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OILFIELD PROCESSIN
VOLUME TWO: CRUDE OIL
Francis S, Manning, Ph.D., PE.
Professor of Chemical Engineering
University of Tulsa
Tulsa, Oklahoma
and
Richard E. Thompson, Ph.D., RE.
Professor Emeritus of Chemical Engineering
University of Tulsa
Tulsa, Oklahoma
With
Contributions
by
William P. Manning, Ph
Coastal Chemical Company
Coauthor of Chapter 12 “Fired Heaters”
Paul Buthod, M.S., PE.
Professor Emeritus of Chemical Engineering and Petroleum Refining
‘The University of Tulsa
Coauthor of Appendix 4 “OPSIM”
and
Kerry L. Sublette, Ph.D.
Professor of Chemical Engineering
‘The University of Tulsa
Coauthor of Chapter 6 "Dehydration of Crude Oil”
Coauthor of Chapter 7 “Desalting of Crude Oil”
Pennwell Books
PENNWELL PUBLISHING COMPANY
TULSA, OKLAHOMA
7eU/Lok yw F749Contents
Preface
Chapter 1
Introduction and Scope
Review Questions
References
Chapter 2
Characterization of Crude Oils
Introduction
Crude Oil Sampling and Analysis
Product Specifications
Review Questions
Problems
Nomenclature
References
Chapter 3
Phase Behavior
Introduction
Fluid Phase Behavior
Equilibrium Calculations
‘Thermodynamics of Vapor-Liquid Equilibria
Nomenclature
Review Questions
References
Chapter 4
‘Water-in-Crude Oil Emulsions
Introduction
Emulsions
Wellhead Emulsions
Emulsion Stability
Settling/Rising Velocities
Potential Emulsification Tendencies
of Production Practices
Emulsion Prevention
Review Questions
Problems
Nomenclature
References
16
18
2
21
21
22
25
25
25
7
29
35.
36
36
39
39
39
4
44
45
52
52.
56
57
7
58
Chapter 5
Field Processing of Crude Oil
Introduction
Design Bases
Processing Operations
Processing Scope
Environmental Considerations
Review Questions
Problems
Nomenclature
References
Chapter 6
Phase Separation of Gas, Oil, and Water
Introduction
Terminology
Physical Description
‘Comparison of Separators
Phase Separation Theory
Design Considerations
Design Examples
Maintenance and Troubleshooting
Review Questions
Problems
Nomenclature
References
Chapter 7
Dehydration of Crude Oil
Introduction
Terminology
Treating Methods
Design Considerations
Design Examples
Operation and Maintenance
Review Questions
Problems
Nomenclature
References
61
or
61
63
6
2B
76
76
7
7
79
79
79
80
90
on
95
101
108
109
109
110
m
113,
113
14
115
131
136
138
140
141
141
142vill Contents
Chapter 8
Desalting of Crude Oil
Introduction
Process Description
Design Considerations
Design Procedures
Operation
Troubleshooting
Review Questions
Problems
Nomenclature
References
Appendix 8-1
Appendix 8-2
Chapter 9
Stabilization and Sweetening of Crude Oil
Introduction
Multistage Separation
Condensate
More-Complex Proces
Sweetening
‘Summary
Review Questions
Problems
Nomenclature
References
Chapter 10
Pumps
Introduction
General Considerations
Centrifugal Pumps
Positive Displacement Pumps
Drivers
Pump Selection
Pump Design Theory
Design Procedure
Installation and Oper
Troubleshooting
Review Questions
Problems
Nomenclature
References
Chapter 11
‘Measurement of Crude Oil
Introduction
Types of Meters
Storage Tanks
145
145
146
149
150
154
155
155
156
156
157
157
158
159
159
160
165
167
168
172
173
173
173
174
175
175
175
176
182
184
185
188
191
195
197
197
199
200
200
203
203
203
206
Lease Automatic Custody Transfer (LACT)
Units
‘Turbine Meters
Orifice Meters
Meter Proving
Mass Flowmeters
Multiphase Flow Metering
Meter Selection
Metering Error
Review Questions
Problems
Nomenclature
References
Chapter 12
Firetube Heaters
Introduction
Combustion
Firetube Heaters
Design
Operation
Review Questions
Problems
Nomenclature
References
Chapter 13
‘Transportation of Crude Oil
Introduction.
Pipeline Design
Heavy Oil Transport
Pipeline Pump Selection
Operation
Construction
Pipeline Cost
Review Questions
Problems
Nomenclature
References
Chapter 14
Energy Conservation
Introduction
Energy Audits
Fired Heaters
Insulation
Prime Movers
Waste Heat Recovery
Dehydration of Crude Oil
Operating Pressure and Vapor Recovery
213
217
219
221
227
229
231
232
234
235
235
237
239
239
240
244
254
263
265
266
267
269
269
269
281
285
286
288
288
288
289
290
291
293
293
295
297
297
300
302
303
304Electrical Power
Miscellaneous
Summary
Review Questions
Problems
Nomenclature
References
Chapter 15
Instrumentation and Process Control
Introduction
Process Control Concepts
Feedback Control
‘Advanced Control Loops
Sensing Devices
‘Control Valves
Controllers and Control Action
‘Safety and Control Applications
Control of Processing Plants
Review Questions
Problems
Nomenclature
References
Chapter 16
Pressure Relief and Flaring
Introduction
Depressuring, Emergency Relief, and Flare
Systems
General Considerations
Pressure Relief Devices
Flaring
Review Questions
Problems
Nomenclature
References
306
31
313
314
314
315
316
319
319
319
321
322
324
324
331
334
338
347
+348
348
349
351
351
352
354
356
365
374
375
375
376
Chapter 17
Case Studies
Introduction
Case Study No. 1
Case Study No. 2
Review Questions
Problems
References
Appendix 1
Glossary of Terms
Appendix 2
Material Balances
Appendix 3
Energy Balances
Appendix 4
OPSIM
Introdu
Use of the Progeam
OPSIM Execution
Example Problems
Description of the Modules
Structure of OPSIM
References
Appendix 5
Conversion of Units
‘Conversion Factors
Appendix 6
Physical Properties of Fluids
Index
Contents
379
379
379
384
388
388
390
301
399
403
406
406
409
4ul
416
422,
423,
424
425
426
430Preface
Oilfield Processing is the second book in the three-vol-
‘ume series on the various surface unit operations com-
monly used in production facilities. Natural gas was
covered in Volume 1 which was published in 1991.
Oilfield waters (both produced and injection) will be
covered in Volume 3.
Hopefully, this book will serve three needs. First, in
the form of typed notes, the current material has been
used as a text for a senior-level, petroleum engineering
design course on surface production and processing.
The authors do appreciate the numerous suggestions
from the University of Tulsa seniors who have used these
notes
Second, this book material has been used in, short
courses for engineers and foremen working in field han-
dling of crude oil. It is hoped that this book will help
engineers in other disciplines learn petroleum produc-
“Third, this book should serve as ¢refiesher and hand-
book for all engineers interested in field handling of
crude oil.
‘The mathematical background required to use this
book has been kept to a minimum to make it easily read-
able and immediately useful. Where advantageous, cur-
rene computer simulation has been identified but com-
puter expertise is not required.
‘The authors were shocked and deeply saddened by the
sudden death of Nelda Whipple on May 21, 1991.
Nelda typed and retyped numerous drafts of Volume 1
and the early versions of much of Volume 2. We miss her
very much,
“The authors express their gratitude and thanks to the
University of Tulsa for providing the opportunity and
environment to write this book. The University of Tulsa
enjoys many long-standing and close relationships with
the petroleum industry. In fact, so many petroleum
industry engineers helped so much that ic is impossible to
document every kindness.
Nevertheless, the authors are pleased to thank the fol-
lowing friends and companies for providing up-to-date
information and for reviewing drafts:
Coastal Chemical Company Don Ballard
Bill Manning
Albere Peck
Scott Dalton
Garvin Fryar
Bob Gibson
Gene Morrison
Joe Provine
Harry Sharkis
Duane Wilson
Wayne Wilson
Mike Hein,
Ed Flaxbare
B.E. Harrell
Floyd Prestridge
Gary Sams
Harry Wallace
Ken Warren
Ron Key
Don Love
Reed Melton
Shannon Melton
Tom Russell
Conoco Inc.
Flow Con
Hughes Anderson
NATCO
‘The Pro Quip Corp.
Radco Inc.
TT. H. Russell Company
While all these friends were exceedingly helpful, some
contributions demand individual recognition. Dr. Bill
Manning coauthored Chapter 12. Professor Kerry
Sublette’ critiques of Chaprers 4, 7, and 8 were tanta-
mount to coauthorship as were Al Peck’s suggested revi-
sions for Chapter 15 and Bob Gibson's review of Chapter
16.
The authors have collectively and individually taught
numerous short courses wotldwide for Amoco
Production, OGCI, Rike Service Inc., and Texaco. This
experience proved invaluable, as did Professor Thompson's
15-year experience with Crest Engineering and Furlow-
Philbeck Engineering,
‘The senior author thanks the University of Tulsa and
the College of Engineering and Applied Sciences for
granting him a sabbatical leave during the 1993 fall
semester to work on this volume.xii Preface
The authors would also like to thank all theie T. U.
colleagues; however, the following deserve special recog-
nition. Dr. E. T. Guerrero encouraged them to teach a
senior-level petroleum engineering course on surface
production. Dr. Keith Wisecarver helped the senior
author with PC and printer problems on many occa-
sions. Carol Guy and Virginia Wood of the University’s
Petroleum Abstracts Division compiled numerous litera-
ture searches. Joan Abrens, Ellen Boswell, and Jim
Murray in the Sidney Born Technical Library cheerfully
found every reference requested.
‘The authors thank Sandra Whitaker for typing many
revisions and changing the format of many chapters
‘The authors acknowledge the help and infinice
patience provided by Marla Patterson and Sue Rhodes
Sesso of PennWell Books.
Finally, and most importantly, the authors thank their
wives, Ardis Amold Manning and Marilyn Thompson
for their patience, understanding, and encouragement.
All too often the authors spent the weekend at the office.