Surface Production Operations, Volume 1, Third Edition: Design of Oil Handling Systems and Facilities

747 Pages·2007·14.31 MB·English

by  Maurice Stewart

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Surface Production
Operations
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Surface Production
Operations
Design of Oil Handling
Systems and Facilities
Ken Arnold
AMEC Paragon, Houston, Texas
Maurice Stewart
President, Stewart Training Company
THIRD EDITION
AMSTERDAM•BOSTON•HEIDELBERG•LONDON
NEWYORK•OXFORD•PARIS•SANDIEGO
SANFRANCISCO•SINGAPORE•SYDNEY•TOKYO
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Contents
Acknowledgments to the Third Edition xix
About the Book xxi
Preface to the Third Edition xxiii
1 The Production Facility 1
Introduction 1
Making the Equipment Work 15
Facility Types 18
2 Process Selection 24
Introduction 24
Controlling the Process 24
Operation of a Control Valve 24
Pressure Control 27
Level Control 29
Temperature Control 29
Flow Control 29
Basic System Configuration 30
Wellhead and Manifold 30
Separation 30
Initial Separation Pressure 30
Stage Separation 32
Selection of Stages 34
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vi Contents
FieldswithDifferentFlowingTubingPressures 34
DeterminingSeparatorOperatingPressures 36
Two-Phase vs. Three-Phase Separators 37
Process Flowsheet 37
Oil Treating and Storage 37
LeaseAutomaticCustodyTransfer(LACT) 40
Pumps 44
Water Treating 44
Compressors 44
Gas Dehydration 48
Well Testing 50
Gas Lift 53
Offshore Platform Considerations 56
Overview 56
Modular Construction 57
Equipment Arrangement 57
3 Basic Principles 61
Introduction 61
Basic Oil-Field Chemistry 61
Elements, Compounds, and Mixtures 61
Atomic and Molecular Weights 62
Hydrocarbon Nomenclature 63
Paraffin Series: (C H ) 64
n 2n+2
Paraffin Compounds 64
Acids and Bases 65
Fluid Analysis 65
Physical Properties 65
MolecularWeightandApparentMolecularWeight 68
Example3-1:Molecularweightcalculation 69
Example3-2:Determinetheapparentmolecularweightof
dryair,whichisagasmixtureconsistingofnitrogen,oxygen,
and small amounts of Argon 69
Gas Specific Gravity and Density 70
Example3-3:Calculatethespecificgravityofanaturalgas
with the following composition 71
Nonideal Gas Equations of State 73
Reduced Properties 80
Example3-4:Calculatethepseudo-criticaltemperature
andpressureforthefollowingnaturalgasstream
composition 81
Example3-5:Calculatethevolumeof1lbmoleofthenatural
gasstreamgiveninthepreviousexampleat120(cid:2)F
and 1500 psia 82
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Contents vii
Example3-6:Asournaturalgashasthefollowingcomposition.
Determinethecompressibilityfactorforthegasat100(cid:2)F
and 1000 psia 88
Liquid Density and Specific Gravity 89
Viscosity 92
Gas Viscosity 93
Liquid Viscosity 94
Oil-Water Mixture Viscosity 95
Phase Behavior 97
System Components 98
Single-Component Systems 99
Multicomponent Systems 101
Lean Gas Systems 103
Rich Gas Systems 103
Retrograde Systems 104
Application of Phase Envelopes 105
Black Oil Reservoir 106
Phase Diagram Characteristics 106
Field Characteristics 106
Laboratory Analysis 107
Volatile Oil Reservoir 107
Phase Diagram Characteristics 107
Field Characteristics 108
Laboratory Analysis 109
Retrograde Gas Reservoir 109
Phase Diagram Characteristics 109
Field Characteristics 110
Laboratory Analysis 110
Wet Gas Reservoir 110
Phase Diagram Characteristics 110
Field Characteristics 111
Dry Gas Reservoir 112
Phase Diagram Characteristics 112
Information Required for Design 112
Flash Calculations 113
Characterizing the Flow Stream 130
Molecular Weight of Gas 130
Gas Flow Rate 130
Liquid Molecular Weight 132
Specific Gravity of Liquid 133
Liquid Flow Rate 134
The Flow Stream 135
Approximate Flash Calculations 136
Other Properties 137
Exercises 142
References 149
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viii Contents
4 Two-Phase Oil and Gas Separation 150
Introduction 150
Phase Equilibrium 151
Factors Affecting Separation 152
FunctionalSectionsofaGas-LiquidSeparator 152
Inlet Diverter Section 154
Liquid Collection Section 154
Gravity Settling Section 154
Mist Extractor Section 154
Equipment Description 155
Horizontal Separators 155
Vertical Separators 156
Spherical Separators 157
Centrifugal Separators 159
Venturi Separators 160
Double-Barrel Horizontal Separators 161
HorizontalSeparatorwitha“Boot”or“WaterPot” 162
Filter Separators 163
Scrubbers 164
Slug Catchers 165
Selection Considerations 165
Vessel Internals 169
Inlet Diverters 169
Wave Breakers 170
Defoaming Plates 171
Vortex Breaker 173
Stilling Well 173
Sand Jets and Drains 175
Mist Extractors 176
Introduction 176
GravitationalandDragForcesActingonaDroplet 176
Impingement-Type 177
Baffles 178
Wire-Mesh 181
Micro-Fiber 186
Other Configurations 187
Final Selection 187
Potential Operating Problems 190
Foamy Crude 190
Paraffin 192
Sand 192
Liquid Carryover 192
Gas Blowby 193
Liquid Slugs 194
Design Theory 195
Settling 195
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Contents ix
Droplet Size 203
Retention Time 203
Liquid Re-entrainment 204
Separator Design 204
Horizontal Separators Sizing—Half Full 204
Gas Capacity Constraint 205
Liquid Capacity Constraint 209
Seam-to-Seam Length 211
Slenderness Ratio 212
ProcedureforSizingHorizontalSeparators—HalfFull 212
HorizontalSeparatorsSizingOtherThanHalfFull 213
Gas Capacity Constraint 214
Liquid Capacity Constraint 215
Vertical Separators’ Sizing 219
Gas Capacity Constraint 219
Liquid Capacity Constraint 222
Seam-to-Seam Length 224
Slenderness Ratio 226
Procedure for Sizing Vertical Separators 226
Examples 226
Example4-1:SizingaVerticalSeparator
(Field Units) 226
Example4-2:SizingaVerticalSeparator(SIUnits) 229
Example4-3:SizingaHorizontalSeparator
(Field Units) 232
Example4-4:SizingaHorizontalSeparator(SIUnits) 233
Nomenclature 234
Review Questions 236
Exercises 239
Bibliography 243
5 Three-Phase Oil and Water Separation 244
Introduction 244
Equipment Description 246
Horizontal Separators 246
Derivation of Equation (5-1) 250
Free-Water Knockout 251
Flow Splitter 252
HorizontalThree-PhaseSeparatorwithaLiquid“Boot” 253
Vertical Separators 255
Selection Considerations 258
Vessel Internals 259
Coalescing Plates 260
Turbulent Flow Coalescers 260
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