Nn | 4 uclavo haaiba Cn 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 F749Contents 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 14 115 131 136 138 140 141 141 142vill 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 213 217 219 221 227 229 231 232 234 235 235 237 239 239 240 244 254 263 265 266 267 269 269 269 281 285 286 288 288 288 289 290 291 293 293 295 297 297 300 302 303 304Electrical 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, 424 425 426 430Preface 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.