Abstract
A patented separator inlet device (SID) technology developed at Saudi Aramco's Research and Development Center (R&DC) is underway for a field trail in a gas-oil separation plant (GOSP) high-pressure production trap (HPPT) in 2014. The function of the SID is to enhance phase separation by promoting droplet coalescence and gas separation for mixed fluids flowing into a horizontal gravity separator vessel.
The paper describes the steps taken to bring the new technology to field stage after a successful R&D phase, detailing the challenges associated with scaling up and field installation of the prototype. Close collaboration between the R&D team, Engineering Services and plant owners, under the supervision of strongly supportive management, was essential for rapid field deployment of prototype technology with unconfirmed impact on the production rate.
The procedure for selecting a candidate separator vessel for the field trial and process integration study will be discussed. The SID installation in the candidate HPPT required modification to the existing operating liquid levels, which triggered a process evaluation study in the initial phase of the project. Engineering calculations and a field test demonstrated the proposed interface level reduction did not affect quality of the water and the oil sampled at the separator outlet ports.
To reduce risk in the absence of detailed industry standards for engineering multiphase flow processes, a combination of numerical modeling, physical testing and process evaluation at the candidate plant was employed in the prototype design and engineering phase.
The fabrication and field installation of the prototype SID were outsourced to an engineering contractor. The vendor contract allowed close monitoring and oversight by a Saudi Aramco R&D team on all design, fabrication and installation tasks. Open communication with the contractor was very useful in the preparation of the industrial deployment of the technology.
