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Handling Emulsion in Oil & Gas Production

Emulsion is the fluid produced from the well: the mixture of oil, water, gas, and other products. It generally refers specifically to the fluid that comes directly from the well, before any separation. After gas has been separated out, the oil and water that remain is called crude oil. Water will be separated next on it’s way to being sold.

Emulsion

 

Emulsion and the Tank Battery

The specifics of what is being pumped from the well determine what sort of tanks and lines you’ll need for a tank battery. The amount you’re pumping will determine the size of the tanks you’ll need. Other factors you’ll want to keep in mind when assembling a tank battery include:

  • The number of wells feeding into the tank battery
  • The crude oil’s API gravity
  • The volume of water coming from the well daily
  • Paraffin production
  • How long the well is estimated to operate
  • Other issues particular to wells and reservoirs

Separating water from oil is a major issue, and one of the more important factors in determining what vessels you’ll need. It will be easier to separate water from lighter oil, as lighter oil moves more quickly and leaves the heavier water behind. Heavier oil may require more tanks and more time to separate enough water for the oil to be sold. Once you’ve determined what vessels you’ll need you can layout the flow line and header, and start putting your tank battery together.

Emulsion

Figure 1. An example diagram outlining a tank battery, with emulsion lines labeled E.

 

Header and Lines

For a tank battery that receives from several wells, a header can be a good idea. This is an arrangement of flow lines, meters, and valves that will allow you to control the flow from different wells. When a lease is pumping only a small amount, the loss from shutting in a few wells to run a test may be small. You could use barrel or bucket tests, or an individual well tester. In that case, a header may not be necessary.

Generally, you’ll need two headers, one for production and one for testing. If one tank battery is serving a large number of wells, you may need a second production header. As the flow lines from the wells approach the tank battery they generally are routed so they run parallel and about 18 inches apart from each other. That distance may seem random, but it’s due to the arrangement of pipes needed to receive the flow lines. A standard arrangement uses a 12 inch nipple and two tees for the header of each flow line, which adds up to needing about 18 inches.

Flow lines can be steel pipe of various types, fiberglass, or a few different types of plastic. The material should be chosen to meet the demands of your particular operation; for example, if corrosion is a major concern, consider fiberglass or plastic over steel. As the lines enter the header, it passes through a 6 inch nipple, meets a union joint and then another 6 inch nipple. A check valve is required next, and then the pipe hits another 6 inch nipple before entering the header proper.

That check valve is an important part of the header, and without it you could lose all the oil produced by all the wells routed through the header if a flow line develops a leak. This can cause the line to lose pressure, and so the fluid will fall naturally back down into the well. The check valve prevents this by closing at a loss of pressure, so that only the fluid in the line is lost. When that happens, there may not be any obvious signs of a problem. The well will continue to show a flow and pumping action at the bleeder valve. Nothing is being produced, however, and the well is simply circulating the fluid.

Emulsion

Figure 2. Lines from several wells flowing into the header. Standard practice is to label the lines at this point.

One major consideration when designing your header is ease of identification. You’ll want your valves higher up, where they can be easily seen. Using quarter round valves is also advisable, as you can see if they are opened or closed at a glance. Using round opening valves is usually not the best option, as they can lead to mistakes. If the header is set up to be controlled automatically, there should be a telltale or indicator on the valves to show which are open and which are closed. Any header design that works for you is fine as long as it is clear where oil is flowing, and which valves are open and closed.

Emulsion

Figure 3. A header that controls three flow lines and a single four inch test line (on the far left).

 

Injecting Chemicals

Chemical separation is necessary for pumped fluid to become saleable oil. It’s common to add chemical to the fluid just after the header, but before the first vessel. For most tank batteries, that means adding a system for injecting chemicals between the header and separator. Adding chemical here makes sure that it is mixed evenly with all the oil. Adding chemical in a flow line before the header could mean that oil from some wells isn’t mixed well, though with high volume operations the flow is great enough this is less of a problem.

For some operations, a barrel on a stand with a method of adding chemicals is enough. Larger operations producing more fluid, and therefore adding more chemical, will need a larger and more involved setup.

Regulations require that tanks with a volume of 600 gallons or more have some backup method of containing its contents. For a chemical tank, a drip pan under the injector’s stand is usually a good way to go. There should be signs informing any crew of the chemical tank’s contents and any hazards it may pose, and more detailed information should also be available.

Emulsion

Figure 4. A basic injection system using a pump and barrel.

Figures 4 and 5 show a couple of example systems for adding chemicals. Figure 4 shows a setup that has been used for decades, and is still common with medium-production operations. Figure 5 shows a newer setup that is used by higher production operations. In that picture, you can see an example of a drip pan as well as signs (on the lower right) offering information about hazards.

Emulsion

Figure 5. More complex injection system for a higher production operation.

Is your appetite for oil & gas operating knowledge insatiable like ours? 😀 If so, check out these related articles below – they’ll be sure to pump you up!!!

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*PLEASE NOTE: 6% is the AVERAGE result of producers who implement the app into their operations..... which means a full HALF of our clients do better 🤑

Centralized Repository

Get full production history, well files, commentary and the like in the hands of the people who need it (when they need it) and enable everyone in the field or office to do their best work.

Reduced Overhead

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Reduced Downtime through Alerts

Gain timely detection of equipment malfunctions or other operational issues and prevent costly breakdowns. With Greasebook, alert your in-house team to issues in the field wherever they're at.

Increased Production

Catch a hole in the tubing or an engine issue immediately when a well begins to slip (not several weeks later when your purchaser statements come in…) 💸 Greasebook is the next best thing to 'sitting shotgun' with each pumper on every route. And because you'll have complete visibility of your assets and your field crew, you'll not only avoid significant expenses associated with repairs and oversights but you'll also produce more oil because of it.

Timely Reports

Weekly, monthly, or missed reports simply don’t cut it. Why? Because longer reporting intervals increase the risk of inaccuracies and discrepancies in your production data, which not only erodes trust in the reported figures but also makes it challenging to analyze trends or forecast future production 📉 With Greasebook, eliminate any excuse NOT to have your production data.

Full Accountability

Gain full transparency of your folks in the field and eliminate boiler housed reports and ‘Kitchen Table Pumping’ for good 🍳

Focus

From one-off wells to lengthy routes, no matter what form your pumping takes, GreaseBook keeps your pumpers focused on moving those production updates from field to office.

Gather

Easily gather everything that matters. Track tank levels, capture notes, administer well tests, submit photos of scanned run tickets. All from the field. All on your mobile device. All over the cellular network.

Connect

Connect with the people who help you get it all done. Communicate, collaborate, and share in real-time with your guys and gals in the field without ever leaving the GreaseBook.

Access

Access fast, accurate gauge sheets. No need to re-key production or manipulate Excel. Just one click and your production is organized into a beautiful screen-friendly layout.

ALLOW US TO IMPLEMENT THE GREASEBOOK FOR YOU AND....

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Everything in one place

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Get paid your due

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Knowledge discovery

GreaseBook acts as your operations watchdog, surfacing any unexpected drops in production, unplanned downtime, or incompetence in the oilfield.

Share Responsibility

Production data syncs across all pumpers who share the responsibility of a particular lease. That means no more calling, no more meeting up to trade-off books, and no more miscommunication.

Mobile Sync

Automatic sync means your production status is available the minute your pumper returns to coverage.

Offline Access

Pumpers retain access to historical production by making their work available even when a connection isn’t.

Guarantee

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57000449
bbls pumped to date
50106001
MCF flowed to date

Simple 8-minute Ramp Up

Average time to learn? 8 minutes (and yes, this goes for those pumpers who are 75 years old still tending wells…)

Custom Reports

Select one of our premade reports or build your own.

Alarm Alerts

Whether it’s a full tank or well is offline, we’ll text or email anyone you want if there’s an issue.

Production Graphs

See the big picture with beautiful production displays which render perfectly on any device.

Field Data Collection

Enter run tickets, BS&W draws, water hauls, track dual product tanks, conduct well tests all via the Greasebook. Now, your real-time monitoring shows right alongside those manual pumper gauges.

Comments

Real-time production is worthless if you don’t have the contextual information to complement it. Tag or search pumper comments by lease, well, or injector/SWD – letting the whole team know precisely what’s going on in the field.

Well Testing and Allocation Engine

Robust well testing and allocation engines to satisfy even the most complex gathering system.

Downtime Tracker

Which wells are down? How long they been down for? Why are they down? Now, you’ll know at a moment’s glance.

State & Government Auto-Report Filer

Yes, you read that right. We’ll produce your State and Government production reports enabling your back office to catch their breath.

Scheduled Reports

Want a report with your coffee every morning at 5AM? Got a WI partner who won’t quit calling to ‘get the numbers’? Set’em up on an automated report and watch the daily minutiae disappear.

Well History Files

A single place for your downhole and surface equipment PDFs, Word Docs, and the like – accessible in both the field and office.

Pumper GPS Tracker

Wanna know how many times your pumper is showing up each month? When was the last time someone set foot on a particular lease? No more “he said, she said” – with GPS tracker, now you’ll know the full story.

Custom Variables

Track any variable at any lease no matter how obscure.

Custom Logic

Components of a production system don’t operate in a vacuum. We make complex math simple so you can focus on analysis NOT spreadsheet jockeying.

Partner/Investor Permissions

Maintain transparency by giving special partners and investors access to their production (and ONLY their production!)

Read-Only Permissions

Giving certain users the ability to ‘look but don’t touch’.

Privacy and security. Keep what’s private pri****.

Bring the most advanced security of any device to your operations. The GreaseBook comes with built-in protections against malware and viruses, and given our open API it gives you the freedom to choose what you share and how you share it. So no matter what you’re doing (or where you’re doing it), GreaseBook helps your private information stay that way.

(just a few of) the products we integrate with

GREASEBOOK INTEGRATIONS

“If you’re unsatisfied for any reason during your 6-week trial, we'll either work with you until it's right or refund 200% of what you paid for the app. How can we do this? We're just that good. But don't take it from me. Check out what our clients are saying below......"
Greg Archbald
Perpetual Student of the Oilfield
Founder of GreaseBook
FEAST YOUR EYES, NON-BELIEVERS 👀👇

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Ask us anything

F.A.Q.

Not really. Simply share with us your Excel reports, paper gauge sheets, or the login to your existing legacy production software and we’ll take care of the rest.

Our petroleum engineers turn-key your entire setup, we’ll reach out once we’re done. Bada bing.

You’re right. And, because no one leaves their house without their phone (and because our app works offline), we eliminate any excuse for your pumpers NOT to send you their data. See, we told you this would be easy.

In addition to both Android and Apple smartphones, the Greasebook also works on any tablet, laptop, or desktop.

While Greasebook has been implemented in many of the country’s largest publicly traded production companies operating thousands of wells, Greasebook is focused on serving the small and mid-sized independent US-based oil & gas operators.

Anywhere, anytime, on any device (phone, tablet, desktop or laptop).

The beauty of the app is once your pumpers start submitting their production via the Greasebook – anyone on your team can access production reports, graphs and well files from any device at any time.

It’s sorta like a centralized place from which everyone on your team can work, without all the calls, text messages and emails that would go on otherwise.

Absolutely. As your pumpers continue to add tickets, comments, pressures, well tests and any other relevant information, your investors will have guest access to as much (or as little) information as you’d like.

Of course, they’ll only see production info for the wells in which they participate.

Oil & gas companies who run Legacy oil and gas software systems expose themselves to major risks (and minor annoyances…)

The complexity of traditional oil & gas production systems is twofold:

  1. Software Problem: Legacy software systems are expensive, outdated, clunky and have extremely complex interfaces. In fact, because of all the support and manual interventions required, continuing to use outdated software can often be more costly than simply upgrading.
  2. People Problem: Legacy software systems take an enormous amount of time to familiarize oneself with. And, anytime an employee quits, retires, or is let go the amount of training required for new employees can be significantly higher than for newer, more user-friendly software.

 

This is a lose/lose. What’s more, given all the set-up fees, training fees, support fees and the like the projected ‘savings’ never materialize and now your forced to contend with fluctuating hydrocarbon prices AND a bloated monthly OPEX.

Talk about getting stuck in the muck!

With Greasebook, office users are 99% proficient with the platform in about 20 minutes.

Within 2 seconds – FROM YOUR SMARTPHONE – you’ll have your answer to any question regarding production, allocations, performance, well history files, commentary, run ticket reconciliation, Custom Reports, State reports, and more – all sliced and diced and customized at the Company, Operator, Battery, Well, State, County, Section, Township, Range, Acquisition, or even Supervisor level…

We’ve been at this for awhile. Greasebook was established in 2012 and now supports more than 400+ oil and gas operators (small ma & pops and publicly traded companies alike) across 20 States and is the fastest growing production software in the patch.

The Greasebook corporate outpost is proudly located in Oklahoma City, Oklahoma 🤠📍

The Greasebook helpdesk is staffed by Petroleum Engineers, Geologists, and Completions Experts Monday through Friday, 8AM to 5PM CST. 

We have a real-time chat through which most questions are answered in 2 minutes or less.

Naturally, some questions are more complex and you’ll want to speak to someone over the phone. In this case, we aim to complete all callbacks within two hours of scheduling.👌

Of course, your Dashboard and Reports are available to you 24/7.

We don’t blame them.

Pumpers have been burned by Legacy Production Systems in the past. 😵

However, given how much upside you stand to gain in the form of time savings and profit, DO NOT make the mistake of letting the tail wag the dog, folks!! 💸

Real talk: the average pumper takes about 8 minutes to learn Greasebook (and that goes for guys in their 80s still tending wells…)

Give us two days and we’ll make believers out of your entire pumping crew….

Still not convinced? Check out Greasebook’s “Pumper Wall of Love” by clicking here and let the pumpers tell you themselves 😘

Let us help you help yourself. Simply send us your existing production info, and we’ll assign a production engineer to turn-key your entire setup for you.

We’ll build your wells, your tank straps, your users and anything else you require.

Finally, once everything has been reviewed by your team, we’ll roll out your pumpers and either train them for you or with you while you focus on more important stuff.

That’s not a question, but actually no.

The average pumper demands anywhere from $125 to $400 per month.

And depending on what you require, Greasebook is priced anywhere from $5-15 well/mo.

So, given how much more you’ll get out of your pumpers, how much we’ll streamline your operations, and how quickly we’ll get this all done for you, we’re actually kind of a bargain.

Our guarantee is two-pronged…

First, run the app for full 6 weeks in your operations. If you’re not completely satisfied, let us know and we’ll DOUBLE your money back.

Second, if for any reason you’d like your money back in first 30 days after paying simply let us know and it’s yours. 🤝

However, if you’re anything like our other 400+ operators you’ll be wondering why you didn’t do this 6 months ago…

We’re ready when you are. Take the quiz and schedule a call here – depending how many operators we have in front of you, there’s a chance we can get you up and running by the end of next week.

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