This focused course provides in-depth technical knowledge on the critical process of treating crude oil to remove water and salt (desalting), which is essential for meeting sales specifications and preventing downstream corrosion and fouling. Participants will cover the mechanisms of emulsion formation and the various technologies used to break them, including heating, chemical injection, and electrostatic dehydration/desalting. The training is centered on optimizing performance and troubleshooting operational issues in both heater treaters and electrostatic desalter units. Mastery of this process ensures high-quality crude oil is delivered for refining, thereby maximizing its commercial value.
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Explain the formation and stabilization of crude oil emulsions (oil-in-water and water-in-oil).
- Select the appropriate chemical demulsifier based on crude oil characteristics and emulsion type.
- Detail the design, operation, and control of vertical and horizontal heater treaters.
- Understand the principles of electrostatic dehydration and the function of the high-voltage grid.
- Analyze and troubleshoot common dehydration and desalting problems (e.g., poor BS&W, upsets).
- Perform basic calculations for heat duty, retention time, and chemical dosage.
- Describe the process of desalting and its importance in preventing refinery corrosion and fouling.
Target Audience
- Production and Process Engineers.
- Oilfield Operations Supervisors and Senior Technicians.
- Facilities Design Engineers for production platforms and central processing units (CPUs).
- Technical Sales Professionals for demulsifier and equipment vendors.
- Refinery Feedstock Quality and Inspection Personnel.
- E&P Technical Staff involved in crude stabilization.
Methodology
- Case Studies: Analyzing historical desalter trips and their impact on crude quality.
- Group Activities: Developing a troubleshooting flowchart for a high BS&W alarm.
- Individual Exercises: Calculating the optimal demulsifier dosage based on bottle tests.
- Discussions on the safety risks associated with fired vessels and high-voltage equipment.
- Scenarios: Adjusting operating parameters (T, P, chemical rate) based on incoming crude changes.
Personal Impact
- Gain specialized technical competence in a high-value-adding production process.
- Develop advanced troubleshooting skills to maintain crude oil sales quality.
- Enhance ability to select and optimize chemical injection programs for cost savings.
- Improve personal value by directly impacting the commercial quality of the product.
- Master the safe operation and maintenance of fired and high-voltage equipment.
- Accelerate career growth in oil production and facilities engineering.
Organizational Impact
- Maximized commercial value and market price for crude oil by meeting sales specifications.
- Significant reduction in downstream corrosion and fouling in pipelines and refineries.
- Lower operating expenses by optimizing heat input and chemical consumption.
- Reduced risk of regulatory penalties or custody transfer rejections.
- Increased production uptime by minimizing unit upsets and maintenance downtime.
- More efficient processing by reducing the volume of produced water handled.
Course Outline
Unit 1: Crude Oil Quality and Emulsion Fundamentals
Section 1.1: Emulsion Basics- Defining crude oil sales specifications (BS&W, salt content, API gravity, vapor pressure).
- Mechanisms of emulsion formation and stabilization (naturally occurring emulsifiers, solids).
- Identifying the types of crude oil emulsions (water-in-oil vs. oil-in-water).
- The impact of emulsion viscosity and temperature on separation difficulty.
Unit 2: Chemical and Thermal Treatment
Section 2.1: Treatment Methods- Principles of chemical demulsification: Coalescence, breaking, and inversion.
- Criteria for demulsifier selection, testing, and optimal injection location.
- The role of heat in reducing viscosity and surface tension (Heater Treaters).
- Design and operating principles of gun-barrel tanks and wash tanks.
Unit 3: Heater Treater Design and Operation
Section 3.1: Equipment Focus- Detailed flow scheme and internal components of vertical and horizontal heater treaters.
- Control philosophy for pressure, level, and temperature stability.
- Calculating retention time and heat duty requirements for treatment.
- Safety considerations for fired equipment in crude oil service.
Unit 4: Electrostatic Dehydration and Desalting
Section 4.1: High-Voltage Systems- Principles of electrostatic coalescence and the function of the AC/DC electric field.
- Detailed operation of electrostatic desalter units (single-stage and two-stage).
- The process of water washing (desalting) to remove formation salts.
- Troubleshooting electrical issues and safety protocols for high-voltage systems.
Unit 5: Operational Troubleshooting and Optimization
Section 5.1: Performance Assurance- Analyzing and correcting common upsets: Over-treating, under-treating, and rapid level swings.
- Impact of production slugging and varying feed properties on unit stability.
- Optimizing chemical dosage and water wash rates for cost-effective treatment.
- Best practices for routine maintenance, vessel cleaning, and inspection.
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