Debottlenecking of Oil and Gas Separation Units to Enhance Oil Production Capacity: A Case Study of Kuwait Oil Company

Abstract

Objective / Scope The oil and gas processing facility was upgraded as part of the project. However, it has been experienced that separation capacity of facility was reduced post installation of new separator under upgradation project. The main objective of this in-house debottlenecking study was to identify contributing factors for reduction in separator handling capacity and carry out required modifications to eliminate these factors. Methods, Procedures, Process This paper shares detail of complete technical study conducted to identify factors affecting capacity of oil and gas separator. This case study includes hydraulic calculations, simulation study and other relevant design calculations. Various design cases were developed to identify and resolve factors affecting separator capacity. The most appropriate solution is selected based on hydraulic calculation and simulation results. Results, Observations, Conclusions It has been concluded that main reason for such limitation in liquid handling capacity of separator was higher elevation of new oil and gas separator installed under project. This piping configuration was creating higher backpressure on exiting wet crude header due to the fact that both these piping were joined together in a common header feeding downstream wet/dual crude oil tanks. So, it was decided to install a new 20″ piping directly from new separator to dual crude oil tank reducing liquid handling load on existing header feeding tank and thereby reducing backpressure on new & old oil and gas separators. This has increased overall capacity of oil processing facility by around 30 MBLPD. Novel/Additive Information This paper explains in detail a lesson learned, which is vital for any brown field project, where such upgradation by major projects may lead to adverse impact on operation of existing facility. It also explains systematic approach to eliminate such bottlenecks, which possibly arise from inappropriate integration of new equipment with existing equipment during project implementation.