Condensate Pipeline Dewatering

Hydrocarbon Condensate Transportation Using Pipeline Condensate

Natural gas production often also produces large volumes of hydrocarbon condensate liquids that may be transported tens or even hundreds of kilometers, for delivery or treatment: for example, from remote offshore platforms or FPSOs to processing onshore. When carbon steel pipelines are used and the condensate contains significant volumes of free water or brine and may also be sour due to H₂S/CO₂, corrosion often results, leading to shortened pipeline life and significant fouling of onshore facilities. Monoethylene glycol (MEG) may also be entrained if used for hydrate suppression at the well.

Multistage Process for Water and MEG Removal from Condensate Pipeline

Water and MEG removal from condensate is a multistage process. First a primary water separator followed by liquid/ liquid coalescers are used for free water and MEG removal. Additional removal of dissolved water can be accomplished by a dissolved water stripper column. If natural gas is also being transported in the same pipeline, the gas may be glycol dehydrated then mixed with the condensate to ensure a dry flow that minimizes pipeline corrosion.

Minimizing Corrosion and MEG Losses in Condensate Pipelines

Achieve consistent water/MEG removal from hydrocarbon condensate
Use carbon steel pipe while minimizing corrosion risk
Minimize energy and opex costs on the dissolved water stripper by reducing free water load and fouling
Achieve downstream opex control and freedom from upsets by minimizing fouling of gas treatment and/or condensate processes from rust and black powder
Minimize MEG losses, through effective recovery, distillation and reuse

Production Challenge/Pall Solution

Challenge	Solution
Minimize corrosion of carbon steel piping due to the presence of free water in the hydrocarbon condensate Minimize MEG losses in the condensate Minimize stripper operating costs	Reduce capex and corrosion operating costs by effectively removing water contamination from carbon steel pipelines, negating the need for expensive internally coated pipe. Maximize MEG recovery from the condensate with reliable removal. Enhance stripper operation by protection from free liquids and solids. Optimize downstream gas plant, stabilizer and/or fractionator performance and minimize opex by effectively controlling ingression of pipeline corrosion products. Conventional glass fiber coalescers will disarm due to surfactants in the condensate—sulfur compounds, additives such as corrosion inhibitors, or well treating chemicals. Disarmed coalescers will let free water downstream, allowing the onset of rapid pipeline corrosion and significant MEG loss. Cyclones, mesh packs or plate separators may not remove the fine droplet emulsion created by the surfactants. High levels of free water and MEG may be seen downstream along with associated corrosion. If MEG is present in the water, it creates very fine emulsions with poor separation efficiency from glass fiber coalescers and separators described above, leading to corrosion and MEG loss. High-efficiency AquaSep® EL or AquaSep XS coalescers operate without disarming to provide effective fine emulsion separation to as low as 15 ppmv free water, ensuring minimal water-related pipeline corrosion and maximum MEG recovery

Challenge

Solution

Minimize corrosion of carbon steel piping due to the presence of free water in the hydrocarbon condensate

Minimize MEG losses in the condensate

Minimize stripper operating costs

Reduce capex and corrosion operating costs by effectively removing water contamination from carbon steel pipelines, negating the need for expensive internally coated pipe.

Maximize MEG recovery from the condensate with reliable removal.

Enhance stripper operation by protection from free liquids and solids.

Optimize downstream gas plant, stabilizer and/or fractionator performance and minimize opex by effectively controlling ingression of pipeline corrosion products.

Conventional glass fiber coalescers will disarm due to surfactants in the condensate—sulfur compounds, additives such as corrosion inhibitors, or well treating chemicals. Disarmed coalescers will let free water downstream, allowing the onset of rapid pipeline corrosion and significant MEG loss.
Cyclones, mesh packs or plate separators may not remove the fine droplet emulsion created by the surfactants. High levels of free water and MEG may be seen downstream along with associated corrosion. If MEG is present in the water, it creates very fine emulsions with poor separation efficiency from glass fiber coalescers and separators described above, leading to corrosion and MEG loss.
High-efficiency AquaSep® EL or AquaSep XS coalescers operate without disarming to provide effective fine emulsion separation to as low as 15 ppmv free water, ensuring minimal water-related pipeline corrosion and maximum MEG recovery

Condensate Pipeline Water/MEG Removal Process Flow Diagram:

¹Gas dehydration processes will be optimized with the addition of SepraSol™ Plus Liquid/Gas coalescers on the gas inlet and outlet, and Ultipleat® High Flow/Marksman™/Coreless filters on the recirculating glycol. See Glycol Dehydration, brochure FCOGGLYDENa for additional information.

Key Application/Filter Recommendations for Condensate Pipelines(other applications not shown)

Application

Prefilters for liquid/liquid coalescer protection

Pall Product

Ultipleat High Flow, Marksman filters, or Profile® Coreless filters to remove incoming solids

Customer Benefits

Low operating costs
Freedom from fouling-related stripper shutdowns

Free water/MEG removal from condensate

AquaSep EL coalescers for water/ MEG removal on high solids condensates

AquaSep XS coalescers for water/ MEG removal on low solids condensates

Low pipeline capex
Improved pipeline opex due to better protection and service life
Reduced stripper energy costs
Optimized MEG recovery and reuse
Controlled downstream plant opex and freedom from upsets due to slugs of pipeline corrosion products

For more information on improving the efficiency of your processes, contact our team of filtration experts.

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Condensate Pipeline Dewatering

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