Separator Demulsifier Control Using Water Separation Profiles
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Solution Overview
Problem
In the oil and gas industry, accurately determining demulsifier dosage in Gas-Oil-Separation Plants (GOSP) is challenging due to variations in production conditions, leading to either demulsifier waste or off-spec production, as existing methods rely on historical data and do not account for real-time changes in crude oil properties and temperature.
Innovation Solution
A method that involves real-time, in-process control using a water separation profile (WSP) to adjust demulsifier dosage based on the response of separator vessels to incremental demulsifier injection rates, accounting for demulsifier inertia and specific process conditions, allowing for precise control of water concentration without historical data reliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If historical data-based demulsifier dosage methods are used, then production stability is maintained, but real-time adaptability to changing crude oil properties and temperature conditions deteriorates
Solution Approach 1:
The patent implements a real-time feedback control system that continuously monitors water concentration in the separator and adjusts demulsifier dosage accordingly. The system measures actual water content and uses this feedback to dynamically modify the demulsifier injection rate, enabling adaptation to changing crude oil properties and temperature conditions while maintaining production stability.
Solution Approach 2:
The patent transitions from static historical data-based dosage determination to dynamic real-time adjustment of demulsifier dosage. The system continuously adapts the demulsifier injection rate based on current process conditions including water concentration measurements, temperature variations, and crude oil property changes, making the dosage control flexible and responsive to real-time conditions.
2Reliability
If increased demulsifier dosage is used to prevent off-spec production, then production quality is ensured, but demulsifier waste increases
Solution Approach 1:
The system uses real-time water concentration measurements from the separator as feedback to precisely control demulsifier dosage. By continuously monitoring actual water content and adjusting demulsifier injection accordingly, the system achieves the minimum effective dosage required to meet production specifications, preventing both over-dosing and under-dosing, thereby eliminating demulsifier waste while ensuring production quality.
Solution Approach 2:
The patent dynamically adjusts the demulsifier dosage parameter based on real-time measurements of water concentration, temperature, and crude oil properties. This parameter optimization allows the system to use only the necessary amount of demulsifier to achieve the required water separation performance, avoiding excessive dosage and reducing chemical waste while maintaining production quality standards.
3Productivity
If real-time demulsifier dosage adjustment is implemented, then demulsifier utilization is optimized, but system complexity increases
Solution Approach 1:
The patent employs a feedback control architecture that, while adding instrumentation for water concentration measurement and automated dosage adjustment, streamlines the overall process by eliminating the need for manual dosage determination and historical data analysis. The automated feedback system simplifies operator tasks and improves demulsifier utilization efficiency despite the added measurement and control components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures stable water concentration at dehydrator inlets, minimizes dehydrator load, and optimizes demulsifier utilization by adjusting demulsifier flow rates according to real-time process data, thereby preventing both over- and under-dosing, ensuring consistent production quality.
Implementation Method 1
Demulsifier chemicals enhance the separation of the tight emulsion of salty water and oil according to specifications related to basic sediment and water content
Implementation Method 2
a high-pressure production trap (HPPT) that separates gas at pressures of 150-450 psig from the crude oil, a low-pressure production trap (LPPT) that separates gas at pressures around 50 psig from the crude oil
Data Source
AI summary
A computer-implemented method includes controlling water separation in a hydrocarbon stream flowing through a separator train including one or more separator vessels located upstream of a dehydrator by adjusting a flowrate of demulsifier added to the separator train by receiving data from a real-time process test of the separation train, quantifying a demulsifier inertia value from the process data, estimating model fit parameters to the process data to generate a water separation profile (WSP) correlating water draw-off and demulsifier flowrate for the separation train, and during operations, modifying the demulsifier flowrate according to the WSP and according to the inertia value to achieve a received target water separation value for the stream entering the dehydrator.