Complex oil-water separator units
Well-drilling, oil well repair work, flushing and recovery of oil may result in extraction of product composed of both oil and water. Extracted components can either be clean or emulsified, under varied conditions, that hamper further oil processing. A solution to this problem lies in continuous separation of two-phase liquid into two streams by centrifugal forces. This process is carried out in a specialized centrifuge.
- centrifuge Type ODB 260
- circulation pump
- pressure water pump
- valves & meters
- water tank
- frame-electric service panel
- service console
- remote control console, no Ex-protection (to be mounted in a safe area)
- spare parts set
- lifting equipment
- feed pumps
- pre-heating system
Flow rate: max. 250 m3/h
Head : max. 4 bar
Lenght: 5365 mm
Width: 3460 mm
Height: 4797 mm
Continuous separation of crude oil, produced water, drain water etc.
Oil fields and refineries
- Simple and space-saving design, automatic operation
- Supplied as a pre-packaged, pre-assembled and tested system
- Applicable in explosion hazardous zones 1 & 2
- Low weight in running state
- Control unit, incl. engine starter and programmable Logic-Control system
- Designed acc. to oil standards
Four-phase oil separation systems
Four-phase high pressure separators for crude oil are designed for separation of solids, liquids degassing followed by separation of gas from liquid droplets, as well as separation of liquids with different densities.
- horizontal four-phase high pressure separator
- four-phase separator, volume min. 100, max. 250 barrel
- compact units
- pipelines with operating pressure min. 3000 psi, max. 10 000 psi
- sizes min.3", max. 8" NPS
- Various pumping methods:
- oils/water pumping
- dry substances transfer
- internal reflux pumping
- Complete data:
- programmable pressure control system
- overall pump, valves and control valve operation monitoring
- Length:40 ft (12.2 m)
- Width:8 ft. 6 in. (2.59 m)
- Height: 9 ft. 6 in. (3.2 m)
- Weight (approx.): 7 300 kg
Oil-heating units complete with:
- intermediate heat-carrier
- convection heater
- No need to use additives to increase oil transport properties, which significantly cuts down expenses in oil pumping.
- Pumped oil itself serves as energy supply for burners; associated gas can be used as fuel just as well.
- Closed cycle technologies are applied to the maximum: combustion gas recycling, use of continuously circulating non-toxic heat-transfer fluid.
- Environmentally friendly oil-heating units.
- Oil-heating units secure set technological mode of an oil pipeline, meeting the highest standards in reliability, safety, automation and control levels, performance and economic parameters.
Oil-heating unit with intermediate heat-carrier
Oil-heating unit (OHU) automatically maintains working temperature set by operator, with accuracy 0,5% of specified value. Furthermore, exit temperature can reach up to 400°C.
OHU has numerous security systems, allowing them to function within prescribed limits. In case acceptable limits are exceeded the unit would stop automatically. Burner flame, heat-carrier temperature, exhaust gases temperature, heat-carrier flow rate, combustion air pressure are monitored non-stop during operation.
Oil-heating unit with convection heater
In these oil-heating units (OHU) crude oil is heated as it is passes through heat-transfer coil. The coil is heated by convection gases enveloping its outer surface. To improve efficiency and to limit burner flame radiation the gases are recirculated. The main advantage of this type of heater is the possibility to prevent surface overheat of fluid through pipe wall, which makes it suitable for crude oil sensitive to overheating.
Fully-convectional design of heat-exchanger allows precise control of pipe wall surface temperature. The heater can operate at surface temperature exceeding that of crude oil by max.2,8°C. Unit capacity ranges from 0.8 to 37 MW. Heaters increase crude oil temperature to the value set by the Customer, reducing its viscosity and thus preparing it for further transportation though main oil lines.
When extraction, crude oil is always accompanied by oil-field (stratal) water (from <1 up to 80-90% of total mass); dispersing in oil, stratal water emulsifies into ‘water-in-oil’ emulsion types (continuous phase- oil, internal phase- water). Their formation and stability are conditioned by the presence of natural emulsifying agents (pyrobitumen, naphthene, tars) as well as by dispersed mechanical impurities (clay, sand, limestone and metal particles). As a rule, stratal water is highly mineralized by sodium, magnesium and calcium chlorides (up to 2 500 mg/l of chlorides even at water content of only 1%); moreover, it is rich in sulfates and hydrocarbonates and mechanical impurities.
The presence of the above mentioned substances and mechanical impurities in oil has a negative impact on oil-refining equipment:
- due to high water content pressure builds up in oil-refining units, resulting in output capacity loss and increase in power consumption;
- due to salt deposition furnace and heat-exchanger pipes require frequent cleaning, calorific efficiency is decreased; additionally, salts are strong corrosion agents (Ca and Mg chlorides hydrolyze giving HCl). Besides salts and mechanical impurities build up in residual oil such as masut and tar, reducing their quality.
Oil dehydration is carried out by breaking down (layering) of water-oil emulsion using demulsifying agents- various surface-active substances. Adsorbing on the interphase boundary these substances stimulate breaking of droplets (globules) of water dispersed in oil. However even drastic oil dehydration resulting in max. 0,1-0,3% strata water content (which is quite a technological challenge already) does not grant optimal output parameters. Due to high mineralization of strata water the content of chlorides is still rather high: 100-300 mg/l (on NaCl basis), in the presence of crystallized salts the percentage is even higher. That is why dehydrating alone is not enough to prepare oil from most oil-fields for further refining. Salts and water remaining in oil are removed by ‘desalting’, an operation not much different form dehydrating. The operation consists in mixing oil with fresh water and emulsion breaking followed by separating oil from flush water now containing salts and mechanical impurities.
Max. salt content in oil at unit output: 5 mg/l
Modular reservoir pressure maintenance units
Reservoir pressure maintenance systems offer the best solution for:
- stratal water pumping and transportation through pipelines;
- oil bed stimulation by pressure build-up;
- pin-point water injection and produced water disposal.
Pumping stations for Reservoir pressure maintenance systems consist of the following components:
- fluid metering and treatment system (feed pipeline)
- regulation system (pressure pipeline)
- automatic control complex (pump control system)
Such combined modular design allows:
- to maintain optimal mode of pump operation
- to initiate emergency shutdown when critical parameter values are reached
All equipment is mounted in a containerized module
Automated operation of station with flow rate set. Frame-type containerized blocks are equipped with heating systems
(ambient temperature: +35°C …-50°C), ventilation and light.
- building-block concept construction design;
- blocks of small size;
- allows prompt transformation and relocation of container;
- reduces costs for installation site preparation works;
- wide range of pumping units to complete the block set;
- scheduled maintenance, assembling and dismantling operations can be carried out without extra load-lifting equipment (truck crane, loaders etc.);
- weatherproof design;
- possibility of integration into automatic process control system of reservoir pressure maintenance.