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To HP separator
WELL#1 PG NRV
WELL#2
PG NRV
To MP separator
WELL#3
PG NRV
To test separator
HP MP Test
Headers
Block diagram well fluids processing
Separator
Crude oil to
dehydrator
WELL
WELL
WELL
WELL WELL
GGS
WELL
WELL WELL WELL
Well connection configuration
WELL
WELL
GGS
WELL
WELL WELL WELL
Well connection configuration
WELL
WELL Pad Pad
WELL GGS
WELL
WELL WELL
Well connection configuration
Central Tank Form (CTF) Well
Well Well
BH
Bath heater
KOD Flare
HP MP
To consumers
Scrubber
BH
BH To flare
Test
Heater treater
HP MP Test Oil
HT
Stb.
To ETP Tank Pump
Typical PFD of GCS
Flare header
MeOH or BH
KOD Flare
HP MP Consumers
Scrubber
To flare
Test Cond.
Stb.
HP MP Test Cond.
Stb.
To ETP Tank Pump
Oil & gas separation
WELL FLUIDS:
• Mixture of oil, gas and water / Free gas
Oil & gas separation
Quality of separated fluids
Separated water:
Depending on retention time,
® Oil content in eff. Water = 0.004% to 2.0%
Special methods and separating techniques can
improve water quality.
Difference in sp.gr. of oil and water less than 0.2
Oil & gas separation
Quality of separated fluids
Separated Gas:
For a separator with suitable mist extractor,
® Oil content in separated gas = 0.101 to 1.0
gal/mmscf
® In case of gas scrubbers oil content in effluent
gas should be less than 0.1 gal/mmscf.
Oil & gas separation
Instruments for measuring quality of separated
fluids:
Measurement
Instrument
Solvent extraction/
Oil & gas separation
Functions of separators
2-phase
3-phase Low pr. Sep.
Vertical (10 - 225psi)
Horizontal Test sep.
Med. Pr. Sep.
Spherical Prodn. Sep.
(225 - 750 psi)
L.T.S.
High pr. Sep.
Elevated sep.
(750 - 1500 psi
Stage sep.
Metering sep. Gravity sep.
Foam sep. Impingement/
coalescence sep.
centrifugal sep.
Oil & gas separation
Stage separation of oil and gas:
® Series of separators operating at sequentially
reduced pressures.
® Liquid is discharged from high pressure separator
into the next lower pressure separator
® Aims at maximum recovery of liquid hydrocarbon
and maximum stabilization of separated fluids.
® Economics limits the no. of stages of separation to
3 to 4
®
Oil & gas separation
Stabilization of crude oil :
•Pressure
•Temperature
•Gas Oil Ratio (GOR)
•Flow rate
•Fluid properties like density, viscosity etc.
Oil & gas separation
® Density difference
® Impingement
® Change of flow direction
® Change of flow velocity
® Centrifugal force
® Coalescence
® Filtering
Oil & gas separation
Gravity Separation
Diff. Densities
Diff. momentum
PRINCIPLES OF SEPARATION (OIL FROM GAS) :
Gravity Separation:
Terminal / Free settling
velocity of droplet
Vt = [4 g Dp ( l - g) / 3 g C’]
PRINCIPLES OF SEPARATION (OIL FROM GAS) :
Impingement :
Filtering :
Coalescing
Coalescing of small droplets (mist/fog)
Settling by gravity
PRINCIPLES OF SEPARATION (OIL
OIL FROM
FROMGAS
GAS):
:
Centrifugal force:
Settling :
Agitation/Baffling:
§Controlled agitation helps removing non
solution gas
§Disperses oil in such a manner that gas readily
escapes
§Allows gas bubbles coalesce and separate
PRINCIPLES OF SEPARATION (GAS FROM OIL ):
Heat :
Chemical :
Centrifugal force :
HORIZONTAL SEPARATOR
section A B
C
2.Secondary or gravity D
Liquid Outlet
separating section
3.Coalescing section Gas Outlet
4.Sump or liquid section VERTICAL SEPARATOR
Mesh
Pad
Two phase
Inlet
A B
A – Primary Separation D
B – Gravity Settling
C – Coalescing
D – Liquid Collecting
Liquid Outlet
Oil & gas separation
®
®
Oil & gas separation
Components of oil and gas separators:
Vane type
Mist Extractor
of free liquid from inlet
Vapor
stream
Outlet
D
v
Two phase
Inlet
Downc ••Inlet
Inlet diverter
diverter //
Inlet
Inlet baffle
baffle //
omer
Impingement
Impingement
baffle
baffle
Liq. Outlet
MAIN SECTIONS/COMPONENTS OF A
SEPARATOR
••Straightening
Straightening vanes/
vanes/
Settling
Settling vanes
vanes
••Defoaming
Defoaming plates
plates
MAIN SECTIONS/COMPONENTS OF A
SEPARATOR
3.Coalescing section
•Coalescer or mist
extractor/demister pad
•Interwoven mesh
•Gets plugged very easily with
heavier hydrocarbons or
deposits
•Requires frequent cleaning
Knitted
Knitted wire
wire mesh
mesh type
type
MAIN SECTIONS/COMPONENTS OF A
SEPARATOR
3.Coalescing section
•Coalescer or mist
extractor/ demister pad
•Does not require
frequent cleaning
•Better suited to crudes
having high wax and
deposition tendency
Vane
Vane type
type
MAIN SECTIONS/COMPONENTS OF A
SEPARATOR
Vortex
Vortex breaker
breaker
SEPARATOR CONFIGURATION:
1.Vertical separator
2.Horizontal separator
3.Spherical separator
4.Centrifugal separator
5.Compact Separators/Hydro-cyclones
mounted devices
SEPARATOR CONFIGURATION:
SEPARATOR SELECTION CRITERIA:
Vertical Horizontal
® Compressor KOD ® Production separator
® Fuel gas KOD ® 3-Phase separation
® Degassing boots ® Reflux drum
® Absorber feed KOD ® Flare KOD
SEPARATOR CONFIGURATION:
3.Spherical Separator
•Most commonly used for
separation of large vol. of
gas from extremely small
vol. of liquid
•High pressure service
where compactness is
desired
•Limited liquid surge
capacity
SEPARATOR CONFIGURATION:
4. Centrifugal/compact separators
- Less maintenance is
involved
- Less space is required
- Light in weight
- Less expensive
Centrifugal/compact separators
• Disadvantages
T
SIZING CRITERIA FOR A SEPARATOR
Surge time : T
•Time it takes for the liquid level to h1
h2
rise from NLL to maximum or HLL,
h3
while maintaining a normal feed flow h4
HLA
without any outlet flow h5
Di
•Based on requirements to HLL
> 70 MOP + 5%
Temperature
® Max design temperature = Max op. temp + 15 oC
® Min Design temperature = Min op. temp – 5 oC
®
Note : Minimum design temperature
must take into account
of depressurization of the
vessel
Sizing of vertical separators
® Calculate settling velocity
®
vs = k [ (l - v )/ v ]1/2
Where
Di = Internal dia, mm
Q = Flow rate, M3/s
® Round the ID to nearest 50 mm.
Sizing of vertical separator T
® Height calculation h1
h2
®
h3
h1= Max 15% of dia. or 400mm
h4
h2= 150mm for mesh pad HLA
h3= max ( 50% of dia. or 600mm) h5
Di
HLL
h4= 400mm +d/2; d: inlet nozzle,mm
Wt= s ( tDiHt+2x1.09xDi2)x10-9
Where
W = Bare vessel weight with ellipsoid head, Kg
t
s = CS density = 7865.55 Kg/m3
Sizing of vertical separators
® Weight calculation
®
- Shell weight with dished head
Wt = s( tDiHt+2x0.842xDi2)x10-9
where:
W = bare vessel weight with dished head,
t
Kg
s= CS density = 7865.55 Kg/m3
Sizing of vertical separators
® Weight calculation
®
Nozzle sizing of separators
Inlet nozzle
Gas outlet
® fluid viscosities.
®
SEPARATOR DESIGN :
Horizontal 3- Separator
•With mesh type ME, efficiency of 98-99% with droplet size smaller than 100
•<
< 300 – 500 mg/l due to environmental restrictions
SEPARATOR SPECIFICATIONS:
Liquid levels
Oil level
•Max oil level < 0.65 x ID
•Normal
Normal oil level = 0.5 x ID, or 1 min. retention time between max. and normal oil level
•Low
Low oil level = 0.1 x ID, or 12” from bottom, or safe height from normal water level to prevent water carry-
through; whichever is greater
Water level
•Height
Height corresponding to water retention time (1 to 2 min. normally), or 12”; whichever is greater
PREVENTIVE MAINTENANCE OF SEPARATORS :
®
Oil & gas separation
Sizes and Capacities :
® Recommended retention time:
Oil gravity Retention time
oAPI (min.)
2-Phase > 35 1
Separators 20-30 1-2
10-20 2-4
® Liquid levels
®
® Maximum oil level : < 0.65 I.D.
®
® Normal oil level : 0.5 I.D. or 1 min.
retention time
between max.
and normal liq.
Level
® Low oil level : 0.1 I.D. or 12”
from bottom
®
® Water/ inter face level : Water retention
time of 1-2
Oil & gas separation
Sizes and Capacities :
Oil capacity
® Calculation based on retention time of the
liquid in the vessel sufficient to obtain
equilibrium between liquid and gas.
® Liquid settling volume (W)
W = VL (t x 1440)
Where VL = Liquid capacity, bbl/d
t = retention time, min.
Oil & gas separation
Design considerations:
separators:
® Nomographs/Curves available
® To size the separator
® To determine the volume of fluid for a
given separator
®
• Suitable for preliminary sizing
®
Oil & gas separation
Capacity of vertical and horizontal
separators:
® Gas capacity : Does not vary directly with a
change in shell length.
® The gas capacity of a horizontal separator is
proportional to its length.
® The liquid capacities depend on the liquid
retained in the settling section of the
separators.
Oil & gas separation
Selection criteria of separators:
® Vertical separator applications
® Well fluids having low GOR.
® Well fluids having sand, etc.,
® Where limitation of space exits
® Slug flow from wells
® Down stream and upstream equipment.
®
Oil & gas separation
Selection criteria of separators:
Oil & gas separation
Valves of separators:
® Pressure guages
® Thermometers
® Pressure reducing regulators
® Level sight glasses
® Safety head with rupture disk
® Piping and tubing
®
Oil & gas separation
Safety features in separators:
® High and low liquid level controls
® High and low pressure controls
® High and low temperature controls
® Safety relief valves
® Rupture disks
®
Oil & gas separation
Problems in oil and gas separation:
® Foaming of crude oil
® Encasing of gas in thin film of oil
® Crudes that are likely to foam
® crudes with oAPI < 40
® Operating temp < 160 0 F
® Crude viscosity > 50 cP
®
Oil & gas separation
Problems in separation:
® Foaming of crude oil
® Effects of foaming
® Reduces the capacities of oil
and gas separators
® Carry over of oil in gas
® Control of liquid levels
Oil & gas separation
Problems in separation:
® Foam management
® Addition of foam depressants
® Special designs for handling foaming
crude
®
®
Oil & gas separation
Problems in separation:
Paraffin
®
Oil & gas separation
Problems in separation:
Sand / silt / mud etc.,
®
Oil & gas separation
Problems in separation:
Corrosion
®
Oil & gas separation
Operation and maintenance:
® Periodic inspection
® Installation of safety devices
® Safety heads / rupture disks
® Mist extractors
® Hydrate inhibition
® Corrosive inhibition
® paraffin controls
Oil & gas separation
Operation and maintenance in oil and gas
separation:
® High capacity operations
® Pressure shock loads
® Throttling of discharge liquids
® Pressure guages
® Guage cocks and glasses
® Cleaning of vessels
®
®
Oil & gas separation
Daily
•Check liquid levels
• Check pressure & temperatures
• Replace broken guage glasses & pressure guages
Periodically
•Lubricate valves
• Clean guage columns
• Check level control valves
•Check back pressure valves
Yearly
•Check pressure relief valves
Oil & gas separation
TROUBLE SHOOTING
LOW LIQUID LEVEL
TROUBLE SHOOTING
DIAPHRAGM OPER. DUMP
VALVE NOT OPERATING
• Pilot failure
• Supply gas failure
• Out of adjustment
• Broken valve stem
• Plugged tubing
• Ruptured diaphragm
• Leak in line from pilot to valve