Overview Gas Processes

1
Design of Natural Gas

Handling Equipment
Course prepared for
Offshore Oil and Gas Engineering program
ENG 8976
by
Majid A. Abdi, Ph.D., P.Eng.
Faculty of Engineering and Applied Science
Memorial University of Newfoundland (MUN)
Winter 2004
2
Schedule and Evaluation Breakdown
Instructional hours per week: 3 lecture hours;
Midterm exam: March 1
st
, 2004;
Evaluation:
Assignments: 10%
Midterm: 25%
projects (term papers): 15%
Final: 50%
3
Course Outline
1. Introduction
2. Fluid Properties
3. Inlet separator design
4. Prevention of hydrate formation and dehydration of
natural gas
5. Natural gas dew point control and liquid recovery
6. Natural gas transmissions systems
7. Natural Gas Compression
8. Natural gas measurement*
9. Heat exchange equipment*
10. Overview of natural gas sweetening processes*
11. Natural gas transportation*
*Optional sections; will be covered only if time allows
4
References
1. Beggs H.D., Gas Production Operation, OGCI publications, 1985, ISBN: 0-930972-
06-6
2. Kumar S., Gas Production Engineering, Gulf Publishing, 1987, ISBN: 0-87201-577-7
3. Rojey A., Jaffret C., Natural Gas Production Processing Transport, Editions
Technip; (1997), ISBN: 2710806932
4. Manning F. and Thompson R., Oil Field Processing of Petroleum, Volume 1:
Natural Gas, Pennwell Publishing, 1991, ISBN:0-87814-343-2
5. 11th Edition GPSA Engineering Data Book, FPS and SI Versions, 1998, by Gas
Processors Suppliers Association
6. Arnold K. and Stewart M., Surface Production Operations; Volume 2; Design of
Gas-Handling Facilities, 2nd Edition, 1999, Butterworth-Heinemann, ISBN: 0-88415-
822-5
7. Kohl A., Nielsen R., Gas Purification, 5th Edition, Pennwell, 1997, ISBN 0-88415-
220-0
8. Mohitpour M., Golshan H., and Murray A. "Pipeline Design & Construction, A
Practical Approach", 2nd edition, ASME Press, 2003, ISBN 0-7918-0156-X
9. Manning F. and Thompson R., Oil Field Processing of Petroleum, Volume 1: Crude,
Pennwell Publishing, 1991, ISBN: 0-87814-354-8
10. Arnold K. and Stewart M., Surface Production Operations; Volume 1; Design of oil
Handling Facilities, 2nd Edition, 1999, Butterworth-Heinemann ISBN: 0-88415-821-7
11. Skinner, D.R., Introduction to petroleum production: well site facilities, Gulf
Publishing Co., 1981, ISBN: 0872017699
12. Brian Research and Engineering (BR&E) technical papers, 2002; see web site at:
http://www.bre.com/technicalpapers/technicalpaper-home.asp
13. Instructors notes on personal field and design experiences
5
World Natural Gas Occurrence and Production
- International Gas Statistics
Natural gas is a major world energy
source.
World natural gas reserves are estimated
at 5893 TCF.
About 72 percent of the worlds natural
gas reserves are found in the Middle East
and the former Soviet Union.
Canada is a major exporter of natural gas.
6
Natural Gas Origin
Biogenic methane
Thermogenic methane
Metamorphism
Abiogenic methane
7
History of Natural Gas
Dates back to thousands years ago
Persians and Indians used it for religious
practices
Chinese used it to desalt sea water
British commercialized natural gas
8
Source: BP
9
World Natural Gas Reserves (2002)
Source: BP
10
World Natural Gas Reserves (2002)
Source: BP
11
World Natural Gas Production (2002)
Source: BP
12
World Natural Gas Production (2002)
Source: BP
13
World Natural Gas Consumption (2002)
14
World Natural Gas Consumption (2002)
15
Source : BP
16
Global Stranded Gas Reserves
17
North American Natural Gas Reserves (2001)
18
Canadian natural gas production/demand by
region (2001)
19
Canadian Natural Gas
20
Canadian Natural Gas (2001)
21
Natural Gas Value Chain
22
Natural Gas Processing
23
Gas Processing Facility Block Diagram
Acid Gas Management Systems
Controlled Release of
emission gases to
Atmosphere
Sulphur
Sales
Sulphur Production
Natural Gas
Well Gas
High
Pressure
Separation
Intermittent solid
removal
Water Vapour
Removal -
Dehydration
NGL Recovery -
Dew Point Control
(DPC)
Acid Gas
Removal
Heating
SALES
GAS
Cooling
Stabilization
Condensate
Sales
Water
disposal
Water handling
Facilities
Compression
LPG Recovery
(C
3
& C
4
)
Propane
and Butane
Sales
24
FLUID PROPERTIES
FLUID PROPERTIES
Characterization of Natural Gas and Its Products
colorless - - - Dry gas
colorless >50 >50,000 - Wet gas
Water white 50-60 3,300-50,000 >0.35 Retrograde gas gas condensate
Colored
dark brown
>40 2,000-3,300 <0.5
Very dark
black oil
<45 <2,000 >0.5 Associated gas from:
Low Shrinkage crude (Low GOR)
Ordinary crude
High Shrinkage Oil (high GOR)
volatile oil
COLOR
O
API SCF/BSTO BSTO/BRF
STOCK-TANK LIQUID TYPICAL GOR SPECTRUM OF PRODUCED SPECTRUM OF PRODUCED
HYDROCARBONS HYDROCARBONS
FLUID TYPE
25
Fluid Properties Natural Gas Constituents
N
2
C
6
+
nC
5
iC
5
nC
4
iC
4
C
3
C
2
C
1
Abbreviation
variable FeS Reservoir fines and iron sulfide
variable - Millscale or rust Solids
variable CH
3
OH(MeOH), EG, etc. Methanol and glycol
variable - Corrosion inhibitors
variable H
2
O Free water or brine Water vapour/Liquid
slugs
1.0-10.0ppm R-S-S-R Disulfides
1.0-10.0ppm R-S-R Sulfides
10-1000ppm R-SH Mercaptans Sulphur compouns
0.2-10.0 CO
2
Carbon Dioxide
0.01-10.0 H
2
S Hydrogen sulfide Acid gases
a few ppm O
2
Oxygen
a few ppm H
2
Hydrogen
a few ppm Ar Argon
0.01-0.1 He Helium
0.2-5.0 N
2
Nitrogen Inert Gases
1.0-3.0 - Hexanes and heavier
0.1-2.0 nC
5
H
12
n-Pentane
0.1-2.0 iC
5
H
12
i-Pentane
0.3-7.5 nC
4
H
10
n-Butane
0.3-2.5 iC
4
H
10
i-Butane
1.0-15.0 C
3
H
8
Propane
3.0-10.0 C
2
H
6
Ethane
59.0-92.0 CH
4
Methane Hydrocarbons
Typical
composition
(volume %)
Formula Components Class
26
Fluid Properties Natural Gas physical
properties
PVT behavior and equations of state
Molecular weight
Density and specific gravity
Critical pressures and temperatures
Gas compressibility factor
Viscosity
Specific heat (heat capacity)
Heating value (Wobbe number/index)
Thermal conductivity
27
Fluid Properties Equations of State
Behavior of ideal gas
Behavior of a real (non-ideal) gas
Compressibility factor approach
Important equations of state
9Van der Waals
9Benedict-Webb-Rubin (BWR)
9Saove-Redlich-Kwang (SRK)
9Peng-Robinson (PR)
9Virial
28
Principal Equation of States
29
Fluid Properties Molecular Weight Mole
concept
Weight of a mole of any substance
Different units in Imperial, SI and CGS
systems
Moles = Weight of a gas component divided by
its molecular weight
Average molecular weight =
] ) .( [
N N
MW y MW

=
30
Fluid Properties Density and Specific Gravity
Density = mass of a unit volume (lb/ft
3
or kg/m
3
)
S = MW/29 (for gases)
or
S.G.= density of liquids/density of pure water @ 60
o
F
o
API =141.5/S.G. -131.5 (for liquid hydrocarbons such as
crude oil)
TZ
SP
g
7 . 2 =
TZ
P MW
g
) (
093 . 0 =
31
Fluid Properties Critical Pressures and
Temperatures
Critical temperature= the maximum temperature at which
the component can exist as a liquid
Critical pressure= vapour pressure of a substance at its
critical temperature
Beyond critical temperature and pressure there is no
distinction between a liquid and a gas phase
P
CN
and T
CN
from Figure
23-2 GPSA
P
PC
= y
N
P
CN
and T
PC
= y
N
T
CN
P
PC
= 709.604 58.718 S
T
PC
= 170.491 + 307.344 S
Thomas et al. equation
32
Physical Property Tables
33
Physical Property Tables
34
Fluid Properties Gas Compressibility Factor
Standing-Katz compressibility charts (Figures 23-3, 23-4, and
23-5 GPSA)
Brown-Katz-Oberfell-Alden charts (Figures 23-7, 23-8, and 23-
9 GPSA)
Acid gas content consideration by Wichert-Aziz correction
factors
from Figure 23-10 GPSA
Compressibility from equations of state
) 1 (
'
' '
B B T
T P
P and T T
PC
PC PC
PC PC PC
+
= =
35
Compressibility charts
Brown-Katz-Oberfell-Alden Z charts
Standing-Katz compressibility charts
36
Fluid Properties Gas Viscosity
Carr et al. correlation (Fig. 23-32 and 23-33 GPSA)
Viscosity of gas mixture from single component data:
Lee et al. for natural gas:
GPSA charts Fig.s 23-30 through 23-38
Dean and Stiel method
=
=
=
n
N
N N
n
N
N N gN
g
MW y
MW y
1
5 . 0
1
5 . 0
1
1
X y and MW T X
T MW
T MW
K where X K
y
g g
2 . 0 4 . 2 01 . 0 / 986 5 . 3
19 209
) 02 . 0 4 . 9 ( 10
, ) exp(
5 . 1 4
= + + =
+ +
+
= =

| |
9 / 8
Pr
5
Pr
9 / 5
Pr
5
Pr
3 / 2 2 / 1
6 / 1
) 10 ( 0 . 34 , 5 . 1
, 0932 . 0 1338 . 0 ) 10 ( 8 . 166 , 5 . 1 ;
) (
4402 . 5
T T for and
T T for
P MW y
T
g
g
PC N N
PC
=
= > =

37
Viscosity Charts
38
Fluid Properties Specific Heat
Definition: amount of heat required to raise the temperature of a
unit mass of a substance through unity
C
p
and C
v
and their relationships (Maxwells equation)
C
p
determination
Hankinsons gravity C
o
p
= A + B.T + C.S + D.S
2
+ E(T.S) + F.T
2
Kays mixing rule
C
p
of natural gas mixture, pressure corrections (GPSA Figure 13-6
and Kumars Book Table 3-3, Figures 3-17 and 3-19)
R C C gases ideal for
v P
T P
T C C
v p
T
v
v p
=

=
) / (
) / (
2
=
=
n
N
o
pN N
o
p
C y C
1
39
Heat Capacity Data
40
Fluid Properties Heating Value/Wobbe Index
Definitions:
Gross Heating Value (GHV) or Higher Heating Value
(HHV):Total energy transferred as heat in an ideal combustion
reaction at a standard temperature and pressure in which all
water formed appears as liquid
Net Heating Value (NHV) or Lower Heating Value (LHV):Total
energy transferred as heat in an ideal combustion reaction at a
standard temperature and pressure in which all water formed
appears as vapour
Heating value determination: H
v
= y
N
H
vN
Wobbe Index: W
O
=HHV/S
1/2
41
Fluid Properties Thermal conductivity
Significance of thermal conductivity Heat transfer calculations
and heat exchanger (line heater, shell and tube, air cooler, etc.)
design
Determination of thermal conductivity gas and liquid (GPSA
Fig.s 23-40 through 23-45)
Lenoir et al. pressure corrections
Gas mixture thermal conductivity
=
) . (
) . (
3
3
N N
N N N
m
MW y
MW k y
k
42
Thermal conductivity Charts
43
Thermal conductivity Charts (cont.)
44
Phase Behavior - Fundamentals
Single component fluid
Two component fluid
Multi-component fluid
Phase diagrams (envelopes)
Pressure-Temperature-Volume (PVT)
Pressure-Temperature (PT)
Pressure composition
Composition-composition
Phase rule
N=C-P+2
45
Phase Behavior Single Component Systems
B
A
C
D
a b c d
e
h
Dense Fluid
region-
supercritical
fluid
g f
Phase
Equilibrium
gas-liquid
gas-solid
Liquid-solid
Triple point
Critical point
46
Phase Behavior: Two-Component Systems
Concept of phase
envelope
Equilibrium lines
Bubble point
Dew point
Critical point
Cricondentherm
Cricondenbar
Rertrograde phase
change
P
r
e
s
s
u
r
e
Cricondenbar
C
r
i
c
o
n
d
e
n
t
h
e
r
m
D
e
w
-
P
o
i
n
t

L
i
n
e
B
u
b
b
l
e
-
P
o
i
n
t

L
i
n
e
V
a
p
o
u
r
p
r
e
s
s
u
r
e
o
f

p
u
r
e

A
V
a
p
o
u
r
p
r
e
s
s
u
r
e
o
f

p
u
r
e

B
C
a
b
d
e
h
j
k
l
P
C
T
C
Two component phase envelop
9
0
%

v
a
p
d
g
f
Temperature
47
Phase Behavior: Multi-Component Systems
C
Condensate
reservoir
Oil reservoir
Gas
reservoir
A
A
B
B
C
C
D
D
E
E
Temperature
P
r
e
s
s
u
r
e
Two-Phase Region
(Gas+Liquid)
C
r
i
c
o
n
d
e
n
t
h
e
r
m
W
e
t

G
a
s
D
r
y

G
a
s
Full wellstream
Source of phase
diagrams
Quantitative phase
behavior
Phase behavior in
separators
48
Phase Behavior: Vapour-Liquid Equilibria
Thermodynamic criteria for equilibrium-
equality of fugacities: f
N,v
= f
N,l
Equilibrium ratio (K values): K=y
N
/ x
N
Equilibrium calculations
Equilibrium flash:
Bubble point: y
N
= z
N
. K
N
= 1.0
z
N
. K
N
> 1.0 guarantees vapour is
present
Dew point: x
N
= z
N
/ K
N
= 1.0
z
N
/ K
N
> 1.0 guarantees liquid is
present
N
N N
N
K L V
F K
V
+
=
) / /( 1
V,
y
N
F, z
N
L,
x
N
A gas-liquid flash separator
49
Phase Behavior: Water Hydrocarbon Systems
Water and hydrocarbons are insoluble in liquid phase
Problems with water saturated gas
Excessive pressure drop
Plugging due to ice and hydrate formation
Sever corrosion in acid and sour gas lines
Water content of natural gas
McKetta and Wehe charts: Fig. 20-3, GPSA
Robinson et al. correlation for sour gases: Fig.s 20-10 and 20-
11, GPSA
Campbell charts: W = y
hc
W
hc
+ y
CO2
W
CO2
+ y
H2S
W
H2S
and
Fig.s 20-8 and 20-9, GPSA)
Equation of state methods; SRK, PR and commercial process
simulators (e.g. HYSYS, ASPEN, PROSIM, PROII, AMSIM,
AQUASIM, SSI, DESIGNII, PROCESS, etc.)
50
Phase Behavior: Water Hydrocarbon Systems
Natural Gas Hydrates
Gas hydrate - pipeline trouble
maker or ?
Prediction of hydrate formation
conditions
Katz Gas gravity
Wilson-Carson-Katz equilibrium-
constant method
Baillie and Wichert method
Equation of state methods
Comparison of techniques to
predict hydrate formation
conditions
51
Water Hydrocarbon Systems: Overall Phase Behavior
of Natural Gas- Hydrates Systems
W
a
t
e
r

D
e
w
-
p
o
i
n
t

C
u
r
v
e
H
y
d
r
o
c
a
r
b
o
n

P
h
a
s
e

E
n
v
e
l
o
p
e
Hydrate
Formation
Curve
L
hc
+L
w
+G+H
L
hc
+L
w
+G
L
w
+G
G
P
r
e
s
s
u
r
e
B. High Water Content
H
y
d
r
o
c
a
r
b
o
n

P
h
a
s
e

E
n
v
e
l
o
p
e
L
hc
+L
w
+G+H L
hc
+L
w
+G L
hc
+G
P
r
e
s
s
u
r
e
W
a
t
e
r

D
e
w
-
p
o
i
n
t

c
C
u
r
v
e
H
y
d
r
a
t
e

F
o
r
m
a
t
i
o
n

C
u
r
v
e
G
L
w
+G
A. Normal Case
A
Temperature Temperature
52
Phase Behavior: Carbon Dioxide Frost Point
Significance of CO
2
freezing- design of turbo-expansion
facilities and cryogenic NGL recovery systems
CO2-methane equilibrium (Liquid-solid-vapour systems)
(see Ref.1, also Fig.s 25-5 and 25-6 of GPSA data book)
Natural gas-CO
2
systems (see Ref. 1)
Predicting CO
2
formation conditions (GPSA charts vs.
process simulators)
53
Natural Gas Properties/Phase Behavior
and
Scope of Natural Gas Field Processing
Process objectives
Transportable gas
Salable gas
Maximized condensate (NGL) production
Gas type and source
Gas-well gas
Associated gas
Gas condensate
Location and size of the field
Remoteness
Climate
size
54
Scope of Natural Gas Field Processing:
Process objectives
Process objectives
Transportable gas
Hydrate formation
Corrosion
Excessive pressure drop (two-phase flow)
Compression requirement (dense phase flow)
Salable gas
Sales quality-pipe line spec. (see Fig. 2-4, GPSA)
Heating value-inert gas and condensate recovery
Maximized condensate (NGL) production
Maximizing crude production
Retrograde condensate gas processing
Inherent value of NGL
55
Type and Source of Natural Gas
Type and Source of Natural Gas
1. Gas-well gas
Wet or dry
Lean or rich
Sour or sweet
2. Associated gas
Enhanced oil recovery (EOR)
Enhancement crude production
3. Gas condensate
Pressure maintenance
Gas cycling operations
56
Filed Location, Size, and Operation
Filed Location, Size, and Operation
Remoteness
Offshore vs. onshore (land) reservoirs
Platform design
Floating gas processing (a new concept)
Climate
Design consideration for harsh environment
Cold vs. warm
Dry vs. humid
Size
Reservoir capacity
Production rate: small vs. large
Gas handling facilities operations
57
GAS AND LIQUID SEPARATION
GAS AND LIQUID SEPARATION
Purpose, principles and terminology

Purpose, principles and terminology
Separation equipment- common
components
Types of separators
Separation principles
Separator design
Factors affecting separation
Operational Problems
58
Gas and Liquid Separation: Separation
Equipment- Major Parts
A - Primary Separation
B - Gravity Settling
C - Coalescing
D - Liquid Collecting
59
Gas and Liquid Separation - Types
of Separators
Gravity (vertical vs. horizontal)
Centrifugal
Filter coalescing
Impingement
Comparison of separators
advantages vs. disadvantages
60
Equipment- vertical separator
Source: Natco
61
Equipment- Horizontal separators
62
Equipment, Two-Barrel (Double-Tube)
horizontal separator
63
Equipment- horizontal filter separator
Filter elements
64
Equipment- mist eliminator arrangement
65
Gas and Liquid Separation: Separation Equipment-
Vane (radial/axial) mist extractor arrangement
Vertical Radial Flow
(VRF) separator
A
B
C
D
Downcomer
J=
g
.V
t
2
= 20 lb/(ft.sec2)
Natco
TM
radial vanes
66
Equipment- Centrifugal separator
67
Equipment- Swirl/cyclonic separators
Porta-Test Whirlyscrub I
TM
Source: Natco
68
Gas and Liquid Separation Separation
principles
]
2
[
2
g
V
A C F
t
D D
= Drag force
Stocks termonal
velocity for:
Re < 1.0
2 6
.) . ( 10 78 . 1
m
t
d G S
V

=

Re for actual natural gas and crude operations
are much larger than 1.0, therefore the
following equations should be iteratively used
to calculate the terminal velocity and drag
coefficient:
34 . 0
3 24
2 / 1
+ + =
Re Re
C
D
2 / 1
] ) [( 0119 . 0
D
m
g
g l
t
C
d
V

=
69
Gas and Liquid Separation Separation principles:
Terminal Velocity/Residence Time calculations
Terminal velocity iterative calculations:
1. Start calculating C
D
using:
2. Calculate Re as:
3. Calculate new values for C
D
:
4. Calculate new values for C
D
:
5. Go to step 2 and iterate until C
D,new
C
D,old
0.001
Residence time definition: Effective vessel volume/flow rate or:
t = V /Q
2 / 1
] ) [( 0204 . 0
m
g
g l
t
d V
t m g
V d
Re 0049 . 0 =
34 . 0
3 24
2 / 1
+ + =
Re Re
C
D
2 / 1
] ) [( 0119 . 0
D
m
g
g l
t
C
d
V

=
70
Gas and Liquid Separation Separator Design
Gas capacity
Liquid capacity
Gas Capacity Calculations: Souders-Browns
Technique
Vessel design considerations
Separator design using manufacturers
separator performance charts
Computer based techniques -
Computational Fluid Dynamics (CFD), etc.
71
Gas and Liquid Separation Sizing Equations
Horizontal separator
Gas Capacity:
Or: , where, from Fig. 4.10 Ref.8
Liquid Capacity:
Seam to seam length: L
ss
= L
eff
+ d/12 for gas capacity and L
ss
= 4/3 L
eff
for liquid capacity
Vertical Separators
Gas capacity:
Or: , where K is defined as above and found from Fig. 4.10 Ref. 8
Liquid capacity:
Seam-to-seam length:
2 / 1
420
(
(
|
|
.
|
\
|
=
m
D
g l
g g
eff
d
C
P
TZQ
dL

(
=
P
TZQ
K dL
g
eff
42
2 / 1
(
(
|
|
.
|
\
|
=
D
g l
g
C K

7 . 0
2 l r
eff
Q t
L d =
2 / 1
2
040 , 5
(
(
|
|
.
|
\
|
=
m
D
g l
g g
d
C
P
TZQ
d

(
=
P
TZQ
K d
g
420
2
12 . 0
2 l r
Q t
h d =
12
40
...... ;........
12
76 + +
=
+
=
d h
L or
h
L
ss ss
72
g
g l
SB t
K V

=
Gas and Liquid Separation: Sizing Equations-
Souders-Brown Technique
2 / 1
] ) [( 0119 . 0
D
m
g
g l
t
C
d
V

=
Terminal Velocity Equation
Souders-Brown Equation
0.4-0.5(L/10)
0.565
0.40-0.50
0.18-0.35
0.12-0.24
API Recomd. K
SB
, (ft/sec.)
- Other lengths
0.38 with mist extractor 10 Horizontal
0.18 without and 0.3 with
mist extractor
10
0.12 without and 0.2 with
mist extractor
5 Vertical
Most commonly used
K
SB
Value
(ft/sec.)
Height, H or
Length, L (ft)
Separator type
API Spec. 12 J (1989) Recommendations for K API Spec. 12 J (1989) Recommendations for K
SB SB
values values
73
Gas and Liquid Separation: Vessel design
considerations
Liquid residence time: 2-4 min
Liquid-gas interface (minimum
diameter/height): 6 ft. vertical height;
26 in. horizontal diameter
Gas specification: 0.1 gal/MMscf
Liquid re-entrainment: API Spec. 12J
Pipe connections:
Fabrication cost
Optimum length to diameter (L/D) or
aspect ratio
2 to 4 10-20
1 to 2 20-30
1 Above 35
API recomnd
Liquid retention
time (min)
Oil gravity
o
API
API Spec. 12J (1989 API Spec. 12J (1989)
74
Gas and Liquid Separation: Separator Design-
manufacturers charts
Source: Natco
75
Gas and Liquid Separation: Separator Design-
CFD modelling
76
Gas and Liquid Separation: Factors Affecting
Separators Performance
Operating and design pressure
and temperature
Fluid composition and
properties (density, Z-factor,
etc.)
Fluid (gas and liquid) flow
rates
Degree of separation
Two vs. three phase
Gas vs. oil - sand and solids?
Surging/slugging tendencies
Foaming and Corrosive
tendencies
Offshore floating vs. land base
static facilities
Sway Surge
Heave
Roll
Pitch
Yaw

Articulated
tower

Guyed tower
platforms

Tension-leg
platforms

Semi-
submersibles

Single point
anchored
tanker
Yaw Pitch Roll Heave Sway Surge
Angular motion Linear motion Motion
77
Gas and Liquid Separation: Operations
Potential Problems
Foaming
Fouling
Solid/sand deposition
Hydrate, paraffin, wax
Corrosion
Liquid carryover and gas blowby
Flow variations
Maintenance
Troubleshooting
78
Gas and Liquid Separation: Operations-
Troubleshooting
1. Low liquid level
2. High liquid level
3. Low pressure in separator
4. High pressure in separator
5. All the oil going out gas line
6. Mist going out gas line
7. Free gas going out oil valve
8. Gas going out water valve on three-phase
9. Too much gas going to tank with the oil
10. Condensate and water not separating in 3-phase
11. Diaphragm operated dump valve not working
79
NATURAL GAS DEHYDRATION
NATURAL GAS DEHYDRATION
Introduction- purpose of gas dehydration
Pipeline specification
Hydrate prevention
Methods of dehydration
Absorption dehydration using glycol
Solid bed adsorption
Expansion refrigeration (LTX units)
Design techniques
Operations of dehydration facilities
80
Natural Gas Dehydration- Hydrate Prevention
Line heating and Low Temperature
Exchange Units (LTX
Inhibition by additives
Types and selection of additives
Inhibitor requirements
Prediction of inhibitor requirements

Injection techniques
Operations and troubleshooting

81
Natural Gas Dehydration-
Hydrate Prevention
Typical Glycol injection system
82
Natural Gas Dehydration- Hydrate Prevention

Process consideration


83
Natural Gas Dehydration- Hydrate Prevention:
Inhibitor Requirements

Hammerschmidts equation
Computer simulation

32 106 62
MW
2335 4000 4000
K
H
Methanol DEG EG
H
K MW d
MW d
W
+
=
) )( (
) 100 )( )( (
84
Natural Gas Dehydration- Hydrate Prevention:
Operations and Troubleshooting
Operations
Vapour losses
Corrosion
Glycol losses
Glycol-water-oil separation
Troubleshooting
Preventing freeze-offs
Improving Glycol-Condensate Separation
85
Natural Gas Dehydration- Glycol Absorption
Advantages over other methods of
dehydration:
Solid desiccant
Expansion refrigeration (LTS or LTX units)
Choice of glycol (EG and DEG vs. TEG)
Process description and elements
Design methods
Process operations
86
Source: Natco
A typical glycol absorption process
87
Process Elements:
1.
1.
Inlet scrubber
Inlet scrubber
2.
2.
Absorber (glycol contactor)
3.
3.
3.
Flash tank
Flash tank
Flash tank
4.
4.
4.
Filters
Filters
Filters
5.
5.
5.
Glycol pump
Glycol pump
Glycol pump
6.
6.
6.
Surge tank
Surge tank
Surge tank
7.
7.
7.
Heat exchangers
Heat exchangers
Heat exchangers
8.
8.
8.
Regeneration system (tower and
reboiler
reboiler
reboiler
)
)
)
9.
9.
9.
Instrumentation
Instrumentation
Instrumentation
Natco bubble cap
88
Process Elements:
1.
1.
1.
Inlet scrubber
Inlet scrubber
Inlet scrubber
2.
2.
2.
3.
3.
Flash tank
Flash tank
4.
4.
Filters
Filters
5.
5.
Glycol pump
Glycol pump
6.
6.
Surge tank
Surge tank
7.
7.
7.
Heat exchangers
Heat exchangers
Heat exchangers
8.
8.
8.
reboiler
reboiler
reboiler
)
)
)
9.
9.
9.
Instrumentation
Instrumentation
Instrumentation
89
Process Elements:
1.
1.
1.
Inlet scrubber
Inlet scrubber
Inlet scrubber
2.
2.
2.
3.
3.
3.
Flash tank
Flash tank
Flash tank
4.
4.
4.
Filters
Filters
Filters
5.
5.
5.
Glycol pump
Glycol pump
Glycol pump
6.
6.
6.
Surge tank
Surge tank
Surge tank
7. Heat exchangers
8. Regeneration system (tower and reboiler)
9. Instrumentation
90
Required information
Inlet gas flow rate, T and P and
composition
Required water dew point
Available utilities
Safety/environmental
regulations
Required TEG
reconcentration
Process flow
sheeting (M&EB)
Equipment sizing
Natural Gas Dehydration- Glycol Absorption:
Design Guidelines
Equipment
Specification
Tables from Natco Natco
91
Equipment sizing:
Contactor
Height (2 to 3 theoretical stages or GPSA Figures
20-53 to 20-58)
Diameter (Sauders-Brown)
Pump (70-80% mechanical efficiency
Pump BHP=(0.000012) (gph) (psig)
Design Guidelines
92
Regeneration package
Flash Tank
Stripping column
Three theoretical
stages
Diameter: 9.gpm
0.5
Reboiler
Duty: 1500.gph
Temp.: 370-390
o
F
Firetube flux: 6000-
8000 Btu/hr.ft
2
Design Guidelines
93
Heat Exchangers
Reflux condenser
Lean-rich glycol HX
Lean glycol cooler
Design Guidelines
94
Operations
Contactor
Inlet gas flow rate
Inlet gas T and P
Len TEG T and
concentration
TEG flow rate
Contactor T
<200 (pefer 180) TEG entering pump
380-400 (prefer 380) Reboiler
210 Top of stripping
column
300-350 TEG to stripping
column
100-150 (prefer 150) TEG to filters
100-150 (prefer 150) TEG to flash tank
5-15 warmer than
inlet gas
TEG to contactor
80-100 Inlet gas
Tempearture (
o
F) Process location
95
Regenerator
Reboiler T
Stripping gas
Column T
Operations
Drizo
Process
96
Glycol care
Oxygen
Thermal decomposition
Low pH
Salt contamination
Liquid HC
Sludge accumulation
Foaming
Operations
97
Glycol pump
Sour gas
Startup/shutdown
Operations
98
Preventive maintenance
Daily
Weekly
Monthly
Annual inspections
Operations
99
Troubleshooting
High exit gas dew-point
High glycol loss (should
be < 0.1 gal/MMscf)
Loss from contactor
Loss from stripping column
Loss from separator
Leaks and spills
Glycol contamination
Poor glycol regeneration
Low glycol circulation
High pressure drop across
contactor
High stripping column
temperature
High reboiler pressure
Firetube fouling/ hotspots/
burnout
Low reboiler temperature
Flash separator failure
100
Natural Gas Dehydration- Solid desiccants
Example Solid Desiccant Dehydrator Twin Tower System (Source: GP Example Solid Desiccant Dehydrator Twin Tower System (Source: GPSA) SA)
101
Natural Gas Dehydration- Solid desiccants
Natcos solid desiccant beds
102
Natural Gas Dehydration- Solid desiccants:
Design
Allowable gas superficial velocity
Pressure drop - vessel diameter: Erguns eq.
Cycle time (6-8 hours)
Bed length: Saturation Zone
(L
S
) and Mass Transfer Zone
heights (L
MTZ
)
) (
4
) )( ( 13 . 0
2
density bulk D
S
L and
C C
W
S
s
s
T ss
r
s
= =
2
V C V B
L
P
+ =
0.000210 0.238 1/16 extrudate

0.000136 0.152 1/16 bead
0.000124 0.0722 1/8 extrudate
0.0000889 0.056 1/8 bead
C B Particle type
Allowable Velocity for Mole Sieve Dehydrator
103
Design (cont.)
Length of mass transfer zone
L
MTZ
= (V/35)
0.3
(Z)
Bed regeneration
Heat duty
Regeneration gas rate
General comments on
dsing
104
Operations
Desiccant installation
Startup
Switching
Operating data
Energy conservation
105
Troubleshooting
Proper design-Design
considerations
Bed contamination
High Dew point
Premature Breakthrough
106
Natural Gas Dehydration- Refrigeration and
Membrane
A typical JT unit for water and NGL removal (source: Natco)
Manufacturer selection guide (source: Natco)
Membrane systems (Source: Air Products)
107
Natural Gas Dehydration- Process Selection
Dehydration methods advantages and
disadvantages
TEG (glycol dehydration)
Solid desiccants
Low temperature
Membranes
Selection recommendations
108
NATURAL GAS LIQUID RECOVERY
NATURAL GAS LIQUID RECOVERY
Why NGL recovery?
NGL components and specifications
Introduction to low temperature processes
Processing objectives
Transportable gas
Sales gas
Maximum NGL recovery
Value of NGL
Liquid Recovery Porcesses
109
Natural Gas Liquid Recovery- Processes
Refrigeration
JT-Valve expansion (LTS)
JT-Turbine Expansion
Oil absorption
Solid bed adsorption
H
y
d
r
o
c
a
r
b
o
n

P
h
a
s
e

E
n
v
e
l
o
p
e
Liquid
Gas
P
r
e
s
s
u
r
e
C B
A
C
C
Refrigeration
Interchange
JT and
Expander
Expander JT
Gas-Gas HX
Temperature
110
Natural Gas Liquid Recovery- Processes:
Joule-Thompson (JT) Valve Expansion
H
y
d
r
o
c
a
r
b
o
n

P
h
a
s
e

E
n
v
e
l
o
p
e
Liquid
Gas
P
r
e
s
s
u
r
e
C
B
A
C
C
Refrigeration
Interchange
JT and
Expander
Expander JT
Gas-Gas HX
A simplified JT Expansion
Process
Temperature
111
Natural Gas Liquid Recovery- Processes: LTS Units
112
Natural Gas Liquid Recovery- Processes: LTS Units
113
Refrigeration
114
Refrigeration
115
Oil absorption
Flow Diagram of a Refrigerated Lean Oil Absorption Process
116
JT Turbine Expansion
H
y
d
r
o
c
a
r
b
o
n

P
h
a
s
e

E
n
v
e
l
o
p
e
Liquid
Gas
P
r
e
s
s
u
r
e
C
B
A
C
C
Refrigeration
Interchange
JT and
Expander
Expander JT
Gas-Gas HX
Temperature
A Simplified Turbo Expansion Flow Diagram
117
Conventional Turbo-expansion System
118
Residue Recycle (RR) Turbo-expansion Process
119
120
121
122
Mixed Refrigerant
123
Solid Bed Adsorption
Solid Bed Adsorption Dew Point Control Units
124
Natural Gas Liquid Recovery- Process Selection
NGL content of the gas
Low: expander process
High: external refrigeration
Inlet gas pressure
High: LTS
Low: Turbine expansion or refrigeration
Gas flow rate
Low: simple valve JT unit, solid adsorption or
membranes
Large: more complex plants
Location (offshore, onshore, or remote areas)
125
Natural Gas Liquid Recovery - Process Design
Process flowsheeting/simulation
EOSs (SRK, PR, etc.)
Software packages (BR&E PROSIM
, Hyprotech
HYSYS
, Aspen
, Chemshire Design II
, SSI
PROCESS
and PRO/II
etc.)
Equipment selection
HXs
Towers
Turboexpanders
Pumping and storage
126
Natural Gas Liquid Recovery Equipment
Selection: Heat Exchangers
Basic Components of a Three Stream
Counterflow Brazed Aluminum Heat Exchanger
Typical Fin Arrangements for Gas/Gas
Exchanger
127
Natural Gas Liquid Recovery Equipment
Selection: Towers, Pumps, and Storage
128
Natural Gas Liquid Recovery Refrigeration
Cycle
Simple Cycle
Process flow diagram
Vapour compression P-H
diagram
1. Expansion
2. Evaporation
3. Compression
4. Condensation
129
Cycle
130
Cycle: Single, vs Multistage Systems
131
Cycle: Single, vs Multistage Systems
132
Cycle: Refrigerant Cascading
133
134
Natural Gas Liquid Recovery Design and
Operating considerations
Oil removal
Liquid surge and storage
Vacuum systems (air leaks
and corrosion)
Vacuum considerations
135
Natural Gas Liquid Recovery Design and
Operating considerations
Material of construction
9no copper in presence of ammonia and sulfur compounds
9Steel is preferred (CS down to -20
o
F)
9Aluminum alloy and SS for very low Ts
9ANSI B31.3 and B31.5 design codes
Refrigeration purity
9Lube oil
9Light and heavy ends
9Process fluid leak
9Air leak and humidity (use drier or methanol wash/purge)
136
Compressors
Compressor types
Centrifugal (>450 HP)
Reciprocating (higher efficiency, multistage)
Screw (high compression ratios up to 10, less noise)
Rotary (low capacity)
137
Natural Gas Liquid Recovery Mixed
refrigerant
138
Kettle type
Allowable refrigerant load in lb/hr per ft
3
vapor space =
Plate fin
Chillers
V L
V
F S

) 869 . 0 (
) 3980 )( .)( . (
139
Natural Gas Liquid Recovery
Refrigeration Control System
Level
9 displacer-type
9 internal float
9 differential pressure
Pressure
9 Compressor suction and discharge
Temperature
9 Chiller (by controlling compressor suction pressure)
9 Low ambient
140
High Compressor Discharge Pressure
High Process Temperature
Inadequate Compressor Capacity
Inadequate Refrigerant Flow to Economizer or Chiller
Operations and trouble shooting

Overview Gas Processes

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Overview Gas Processes

Uploaded by

Copyright:

Available Formats

1

Design of Natural Gas

Purpose, principles and terminology

Prediction of inhibitor requirements

Operations and troubleshooting

Types and selection of additives

Prediction of inhibitor requirements

Operations and troubleshooting

Types and selection of additives

Operations and troubleshooting

0.000210 0.238 1/16 extrudate

You might also like