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Contents
Page
Training Targets
21
34
Visual Cues
Training Targets
When you have completed Workbook 2 of this unit you will be able to :
Explain the basic principals of process control
Describe the equipment used in separator level control
Describe a simple separator safety system
Explain the routine operational checks on a separator
Describe in simple terms a separator start up procedure
Introduction
Section
4 - Control of Separators
In the last part of Section 3 of this programme you
looked at the external features of separators. Two
of the items you saw were pressure gauges and
level sight glasses. These pieces of equipment are
used to enable the operator to check pressure and
liquid levels inside the vessels.
Pressure and liquid level are features of the
process which can vary. Each can increase or
decrease with variations in separator throughput.
However, in order to obtain optimum separation,
the pressure and liquid level must be maintained
at a constant value.
So, apart from the equipment used to check the
liquid level and pressure, separators have two
major controls.
*
*
*
*
Liquid Level
Pressure
Temperature
Fluid Flow
Correcting
Unit
*
*
*
*
The
The
The
The
Process Variable
Measuring Unit
Controller
Correcting Unit
Process Variable
Measuring
Unit
desired
value
measured
value
correcting
signal
Controller
Figure 26 : The Control Loop
The Controller
Figure 27
Figure 28
But Joe is keeping his eye on the level indicator
and sees the change in level. He compares the
new measured value with the desired value and
notes that the level has increased. In order to
reduce the level again the valve in the outlet line
must be opened more. Joe does this manually and
increases the outlet flow until the measured value
of the liquid level once again matches the desired
value.
This is shown in Figure 29.
Figure 29
Joe, the controller, has maintained a constant level
in the tank by :
Comparing the measured value of the level in
the tank with the desired value.
Noting the difference between measured and
desired values.
Sending an appropriate signal to the correcting
element in the loop. (In this case an instruction
to his hands to open the valve).
Test Yourself 7
Fill in the missing words from the following paragraph.
That part of a continuous process which an operator wishes to control within certain limits is
called the ................ ................, and its target value is called the ................ value.
A measuring unit obtains a measured value from the process and feeds it to a
.................................... whose job it is to compare the two values. If a deviation exists
between the two values, the ........................ sends a correcting signal to the final element
in the loop - a correcting unit which is usually a ................ ................ .
Displacer Mechanism
This piece of equipment measures liquid level by a method
which is based on the principle of Archimedes. The
principle states that, if a body is immersed in a liquid, it
will apparently lose weight equal to the amount of liquid it
displaces.
So, a cylindrical weight partially submerged in a liquid will
have a certain apparent weight. (Less than its actual weight
because of the buoyancy effect of the liquid.)
If the liquid level rises or falls, then more or less of
the cylinder will be submerged. Its apparent weight will
therefore vary. The apparent weight can be measured to
give an indication of the level of the liquid.
Figure 31 on the next page, shows how the apparent
weight varies with the liquid level.
Figure 31a
Figure 31b
The displacer is suspended from one end of a float rod, marked (A) on the figure. The other end of the float rod
is supported on a knife edged bearing (B).
Level Controller
We have seen already that the job of a controller is to
compare 2 signals, the measured value signal and the
desired value signal. If a deviation exists between the
two, the controller then has to send a correcting signal
to a control valve.
CONTROLLER
measured
value
Desired
value
DIFFERENTIAL
MECHANISM
to recorder
20 SUPPLY AIR
FLAPPER/NOZZLE
UNIT
FEED BACK
UNIT
PILOT
VALVE
TO CORRECTING
ELEMENT
Figure 33
10
11
Supposing the measuring element output gave an increased pressure signal. The M.V. bellows
would expand against the D.V. bellows. This movement would cause the free end of the force bar to
move. The movement could then be fed to the flapper/nozzle assembly as a deviation.
Force balance is the mechanism most commonly used in Pneumatic Controllers.
I have mentioned several times the flapper/nozzle unit. Lets look now at this piece of equipment.
Flapper/Nozzle Assembly
The flapper/nozzle unit consists of three items, the flapper, the nozzle and the restrictor.
Figure 36 is a simplified drawing of the unit.
12
Figure 37
You can see from the graph, that the section of the
curve between points 1 and 2 is almost a straight
line. The nozzle back pressure varies from 0.2 bar at
point 1, to 1.0 bar at point 2. Between the 2 points,
the back pressure obtained will be proportional to the
distance that the flapper is away from the nozzle.
Pneumatic instruments are usually designed to
operate over a standard pressure range. This range
must lie on the straight line portion of the graph
which you saw in Figure 37.
13
nozzle
Feedback Unit
Feedback simply means feeding back the output
signal of the controller to the input of the same
unit. This allows relatively large movements of the
differential unit to cause very small movements of
the flapper. We will see how this is done shortly.
Feedback is also used to introduce more complex
control actions to the loop. These control actions
are beyond the scope of this programme. However,
you will come across them if you follow other
programmes covering Instrumentation and Control,
in the Petroleum Processing Technology Series.
We can see now how a simple feedback unit
works.
The mechanism is shown in Figure 38.
14
control signal
When this state is reached, the flapper will have moved very slightly nearer to the
nozzle. Just enough to increase the output to the correcting unit.
Pilot Relay
The final unit in our pneumatic controller is the pilot relay. This is a device which is
connected to the nozzle back pressure line.
diaphragm
actuator spring
The controller output has to operate an actuator on the correcting element which is
usually a control valve. This actuator, as you will see, requires a relatively large volume
of air. Because of the restriction in the supply line to the nozzle, only a limited volume of
air can be supplied to the actuator. The pilot relay can boost this air supply, for proper
operation of the valve.
valve stem
I think that this explanation of what the pilot relay does is sufficient at this stage.
valve plug
valve body
You will remember from our simple example earlier, that Joe had to open and close the
valve in the outlet line from the tank. He was operating a level control valve manually. In
an automatic control system, however, the control valve is operated by the signal from
the controller. In the case of a pneumatic controller the signal is air pressure, which
varies between 0.2 and 1 bar.
valve seat
There are many different types-of control valve in use. Figure 39 is a simplified drawing
of a typical valve which could be used in a level control application.
15
diaphragm
actuator spring
valve stem
valve body
valve plug
valve seat
16
Test Yourself 8
The following items from a level control loop are part of the measuring unit, the level controller
or the level control valve. Indicate by a tick in the box provided, to which part of the system each
belongs.
Measuring Unit
Level Controller
pilot relay
differential mechanism
actuator spring
valve plug
diaphragm
feedback unit
float rod
valve stem
the pressure
17
Activity
Think about the way in which a pressure gauge works. How could the measured pressure
be transmitted to the flapper of a controller ?
18
Test Yourself 9
In the pressure control loop I have just
described, is the control valve in the fail
open or fail closed mode?
19
Summary of Section 4
Before going on to summarise Section 4, I should emphasise once again that the subject of process measurement and control is very complex. We have only
scraped the surface of the subject in this section but you should now know how a simple control system works.
We started the section by considering the four
most common process variables :
Liquid Level
Pressure
Temperature
and
Fluid Flow
The
The
The
The
process variable
measuring element
controller
correcting unit
The
The
The
The
differential mechanism
flapper/nozzle assembly
feedback unit
pilot relay
20
Activity
Jot down in the space below your ideas of what might result from the following separator
malfunctions.
21
LCV 01
Figure 41
22
Figure 42
You will notice that the switches are designated LSHH
and LSLL These stand for LEVEL SWITCH HIGH-
23
You can see that the bridle is connected via valves to the
top and bottom of the separator.
Take a look at Figure 43 and identify the bridle which
incorporates the level controller, the level alarms, the level
switches and the sight glasses. You will remember from
Section 3 that the sight glasses give a visual indication of
the actual level inside the separator. Note that there are
two sight glasses which overlap each other. The normal
operating level would lie within the overlap, enabling the
level to be checked through both sight glasses.
We have just looked at the oil side of the separator. In a 3
phase vessel, the water level must also be controlled.
Of course, in this section of the vessel, the water is
covered by a layer of oil. So there is an interface between
the water and oil. It is this interface which is measured by
the controller.
Apart from that, the control and safety of the water end of
the separator works in a similar manner to the oil end.
24
Test Yourself 10
Make a simple sketch of the water outlet end of a separator.
Your sketch should show an instrument bridle with the
relevant instrumentation.
You saw in the introduction to this section that an increase or decrease in pressure in
the separator is also potentially hazardous. Let's look now at this problem.
I am sure that by now you will have realised that there are several degrees of pressure
protection on a separator.
Look at Figure 44. This shows a simple pressure control loop.
Figure 44
25
PSVs are special valves fitted to the top, or gas sectionof the separator. At a pre-determined pressure, which is
higher than the set pressure of PSHH 01, the valves will
open and gas from the separator is vented. Usually the
vented gas goes to a flare.
Let us take a more detailed look at pressure safety
valves.
Figure 45
If either of these switches are activated, the separator is
made safe by isolating it via ESD valves.
Separators are designed to operate at a certain pressure.
26
PSV A
Figure 46
27
Pressure Safety Valves can vary in design and construction but the most
common type is one which relies on a spring to hold a valve closed.
Figure 47 is an illustration of this type of valve.
Rupture Discs
A rupture disc is a disc of malleable metal which is designed
to burst at a pre-set pressure. Figure 48 is an illustration of
a rupture disc and how it is installed.
The rupture disc is fitted to protect the seats of the PSV from
corrosion and is normally set to fail at a pressure just below
the set point of the PSV. To assist the disc to spread out as
it fails, a disc cutter is normally positioned just above the
rupture disc.
Figure 47
28
Activity
rupture disc
disc cutter
rupture disc
29
LCV-02 ESDV3
ESDV2 LCV-01
Figure 49
30
ESDV 2
ESDV 3
ESDV 4
Activity
Look at Figure 49 and locate the four different controllers. Write down what each controller
does and what it uses to achieve the control required.
YES. There are FOUR controllers, its not a printing error!
31
Before we finish this section, let us look, once again, at the overall sequence of events which could occur
if control of one of the process variables is lost.
Use Figure 50 to follow the sequence.
32
Summary of Section 5
In this section on separator safety systems we have covered a very complex subject in a rather simplistic
way. Once again I must emphasise that the situations I described are not taken from any particular
process or separation system. Each process is unique. If you are involved with process operations,
you should make sure that you are completely familiar with the equipment on your own particular
installation.
At the start of this section we considered the consequences of losing either level or pressure control in a
separator. You saw that loss of control could result in a potentially hazardous situation.
generate alarms
We looked first at the problem of level control. You saw that an increasing or decreasing level can :
Moving to pressure control, you saw that alarms and shutdowns are also initiated by the pressure going
too high or too low.
You also saw that additional pressure safety features such as Pressure Safety Valves and Rupture Discs
may be fitted to a separator.
We finished the section by having a brief look at ESD Systems and valves, and you saw an example of
a simple sequence of events which could occur on loss of level control.
Now that you have completed Section 5, you can move on to the final section in this unit, where we will
look at separator operations.
33
34
Emulsions
A common operating problem is that caused by the
water and oil forming an emulsion.
This is a mixture of two immiscible liquids where
one of the liquids is dispersed throughout the other
in the form of very small droplets. In the oilfield, the
dispersed liquid is usually the water.
An emulsion may be classed as tight or loose.
Milk is a tight emulsion. It is a mixture of butter fats
and water and it cannot be easily broken.
Salad dressing is a loose emulsion. It is a mixture
of oil and vinegar. When you shake the bottle an
emulsion forms and the small globules of oil and
vinegar can be seen with the naked eye. If you let
the bottle stand for a few minutes the emulsion will
break down and the oil will begin to float on the top
of the vinegar.
If emulsions are found in a separation process they
may be tight or loose. The type will depend, for
example, on the nature of the oil being produced
and the amount of water present.
One of the functions of a separator is, of course,
to remove the water from the oil. The presence
of an emulsion could obviously make this more
difficult. In fact, in extreme cases, water removal
from an emulsion may have to be done in a special
treatment plant.
Foaming
Another problem which may be found in separators
is that of foaming.
This is caused when the oil fails to release the gas
quickly enough as it passes through the vessel, and
a layer of oily bubbles forms on top of the liquid
surface.
The level control displacer on the oil side of the weir
is designed to operate in a liquid. It cannot float in
foam.
When the float sinks in the foam it indicates a false,
low level to the level controller and the oil outlet
valve will close. This can result in the carry-over of
liquids with the gas stream and a possible shutdown
of the gas facilities downstream.
To stop this happening, anti-foam agents are often
injected into the inlet stream to prevent foaming.
35
Slugging
A third, but less common, problem in separators is
that of slugging.
Slugging occurs when, for some reason or another,
there is an intermittent, rather than a constant, flow
of well fluids into the separator. In some instances
the flow may cease altogether for a few seconds
and then a slug will arrive.
This intermittent flow can cause rapid fluctuations
in separator levels and pressures. The controllers
react to these changes by rapidly opening and
closing their respective valves in an attempt to bring
the situation under control. In severe cases the
control system may become unstable resulting in a
shutdown.
These are the three most common problems
associated with the operation of separators.
We will now have a look at a simple start-up
procedure and a simple shut-down procedure for
our separator train.
Start-up Procedure
Before a start-up procedure is initiated, a number
of checks have to be made to ensure that the
separation train is ready.
We will assume that the separators are empty, but
are in a condition to receive hydrocarbons.
We will first check that:
all the valves, in the inlet manifold upstream
and the pipework downstream, are in the
correct open/closed position for start-up.
well fluids will be available when we require
them.
36
37
When the oil level reaches the set point of LSLL01, we can re-activate it. ESDV 1 is now fully
under the control of the ESD system. ESDV 2
will also be opened and LC-01 will take over
control of the oil level.
Shut-down Procedure
38
Blow-down Procedure
One procedure we have not mentioned is blowdown.
As we have already explained, ESDV 5, which is
shown in Figure 52, is a blow-down valve. It is fitted
so that we may depressurise the separator in a rapid,
but controlled, manner.
The control logic of a blow-down valve on a separator
is often designed so that it will not open if any of the
other ESDVs on the vessel are open.
The blow-down valves may be activated :
39
Test Yourself 11
The following statements refer to :
a
b
c
operational checks,
separator problems,
or
separator start - up procedures
40
Summary of Section 6
In Section 6, the final section in this unit on Oil and Gas Separation Systems, we have had a brief look at the operation of separators.
We started by considering the routine operational checks that an operator may have to make on a regular basis during the course of his shift or tour of duty. You saw that the
operational variables of level and pressure are constantly monitored. You also noted that the operator keeps a close look out for possible leakages which could give rise to
potentially hazardous situations.
Although separator operations are usually trouble free, there are some problems which
may be encountered. You saw that potential problems included :
emulsions
foaming
slugging
Finally we looked at three basic procedures, including start-up, shut-down and blowdown. We went through a step-by-step procedure to be followed when starting a
separation system. The procedure was a hypothetical one, based on the separators
described in previous sections of the unit. We then looked at shut-down and blowdown in more general terms.
Before you leave this unit and move on to another unit in the Petroleum Processing
Technology Series, I must make some final comments regarding the operation of
process plant:
The Unit that you have just completed relates to separation
in general. It is not meant to describe any particular plant or
process
41
Check Yourself 7
Fill in the missing words from the following paragraph.
That part of a continuous process which an operator wishes to control within certain limits is
called the PROCESS VARIABLE, and its target value is called the DESIRED value. A
measuring unit obtains a measured value from the process and feeds it to a CONTROLLER
whose job it is to compare the two values. If a deviation exists between the two values, the
CONTROLLER sends a correcting signal to the final element in the loop a correcting unit
which is usually a CONTROL VALVE.
42
Check Yourself 8
Check Yourself 9
The following items from a level control loop are part of the measuring unit, the level controller
or the level control valve. Indicate by a tick in the box provided, to which part of the system each
belongs.
Measuring Unit
Level Controller
differential mechanism
pilot relay
torque tube rod
actuator spring
valve plug
flapper nozzle assembly
diaphragm
feedback unit
float rod
valve stem
43
Check Yourself 10
Check Yourself 11
Indicate, to which of the three areas, a, b or c, each
statement belongs.
Figure 53
Figure 53 shows the water end of a 3 phase
separator. An instrument bridle is connected to
the separator with the top connection in the oil
and the bottom connection in the water. The
instrumentation on the bridle is identical to the
instrumentation on the bridle at the oil end of
the separator.
(c)
(c)
(a)
(b)
(c)
(a)
(a)
(b)
(c)
(c)
44