Essentials of Oil and Gas Utilities: Process Design, Equipment, and Operations

595 Pages·2016·17.51 MB·English

by  Alireza Bahadori

Essentials of Oil and
Gas Utilities
Process Design, Equipment,
and Operations
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Essentials of Oil and
Gas Utilities
Process Design, Equipment,
and Operations
Alireza Bahadori, PhD
School of Environment, Science & Engineering
Southern Cross University, Lismore, NSW, Australia
AMSTERDAM • BOSTON • HEIDELBERG • LONDON
NEW YORK • OXFORD • PARIS • SAN DIEGO
SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO
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Notices
Knowledge and best practice in this field are constantly changing. As new research and experience broaden our
understanding, changes in research methods, professional practices, or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any
information, methods, compounds, or experiments described herein. In using such information or methods they
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ISBN: 978-0-12-803088-2
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Dedicated to the loving memory of my parents,
grandparents, and to all who contributed so much
to my work over the years
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Contents
Biography ............................................................................................................................................xxv
Preface ...............................................................................................................................................xxvii
Acknowledgments ..............................................................................................................................xxix
CHAPTER 1 Fuel Systems ..........................................................................................1
1.1 Fuel-Supplying Systems ...............................................................................................1
1.1.1 Fuel Selection ....................................................................................................3
1.1.2 Gaseous Fuel ......................................................................................................3
1.1.3 LPG Vaporizer ...................................................................................................5
1.1.4 Liquid Fuel .........................................................................................................5
1.1.5 Fuel Oil System .................................................................................................5
1.1.6 Refinery Gasoline Fuel ......................................................................................7
1.2 Fired Heaters Fuel System ............................................................................................7
1.3 Minimum Data Required for Basic Design ..................................................................8
1.4 Atomizing Steam and Tracing ....................................................................................10
1.5 Shut-Off Systems ........................................................................................................10
1.6 Gas Turbine Fuel Alternatives ....................................................................................11
1.6.1 Gaseous Fuels ..................................................................................................11
1.6.2 Liquid Fuels .....................................................................................................12
1.6.3 Classification of Petroleum Fuels ....................................................................12
1.7 Operation of Heat-Off and Emergency Shutdown Switches ......................................13
1.7.1 Heat-Off Switch ...............................................................................................13
1.7.2 Emergency Shutdown Switch ..........................................................................14
CHAPTER 2 Compressed Air Systems .....................................................................15
2.1 Compressed Air Systems ............................................................................................15
2.2 Selecting the Size and Number of Compressors ........................................................21
2.3 Locating the Compressors ..........................................................................................22
2.4 Automatic Warning and Shutdown Systems ..............................................................22
2.5 Nonlubricated Air Compressors .................................................................................22
2.6 Compressed Air Distribution System .........................................................................22
2.7 Air Storage (Air Receiver) .........................................................................................23
2.8 Inlet and Discharge Piping .........................................................................................23
2.8.1 Air Inlet ............................................................................................................23
2.8.2 Inlet Piping .......................................................................................................24
2.8.3 Air Filters .........................................................................................................24
2.8.4 Discharge Piping ..............................................................................................24
vii
viii Contents
2.9 Refinery Air System ...................................................................................................25
2.9.1 Instrument Air ..................................................................................................25
2.9.2 Plant Air ...........................................................................................................26
2.10 Air Dryers ...................................................................................................................26
2.10.1 Desiccant Type Dryer ....................................................................................26
2.10.2 Instrumentation ..............................................................................................26
2.10.3 Air Filter ........................................................................................................26
2.10.4 Performance Characteristics ..........................................................................27
2.11 Moisture Content of the Air .......................................................................................27
2.11.1 Effect of Pressure and Temperature on Relative Humidity ............................27
2.12 Effect of Temperature and Pressure on Dew Point ....................................................28
2.13 Pressure Dew Point .....................................................................................................32
2.14 Effect of Moisture on Air Compressor Intake Capacity .............................................33
2.15 Pipe Components Definition of Nominal Size ...........................................................35
2.16 Instrument Air Quality and Quantity ..........................................................................35
2.17 Segregation .................................................................................................................36
2.18 Tool Air Supply ..........................................................................................................38
2.19 Air Supply Plant .........................................................................................................38
2.20 Air Compressors .........................................................................................................39
2.20.1 Compressor Specification ..............................................................................39
2.20.2 Compressor Piping ........................................................................................39
2.20.3 Compressor Controls .....................................................................................40
2.21 Air Drier .....................................................................................................................40
2.21.1 The Desiccant ................................................................................................40
2.21.2 Regeneration ..................................................................................................40
2.21.3 Switching .......................................................................................................41
2.21.4 Filters .............................................................................................................42
2.21.5 Drier Specification .........................................................................................42
2.21.6 Aftercooler.....................................................................................................42
2.22 Buffer Vessel (Air Receiver) ......................................................................................42
2.23 Air Supply Piping .......................................................................................................43
2.23.1 Lay Out ..........................................................................................................44
2.23.2 Pipe Sizes ......................................................................................................44
2.23.3 Piping Details ................................................................................................44
2.24 Air Supply for Plant-Mounted Instruments ................................................................45
2.25 Air Supply in the Control Center ................................................................................45
CHAPTER 3 Fresh and Spent Caustic Units and Chemical Injection Systems ......59
3.1 Process Requirements of Fresh and Spent Caustic Units ...........................................60
3.1.1 Fresh Caustic Unit ...........................................................................................60
3.1.2 Design Requirements .......................................................................................61
Contents ix
3.2 Design Requirements ..................................................................................................61
3.3 Spent Caustic Treating Unit .......................................................................................62
3.4 Chemical Injection Systems .......................................................................................63
3.4.1 Feed Concepts ..................................................................................................63
3.4.2 Chemical Feed Equipment Used in Water Treatment .....................................63
3.4.3 Accessories ......................................................................................................64
3.4.4 Chemical Additive Feeding Systems ...............................................................66
3.4.5 System Design and Operation of Chemical Feeders for
Cooling Towers ...............................................................................................67
3.5 Equipment Design and Selection ................................................................................67
3.6 General Requirements for Design and Construction of Chemical Dosing
Units in a Water Treating System ..............................................................................68
3.6.1 Construction .....................................................................................................68
3.6.2 Materials ..........................................................................................................69
3.6.3 Instrumentation and Control ............................................................................69
3.6.4 Mechanical .......................................................................................................69
3.7 General Design Requirements of Chemical Feed Equipment ....................................71
3.7.1 Cooling Tower Warm Lime Softener ..............................................................71
3.7.2 Clarifier ............................................................................................................71
3.8 General Design Requirements of Metering Pump in Chemical Injection Systems ....72
3.8.1 Installation .......................................................................................................72
3.8.2 Location ...........................................................................................................72
3.8.3 Installation Tips ...............................................................................................72
3.8.4 Suction Line .....................................................................................................73
3.8.5 Relief Valve .....................................................................................................74
3.8.6 Back Pressure ...................................................................................................74
3.8.7 Siphoning .........................................................................................................75
3.8.8 Slurries .............................................................................................................76
3.9 General Design Requirements of Package Type Chemical Injection Systems ..........77
3.9.1 Scope of Supply ...............................................................................................77
3.9.2 Design Requirements .......................................................................................77
3.10 Scale Control ..............................................................................................................78
3.11 Sludge Conditioning ...................................................................................................78
3.11.1 Caustic Embrittlement ...................................................................................78
CHAPTER 4 Steam Boilers .......................................................................................81
4.1 Special Design Features .............................................................................................83
4.1.1 Drums and Steam Generators ..........................................................................84
4.1.2 Doors and Openings ........................................................................................85
4.1.3 Ducts and Stacks ..............................................................................................85
4.1.4 Burners .............................................................................................................86