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Optimizing Separator Operating Pressures to Minimize Flash Losses: Insights from the EPA Gas STAR Program

The U.S. EPA's Natural Gas STAR Program presents a case for optimizing separator operating pressures to significantly reduce flash losses. Flash gas, often vented or flared, results from pressure drops during oil separation. By minimizing the operating pressure of low-pressure separators, operators can reduce emitted gas and enhance sales gas recovery. This report details specific methodologies implemented by Devon Energy to optimize operations efficiently, showcasing potential annual profit increases of approximately $7,000, while also conserving natural resources and reducing greenhouse gas emissions.

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Optimizing Separator Operating Pressures to Minimize Flash Losses: Insights from the EPA Gas STAR Program

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  1. U.S. Environmental Protection AgencyNatural Gas STAR ProgramOptimize Separator Operating Pressures to Reduce Flash LossesSPE Paper 94373B. Boyer - COMM Engineering &S. O'Connell, Devon Energy Corp.

  2. Outline • Introduction • Flash Losses • Opportunity • Methods Used • Conclusions

  3. Introduction • STAR BMPs examples of Optimization • Many opportunities exist • Many solutions needed • Flash gas from separators and storage tanks are natural gas product

  4. Flashing Losses • Flashing losses result from oil pressure drops during the separation process • Flash gas routinely vented to the atmosphere or burned in a flare • Sources of flash to atmosphere include separators, heater treaters, storage tanks • Higher BTU gas from storage tanks

  5. Flashing Losses • Intermediate flash • Intermediate pressure separators that send oil to low pressure separator or heater treater • Computer simulations • Fixed roof atmospheric storage tanks • Pipeline pigging operations • Gas plant inlet separators dumping to storage tanks

  6. Typical Flash Destination

  7. Optimization Opportunity • Minimize operating pressure of low-pressure separators that dump to storage tanks to reduce flash losses • Results in decreased gas vented by storage tanks and increased gas to sales • Minimal cost to implement with immediate payback

  8. Why Optimize Separators? • Easy, inexpensive to increase profits • Gas STAR Program reporting • Conserves natural resources • Greenhouse Gas emission credits • Reduce volatile organic compounds (VOC) • Reduce benzene and other hazardous air pollutant emissions

  9. Devon Energy Corp. Case Study • Surveyed facilities • Chose G.A. Ray No. 93 Facility • Optimize separator pressures to increase gas to sales minimal costs • Field cooperation – sampling, optimization options, implementation

  10. Method • Step1. Choose Flowrate Estimation Method • Step 2 – Collect Process Data • Step 3 – Determine existing GOR and flash rate • Step 4 – Determine and implement optimal operating pressures • Step 5 – Determine new GOR and flash rate after lowering operating pressures • Step 6 – Calculate the reduction in vent gas and the monetary value of the vent gas

  11. Additional Solution • Install vapor recovery after optimization when adequate amount of gas vented • See Natural Gas STAR’s Lessons Learned document: “Installing Vapor Recovery Units on Crude Oil Storage Tanks” (www.epa.gov/gasstar)

  12. Conclusions • Methane emissions • Before optimization = 653,000 scf/year • After optimization = 317,000 scf/year • Increased potential net to sales = 336,000 scf/year • Increase profits to approx. $7000/year • Devon reporting this data to Gas STAR Program

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