Surface Facilities - Gathering, Collection and Treatment

Prof. T. Kumar
Dept. of Petroleum Engg
IIT(ISM) Dhanbad826004

INTRODUCTION
• In this section we will study the processes and paths through which the crude oil undergoes
before reaching the refineries.
• This is called surface treatment of crude oil.
• Under this section we shall study in detail the following topics:
 Oil and gas gathering systems,
 Emulsion treatment systems,
 Oil and gas separation systems,
 Oil treatment systems,
 Gas treatment systems.

GROUP GATHERING STATION

• The streams of wells producing crude oil and natural gas are conveyed to centers located
on the oil field.
• A system comprising piping, pipe fittings and central facilities permits us to separate the
liquid from the gas, to measure the quantity of both, to adjust their properties so as to fall
within sales contract and/or other specifications, and to transport them to the consumer or
refineries.
• The system through which the crude is collected from different wells across the field
and transported to refineries is called oil and gas gathering system.

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1. GROUP GATHERING STATIONS (GGS) OR WELL CENTRES
Group gathering station is the basic unit of taking production from any oil field. The functions
of GGS's are:
 Testing
 Separation (Oil/Water/Gas)
 Treatment (Oil/Water)
 Storage (Oil)
 Disposal (Oil/Water/Gas)
 To work as intermediate pumping station
 To meet above functions a GGS has following facilities:

 Testing: Manifold

 (Oil Manifold, Water Injection Manifold, Gas Lift

 Manifold)
Separation : Test Separator, Group Separators.
Treatment : Chemical Dosing System, Heater Treater
Storage : Tanks
Disposal : Pump House/Pipelines to CTFs
: Evaporation pits / Effluent disposal pumps
: Gas Flare Unit / Pipelines
: Fire Fighting Facilities
: Pigging facilities on collector lines
Pumping : Pumps

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FUNCTIONS OF A GGS

 Gathering of fluid from different wells,

 Single and multiple separation,
 Dehydration,
 Drying,
 Sweetening,
 Natural gasoline extraction,
 Use of produced gas,
 Heat treatment,
 De-emulsification.
REQUIREMENT FROM GATHERING STATION: GGS
i. Separate oil, gas and water in the most efficient manner.
ii. Treating of oil emulsion for removal of water.
iii. Separation and dispatch of high pressure gas from low pressure oil.
iv. Metering oil, gas and water.
v. Provide temporary storage of oil.
vi. Arrangement for disposal of water and low pressure gas.
The type of GGS to be designed will depend on a number of factors like-
i. Presence of water and its state in oil i.e emulsion and extent of treatment required.
ii. Presence and quantities of sand in the hydrocarbon.
iii. Wax content of crude.
iv. Number of wells to be served by primary gathering facilities (in individual or groups).
v. Nature of flow in the flow lines: gravity or pressure system in which well fluids may
flow separately or together.
OPERATIONS IN GGS:
• Gathering of fluids from wells.
• Single or multistage separation.
• Dehydration.
• Drying.
• Sweetening.
• Desalting.
• Natural gasoline extraction.
• Use for gas life operations, Heating

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• Gathering and separation systems fall into three general groups.
• The first group includes production system of extremely high capacity wells.
• Each well has its own facilities for separation and metering, possibly also for treatment.
The setup is seldom economical.
• A more common system involves gathering and separation facilities permitting of
common handling of several well streams. In this case individual wells are connected
to well centers (group stations).
• Each well stream is transported to the well centre in an individual flow line.
• The flow lines at the gathering station have check valves and connect to group and test
header through pipe and valve manifold.
• The flow from a well is to be tested and diverted to test header where as other wells
produce into group header.
• The test header is connected to a battery of test separators and metering devices. The
group header feeds to the group separators.
• The produce from two stream later join common treatment /storage and transportation
system.
• In the third group several wells produce into a common flow-line. Oil, gas and water
production of individual wells are metered intervals by means of portable well testers
installing at the well sites.
• All other treatment takes place at the central station.
• Of the three systems, the well centre or group station system is more common.

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 i. Production from flowing wells, undergo two-stage gas separation.
ii. High-pressure first stage gas is used for gas lift production or fed in pipeline for long
distance transmission.
iii. Central gauging and dispatch facility for all wells regardless of the methods by which
they are produced.
iv. Facilities for periodic testing of individual wells.
v. Metering and handling facilities for water, oil and gas from production as well as testing
sub-system.
vi. Production from flowing wells reaches gathering point by formation pressure, from gas-
lift wells by increasing the load on the compressor and from pumping wells by
increasing somewhat load on the sub-surface pump.

EQUIPMENT AT GGS
• Manifold
• Bath heater
• Separator
• Heater treater
• Chemical injection system
• Flare
• Storage tanks
• Pumping system
• Gas compressor for sales/gas lifting

OIL AND GAS SEPERATOR

• The physical separation of these components is achieved by using a separating vessel
called oil and gas separators it can be defined by their geometry and position.
• Cylindrical separator –
1. Vertical separator
2. Horizontal separator
• Single barrel
• Double barrel
• Spherical separators.

SEPARATION SYSTEM
As the multiphase well fluids move from the formation to the gathering point, pressure steadily
declines with attendant evolution of gas and vapour, which interferes with the motion of the
fluid. To avoid operational troubles and loss of gas, it is separated from the oil in gas separators
(traps) of various designs. Separation is aided by reduction of pressure, by breaking up the fluid
flow in to jets, by changing the direction of the flow, and by other methods. The operation of
gas separation consists in separating the dissolved and occluded gas in the oil droplets entrained

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by the gas, retaining the essential constituents of gas and oil, breaking up froth and preventing
its formation.

Gas separators are classified according to-

i. The type of well served: flowing, gas lift, pumping combined.
ii. Shape and position: cylindrical, spherical, vertical and horizontal etc.
iii. The nature of the main operative force: gravity, centrifugal or combined.
iv. The working pressure: vacuum (up to 1 atm), low pressure (up to 6 atm) medium
pressure (up to 16 atm) and high pressure (above 16 atm).
v. The number of well served: individual and central.
vi. Function: Separation or measuring
vii. Method of manufacture: Welded, riveted etc.

SEPARATOR COMPONENTS
• Primary separation: - It is for separating bulk of liquid from well stream and also to remove
quickly slugs and large droplets of liquid from gas stream so as to minimize turbulence and
re-entrainment space of liquid particles.
• Liquid accumulation section: - It’s for receiving and disposing of liquids collected.
• Secondary separation section: - It’s for removing the smaller liquid droplets. Principle of
separation is gravity settling from the gas stream
• Mist extraction section: - It’s for removing entrained droplets too small to settle by gravity.
This section uses elements on vanes, wire mesh or plates to coalesce the very small droplets
of liquid in final separation before gas leaves the separators.

KINDS OF SEPARATORS
• Classification of separators on the basis of phases:-
Two phase - separates oil and gas
Three phase- separates oil, water & gas
• Distinction on the basis of shape:-
Vertical separator
horizontal separator
spherical separator
In oil & gas separator, the liquid and gas components that exists at a specific temperature and
pressure are mechanically separated from well hydrocarbon stream. These may be referred to-
i. Oil & gas separator.
ii. Separator.
iii. Stage separator.
iv. Trap
v. Knockout drum
a. Water knock out drum.
b. Liquid knockout drum
vi. Flash chamber.

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 vii. Suspension vessel (separator)
viii. Scrubber (Gas scrubber)
a. Dry type.
b. Wet type.
ix. Filter (Gas filter)
a. Dry type
b. Wet type.

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Production Separator Principles – sample video 4.5 min.

https://www.youtube.com/watch?v=vhkcGCUN_Uo

• The well fluid/ stream enters the separator through the inlet which is situated ½ to 2/3
of the separator height and can be tangential/ baffle or conical which impart centrifugal
and gravitational forces for the efficient primary section.
• A conical baffle at times is provided which separates the liquid accumulation from the
primary separation section to ensure a quite liquid surface to liquid level float operation
and an easy release of solution gas.
• The separated gas travels upwards through the second separation section where the
heavier entrained liquid particles settle out.
• As the liquid reaches the equilibrium, gas bubbles counter flow to the direction of the
liquid flow and eventually migrate to the vapour space.
• The gas then flows through a vane/ knitted wire type mist extractor where liquid
particles 10 microns and larger in diameter accumulate until they gain sufficient weight
to fall in to liquid accumulation section.
• Sediments entering the separator accumulate in the bottom where they are flushed out
through the drain connection. These are provided with a level control device at liquid
outlet, pressure controller on the gas outlet and a safety valve mounted on the gas outlet.

• Horizontal separators are classified as single tube (ST) or double tube (DT) type. The
well head stream enters the separator and hits an inlet dished deflector or angle baffle
causing a sudden change in momentum.
• The well stream then strikes the side of the separator, producing maximum initial
separation of gas and liquid accumulation section provides the retention time required
to let entrained gas evolve out of the liquid and rise to the vapour gas space.
• This also provides a surge volume, to handle intermittent slugs of the liquid.
• The liquid then leaves the separator through the liquid dump valve regulated by a level
controller.

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 • The separated gas flows through a straightening section, which removes turbulence,
and the additional liquid particles settle out as the gas stream flows through the second
separator section.
• The gas then passes through the mist extractor where liquid particles 10 micron and
larger in size are removed.
• The pressure in the separator is maintained by a pressure controller, which senses the
changes in the separator and sends a signal either to open or close the PCV accordingly.
• By controlling the gas output rate the pressure in separator is maintained.
• Normally these single tube separators are operated half full of liquid to maximize the
surface area of the gas liquid interface.

It consists of an upper separator section and lower liquid chamber. Well fluid/ enters the upper
tube. Liquids fall through the first connecting pipe into liquid reservoir (i.e. bottom tube) thus
separating the liquid accumulation section, and wet gas flows through this to the upper tube
where the entrained liquids separate owing to their difference in density and to the scrubbing
action of mist extractor.
These separators are common where there is a low liquid flow rate. These type is also
uses frequently as filter separators on compressor inlets, final scrubber upstream of glycol
contact towers and instrument/ fuel gas application for high-gas/ low liquid flow application.
(a)Testing
As a number of wells are connected to a GGS, the wells need to be tested regularly for
generating test data for proper monitoring and evaluation of field performance. It is achieved
by producing the well through test header in the manifold through test separators to storage
tank. Oil, Water and Gas flow rates of the well are determined.
(b) Separation
Gas from liquid (oil and water) is separated in two phase separators in one or more stages based
on following main considerations:
Maximizing liquid recovery
 Utilization of separated gas which requires certain pressure for transportation up to point
of use
 Minimizing back pressure on wells
The oil after separation is routed through heater treater to storage tanks under pressure and gas
is transported further for utilization through pipelines.

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(c) Treatment
The liquid separated in separators may require some treatment for proper separation of oil and
water. This can be achieved by:
(i) Chemical treatment - use of demulsifier and
(ii) Thermal and electrical treatment - in heater treater.
(d) Storage
Generally 10 - 15 days storage is created in GGS's for storage of oil for smooth function of
GGS's. The tanks have facilities for volumetric measurements and sample collection for BSW
measurements.
(e) Disposal
Oil: Oil from storage tanks is pumped to CTF for onward transportation to Refinery.
Water: Free water from Heater Treater and the separated water from oil tanks are diverted to
evaporation pits where from it may be pumped to effluents plants for further treatment and
disposal or may be evaporated as such.
The cost of GGS depends on fluid handling and treatment capacities and it may be of the order
of Rupees three to five crores.

2. Central Tank Farm (CTF):

Oil from various GGSs is collected in central tank farm for further transportation to refineries.
Besides having storage and pumping facilities the CTF may have final crude treatment facilities
to meet the specifications of Refinery requirement of BSW and salinity. Storage capacity is
generally created for 7 to 15 days storage. The cost of CTF in present day context may be of
the order of Rs.6 to 8 Crores.

TREATING SECTION
• The treating section consists of some method of dehydration such as using wash tanks,
heater treater or electrical dehydration.
• The principal purpose of the treatment is to remove water, sand and other contaminants
from oil.
• In most cases, the waste-water must be cleaned to meet the requirements of the local water
quality standard.
• Often the water is further processed for water flood applications or for lease as steam
generator feed water in some locations where the water has chemical composition and
properties.

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EMULSION TREATMENT SYSTEM
• Oil enters the treating section from separators, where it has been essentially degassed, and
flows to the dehydration equipment.
• Dehydration may be accomplished by one or a combination of several methods ranging
from simple tank setting to complex methods like thermal electrical treater etc.
• In side the gun barrel emulsion treatment following steps are taken:-Crude is preheated up
to 40 degree Celsius in a HEATER TREATER.
• Rushed through the baffle plates which help in coalescing.
• Crude is coalesced by subjecting the water oil emulsion to high voltage electric field. The
dispersed water (conducting phase) in the non conducting phase, oil can be coalesced with
electrostatic field.

Knockout drum
• A knock out drum may be used to remove only water from the well fluid or all liquid,
oil and water from gas.
• In WKO the gas & liquid are discharged together & water is separated and discharged
from the bottom of the vessel.
• A liquid knockout is used to remove all liquid, oil and water from gas.
• A flash chamber refers to Oil & Gas separator operated at low pressure, with the liquid
from a high pressure separator being flashed into it and this is used as last stage of
separation before flashing it to storage.

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Free Water Knock Out

Free Water Knock out (FWKO)

Expansion vessel
• An expansion vessel is the first stage separator vessel on a low temperature or cold
separation unit.
• This vessel may be equipped with a heating coil to melt hydrates, or a hydrate-
preventive liquid such as alcohol or glycol may be injected into the well fluid just prior
to expansion into this vessel.
Scrubber
• A scrubber may be similar to an oil and gas separator. It is used to handle fluid that
contains less liquid than that produced from oil and gas wells.
• Gas scrubbers are normally used in gathering, sales, and distribution lines where they
are not required to handle slugs or heads of liquids as it is the case with an oil and gas
separator
• The dry type gas scrubber
• The wet type gas scrubber
• Filter or Dust Scrubber
The dry type gas scrubber
• utilizes mist extractors and other internals similar to oil and gas separators, with
preference shown on the coalescing type mist extractor.
The wet type gas scrubber
• passes the stream of gas through a bath of oil or other liquid that washes the dust from
the gas.
• The gas is then flowed through mist extractors where all removable liquid is separated
and/or water.

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Typical filter separator

Filter Separators
• Filter separators are commonly used on compressor inlets in field compressor stations,
final scrubbers upstream of glycol contact towers, and instrument/fuel gas applications.
• The design of filter separators is proprietary and dependent upon the type of filter
element employed.
Filter or Dust Scrubber
• The term filter (gas filter) can be used to refer to a dry type gas scrubber, especially if
the unit is being used primarily to remove dust from gas stream.
• A filtering medium is used in the vessel to remove dust, line scale, rust, and other
foreign material from gas.

Heater Treater

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• A level control in the oil surge chamber operates a dump valve on the oil outlet line
regulating the flow of oil out the top of the vessel to maintain a fluid packed condition.
• The inlet section must be sized to handle settling of the free water and heating of the oil.
• The coalescing section must be sized to provide adequate retention time for coalescence to
occur and to allow the coalescing water droplets to settle downward countercurrent to the
upward flow of the oil.

EMULSIFIED OIL
• An emulsion is defined as the system in which one liquid is relatively stably distributed or
dispersed in the form of droplet in another substantially immiscible liquid.
• The liquid which occurs at discrete articles is known internal or dispersed or discontinuous
phase and the other liquid is known as external dispersing or continuous phase.
• Two phases in emulsion-
1. Continuous phase
2. Dispersed phase.
• Three types of emulsions:
1. Normal emulsion: Water in Oil Emulsion. Stable emulsion that is not easily separable and
unstable emulsion that is easily separable.
2. Invert emulsion: oil in water emulsion like milk.
3. Induced emulsion: Purposefully prepared emulsion.
STABILITY OF EMULSIONS: Factors for stability of emulsion
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:

EMULSION TREATING THEORY

• Chemical de-emulsifiers sold under various trade names, such as Tretolite, Visco, and
Breaxit, are highly useful in resolving emulsions. De-emulsifiers act to neutralize the
effect of emulsifying agents. Typically, they are surface active agents and thus their
excessive use can decrease the surface tension of water droplets and actually create
more stable emulsions.
There are four important actions required of a de-emulsifier:
1. Strong attraction to the oil-water interface.
2. Flocculation.
3. Coalescence.
4. Solid wetting
• When these actions are present, they promote the separation of oil and water.
• The de-emulsifier must have the ability to migrate rapidly through the oil phase to the
droplet interface, where it must compete with the more concentrated emulsifying agent.
• The de-emulsifier must also have an attraction for droplets with a similar condition. In
this way large clusters of droplets gather which, under a microscope, appear like
bunches of fish eggs.

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COALESCENCE
• The process of coalescence in oil treating systems is time dependent.
• In dispersions of two immiscible liquids, immediate coalescence seldom occurs when two
droplets collide.
• If the droplet pair is exposed to turbulent pressure fluctuations, and the kinetic energy of
the oscillations induced in the coalescing droplet pair is larger than the energy of adhesion
between them, the contact will be broken before coalescence is completed.
Time to grow droplet

When the energy of oscillations is very low so that "bouncing" of droplets approaches zero, j
approaches 3. Assuming a value of 4,

Assuming d0 is small relative to the droplet size

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 increases with retention time in the coalescing section, and with
heat input, which excites the system leading to more collisions of small droplets.
• Droplet size decreases with oil viscosity, which inhibits the movement of the particles and
decreases the force of the collision

DEHYDRATION: Methods of Dehydration

• Gravity Method
• Thermal treatment.
• Chemical treatment.
• Electrical treatment
• Chemi-electrical treatment.
• Thermo-electrical treatment
• Centrifuging treatment
• Filtration treatment.

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Gravity Method
• Most oil-treating equipment relies on gravity to separate water droplets from the oil
continuous phase, because water droplets are heavier than the volume of oil they displace.
• However, gravity is resisted by a drag force caused by the droplets' downward movement
through the oil. The downward velocity is estimated by
• V = D². Δρ/(μ1 – μ2)
Where, D is the diameter of water droplet, Δρ is the difference in densities of water droplet and
oil droplet, μ1 – μ2 is the difference in viscosities of oil and water which depends on
temperature.
Thermal Treatment
Thermal treatment is performed by heater treater. It is employed for reducing the viscosity and
surface tension and also to improve the solubility of the stabilizing film. This can be achieved
by either rupture of the film or the coalescence.
Purpose of crude oil desalting:
• Crude oil introduced to refinery processing contains many undesirable impurities, such as
sand, inorganic salts, drilling mud, polymer, corrosion byproduct, etc.
• The salt content in the crude oil varies depending on source of the crude oil.
• When a mixture from many crude oil sources is processed in refinery, the salt content can
vary greatly.
• The purpose of desalting is to remove these undesirable impurities, especially salts and
water, from the crude oil prior to distillation.
Benefits of Crude Oil Desalting
• Increase in crude throughput
• Less plugging, scaling, coking of heat exchanger and furnace tubes
• Less corrosion in exchanger, fractionators, pipelines, etc.
• Better corrosion control
• Less erosion by solids in control valves, exchanger, furnace, pumps

The desalting process is completed in the following steps:

• Dilution of water injection and dispersion
• Emulsification of diluted water in oil
• Distribution of the emulsion in the electrostatic field
• Electrostatic coalescence
• Water droplet settling
++0++

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