Field Trials Scheduled for New Compact Dehydration Technology:田间试验计划新的紧凑型脱水技术.pdf
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1、Copyright 2003, Offshore Technology Conference This paper was prepared for presentation at the 2003 Offshore Technology Conference held in Houston, Texas, U.S.A., 58 May 2003. This paper was selected for presentation by an OTC Program Committee following review of information contained in an abstrac
2、t submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Offshore Technology Conference or its officers.
3、 Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be cop
4、ied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Abstract Significant improvements in the capacity and performance of existing oil dehydrators and desalters are expected from an improved, patent pending, transformer and controller system. This e
5、lectrostatic system is now ready for a field trial in South America. Production at the selected facility is currently at 45,000 bopd per unit on a medium gravity crude oil. This oil is currently being processed by five 10-ft. diameter x 45 ft. long electrostatic dehydrators using combined AC/DC elec
6、trostatic technology. Pilot studies utilizing the improved transformer / controller have demonstrated capacity improvements exceeding 30% above existing technology or outlet BS&W reductions between 10 to 30%. To confirm these results and define the limits of this new technology, a series of schedule
7、d field trials has been planned. In addition, several other vessel modifications will include upgrading the inlet spreader design, and installing new high voltage electrodes. Once these improvements are made and the new compact electrostatic technology is implemented, it is estimated the vessel capa
8、city will increase significantly, while maintaining the required oil specification. If successful, this electrostatic transformer and controller may provide producers and refiners with a new technology to process highly conductive, viscous oils. Testing Objective Utilizing a South American oil facil
9、ity, a new electrostatic dehydration technology is scheduled to be field tested. The objective of these tests is to quantify improvements to the oil dehydration process, demonstrate the robustness of the equipment and establish confirmation of the laboratory test results. Facility The production fac
10、ility shown in Figure 1 has five oil dehydration vessels operating in parallel. Each horizontal dehydrator is 10 ft OD x 45 feet long x 125 psig with Dual Polarity electrostatic technology, open bottom spreaders, either steel or composite high voltage electrodes and pipe collectors. The Dual Polarit
11、y transformers are 480 volt, single phase rated for 150 kVA. Following an upgrade of three vessels to improve performance, a fourth vessel is scheduled to be retrofitted with a new electrostatic transformer including step/start switchgear and PC-based process controller. The facility has the capabil
12、ity to increase the oil flow to the test vessel so the limits of the technology can be investigated. Application The facility is currently processing a 27.1 API oil at flow rates varying between 45,000 bopd to 60,000 bopd per vessel. The operating temperature is maintained at 140 F and the operating
13、 pressure is 80 psig. At operating temperature the dry oil viscosity is 8.9 cp. The inlet water cut typically ranges between 20 to 30%. The outlet specification is less than 1% BS&W and is routinely met by the dehydration process. These vessels use Dual Polarity electrostatic technology, as shown in
14、 Figure 2, to treat the inlet oil/water mixture.1 Design features include inlet spreaders to distribute the incoming fluid evenly along the length and across the width of the vessel. The spreaders are open-bottom box-type, which permits bulk separation of free water and solids. Oil/water interface i
15、s established just below the spreader holes so the inlet fluids are distributed into the oil phase. OTC 15353 Field Trials Scheduled for New Compact Dehydration Technology Gary W. Sams and Harry G. Wallace, NATCO Group Inc. Figure 1 Field Site 2 OTC 15353 Approximately 24 inches above the interface
16、is an array of electrodes. These steel electrodes are arranged in parallel at a spacing of 6 inches. The steel electrodes are 6 inches high and at their ends approach within 6 inches of the vessel wall. Alternating electrodes are energized with a positive voltage and adjacent electrodes are energize
17、d with a negative voltage. The positive and negative voltages are supplied from a 100% reactance, 23 kV (rms) transformer. A single collector is located at the top of the vessel containing a series of holes located on opposite sides. The collector is optimized to ensure uniform collection along the
18、length of the vessel. A single outlet nozzle is located near the center of the vessel. Following installation of the new electrostatic transformer, it is expected the oil flow can be significantly increased by as much as 30% without an increase in the effluent BS&W levels. Alternatively, the new tec
19、hnology is expected to lower the effluent BS&W 10 to 30%. Technology The electrostatic technology to be applied utilizes a proprietary process controller and transformer package to produce an electrostatic field that can easily be optimized for any crude oil. This technology has been in development
20、for over 4 years and has demonstrated remarkable performance improvements in pilot facilities. The transformer consists of three primary components that are packaged in a single oil-filled enclosure. Designed to operate on three phase, 480 volts (50 / 60 Hz) the technology overcomes the load balance
21、 problem normally encountered with single phase electrostatic processes. First, the 480 volts is conditioned using IGBT technology (isolated gate bipolar transistors) to produce a variable amplitude and variable frequency voltage supply for the primary of the transformer. Second, the medium frequenc
22、y transformer steps up the input voltage to a secondary voltage level necessary to promote effective coalescence. Third, the secondary voltage is rectified into positive and negative half-wave outputs. These polarized, half-wave voltages are then applied to the electrodes in a Dual Polarity dehydrat
23、or. A PC-based process controller defines the voltage control environment to match the specific needs of the production. For example, where highly conductive crude oils are processed ( 80 nS/m), the frequency can be increased to maximize the energy delivered to the oil dehydration process. Utilizing
24、 a medium frequency transformer overcomes the voltage decay associated with conventional 50/60 Hz transformers. In wet crude oils the effective impedance may be very low, resulting in a rapid, voltage decay from the process electrodes. This decay reduces the effectiveness of the dehydration process
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