Contaminant Control: a New Approach David Burns davbur@sps2test Scientific Process Solutions

Contaminant Control:Contaminant Control: a New Approacha New Approach

David [email protected]

Scientific Process Solutionsa division of Perry Equipment Corporation

Scientific Process Scientific Process Solutions (SPS) is a Solutions (SPS) is a division of Perry division of Perry Equipment Corporation Equipment Corporation (PECO) that offers field (PECO) that offers field contaminant contaminant measurement and measurement and consulting services.consulting services.

SPS serves the natural gas SPS serves the natural gas transmission and transmission and processing, chemical processing, chemical processing, refining, and processing, refining, and power generation power generation industries. industries.

IntroductionIntroduction

Contaminants and Contaminants and Contaminant MixturesContaminant Mixtures

Contaminant TypesContaminant Types–SolidsSolids–LiquidsLiquids–Semi-solidsSemi-solids–FoamsFoams–Emulsions Emulsions

Common solid Common solid contaminantscontaminants

– Formation solids (reservoir and frac Formation solids (reservoir and frac sand)sand)

– Corrosion solids (iron sulfide, iron Corrosion solids (iron sulfide, iron oxide)oxide)

– Precipitating solids (elemental sulfur, Precipitating solids (elemental sulfur, salt compounds)salt compounds)

SolidsSolids

Formation Formation SolidsSolids

Corrosion Corrosion SolidsSolids(Iron Sulfide)(Iron Sulfide)

Sulfur CompoundsSulfur CompoundsPrecipitating Precipitating SolidsSolids

Siloxane CompoundsSiloxane CompoundsPrecipitating Precipitating SolidsSolids

lube oillube oil salt water or brinesalt water or brine water condensatewater condensate hydrocarbon condensatehydrocarbon condensate crude oilcrude oil glycol (TEG)glycol (TEG) gas processing aminesgas processing amines corrosion inhibitorscorrosion inhibitors biocidesbiocides foaming agentsfoaming agents defoaming agentsdefoaming agents mecurymecury

LiquidsLiquids

Semi-solids are usually mixtures of solid and liquid Semi-solids are usually mixtures of solid and liquid contaminantscontaminants

Semi-solidsSemi-solids

Foams are mixtures of gases and liquidsFoams are mixtures of gases and liquids

FoamsFoams

Emulsions are mixtures of different liquids and gas Emulsions are mixtures of different liquids and gas

EmulsionsEmulsions

Contaminants and Contaminants and Contaminant MixturesContaminant Mixtures

Each of these different types of contaminants Each of these different types of contaminants and contaminant mixtures can cause serious and contaminant mixtures can cause serious process problems if the filtration separation process problems if the filtration separation system is not properly designed to handle them. system is not properly designed to handle them. Hard to remove contaminant mixtures are Hard to remove contaminant mixtures are more common than ever due to increased use more common than ever due to increased use of well head and pipeline injection chemicals.of well head and pipeline injection chemicals.Greater contaminant removal performance is Greater contaminant removal performance is required today, due to the increased use of required today, due to the increased use of industry technology like formulated processing industry technology like formulated processing solvents, membrane separators, gas fired solvents, membrane separators, gas fired turbines, LoNox nozzles and burner tips. turbines, LoNox nozzles and burner tips.

Filtration technology has greatly advanced Filtration technology has greatly advanced over the last few years to meet industry’s over the last few years to meet industry’s need for improved performance. need for improved performance.

This advancement in new filtration This advancement in new filtration technologies makes the equipment selection technologies makes the equipment selection process even more difficult.process even more difficult.

Filtration & Separation DevicesFiltration & Separation Devices

Filtration & Separation DevicesFiltration & Separation DevicesGas FiltersGas Filters

Technology Typical Application PerformanceCharacteristics

Dry Gas Filters Solids removal. Uses replaceable filter elements andhas a limited dirt holding capacity.

Knock Out Drums Removal of bulk pipeline liquids. Large liquid handling capacity and lowremoval efficiency.

Vane Separators Removal of continuous pipelineliquids. Used usually upstream ofother more efficient filtrationequipment.

Low cost with moderate removalefficiency.

Wire Mesh Separators Removal of continuous pipelineliquids. Usually used on the suctionand discharge of compressors.

Low cost and low removal efficiency.

Centrifugal Separators Removal of low surface tensionpipeline liquids and semi-solids.

Low cost, high pressure drop andimproved removal efficiency.

Cyclones Removal of bulk pipe solids. Low cost, no replacement parts andimproved removal efficiency.

Scrubbers Removal of small liquid slugs. Low cost and moderate removalefficiency

Slug Catchers Removal of large liquid slugs. Large vessels or piping systems withvery low removal efficiency.

Filter Separators Removal of pipeline liquids and solids. Uses replacement elements and hasa good removal efficiency. Lowelement replacement cost.

Coalescers Removal of low surface tension liquidsand aerosols.

Excellent removal efficiency. Lowcontaminant handling ability. Highelement replacement cost.

Gemini Purasep Coalescer Removal of low surface tension

liquids, solids, and aerosols.Excellent removal efficiency.Moderate contaminant handlingability. Moderate element replacementcost.

Filtration & Separation DevicesFiltration & Separation DevicesLiquid FiltersLiquid Filters

Technology Typical Application PerformanceCharacteristics

Cartridge Filters Solid and semi-solid removal. Uses replaceable filter elements andhas a limited dirt holding capacity.Removal efficiency depends onelement technology used. Usuallyused where excellent removalefficiency is needed.

Hydrocyclones Removal of bulk pipeline solids. Large solids handling capacity withmoderate removal efficiency.

Basket Strainers Removal of bulk pipeline solids. Usedusually upstream of other moreefficient filtration equipment.

Low cost with moderate to lowremoval efficiency.

Bag Filters Removal of pipeline solids. Low cost. Removal efficiencydepends on contaminant and bagtechnology used. Low bagreplacement cost. Short life whensemi-solids are present.

Liquid Phase Separators orCoalescers

Separation of two immisible liquids.Removal of free moisture from fuels. .

Excellent separation efficiency. Highelement cost. Low solids handlingability.

A system’s contaminant content and properties A system’s contaminant content and properties dictate the separation technology used. dictate the separation technology used.

It is important to provide detailed scientific data on It is important to provide detailed scientific data on a system’s contaminant species on RFQ process a system’s contaminant species on RFQ process data sheets.data sheets.

Detailed scientific data on a system’s contaminant Detailed scientific data on a system’s contaminant species will help insure that filtration separation species will help insure that filtration separation technologies are selected that will provide the technologies are selected that will provide the required removal efficiency at an optimum required removal efficiency at an optimum operational cost. operational cost.

Optimally designed filtration and separation Optimally designed filtration and separation equipment will save money. equipment will save money.

The Contaminant Dictates the The Contaminant Dictates the MethodMethod

Field ExperiencesField ExperiencesExample 1Example 1

This processing facility had 4 coalescers experience a This processing facility had 4 coalescers experience a decrease in removal performance. decrease in removal performance.

The additional vane mist extractor had been selected The additional vane mist extractor had been selected for use on the coalescers to handle high liquid loads.for use on the coalescers to handle high liquid loads.

However, over 4 years time the extreme solids loading However, over 4 years time the extreme solids loading eventually plugged off the drainage ports of the vane eventually plugged off the drainage ports of the vane mist extractors, sending more liquid to the coalescer mist extractors, sending more liquid to the coalescer elements than they could handle. elements than they could handle.

Had up front contaminant testing been done on this Had up front contaminant testing been done on this system, the large solids load would have lead filtration system, the large solids load would have lead filtration designers to use a different technology to protect the designers to use a different technology to protect the coalescer elements for the system’s high liquid and coalescer elements for the system’s high liquid and solids contaminant content. solids contaminant content.


The SolutionThe Solution– Solvent and steam cleaning failed. Solvent and steam cleaning failed. – Coalescers had to be cut open to be cleaned. Coalescers had to be cut open to be cleaned. – Coalescers were put back into service.Coalescers were put back into service.– Bulk solids loading removal technologies are being Bulk solids loading removal technologies are being

reviewed for installation upstream of the coalescers. reviewed for installation upstream of the coalescers.


A custody transfer station was having A custody transfer station was having problems with liquid contamination fouling problems with liquid contamination fouling pressure control and measurement equipment. pressure control and measurement equipment.

A surplus filter separator was sized for the gas A surplus filter separator was sized for the gas flow rate and installed to eliminate the flow rate and installed to eliminate the contamination causing the problems. contamination causing the problems.


The problems continued.The problems continued. SPS was hired to test the contaminant loading SPS was hired to test the contaminant loading

entering and exiting the filter separator. entering and exiting the filter separator.


The inlet gas stream was measured to contain The inlet gas stream was measured to contain 98 liters per day of free liquid contaminant 98 liters per day of free liquid contaminant entering the filter separator. entering the filter separator.

The filter separator outlet gas stream was The filter separator outlet gas stream was measured to contain 98 liters per day of free measured to contain 98 liters per day of free liquid contaminant entering the filter liquid contaminant entering the filter separator. separator.

The liquid was identified to be lube oil with a The liquid was identified to be lube oil with a surface tension of 28 dynes/cm. surface tension of 28 dynes/cm.


ConclusionConclusion– The liquid contaminant’s surface tension was too low for The liquid contaminant’s surface tension was too low for

a filter separator to work properly. a filter separator to work properly. The SolutionThe Solution

– A slug catcher and high liquid loading horizontal A slug catcher and high liquid loading horizontal coalescer were installed in place of the filter separator. coalescer were installed in place of the filter separator.

The ResultThe Result– Test results of the new system measured an outlet Test results of the new system measured an outlet

contaminant content of 0.43 PPB(wt) or about 0.007 contaminant content of 0.43 PPB(wt) or about 0.007 liters of carryover per day.liters of carryover per day.

– Pressure control and measurement equipment are now Pressure control and measurement equipment are now working properly. working properly.


This gas element came under This gas element came under attack from a contaminant attack from a contaminant that was not chemically that was not chemically compatible with it’s media compatible with it’s media material. material.

It is important to study the It is important to study the chemical compatibility of all chemical compatibility of all of a system’s contaminant of a system’s contaminant species with any filter species with any filter materials that might be used.materials that might be used.

This is a case where a filter This is a case where a filter element problem can go element problem can go undetected contaminating undetected contaminating downstream processes. downstream processes.


The SolutionThe Solution– A chemically compatible element material was A chemically compatible element material was

selected and installed in service. selected and installed in service. – No other process problems have been reported. No other process problems have been reported.


A natural gas fired A natural gas fired turbine failed it’s NOx turbine failed it’s NOx emissions requirement. emissions requirement.

The turbine’s LONOx fuel The turbine’s LONOx fuel gas nozzles were found gas nozzles were found to be damaged and to be damaged and partially plugged off with partially plugged off with contaminant. contaminant.

The LONOx nozzles were The LONOx nozzles were protected by a 1 micron protected by a 1 micron filtration separation filtration separation system. system.


ConclusionConclusion– The standard 1 micron filtration vessel was not The standard 1 micron filtration vessel was not

efficient enough for the system’s contaminant size.efficient enough for the system’s contaminant size. The SolutionThe Solution

– A 0.3 micron high dirt loading coalescer vessel was A 0.3 micron high dirt loading coalescer vessel was installed.installed.

The ResultThe Result– The turbine passed it’s next NOx emissions test.The turbine passed it’s next NOx emissions test.– No additional nozzle damage has occurred. No additional nozzle damage has occurred.


A gas processing facility A gas processing facility was experiencing plant was experiencing plant iron sulfide iron sulfide contamination resulting contamination resulting in excessive TEG and in excessive TEG and amine filter element amine filter element changes. changes.

The system’s inlet gas The system’s inlet gas 0.3 micron coalescer was 0.3 micron coalescer was tested and found to be tested and found to be allowing iron sulfide allowing iron sulfide contamination to pass contamination to pass downstream. downstream.


ConclusionConclusion– The standard 0.3 micron element technology was not The standard 0.3 micron element technology was not

sufficient to remove the system’s iron sulfide sufficient to remove the system’s iron sulfide contaminant.contaminant.

– Dry pipeline conditions and high velocities worked to Dry pipeline conditions and high velocities worked to shear the iron sulfide contaminant size distribution to shear the iron sulfide contaminant size distribution to be partially under 0.3 microns in size. be partially under 0.3 microns in size.

The SolutionThe Solution– An iron sulfide removing element technology was An iron sulfide removing element technology was

installed in the existing coalescer. installed in the existing coalescer. – An upstream water wash system was also installed.An upstream water wash system was also installed.


The resultThe result– Down stream element life was extended by 7 times. Down stream element life was extended by 7 times. – The water wash system worked with the iron sulfide The water wash system worked with the iron sulfide

element technology to wash the contaminant off of element technology to wash the contaminant off of the coalescer elements extending their life to over a the coalescer elements extending their life to over a year and counting. year and counting.


Gather information on your system’s contaminant Gather information on your system’s contaminant species before entering the bidding process.species before entering the bidding process.

Have liquid samples from the system or at least a Have liquid samples from the system or at least a nearby system analyzed for identification, surface nearby system analyzed for identification, surface tension, viscosity, pH, density, total suspended tension, viscosity, pH, density, total suspended solids loading, and solid particle size.solids loading, and solid particle size.

If possible, have the system on-line tested for If possible, have the system on-line tested for contaminant loading and size. Testing done on-contaminant loading and size. Testing done on-site will provide important contaminant content site will provide important contaminant content data that is not available from laboratory tests. data that is not available from laboratory tests.

A New ApproachA New Approach


Field Testing ProtocolsField Testing ProtocolsDCM (Direct Contaminant Measurement Laser Testing)DCM (Direct Contaminant Measurement Laser Testing)

CCM (Coalescer Contaminant Measurement Testing)CCM (Coalescer Contaminant Measurement Testing)

SCM(Solids Contaminant Measurement Filter Disk SCM(Solids Contaminant Measurement Filter Disk Testing)Testing)


DCM DCM Direct Contaminant MeasurementDirect Contaminant Measurement


DCM DCM Direct Contaminant MeasurementDirect Contaminant Measurement

DCM SpecificationsDCM Specifications

The DCM protocol utilizes a high pressure laser particle The DCM protocol utilizes a high pressure laser particle counter to measure and quantify aerosol contaminant in counter to measure and quantify aerosol contaminant in a gas stream. The protocol is used for testing down a gas stream. The protocol is used for testing down stream of coalescers, Gemini Purasep units, and filter stream of coalescers, Gemini Purasep units, and filter separators.separators.

Measurement range 0.3 - 8 micronMeasurement range 0.3 - 8 micron Operating pressure range 2 - 2000 psiOperating pressure range 2 - 2000 psi Operating temperature range 40 - 180 deg. FOperating temperature range 40 - 180 deg. F Maximum aerosol content 30 ppmMaximum aerosol content 30 ppm Maximum gas velocity 30 ft/secMaximum gas velocity 30 ft/sec

Scientific Process SolutionsDirect Measurement Contaminant AnalysisHigh Pressure Laser Field Test Report

Test Summary No. 1Date: 22-Jan-04

Client: Tested By: T. Borjon, D. BurnsTesting Location: Vessel Type: Gemini

Vessel Model No: PGCPH-18-382-34-750 Element Type: PGC-382

Input Values Calculations Testing NotesVessel Flow Rate: (MMSCFD) 147 Compressibility: 0.925 Liquid Surface Tension: (dyn/cm)Operating Pressure: (PSIG) 586 Flow Rate: (acfh) 144316 Sample Collection Time: (sec.) 10Operating Temperature: (F) 81 Gas Density: (lbs/ft3) 1.946 Sample Connection: PipelineSpecific Gravity: 0.6 X-Sec Area: (ft2) 6.305 Atm Press. 14.7Vessel ID: (inches) 34 Sample Velocity: (ft/hr) 22889 Sampling Duration 11:03-12:03 (min) 60Liquid Density: (lbs/ft3) 50 Flow Meter Setting: (ml/sec) 16.0

Number of Samples: 360 Sample Sequence: 10 Sec

Ave. Particle Particle Sample Average Total Accumulated Sample Wt: (lbs/10sec) 1.99E-12Size (micron) Wt (lbs) Average Sample wt Total Accumulated Sample Wt: (lbs/sec) 1.99E-13

0.300 2.49E-17 34022.43 8.4863E-130.350 3.96E-17 15257.16 6.0432E-13 Carryover PPM (wt) 0.0073680.400 5.91E-17 6926.63 4.0954E-130.450 8.42E-17 1405.64 1.1833E-13 Carryover Gal/Day 0.005950.500 1.15E-16 25.15 2.9042E-150.550 1.54E-16 22.25 3.4202E-15 Notes:0.600 2.00E-16 2.14 4.2784E-160.650 2.54E-16 0.09 2.2489E-17 0.700 3.17E-16 0.01 1.7555E-180.750 3.90E-16 0.00 1.0796E-18 0.800 4.73E-16 0.01 6.5512E-18 1.000 9.24E-16 0.01 5.1182E-183.000 2.49E-14 0.00 05.000 1.15E-13 0.00 08.000 4.73E-13 0.00 0 Ave Total Counts 57662

Average Particle Counts Versus Micron Size

05000

10000150002000025000

3000035000400004500050000

0.300 0.350 0.400 0.450 0.500 0.550 0.600 0.650 0.700 0.750 0.800 1.000 3.000 5.000


CCM CCM Coalescer Contaminant MeasurementCoalescer Contaminant Measurement


CCM CCM Coalescer Contaminant MeasurementCoalescer Contaminant Measurement

CCM SpecificationsCCM Specifications

The CCM test coalescer system is designed to measure The CCM test coalescer system is designed to measure free liquids and aerosols in almost any application. The free liquids and aerosols in almost any application. The CCM unit is commonly used for testing gas separators CCM unit is commonly used for testing gas separators and scrubbers. The unit can also be used to quantify and scrubbers. The unit can also be used to quantify the inlet gas streams to coalescers, Gemini Purasep the inlet gas streams to coalescers, Gemini Purasep units, and filter separators.units, and filter separators.

Liquid collection range 0.3 micron - free liquidLiquid collection range 0.3 micron - free liquid Operating pressure range 2 - 1480 psiOperating pressure range 2 - 1480 psi Operating temperature range - 40 - 250 deg FOperating temperature range - 40 - 250 deg F Testing sample line size 1/2” - 1” Testing sample line size 1/2” - 1”

Scientific Process SolutionsCoalescer Contaminant Measurement Analysis

Test Summary No. 6Date: Nov. 5, 2003

Client: File Name: Testing Location: Compressor Station Tested By: Tomas Borjon, David BurnsVessel Name/No: Test Vessel Type: 77V-1-312-8-1480

Sample Point: Upstream Pipeline High Point Vent Element Type: NGGC312

Input Pipeline Values Calculations Input Test Vessel ValuesPipeline Flow Rate: (MMSCFD) 81.3 Compressibility: 0.912 Operating Pressure: (PSIG) 341Operating Pressure: (PSIG) 319 Flow Rate: (acfm) 2360 Operating Temperature: (F) 60Operating Temperature: (F) 81 Gas Density: (lbs/ft3) 1.371 Sampling Line Diameter ID:(inch) 1Specific Gravity: 0.75 Pipeline X-Sec Area: (ft2) 2.021 Sampling pipe X-sec Area: (ft2) 0.0055Pipeline ID: (inches) 19.25 Gas Velocity: (ft/min) 1167.54 Sample Line Velocity: (ft/min) 1100.08Liquid Density: (lbs/ft3) 50

Initial Totalizer Reading: (cuft) 0 Test Vessel Flow Rate: (acfm) 6.00

Final Totalizer Reading: (cuft) 1440

Test Start Time: 12:15:00 Total Testing Period: (minutes) 240 Test Start DP: (in of WC) 0Test Finish Time: 4:15:00 Total Testing Period: (hours) 4.00 Test Finish DP: (in of WC) 0

Liquid Collection Log Liquid Collection Summarys

Time Upper Sump Lower Sump Total Liq Total Amount of Liquid Collected: (milliliters) 20(milliliters) (milliliters) (milliliters) Total Amount of Liquid Collected in Upper Sump (aerosols): (milliliters) 20

4:15:00 20 0 20 Total Amount of Liquid Collected in Lower Sump (free liq): (milliliters) 00 Total Liquid Mass Collected: (lbs) 0.03530 Total Liquid Mass Collected in Upper Sump (aerosols): (lbs) 0.03530 Total Liquid Mass Collected in Lower Sump (free liq): (lbs) 0.0000000 Total Mass of Gas Tested00 Total Gas Tested During Testing Period: (cuft) 14400 Total Gas Tested During Testing Period: (lbs) 1974.89000 Liquid Contaminant Content Level00 Liquid Aerosol Content in the gas: (PPM wt) 17.90 Free Liquid Content in the gas: (PPM wt) 0.00

Totals 20 0 20 Total Liquid Content in the Gas Stream: (PPM wt) 17.9

Special Testing Notes: Pig entered plant receiver at 2:50 p.m.


SCM SCM Solids Contaminant MeasurementSolids Contaminant Measurement


SCM Particle Sizing Laboratory EquipmentSCM Particle Sizing Laboratory Equipment


SCM SCM Solids Contaminant MeasurementSolids Contaminant Measurement

SCM SpecificationsSCM Specifications

The SCM testing protocol is used to quantify solid or semi-The SCM testing protocol is used to quantify solid or semi-solid contaminant content in a gas stream. Microscopic solid contaminant content in a gas stream. Microscopic analysis can be added to provide a particle size analysis can be added to provide a particle size distribution.distribution.

Operating pressure range 2 - 2000 psiOperating pressure range 2 - 2000 psi Operating temperature range - 40 - 250 deg fOperating temperature range - 40 - 250 deg f

Provide the contaminant data on filtration Provide the contaminant data on filtration separation specification data sheets for E&C’s separation specification data sheets for E&C’s to include during the bidding process.to include during the bidding process.

Performance verify new and existing filtration Performance verify new and existing filtration and separation equipment. Include and separation equipment. Include performance verification in initial equipment performance verification in initial equipment scope of supply. scope of supply.

Have process optimization studies done for Have process optimization studies done for your plant or facility’s contaminant control your plant or facility’s contaminant control equipment.equipment.


The ResultThe Result– Scientific contaminant data provided on RFQ data Scientific contaminant data provided on RFQ data

sheets will result in the purchase of filtration sheets will result in the purchase of filtration separation systems that will provide optimum separation systems that will provide optimum operational performance at an optimum capital and operational performance at an optimum capital and operational cost.operational cost.

– Performance verification of new and existing Performance verification of new and existing equipment will identify problems before additional equipment will identify problems before additional damage to expensive downstream equipment damage to expensive downstream equipment occurs. occurs.

– Process optimization studies of contaminant control Process optimization studies of contaminant control systems will lower overall plant operational cost. systems will lower overall plant operational cost.


Thank you for your kind attention.Thank you for your kind attention.

Questions???Questions???

Date post:	24-Jan-2016
Category:	Documents
Upload:	river
View:	27 times
Download:	0 times

Contaminant Control: a New Approach David Burns davbur@sps2test Scientific Process Solutions

Documents