FMSP 2

University of Technology /Oil & Gas Engineering Department
Field Measurements and Surface Production

Asst. Lect. Mohammed A. Ahmed
Field Measurements and Surface Production / lecture (2)
Safety Control System & Facility piping & Pipeline Systems
Safety Control System
The purpose of safety systems is to protect personnel, the environment, and the facility.
The major objective of the safety system is to prevent the release of hydrocarbons from the
process and to minimize the adverse effects of such releases if they occur. This can be
achieved by the following:
 Preventing undesirable events

 Shutting-in the process
 Recovering released fluids
 Preventing ignition
The modes of safety system operation include:
 Automatic monitoring by sensors
 Automatic protective action
 Emergency shutdown
Protection concepts and safety analysis are based on undesirable events, which include:
A. Overpressure caused by
1. Increased input flow due to upstream flow-control
device failure
2. Decreased output flow due to blockage
3. Heating of closed system
B. Leak caused by
1. Corrosion
2. Erosion
3. Mechanical failure due to temperature change,
overpressure and under-pressure, and external impact force
C. Liquid overflow caused by
1. Increased input flow due to upstream flow-control
device failure
2. Decreased output flow due to blockage in the liquid discharge
D. Gas blow-by caused by
1. Increased input flow due to upstream flow-control device failure
2. Decreased output flow due to blockage in the gas discharge
E. Under pressure caused by
1. Outlet flow-control device (e.g., choke) failure
2. Inlet blockage
3. Cooling of closed system
F. Excess temperature caused by
1. Over fueling of burner
2. External fire
3. Spark emission
Safety device symbols



Safety system designs for surface wellhead flowlines
Safety system design for pressure vessel
Safety system design for pipeline pumps
Controlling the Process

Before discussing the process itself, it is necessary to understand how the process is
controlled.
Operation of a Control Valve: Control valves are used throughout the process to control
pressure, level, temperature, or flow. All control valves have a variable opening or orifice.
For a given pressure drop across the valve, the larger the orifice is, the greater the flow
through the valve will be.
 Pressure Control The hydrocarbon fluid produced from a well is made up of many
components ranging from methane, the lightest and most gaseous hydrocarbon, to
some very heavy and complex hydrocarbon compounds. Because of this, whenever
there is a drop in fluid pressure, gas is liberated. Therefore, pressure control is
important.
 Level Control It is also necessary to control the gas/liquid interface or the oil/water
interface in process equipment. This is done with a level controller and liquid dump
valve. The most common forms of level controllers are floats and displacers, although
electronic sensing devices can also be used. If the level begins to rise, the controller
signals the liquid dump valve to open and allow liquid to leave the vessel. If the level in
the vessel begins to fall, the controller signals the liquid dump valve to close and
decrease the flow of liquid from the vessel. In this manner the liquid dump valve is
constantly adjusting its opening to assure that the rate of liquid flowing into the vessel is
matched by the rate out of the vessel.
 Temperature Control The way in which the process temperature is controlled varies. In a
heater a temperature controller measures the process temperature and signals a fuel
valve to let either more or less fuel to the burner. In a heat exchanger the temperature
controller could signal a valve to allow more or less of the heating or cooling media to
bypass the exchanger.
 Flow Control It is very rare that flow must be controlled in an oil field process.
Normally, the control of pressure, level, and temperature is sufficient. Occasionally, it is
necessary to assure that flow is split in some controlled manner between two process
components in parallel, or perhaps to maintain a certain critical flow through a
component. This can become a complicated control problem and must be handled on
an individual basis.
Facility piping & Pipeline Systems
Once the type and character of the fluid that needs to be handled are known, then the
designer must determine what type of piping system is needed. The solution will emerge as
the design progresses. Piping and pipeline systems include processing equipment, such as
separators, heaters, and tanks, that are interconnected by piping consisting of pipe, valves,
fittings, pumps/compressors, instrumentation and other specialty elements, and support
systems such as racks and/or hangers. The facility piping and pipeline systems associated with
producing wells include, but are not limited to, the well flowline, trunk line, facility (on-plot)
interconnecting equipment piping within the production facility, gathering or sales
pipelines, and transmission pipelines. A brief description of the aforementioned facility
piping and pipeline systems follows:
Flowline: A well flowline identifies a two-phase line from a wellhead to a production

manifold or separator. The line between a production manifold and the first separator is
sometimes referred to as a flowline but is generally referred to as a production header.
Flowlines range in size from 2 in. (50.8 mm) to 20 in. (508 mm).
Trunkline:
A trunkline is a larger line that connects two or more well flowlines that carry the
combined well streams to the production manifold. Trunklines range from 10 in.(25.4 mm)
to 42 in. (106.8 mm).
Manifold:
A manifold is a combination of pipes, fittings, and valves used to combine production from
several sources and direct the combined flow into appropriate production equipment. A
manifold may also originate from a single inlet stream and divide the stream into multiple
outlet streams. Manifolds are generally located where many flowlines come together, such
as gathering stations, tank batteries, metering sites, separation stations, and offshore
platforms. Manifolds also are used in gas lift injection systems, gas/water injection
systems, pump/compressor stations, and gas plants and installations where fluids are
distributed to multiple units. A production manifold accepts the flow streams from well
flowlines and directs the combined flow to either test or production separators and tanks.
Production header (and/or test header):
In a gathering system, the production header connects flowlines from several wells into a
single gathering line that is routed to a test separator. The header has production and
testing valves to control the flow of each well, opening and closing selected valves to route
flow from specific wells directly to the production facility or separately to testing vessels.
Production headers measure well production oil, water, and gas rates by directing
individual wells through a test header to the test separator with its special metering
equipment.
Gathering system:
A gathering system consists of a line downstream of field manifolds or wellhead separators
conveying fluid from multiple wells and leading to the production facility. The gathering
system may handle condensed hydrocarbon liquids, water, and corrosive.
Separation station:
A separation station separates the well stream into gas, oil, and/or water. Increasing the
number of stages of separation increases the liquid recovery.
Compressor station:
A compression station consists of a gas compressor with its associated piping, coolers, and
scrubbers. Low-pressure gas is normally boosted to sales or injection pressure by the
compressor.
Pumping station:
A pumping station consists of a pump and associated piping with the purpose of boosting
liquid pressure to provide the energy for transmission and distribution of a liquid.
Production facility:
A production facility is a facility for the field handling, conditioning, treating, processing,
and/or measuring of gas, oil, and/or water.
Facility (on-plot) interconnecting piping:
Facility piping consists of piping within a well-defined boundary of processing plants,
piping compression stations, or pumping stations. The piping is used for conducting a
variety of fluids within those boundaries as required.
Transmission line:
A transmission line consists of a cross-country piping system for transporting gas or liquids,
usually over long distances. They normally transfer custody from production facility to
pipeline system inlet—may transfer again at final destination (outlet to a customer). The
inlet is normally the custody transfer point or the production facility boundary with the
outlet at its final destination, for example, processing plants and refineries. Transmission
lines are usually long and have large diameters. Transmission lines also transport
hydrocarbon fluids from producing fields to processing plants or refineries and from plants
and refineries to marketing centers.
Injection line
An injection line is similar to a gathering line but flows in the opposite direction (toward
the wells). Injection lines transport high-pressure gas or water to wellheads for injection
into the producing formation. Fluids are injected for reservoir enhancement, production
enhancement, gas conservation, gas lift, produced water disposal, water flood, and steam
flood.
Facility design considerations
After identifying the fluid characteristics and general system components, the facility is
designed, which involves establishing the facility piping layout, developing engineering
drawings, and specifying the facility piping and pipeline systems. The facility layout requires
the positioning of various pieces of process equipment within the designated space, the
placement of instrumentation, control, and safety devices, and the location and design of
pipe supports.
The next step is to develop facility design drawing and specifications. The drawings required
include the block diagram, process flow diagram (PFD), piping and instrumentation diagrams
(P&IDs), equipment layout drawings and plot plans, piping arrangement and isometric
drawings, and instrumentation and control drawings.
Piping design and layout process begin with sizing the piping system for anticipated fluid
flows that conform to the applicable codes, standards, and recommended practices and
company design criteria, specifications, and policies.
Piping line size and wall thicknesses must be determined. Line sizing requires evaluating
pressure drop and fluid velocity to avoid excessive break horsepower (BHP) to boost
pressure to transport the fluid and accommodating available piping inlet and discharge
pressures and allowable pressure drop requirements. Fluid velocities must prevent erosive
velocities, destructive water hammer, and liquid and/or solids from settling and collecting
in the bottom of the pipe.
The pipe wall thickness must withstand the maximum internal burst and external collapse
pressures. The internal burst pressure includes initial, transient, and flowline
considerations. External collapse resistance includes onshore overburden loads and
offshore considerations. The wall thickness must meet applicable design standards such as
ASME B31.3, B31.4,and B31.8.
Piping system components
 Fittings:
Fittings make directional changes in a piping system and connect pipes, sometimes of
different sizes. The following are commonly found pipe fittings:
• Elbows—usually either 90 or 45.
• Caps.
• Saddles—used to form a connection between two pipes when a fitting is not already
present.
• Reducers/Expanders—used to either reduce or increase the pipe diameter. An expansion
may be required if the fluid is a flashing liquid, i.e., one that is forming vapor as its pressure
drops.
The selection of a pipe fitting depends upon factors such as the following:
1- Pipe diameter, 2- Pipe material, 3- Pressure and temperature ratings
4- Service requirements
Methods of connecting pipe The most commonly used connections in the oil industry
include the following:
1-Threaded connections , 2- Socket-welded connections , 3- Butt-welded connections
4-Bell and spigot , 5- Groove and clamp
Each piping system must include fittings. Fittings are used to make:
1- changes in direction.
2- changes in pipe size.
3- side connections.
4- closures.
 Temporary quick connections and couplings
Quick connections
There are two connectors specifically designed for temporary use. The first is the “lever”
type with double lever clamping. The second is the “screw” type with a captive nut, that is,
“hose connector”. These connectors are typically used to temporarily connect process
vessels. Some temporary connectors include a built-in valve.
Bolted quick couplings
Depending on joint and gasket and the service conditions, these connections can be used in
either temporary or permanent installations. These couplings are particularly useful for
constructing short-run process installations, making repairs and facility modifications.
Couplings for grooved components and pipe
These couplings are used with steel, cast iron, reinforced fiberglass plastic, and plastic pipe.
The ends are either grooved, welded, or cemented to the pipe ends. Fittings, such as the
Victaulic and Gruvagrip couplings, are available for low-pressure (less than 100 psi) water
service. Temporary lines aboveground can be quickly assembled or disassembled. These
connectors are not fire-safe, and if used in combustible material service, care should be
exercised to keep them out of areas where danger of fire exists.
These 3 components make up a grooved coupling.
 the gasket
 the housings
 the nuts and bolts
Compression sleeve couplings
These couplings are typically used for air, water, oil, and gas. These couplings allow quick
fitting and removal, joint may take up deflection and expansion, and end preparation is not
required.
 Expansion joints and flexible piping
Expansion joints
As the temperature of a fluid increases, the pipe expands. This expansion can be taken up by
rerouting or respacing the pipe, using expansion loops, using cold springs, and using
bellows. The following figure show a simple bellows-type expansion joint that can be used
to accommodate movement and absorb vibration in piping systems.
Piping expansion loops
A “U” is configured in the middle of a length of pipe, and its center is restrained with a
bracket. Each side of the pipe run coming into the “U” is hung with a hanger or guide,
which allows the pipe to move back and forth.
Flexible piping
Rigid pipes with “swivel” joints or “ball” joints are used to fill and empty tankers and
railcars. When there is a need for a temporary connection or where vibration or movement
occurs, flexible hoses are commonly used. These hoses are available in chemical-resistant
and/or armored in regular or jacketed forms.
 Valves
The satisfactory performance of any piping system depends to a large extent upon the proper
selection and location of the valves that control and regulate the flow of fluids to the
connected equipment. Valves are made in a variety of designs, which are intended to perform
a number of specific functions. The wide range of valve types available requires that the
designer has knowledge of the characteristics of each valve type in order to select the proper
valve for a specific application.
Uses of valves
The following table provides guidance for classifying valves according to their function.
Valve Functions
Valve functions are generally broken into two major service categories: on/off service and
throttling (regulating flow) service. Valves commonly used in on/off service include gate
valves, plug valves, and ball valves. Valves used in throttling service include globe valves,
butterfly valves, diaphragm valves, and pinch valves. Some valves can be used in both on/off
and regulating services. In addition, there are specialty valves that are designed for specific
functions such as minimizing backflow (check valve), switching (three-way diverter valve),
and relief.
Valve Types
The five general valve types are the following:
1- Gate valve
2- Plug valve
3- Ball valve
4- Globe valve
5- Butterfly valve
Gate Valves
Gate valves are characterized by a “gate” that closes in a plane perpendicular to the flow of
fluid. They are used primarily for on/off, non-throttling service. Shearing of high-velocity flow
will cause a partially open disk to vibrate and chatter, which will damage the seating surfaces
and prevent a tight seal. They are suitable for most fluids including steam, water, oil, air, and
gas.
Gate valves are more commonly used in refineries and petrochemical plants where pressure
remains relatively low, but temperature may be very high. Gate valves are used less in
upstream oil and gas production facilities due to high operating pressures, long
opening/closing times, and severe environmental conditions when operating in marine
atmospheres.
Plug Valves
The plug valve is a rotary valve in which a plug-shaped seating element is rotated through
90° (1/4 turn) to engage or disengage a port in the plug with the ports in the valve body. The
shape of the plug can be either cylindrical or tapered but is generally tapered to allow
adjustment of clearance between the plug and the seat on some models.
Plug valves are used in on/off service and can be used in moderate throttling applications
but only in small sizes. They are also used in locations where a valve requires frequent
operation, such as reciprocating compressor lead lines and well manifolds Plug valves are
also used for light hydrocarbons, viscous hydrocarbons, gases, and corrosive products.
Cylindrical and taper plug valves are exclusively used for stop valves.
The pressure drop for plug valves is generally low and disappears when the valve is fully open.
They are usually less expensive than ball valves and are manufactured in lubricated and non-
lubricated designs. The disadvantages of plug valves are its lack of visual indication on opening
and closing and it requires lubricated plugs for perfect sealing, except for spherical rotating
plugs.
Ball Valves
Ball valves are used for both on/off and throttling service. Ball valves are similar to plug
valves but use a ball-shaped seating element. They are quick opening and require only a
quarter-turn to open or close. They require manual or power operators in large sizes and at
high operating pressures to overcome the operating torque. They are equipped with soft
seats that conform readily to the surface of the ball and have a metal-to-meal secondary seal.
If the valve is left partially open for an extended period under a high pressure drop across the
ball, the soft seat may ecome damaged and may lock the ball in position. Ball valves are best
suited for stopping and starting flow but may be used for moderate throttling. Compared
with other valves with similar ratings, ball valves are relatively small and light.
Globe Valves
Globe valves are valves in which the seating element (disk) is moved on and off
perpendicular to the plane of the seat. The seat opening varies in direct proportion to the
travel of the disk. Globe valves are well suited for applications requiring flow regulation. The
seating load can be effectively controlled by the stem, thus giving the globe valve good
sealing characteristics. Globe valves are generally used for:
1- throttling or control applications and where positive shutoff is required.
2- On/Off duty, provided the high resistance from the change in flow direction is not
objectionable.
3- applications that require the valve to be operated frequently due to the short travel of the
disk between the open and closed positions.
4- applications requiring frequent valve maintenance since the disk and seat can be replaced
fairly rapidly and with minimum difficulty.
Butterfly Valves
The butterfly valve is a rotary valve in which a disk-shaped seating element is rotated 90° to
open or close the flow passage. They are used in throttling service, particularly where large-
size valves with automatic actuators are required. They offer a size and weight advantage over
plug and ball valves.

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University of Technology /Oil & Gas Engineering Department

Field Measurements and Surface Production

 Preventing undesirable events

Safety device symbols

Safety device symbols

Safety device symbols

Controlling the Process

Flowline: A well flowline identifies a two-phase line from a wellhead to a production

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