Emulsions and Electrostatic Treater Principles
At some point in the life of every oil well an
unacceptable amount of water will be
produced with the oil. Water usually seeps
into the formation as oil and gas are
produced from the reservoir. Generally,
the older the well the more water
produced.
As well fluids move through the formation,
artificial lift equipment, etc., oil and water
are mixed. Production separators are used
to separate the mixed fluids. Two-phase
separators separate natural gas from the
liquids. Three-phase separators separate
natural gas and the liquids, e.g., oil from
free water.
Well fluids which do not easily separate,
referred to as emulsions, must be treated
before they will separate into the various
components. Electrostatic treaters are
used to treat or break emulsions.
Treating emulsions is an expensive
process. To ensure treating is done at the
lowest cost, prop-erly sized equipment
must be installed, maintained and
monitored. Complete records should be
kept for each lease, e.g., chemical usage,
fuel gas, etc.
1
 When the opposite happens, an oil-in-
water emulsion is formed. Emulsions may
be tight (difficult to break) or loose (easy to
break) depending on the type and amount
of emulsifying agent present.

Emulsifying Agents

An emulsifying agent is a substance that

promotes the formation and stability of an
emulsion. This is accomplished by the
emulsifying agent collecting on the surface
of water droplets and forming a tough film
which keeps the droplets from joining.
Emulsifying agents commonly found in oil
Emulsions field emulsions include asphalt, resins,
paraffins, and oil soluble organic acids.
Some water produced with oil readily Different emulsifying agents occur
separates from the oil and is referred to naturally in different reservoirs.
as free water. On the other hand, some
water produced is mixed in such a way
with the oil that treating is necessary to
separate them. Such a combination of oil
and water is called an emulsion.
In an emulsion one of the liquids is spread
out, or dispersed, throughout the other in
the form of small dropiets. In oil field
emulsions, water is usually dispersed in oil
and is referred to as a water-in-oil
emulsion.

In order to break an emulsion, the film

must be neutralized or destroyed by using
treatment methods. Treating is usually
done in the field using various types of
equipment (free-water knockouts,
separators, heater treaters, electrostatic
treaters, etc.) and by adding chemicals to
the emulsion immediately after it is
produced.

2
Emulsion Stability
A stable emulsion is one which will not
break down or separate without some
form of treating. The stability of an
emulsion is dependent on several factors :
• Emulsifying agent. The effect
depends on the type of agent and
conditions under which the emulsion
is produced. The formation of a stable
emulsion would be very difficult
without an emulsifying agent.
• Viscosity of oil. Oil with a high
viscosity (resistance to flow) tends to
keep water droplets in suspension
creating a more stable emulsion.
• A.P.I. gravity of oil. Oil with a low
A.P.I. gravity tends to keep water
dropiets in suspension creating a
more stable emulsion.
• Water percentage. Generally, a
smaller percentage of water in an
emulsion means greater stability.
• Agitation. Increased agitation
means greater dispersement of water
and greater stability.
• Droplet size. Emulsions containing
small water droplets are more stable
because small droplets are lighter and
will not settle out as easily.
• Age of emulsion. The longer an
emulsion remains untreated, the
harder it is to break.
Treating Emulsions
Water produced from reservoirs may vary
from a small fraction of one percent to 99
percent. Pipeline companies do not pay
for water; therefore, most or the water
must be removed before it can be
delivered to the pipeline. In most cases
this requires treating an emulsion.
An emulsion should be tested frequently.
No two emulsions are alike. Even the
emulsion from a single weli changes over
time thereby requiring changes in the
treatment process. The treating process
must be monitored carefully since revenue
is affected by the gravity of oil. Natural gas
also generates considerable revenue for
our company and must be monitored
closely to ensure maximum yield and
minimal waste.
Treating emulsions may include one or
more of the following procedures: allowing
settling time, applying heat, injecting
chemicals, using electricity, or operating
mechanical devices.
Settling Time
The time needed to completely separate
an emulsion is called settling time. The
settling rate of a water-in-oil emulsion is
affected by viscosity, size of water
droplets, and gravity.
If the oil has a high viscosity (thick), then
the water droplets cannot move without
considerable resistance and wilt not settle
out easily.
3
Settling rate is also affected by the size of
the water droplets. Smaller droplets are
lighter and take longer to separate through
settling.
If the difference in A.P.I. gravity between
water and oil (the gravity differential) is
small, separa-tion is slow. However, water
weighs more than oil and will eventually
settle to the bottom of a vessel. Some
emulsions can be adequately treated with
settling alone. Others need additional
treatment procedures which are designed
to speed up the settling process.
Applying Heat
The ideal way to treat oil is without heat;
however, treatment frequently requires
heat to speed up separation. Heat by itself
will not break an emulsion, but it aids in
several ways: (1) Heat causes water
droplets to move faster and strike each
other with greater frequency and force.
When the droplets collide, the film of
emulsifying agent ruptures, and larger,
heavier droplets form. They then yield to
gravity differential and settle out; (2) Heat
lowers the viscosity of oil and allows the
water droplets to settle out more easily;
and (3) Heat speeds up chemical action.
Chemicals make the fiim of emulsifying
agent around water droplets rigid. When
heat is applied, the water droplets expand
and break the film. The droplets can then
merge into larger ones and settle out.
Heat must be applied only as needed
because too much heat will waste energy
(fuel) and cause greater wear on the
equipment. Also, excessive heat can cook
off the lighter ends of crude oil
which will change the oil's gravity and
result in lost revenue.
Adding Chemicals
Emulsion breaking chemicals are injected
into the well stream ahead of the
electrostatic treater. They react with the
film around water droplets, destroying or
neutralizing the film, thereby al-lowing the
droplets to coalesce (combine) and
separate from the oil.
There must be sufficient agitation to allow
the chemical to come into contact with
each water droplet. The amount and type
of chemical required directly affects how
well the emulsion breaks and the time
needed for settling. Also, the warmer the
emulsion, the less chemical is needed.
Chemicals must be applied only as
needed because too much chemical is
wasteful and could cause an oil-in-water
emulsion to form. This would allow oil to
leave the vessel through the water outlets,
resulting in lost revenue\and
environmental pollution.
Using Electricity
Electricity, usually used in conjunction with
heat and chemicals, will separate oil and
water. The vessel used to do this is called
an electrostatic treater and will be
discussed in sections two and three of this
module.
Using Mechanical Devices
Devices such as gun barrels and free-
water knockouts are used in the treatment
of emulsions. A gun barrel is basically a
settling tank used to separate oil and water
in the field. After emulsified oil has been
heated and treated with chemicals, it is
pumped to the gun barrel where water and
oil separate by gravity setting. Gun barrels
are largely being replaced by heater
treaters or electrostatic treaters but are still
4
common, especially in older fields.
A free-water knockout is a gravity-type
separator used to remove excessive water
from the produced fluid ahead of the
treating unit. Sometimes a filter or
excelsior, called hay, is used to catch
Electrostatic Treater Design
An electrostatic treater is a pressure vessel
which combines all the equipment
necessary to treat an emulsion.
Sometimes it is referred to as a chem-
electric or electrochemical treater. its
overall goal is jobreak the emulsion and
allow water to settle so that clean oil can
be obtained.
The specific combination of treating
methods in a given unit will vary depending
on the type of treatment and the unit's
position within the treating system.
Electrostatic treaters can be direct-fired or
use an external medium for a heat source.
Electrostatic Treater
The electrostatic treater, like other
emulsion treaters, uses both heat and
chemicals to break an emulsion. However,
particles of oil that may be entrained in the
free water as it passes through the filter.
The free water is drained off and only
emulsion passes on to the treating unit.
This device prevents over-loading of the
treating vessel and saves fuel.
the electrostatic treater also uses an
electrical charge to help coalesce water
droplets so they will settle out.
The electrostatic treater for any given
lease is designed to handle the well fluids
of that lease. Any number of modifications
in the basic design can be made. For
example, both the size of internal sections
and the amount of heat required may vary.
Selection of the right treater with emphasis
on the right combination of functions
depends on factors such as climate,
amount and type of well fluids to be
handled, and the characteristics of the
emulsion being treated. Treating should be
done at the least possible least cost,
possible addition of heat, and the least
possible loss of oil gravity.
Electrostatic treaters receive the emulsion
which has already been chemically
treated. The emulsion enters the top, and
then flows horizontally through various
treating sections. Each step brings the
emulsion closer to the desired result of
complete separation of oil, gas and water.
5
External Components
The external or outside components of an
electrostatic treater are those that are
readily ap-parent. Located all around the
treater, they serve varying purposes as
the treating process is taking place
internally.
• Fire Boxes. The fire boxes contain
gas burners which provide a heat
source for the treater. Most
electrostatic treaters will have two or
three fire boxes.
• Stacks. The stacks are metal
cylinders from which exhaust gases
are vented after flowing through the
firetubes.
• Thermometer. The thermometer
indicates the temperature at which
the emulsion is being treated.
• Thermowell. The thermowell
provides a location for the thermostat
temperature probe which allows a
thermostat to maintain the desired
treating temperature in the vessel.
• Inlet Line. Produced fluids
(emulsions) enter the treater through
the inlet line.
• Gas Equalizer. This pipe allows
gas pressure to be equalized
between internal sections of the
treater.
• Gas Outlet. Gas leaves the treater
and enters the gas outlet line through
6
the gas outlet. Some treaters have a
gas dome which is designed to
remove any liquid particles entrained
in the gas stream prior to leaving the
vessel.
• Gas Back-Pressure Valve (not
shown). This valve, located on the
gas outlet line, maintains sufficient
pressure in the vessel to dump
liquids.
• Safety Device. The safety device
may be a relief valve, rupture disc or
both. They are designed to open or
burst if too much pressure builds up
in the treater.
• Oil Outlet. Oil leaves the treater
and enters the oil outlet line through
the oil outlet.
• Oil Dump Valve. This valve is
located on the oil outlet line. The oil
• Make-up Gas Line (not
shown). Some treaters may have a
make-up gas line with a regulator to
maintain proper operating pressure of
the unit.
• Free Water Outlet. Free water,
which has settled out of the emulsion,
leaves the unit through this outlet
located on the bottom of the treater.
• Free Water Level Controller. This
device maintains the free water level
in the treater.
• Free Water Dump Valve. This
valve is located on the free water
outlet line. It allows free water to
leave the vessel.
dump valve allows clean oil to leave
the treater and is controlled by a level
controller.
• Treated Water Outlet. Treated
water, which has settled out of the
7
oil, leaves the unit through this outlet
located on the bottom of the treater.
• Treated Water Dump Valve. This
valve is located on the treated water
outlet line. It allows treated water to
leave the vessel.
• Treated Water Level
Controller. This device maintains the
treated water level in the treater.
• Drains. On the bottom of the
treater are drains to empty the vessel
for repairs or to remove accumulated
solids, e.g., sand, clay, etc.
• Transformer. The transformer
steps up incoming voltage to create
• .
the high-voltage electrostatic field in
the treater.
• Sight Glasses. These devices
enable a pumper to see the water/oil
interface levels in the treater. They
help him to determine abnormal fluid
levels (upset condition).
• Gas/Air Supply Lines. These lines
provide gas or compressed air to the
level controllers so they can work
properly. Gas/air supply lines usually
contain a regulator, drip trap, and
filter to help supply clean, dry gas or
compressed air to the level
controllers
8
Internal Sections
The internal sections are arranged in the
following order from fire boxes to
opposite end of the treater: inlet section,
surge section, and treating section.
Inlet Section. The inlet section, which is
the first section to receive emulsion,
serves two purposes. Entrained gas
separates and leaves through the gas
outlet thus preventing agitation of the
emulsion later. Also, free water which has
separated upon entry to the treater and
after being heated by the firetubes, falls
to the bottom where it is drained from the
unit.
• Baffle. The baffle separates the
gas separation area from the heating
area of the inlet section. It helps to
divert incoming emulsion to the
bottom of the treater.
• U-Shaped Hood or
Downcomer. This device covers the
firetubes in the gas separation area. It
diverts incoming emulsion to the
bottom of the treater.
• Water Wash. In this area of the
inlet section, the emulsion gives up
free water. Water washing is the
process where large water droplets
coalesce with small water droplets
and settle out
9
 • Flow Spreader. The flow spreader
disperses emulsion along the length
of the firetubes to ensure maximum
use of the heating area by using the
total surface area of the firetubes.
• Firetubes. The firetubes supply
heat to the emulsion causing oil
viscosity to be lowered so water
droplets can settle out.
• Weir. This is a dam-like device
over which emulsion from the inlet
section flows into the surge section.
Surge Section. The surge section is the
middle section which serves to keep the
treating section "fluid-packed," that is,
liquid completely filling the treating
section with no gas on top.
• Clean Oil Distribution Pipe. This
pipe connects the clean oil collection
header with the oil outlet located near
the bottom of the surge section.
Some units do not have an internal
distribution pipe and oil is removed
from the top of the treater.
Treating Section. Final treating and
settling of the emulsion takes place in this
section.
• Flow Spreader. The flow spreader
receives emulsion from the surge
section and disperses it along the
length of the treating section to
ensure uniform distribution over the
electrical grids.
• Electrical Grids. There are two
electrical grids made of steel rods.
The lower grid is electrically charged
while the upper grid is grounded.
Grids are suspended from the vessel
shell with insulated hanger rods.
10
 • Clean Oil Collection Header. This
header runs horizontally across the
top of the treating section and is used
to skim off clean oil for removal from
the vessel.
Monitoring and Safety Devices.
In order to operate properly and safely,
every electrostatic treater is equipped
with safety devices and monitoring
features.
• Fiame Arrestors. Flame arrestors
fit on the front of fire boxes. They
have a series of aluminum vanes
placed very closely together so heat
generated in fire boxes is dispersed
in the air before it can cause a fire
outside the vessel. Flame arrestors
should be used on any fired emulsion
treater.
• Fuel Gas Scrubber. The fuel gas
scrubber prevents entrained liquids
from "going to the burners with the
fuel gas. If the scrubber fills with
liquid, a float rises and shuts off a
valve which stops gas from flowing to
the burners, preventing the possibility
of a fire. The scrubber has a drain
valve that the pumper should open
each day to drain off liquids collected
in it.
• Safety Relief Valve. A safety relief
valve is a pressure-relieving device
designed to open at a pre-set
pressure to relieve excessive
pressure within a vessel or line. It
may also be called a pop valve.
• Rupture Disc. A rupture disc is a
fail-safe pressure relief device made
of metal that is designed to burst at a
pre-set pressure. The pre-set
•
pressure is usually at or below the
maximum safe working pressure of
the treater.
• Sight Glasses. Sight glasses or
gauge glasses are not safety devices
themselves, but they have safety
features built in. They are the best
way for the pumper to see if the
treater is doing its job. If the sight
glass is broken, a safety feature of
the sight glass valve will cause a steel
ball to seat and shut off the flow.
However, if the sight glass valve is
not wide open, the ball will not seat.
• Low Level Controller. The low
level controller is a safety device
installed on an electrostatic treater to
ensure that the firetubes are always
covered with liquid. It is designed to
shutdown the burners if liquid level
falls below the desired level. Shutting
down the burners keeps the firetubes
from overheating, which results in
tube failure and a safety hazard.
• Indicator Light. The indicator
light, located on the transformer,
remains on as long as the electrical
grids are functioning properly or
unless power has been lost to the
treater.
• Voltmeter. The voltmeter
measures the voltage of incoming
electricity to the treater. It should
read 220 or 440 volts during normal
operation depending on the electrical
power source.
• Circuit Breaker. A circuit breaker,
located between the power source
and the transformer, protects the
transformer from power surges.
• Ammeter. Some electrostatic
treaters have an ammeter to measure
the strength of electric current across
the grids.
11
Electrostatic Treater Operation

Electrostatic treaters are used for three-

phase separation: separating oil, water
and gas. Chemicals are usually injected
into the emulsion upstream from the
treater. Therefore, the treating process has
already begun by the time the emulsion
reaches the treater. Emulsion enters the
inlet section at the top of the unit and falls
to the bottom of the vessel. It then travels
upward across the firetubes and spills over
a weir into the surge section. From the
surge section, emulsion flows through a
spreader into the treating section where
final separation of water and oil takes
place.

12
Inlet Section.

Emulsion enters the treater, splashes over

the U-shaped hood or downcomer and
flows down-ward to the bottom of the
vessel. Free gas is released as emulsion
strikes the hood or down-comer and rises
to the top of the inlet section. Most free
water in the emulsion quickly settles out
and the remaining lighter liquids move
upward through the water, which serves
as a heated wash.

As the emulsion continues to rise, it flows

through a spreader which disperses
emulsion along the length of the firetubes.
This action ensures maximum use of the
firetubes for heating emulsion.

Several things happen as emulsion moves

Surge Section.
upward across the firetubes. The firetubes
heat the emulsion which aids in separation
A major purpose of the surge section is to
of oil and water. Heated emulsion rises
keep the treating section "fluid-packed."
and spills over a weir out of the inlet
Fluid- packed is when a vessel or section
section. Water, which has separated from
of a vessel is completely full of liquid with
the emulsion, settles to the bottom of the
no gas on top.
inlet section for removal. Gas, which has
separated from the emulsion, rises to the
top of the inlet section. A gas equalizer
pipe allows the gas from both sides of the
baffle to be equalized, gathered, and
removed from the vessel through the gas
outlet.

Some treaters have a heat exchanger

installed on the inlet line. If used, incoming
emulsion is preheated by the heat of
outgoing oil. Therefore, the firetubes need
to provide less heat. The settling time for
incoming oil is decreased, and the
outgoing oil is cooled to a desirable
storage temperature which minimizes
vaporization and maintains a higher oil
gravity.

13
No clean oil leaves the treating section
unless an equal amount of fluid enters the
surge section. This is controlled by a float
in the surge section which is mechanically
linked to the oil dump valve.
Treating Section.
Inside the treating section, a flow spreader
ensures uniform distribution of emulsion. It
is in this section that final treating and
settling takes place. From the spreader
emulsion rises upward toward the high-
voltage, alternating-current, electrical
grids. The lower grid is charged with
15,000- 20,000 volts of electricity while the
upper grid is grounded. Electrostatic
treating begins below the lower grid and is
completed between the upper and lower
grids where water droplets coalesce and
settle out.
heated emulsion rises through the
electrostatic field, water droplets are given
an electrical charge, which causes them to
become elongated and polarized. When a
water droplet becomes polarized, it
acquires a positive ( + ) charge on one end
and a negative (-) charge on the other end.
Alternating current on the lower electrical
grid GRIDS causes it to reverse polarity
(change from positive to negative) 120
times per second or 60 cycles per second.
This causes the water droplets to move
around rapidly and collide with each other
with enough force to break the thin film
surrounding each droplet.
The water droplets coalesce into larger
droplets and settle to the bottom of the
treating section for removal. Oil, which has
separated from the water, rises to the top
of the treating section. A clean oil col-
lection header skims off the clean oil for
removal from the treater.
Electrical System.
14

The electrical system consists of a step-up
transformer and two electrical grids
(electrodes). Step-up transformers
increase the incoming voltage to a higher
level, e.g., most electrostatic treaters are
supplied by 440 volts which is then
stepped-up to 15,000-20,000 volts to
produce the electrostatic field around the
grids.
The two grids are suspended one above
the other in the treating section. The upper
grid is grounded to the vessel shell and is
adjustable so that the electrostatic field
can be regulated to meet varying
coalescing requirements. The lower grid is
not grounded and receives the electrical
output from the transformer. Both grids
are suspended from the top of the vessel
shell by insulated hanger rods. All
components of the electrical system are
designed for high voltage service.
The transformer is the heart of the
electrical system. Most electrostatic
treaters have a reac-tance type
transformer which has a reactor to protect
the transformer from power surges and
high voltage dispersion. These
transformers are oil-immersed and meet
all reasonable electrical safety
requirements. A circuit breaker, located
between the power source and the
transformer, protects the transformer from
electrical power failures. A fused
disconnect at the power source is
recommended for maximum safety.
Fluid Levels.
Oil level in the treating section is
maintained by the oil dump valve, which is
operated by a float in the surge section.
When emulsion rises above a pre-set level
in the surge section, the float rises with the
emulsion and causes the dump valve to
open, which allows oil to leave the vessel.
When the emulsion returns to the pre-set
level, the dump valve closes and allows oil
to accumulate in the treating section.
Free water and treated water levels in the
treater are maintained by water dump
valves. As with the oil dump valve, water
dump valves open to remove water when
the interfaces rise above pre-set levels and
close when the interfaces return to pre-set
levels.
Both water dump valves operate by means
of Interface level controllers which use gas
or compressed air to open and close the
dump valves. This is achieved by the level
controller diverting gas or compressed air
to the diaphragm of the dump valve. Gas
or compressed air pressure offsets the
spring tension holding the diaphragm in
the closed position. This action lifts the
diaphragm and allows water to flow
through the dump valve. When the
interface returns to its pre-set level, the
level controller vents the gas or
compressed air and allows the diaphragm
to seat, closing the dump valve.
Some electrostatic treaters are designed
to allow water in the inlet section to join
water in the treating seciion before being
removed from the treater. This
arrangement utilizes one dump valve and
level controller to maintain water ievels in
the treater. Mechanically operated oil
dump valves and gas-operated water
dump valves have been discussed in this
manual. Other types of oil and water dump
valves may be used on electrostatic
treaters.
Operating Temperature.
Operating temperature is important and
will vary from lease to lease. The lowest
possible temperature to adequately treat
15
the emulsion should be used. In warmer
climates, heating may be necessary only in
colder months.
When heating is required, lower
temperatures can be used in electrostatic
treaters than in conventional heater
treaters. Treating temperatures normally
range between 85°F and 135°F.
Temperature of emulsion in the inlet
section should be somewhere around
140°F so the tem-perature of fluid in the
treating section around the grids never
falls below 70°F. If fluid temper-ature gets
below this level, the grids will not have the
proper treating effect on the emulsion. The
relation of chemicals to temperature is an
important factor to be considered. Usually
less chemical is required to treat a warm
emulsion. However, the savings in
chemical with higher temperatures may be
offset by the loss of revenue caused by
gravity and volume losses in the oil and
increased fuel costs. Temperature
controls or thermostats are an important
part of any emulsion treater. If they fail to
function properly, the burners could
remain off or on all the time.
If they remain off, the emulsion may cool
so that it does not completely break up. If
the burners remain on, the treater may
overheat and be damaged, the lighter
ends of the oil may be cooked off changing
gravity, and oil volume will be decreased
resulting in lost revenue.
Firetubes should be inspected at periodic
intervals. Since most emulsions being
treated contain a certain amount of sludge
and solids, the firetubes should be
checked for corrosion, rust and
accumulation of scale.
The burner flame should aim straight down
the center of the firetube. If it hits the
firetube directly, a hot spot will form and
premature firetube failure will occur. The
burner should come on and burn steadily
for a long period of time rather than
blasting on and off. A yellow flame with just
enough air to keep from forming soot is
best.
Operating Pressure.
Electrostatic treaters operate under
working pressures of 5 to 50 psi. The
maximum working pressure for a treater
can be found on the manufacturer's
information plate attached to the treater.
The type of valves and controls used
varies depending on the treater
construction. Oil, water, and gas
discharge lines must be equipped with
controls. Since electrostatic treaters
operate under pressure, they should be
equipped with pressure relief devices that
16
have enough capacity to protect the
treater if pressure increases.
Gas leaving at the top of the treater is
controlled by a gas back-pressure valve
which controls the pressure in the treater.
The inlet and surge sections are held at a
slightly higher pressure than the treating
section. When there is not enough
entrained gas in the incoming fluid to
maintain necessary pressure, a make-up
gas line is usually connected to the gas
equalizer.
There are several reasons why a higher
pressure is maintained in the first two
sections.
• The differential pressure assures a
positive flow of fluid from the surge
section to the treating section.
• The treating section must be fluid-
packed.
• There must be enough differential
pressure to move the clean oil to
storage tanks.
Pressure of the natural gas used to fire
the electrostatic treater must be
regulated. Any pressure
over the range of the thermostat will keep
the thermostat from closing and
overheating of the
treater will result.
Troubleshooting.
• Emulsion in the Lease
Tank. Emulsion in the lease tank is an
indication that the proper chemical-
heat combination is not being applied.
Both the chemical injector and treater
should be checked for any necessary
corrections. If neither is
malfunctioning, it may be that the
characteristics of the emulsion have
changed and a different chemical is
required.
• Free Water in the Lease Tank. If
the water outlet lines are plugged or
the water dump valves do not open,
water has nowhere to go except out
the oil outlet into the lease tank. If the
valves are operating properly, it may
be that the treater simply cannot
handle the amount of free water
produced, and a free- water knockout
unit should be installed upstream of
the treater.
• Oil in the Water Disposal System.
This can happen if the oil outlet is
plugged, the oil dump valve is stuck
closed, or the water dump valves are
stuck open. Sometimes when the oil
outlet on a treater is below the oil inlet
on the lease tank and the back-
pressure valve fails to hold a positive
pressure on the treater, oil will go
through the water outlets into the
water disposal system.
SAFE LIGHTING PROCEDURE
Recommended steps for safely lighting a
gas-fired electrostatic treater.
STEPS
1. Close pilot valve, gas burner valve,
and main gas supply valve.
2. Be sure all gas is vented from
firetube and flame arrestor is in place.
3. Be sure firetube is covered with
fluid.
4. Stand to one side while inserting
burning torch. This protects the
operator from ignition of residual
vapors.
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 5. Adjust torch position to ignite pilot.
y6. Open main supply valve.
6. Slowly open pilot valve.
7. Open burner valve after pilot is
lighted and torch removed.
8. Adjust gas and air mixture to obtain
proper flame.
9. Set fuel pressure as low as possible
to maintain proper temperature.
MAINTENANCE CHECKS
For smooth operation, the following
maintenance checks should be performed
as indicated :
STEPS :
• Daily
1. Check indicator light on
transformer. It should always be on
and bright.
2. Check the voltmeter. It should read
220 or 440 volts depending on
electrical power source.
3. Check free and treated water levels
using sight glasses. Adjust levels if
necessary.
4. Check gas back-pressure valve for
correct vessel pressure. Adjust
pressure if necessary.^
5. Check the oil dump valve linkage.
6. Check the water dump valves for
condensation or accumulation of
liquids in the gas/air supply lines by
opening the bleed valves provided.
7. Drain the drip traps that supply
gas/air to the water dump valves.
8. Check treater temperature to make
sure fires aren't out and the
thermostat is operating in the right
range. Adjust temperature if
necessary.
9. Drain the fuel gas scrubber.
10. Check chemical pump and
chemical surge tank.
• Weekly
1. Open the bottom drains on the
treater briefly. This will prevent build-
up of sediment and help prevent drain
clogging.
2. Sight glass valves should be
checked to prevent clogging. Sight
glasses should be cleaned if needed.
3. Take inlet and outlet samples to
check BS&W content.
• Monthly
1. Check the burners and pilots for
good performance. Clean if
necessary.
2. Check the burners to make sure
they remain centered in the firetubes.
3. Check the flame arrestors to make
sure they are not clogged. Clean if
necessary.
• Yearly
1. Inspect and clean entire vessel.
Use proper safety procedures for
confined space entry.
2. Inspect the firetubes, remove from
vessel and check for heat stress and
cracks.
3. Inspect the fuel gas scrubber float
to make sure it works.
4. Inspect dump valves. Clean and
repair if necessary.
WATER LEVEL CHECKS
Water levels are pre-set. When the water
level changes, these checks can be done
to restore it to the pre-set condition :
• PROBLEM : Low Water Level
POSSIBLE CAUSE : Emulsion build-
up at the interface. Increased weight
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 of emulsion on the water will cause
the level to drop.
• PROBLEM : No Water Level
POSSIBLE CAUSE : Low gas
pressure. Back-pressure valve may
be leaking or set too low. Safety relief
valves may be leaking.
An oil valve stuck in the closed
position. This would force all liquid
out the water dumps or the gas
outlet.
Circulating pump rate is too high.
More volume than the treater can
handle.
Leaking water dump valves. This
would cause loss of the fluid seal and
low gas pressure.
• PROBLEM : High Water Level
POSSIBLE CAUSE : Plugged water
dump lines. Usually caused by scale
build up.
There are many problems that can occur
with electrostatic treaters. If you observe
unusual conditions, check with your field
foreman.
GLOSSARY
• Alternating Current : (A.C.)
Electrical current which reverses flow
at regular intervals, usually 120
reversals per second or 60 cycles per
second.
• A.P.I. Gravity : Specific gravity as
defined by the American Petroleum
Institute.
• BS&W : Basic sediment and water.
• Coalesce : Combining water
droplets into larger droplets so they
will settle out of oil.
• Direct Current : (D.C.) Electrical
current which flows continuously in
one direction.
• Emulsifying Agent : The substance
which determines the stability of an
emulsion; it forms a film around the
suspended droplets.
• Emulsion : Mixture of liquids which
can only be separated by a treating
process.
• Emulsion Stability : Measured by
the degree of difficulty in breaking the
emulsion; affected by several factors.
• Fluid-Packed : Condition when a
vessel or section of a vessel is
completely full of liquid with no gas on
top.
• Free Water : Water which readily
separates from other fluids.
• Interface : The point at which the oil
and water meet.
• Loose Emulsion : An emulsion
which is easy to break.
• Polarized : When a substance
acquires a positive ( + ) charge on one
end and a negative (-) charge on the
other end.
• Settling Time : Time it takes for
water to separate from oil.
• Sight Glass : Device located on the
outside of a vessel used for monitoring
liquid levels.
• Three-Phase Separation :
Separating gas, oil, and water.
• Tight Emulsion : An emulsion
which is difficult to break.
• Treated Water : : Water which
separates from other fluids only after
treating with heat, chemicals, etc.
• Two-Phase Separation :
Separating natural gas from liquids.
• Viscosity : Thickness of oil;
resistance to flow.
• Weir : A dam-like device which
controls liquid level and flow through
the electrostatic treate
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