottle tests
- Field tests
GRAVITY SEPARATION
1.78 x 10-6 () Stokes’

ut = d 2 
m Law
Where ut = downward velocity of the water droplet relative to the oil
continuous phase, ft/s
dm = diameter of the water droplet, micron
 = difference in specific gravity between the oil and water
 = dynamic viscosity of the oil continuous phase, cp
Several conclusions can be drawn from Stokes’ Law:
1) The larger the size of a water droplet, the larger the square of its
diameter, and thus, the greater its downward velocity
2) The greater the difference in density between the water droplet and
the oil phase, the greater the downward velocity
3) The higher the temperature, the lower the viscosity of the oil, and
thus the greater the downward velocity.

GRAVITY SEPARATION
Coalescence
d j – (d o) j
t= 
6  Ks
Where do = initial droplet size

d = final droplet size
 = volume fraction of the dispersed phase
Ks = empirical parameter for the particular system
j = an empirical parameter always larger than 3 and
dependent on the probability that the droplets will
bounce apart before coalescence occurs

GRAVITY SEPARATION
Coalescence
When the energy of the oscillations is very low so that bouncing of
droplets approaches zero, j approaches 3. Assuming a value of 4, the
minimum time required to obtain a desired particle diameter can be
expressed.
 d 4 – (do) 4
t= 6  Ks
Assuming do is small relative to the droplet size we wish
to grow by coalescence in our gravity settler, the equation
can be approximated:
d4
t=
2 Ks

GRAVITY SEPARATION
Coalescence
The following qualitative conclusions for coalescence in a gravity settler
can be drawn from this relationship:
1) A doubling of residence time increases the maximum size drop
grown in a gravity settler less than 19 %. If the value of “j” is greater
than 4 the growth in droplet diameter will be even slower.
2) The more dilute de dispersed phase, the greater the residence time
needed to “grow” a given particle size. That is, coalescence occurs
more rapidly in concentrated dispersions. This is the reason that oil
is “water washed” by entering the treating vessel below the oil-water
interface in most gunbarrels and treaters. Floculation and
coalescence therefore occur most effectively at the interface zone
between oil and water
GRAVITY SEPARATION
Viscosity
1) Laboratory tests at various temperatures
2) ASTM D 341
3) Beggs and Robinson Equation
 = 10x – 1
Where:  is the oil viscosity, cp
T = oil temperature, ºF
x = y (T)-1.163
y = 10z
z = 3.0324 – 0.02023 o
o = oil gravity, º API
4) eff / c = 1 + 2.5  + 10 2 (modified Vand’s equation)
Where: eff = effective viscosity, cp
c = viscosity of the continuous phase, cp
 = volume fraction of the disconinuous phase
GRAVITY SEPARATION
Viscosity

GRAVITY SEPARATION
Viscosity
4) The viscosity of the produced water depends on the amount of
dissolved solids in water as well as the temperature, but for most
practical applications it varies from:
1.5 to 2.0 cp at 50 ºF
0.7 to 1.0 cp at 100 ºF
0.4 to 0.6 cp at 150 ºF
When an emulsion of oil and water is formed, the viscosity of the
mixture may be substantially higher than either the viscosity of the oil
or that of the water taken by themselves

GRAVITY SEPARATION
Viscosity

GRAVITY SEPARATION
Temperature Effects
Adding heat to the incoming oil/water stream is the traditional method of
separating the phases.
1. Reduces the viscosity of the oil phase. This results in a more rapid
settling velocity
2. Causes a significant loss of the lower boiling point hydrocarbons
(light ends). This results in a “shrinkage” of the oil
3. Increasing treating temperature also has the disadvantage of making
the crude oil that is recovered in the storage tank heavier and thus
decreasing its value.
4. Increasing the temperature may lower the specific gravity at treater
operating pressure of both the oil and the water. In most cases, if
treating temperature  200 ºF this change can be negleted.
5. The less heat that is used, the better. Economic effect.
GRAVITY SEPARATION
Temperature Effects

GRAVITY SEPARATION
Heat Input Equations
The heat input and thus the fuel required for treating depend on:
- The temperature
- The amount of water in the oil
- The flow rate
It requires about twice as much energy to heat water as it does to heat

oil.
For this reason, it is beneficial to separate any free water from the
emulsion to be treated with either a free-water knockout located
upstream of the treater or an inlet free-water knockout system in the
treater itself.
Q = 16 qo T (0.5 o + 0.1)

GRAVITY SEPARATION
Heat Input Equations

Where: Q = heat input, Btu/hr
qo = oil flow rate, bpod
T = increase in temperature, ºF
o = specific gravity of oil relative to water
And assuming that the free water has been separated from
the emulsion,
the water remaining is less than 10% of the oil, and the
treater is insulated to minimize heat losses.

GRAVITY SEPARATION
Water Droplet Size and Retention Time
The droplet diameter is the most important single parameter to control
to aid in water settling since this term is squared in the settling equation.
A small increase in diameter will create a much larger increase in
settling rate.
Qualitatively, droplet size is expected to:
- Increase with the retention time in the coalescing section
- Increase with the heat input
- Decrease with the oil viscosity
Increasing retention time in the crude oil treating system may not be
very cost effective. Water droplet should be allowed to grow of
sufficient size to settle in the vessel.

GRAVITY SEPARATION
Coalescing Media
Promote the coalescence of the water droplets by creating
an obstruction to the flow of the small water droplets,
promoting random collision of these droplets for
coalescence. When the droplets are large enough, they
will fall out of the flow stream by gravity.
This may allow lower treating temperatures. However, these

media have a tendency to clog with time and are difficult to
remove. They are no longer in common use.
The most common coalescing media is wood excelsior,

which is referred to as a “hay section”.

GRAVITY SEPARATION
Electrostatic Coalescers
Coalescing of the small water drops dispersed in the crude can be
accomplished by subjecting the water-in-oil emulsion to a high-voltage
electrical field. When a non-conductive liquid (oil) containing a
dispersed conductive liquid (water) is subjected to an electrostatic field,
the conductive particles or droplets are caused to combine by one of
three physical phenomena:
1) The droplets become polarized and tend to align themselves with the
lines of electrical force.
2) Droplets are attracted to an electrode due to an induced charge
3) The electrical field tends to distort and thus weaken the film of
emulsifier sorrounding the water droplet

GRAVITY SEPARATION
Electrostatic Coalescers
The attraction between the droplets in an electric field is
given by:
Ks 2 (dm)6
F= 4
(with S ≥ dm)
S
Where: F = attractive force between droplets

Ks = constant for system
 = voltage gradient
dm = diameter of droplets
S = distance between droplets
TREATING EQUIPMENT
Vertical Treaters
Vertical treater
schematic

TREATING EQUIPMENT
Horizontal Treaters
Horizontal heater-
treater schematic

OIL DEHYDRATION
GUN BARREL TANK

Gas
Emulsion + Gas
Water
Oil
Water Hot Water

OIL DEHYDRATION
Heating efect in heavy crude oil viscosity

(11 °API)
g D (dw – do)2
Vs =
o
where:
Vs = Sedimentation Speed
g = Gravity acceleration
D = Water droop diameter
dw = Water density
do = Oil density
o =oil viscosity

OIL DEHYDRATION
Combine efect of temperature increase and dilute salt in water with

specific gravity
g D (dw – do)2
Vs =
18o
Where:
Vs = Sedimentation speed
G = Gravity acceleration
D = Water droop diameter
dw = Water density
do = Oil density
o= Oil viscocity

TREATING EQUIPMENT
Electrostatic Treaters
Horizontal
electrostatic treater
schematic

OIL DEHYDRATION
ELECTROSTATIC DEHYDRATOR

OIL DEHYDRATION
ELECTROSTATIC DEHYDRATION
(-) (-)
OIL
++ + +++ +
++ +
++ +
d1 ++++ +
__ __ _
___
OIL d2
++ + +++ + __ _ _
++ + _ __ _
d1
__ __ _
___
(+) (+)
OIL DEHYDRATION
ELECTROSTATIC DEHYDRATOR

EQUIPMENT SIZING AND THEORY

Settling Equations
Horizontal Vessels Vertical Vessels

qo  qo  1/2
d Leff = 438 d = 81.8
( ) dm2 ( ) dm2
Where d = diameter of vessel, in.

Gunbarrels qo = oil flow rate, bpod
 = oil viscosity, cp
F qo  1/2 Leff = length of coalenscing section, ft
d = 81.8  = difference in specific gravity
( ) dm2 between oil and water (relative
to water)
F = short-circuiting factor
= 1 for d < 48 inches
> 1 for d > 48 inches
Residence Time Equations
Horizontal Vessels Vertical Vessels

qo (tr)o qo (tr)o
d2 Leff = d2 h=
1.05 0.12
Where tr = retention time, min

Gunbarrels
qo = oil flow rate, bopd
F qo (tr)o h = height of the coalescing section, in.
d2 h=
0.12
F = short-circuiting factor
= 1 for d < 48 inches
> 1 for d > 48 inches

Water Droplet Size
In order to develop a treater design procedure, the water droplet size to be use
in the settling equation to achieve a given outlet water cut must be determined.
Qualitatively, it is to be expected that the minimum droplet size that must be
removed for a given water cut to:
1) Increase with retention time in the coalescing section

2) Increase with temperature, which tend to excite the system, leading to more
collisions of small droplets
3) Increase with oil viscosity, which tend to inhibit the formatiion of small
droplets from shearing that occurs in the system
Assuming that the minimum droplet size of droplets that must be settled is a
function only of oil viscosity, the following correlation was developed:


Water Droplet Size
dm1% = 200 μ0.25 for μo < 80 cp
Where dm1% = diameter of water droplet to be settled from the oil to

achieve 1% water cut, microns
μ = viscosity of the oil phase, cp
And
For electrostatic treaters
dm1% = 170 μ0.4 for 3 cp < μo < 80 cp

Water Droplet Size

For μo < 3cp
Note: The two equations intersect at 3 cp, and
qo  1/2 electrostatic treaters would not be expected to
operate less efficiently at this range.
d = 81.8 Additionally, the data from which the
( ) dm2 electrostatic treater droplet size correlation was
developed did not include oil viscosities < 7 cp
For the minimum droplet size

dm / dm1% = wc0..33
Where:
dm = diameter of water droplet to be settled from the oil to achieve a
given water cut (wc), microns
wc = water cut, percent
Water Droplet Size

Flow rate vs. treating
temperature for
convencional and
electrostatic treaters
Note: This figure represents an approximated
relationship derived from the two equations for
dm1% in terms of the flow rate of emulsion (given
in bpd) flowing vertically through a horizontal
cross-section area of 1 ft2. For a horizontal
treater with vertical flow through the coalescing
section, the flow area can be approximated as
the diameter of the vessel times the length of
the coalescing section.

DESIGN PROCEDURE
Choose a treating temperature.
1. Determine oil viscosity at treating temperature.
2. Determine the diameter of the water droplet that must be removed

from the oil at treating temperature.
3. Determine the treater geometry necessary to satisfy settling

criteria for horizontal vessels, vertical vessels or gunbarrels.
4. Check the geometry to assure it provides sufficient retention time

for horizontal vessel, vertical vessels or gunbarrels.
5. Repeat to procedure for different assumed treating temperatures.

EMULSIONS
Mixes of two liquids non miscible where one is dispersed, constituting

the internal phase and the other is the dispersant environment or
external phase.
Emulsion W/O Emulsion O/W Emulsion O/W/O

DIRECT REVERSE MULTIPLE
Water Water Water

Water Water Water Oil Oil Oil
Oil Oil Water Water Oil Oil
Water Oil Oil
Water Water Oil
Water Water Water
- Two non miscible liquids: oil and water

- Stabilizing agent: surfactant, soap, fines, paraffin, asphaltene
- Mix energy: agitation, pump, orifices
SURFACTANTS
Molecules constituted by not polar part, without load, a

hydrocarbon and a polar part, with load of hetheroatoms
carbonates, sulfates and they have superficial activity, that it is
located in the interface oil / water
Water
O
CH3-CH2-CH2-(CH2)n-C
O Na
NO POLAR
POLAR

OIL DEHYDRATION
Definition: process to separate water from oil until levels of bottom

sediment and water (BS&W) below the market specifications, typically
less than 1%.
GAS
Emulsion W/O Emulsion

O/W
OIL + WATER
WATER
GAS
OIL
WATER
OIL DEHYDRATION
TO DESTABILIZE EMULSION IS REQUIRED:

- Destabilizing agent that reduce the external cast: surfactant, temperature, magnetic
field, salts
- Mix energy: promote effective collides
- Coalescence: union of small drops to form big drops
-
-
Water -
+
+ - +
- +
-+ +-
+ +-
- + + -+ - - + Water + -+ -
+-+- +-+-
+ +
- -
+ +
- -
+
-
+
-
OIL DEHYDRATION
Floculation
Water Water Water Agua

Oil
Oil Oil
Temp., Dem. ,Mix.
Water Water Agua Agua Oil
Oil
Oil
Water Water
Water
Separation Coalescence

OIL DEHYDRATION
OPERATIONAL PROCEDURE
-SETTLING TANKS
- FREE WATER KNOCKOUT
- MECHANICAL SEPARATORS
- HEATER / TREATERS
- GUN BARREL TANK
- ELECTROSTATIC
- CENTRIFUGAL
- CYCLONICS SEPARATORS

DEHYDRATION BY SETTLING
1. Chemical Injection
2. Filled tank and

retention time
3. Water Separation
and Drainage
Water to Treatment
System
4. Oil treated
Oil to Refinery or ship

WATER TREATMENT
USES OF PRODUCTION WASTE WATER
Recycling: Disposal:
• Steam Genaeration • Aquiefers
• Watering • River and Lake
• Enhanced Recovery • Ocean
• Animal Consumption • Re-injection
• Domestic Comsumption
Depending of final use water will have specific quality

requirements

WATER TREATMENT
CHEMIST
- Destabilize oil/water emulsión with polymers and/or surfactants
- Solid separation with floculants and/or coagulants selected by each kind of emulsion
and solids
SEPARATOR EQUIPMENTS
- API Separator , not use by standards environment
- Surge Tanks, replace API Separator
- Coalescence Tubing
- Flotation by disolved air. DAS
- Flotation by forced air. IAF o IGF
- Plate Seaparators
- Floculators
- Sand Filters /gravel, special filler

WATER TREATMENT
API SEPARATOR API
Water
Water
+ Oil

WATER TREATMENT
Oil
Water + Oil
Water
Surge Tanks

WATER TREATMENT
FLOTATION BY DISOLVED AIR
Air Oil
Water to PRESSURE
be treated Water
Water

WATER TREATMENT
FLOTATION BY FORCED AIR
Engine
Air Inlet

WATER TREATMENT
Gas
Part. > 150 mu and oil. < 100 ppm
Part. < 20 mu F
< 20 ppm I
L
T
E
R
Chem. Part. < 5 mu

and < 5 ppm oil
Secondary recovery purpose
Disposal Injection

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5.

1 Copyright ©2012 NExT. All rights reserved

Gathering Separation Treatment Storage Transportation

2 Copyright ©2012 NExT. All rights reserved

3 Copyright ©2012 NExT. All rights reserved

4 Copyright ©2012 NExT. All rights reserved

5 Copyright ©2012 NExT. All rights reserved

7 Copyright ©2012 NExT. All rights reserved

Well trunk line

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Pipelines in series Parallel pipelines

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NON CONVENTIONAL PRODUCTION MANIFOLD WITH A

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NON CONVENTIONAL PRODUCTION MANIFOLD WITH A

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GATHERING SYSTEM ENDS AT THE FLOW STATION

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 The produced fluids from the wellhead are a

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INLET GRAVITY SETTLING SECTION

LIQUID COLLECTION SECTION

INLET DIVERTER LIQUID OUT

LEVEL CONTROL VALVE

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A. INLET C. DIVERTER E. MIST EXTRACTOR G. DRAINAGE

B. IMPACT ANGLE D. WAVE BREAKER F. GAS OUTLET H. LIQUID OUTLET

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LIQUID COLLECTION LIQUID OUT

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• More expensive than horizontal • Only part of shell available for

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28 Copyright ©2012 NExT. All rights reserved

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Momentum change throws liquid Gas

Velocity decreased on inside

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33 Copyright ©2012 NExT. All rights reserved

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• Check pressure and level control instruments as much as possible.

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4. Check that the flare valve

2b. If it is not necessary to drain the

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2. Set operating pressure in the

1. Check that the liquid outlet

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POTENTIAL OPERATING PROBLEMS

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Growth of water layer with

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