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SPM Oil and Gas Processing Series
SPM-3010 Advanced Gas Oil Separation Process (GOSP)

Click to view schematic display A Click to view schematic display B Click to view schematic display C Click to view schematic display D
        
Click to view schematic display E Click to view schematic display F Click to view schematic display G Click to view schematic display H
        
   
Click to view schematic display I Click to view schematic display J

Process Description

The Advanced Gas-Oil Separation Process includes three crude oil production wells, High and Low Pressure Production Manifolds, a Test Manifold, a Test Separator, and two parallel gas-oil-water separation trains.

Crude oil from the wells can be routed to any of the three collection manifolds. Crude oil from the two production manifolds is routed to either of the 3-stage separation trains. Crude oil from the test manifold is routed to the test separator to determine a well's characteristics before placing the well into production service.

Each separation train consists of three 3-phase separators operating at successively lower pressures to separate the crude oil into oil, gas and water streams. Gas released from the 2nd and 3rd Stage separators is compressed and combined with gas from the 1st Stage Separator and sent to treating. Water from each separator is collected and sent to water treating for disposal.

Crude oil from the High Pressure Production Manifold is routed to the 1st Stage Separator. Flashed gas from the 1st Stage Separator combines with compressed flash gas and sent to treating for water removal. Crude oil from the 1st Stage Separator is sent to the 2nd Stage Separator along with oil from the Low Pressure Production Manifold.

Flash gas from the 2nd Stage Separator is combined with compressed flash gas from the 1st Stage Separator and the combined gas is cooled and compressed in two successive stages before combining with the flash gas from the 1st Stage Separator. Condensate from cooling the combined gases is separated before compression in a Suction Knockout Drum. Condensate and crude oil from the 2nd Stage Separator is routed to the 3rd Stage Separator.

Flash gas from the 3rd Stage Separator is cooled and compressed in the 1st Stage of the Gas Compressor. Condensate from cooling the flash gas is separated before compression in a Suction Knockout Drum. The condensate is returned to the 1st Stage Separator by gravity. Crude oil from the 3rd Stage Separator is sent to storage.

Gas from 2nd Stage of the Gas Compressor is cooled and condensate is separated before compression in a Suction Knockout Drum. The condensate is routed to the 2nd Stage Separator.


Instrumentation

Wells And Manifolds Section
The choke valves on the Wellheads #1, #2 and #3 are manually controlled with HIC-001, HIC-002 and HIC-003, respectively. The emergency shutdown valves are under control of the interlocks associated with each well (see section on interlocks). Each well is lined up to one of the three manifolds using switches. Well #1 uses switches HS-001A, HS-001B and HS-001C. The switches for Wells #2 and #3 are similarly tagged to the well number. The flow from each well should only be lined up to one of the manifolds at a time. The control system will not prevent lining up a well to more than one manifold.

Test Separator Section
The oil level of the Test Separator D-001 is controlled by LIC-001. The destination of the oil is determined by using switches HS-008A and HS-008B. HS-008A lines up oil to the 2nd Stage Separator D-201A while HS-008B lines up oil to the 3rd Stage Separator D-301A. The oil flow is indicated on FI-004. The water/oil interface level of D-001 is controlled by LIC-002.

The produced water flow is indicated on FI-005.

The pressure of the gas produced in D-001 is indicated on PI-004 and its temperature is indicated on TI-004. Gas can be lined up to the 3rd Stage discharge line of Gas Compressor K-101A using HS-007A or to the 1st Stage discharge line of K-101A (E-201A inlet) using HS-007B. The produced gas flow from D-001 is indicated on FI-006.

A Train 1st Stage Separator Section
The produced oil level of the 1st Stage Separator D-101A is controlled by LIC-101A. Oil flow is indicated on FI-104A.

The water/oil interface level of D-101A is controlled by LIC-103A. The produced water flow is indicated on FI-105A.

PIC-104A is an emergency vent to flare that will open if the pressure of D-101A rises above 1,800 PSIG. It is designed to open before the pressure safety valve PSV-101A opens (setpoint = 2,000 PSIG). It can also be used to depressure D-101A at shutdown.

A Train 2nd Stage Separator Section
The produced oil level of the 2nd Stage Separator D-201A is controlled by LIC-201A. Oil flow is indicated on FI-204A.

The water/oil interface level of D-201A is controlled by LIC-203A. The produced water flow is indicated on FI-205A.

PIC-201A is an emergency vent to flare that will open if the pressure of D-201A rises above 450 PSIG. It is designed to open before the pressure safety valve PSV-201A opens (setpoint = 490 PSIG). It can also be used to depressure D-201A at shutdown.

A Train 3rd Stage Separator Section
The produced oil level of the 3rd Stage Separator D-301A is controlled by LIC-301A. Oil flow is indicated on FI-304A.

The water/oil interface level of D-301A is controlled by LIC-303A. The produced water flow is indicated on FI-305A.

PIC-301A is an emergency vent to flare that will open if the pressure of D-301A rises above 90 PSIG. It is designed to open before the pressure safety valve PSV-301A opens (setpoint = 490 PSIG). It can also be used to depressure D-301A at shutdown.

A Train 1st Stage Compression Section
TIC-302A controls the outlet temperature of 1st Stage Suction Cooler E-301A by adjusting the cooling water flow through E-301A.

The condensate level in 1st Stage Suction K.O. Drum D-302A is controlled by LIC-302A which controls the flow of condensed liquid to the 3rd Stage Separator D-301A. LHH-302A is a trip sensor for the interlock system of K-101A. The pressure of D-302A is controlled by PIC-302A which adjusts the net flow out of the 1st Stage of Gas Compressor K-101A to the 2nd Stage Suction Cooler E-201A.

A Train 2nd Stage Compression Section
TIC-202A controls the outlet temperature of 2nd Stage Suction Cooler E-201A by adjusting the cooling water flow through E-201A.

The condensate level in 2nd Stage Suction K.O. Drum D-202A is controlled by LIC-202A which controls the flow of condensed liquid to the 3rd Stage Separator D-301A. LHH-202A is a trip sensor for the interlock system of K-101A. The pressure of D-202A is indicated on PI-202A.

FIC-201A is designed to keep a minimum flow through the 2nd and 3rd Stages of K-101A. At design conditions FIC-201A's output is 0% because the gas flow is above the minimum. This control keeps K-101A's 2nd and 3rd Stages out of surge conditions. Surge can lead to damage of the Gas Compressor as gas rapidly reverses within the compressor, leading to heat-up and excessive vibration. The outlet temperature of the 2nd Stage is indicated on TI-203A. THH-203A is the trip sensor for the interlock system of K-101A. The differential pressure across the 2nd Stage of K-101A is indicated on PDI-201A.

A Train 3rd Stage Compression Section
TIC-102A controls the outlet temperature of 3rd Stage Suction Cooler E-101A by adjusting the cooling water flow through E-101A.

The condensate level in 3rd Stage Suction K.O. Drum D-102A is controlled by LIC-102A which controls the flow of condensed liquid to the 2nd Stage Separator D-201A. LHH-102A is a trip sensor for the interlock system of K-101A. The pressure of D-102A is indicated on PI-102A.

The outlet temperature of the 3rd Stage is indicated on TI-103A. THH-103A is the trip sensor for the interlock system of K-101A. The differential pressure across the 3rd Stage of K-101A is indicated on PDI-101A. HK-101A is a switch to start and stop the motor of K-101A.

The pressure of the total gas flow produced by flashing and compression is controlled by PIC-101A which adjusts the flow to the Gas Dehydration Unit. The total gas flow is indicated on FI-101A.