GENERAL INSTRUCTION AND OPERATION GUIDE OF

ELECTROSTATIC TREATMENT
SESSION A: General Instruction of Desalter
Date: March, 2016
By: Morito Maruyama
CAMERON supplied items

CAMERON supplied 
TWO IDENTICAL EDD SINGLE DESALTERS
for DUMAI REFINERY RU ‐ II

CRUDE DISTILLATION UNIT 2

100-A-301-V01A : Single Stage Electro-Dynamic Desalter (EDD)
100-A-301-V01B : Single Stage Electro-Dynamic Desalter (EDD)

2
Typical Crude Treatment Process Flow (Desalter)

3
Why DESALT? – In Refinery –

Meet Customer’s Specification and Improve Oil Product Quality
1) Removal of Chloride Components
Corrosion issue
 Reduce Tower internals corrosion
 Reduce cost of chemical injection
 Reduce maintenance cost
2) Removal of Sediment and Mud
Plugging issue
3) Reduction of Suspended Solids
Fouling issue
4) Extension of Life Catalyst
Catalyst poisoning by metals

4
What is dehydration?

DEHYDRATION:
Removal of Free Water and Emulsified Water.

In oil field terminology, this is DEHYDRATION

Free Water
Large droplet size
Most loosely held form of water
Separates on standing

Emulsified Water
Micron sized droplets
Does not separate on standing

5
Water Particles and Emulsion Model

Emulsion Model

Droplet size:                  Generally  1 ‐ 10 micron
Water / Oil Ratio:       ~ 1 Vol.%
Number of Droplets:   ~ 1.5 x 1014 / m3 of oil *
Total Surface Area:     ~ 12,000 m2 / m3 *

* Values based on 5 micron size droplets.

6
What is desalting?

DESALTING is a process of washing crude oil with fresh 
water (dilution water) to remove water soluble impurities.

MIXING contact between fresh water and brine
Phase Contacts  ‐ Mixing Valve DP
‐ Static Mixer Elements
‐ Electrostatic Mixing (EDD only)

SEPARATION resolution of the phases
‐ Coagulation – Destabilization (chemical reaction) 
‐ Flocculation – Gathering of destabilized drops
‐ Sedimentation – Gravitational separation of the phases

7
Typical Process Flow Diagram

Dilution Water

Desalter

Crude Oil

Mixing Valve

Recycle Water

8
Mechanical Force Wash Crude Oil
Injection: Distribution of Water
‐ Upstream of Heat Exchangers
‐ Before Mixing Valve / Static Mixer
‐ Counter flow in Desalter Vessel (EDD only)

Mixing: Phase Contact
‐ Mixing Valve DP
‐ Static Mixer Elements
‐ Electrostatic Mixing (EDD only)
Static Mixer 
Elements

Mixing Valves

9
Mixing vs Dehydration and Desalting

dp=0.5 ‐1.0 bar

10
Water in Oil Separation Processes

1. Separation by Gravity

2. Chemical Pretreatment

3. Heat Addition

4. Electrostatic Coalescence

11
Water in Oil Separation: Separation by Gravity

Stokes' law

Settling  K(w  o )gd

2

Rate 

where:
K = Constant  g = gravity factor
d = droplet diameter  = Oil viscosity
w = Water density o = Oil density

12
Water in Oil Separation: Chemical Pretreatment

Demulsifiers
injected into the production stream ahead of the dehydration 
step.
Separation: Phase Disengaging
‐ Coagulation – Destabilization (chemical reaction) 
‐ Flocculation – Gathering of destabilized drops
‐ Sedimentation – Gravitational separation of the phases

Application of Demulsifiers
Time
Temperature
Agitation
Dosage

13
Water in Oil Separation: Heat Addition

• Higher Process temperature lowers oil viscosity

• Specific gravity difference between oil and water is increased

• Aids in dispersion of the demulsifier

• Thermal expansion of water droplets weakens the stabilizing 
film

DISADVANTAGES
Operating expenses
Loss of crude handling volume

14
Water in Oil Separation: Heat Addition

Comparison of Oil/Water Separation
at 40oC at 90oC

Oil / Water separation perform well at high temperature!

15
 Water in Oil Separation: Electrostatic Field

Neutral 
water 
droplet

Water droplet 
expands under 
Electrostatic field 

Water droplets 
attract under 
Electrostatic field 

16
 Water in Oil Separation: Electrostatic Field
Coalescing Forces 

2 6
KE r
F 4
d
F = Force of attraction between water droplets
K = System constant
E = Voltage gradient (volts/meter)
r = droplet radius
d = Distance between droplets (dr)

Very sensitive to droplet size: r (to the 6th power )
Sensitive to distance: d (to the 4th power )

17
Types of Desalter / Treater

1. AC Type Desalter / Treater (AC)
 Existing Desalters

2. Dual Polarity Desalter / Treater(DP)
3. Electro Dynamic Desalter (EDD)
 100‐A‐301‐V01A & B

4. Dual Frequency Treater/Desalter(DF) 

18
Transition of Electrostatic Technology

DC Field Electrode Metal  DC Field Electrode Composite
Plates Plates

Combined
AC DP DP or EDD
Desalter Desalter Desalter
EDD
+ + Desalter / 
Dehydrator
+
AC  DP  DF 
Dehydrator Dehydrator Dehydrator
Up to API 
14  to 20
Variable Frequency
PETRECO
Cylectric
BILECTRIC®
HOWMAR Tri‐Volt®

19
Transition of Cameron’s Technology
4th Generation
1st Generation 2nd Generation 3rd Generation
(Super Dehydrator)

YEAR DEVELOPED 1960 1970 1990 2003 

NAME Alternative Current Dual Polarity Electric Dynamic  Dual Frequency

(TYPE) (AC) (DP) (EDD) (DF)

ELECTROSTATIC FIELD AC Field DC + AC Field DC + AC Field DC + AC Field

Composite
ELECTRIC GRID Metal Rods Metal Plates *1 Composite Plates
Plates
Mixing Valve + 
WATER WASHING Mixing Valve Mixing Valve Electrostatic  Mixing Valve
Mixing
Variable Variable
VOLTAGE Constant (20kV) Constant (20kV)
(20‐40kV) (15‐23kV)

Constant  Variable 
FREQUENCY Constant (50/60Hz) Constant (50/60Hz)
(50/60Hz) (15~800Hz)

Note *1: Composite plates can be applied

20
AC Desalter (1st Generation)

PFD（Single AC Desalter）

< Problems >
1. AC Field Disappearance Caused by Electric Spark
2. Handling Difficulty of High Emulsion Crude
3. Less water injection (less oil/water mixing)

21
Electrostatic Field (AC)

Increasing water
concentration

+ Di-Electrophoretic
_ _ Force + +
_ +_ _
+ _
+
+
Dipole
_ +
Force _+
+ _
_ _ _ _ _ _ _
+ _+ + _+ + _+ + _+ + _+ + _+ + _+

Oil/Water Interface

22
 Droplet Coalesce Process in AC Field

1. Aligned along the  2. Move 3. Coalesce/ Settle

electrostatic field

- +- +
- + - + - +
- + - +
- + - + - +

- + - + - + Settle

+ - + - + -

* Positive & Negative is switching Every 50 / 60 Hz in AC Field

23
 AC Type Treater / Desalter

PETRECO® BILECTRIC® Treater

Oil
Electrode / Grids

Thinnest possible
Interface thickness Interface

Increased residence
Water
Minimal turbulence

Solids
24
 Summary: AC Desalter

AC Field Benefits, Including:
 Dipolar Attraction
 Film Stretching
 Water Tolerance

But There are Limitations:
 Minimal Drop Movement
 Limits on Useful Field Strength
 Much mud accumulation

25
Dual Polarity® (2nd Generation)

PFD（Single DP Desalter）

3 ‐ 5%

*1

Mixing valve

3 ‐ 5% Internal rcycle

Note *1: Composite plates can be applied

26
 Electrostatic Field (AC + DC)

Inside Desalter
1. Crude feed
② 2. AC Field (large droplet)
3. DC Field (small droplet)
Interface 4. Treated Crude
①

Crude
27
 Droplet Coalesce Process in DC Field

1. Attract

2. Charge

3. Coalesce

4. Settle

Settle

+
* Constantly, Positive & Negative is applied in DC Field
-
28
Dual Polarity®: Vessel Internals

Upper View

Side View

Bottom View

29
 Summary: Dual Polarity®Desalter

• Droplet Coalescence : AC Field + DC Field

• Electrode : Plate type

1. More wash water injection rate (compare 
with AC system)
2. Deeper Coalescing Field
(compare with AC system)

Improved Dehydration  Interface

Performance 

30
Electro-Dynamic® Desalter (3rd Generation)

STEP 1
Overhead : 3vol % water injection

STEP 1: Mixing
STEP 2: Coalescing
STEP 3: Settling
STEP 3

STEP 2

Mixing + Coalescing results superior Desalting than others.

31
Features of EDD
 Counter Flow Water Dilution provides multi‐stage contacts

WASH 
ELECTRODE WATER
HEADER
PLATES

DOWNWARD
UPWARD WATER FLOW
OIL FLOW

COUNTERFLOW WATER WASHING PROCESS

32
Features of EDD
 Counter Flow Water Dilution provides multi‐stage contacts

WASH 
ELECTRODE WATER COUNTERFLOW 
HEADER
PLATES WATER WASHING
UPWARD BRINE DROPLETS 
DOWNWARD
UPWARD WATER FLOW
OIL FLOW

Dilution water FIC Crude Out

Overhead Dilution water

~5 vol % ~3 vol %
Variable Voltage
FIC

M.V 2nd Mixing  

Crude In (Electrostatic mixing)

Effluent water
1st Mixing
(Mechanical mixing)
33
Features of EDD
Load Responsive Control (LRC) provides ELECTROSTATIC MIXING
Voltage Dilution Water
42 kV 35 kV 22 kV

18 kV 20 kV 18 kV Time (Sec.)

Emulsion 
Heavy &  During  Flow
Ordinary
Dirty  Crude 
Crude
Crude Switch

Parameters Setting (typical)
Operation Mode Dispersing (sec.) Mixing (sec.) Coalescing(se Settling (sec)
c.)

Heavy & Dirty  <API   0.8 sec. (42kV) 2 sec. 3 sec.

Crude 25 (18kV) 0.5 sec. (18 kV)

Ordinary  >API   0.8 sec. (35kV) 1.5 sec. 2 sec.

Crude 25 (20kV) 0.5 sec. (20kV)

During Crude  3 sec. (22KV) 3 sec. 3 sec.

Switching (18kV) 3 sec. (18KV)

34
Load Responsive Control (LRC)

• Voltage Control
• Time setting/ control
• Process monitoring

Voltage Setting
‐ Mix Voltage ‐ Settle Voltage

Time Setting
‐ Disperse time ‐ Mix time
‐ Coalesce time ‐ Settle time

35
Load Responsive Control (LRC)
SYNC Board: Synchronize the transformers
LRC Panel

LRC Board: Control each transformer

36
 Load Responsive Control (LRC)

LRC PC to set parameters & Monitoring conditions

Setting Alarm

Current Apply Voltage

37
Summary: Electro-Dynamic® Desalter (3rd Generation)

• Droplet Coalescence : AC Field + DC Field

• Electrode : Plate type (Composite electrode)

1. More wash water injection rate (compare 
with AC system)
2. Deeper Coalescing Field
(compare with AC system)
3. Oil/ Water Mixing: Mixing valve 
+ Electrostatic mixing Interface 
level

Improved Desalting Performance

38
EDD Case Study-1: Heavy Crude Processing
CASE‐1 : Desalter Optimization for Heavy Crude Processing
Background:
Introduced EDD as a new 2nd stage Desalter to meet the demand of  
heavy oil processing (API up to 25) based on already proven 
performance in the other train (#J92‐010) .
Reduce the overhead chloride 
Reduce NaOH injection
Avoid desalter upset from over‐current
Avoid oil carry under
Keep Desalter clean from sludge accumulation

30

25 Test method for salts-in-crude:

Salts‐in‐Crude (ppm)

Extraction by hot water, and chloride

SALTS OUT (ppm)

20
CRUDE API
Crude API

15 measurement by ion-chromatography.
10

5 Raw Crude API gravity

0
Salts in Desalted Crude
6/7

6/17
6/18
6/19

6/22
6/23
6/24

6/27

7/5
7/6
7/8

7/11
7/12
7/13
(ppm as NaCl )
Salts OUT API
Optimization of LRC while tuning ‘Mixing & Settling voltage and time settings’

39
 EDD Case Study-1: Heavy Crude Processing
CASE‐1 : Desalter Optimization for Heavy Crude Processing
Chloride Test was changed by Hot Extraction & Ion‐chromatography, 

30 (conductivity method was no longer used)
Salts‐in‐Crude (ppm)

25

20 Pre‐test for impact on salts‐in‐crude by 
Crude API

LRC ( Chloride by conductivity method) Tuning:  Tuning: 

15 'Mixing and Settling  'Dispersing/   Mixing/ Coalescing/ Settling Times' 
Voltage'  at fixed Mixing and Settling voltage.
10

0
6/ 7

6 /1 6

6 /1 7

6 /1 8

6 /1 9

6 /2 0

6 /2 1

6 /2 2

6 /2 3

6 /2 4

6 /2 4
6 /2 5
6 /2 6
6 /2 7
6 /2 8
6 /2 9

7/ 4
7/ 5
7/ 6
7/ 8
7/ 9
7 /1 0
7 /1 1
7 /1 3
7 /1 4
7 /1 5
7 /1 6
7 /1 7

8/ 4
8/ 5
8/ 6
8/ 7
30 Crude API
Salts‐in‐Crude (ppm)

25 Salts‐in‐Desalted Crude (ppm as NaCl)
Salts‐in‐desalted crude were lower than 1ppm.
Crude API

20

15 Final Optimization: Result:
10
Tuning 'D/M/C/S times'  Salts in desalted crude during Heavy Crude 
Processing (API around 25) were maintained at 
5 almost same level of mid and lighter crude (API 
0
over 30).
9/2

9/3

9/4

9/5

9/6

9/7

9/8

9/9

9/10

9/11

9/12

9/13

9/14

9/15

9/16

9/17

9/18

40
 EDD Case Study-2: Reduction of Tower Overhead Chloride

Chloride inTower Overhead Accumulator Water 

Start of EDD（2nd stage)
2‐stage Operation:
1st Stage: AC Desalter (existing)
Chloride (ppm ) 
2nd Stage: EDD (add new)

5.4 wt ppm (Ave.)
15.7 wt ppm (Ave.)

Single stage Operation:
Existing AC Desalter
Result:
Chloride in Tower Overhead Water during Heavy Crude Processing ( API 
between 23 – 28 ) was decreased to the level as well as mid and lighter 
crude oil.

41
 EDD Case Study-3: Conductive Crude Processing
Upset in #2 CDU(AC Desalter) :
Conventional AC Desalter in other unit could no
longer treat the high conductivity crude due to
upset of desalter.
⁃ Secondary voltage dropped to only 3kV and
nearly short-circuit condition.
⁃ Immediately cut off the wash water and power
supply
#3 CDU (EDD) :
EDD Desalter could maintain 12kV and
desalting performance even for the same high
conductivity crude.
⁃ Water in desalted crude within acceptable range
⁃ Chloride in desalted crude within acceptable
range, and overhead chloride remained same.

Ampere KV

30
200
Ampere, A

kV and Ampere
Voltage, kV
20
EDD avoids desalter upset and
move up and 13 - 14 kV achieves successful desalting
down under LRC
100 even for blends of:
10 High conductivity crudes
High TAN crudes
High water content crudes
Ordinary Crude Conductive (Hi- TAN) CRUDE
0 0
Tank Time
Change

42
 Suspended Solid (SS) removal by EDD

Single EDD Operations at Japanese Refineries show better removal of SS

○ Refinery A
△ Refinery B
‐‐‐50% removal

43
Effluent Water Quality of EDD

Single EDD Operation at Japanese Refinery

Effluent water Analysis data

Day 1 Day 2 Day 3

Operating Temp. 129 oC 130 oC 131 oC

Crude API 33.2 31.5 32.8

Oil contents 36.0 mg/L 10.7 mg/L 28.7 mg/L

Flux Rate: 138 bpd/ft2
Oil retention time: 15 min
Water retention time: 30 min

44
 Desalter Internals
AC DP EDD DF
Electrode Rod Steel Plate *1 Composite Composite
SPRAY TYPE
Inlet Distributor or Hi-Flo TYPE Hi-Flo TYPE Hi-Flo TYPE
Hi-Flo TYPE
Oil Collector ◯ ◯ ◯ ◯
Mud trough ◯ ◯ ◯ ◯
Mud Wash Assembly ◯ ◯ ×(OPTION) ×(OPTION)
Field: ◯ Field: ◯
Sludge Drain Field: ◯ Field: ◯
Refinery:× Refinery:×
(Interface Drain) Refinery: ◯ Refinery: ‐
(OPTION) (OPTION)
Overhead Dilution
- - ◯ -
Water Header
Water Effluent Header As per Customer requirement
Note *1: Composite plates can be applied
45
Electrostatic Grids: Composite Electrodes

 Composite Electrodes – consist of plates of composite (fiber reinforced plastic) 
construction with graphite or carbon embedded in the central portion of the plate 
to impart conductivity along the length of the plate. 

Advantages of Composite Electrodes
‐ Tolerant of high water content dispersions
‐ More effective treatment of conductive liquids
‐ Produce a graduated field for better drop growth
‐ Less slippage or by‐passing of untreated process liquids due to arcs
‐ Provide greater retention time in the electrode zone

46
Electrostatic Grids: AC Grids

Easily loses electric field once spark happens 

Cannot handle high water content

47
 Composite Electrode Performance

Laboratory Performance Comparison

Dual Polarity vs. AC --- Steel vs. Composite
1.2
AC - Steel
1
Outlet BS&W, %

Outlet BS&W 0.5vol%
DP - Steel
0.8 ‐ AC(Steel) :
DP - Composite 3.6mID x 12mT/T
0.6 ‐ DP(Steel) :
3.6mID x 8.5mT/T
0.4 *
‐ DP（Composite） :
3.6mID x 6.5mT/T 
0.2
* Feed rate 100,000BPD case
0

150 200 250 300 350 400 450

Treatment Rate, BOPD/sq ft

48
Type of Inlet Distributor

For Petreco AC Desalter Pipe (Conventional) Box (Conventional)

・Bilectric
・Cylectric

Spray Type Hi‐Flo Low Velocity Type

49
Pipe Spreader/Deflector - Hi-Flo Distributor

 Hi‐Flo Distributor – even distribution of process fluid and reduces fluid 
velocity before it is released into the body of fluid in vessel

Steel Grid Plates 
Bottom of the vessel (DP)
Feed Inlet Pipe

Spreader Pipes

Deflector

Mud Wash 

50
Hi-Flo Distributor

 Hi‐Flo Distributor – even distribution of process fluid and reduces fluid 
velocity before it is released into the body of fluid in vessel

Deflector

Typical Distributor Hi‐Flo Distributor

51
Oil Collector Header & Hangers
Suspend and supports the electrically charged components within the pressure 
vessel while insulating them from other components within the vessel

Typical Hangers & Collector Pipe for FPSO Wave Motion
Refinery

52
 Sludge Accumulation
Improvement 
Problems 
Sludge accumulation becomes a real issue after 
After introducing EDD desalter system, sludge 
increasing heavy crude processing, and required cleaning  accumulation become no longer big issue, actually 
every Turn Around Maintenance. no accumulation.
Sludge height at the end portion reached  the bottom   A large amount of recycle water (2nd stage) 
level of the manway.  Mud needs vacuum cars and spends  contributed to sludge wash‐out  continuously.
two days more for removal.   Still brine water do not need special treatment in 
the Waste Water System.
3660 ID x 9800 T‐T

Sludge height reached  the 
bottom level of the 
manway

Before Cleaning After Cleaning

53
 Typical Mud Wash System

［Operation: 10 – 30 min./ header］

Crude Out

Crude In
Water out

54
 MUD WASH in EDD System
Dilution Water to Top of Vessel, 
3 vol% and more
Fresh Water
Crude OUT
Less  solids exit to 
Hex and Heater 
0.5 ‐ 1 vol% 2 – 5 vol%

Crude IN
Solid comes in Sediment  Solids exit continuously in 
continuously Effluent Water

Much Recycle water 
Recycle Water to 1st
Stage (if 2‐stage)
7–10 vol% will not allow 
Continuous Solid exit to  Solid Accumulation
1st stage desalter
 Mud wash is not required 
with 7‐10vol% recycle. 55
Mud Accumulation in EDD and AC

EDD Desalter AC Desalter

（with Recycle 10%） （with recycle 5％）

Pictures taken in Japanese Refinery

56
Sludge Drain (Interface Drain)

Typically those interface draining apparatus are furnished in field

Desalters/Dehydrations in oil production areas.
57
Desalter Accessories - Transformer
EDD Transformer
• Transform line voltage to a level high enough to create 
emulsion by electrostatic force, 0‐60kV Variable Voltage.

58
Desalter Accessories - Entrance Bushing

Means of entry of electrical voltage to the vessel
& Most important parts to maintain power in vessel

For Refinery Use  For Oil Fields 
(High Temp Service) (Low Temp Service)

59
Entrance Bushing, Conventional AC Type

Insulation oil

Vent line

Crude Gas venting is always needed at 

Howe Baker Type AC
Howmar Type AC

60
 Entrance Bushing, PETRECO AC (CAMERON) Type

Insulation oil

Crude

Gas venting is not needed

61
Entrance Bushing, DP/EDD/DF (CAMERON) Type

Insulation oil

Crude

Gas venting is not needed

62
 Entrance Bushing
Crude Vaporize Case
Conventional AC Type CAMERON Type

SPARK

Vapor
Vapor

Teflon part:  Teflon part: 
surrounded by vapor No vapor 
(Surrounded by crude)

63
THANK YOU FOR YOUR ATTENTION

Homat Horizon Bldg. 6‐2 Goban‐cho, Chiyoda‐ku,
Tokyo 102‐0076 Japan

cameronjapan@c‐a‐m.com
TEL : 81‐3‐6893‐4210
FAX : 81‐3‐3288‐1904

64