Natural Gas Processing

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1 Natural Gas Processing Technology and Engineering Design Alireza Bahadori, Ph.D. School of Environment, Science and Engineering, Southern Cross University, Lismore, NSW, Australia AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO ELSEVIER Gulf Professional Publishing is an imprini of Elsevier

2 Contents About the Author Preface xvii X1X CHAPTER 1 Overview of Natural Gas Resources i 1.1 The formation of natural gas Conventional natural gas resources Gas reservoir fluids Unconventional natural gas resources Hydraulic fracturing 15 Further reading 20 CHAPTER 2 Natural Gas Properties 23 CHAPTER Fluid distribution in reservoir Phase behavior of hydrocarbon systems Pressure-volume-temperalure properties of hydrocarbon fluids Gas compressibility factor Equation of state Gas specific gravity Gas density Specific volume Isothermal compressibility of gases Gas formation volume factor Standard volume Acentric factor Viscosity Thermal conductivity Gross heating value of natural gases 53 References 56 Further reading 57 Single-phase and Multiphase Flow in Natural Gas Production Systems Basic fluid flow theory Process pipe sizing for plants located onshore single phase Process pipe sizing for plants located offshore Transmission pipelines ^4 3.5 Two-phase mixture properties 3.6 Two-phase flow pressure drop 3.7 General aspects in design of piping systems in oil, gas, and petrochemical plants 100 vii

3 viii Contents _, 3.8 Isometric drawings Line identification list 3.10 Pipe supports 3.11 Pressure testing diagram 3.12 Tie-in diagram J^ Above-ground piping systems Valves Flanges 3.16 Instrument piping 3.17 Sample systems 3.18 Vents and drains Blow-down Utility piping Piping adjacent to equipment Piping flexibility Piping supports I Insulation Piping connections to existing plant Underground piping systems 146 References Further reading '47 ^ ^ 117 '4V CHAPTER 4 Gas-Liquid Separators Gravity settling Gas-liquid separators in oil and gas processing Conventional gas-liquid separators Design criteria of separators Gas-liquid separator sizing Specification sheet Mist eliminator type and installation point Centrifugal gas-liquid separators Flare knock-out drums Gas-liquid filler separators Process requirements of vessels, reactors, and separators Nature of the feed 4.13 Solid-liquid separators Typical equations, which can be used for terminal velocity calculation Vessels Reference Further reading 220 CHAPTER 5 Gas Compressors Type selection criteria 5.2 Centrifugal compressors

4 Contents ix 5.3 Design criteria Reciprocating compressors Axial compressors Screw compressors Rotary compressors Compressor cooling water jacket Atmospheric pressure Specification sheets Material for axial and centrifugal compressors and expander-compressors Centrifugal and axial compressors Integrally geared compressors Expander-compressors 269 Reference 271 Further reading 272 CHAPTER 6 Blow-Down and Flare Systems Blow-down system for vapor relief stream Blow-down system for liquid relief stream Design of disposal system components Sizing a knock-out drum Quench drum Flares Burning pits Determination of liquid level in a horizontal vessel Sample calculation for sizing a flare stack Process design of emergency measures 304 References 310 Further reading 310 CHAPTER 7 Safety Relive Valves Design Provisions of pressure safety relief valves Provisions of temperature safety valves Provisions of vacuum safety valves Provisions of rupture disks Spare safety valves Selection of type Closed spring type valves Safety valves with lifting devices Temperature safety relief valves Safety valve caps 7.11 Safely valve drains Rupture disc types Safety valve bonnet

5 x Contents 7.14 Set pressure 7.15 Pressure safety or relief valve set pressure 7.16 Temperature safety valve set pressure 7.17 Rupture disc set pressure 7.18 Vacuum relief valve set pressure Sizing Vacuum relief valve sizing QTQ JJO 7.21 Temperature safety valve sizing Rupture disc sizing 7.23 Emergency vapor depressuring systems 7.24 Arrangement of safety relief valves Location on vessels 3^ Location of safety valve nozzles to minimize turbulence Location of safety valve nozzles to minimize pulsation Inlet piping of safety relief valves Discharge piping of safety relief valves Block valves Discharge piping support 7.32 Position Discharge piping of temperature safety ii:> Jjy valves Venting and draining philosophy Vapor venting Liquid venting Safety valve bonnet venting Safety valve draining Sizing for gas or vapor relief Sizing for liquid relief Material and engineering for pressure and vacuum relief devices Design of rupture disks Material Inspection and shop tests Marking, documentation, and preparation for shipment General specification for springs of pressure relief valves Testing and dimensional checks 364 References 369 Further reading 369 CHAPTER 8 Sizing of Valve and Control Valve Manual valves Check valves Control valves Control valve sizing Calculating Cv for liquids 388

6 Contents xi 8.6 Liquid sizing examples Calculating Cv for gases Calculating Cv for two phase flow Engineering and material for control valves Control valve body size and flange rating Control valve characteristics Control valve manifold design Control valve block and bypass valves Control valve packing and sealing Control valve noise and vibration caused by sonic flow Control valve actuators Actuator construction materials 437 Further reading 438 CHAPTER 9 Natural Gas Dehydration Phase behavior of dehydrated natural gas Water content of natural gases Gas water content prediction using generalized charts Gas water content prediction using empirical methods Methods based on EOS Hydrates in natural gas systems Thermodynamic model for the hydrate phase Hydrate predictions for high C02/H2S content gases Hydrate inhibition Natural gas dehydration methods Adsorption of water by a solid 474 References 477 Further reading 478 CHAPTER 10 Natural Gas Sweetening Chemical solvent processes Process selection Chemical reaction processes Simplified design calculations General considerations Corrosion in gas sweetening plants Flash tank Combined physical/chemical purification processes Carbonate process Physical absorption methods Solid bed sweetening methods (batch Processes) Process design 512 Reference 516 Further reading 516

7 xii Contents CHAPTER 11 Sulfur Recovery ^ The Claus process 11.2 Technology overview 11.3 Acid gas enrichment 11.4 Oxygen enrichment 11.5 Reheat methods 11.6 Combustion operation 11.7 Sulfur condenser operation 11.8 Waste heat recovery operation 526 COQ C90 J- S9Q 11.9 Catalyst converter operation Claus tail gas treating process selection Contact condenser (two-stage quench) Solvent selection criteria in the tail gas unit Ammonia destruction in a TGU (RACTM) BSRSelectox 545 Reference 545 Further reading 545 CHAPTER 12 Liquefied Petroleum Gas (LPG) Recovery Properties Natural gas liquids processing Fractionation Packed columns Basic design requirements Fractionation and system configuration Absorption/stripping Control and optimization Storing and handling of liquefied petroleum gases (LPGs) Design considerations Transfer of LPG within the off-site facilities of oil and gas processing (OGP) plants Pressure storage spheres for LPG Material selection General information Design of pressure storage spheres Nozzles and connections Mountings Access facilities Fabrication Insulation 589 Reference 590 Further reading 590

8 Contents xiii CHAPTER 13 Liquefied Natural Gas (LNG) The LNG chain The LNG liquefaction facility Liquefaction process LNG storage In-tank pump process objectives LNG shipping Liquefaction and refrigeration Basic single flow LNG process Multistage MR process Mixed fluid cascade process Classification of natural gas liquefaction processes Type of LNG plants Liquefaction cycle for LNG FPSO Proposed LNG liquefaction processes for FPSO Storage and transfer facilities of LNG 627 References 631 Further reading 631 : CHAPTER 14 Basic Engineering Design for Natural Gas Processing Projects Contents of BEDP Items common for all units Manuals Individual items for each unit Specifications and data sheets Drawings Recommended practice for feasibility studies Prefeasibility studies Outline of prefeasibility study Feasibility studies Production program and plant capacity Technology choice Selection of machinery and equipment Civil engineering works Estimates of overall investment costs (capital cost estimates) Organization and overhead costs Human resources Implementation, planning, and budgeting Financial analysis and investment appraisal Method of investment appraisal Break-even analysis Preparation of basic engineering design data 696

9 xiv Contents Data preparation of utilities (utility summary tables) Data preparation of effluents Data preparation of catalysts and chemicals 7)7 Further reading CHAPTER 15 Detailed Engineering and Design for Natural Gas Processing Projects Detailed implementation plan Project schedule and control services Quality assurance and control 7^ Detailed design and engineering Procurements services 15.6 Supply of materials Detail design & engineering documents " Supply of spare parts, miscellaneous equipment and materials, chemicals and catalysts 15.9 Reimbursable items Process flow diagram (PFD) and piping and instrumentation diagrams Identification and numbering of equipment Description of equipment Description of instrumentation Material balance table " Piping and equipment symbols Piping & instrumentation diagrams (P&IDs) Minimum information to be shown on P&IDs Equipment indication Instrumentation Piping Special requirements General notes Design criteria for preparation of P&IDs Bypass for safety/relief valve Criteria lor utility flow diagrams Preparation of P&IDs Handling of licensed process Revisions of P&1D Block and bypass valves for control valve Philosophy of instrumentation installation 800 Further reading 801 1A~\ 7^ CHAPTER 16 Start-up Sequence and Commissioning Procedures Preparation prior to initial start-up Final inspection of vessels 8] ]

10 Contents xv 16.3 Flushing of lines Instruments Acid cleaning of compressor lines Breaking-in pumps 8' Breaking-in compressors Dry-out and boil-out Catalyst loading Tightness test Normal start-up procedures Catalytic units reactor section air purging and gas blanketing Heat exchanger activation Vacuum test Establish flow in the unit Inhibitor/chemical injections Typical acid cleaning procedure for compressor lines The acid-cleaning operation Typical healer dry-out procedure Typical chemical boil-out sequence Basic considerations in preparing operating manuals Safety manual/quality manual Non-licensed processes Noteworthy points Design basis Plant technical and equipment manuals 837 Further reading 83^ Glossary of Terms 841 Index 853

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