DGF Retrofit Case Studies – Case 2

RETROFITTING PRODUCED WATER VESSELS FOR
BETTER RESULTS FOR THE OIL AND GAS
INDUSTRY
MONOSEP® PRODUCTS AND SERVICES
Company Profile
Siemens Water Technologies in the Oil and Gas Upstream
market is made up of USFilter, Monosep, and Zimpro Products
USFILTER designed and sold first API in early 1930’s.
Siemens purchased USFilter in 2004 which became Siemens
Water Technologies
Monosep founded in 1972 and bought by Siemens Water
Technologies (SWT) in 2005.
SWT provides Produced Water and wastewater treatment systems
and products, including Oily Water Separation Products for
Produced Water, and Flowback Services.
Our staff includes Sales/Marketing, Engineering, Manufacturing and
Field Service.
Approximately 260 employees in 3 main locations, including
Houston, TX, Lafayette, LA, and Rothschild, WI.
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Slide 2
Revenues of ~US$60 million per year for Upstream Oil and Gas,
part of the approx. US$100 Billion for all of Siemens.
Primary, Secondary, and Tertiary
Equipment
Primary Separation
Hydrocyclones
Solid/Liquid
Liquid/Liquid
Corrugated plate separators (CPS)
Skimmer
Secondary Separation
Dissolved Gas Flotation (DGF)
Spinsep – Vertical Vessel
Veirsep
Combosep
Cyclosep
Induced Gas Flotation (IGF)
Hydrocell
Quadricell
Tertiary Separation
Coalescing filter
Cartridge filter
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Slide 3
Walnut shell filter
Primary Question: What happens when
environmental standards rise (such as with
OSPAR) but you don’t have a produced water
system that is able to meet those specs.
Secondary Question:What happens when you
don’t have enough space/footprint within your
facilities to allow for additional process equipment.
Slide 4
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During the 1970’s, typically a CPI was followed by an induced gas
floatation vessel (or only an IGF by itself). O/B specs were 30ppm
or above and were not tightly monitored.
Courtesy of ProAnalysis,AS
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Slide 5
After 1970’s, hydrocyclones were installed to reduce overall
footprint of primary vessel and then followed by a degassing vessel.
O/B specs were still the same and were not tightly monitored.
-Over 220 producing platforms in the North Sea.
-More than 50% are older than 20 years
Slide 6
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OSPAR began its first real year of application in 2007 where
O/B oil must be reduced 15% below a field’s Year 2000
level. High financial penalties are to be paid if targets are not
met. The Norwegian Sector commits to continuously reduce
below these levels.
Slide 7
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A solution is to retrofit a process vessel/tank
downstream of the primary deoiler
(CPI/Hydrocyclone) such as a degassing vessel
with a gas inducing pump to allow for better
floatation to remove oil droplets.
Slide 8
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Flotation Process
By attaching a small gas bubble to an oil droplet, it will
decrease the density of the droplet which will increase the
rate at which it will rise to the surface.
° •°° ↑ ° •° ↑° ° •°
Critical Flotation Criteria
Population of Gas Bubbles
Size of Gas Bubbles
Distribution of Gas Bubbles
Oil Droplet “Rate of Rise”
Slide 9
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A degassing vessel
allows this process to
occur naturally as
pressure within the
vessel drops below
bubble point allowing
natural gas to form and
create bubbles as it
comes out of solution.
Slide 10
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Siemens Water Technologies enhances this
process by adding bubbles to the downstream
vessel to improve oil recovery from produced
water.
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Flotation Bubble Technology
DGF Pump Technology
Greater bubble dynamic
flexibility
Reduced maintenance
costs
Capable of dissolving gas
into solution
Bubble sizes ranging from
1 to 100 microns
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Slide 14
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DGF vs. IGF Technology Comparison
DGF produces smaller micron gas bubbles than IGF
DGF produces a much greater population of gas bubbles
than normal degassing.
DGF can “Dissolve” gas into produced water.
DGF
Degassing
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Slide 15
40x Magnification
DGF Retrofits/Conversions
Slide 16
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DGF Conversion List
RETROFIT/CONVERSION TRACKING LIST
Project #
CLIENT
LOCATION
DATE
REMARKS
2869
Taylor Energy
MC20
Feb-04
Multisep to DGF conversion
2921
Millenium
ST 77A
Feb-04
Wemco refurbish
2891
Devon
EC 344B
Dec-03
Precipitator to DGF conversion
2849
Devon
SMI 23G
Sep-03
Envirolink to DGF conversion
2828
Elpaso
EI 372
Aug-03
IGF refurbish
2782
Chevron
MP 30A
Jul-03
IGF refurbish
2786
J.M. Huber
ST 27E
Aug-03
Petrolite to Eductor conversion
2667
BP
EI 240
Jun-03
IGF refurbish
2726
Devon
EI 330C
Jul-03
Skimmer to DGF conversion
2642
J.M. Huber
WC 238A
Mar-03
Monosep to DGF conversion
2680
Anadarko
SS 204A
Jun-03
Envirolink to DGF conversion
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Devon
SMI 128A
Aug-03
IGF to DGF conversion
2519
El Paso
GA 255A
Jul-02
IGF refurbish
2483
J.M. Huber
ST 21D&H
May-02
Wemco retrofit
2463
Ocean Energy
EI 51B
Apr-02
ECI unit to Eductor conversion
2463
Ocean Energy
EI 51B
Apr-02
Skimmer to DGF conversion
2398
Newfield
HI 536C
Apr-02
IGF upgrade
2359
Marathon UK
Brae "A"
Feb-02
Tridair to eductor system
2300
Chevron
MP 133C
Oct-01
Chemlink to DGF conversion
2296
Chevron
Verm 214A
Apr-01
Sparge tower conversions
2233
Tri-Union
EI 277
Mar-01
IGF upgrade
2228
Thums
Long Beach
May-01
Wemco to DGF conversion
N90120
On Site Services
Trinidad
Nov-06
Verisep IGF to DGF
N90125
BP
Holstein
Dec-06
Degasser to DGF Conversion
N90151
Nexen
EI-257-C
Feb-07
Skimmer to DGF conversion
N90196
Arena
HI-547-B
Dec-06
Skimmer to DGF conversion
N90173
Dana
Tern Platform
May-07
Skimmer to DGF conversion
N90137
Bolland
Peru
Nov-06
API tank to DGF
N90138
Bolland
Peru
Nov-06
API tank to DGF
N90252
Nexen
EI-2578-B
May-07
Skimmer to DGF conversion
Slide 18
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2591
DGF Retrofit Case Studies
Case 1
DGF Retrofit of Sparge Vessel (2001)
Case 2
DGF Retrofit of Degasser (2006)
Slide 19
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DGF Retrofit Case Studies
Case 1 – Sparge Retrofit (2001)
Slide 20
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DGF Retrofit Case Studies – Case 1
Objectives
Eliminate sparge tubes
Improve level control
Lower labor cost
Lower sock filter cost
Improve overboard water quality
Optimize chemical cost
Evaluate current processing equipment/make
recommendations
Slide 21
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DGF Retrofit Case Studies – Case 1
Results
Gas savings: 74 mcf x $3.00 = 222 per day x 365 = $81,030
Solid sock filter savings: $442 x 365 = $161,330
Filter disposal 12 bins per year @ 2000 = $24,000
Labor savings = $12,288
Chemical savings: $36 x 365 = $13,140
Total Yearly Savings: $365,000
Slide 22
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DGF Retrofit Case Studies – Case 2
Objectives
Optimize existing degasser
Improve level control
Improve overboard water quality as part of a system wide
produced water project
Evaluate current processing equipment upstream and
downstream of degasser and make recommendations
Slide 23
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DGF Retrofit Case Studies – Case 2
Solutions
Design new internals for degasser and skim tank
Add DGF technology to degasser
Slide 24
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DGF Retrofit Case Studies – Case 2
TAG# HO-PBE-4 3 1 5 /4 3 1 6
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Slide 25
DGF Pump
DGF Retrofit Case Studies – Case 2
Globe Valve
Added Internals
Slide 26
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DGF Retrofit Case Studies – Case 2
Slide 27
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P&ID
Slide 28
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Cost Savings Results
Results
Water Clarifier Reduction = 36 GPD
Anticipated demulsifier reduction = 45 GPD
Total Anticipated Saving = $1,084.33 / day
Slide 29
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Performance Curve
DGF Pump Performance With Chemical Optimization
350.0
Note: The corrosion inhibitor pump from A10
was repaired and brought up to rate at the
same time of the upset and could have
contributed to the upset. The effects of C.I. to
water quality with low water clarifier injection
rates, will be monitored.
The pad should be reduced or diminish with
demulsifier rates high and water clarifier rates
reduced.
There was no overboard sheening event, and oil
and grease levels met the daily acceptable
average of 29 PPM.
250.0
150.0
3 :3
4 :0 0 P M
4 :3 0 P M
10 0 P
: M
1 1 45 P
;4 M
2 :0 5 P
M
3 :0 0 A M
0
4 :5 A M
7 :0 0 A M
9 :0 0 A M
10 0 A
M
:
11 00 A
:3 0 M
12 A
:3 M
1 :3 0 P
M
2 :3 0 P M
0
3 :3 P M
4 :3 0 P M
6 :0 0 P M
8 :0 0 P M
10 0 P
:0 M
2 :2 0 P
M
4 :2 0 P
M
0
6 :0 A M
5 :0 0 A M
7 :0 0 A M
10 0 A
:0 M
2 :20 A
M
5 :0 0 P M
0
7 :0 P M
10 0 A
:0 M
2 :00 A
M
5 :0 0 P M
0
8 :0 P
0 M
4 :0 A M
7 :2 0 P M
9 :3 0 A M
0
4 :0 A M
8 :0 0 P M
9 :3 0 A M
11 0 A
:0 M
2 :00 A
M
4 :0 0 P M
7 :3 0 P M
10 0 A
:0 M
12 0 A
:0 M
2 :0 0 P
M
4 :0 0 P M
0
PM
50.0
10/23
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10/27
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10/28
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10/29
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10/30
10/30
10/30
10/30
O il an d G r ea se P P M
Demulsifier reduced too low
causing dirtier water and the LP
Sep level dropped to 75% at 4:00
PM, thus it was proven that extra
demulsifier is needed to tightenDGF Pump Performance
up solids from the pad in the LP
Very Good, Allowing
Sep.
Water Clarifier to be
Reduced by 64% and
WSO Control(ZB307) by
73%
-50.0
10/30
Date/Time
PW Deg. In
PW Deg. Out
Overboard
Slide 30
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Slide 31
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CONCLUSIONS
ENHANCED OIL RECOVERY DOES OCCUR
REDUCED CHEMICAL REQUIREMENT OCCURS
NO SIGNIFICANT ADDITIONAL FOOTPRINT REQUIRED
Slide 32
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