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HOW TO SEPARATE SAND IN HEAVY AND EXTRA

HEAVY OIL FIELDS SURFACE FACILITIES


José Márquez and Adriana Brito
Contents

• Introduction

• Sand handling surface systems

• Selection Methodology of the desander type

• Summary and conclusions

• Final comments
Introduction
Production systems: sand problems

Sand problems

•Unconsolidated reservoir
•Long production fields
•Artificial lift inappropriate operation

Faja → Unconsolidated reservoir

Water-oil-gas-sand
Introduction
Production systems: sand problems

Sand management strategies→ minimize sand inflow

The first step: Sand control systems


•Slotted liners
•Screens
•Gravel pack

Water-oil-gas-sand
Introduction
Production systems: sand problems

Gas

Gas
Treatment

liquid-gas-sand
flow

Liquid-liquid Oil to
Crude storage or
treatment upgrading

Production operational shutdown due to:


Volumetric capacity reduction (efficient processes)
Erosion and corrosion (mechanical integrity)
Piping systems obstruction (pressure drop increase)

The question: How could the impact of this consequences be reduced?


Sand handling surface systems
Liquid-gas-sand flow Liquid-gas-sand flow

C1 C2
Desanding
C1>>C2

Sand
Accumulation

Slurry

Sand Liquids
Cleaning

Wet sand
Sand
drying
Sand

Sand
Final disposal
transportation

C: is sand concentration
Sand handling surface systems
Liquid-gas-sand flow Liquid-gas-sand flow

C1 C2
Desanding
C1>>C2

Sand
Accumulation

Slurry

Sand Liquids
Cleaning

Wet sand
Sand
drying
Sand

Sand
Final disposal
transportation

C: is sand concentration
Selection Methodology
Information for selecting the desander
Fluid properties:
API Gravity Viscosity (cP) GOR (scf/bbl)
16 750 200 - 1200

Sand properties:
Sand consists of quartz and clay represent approximately 80 % (wt).
Particle diameters ranged from 8 to 679 µm
Percentiles of this sample are given in µm and these values are:
• D10 = 356.5, D40 = 174.6, D50 = 133, D70 = 67.5, D90 = 29.
Sand density is about 2,600 kg/m3.
Sand concentration is 0.0018 % (vol/vol)

Considerations:
In order to remove at least 90 % of sand, it is necessary to separate
particles diameter of 29 µm or larger.
Selection Methodology

Stages of selection methodology:

1. A separation process type selection

2. A technology pre-selection considering particle size and sand


concentration

3. The effects of liquid properties on pre-selected technologies

4. Final choice using a matrix selection method


Selection Methodology

Stages of selection methodology:

1. A separation process type selection

2. A technology pre-selection considering particle size and sand


concentration

3. The effects of liquid properties on pre-selected technologies

4. Final choice using a matrix selection method


Pre-Selection Considering Particle Size and Sand Concentration

Selection Guide of Separation Equipment (Svarovsky, 2000)

Particle Size dp< 5µm 5< dp < 50µm dp > 50µm

Solid Concentration Low High High Low Low High

Deep bed filter Cake filtration Settling tanks Filtering


Cartridge filters RV filters Centrifugal Centrifuges
Technology
Precoat filtration Pressure Filters devices
Sedimenting Plate and Frame Screen filter
Centrifuges filters
Data:
Particle diameter ranged from 8 to 679 µm
Sand concentration = 0.0018 % (vol/vol)
Low concentration < 0,5 % (vol/vol)
Pre-Selection Considering Particle Size and Sand Concentration

Selection Guide of Separation Equipment (Svarovsky, 2000)

Particle Size dp< 5µm 5< dp < 50µm dp > 50µm

Solid Concentration Low High High Low Low High

Deep bed filter Cake filtration Settling tanks Filtering


Cartridge filters RV filters Centrifugal Centrifuges
Technology
Precoat filtration Pressure Filters devices
Sedimenting Plate and Frame Screen filter
Centrifuges filters

Pre-selected Technologies
Selection Methodology

Stages of selection methodology:

1. A separation process type selection

2. A technology pre-selection considering particle size and sand


concentration

3. The effects of liquid properties on pre-selected technologies

4. Final choice using a matrix selection method


Settling tanks/vessels:
viscosity and density influence
Considerations:

1. Settling velocity is determined by Stokes' law.


 S   L  * g d P 2
VS 
18 *  L
2. Residence time considered that the particles must travel one meter
L
tr 
VS
3. Solid density is a constant value of 2600 kg/m3.

4. Finally, sensibility with liquid density, liquid viscosity and particle diameter.
Settling tanks/vessels:
viscosity and density influence
100000 1020
Dp=679 µm
Dp=510 µm
Dp=340 µm
10000 1000
Dp=148 µm
Dp=74 µm
Dp=29 µm
1000 Dp=8 µm 980
Viscosity 750 cP
Density (kg/m3)
100 960

Density (kg/m3)
tr (hr)

10 940

1 920

0.1 900

0.01 880

0.001 860
1 10 100 1000 10000 100000
Viscosity (cP)

For the same diameter, tr varies 2507 times


For 750 cP, tr range from 0.5 hr to 3744 hr (156 days)
For removing at least 90% of sand, tr is 158 hr (aprox 7 days)
Settling tanks/vessels:
viscosity and density influence
100000 1020
Dp=679 µm
Dp=510 µm
Dp=340 µm
10000 1000
Dp=148 µm
Dp=74 µm
Dp=29 µm
1000 Dp=8 µm 980
Viscosity 750 cP
Density (kg/m3)
100 960

Density (kg/m3)
tr (hr)

10 940

1 920

0.1 900

0.01 880

0.001 860
1 10 100 1000 10000 100000
Viscosity (cP)

“High liquid viscosity and density affect settling


tanks/vessels performance”
Centrifugal Devices:
viscosity influence
Swirl tube experiment:
• It is a well bottom desander which
works under centrifugal
separation.

• This was tested at several flow


rates, using liquids of different
viscosities and several particle
diameters.

• Separation efficiency decrease as


liquid viscosity increase or as flow
rate decrease
Separation efficiency vs. volumetric flow rate
for different viscosity and Dp=900 m • It is clear that for viscosities
(Martins et al, 2005) above 100 CP, performance
would be very low.
Screen filters:
viscosity and density influence

•It is not necessary density difference between phases

•It does not require residence time. The separation is


immediate

•Liquid viscosity and density do not affect its performance


Selection Methodology

Stages of selection methodology:

1. A separation process type selection

2. A technology pre-selection considering particle size and sand


concentration

3. The effects of liquid properties on pre-selected technologies

4. Final choice using a matrix selection method


Matrix Selection Methodology
Considerations:

1. The criteria and solutions weighting method

2. Technological solutions are the pre-selected technologies

3. Eleven criteria are selected, these were evaluated from 1 to 11, where 11
correspond to the most important criterion and 1 the less important.

4. Each criterion was evaluated for each technological solution based on


performance.
Performance qualification
Low Medium High
1 2 3

5. The final solution is obtained when the value given of each criterion is
multiplied for the value of performance given to each technology,
Matrix Selection
Qualification of technological solutions
Qualification Settling Centrifugal Screen
Criteria of criteria Tanks/vessels devices filters
(Cj) (S1j) (S2j) (S3j)
Handle Viscous liquid (C1) 11 3 1 3
Separation efficient (C2) 10 2 1 2
Residence time (C3) 9 1 2 3
DP<29 µm (C4) 8 2 1 3
CS<0.5 % (C5) 7 3 3 3
Mobile parts (C6) 6 3 3 3
Energy require (C7) 5 3 3 3
Pressure drop (C8) 4 1 2 1
Flow rate (C9) 3 2 2 3
Operational cost (C10) 2 2 2 1
Operational flexibility (C11) 1 2 2 2
Matrix Selection
Algebraic solution
Settling Centrifugal Screen
Tech
Tanks/vessels devices filters
Criteria
(PS1) (PS2) (PS3)
Handle Viscous liquid (C1) 33 11 33
Separation efficient (C2) 20 10 20
Residence time (C3) 9 18 27
DP<29 µm (C4) 16 8 24
CS<0.5 % (C5) 21 21 21
Mobile parts (C6) 18 18 18
Energy require (C7) 15 15 15
Pressure drop (C8) 4 8 4
Flow rate (C9) 6 6 9
Operational cost (C10) 4 4 2
Operational flexibility (C11) 2 2 2
Total score 148 121 175
Solution

Screen filters are the best solution to perform desanding in


heavy and extra heavy oil fields. Then, settling tanks/vessels
will be the second option, while centrifugal devices are the
last one.
Summary and conclusions
1. Considering the process type, particle diameters and given sand concentration, it
was determined that technologies working under gravitational sedimentation,
centrifugal sedimentation and filtration could be used in order to remove sand.

2. The residence time is an important variable in gravitational and centrifugal


separation processes, while for filtration processes is not. This is basically because
the density difference between the phases is required for the sedimentation
process, while for filtration, it is not necessary.

3. Regarding the influence of the liquid density and viscosity on gravitational


sedimentation processes can be said that:
a. The Residence time increase as both density and viscosity increase, also, as particle
diameter decrease because settling velocity is reduced.
b. The residence times would be very high to remove at least 90 % of sand, it is about 180
hours, and this fact is mainly related at the high oil viscosity.
Summary and conclusions
4. With reference to centrifugal sedimentation technologies can be said that:
a. Efficiency decrease as either viscosity increase or particle size decrease
b. Centrifugal technologies could work better if liquid viscosity is below 200 cP,
therefore, liquid viscosity is the most important parameter to define if centrifugal
technology is applicable or not.

5. With respect to filter screen can be said that the separation performance does
not depend on liquid properties because it does not need residence time,
therefore, the density difference between the phases and liquid viscosity are
not variables that could affect the sand separation

6. Finally, screen filters were selected as the best solution to perform desanding in
heavy and extra heavy oil fields.
Final comments
•Regardless of desanding system installed, it must be designed with a capacity to
accumulate sand for some days, but avoiding extreme compaction and facilitating
sand removal.

•Gravitational and centrifugal sedimentation technology applications could be used if


liquid viscosity is reduced .

•Sand production problems could be reduced if sand management philosophy is used


from project definition
Control

Sand
Management

Handling Diposal
Faja Petrolifera del Orinoco the largest reservoir of heavy and extra heavy oil

Thank you

HOW TO SEPARATE SAND IN HEAVY AND EXTRA


HEAVY OIL FIELDS SURFACE FACILITIES
José Márquez and Adriana Brito

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