Processing facilities

Processing Facilities. The phenolic-foam-producing process is simUar to that used with rigid polyurethane foams. Production of composite sandwich panels, board-type products, pipe covers, are possible. 

For manufacturing composite sandwich panels by laminating, a coating apparatus for the adhesive (chloroprene-base and polyurethane-base adhesives are preferable) and a press is needed. 

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The non-hydrocarbon components of crude oil may be small in volume percent, typically less than 1 %, but their influence on the product quality and the processing requirements can be considerable. It is therefore important to identify the presence of these components as early as possible, and certainly before the field development planning stage, to enable the appropriate choice of processing facilities and materials of construction to be made. 

Reservoir fluid sampling is usually done early in the field life in order to use the results in the evaluation of the field and in the process facilities design. Once the field has been produced and the reservoir pressure changes, the fluid properties will change as described in the previous section. Early sampling is therefore an opportunity to collect unaltered fluid samples. 

From the above plot, it can be seen that the recovery factor for gas reservoirs depends upon how low an abandonment pressure can be achieved. To produce at a specified delivery pressure, the reservoir pressure has to overcome a series of pressure drops the drawdown pressure (refer to Figure 9.2), and the pressure drops in the tubing, processing facility and export pipeline (refer to Figure 9.12). To improve recovery of gas, compression facilities are often provided on surface to boost the pressure to overcome the pressure drops in the export line and meet the delivery pressure specified. 

Viscosity and Density - which help determine how easily the fluids will move through the process facility. 

Gas processing facilities generally work best at between 10 and 100 bar. At low pressure, vessels have to be large to operate effectively, whereas at higher pressures facilities can be smaller but vessel walls and piping systems must be thicker. Optimum recovery of heavy hydrocarbons is achieved between 20 bar and 40 bar. Long distance pipeline pressures may reach 150 bar and reinjection pressure can be as high as 700 bar. The gas process line will reflect gas quality and pressure as well as delivery specifications. 

Gas is sometimes produced at very high pressures which have to be reduced for efficient processing and to reduce the weight and cost of the process facilities. The first pressure reduction is normally made across a choke before the well fluid enters the primary oil / gas separator. 

If produced gas contains water vapour it may have to be dried (dehydrated). Water condensation in the process facilities can lead to hydrate formation and may cause corrosion (pipelines are particularly vulnerable) in the presence of carbon dioxide and hydrogen sulphide. Hydrates are formed by physical bonding between water and the lighter components in natural gas. They can plug pipes and process equipment. Charts such as the one below are available to predict when hydrate formation may become a problem. 

Gas turbine driven centrifugal compressors are very efficient under the right operating conditions but require careful selection and demand higher levels of maintenance than reciprocating compressors. Compression facilities are generally the most expensive item in an upstream gas process facility. 

In areas where seabed relief makes pipelines vulnerable or where pipelines cannot be justified on economic grounds, tankers are used to store and transport crude from production centres. The simplest method for evacuation is to pump stabilised crude from a processing facility directly to a tanker. 

As introduced in Section 14.2, bottlenecks in the process facilities can occur at many stages in a producing field life cycle. A process facility bottleneck is caused when any piece of equipment becomes overloaded and restricts throughput. In the early years of a development, production will often be restricted by the capacity of the processing facility to treat hydrocarbons. If the reservoir is performing better than expected it may pay to increase plant capacity. If, however, it is just a temporary production peak such a modification may not be worthwhile. 

The role that a host facility plays in an incremental development project can vary tremendously. At one extreme all production and processing support may be provided by the host (such as gas lift and water treatment). On the other hand, the host may just become a means of accessing an export pipeline (if a production and processing facility is installed on the new field). 

Handling production from, and providing support to, a satellite field from an older facility is at first glance an attractive alternative to a separate new development. However, whilst savings may be made in capital investment, the operating cost of large processing facilities may be too much to be carried by production from a smaller field. 

Companies which own process facilities and evacuation routes, but no longer have the hydrocarbons to fill them, can continue to operate them profitably by renting the extra capacity or by charging tariffs for the use of export routes. 

Onshore processing facilities, and modules brought onshore, have to be cleaned of all hazardous compounds and scrapped. Cellars of single wells, drilling pads, access roads and buildings will have to be removed. If reservoir compaction affects the surface area above the abandoned field future land use may be prevented, in particular in coastal or low land environments. 

In order to operate a process facility in a safe and efficient manner, it is essential to be able to control the process at a desired state or sequence of states. This goal is usually achieved by implementing control strategies on a broad array of hardware and software. The state of a process is characterized by specific values for a relevant set of variables, eg, temperatures, flows, pressures, compositions, etc. Both external and internal conditions, classified as uncontrollable or controllable, affect the state. Controllable conditions may be further classified as controlled, manipulated, or not controlled. Excellent overviews of the basic concepts of process control are available (1 6). 

Table 1. Conceptual Levels in a Process Facility Control Hierarchy...

Generally, recyclables are either coUected at curbside or deposited by consumers at various types of drop-off locations, such as local recycling centers, community service clubs, dealers, and commercial buyback centers. Curbside coUections of recyclables can be accompUshed either in conjunction with the pickup of aU MSW or as a separate activity. Co-coUection systems range from complete commingling of aU waste for later separation at a mixed waste processing facility to transporting essentially source-separated recyclables in the same tmck as MSW. 

MANSFIELD Engineering Design for Process Facilities MEYERS Handbook of Petroleum Refining Processes,... 

Separation of recoverable materials, usually at a processing facility... 

Government regulations reqmre hazard and risk analysis as part of process safety management (PSM) programs. These are part of the process safety programs of many chemical process facilities. 

Understanding the chemistry of the process also provides the greatest opportunity in applying the principles of inherent safety at the chemical synthesis stage. Process chemistry greatly determines the potential impact of the processing facility on people and the environment. It also determines such important safety variables as inventory, ancillary unit operations, by-product disposal, etc. Creative design and selection of process chemistry can result in the use of inherently safer chemicals, a reduction in the inventories of hazardous chemicals and/or a minimization of waste treatment requirements. 

Process Safety A discipline that focuses on the prevention and mitigation of fires, explosions, and accidental chemical releases at process facilities. Excludes classic worker health and safety issues involving working surfaces, ladders, protective equipment, etc. 

PSSR Completion Summary The following issues have been resolved and the undersigned believe the process/facility is ready for startup. ... 

Changes made to modify the process/facility have been reviewed and authorized by the ABC Co. Management of Change program. ... 

Process Safety Management (PSM) A program or activity involving the application of management principles and analytical techniques to ensure the safety of chemical process facilities. Sometimes called process hazard management. Each principle is often termed an element or component of process safety. 

QRA can be used to investigate many types of risks associated with chemical process facilities, such as the risk of economic losses or the risk of environmental impact. But, in health and safety applications, the use of QRA can be classified into two categories ... 

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