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Facilities Design Shift Horizontal Equipment in Oklahoma Scott King
Facilities Review in Oklahoma
• Identified areas for improvement – Design criteria is outdated for play types – Vertical separation, cannot sustain a varied, nimble, and adaptable
process flow – Criteria for justifying vertical equipment
• What are we going to solve? – Liquids rich plays demand alternative solutions
• Do we need to change?
2
Current Design: Vertical Separation
• Most commonly used in mid-continent
• Historically relevant in Mid Continent due to gas plays
• Footprint was of design importance • Readily available with fabricators • Sub-optimal with higher liquid
volumes
3
Change in Design
• Horizontal Heater Treater – Heating element in oil
phase – Efficient emulsion control
• Horizontal Separation – Increase liquid handling – Efficient and longer retention time – Sufficient gas handling with pressure
control – With proper controls and operation,
rental flowback equipment can be minimalized
– Reduced separator sizing
4
Basic Horizontal Separator
Design Criteria • Flowback Elimination • 500 PSIG MAWP • Mechanical Dumps • Sand Pan • Multiple Solid Drains • Clean Out Ports • Weir (18” height) • Direct inlet
5
Basic Horizontal Heater Treater
Design Criteria • Mechanical Dump • No adjustable water leg • 125 PSIG MAWP • Multi-stage separation
capabilities • Additional oil residence time • Sales/Tank/VRU gas flow • Volume specific
6
Flowback System – Engineered
Design Ideals • Minimal fittings and
elevation changes downstream of choke
• Utilize swab choke for repairs
• Minimal rental iron
7
Equipment Layout
Perpendicular Layout • Simplified piping • Spacing requirements • Construction Efficiencies
in cost and time
50ft.
65ft.
Meters
10ft.
7ft.
8
Change in Construction
• Horizontal Process Equipment – Larger footprint – All devices at ground level – Spacing still important – Need at least 15 psig to push fluids to storage – Develop strategies of equipment placement
• Parallel or Perpendicular
9
Change in Flowback
• Chokes at equipment • 30 days of flowback rental equipment
– Only utilize plug catcher, sand separator, frac tank, and minimal piping • Multiple flow regimes through process equipment
– Frac tank hookup in swab line – Ability to move all flow through either swab choke
10
Full Process Flow Diagram (PFD)
3" Sch. 160Welded Flowline
Buried
2" Sch. 402" Sch
. 40
2" Sch. 40
1" Sch. 40
Kimray 330 SGT-‐BP 3" BPV
4" Sch. 40
¼” NPT Piping
To Heat Trace
To SSV
To Flare Supply
500 BBLOil Tank
500 BBLOil Tank
Vent
Kimray212 SGT-‐BP
500 BBLWater Tank
Recirc lineFitting
Recirc lineFit ting
1" PSV125 PSIG
Blowdown
To VRU Supply
3" Sch. 40MRO Chk Meter Skid
Custody Transfer
2" Sch. 40
2" Sch. 40
1" Sch. 40
1" Sch. 40
2" Sch. 40
To Heater Treater Scrubber
To VRT or Tanks
From Heater Treater / VRT
From Supply Dump
8 oz./-‐0.4 oz. 8 oz./-‐0.4 oz. 8 oz./-‐0.4 oz.
4" Pressure (6 oz.) /Vacuum Relief (-‐0.4 oz)
Valve (Enardo)
2" Sch. 40
From Compressor
Dump
From VRU Compressor
Dump
SSV1-‐13/16"
10,000 PSIG
3/8" SSTubing
To VRTFrom VRT
Midstream Meter Skid
From VRU
Rev. 0: Create PFD
Horizontal EQ (Flowback)Initial Process Flow Diagram (PFD)
2" Sch. 40
3/8" SSTubing To LPS Oil Dump
To Compressor From Compressor
From Flare Dump
To Flare
2" Sch. 40 2" Sch. 40 2" Sch. 40
2" Sch. 40
2" Sch. 40
3" Sch. 40FlowbackChoke
SwabChoke
Frac TankFi tting
KimrayCBA 250 SOA
3" PSV250 PSIG
Kimray 850 HUTA
KimrayCBA 250 SOA
Which Valve?
KimrayCBA 250 SOA
Kimray 850 HUTA
KimrayCBA 250 SOA
48"x20'
125 MD (H)HT
From Supply
Drain
2" PSV125 PSIG
Blowdown
Make 4" Sch. 40 for H2s Treating?
Move scrubber here to take advantage of pressure drop, cool gas, and possibly
remove excess chemical?Straddle BPV?
Install a “P” Trap?
36"x10'
500 MD (H)LPS
Can run line to sales with BPV set to open to tanks / VRT @ 100 psig
• Inlets and gas outlets are planned to be 4" threaded couplings• Liquid dumps/drains are 2" threaded couplings• Dump controllers are planned to be mechanical• Heater treater will be 125 psig to possibly sell gas if line pressure is low enough• Move fuel scrubber to downstream of BPV? Or straddle BPV with two 1" fittings• Flow-‐back operations: Utilize flow-‐back choke, divert through swab choke to
repair flow-‐back choke, routinely drain LPS.• 4" or 6" Clean out flanges will be placed in LPS to assist in cleaning potential solids
from separator.
Clean out flange
“P” trap with BPV StraddleIf LP is low, can take gas from upstream
of BPV
11
Initial Layout and Piping
12
Flowback - Current Set Up
• Equipment Requirements – (1) 2" Double Buster Flowback Tank – (245') 2" 1502 Piping – (27) 2" Plug Valves – (2) 15K Choke Manifolds – (65) Hobbles – (30’) 3" 1502 Piping – (1) 3" Double Plug Catcher w/ screen
(15K; ¼” holes) – (1) Safety Valve – (1) 1440 PSGI 3-Phase Test
Separator
13
1440 PSIG Test Separator
Plug Catcher
Choke Manifold 1
Choke Manifold 2
Sand Separator Hookups
2" Double BusterFlowback Tank
GB GB
Flowback Setup (A)
Safety Valve
3" 15022" 1502MRO Owned
Piping Legend
Spill Mats (Separate Bid)
Flowback - New Set Up
• Equipment Requirements – (50') 2" 1502 Piping – (12) 2" Plug Valves – (50) Hobbles – (30’) 3" 1502 Piping – (1) 3" Double Plug Catcher w/ screen
(15K; ¼” holes) – (2) 3" Gate or Plug Valves – (1) 2” Double Buster Flowback Tank
14
Plug Catcher
3" 15022" 1502MRO Owned
Piping Legend
Plumb to Swab Line
Swab Choke
Flowback Choke
500 psig MD Horizontal Sep.
3" Sch. 160 2" Sch. 40
Plumb to Frac Tank
2" Double BusterFlowback Tank
Questions
? 15