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Produced Water TreatmentProject Profile
Project Name: Melut Basin Oil DevelopmentProject Name: Melut Basin Oil Development
Client Name: PDOC, Client Name: PDOC, PetroliumPetrolium
EPC: EPC: DodsalDodsal
Consultant: Mott MacDonaldConsultant: Mott MacDonald
Plant Location: Adar/ Agordeed Field Plant Location: Adar/ Agordeed Field
Scope: Scope: Design, Build, and installation Super.Design, Build, and installation Super.
Go Ahead Date: January Go Ahead Date: January -- 20052005
Delivery Date: May Delivery Date: May -- 20052005
Capacity: 1920 M3/dayCapacity: 1920 M3/day
Source of Water: Oil Wells Source of Water: Oil Wells –– Produced WaterProduced Water
Development Oman CompanyDevelopment Oman Company
–– SudanSudan
Sudan Oil Production: 250,000 bbl/d (2004)Sudan Oil Production: 250,000 bbl/d (2004)
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Criteria for Awarding the Job
Critical Delivery < 5 MonthsCritical Delivery < 5 Months
Compact DesignCompact Design
Robust and Reliable DesignRobust and Reliable Design
Economic ApproachEconomic Approach
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Design Conditions
Inlet Pressure: AtmosphericInlet Pressure: Atmospheric
Outlet Pressure: 1.29 BargOutlet Pressure: 1.29 Barg
Operating Temperature: 55 Deg. C.Operating Temperature: 55 Deg. C.
Design Pressure: 10 BarDesign Pressure: 10 Bar
Design Temperature: 80 Deg. C.Design Temperature: 80 Deg. C.
ANSI Class: 150#ANSI Class: 150#
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Water to Oil RatioWater to Oil Ratio
New Well: < 1New Well: < 1
Old Well: > 3 up to 10Old Well: > 3 up to 10
North Sea:North Sea: 70% water, 30% oil70% water, 30% oil
N. America: N. America: 92% water, 8% oil92% water, 8% oil
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Main Impurities in Produced WaterDissolved SolidsDissolved SolidsHeavy MetalsHeavy MetalsVarious Oils (emulsified and nonVarious Oils (emulsified and non--emulsified)emulsified)Suspended SolidsSuspended SolidsDissolved Gases (ODissolved Gases (O22, CO, CO22, and H, and H22S)S)Iron ScalesIron ScalesBacteriaBacteriaPhenols, toluene, and other toxic compoundsPhenols, toluene, and other toxic compoundsRust and Corrosion ByproductsRust and Corrosion ByproductsSand GrainsSand GrainsRadioactive ElementsRadioactive ElementsBacteriaBacteriaTreatment ChemicalsTreatment Chemicals
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WHAT DO WE REMOVE?Free OilFree OilSand and TurbiditySand and TurbidityDissolved gasesDissolved gasesBacteria and VirusesBacteria and Viruses
WHY?
Reduce harmful emissions to the environmentReduce harmful emissions to the environmentProtect downstream equipment from erosionProtect downstream equipment from erosionPrevent harmful & dangerous gasses from entering Prevent harmful & dangerous gasses from entering the atmospherethe atmosphereImprove well Improve well injectivityinjectivity
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Typical Oil Discharge Limits
Location Limit North Sea 40 mg/l
Arabian Gulf 15 to 40 mg/l Gulf of Mexico 29 mg/l
India 48 mg/l Onshore 0-5 mg/l
Sudan 50 mg/l
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Raw Water Analysis
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Injected Water Quality
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Equipment Typically Used inEquipment Typically Used inProduced Water TreatmentProduced Water Treatment
••Surge DrumsSurge Drums
••22--phase separatorsphase separators
••33--phase separatorsphase separators
••Liquid/Liquid HydrocyclonesLiquid/Liquid Hydrocyclones
••Solid/Liquid HydrocyclonesSolid/Liquid Hydrocyclones
••Multiphase Wellhead DesandersMultiphase Wellhead Desanders
••DegassersDegassers
••Single Cell FlotationSingle Cell Flotation
••Induced Gas FlotationInduced Gas Flotation
••Filter Filter Coalescer
••Cartridge FiltersCartridge Filters
••Chemical Injection PackagesChemical Injection Packages
••Gas Pressure LetGas Pressure Let--down Stationsdown Stations
••Hydraulic Wellhead Control Hydraulic Wellhead Control
••Gas FiltersGas Filters
••Packed TowersPacked Towers
••Gas CyclonesGas Cyclones
••Control PanelsControl Panels
••Analyser Houses and LaboratoryAnalyser Houses and Laboratory
Coalescer
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PRODUCED WATER DEOILING EQUIPMENT OPTIONSPRODUCED WATER DEOILING EQUIPMENT OPTIONS
Surge TanksSurge Tanks To collect fluids that are subject to regular surge To collect fluids that are subject to regular surge or upset conditionsor upset conditions
Collection VesselsCollection Vessels To collect fluids from multiple sourcesTo collect fluids from multiple sourcesDeoiling HydrocyclonesDeoiling Hydrocyclones Primary Separation for the removal of oil from Primary Separation for the removal of oil from
waterwaterTitled Plate InterceptorsTitled Plate Interceptors Primary separation for the removal of oil from Primary separation for the removal of oil from
waterwaterCentrifugesCentrifuges Primary Separation for the removal of oil from Primary Separation for the removal of oil from
waterwaterDegassersDegassers Removal of gas from water and a final polishing Removal of gas from water and a final polishing
stagestageInduced Gas FlotationInduced Gas Flotation Secondary Separation for the removal of oil from Secondary Separation for the removal of oil from
waterwaterFilter CoalescersFilter Coalescers Removal of oil from waterRemoval of oil from waterDeep Bed Media FiltrationDeep Bed Media Filtration Removal of solids and oil from waterRemoval of solids and oil from waterAdsorption FiltrationAdsorption Filtration Removal of oil from waterRemoval of oil from water
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PRODUCED WATER DESANDING EQUIPMENT OPTIONSPRODUCED WATER DESANDING EQUIPMENT OPTIONS
Cyclonic Wellhead Cyclonic Wellhead DesanderDesander
Coarse Sand Removal between 100 to Coarse Sand Removal between 100 to 150 microns150 microns
Coarse StrainerCoarse Strainer All solids removal down to about 80 All solids removal down to about 80 micronsmicrons
Produced Water Produced Water Desanding Desanding HydrocycloneHydrocyclone
Mid range sand removal down to about Mid range sand removal down to about 30 to 40 microns30 to 40 microns
Deep Bed Multi Media Deep Bed Multi Media FiltrationFiltration
Fine Solids removal down to 5 micronsFine Solids removal down to 5 microns
Cartridge FiltersCartridge Filters Coarse to Fine Solids removalCoarse to Fine Solids removal
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KEY DESIGN FACTORS:KEY DESIGN FACTORS:
-- Onshore or Offshore?Onshore or Offshore?-- Destination of Produced Water?Destination of Produced Water?-- New Plant, Expansion, Upgrade New Plant, Expansion, Upgrade or Retrofit?or Retrofit?-- Type of Field Type of Field –– Oil or Gas?Oil or Gas?
Process Conditions:Process Conditions:••Flow rate /TurndownFlow rate /Turndown••Pressure/Temperature/ViscosityPressure/Temperature/Viscosity••Composition of Feed StreamComposition of Feed Stream
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Main Process Diagram
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Main Process Diagram
2 m3/hr20,000 ppm
82 m3/hr500 ppm
80 m3/hr50 ppm
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See Through View
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Parameters affecting PerformanceParameters affecting Performance
Stokes Low
-- Oil Droplet Size (Shear, Valve location, bends)Oil Droplet Size (Shear, Valve location, bends)-- Pressure Differential Ration (PDR = 1.9)Pressure Differential Ration (PDR = 1.9)
--Example: Feed 7 Bar; Water: 4.5 Bar; Oil: 2 BarExample: Feed 7 Bar; Water: 4.5 Bar; Oil: 2 Bar-- Reject Ratio > 2%Reject Ratio > 2%-- Water lower viscosity at higher temperatureWater lower viscosity at higher temperature-- Oil viscosity: Low viscosity oil can shear easilyOil viscosity: Low viscosity oil can shear easily……-- Specific Gravity Difference.Specific Gravity Difference.-- Cyclone Diameter, Length.Cyclone Diameter, Length.-- Emulsion breakers, coagulants, surface tensionEmulsion breakers, coagulants, surface tension-- Gases up to 10% (Displaces Oil on the overflow)Gases up to 10% (Displaces Oil on the overflow)
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Advantages of HydrocyclonesAdvantages of Hydrocyclones
•• High efficiencyHigh efficiency•• compact designcompact design•• Low weightLow weight•• Directly replacementDirectly replacement•• Low CAPEX and low OPEXLow CAPEX and low OPEX•• No moving partsNo moving parts•• Little or no maintenance costsLittle or no maintenance costs•• Reliable and PredictableReliable and Predictable•• Consistently PerformanceConsistently Performance•• Wide material selection Wide material selection
(stainless & duplex steels, (stainless & duplex steels, ceramics, etc) ceramics, etc)
•• Insensitive to motion or Insensitive to motion or orientation
•• Modular (parallel to handle Modular (parallel to handle changes in treating capacities.changes in treating capacities.
•• Portable.Portable.•• Little instrumentation for Little instrumentation for automautom..•• WellWell--understoodunderstood•• Simple to operate, maintain, Simple to operate, maintain,
troubleshoot.troubleshoot.•• No special tools and little No special tools and little
operator training required.operator training required.
orientation
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Typical Production FluidsFluids in
Separator =Oil & Water
PW Package Inlet (from Separator)
< 500 ppm
Hydrocyclone Outlet
< 50 ppm
PW Package Outlet
< 30 ppm
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Multimedia FiltersMultimedia FiltersSpecial Design FeaturesSpecial Design Features
•• Low Operational Flux (6 to 9 m3/hr/m2 or 2.5 to 3.5 gpm/ft2)Low Operational Flux (6 to 9 m3/hr/m2 or 2.5 to 3.5 gpm/ft2)•• Extended Media Height (1.7 m or 5.5 ft)Extended Media Height (1.7 m or 5.5 ft)•• Special Wedge wire collection systemSpecial Wedge wire collection system•• High Backwash flow rate: 35 m3/hr/m2 on two intervalsHigh Backwash flow rate: 35 m3/hr/m2 on two intervals•• Provision for future air scouringProvision for future air scouring
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Multimedia FiltersMultimedia FiltersOperational AspectsOperational Aspects
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Multimedia FiltersMultimedia FiltersSequence of OperationSequence of Operation
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Unique FeaturesUnique Features
•• Hydraulic simulation calculations.Hydraulic simulation calculations.•• Two skids only to minimize site activities.Two skids only to minimize site activities.•• All skid Interconnecting pipe work, one pipe tie pieceAll skid Interconnecting pipe work, one pipe tie piece•• Compact skid dimension 14.4 x 3.5 metersCompact skid dimension 14.4 x 3.5 meters•• Soft soil Pillars Soft soil Pillars •• SST316 ANSI B73.1 pumps (API mechanical seal fitted with SST316 ANSI B73.1 pumps (API mechanical seal fitted with
plan #62 flushing)plan #62 flushing)•• Dosing systems were preDosing systems were pre--engineered and skid mounted, engineered and skid mounted,
complete with dosing pumps, FRP chemical tanks, mixers complete with dosing pumps, FRP chemical tanks, mixers and corrosion resistant ejectors.and corrosion resistant ejectors.
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Extra TreatmentExtra Treatment
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Raw Water Tank
Quantity: One (1)Quantity: One (1)
Capacity: 10 m3Capacity: 10 m3
Make: Carbon SteelMake: Carbon Steel
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Cyclone Feed Pumps
Quantity: Two (2)Quantity: Two (2)
Capacity: 80 m3/hr at 7 BarCapacity: 80 m3/hr at 7 Bar
Make: Stainless Steel 316Make: Stainless Steel 316
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Deoiler - Hydrocyclone
Quantity: One (1) DutyQuantity: One (1) Duty
Capacity: 80 m3/hr at 7 BarCapacity: 80 m3/hr at 7 Bar
Make: Carbon Steel Shell/ SS Make: Carbon Steel Shell/ SS
Duplex LinersDuplex Liners
Feed Oil Level: 450 ppmFeed Oil Level: 450 ppm
Outlet: Less than 20 ppmOutlet: Less than 20 ppm
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Multi-Media Filters
Quantity: Three (3) DutyQuantity: Three (3) Duty
Capacity: 80 m3/hrCapacity: 80 m3/hr
Make: C. St. Epoxy CoatedMake: C. St. Epoxy Coated
Diameter: 96Diameter: 96””
Feed TSS: 20 ppmFeed TSS: 20 ppm
Outlet TSS: < 1 ppmOutlet TSS: < 1 ppm
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Free CO2 Stripper
Quantity: One (1) DutyQuantity: One (1) Duty
Capacity: 80 m3/hrCapacity: 80 m3/hr
Make: FRPMake: FRP
Diameter: 1.5 X 4 M HDiameter: 1.5 X 4 M H
Feed CO2: 2,400 ppmFeed CO2: 2,400 ppm
Outlet CO2: < 10 ppmOutlet CO2: < 10 ppm
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Cartridge Feed Pumps
Quantity: Two (2)Quantity: Two (2)
Capacity: 80 Capacity: 80
m3/hr at 4Bm3/hr at 4B
Make: C.S.Make: C.S.
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Micron Cartridge Filters
Quantity: Two (2)Quantity: Two (2)
Capacity: 80 m3/hrCapacity: 80 m3/hr
Make: St. St. 316Make: St. St. 316
Rating: 5 Micron Rating: 5 Micron -- AbsAbs
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Chemical Dosing Systems
Quantity: Two (2)Quantity: Two (2)
Type:Type:
BiocideBiocide
O2 ScavengerO2 Scavenger