INTRODUCTION
A producer in Potrero del Llano field in Poza Rica, México, needed to replace the obsoleted 12PL Pilot on some of their production separators.
PROBLEM
Their vertical separators didn’t have any 2” FNPT or ANSI connections available, which were required to install a float level controller. There was also no possibility of making any modifications to existing vessels to allow for this.
Production Details
- Production Type: Oil Facility
- Oil Volume: 50-500 BPD
- Water Volume: 10-50 BPD
- Gas Volume: 1 mmscf/d
- Solids in Fluid: Very Low
- Corrosiveness: Low
- H2S: Less than 10 PPM
- Upstream Pressure: 35 PSIG
- Downstream Pressure: Atmospheric (Discharge to storage tank)
- Vessel Type: Vertical 2-Phase Separator
SOLUTION
The operator worked with technicians at Flow Control Measurement, Kimray’s authorized distributor in Mexico, to trial a solution called Gap Control.
To incorporate this, they installed 2 pneumatic level switches—one direct and one indirect—operated with a 3 PGB Bistable pilot to operate the existing 4” low pressure control valve.
Both pneumatic switches were installed together with 2 external float cages using 1” pipe tubing and connected to existing 1” connections on the vessel.
In order to provide better control on the pneumatic system, a drip pot and supply gas regulator were installed with pressure gauges on the line to monitor the pressure between the pilot and control valve.
An initial trial was performed with a vertical separator running for 4-8 hours every 2-3 days.
Date of Installation: November 30, 2023
RESULTS
After three months of operation, the system was working without any problems or troubleshooting needing to be performed.
Due to the success of this solution, a second trial was initiated with a vertical separator operating 24/7 and is experiencing the same positive results after one month of operation.
The producer was pleased to find a solution for their existing problem and especially pleased that they could continue using Kimray equipment, as they had built a lot of trust in the brand.