Total E&P Training Course March 2010

Slide 1

EPCON CFU Operator Training Course Total E&P Cameroun BAP 365

March 2010

boblebilde_presentasjonerEpcon-logo-med-sloganM-I EPCON

EPCON CFU Operator Training Course

Contents:

Explain the EPCON CFU TechnologyOperation and Maintenance

Perform troubleshooting

Optimize performance

Total E&P Cameroun BAP 365


What is an EPCON CFU?

Acompactflotationunit (CFU) which separates oil and gas from produced water

Fuel gas or nitrogen gas as flotation gas

Cyclonic inlet



DEGASSER/FLOTATION

CFU

CFU

CFU

CFU

DISCHARGE

DISCHARGE

DISCHARGE

1ST SEPERATOR

2ND SEPERATOR

1. STAND-ALONE SOLUTION

2. POLISHING SOLUTION



4. WATER KNOCK OUT

GAS

OIL

FROM WELL

HYDROCYCLONE / PW SEPARATOR

CLEAN SIDE

OILY SIDE / FOAM SEPARATOR

CENTRIFUGE

REJECT

CFU

CFU

DISCHARGE

REJECT

CFU

REJECT



OIL & GAS

6. DISPLACEMENT OF BALLAST WATER

7. SLOP WATER

DISCHARGE

8. BULK SEPARATION

DISPLACEMENT BALLAST WATER

SLOP WATER

CFU

CFU

DISCHARGE

CFU

CFU

CFU

CFU

DISCHARGE

REJECT



Degasser

PCV

Discharge to sea

Globe valve

LP Flare

Pump

To SeparatorA, B or C


CFU

RejectVessel


FI

FI

PT

CFU

PCV

CFU

WATER OUTLET

REJECT OUTLET

WATER INLET

GAS



WATER

REJECT

INLET

Oil & gas phase

Water separationPhase

Water Phase

Oil in Water PhasePOSSIBLE WITH ENTRAINED GAS

Gas

1% LIQUID, OF TOTAL INLET FLOW

30 SECONDS RETENTION TIME

0.1 Sm3 PER 1 m3OF WATER

Chemical



Important parameters

Oil droplet size

Upstream chemicals

Water chemical rates

Formation water vs. injection water

Solids

Shear forces from upstream equipment (pumps, valves, etc.)

Zeta potential

Salinity

Pressure



Anonym testEmulsion on P-31 PetrobrasStable Emulsion

Inlet4500 ppm

1st stage105 ppm

2nd stage9 ppm

Inlet61 ppm

2nd
stage61 ppm



Pressure:

Reject back pressure

Water outlet back pressure (downstream)

Inlet pressure

Flotation gas pressure



Control philosophy

The purpose of control philosophy is to ensure optimalprocess conditions for obtaining the best possibleseparation of oil from water



Tuning parameters:

Reject valve opening

Amount of flotation gas

Pressure in the CFU



Daily follow-up:

Collecting samples

Control of gas supply

Oil/water ratio reject lines

C:\Program Files\Microsoft Office\MEDIA\CAGCAT10\j0293236.wmfTotal E&P Cameroun BAP 365


Optimizing reject flow:

Too much reject results in an unfavourable amount of water in the reject, but it rarely has a negative impact on the OiW out of the CFU

Choking the reject too much will result in a decrease of the level and the OiW out of the CFU will increase

Check the level in the CFU after closing the reject sample point due to an increase in reject when the sample point is opened



Optimizing flotation gas amount:

0,1 Sm3 gas/m3 water for CFU pressure 0-2 barg

Dispersed gas in the produced water

Density difference oil/water

Surface tension oil droplets (Zeta potential)

Use of chemicals

More than 2 barg in CFU Increase gas

Actual volume vs. Standard volume




Must be sufficient gas to transport the oil to the top of the CFU. Insufficient gas is much worse than an excessive amount of gas.

Critical that both liquid and gas appear in the reject sample point. Choke globe valve until only gas appears. Then open 1/8 until a small amount of liquid appears.

Continued tuning of the gas must be performed based on OiW results from the lab.




Verification of gas flow in the case of malfunctioning gas flow meters:

Open reject sample point and choke the gas flow supply control valve to a near maximum and observe that the reject in the sample point behaves more calmly and that the liquid phase increases. By opening the control valve fully the reject in the sample point should behave more turbulent and the amount of gas will increase. After a short while it is possible that just gas will be observed.

Method 1:




Verification of gas flow in the case of malfunctioning gas flow meters:

Choke the gas flow supply control valve to a near maximum, close the reject valve (and reject sample point) and observe that the level in the CFU is decreasing. Increase the opening of the gas control valve and observe that the level decreases more rapidly.

Flow of gas in the gas line submits a sound which especially near the check valve is clearly audible.

Method 2:

Method 3:




Prevention of clogged gas nozzles:

The cause of clogged nozzles is incorrect procedures at start-up and shut-down. When water exists in the inlet header it should be kept a minimum of gas flow. This will prevent water from entering the gas line. During shut-down the gasflow should continue until the CFU is drained below the inlet. During start-up gas flow should commence before water flow. This will prevent oil, water and particles entering the gas nozzles.




Prevention of damaged VA gas meters:

Gently increase the flow of gas upon start up of gas flow. This will prevent the gas meters suffering damage from the sudden increase in pressure.



General advice for obtaining efficient cleaning:

C:\Documents and Settings\RLied\Local Settings\Temporary Internet Files\Content.IE5\SAKIYKXS\MCj04398280000[1].pngTry to keep the reject flow to a minimumdue to capacity limitations in the reject lines and/or downstream systems

Keep the pressure in the EPCON CFU vessels at a minimum. This ensures less need for flotation gas, less reject and less wear and tear on the reject control valve.

When pressure in the EPCON CFU is decreased the reject valve opening can be increased




C:\Documents and Settings\RLied\Local Settings\Temporary Internet Files\Content.IE5\SAKIYKXS\MCj04398280000[1].pngDo not perform sampling if the level in the EPCON CFU is not stable. This can result in low or no efficiency from the unit.

The liquid and gas from the reject sample points will behave differently depending on the pressure and length of tubing. The vital point is that it exists both liquid and gas in the sample. Tuning can be performed by collecting the liquid in a bottle and examine the ratio between oil and water




C:\Documents and Settings\RLied\Local Settings\Temporary Internet Files\Content.IE5\SAKIYKXS\MCj04398280000[1].pngThe EPCON CFU has a turndown of 20% of design flow. Flow rates within this requirement will not suffer from reduced efficiency. A produced water flow rate of below this will suffer from insufficient velocity in the inlet with the result that the flotation gas will have no effect. Flow rates exceeding design flow will have varying results depending on the installation.




C:\Documents and Settings\RLied\Local Settings\Temporary Internet Files\Content.IE5\SAKIYKXS\MCj04398280000[1].pngClean the gas nozzles in the mixers

Remove the insert pipes

Increase the diameter of the gas nozzles by boring

Chemicals



Troubleshooting


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