Deskripsi
Key Features:
- Triple-Phase Precision Separation – Achieves <1% residual oil-in-water and <0.5% water-in-oil
- Self-Adaptive Control – Automatically adjusts to fluctuating flow rates (10–100% capacity)
- Compact Modular Design – 50% smaller footprint vs. conventional separators
- Predictive Maintenance – Machine learning detects fouling/emulsion risks 48+ hours in advance
- Cloud Connectivity – Remote monitoring via SCADA/IIoT platforms
Core Components:
(1) Intelligent Separation Module
- Inlet Cyclonic Distributor – Ensures even flow distribution and preliminary gas-liquid separation
- Coalescing Plates – High-efficiency polymer composite plates for fine separation
- Electrostatic Coalescer – Breaks stubborn emulsions (optional for heavy crude)
- Smart Weir System – Automatically adjusts oil/water interface level
(2) Monitoring & Control System
- Multiphase Flow Meter – Real-time measurement of oil/gas/water ratios (±2% accuracy)
- Density/Pressure/Temperature Sensors – Integrated PT100 and radar gauges
- Edge Computing PLC – Runs adaptive PID algorithms for process optimization
(3) Auxiliary Systems
- Automatic Dumping Valves – Periodically discharge separated phases
- Chemical Injection Skid – Demulsifiers and antifoam agents (optional)
- Explosion-Proof Enclosure – ATEX/IECEx certified for hazardous areas
Technical Specifications:
| Parameter | Specification |
|---|---|
| Design Pressure | 1.0–6.9 MPa |
| Operating Temperature | -20°C to 150°C |
| Throughput Capacity | 50–5,000 m³/day |
| Gas Handling Capacity | Up to 500,000 m³/day |
| Separation Efficiency | Oil: >99.5%, Water: >99%, Gas: >99.9% |
| Materials | Carbon steel/316L stainless steel/duplex |
Working Principle:
- Inlet Conditioning: Wellstream enters through cyclonic distributor for initial gas breakout.
- Primary Separation: Gravity and coalescing plates separate bulk oil/water phases.
- Fine Separation: Electrostatic fields (if equipped) break micro-droplet emulsions.
- Phase Export:
-
-
Gas to compression/treatment
-
Oil to storage/tanks
-
Water to treatment/reinjection
-
-
Smart Adjustment: Continuous sensor feedback optimizes weir heights and dump cycles.
Performance Advantages:
- 30% faster separation vs. conventional vessels
- 20% reduction in chemical consumption
- Zero human intervention in routine operations
- 40% lower CAPEX due to compact design
Applications:
- Onshore/offshore production facilities
- High-GOR (Gas-Oil Ratio) fields
- Heavy oil fields with stable emulsions
- Marginal fields requiring modular solutions
Case Study: Bohai Bay Offshore Platform:
- Challenge: Unstable emulsion in 25°API crude with 80% water cut
- Solution: Installed ITPS-3000 system with electrostatic coalescer
- Results:
↗ Oil-in-water reduced from 3,000 ppm to <200 ppm
↘ Chemical demulsifier usage cut by 35%
→ Achieved API 12J compliance for over 2 years
Certifications & Standards
- API 12J (Specification for Oil-Gas Separators)
- ASME Section VIII Div. 1 Pressure Vessel Code
- PED 2014/68/EU (EU Pressure Equipment Directive)
- NACE MR0175 for sour service environments
Why Choose This System:
- Plug-and-play operation – Reduces commissioning time by 60%
- Adaptive to changing wellstream conditions – Handles slugs and foams
- Lifetime technical support – Global service network with spare parts guarantee
Ulasan
Belum ada ulasan.