Surface Production Operations: Vol 2: Design of Gas-Handling Systems and Facilities, Third Edition

685 Pages·2014·54.464 MB·English

by  Maurice Stewart

VOLUMETWO
SURFACE PRODUCTION
OPERATIONS
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VOLUMETWO
SURFACE PRODUCTION
OPERATIONS
Design of Gas-Handling Systems
and Facilities
3rd Edition
MAURICE I. STEWART, Jr. PhD, PE
Principal, Stewart Training and Consulting LLC,
McLean, Virginia, USA
AMSTERDAM (cid:129) BOSTON (cid:129) HEIDELBERG (cid:129) LONDON
NEW YORK (cid:129) OXFORD (cid:129) PARIS (cid:129) SAN DIEGO
SAN FRANCISCO (cid:129) SYDNEY (cid:129) TOKYO
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CONTENTS
Preface ix
Acknowledgments xi
1. Overview of Gas-Handling, Conditioning, and Processing
Facilities 1
1.1 Heating 2
1.2 Separation 3
1.3 Cooling 3
1.4 Stabilization 4
1.5 Compression 4
1.6 GasTreating 5
1.7 GasDehydration 6
1.8 GasProcessing 6
2. Basic Principles 9
2.1 Introduction 9
2.2 FluidAnalysis 9
2.3 PhysicalProperties 9
2.4 FlashCalculations 28
2.5 CharacterizingtheFlowStream 30
2.6 UseofComputerProgramsforFlashCalculations 32
2.7 ApproximateFlashCalculations 32
2.8 OtherProperties 32
2.9 PhaseEquilibrium 36
3. Heat Transfer Theory 39
3.1 Objectives 39
3.2 WhatIsaHeatExchanger? 40
3.3 ProcessSpecification 47
3.4 PressureDropConsiderations 48
3.5 BasicHeatTransferTheory 52
3.6 DeterminationofMeanTemperatureDifference 54
3.7 SelectionofTemperatureApproach(△T ) 61
2
3.8 DeterminationofHeatTransferCoefficient 62
3.9 CalculationofFilmCoefficients 70
3.10 TubeMetalResistance 84
3.11 ApproximateOverallHeatTransferCoefficients 84
3.12 DeterminationofProcessHeatDuty 86
References 97
v
vi Contents
4. Heat Exchanger Configurations 99
4.1 Overview 99
4.2 Shell-and-TubeExchangers 99
4.3 Double-PipeExchangers 135
4.4 Plate-FinExchangers 138
4.5 Plate-and-FrameExchangers 143
4.6 Indirect-FiredHeaters 146
4.7 Direct-FiredHeaters 172
4.8 Air-CooledExchangers 180
4.9 CoolingTowers 193
4.10 OtherTypesofHeatExchangers 195
4.11 HeatExchangerSelection 195
4.12 CommentsonExample4.3 211
Exercises 211
5. Hydrate Predictionand Prevention 215
5.1 Objectives 215
5.2 Overview 215
5.3 WaterContentofGas 216
5.4 GasHydrates 224
5.5 PredictionofOperatingTemperatureandPressure 225
5.6 TemperatureDropDetermination 227
5.7 HydratePredictionCorrelations 229
5.8 HydratePrevention 234
5.9 HydrateInhibition 250
Exercises 256
6. Condensate Stabilization 259
6.1 PartialPressures 259
6.2 MultistageSeparation 260
6.3 MultipleFlashesatConstantPressureandIncreasingTemperature 261
6.4 Cold-FeedDistillationTower 262
6.5 DistillationTowerwithReflux 265
6.6 CondensateStabilizerDesign 266
6.7 TraysandPacking 269
6.8 CondensateStabilizerasaGas-ProcessingPlant 276
6.9 LowTemperatureExtractor(LTX)UnitasaCondensateStabilizer 277
7. Dehydration 279
7.1 Overview 279
7.2 Adsorption 279
Contents vii
7.3 Absorption 308
7.4 GlycolDehydration 310
7.5 SystemDesign 328
7.6 MercuryConsiderations 349
7.7 SpecialGlycolDehydrationSystems 352
7.8 SystemsUtilizingGlycol-GasPoweredPumps 355
7.9 SystemsUtilizingElectricity-DrivenPumps 356
7.10 NonregenerableDehydrator 362
7.11 PhysicalPropertiesofCommonGlycols 364
8. Glycol Maintenance, Care, andTroubleshooting 375
8.1 PreventiveMaintenance 375
8.2 GeneralConsiderations 385
8.3 EliminatingOperatingProblems 404
8.4 ImprovingGlycolFiltration 427
8.5 UseofCarbonPurification 430
9. Gas Sweetening 433
9.1 ProcessingNaturalGas 433
9.2 AcidGasConsiderations 441
9.3 SweeteningProcesses 444
9.4 SolidBedProcesses 444
9.5 ChemicalSolventProcesses 452
9.6 PhysicalSolventProcesses 462
9.7 DirectConversionProcesses 466
9.8 DistillationProcess 473
9.9 GasPermeationProcess 474
10. Gas Processing 541
10.1 NaturalGasLiquid(NGL)RecoveryConsiderations 541
10.2 ValueofNGLComponents 542
10.3 GasProcessingTerminology 543
10.4 LiquidRecoveryProcesses 544
10.5 ProcessSelection 555
10.6 Fractionation 556
10.7 DesignConsiderations 557
11. Safety Systems 559
11.1 BasicSafetyConcepts 560
11.2 DevelopingaSafeProcess 567
viii Contents
11.3 APIRP14C 574
11.4 SafetyManagementSystems 596
11.5 SafetyCaseandIndividualRiskRate 599
11.6 ReliefValvesandReliefSystems 600
11.7 FlareandVentDisposalSystems 615
References 634
Appendix A: Case Study: Membrane/AmineHybrid
GrissikGas Plant, Sumatra, Indonesia 635
Appendix B: Case Study: The Judge Digby Gas Plant Hikes
Production with Quick SolventChange-Out 651
Index 661
PREFACE
As teachers of surface production facility design in petroleum engineering
programs at Louisiana State University and the University of Houston,
KenandIrealizedthatnosinglesourcecouldbeusedasatextinthisfield.
We found ourselves reproducing pages from catalogs, reports, and projects
wehaddonetoprovideourstudentswiththebasicinformationtheyneeded
to understand our lectures and carry out their assignments. More impor-
tantly, the material that did exist usually contained nomographs, charts,
and rules of thumb that did not refer to the basic theories and underlying
assumptionsuponwhichtheywerebased.AlthoughVolume2oftenbuilds
uponinformationthatwaspresentedinSurfaceProductionOperations,Vol-
ume 1: Design of Oil-Handling Systems and Facilities, it does present the
basic concepts and techniques necessary to select, specify, and size gas-
handling, conditioning, and processing equipment. After the initial release
ofthefirsttwovolumes,werealizedthatmanytopicsneededtobecovered
inmoredepth.Asaresult,threeadditionalvolumeswereaddedtotheseries,
tobepublishedatalatertime.Volume3coversthedesignoffacilitypiping
and pipeline systems, as well as relief and vent disposal systems; Volume 4
covers rotating equipment, specifically pumps, compressors, and drivers;
andVolume5coversinstrumentation,processcontrol,safetysystems,elec-
trical installations in hazardous (classified) locations, and project and risk
management.
Volume 2, which covers one semester’s work or a two-week short
course,focusesontheprocessesandequipmentinvolvedwithgas-handling,
conditioning,andprocessingfacilities.Theobjectiveofgas-handling,con-
ditioning, and processing facilities is to separate natural gas, condensate, or
oilandwaterfromagas-producingwellandconditionthesefluidsforsaleor
disposal.Specificareasaddressedbythisvolumeincludebasicprinciplesand
fluid properties, process selection, heat transfer and heat exchanger equip-
ment, hydrate prediction and prevention, condensate stabilization, com-
pression, dehydration, acid gas treating, and gas processing. As was the
case with Volume 1, this text covers topics that are common to both oil-
and gas-handling production facilities, such as surface safety systems.
Throughoutthetextwehaveattemptedtoconcentrateonwhatweper-
ceive to be modern and common practices. We have personally been
involved in the design and troubleshooting of such modern facilities
ix