原油加工设备优化生产的解瓶颈技术

Jagadeesh Unnam, Carola Rawson, Sammay Hernandez, Raqib Ali Shah
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引用次数: 0

摘要

当作业者对设备在设计条件下的性能和安全性感到满意时,他们自然会要求服务公司提高产量。虽然在原油处理设施的初始设计基础上增加产能似乎比增加天然气处理设施更安全,但必须使用去瓶颈研究来检查许多点,以确保安全可靠的运行。斯伦贝谢生产设施工程和运营团队合作进行了一项去瓶颈研究,将中东原油加工设施的产能提高了40%,这有助于实现年度生产目标。去瓶颈研究需要对处理流程有深入的了解,并尽早发现存在重大限制的设备,在原油处理设施中,这些设备是油流程设备(即加热器、处理机和脱盐器)。验证这两件设备是克服增加产能挑战的第一步。加热器的原始设计使用了强制通风燃烧器系统,研究表明,在安全释放增加吞吐量所需的热量方面存在严重限制。需要对燃烧器类型和配置进行更改;除了对燃气列车进行修改外,还安装了自然通风燃烧器系统。这一变化使更大的热量释放,而不损害加热器的机械完整性;然而,由于传热表面积的限制,对工艺流体的总负荷仍然有限。为了克服这一挑战,设计了一个机械装置(湍流器)来增加对流换热系数。这些变化的综合影响导致了所需的热负荷输送到加工流体。对于脱盐,挑战在于如何达到所需的盐规格。研究的关键变量是洗涤水的盐度、混合效率和可行的脱水程度。由于所使用的洗涤水含盐量高,并且限制了混合效率和实现深度脱水的能力,因此建议将洗涤水源改为淡水。详细的盐平衡计算表明,使用淡水可以增加产量。此外,对其他工艺设备、储罐及其通风系统、泵、管道系统、阀门、仪器和公用事业系统进行了充分检查,并确认仅进行了最小的更改即可适应增加的容量。根据批准的变更管理程序和操作团队对整个加工设施的工艺参数的优化,实施了所需的修改。这确保了在比设计提供的流量高出40%的情况下平稳安全的运行。作为技术所有者、集成商和处理设施运营商,服务公司有独特的机会进行详细的系统范围研究,寻求实时性能反馈,并了解限制、约束和扩展机会。这些改进还通过提高供暖系统的效率,确保了温室气体排放量的大幅减少。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
The Art of Debottlenecking to Optimize Production in a Crude-Oil Processing Facility
When operators feel comfortable with the performance and safety of a facility producing at its design conditions, it becomes natural for them to push the service company to produce even more. While it might appear safer to increase the capacity beyond the initial design of a crude-oil processing facility than a gas processing facility, many points must be checked using a debottleneck study to guarantee a safe and reliable operation. Schlumberger production facilities engineering, and operations teams collaborated on a debottleneck study to increase the capacity of a Middle East crude-oil processing facility by 40% of its design, which helped to achieve the annual production targets. Debottleneck studies require deep knowledge of the processing train and early identification of equipment presenting significant limitations, which, in a crude-oil processing facility, is the oil train equipment (i.e., heater treater and desalter). Validating these two pieces of equipment was the first step to overcoming challenges to increasing capacity. The original design of the heater treater used a forced-draft burner system, and the study showed severe limitations to safely releasing the necessary heat for the increased throughput. A change to the burner type and configuration was identified as a need; a natural-draft burner system was installed in addition to modifications to the fuel-gas train. This change enabled a greater heat release without compromising the mechanical integrity of the heater; however, because of limitations regarding the heat transfer surface area, total duty to the process fluid remained limited. To overcome this challenge, a mechanical device (turbulator) was designed to increase the convective heat transfer coefficient. The combined effect of these changes resulted in the delivery of the required heat duty to process fluids. For desalting, the challenge was in achieving the required salt specification. Key variables studied were the salinity of the wash water, mixing efficiencies, and the feasible extent of dehydration. Because of the high salinity of the wash water that was being used and limits to the mixing efficiency and ability to achieve deep dehydration, the recommendation was to change the wash-water source to fresh water. Detailed salt balance calculations demonstrated the incremental production increase from using fresh water. In addition, adequacy checks of other process equipment, storage tanks and their venting systems, pumps, pipework, valves, instruments, and utility systems were reviewed and confirmed to be suitable for the increased capacity with only minimal changes. The required modifications were implemented following the approved change management procedures and optimization of the process parameters of the entire processing facility by the operations team. This ensured a smooth and safe operation at a 40% greater flow rate than that provided by the design. Being the technology owner, integrator, and processing facility operator allowed the service company a unique opportunity to conduct a detailed system-wide study, seek real-time performance feedback, and understand the limits, constraints, and opportunities for expansion. These modifications also ensured considerable reductions in greenhouse gas emissions by means of enhancements to the efficiencies of the heating systems.
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