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Separation Unit
Separation
that happens in Oil – Gas Separators : Separate the reservoir water and gaseous phase from oil
by more separation stages, connected in cascade and working at decreasing pressures; –
Convey separately the various phases to the relative treatment Units
Oil Stabilization Unit
– Separate the reservoir free-water emulsified with high viscosity crudes, by heating and suitable
settlement times in proper equipment (gun barrel, desalter, heater treater).
– Wax removal.
– Stabilization:
– Stabilize the crude coming from primary treatment, at temperature and pressure required by
transport and storage in accordance with sale specifications.
– Crude transfer to storage or export pipeline.
Gas Sweetening
– Assure the removal of acid fractions from a gaseous stream to reach the specification
characteristics; the sweetening process involves the removal of CO2, H2S and mercaptanes.
– Sweetening can be carried out by one or two processes in series; in the case of two processes:
Furthermore, selective processes can be utilized for the single gases to be removed. Function
can include, according to the reservoir gas characteristic, a sulfur recovery plant, a H2S flare to
avoid atmospheric contamination.
Water Injection
– Supply high quantities of water, suitably treated, to the pressure required for injection into the
reservoir in order to increase recovery of remaining oil.
Treatment includes:
– wet gas: gas below or close to the dew point: water and/or condensates are present or may
develop.
– dry gas: gas is significantly above the dew point thus free from liquid phase
Liquid Hydrocarbons
– Water associated with the production fluid could have the following origin:
– Condensed Water: caused by condensation from wet gas hydrocarbons (due to pressure
and/or temperature variations). Very low mineral content, low chlorides, low pH (typically 3 – 4)
– Formation (or production) Water: present in the reservoir and carried over together with the
production fluid in oil and multiphase systems. It is characterized by higher pH (4 – 5.5) and high
chlorides content (typically 10’000 – 100’000 mg/l) .
– The content of the production water is expressed as “water cut” that is the percentage of the
water on the total liquid.
– During production the fluid in the reservoir is subjected to isothermal expansion which, in the
case of wet gas can lead to condensation of gas in the reservoir initially gas monophase.
– Throughout the tubing, fluid is subjected to a polytrophic transformation (decrease of
temperature and pressure from bottom hole to wellhead) which can give place to:
– gas phase formation in oil wells, when the bubble point pressure is reached,
– liquid phase (gas or light hydrocarbons) condensation in the case of retrograde condensation
of gas wells.
– the production fluid is classified “SOUR” if H2S is present and classified “SWEET” if it is not.
– fluid is called “CO2 –dominated” if the CO2/H2S > 200 and H2S dominated otherwise.
– Associated water amount (water cut), origin (formation or condensation), pH and chlorides
content are also of major importance.
– OTHER: Check for presence of SRB, Elemental Sulphur, Mercury, Solid Particle (Sand) or
contamination with Oxygen.
– CO2 Corrosion
– Sulphide Stress Cracking (Sour Service) “SSC”
– Hydrogen Damage (Sour Service), “HIC, SOHIC, Blistering”
– Erosion Corrosion
– Galvanic (Bi-Metallic) Corrosion
– Microbiological Induced Corrosion, “MIC”
– Localized Corrosion (pitting, crevice).
– In oil system, water wetting is uncertain between 5% to 40% water. This can be a function of
crude type and flow
regime.
– SECOND, LIQUID WATER MUST WET THE SURFACE OF CARBON STEEL EQUIPMENT.
Therefore, gas-to-oil ratios, water cuts, flow effects and flow pattern are used as rules-of-
thumb.
– Possible corrosion forms caused by produced fluids strictly depend on the metallic material in
contact with the fluid.
– To assess the corrosivity of the produced fluids – and particularly concerning CO2 corrosion –
reference is first made to carbon and low alloy steels as base case for material selection.
– For the most common O&G production fluids, the following forms of corrosion shall be
anticipated and evaluated for candidate materials: