Production Equipment

PRODUCTION EQUIPMENT
STATIONERY & ROTARY

OGS-ZTP-GT-TRM-0007
MAIN TOPICS
1. Common Static Equipment used in Oil & Gas field
 Separators
 Storage Tanks
 Slug Catcher
 Gas Scrubber
 Flare Knock out Drum
 Towers and Columns
 Heat Transfer Equipment
 Heat Exchangers
 Air Coolers
 Plate Heat Exchangers
 Pipes, valves & fittings
MAIN TOPICS
2. Rotating Equipment used in Oil & Gas field

 Pumps
 Compressors
 Turbine
 Engines
Common Static Equipment used in Oil & Gas field
Static Equipment related STD;
ASME Section VIII-1 Rules for Construction of Pressure Vessels

TEMA Class B Pressure vessels for chemical process services
TEMA Class C Pressure vessels for general commercial
applications
TEMA Class R Pressure vessels for the severe requirements
of petroleum processing
API 650 Welded Steel Tanks for Oil Storage
API 620 Design and Construction of Large Welded Low
Pressure Storage Tanks`
API 572 Inspection of Pressure Vessels (Towers,
Drums, Reactors, Heat
Exchangers, and Condensers)
API 521 Flare Knock out Drum (KOD) Design & Sizing
Static Equipment related STD;
ISO 16812 or API 660 Shell & Tube Heat Exchanger

ISO 13706 or API 661 Air Cooled Heat Exchangers
ISO 15547 or API 662 Plate Heat Exchangers for General Refinery
Services
API 598 & API 6D Valves
API 520 & API 576 PSV Selection & Inspection
ANSI B31.3 Piping Code
ANSI B36.10 Piping Specs
ANSI B16.5 Flange Code
ANSI B16.20 Metallic Gasket
ANSI B16.21 Non Metallic Gasket
Separators
Separator are vessels is in which gas, oil and water are
separated from each other. The principle of separation relies on
gravity, gas, oil and water havig different densities
If solid particles are entrained in the fluid they will also be
separated at the bottom of separator.

Separators Classification
Separators are classified according to the shape:

 horizontal
 vertical
 Spherical
Or Phases Separated:
 Two-phases
 Three-phases
Horizontal 2-Phases Separators

Horizontal 3-Phases Separator

Vertical Separators
Separation Quality;
Separators are required to provide oil/gas streams that meet

saleable pipeline specification.
Oil must have less than 1% (by volume) water.

Water stream must have less than 20 ppm of oil.
Slug Catcher Vessel

Slug Catcher Finger-Type

Gas Scrubber
A device to remove dirt,

water, foreign matter, or
undesired liquids that are part
of the gas flow stream.
A scrubber is used to protect

downstream rotating
equipment or to recover
valuable liquids from gas.
Flare Knockout Drum
The purpose of KOD to

remove any liquid from the
relieved gases & to ensure
Flare gas is free from any
liquid.
Knockout drum design and

sizing basis as per API-521.
KOD MOH or SD is required

plant total SD and to be
considered as the critical path
for the plant SD.
Pressure Vessels
Storage Tanks
In industry, there are many different types of equipment used for

the storage of liquids and gases
Storage Tanks can be:
 Fixed or Floating Roof

 Vertical and Horizontal Cylindrical
 Spherical
Storage Tanks
 Fixed Roof
TYPICAL CONICAL ROOF STORAGE TANK

VAPOUR VENT
INERT
GAS SUPPLY
RELIEF
THIEF OR
VALVE
GAUGE HATCH
FOAM
INJECTION BOX
SIGHT CLASS
(LEVEL GAUGE)
SHOWING
ROOF ACCESS POSSIBLE COMPINATIONS
LADDER
OF
ACCESSORIES & CONNECTIONS
ACCESS
MANHOLE
GROUND LEVEL
BUND
AREA FILL/PUMPOUT
LINE
EARTH
CONECTION DRAIN
Fixed roof storage tanks pumping out or drain protection

Storage Tanks
 Floating Roof
Storage Tanks
 Spherical Tanks
Storage Tanks
Towers and Columns
Towers are classified according to the type of “internals” in the

tower, and according to the function performed by the tower.
Tower Dimensions: Towers typically range in diameter from 3 to 20

FEET and in height from 20 to 150 FEET.
Towers and Columns “internals”
Towers may contain trays. If the

tower contains trays, the vessel
is called a tray tower, or
synonymously a tray column.
Trays are generally divided into

three categories:
• Sieve Trays
• Valve Trays
• Bubble Cap Trays

Towers and Columns
Sieve Trays Bubble Cap Trays
Valve Trays
Tower may contain

packing. If the tower
contains a packing, the
vessel is called a packed
tower, or packed column.
Random Packings
Structured Packings
Packing Versus Trays:
A tray column that is facing throughput problems may be

debottlenecked by replacing a section of trays with packings. This
is because: Packings provide extra interfacial area for
liquid/vapour contact efficiency of separation is increased for the
same column height packed columns are
shorter than trayed columns
Towers and Columns
Tower/Column Applications;
• Distillation
• Stripping
• Absorption
• Adsorption
• Extraction.
Towers and Columns

Heat Transfer Equipment
The various types of heat transfer equipment are generally

defined by the function fulfilled in a process. Following are
typical heat transfer equipment used in processing industries.
As example for heat transfer equipment:

 Shell & Tube Heat Exchanger (ISO 16812 or API 660)
 Air Cooled Heat Exchangers (ISO 13706 or API 661)
 Plate Heat Exchangers for General Refinery Services. (ISO 15547
or API 662)
Heat Exchangers
Heat is exchanged between two streams. Exchangers are used to

remove heat from streams which are required to be cooled, and
transfer heat to streams which are required to be heated.
The basic design data:

 Q = total heat transfer
 ∆T = temperature difference between the two media
 “U” is a function of many variables;
 “A” is the area of retaining wall between the two flowing media.
Main Types & Components of Heat Exchangers
A - Shell and Tube Heat Exchanger

The shell and tube heat exchanger is further divided into three categories as
1. Fixed tube sheet

3. Floating head
3. U - Tube

B- Air Cooled Heat Exchangers
Cold air being blown over the tubes, which containing the
process fluids for cooling.

C- Plate Heat Exchangers

Pipes, valves & fittings
Pipe design
Pipes are designed according to:
 Maximum Steady State Pressure
 Temperature
 Flow rate
 Chemical characteristics of fluid
Pipes materials
Pipes materials can be:
 Metals and alloys
 Plastic
 Glass (for laboratory and special application)
 Composites
Selection bases;
 Design data (mechanical, chemical)
 Economics consideration
Pipes, valves & fittings – Piping Schedule


Flanges
Flanges are mechanical devices used to connect elements in piping
system where it is necessary to disconnect equipment or parts of
the piping for maintenance.
There are several types of flanges:

 Screwed
 Slip-on
 Welding neck
 Socket-weld flanges
 Lap joint (with free flange)
 Blind
 Spectacle Blind
Flanges
Slip-on Flange Screwed Flange WN Flange
Socket-weld Flange
Lap joint Flange
Flange Face

Fittings
Flange gasket
The types most commonly used are:

 Non-metallic flat type: it is the most used gasket in the field
of low temperature and medium pressures.
 Metallic
 Ring-joint
Flange gasket Non-metallic
Metallic Ring-joint

Valves
Valves are mechanical equipment designed to interrupt or regulate

a fluid flow.
Common Valves types in O&G industry:
 Gate valves
 Globe valves
 Ball valves
 Butterfly valves
 Check valves
 Pressure Safety Valves
Valves
Selection of valves is carried out on the base of:

 Design Data (mechanical, chemical)
 Function Required (regulation, control, isolation, pressure relief)
Gate Valves
Gate Valves
Globe Valves
Ball Valves
Ball Valves
Butterfly Valves
Check Valves
Pressure Safety Valves

Common Rotating Equipment used in Oil & Gas field
Rotating Equipment related STD;
API 610 Centrifugal pumps

API 674 & API 676 Positive displacement pumps
API 618 Reciprocating Compressors
API 617 Centrifugal Compressors
API 616 Gas Turbines
Pumps
Pumps are used to transform mechanical energy supplied by a driver

(electric motor or combustion motor, or turbine) into hydraulic energy
(mainly pressure). The increase in pressure of the propelled fluid
usually serves to:
• Lift the fluid;

• Increase flow speed;
• Overcome back pressure;
• Overcome pressure drops.
Pumps Classification
Pumps classification
Typical range performance of common pump types

Pump Installation Characteristics
Hg = static head or total geodetic height

ha = suction head
hm = discharge head
NPSH = net positive suction head
Pumps Types
Centrifugal pump operating principle

1. The liquid flows in along the axis of the pump via the
distributor and the centrifugal force generated by the vanned
wheel’s rotation drives it toward the outside of the wheel.
2. It acquires high kinetic energy, which is converted into pressure
energy in the manifold, where the cross-section increases.
Typical range performance of common pump types

Centrifugal pump
Direction of flow relative to the axis of the shaft.

Centrifugal pump Types
Centrifugal pump
Impellers Types
Centrifugal pump
Impellers Types
Open impeller
Leakage across the vanes is limited by a close
axial clearance on either side.
The close axial clearances make them
unsuitable for abrasive materials.
Semi-open impellers
A semi-open impeller has a full shroud on one side of
the impeller waterway, usually on the back.
The shroud improves the impeller bending strength &
and the impeller-to-casing clearance
Is widely used to handle fibrous slurries and abrasives
in chemical, paper and severe industrial services
Centrifugal pump
Impellers Types
Closed impeller
• Closed impellers are more
expensive to manufacture, but are
more efficient and handle higher
heads
• Wear rings are replaceable and
relatively cheap compared to the
cost of the impeller and casings
and eliminate the importance of
side clearance between the
impeller and the casing.
Double suction impeller

Pumps Types
Centrifugal pump performance

Pumps Types
Centrifugal pump performance

Net Positive Suction Head
NPSHavailable > NPSHrequired

Pumps Types
Positive displacement pumps
Rotary pumps consist of a moving part which rotates actuated by a

rotational movement around an axis which itself rotates in the pump
barrel and induces movement of the pumped liquid by displacement of
the volume from the suction point to the discharge point.
Pumps Types
Reciprocating pumps
A reciprocating pump is one with forward and backward operating
action.
Types of reciprocating pumps:
1. Piston pump.
2. Plunger pump.
3. Diaphragm pump.
Pump Types
Reciprocating pumps (Piston pumps);

1. Single acting simplex pump
2. Double acting simplex pump
3. Single acting duplex pump.
4. Double acting duplex pump

Pump Types
Reciprocating pumps (Piston pumps);
Pump Types
• Housing
• Discharge Outlet Valve
• Piston Rings
• Shaft
• Cylinder • Piston
• Suction Inlet Valve
Reciprocating Piston pumps

Pump Types
Positive displacement pumps Performance
Compressors: a machine used to added energy to a gas
Why the gas is compressed?
1. To move gases from place to place and to overcome friction in

pipes & fittings.
2. To reduce the volume of vessels and equipment handling large
amount of gas.
3. To liquefying the gas.
4. To increase the pressure of the gas to a level required in some
chemical reactions.
Compressors
1. Continuous-Flow Compressors
 Centrifugal Compressor
 Axial Flow Compressor
2. Positive Displacement compressors

 Reciprocating Compressor
 Rotary Compressor
Compressors Selection Criteria

Centrifugal Compressor Process Design Parameters
“Design data” to select a centrifugal

compressor:
 Rotational speed  For variable speed drives the

“normal speed” is usually 90-97% of
 Number of impellers
the rated speed, allowing for
 Impeller diameters contingencies.
 Compression efficiency  For constant speed drives, design is
 Power absorbed done for the rated point, i.e. on the
100% speed line.
 Driver rating
 Performance characteristics
 Casing arrangement
Centrifugal Compressor Process Design Parameters
The “process design parameters”:

‘Rated point’ defined by API 617:
 Flow rate
 Highest volumetric flow rate
 Gas composition
 Lowest molecular weight
 Inlet pressure and temperature
 Highest head or pressure ratio
 Outlet pressure
 Highest inlet temperature
 Train arrangement (series,
parallel, etc)
To avoid over-design, the usual practice is to select a “normal operating

point” at which the machine is expected to operate for most of its life.
Centrifugal Compressor Performance

Multi Stage Reciprocating Compressor

Reciprocating Compressor
Reciprocating Compressor
Gas Turbine
Gas turbines in which air is compressed, combustion occurs at

constant pressure, and expansion over the turbine occurs back
to the starting pressure.
Brayton cycle: thermodynamic ideal cycle.

Gas Turbine
Gas Turbine Operating Parameters

The performance of a gas turbine engine, meaning its power output and
fuel consumption, is influenced by a variety of factors.
 Environmental factors  Inherent characteristics

 Ambient Pressure  Turbine inlet temperature
 Ambient Temperature  Pressure Ratio
 Humidity  Fuel Heating Value
 Thermal Efficiency
TURBINE INLET TEMPERATURE PRESSURE RATIO
 It is this value that determines  Ratio of the discharged air pressure

the highest effective energy state to suction air pressure.
of the working fluid within the  A measure of the internal energy
turbine. imparted to the air by the
compressor.
Thermal Efficiency vs. Turbine Inlet Effect of Machine Efficiency on Thermal Efficiency
Temperature
THERMAL EFFICIENCY
 Ratio of the work output (W) to the

FUEL HEATING VALUE heat input (Q1) in the same energy
units:
 It is a measure of the available
energy possessed by fuel. W
h
 The ratio of HHV to LHV depends Q1
on the composition of the fuel.
 lf Q2=energy not converted into
 The greater the heating value, the useful work :
smaller the quantity that must be
W  Q1  Q2
burned for a given output.
( Q1  Q2 )
W 
Q1
Reciprocating Engines
 Diesel Engine
Diesel Engine
 Diesel Engine
Diesel Engine
Diesel Engine operating systems;

• Fuel System
• Inlet Air System
• Exhaust System
• Lube Oil System
• Cooling System
• Starting System
• Protection System

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PRODUCTION EQUIPMENT

STATIONERY & ROTARY

2. Rotating Equipment used in Oil & Gas field

Static Equipment related STD;

ASME Section VIII-1 Rules for Construction of Pressure Vessels

Static Equipment related STD;

ISO 16812 or API 660 Shell & Tube Heat Exchanger

Separator are vessels is in which gas, oil and water are

separated from each other. The principle of separation relies on

gravity, gas, oil and water havig different densities

If solid particles are entrained in the fluid they will also be

separated at the bottom of separator.

Separators are classified according to the shape:

Horizontal 2-Phases Separators

Horizontal 3-Phases Separator

Separators are required to provide oil/gas streams that meet

Oil must have less than 1% (by volume) water.

Slug Catcher Vessel

Slug Catcher Finger-Type

A device to remove dirt,

A scrubber is used to protect

Flare Knockout Drum

The purpose of KOD to

Knockout drum design and

KOD MOH or SD is required

In industry, there are many different types of equipment used for

Storage Tanks can be:

 Fixed or Floating Roof

TYPICAL CONICAL ROOF STORAGE TANK

Fixed roof storage tanks pumping out or drain protection

Towers and Columns

Towers are classified according to the type of “internals” in the

Tower Dimensions: Towers typically range in diameter from 3 to 20

Towers and Columns “internals”

Towers may contain trays. If the

Trays are generally divided into

• Bubble Cap Trays

Towers and Columns

Sieve Trays Bubble Cap Trays

Towers and Columns “internals”

Tower may contain

Towers and Columns “internals”

Towers and Columns “internals”

Packing Versus Trays:

A tray column that is facing throughput problems may be

Towers and Columns

Towers and Columns

Heat Transfer Equipment

The various types of heat transfer equipment are generally

As example for heat transfer equipment:

Heat Transfer Equipment

Heat is exchanged between two streams. Exchangers are used to

The basic design data:

 ∆T = temperature difference between the two media

 “U” is a function of many variables;

Heat Transfer Equipment

Main Types & Components of Heat Exchangers

A - Shell and Tube Heat Exchanger

Heat Transfer Equipment

1. Fixed tube sheet