SPE-177213-MS

Fast Wash Tank Design Algorithm for Early Production Facilities (EPF)
E. Reina, L. Vargas, N. Romo, H. Venegas, and P. Delgado, Tecna del Ecuador

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Latin American and Caribbean Petroleum Engineering Conference held in Quito, Ecuador, 18 20 November
2015.

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Abstract
An algorithm has been evaluated to offer a fast and simple design of a primary crude dehydration system
consisting of a low capacity wash tank train, installed as Early Production Facilities (EPF) to achieve a
crude oil specification not greater than 0.5% Basic Sediment and Water (BS&W) with average water cut
at inlet of 30%.
The estimation method allows to perform routine calculations to determine the crude oil residence time
available for water separation inside the equipment, water droplet diameter and water cut within the oil
pad at different heights using a short-circuit factor (F) always greater than 1. As a result, short-circuit
factor of 1.4 is verified to be a good value to ensure separation of phases in low-capacity tanks. In
addition, tank dimensions are given based on API-12F specification for a nominal capacity of 500 bbl. for
the 12 ft diameter and 25 ft height. Moreover, the designer must take into account different tank internal
configurations to improve its efficiency.
Different dehydration configuration can be arranged using 500 bbl. low-capacity wash tanks installed
in series. One (01) train consists of two (02) wash tanks, and as the required processing fluid capacity is
higher, similar trains in parallel must be added to increase the dehydration system throughput.
Retention time and settling theory were used and applied to the system described above and deter-
mining that the oil quality is related to the maximum size of water drops carried-out over O/W interface
and being smaller as the oil reaches the outlet connection which is close to the top of the tank. These sizing
techniques allowed the BS&W and water droplet diameter being estimated as a function of the oil-column
height, residence time and temperature.
Different effective heights through the wash tank oil pad are checked at various operational temper-
atures which allow the dispersed water droplets to settle out from the oil with different velocities and,
hence, being able to evaluate several water cuts (%BS&W). EPF conformed by two trains of 4
low-capacity tanks each; working in parallel, provided a processing capacity of 12000 BFPD to meet a
desired 0.5 %BS&W specification for given oil and water physical properties. Initial investment,
operational costs and implementation time were favourably reduced during the early production stage
until the permanent facilities were installed, thereby avoiding sophisticated technologies that could result
in expensive and late industrial project deployments.
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Introduction
In producing operations it is often necessary to separate two immiscible liquids, the light and heavy
phases, which may include production water with crude oil. A typical example in onshore production
facilities is the crude oil dehydration or separation of water from the crude oil before being sent to storage
or transportation for further treatment in downstream processes such as refining, where tight water cut and
salt content specifications must be achieved (generally 0,5% to 1%).
Beginning early production, while full field development is being planned and permanent facilities are
only projected or in phase of engineering and design; Early Production Facilities (EPF) can be used as a
solution, much more for small reserves, where it would be uneconomical to produce with a permanent
facility that require high implementation times, costs and experienced personnel to operate them. Thereby,
in some cases, the EPF becomes the permanent solution. Due to this, prefabricated low-capacity tanks
with reconfiguration flexibility would be highly useful if proved that they can be arranged as an EPF oil
dehydration train system.
Little has been published on liquid/liquid two phase separations, with most information in private
corporate design files. This article attempts to address an algorithm for designing a primary crude oil
dehydration system for a low capacity wash tank train considered as Early Production Facility and by
covering basics of gun barrel tanks design theory.
The method involves process variables that can be easily measured or known, some of them are:
operational temperatures, water cut at inlet, crude oil physical properties as viscosity and both the water
disperse and the oil continuous phase densities.
Effective separation heights, residence times required for the crude oil dehydration and different
process parameters which include short-circuit factor, water drop diameter and settling time are estimated
based on standard tank capacities of 500 bbl. (12 ft diameter and 25 ft height).

Theory
Droplet settling theory application
Terminal velocity is the maximum speed a water disperse droplet achieves while falling through the oil phase.
When water droplets are settling out from the oil, gravity pulls them down while the viscosity of the crude
pushes back up. At first, the force of gravity is stronger than the resistance to flow (Oil viscosity), and water
droplets accelerates. But while gravity remains constant, the viscous resistive force increases with increasing
velocity. Eventually, these two forces balance (Gravity force is offset by the drive-up force), and the water
droplets stop accelerating and continue their fall at this constant, terminal velocity.
According to settling theory for two immiscible liquid phases, the driving force to achieve separation
of a dispersed phase (water) from a continuous phase (oil) is given by Stokes law which states that the
flow of settling heavy droplets (Terminal velocity) in the light liquid phase is considered laminar and is
govern by the following (Arnold, 2008):
(Eq. 1)

From Eq. 1, it can be seen that:

The settling velocity of a droplet is inversely proportional to the viscosity of the continuous phase.
Hence, it is more difficult or requires more time to settle the droplets out of the continuous phase
with the greater viscosity due to the terminal droplets velocity are lower. Temperature is a process
variable that can be easily controlled to improve separation by increasing it as much as possible
(with a recommended limit of 175 F) depending on liquid bubble pressure since loss of valuable
light liquid compounds must be avoided. Summarizing, as the oil viscosity is higher, the more
difficult the dehydration will be.
SPE-177213-MS 3

The larger the water droplet size, less time it will take for the droplet to achieve the O/W interface,
given that the settling velocity increases.
The greater the difference in specific gravities between the oil and water, the greater the terminal
velocity will be. In other words, the lighter the oil to be processed (Lower API gravity), the easier
it will be the crude dehydration process so that, for a given wash tank size, higher flow of fluid
can be treated if physical properties remain constants.
The total height of oil pad defined as the distance between the O/W interface and the wash tank
spillover line allows the water droplet required settling time to be estimated using Eq. 2 (Douglas, 2002):
(Eq. 2)

Retention time theory application

The basis unit of measurement of wash tank performance is the oil retention time defined as being the time
that an average molecule remains within the vessel. The equipment is sized to provide a required oil
retention time in the coalescing settling section (Volume) to enable oil/water separation. The oil retention
time in the equipment can be given by Eq. 3 (Douglas, 2002):
(Eq. 3)

Where the crude oil velocity is estimated as follows:

(Eq. 4)

Retention time vs. droplet settling theories

In sizing and/or evaluating an oil/water wash tank separator, the heights of the light and heavy liquids are
assumed, fixing the O/W interface level, and the settling velocity and water droplets settling time are then
calculated as explained earlier, as well as the oil residence time is determined next.
For the liquids to separate, the residence time of the crude must always be greater than the time
required for the water droplets to settle out of the continuous oil liquid phase. If this condition is not
satisfied, then the procedure is repeated varying the interface O/W level, the flow rate or providing higher
treating capacity by installing another train in parallel, since the wash tank diameter and height are fixed
and given based on API-12F 500 bbl. capacity.
As discussed above, to ensure oil/water separation the following relationship must always be fulfilled:
(Eq. 5)

Water droplet sizing techniques

As known so far, the water droplets dropout velocity and water cut will depend on droplet diameters, so
it becomes mandatory to predict a water droplet diameter, which must be separated from the oil
continuous phase to meet a required %BS&W specification. Additionally and what is more interesting,
though, is enable estimate water droplet diameters and hence water cuts at different operational temper-
atures (changing oil viscosity) through the height of oil pad.
In vertical vessels, the relationship between water droplet diameter and volumetric oil flow rate, oil
viscosity, vessel diameter and liquid densities is derived, resulting in the following general sizing
equation:
(Eq. 6)

In a horizontal vessel, the relationship between vessel diameter times the effective length is a function
of water droplet diameter, volumetric oil flow rate, oil viscosity and liquid densities. It is presented by
Arnold (2008) as:
4 SPE-177213-MS

(Eq. 7)

Different regression equations have been developed from experimental data to determine the water cut
in oil, if the actual water droplet size (dm) and the water droplet diameter to achieve 1 %BS&W
(dmi%)are known. It recommends using the next two equations when the crude oil viscosity is less than
80 cp, which is our case study (Arnold, 2008):
(Eq. 8)

(Eq. 9)

In summary, the continuous phase residence time defines the disperse phase separation. However, in
practice, the dehydration process is affected by the fact that perfect and/or evenly fluid distribution across
the entire wash tank cross-sectional area is unlikely to occur. Other disturbances can be mentioned, i.e.,
turbulences, foaming and presence of excessive gas. Thus, a factor must be incorporated such that
inefficiencies are taken into consideration. This factor is known as Short-Circuit Factor F, which is
recommended to have always a value greater than 1.
EPF Oil Dehydration Process
Figure 1 shows the process flow diagram implemented for the crude oil dehydration process as Early
Production Facility (EPF), using low-capacity wash tanks interconnected in series. It is important to
highlight that the dehydration methodology used is assuming that the oil is already degassed using a gas
boot. If the fluid is saturated and expanded into the system, then foamy material and turbulence caused
by gas bubbling through the oil will affect the water separation efficiency.

Figure 1Oil dehydration system used as Early Production Facility

SPE-177213-MS 5

To assure proper crude oil dehydration once the design was culminated, an integrated system,
consisting of four (04) 500 bbl. wash tanks and their associated control and instrumentation were installed
in series to form a single treating train. The fluid with 30% water cut flows into the first tank through a
linear spreader, which is immersed below the O/W interface, distributing it evenly throughout the water
pad thickness while rising up to the interface, accumulating oil at the top (where the dehydration occurs)
and then flowing out via the spillover line into the second tank which is as well, capable of operating in
the manner intended for the first one. It is recommended to consider a third and fourth tank which can be
used as water cut monitoring and stock tanks, respectively.

Figure 2Water/Oil dehydration and forces involved

Data and Results

The Early Oil Production Dehydration Facility consists of two separation trains with a common external
gas boot. Each train is grouped with at least two tanks of 500 bbl. nominal capacities, operating as wash
tanks and interconnected in series.
The design basis and process conditions considered to perform the study are detailed as follows:
The system is designed for a maximum fluid volumetric flow rate of 12000 BFPD with 30
%BS&W.
The fluid operational temperature is 120 F; however, an oil dehydration sensibility analysis is
performed considering temperatures in the range of 100 F to 140 F.
The following laboratory assay data was used for characterizing the petroleum fluid:
Oil density: 26 API gravity.
Viscosity at two different temperatures:
a. Viscosity 1: 19.19 cP @ 100 F.
b. Viscosity 2: 10.86 cP @ 140 F.
Oil viscosity and density were able to be estimated at 110 F, 120 F, 130 F and 140 F once the oil was
characterized. This allows the performance of the dehydration system to be evaluated at several process
conditions and define an optimal operational point.
6 SPE-177213-MS

Following the calculation methodology explained in previous sections, the results that have been
achieved are shown in Figure 3, 4 and 5.

Figure 3Water cuts vs. Effective height at different temperatures (Inlet 30 %BS&W)

Figure 4 Water droplet diameter vs. Effective height at different temperatures (One Train)
SPE-177213-MS 7

Figure 5Water cuts vs. Residence time (One Train)

Figure 3 shows the behavior of the water cut (%BS&W) in relation to the oil pad height at different
temperatures. An effective oil height of 40 ft between the two wash tanks is considered. As can be seen,
the minimum water content in crude oil is achieved when the operational temperature and the oil
volume/height are at their maximum value of 140 F and 40 ft, respectively. This is due to an increase in
the crude oil residence time and significant decrease in oil viscosity. However, the operating cut water
reached a value of 0.42 %BS&W at 120 F.
Figure 4 illustrates that the size of the water droplets that must be removed from the oil continuous
phase for the given treating system and meet a 0.5 %BS&W specification is 290 microns at 120 F. In
general, it is possible to say that the size of the water droplets that must be dropped out from oil to comply
with a certain %BS&W specification increases as viscosity increases or what is the same, as temperature
decreases for a given system. Furthermore and as per curves shown, the water droplet size decreases as
the effective oil pad height increases and hence the water cut is reduced.
As shown is Figure 5, the higher the oil residence time (tro) within the equipment, the lower the water
cut will be (tro) as becomes greater than the required water settling time(tsw)

Discussion
The method establishes a short-circuit factor (F) of 1.4 which enable the wash tanks EPF dehydration
system to define an over-design and providing it with the necessary efficiency to overcome any process
upset and ensure a %BS&W crude specification. The process designer can increase or decrease the F
factor value based on crude oil physical properties, vessel internals installation, avoiding turbulences and
fluid channeling across the wash tanks.
The equation derived for horizontal vessels to determine the water droplets diameter is used only to
estimate the oil water cut at different heights. The results that have been achieved and shown in this paper
were corroborated by monitoring the dehydration system at site during start-up and steady-state produc-
tion, resulting in similar values to those estimated by the defined method; that is, a lower %BS&W as the
fluid flows upward to the top of the tank.
It is important to add that it would be useful to envisage a demulsifier injection system to improve the
dehydration performance by breaking the Water/Oil emulsion. Chemical requirements must be assessed
during production testing and/or the dehydration system start-up.
8 SPE-177213-MS

Conclusions
The calculation method presented in this article brings to say that it is possible to separate water
from production crude oil, with medium API gravity, using dehydration trains conformed by
API-12F tanks to obtain oil with low water cut close or lower than 0.5 to 1%. In addition, different
water droplets diameter and %BS&W were estimated along the oil pad height and at various
operating temperatures. It is necessary to clarify that if higher oil quality with more stringent
%BS&W specifications shall be met, then other dehydration technologies must be used.
The EPF dehydration system using two trains and each one consisting of two 500 bbl. wash tanks
capacity installed in series, provides an oil processing capacity per train of 6000 BFPD with 30
%BS&W for the given physical properties (26 API for crude). A maximum 0.5 %BS&W
specification is at all times ensured. However, an in-depth study must always be performed since
every oil field may have different characteristics.
Most bulk water content is removed in the first wash tank with 1.2 2 %BS&W at outlet oil
stream. The oil water cut specification is achieved in the second wash tank as the residence time
increases and the water droplets diameter are reduced along the oil pad height.
A short-circuit factor (F) of 1.4 was determined to be conservative when designing oil dehydration
systems using low-capacity wash tanks of 500 bbl. installed in series. This further proves that the
process efficiency is subject to wrong flow patterns (Turbulences) and poor flow distribution
across the entire water pad (Channeling). Similarly, when designing in cold weather, the F factor
may result in much higher values since heat transfer with ambient could cause the process
temperature to decrease and hence the dehydration efficiency; energy conservation have to be
considered in such cases.
The explained Early Production Facilities allows starting oil production before sophisticated
permanent facilities are installed and delivering oil within right product specifications.

Nomenclature
A Cross-sectional area (ft2).
BFPD Barrels of fluid per day.
d Minimum vessel internal diameter, (in).
dm Water droplets diameter, (m).
dmi% Diameter of water droplet to be settled from the oil to achieve 1% water cut, (m).
EPF Early Production Facilities.
F Fahrenheit degrees of temperature.
F Short-circuiting factor, (dimensionless).
ho Oil coalescing height (ft).
hw Water pad height (ft).
Leff Coalescing section length, (ft).
O/W Oil/Water interface.
Qo Oil flow rate, (BOPD).
SG Difference in specific gravity between oil and water (dimensionless).
tsw Required settling time for water droplets through oil continuous phase, (s).
tro Oil residence time, (s).
vt Water droplets settling velocity, (ft/s).
vo Oil velocity, (ft/s).
WC Water cut, (%BS&W).
o Oil viscosity, (cp).
SPE-177213-MS 9

References
Arnold, K. and Stewart, M. 2008. Surface Production Operations, Volume1, Design of Oil Handling
Systems and Facilities, Third edition. Houston, Gulf Professional Publishing Co.
Douglas, E. 2002. Oil and Gas Production Surface Facility Design and Rating. In Industrial Chemical
Process Design, first edition, chapter 4, pp. 117158. New York, USA: McGraw-Hill Co.
Francis, M. and Richard, T. 1995. Oilfield Processing, Volume 2, Oklahoma: Crude Oil PennWell-
Publishing Co.