5000 BOPD & 10000 BOPD EARLY PRODUCTION FACILITY
Pyramid E&C has generic, pre-engineered modular units available for rental for 5,000 BOPD & 10000 BOPD Crude Oil Production. These facilities fit into several containerized modules suitable for sea and road transport. The rental EPF is reasonably complex to provide saleable crude oil. The use of the unit on a rental basis allows the customer to start production and thus revenue generation as soon as possible. Our robust equipment design ensures hassle-free operation for customers.
The pre-engineered modular unit has capability of handling range of inlet parameters listed below.
- Capacity : 5,000 BOPD or 10000 BOPD
- Nature of Crude : Sweet / Sour
- Crude Grade : API 15 and above
This units are designed for 5000 BOPD & 10000 BOPD to produced crude with specification provided below.
- BS & W (volume) : ≤ 0.5 %
- Salt Content : ≤ 8 PTB
- RVP : ≤ 10psia
- H2S Content : ≤ 20 ppm wt.
- H2O : ≤ 7 Lb/MMSCFD
- H2s : ≤ 5 PPM
- CO2 : ≤ 20%
The well-stream may consist of crude oil, gas, condensates, water and various contaminants. The purpose of the separators is to separate gas, hydrocarbon liquid & aqueous phases. Separated gas, hydrocarbon liquid & aqueous phases are further treated to meet above mentioned product & gas specification.
Two-Phase Separation / MP or HP Separator:
The well stream fluid from the Inlet Manifold is flashed in the Two-Phase Separator which operates at a higher pressure. Separator can be horizontal or vertical. The liquid (oil, emulsion) leaves the vessel at the bottom through a level-control valve. The gas leaves the vessel at the top, passing through a mist extractor to remove the small liquid droplets in the gas. This provides the initial separation between hydrocarbon and gas.
Crude Preheat Exchanger:
The Oil from the two- phase separator is heated in crude-crude heat exchanger by recovering heat from hot treated crude as shown in below figure.
Three-Phase Separation / LP Separator:
Heated Crude enters the three-Phase Separator, which operates at a lower pressure for oil, gas and water separation. Gas from the Separator is either flared (depending upon quantity) or sent to gas processing unit which includes gas compression, sales gas treatment, conditioning and then sent to export pipeline. The produced water is treated in produced water treatment package & then sent to battery for disposal.
Desalting is a process to remove salts and other contaminants from crude. Single Stage or two stage desalter packages are used depending upon process parameters and salt removal requirements. The standard design is based on single stage desalter. The oil from the three-phase separator is pumped to the desalter using desalter feed Pumps. Wash water is pumped through a Wash Water Pre-Heater and then mixed with the Crude Oil using a mixing valve or static mixer. The brine from desalter is mixed with the produced water which is coming from three phase separator for treatment and disposal.
After separation of water and gas crude oil must be stabilized to remove light end hydrocarbons to achieve the vapor pressure and H2S removal required for safe storage and transportation. In case of sour crude, when the stable oil still contains a high level of H2S, the stream can be stripped by means of sweet gas or nitrogen stream in a stabilizer column along with the reboiled stripping. The gas from the stabilizer is either flared or can be sent to gas compression unit. For smaller capacity EPF alternate design can be considered with heater treaters for achieving RVP & BS&W.
The scheme selection for EPF depends on inlet water cut, BS&W & salt specification of product. Our Standard designs includes heater treater for 5000 BOPD capacity & stabilizer column for 10000 BOPD capacity
Gas Compression & Treatment:
Pyramid E&C offers custom design for gas compression & treatment unit. The purpose of gas treatment is to clean the gas for unwanted impurities and get it to the desired condition before it is exported. The composition of the gas is the decisive factor for which gas treatment procedures that are used. The most common cleaning procedures are gas sweetening (remove CO2& H2S), dehydration and hydrocarbon recovery. The purpose of cleaning the gas of its impurities is to improve the gas quality, avoid dangers to the process plant or pipeline from e.g. corrosion or enable the gas to be brought to the desired export condition.
Produced Water Treatment:
The hydrocarbons in the water are oil that did not separate off in the separators and dissolved gas. First the oil is removed using hydrocyclones; the oil is lead back to the separator system. The gas is removed from the water by decreasing the pressure thus decreasing the solvability in the water. The gas is separated off before the water is sent to disposal.
Crude Oil Storage:
Stabilized Oil is pumped. through the crude-crude exchanger, where it is cooled by the Crude feed. The stabilized oil is further cooled by an Air Cooler and then stored in Crude Oil Storage Tanks. Transfer Pumps to loading bays for truck loading. Standard design can be customized to meet the client & field requirement.