Production Surface

Equipment

Prepared by
Scientific Committee of
Oil and Gas department, Runaki Institute

2024

Table of Contents
CHAPTER ONE..........................................................................................................................................1
1.1 History of production surface equipment:.........................................................................................1
CHAPTER TWO.........................................................................................................................................3
2.1 Well head:.............................................................................................................................................3
2.1.1The wellhead consists of two components:.........................................................................................3
2.1.2 How does a wellhead work?...............................................................................................................5
2.2 Blowout preventer:..............................................................................................................................6
2.2.1 Types of Blowout Preventer................................................................................................................6
2.2.2What is the function of Blowout Preventer?........................................................................................8
2.3 The Christmas tree:.............................................................................................................................9
2.3.1 What is the function of Christmas tree?..............................................................................................9
2.3.2 Christmas tree valves:.......................................................................................................................10
CHAPTER THREE...................................................................................................................................16
3.1 What Is a Valve?................................................................................................................................16
3.2 Classification of valve:.......................................................................................................................17
3.2.1 Rotary:..............................................................................................................................................17
3.2.2 Linear...............................................................................................................................................20
3.2.3 Self-actuated.....................................................................................................................................23
3.3 Components of valves........................................................................................................................25
CHAPTER FOUR.....................................................................................................................................27
4.1 Separator:..........................................................................................................................................27
4.2 Purpose of Oil and Gas Separation:.................................................................................................28
4.3 Types of Separators:..........................................................................................................................29
4.3.1 Basic types:.......................................................................................................................................29
CHAPTER FIVE.......................................................................................................................................33
5.1 Storage:..............................................................................................................................................33
5.2 Types of storage Tanks:.....................................................................................................................34
5.2.1 Atmospheric storage tanks:...............................................................................................................34
5.2.2 Pressure storage tanks:......................................................................................................................37
5.2.3 Refrigerated storage tanks:...............................................................................................................38
CHAPTER SIX.........................................................................................................................................39
6.1 Transportation:..................................................................................................................................39
6.1.1 Pipeline.............................................................................................................................................39
6.1.2 Marine Tankers and Barges...............................................................................................................41
6.1.3 Motor Vehicle and Railroad Transport of Petroleum Products..........................................................41
6.2 Transportation equipment’s through pipelines:..............................................................................42
6.2.1 Pumps:..............................................................................................................................................42
6.2.2 Types of Industrial Pumps Used in the Oil and Gas Industry............................................................43
6.2.3: Compressor:....................................................................................................................................48
CHAPTER SEVEN...................................................................................................................................49
7.1 Flow meter..........................................................................................................................................49
7.2 Types of flow meters:.........................................................................................................................50
7.2.1 Differential Pressure Flow Meters....................................................................................................50
7.2.2 Orifice Flow Meters.........................................................................................................................50
7.2.3 Venturi Flow Meters.........................................................................................................................51
7.2.4 Pitot Tube Flow Meter......................................................................................................................51
7.2.5 Positive-displacement flow meter.....................................................................................................52
7.2.6 Volumetric flow meter......................................................................................................................52
7.2.7 Turbine Flow Meters........................................................................................................................53
7.2.8 Vortex Flow Meters..........................................................................................................................53
7.3 Pressure and temperature sensors....................................................................................................54
7.3.1 Pressure sensors................................................................................................................................54
7.3.2 Temperature sensors.........................................................................................................................55
CHAPTER EIGHT....................................................................................................................................56
8.1 Heat exchangers:...............................................................................................................................56
8.2 Heat exchangers serve many industries:..........................................................................................57
8.3 Types of heat exchanger in oil industry:..........................................................................................57
8.3.1 Shell and Tube Exchangers...............................................................................................................57
8.3.2 Evaporators and Boilers....................................................................................................................58
8.3.3 Double Pipe Thermal Exchangers.....................................................................................................58
8.3.4 Plate Heat Exchangers......................................................................................................................59
CHAPTER ONE
INTRODUCTION OF EQUIPMENTS

Equipment: Equipment most commonly refers to a set of tools or other

objects commonly used to achieve a particular objective.

1.1 History of production surface equipment:

During the mid1800's, there was a thriving salt producing industry in the
U.S.A. (West Virginia and Pennsylvania), based on the evaporation of
natural brines to recover salt. Crude oil was a troublesome contaminant
that would often accompany the produced brine. It was skimmed off in
the evaporation pools and discarded. Many enterprising salt producers,
however, bottled the oil and sold it at "medicine shows".

All phases of petroleum technology have kept pace with this expansion
through the never-ending search for better and more efficient methods.
Production techniques have advanced from the very crude wooden
troughs and pipes used in the early development of the industry to the
modern complex gathering systems, staged separation, and treating
plants. Transportation has evolved from the wooden barrels filled at the
wellhead to a system of pipelines and tank trucks connecting all parts of
the country.
Figure 1.1 History of production surface equipment
CHAPTER TWO
TYPES OF PRODUCTION SURFACE EQUIPMENT

2.1 Well head:

A wellhead is defined as the essential equipment assembly located at the
opening of a well, responsible for regulating the extraction of
hydrocarbon derivatives from underground formations, preventing leaks,
and controlling pressure.

Figure 2.1: wellhead

2.1.1The wellhead consists of two components:

(1) the casing head
(2) the tubing head
.
1.The casing head: consists of heavy fittings that provide a seal between the casing
and the surface. The casing head also serves to support the entire length of casing
that is run all the way down the well. This piece of equipment typically contains a
gripping mechanism that ensures a tight seal between the head and the casing
itself.

2.The tubing head is much like the casing head and provides a seal between the
tubing, which is run inside the casing, and the surface. Like the casing head, the
tubing head is designed to support the entire length of the casing, as well as
provide connections at the surface, which allow the flow of fluids out of the well to
be controlled.
2.1.2 How does a wellhead work?
1. A wellhead works by providing a structural and pressure-containing interface for
the drilling and production equipment at the surface of the well.

2.The wellhead is connected to the casing or tubing that runs down the wellbore,
and it seals the annular space between the wellbore and the casing or tubing.

3.Wellheads also include valves and fittings that are used to control the flow of oil
or gas from the well. The valves open and close to allow the oil or gas to flow out
of the well and into the production facilities.

Figure 2.2: wellhead and Christmas tree

2.2 Blowout preventer:
The blowout preventer is a safety sealing wellhead device commonly used in
oilfields to prevent blowouts. It is used to close the wellhead during oil testing,
workover, well completion and other operations to avoid blowout accidents. It
combines the functions of full sealing and semi-sealing into one, has the
characteristics of simple structure, easy operation, high-pressure resistance.

2.2.1 Types of Blowout Preventer

Blowout preventer is the most important well control device, which plays an
important role in drilling, especially underbalanced drilling. The common
hydraulic blowout preventer mainly has two types:
1.Annular BOP

Designed for safe good pressure control during drilling and workover operations,
the Annular BOP is a large valve designed to seal, control and monitor oil and gas
wells. The valve rotates during drilling to maintain a seal around the drill pipe. The
Annular BOP helps to maintain a good seal on the oil to prevent catastrophic blow-
outs.

2.Ram BOP

A ram BOP is a blowout preventer that uses a pair of steel plungers that oppose
each other rams. The Ram BOP consists of two halves of a borehole cover that are
separated from the middle. A large-diameter hydraulic cylinder, usually retracted,
forces the two halves of the cover together in the middle to seal the borehole.
These covers are made of steel for strength.
2.2.2What is the function of Blowout Preventer?
The function of the drilling blowout preventer is to quickly and timely close the
wellhead when there is an overflow or kick in the well to prevent blowout
accidents. The blowout preventer needs to meet the requirements of the drilling
process, be reliable, easy to operate, and can quickly close and open the wellhead.
It can be controlled not only on the drill console of the drilling rig, but also on a
remote console far away from the wellhead. The device should have a certain
pressure capacity to achieve controlled blowout, well killing and tripping of
drilling tools.

Figure 2.3: Controlling system of BOP

2.3 The Christmas tree:
(so named, because of its many branches that make it appear somewhat like a
Christmas tree) is the piece of equipment that fits atop the casing and tubing heads
and contains tubes and valves that serve to control the flow of hydrocarbon
derivatives and other fluids out of the well. The Christmas tree is the most visible
part of a producing well and allows for the surface monitoring and regulation of
the production of hydrocarbon derivatives from a producing well.

2.3.1 What is the function of Christmas tree?

1.Allow reservoir fluid to flow from the well to the surface safely in a controlled
manner.

2.Allow safe access to the wellbore in order to perform well intervention

procedures.

3.Allow injections as water or gas injection.

4.Provide access to hydraulic line for a surface control sub surface safety valve
(SCSSSV)

2.3.2 Christmas tree valves:

1.Mater Valve:

A master valve is located above the tubing hanger and its function is to allow the
well to flow or shut the well in. Typically, there are two master valves. One is
called a lower master valve and another is an upper master valve. Two valves are
often used because they provide redundancy. If one master valve cannot function
properly, another valve can perform the function.

Figure 2.4: Master valve

2.T type fitting (T-Block)

T type fitting (T-Block) allows diversion of flow stream from vertical to a

horizontal flow line.

Figure 2.5: T-Block type

3.Wing Valve (Flowing Wing)

A wing valve is located on the side of a Christmas tree and it is used to control or
isolate production from the well into surface facilities. Depending on each design
of a Christmas tree, it can be equipped with one or two wing valves. Some
operators require two production wing valves, one as a main production and
another one as a backup.
Figure 2.6: Wing valve
 Figure 2.7: Production and king wing valve

4.Choke:

Choke is the smallest restriction in a Christmas tree, and its function is to control
the production rate of a well. It is also use to control sand production in some
cases. A choke restricts areas for production flow through a bean or an orifice
inserted into a choke body. The smaller diameter of the beam results in the lower
the production rate.

Figure 2.8: Choke Valve

There are Two types of chokes:

1) positive choke: with interchangeable beans

2) adjustable choke: which allows adjusting the choke size easily.

5.Swab Valve

On a Christmas tree, a swab valve is the topmost valve providing vertical access to
the well for well intervention operations conducted by wireline, slickline, coiled
tubing or a snubbing unit.
 Figure 2.9: Swab Valve

6.T-Cap and Pressure Gauge

T-Cap is a flange located on top of the swab valve which allows a wireline
lubricator or a coiled tubing/ snubbing unit BOP to connect to a well in order to
perform well intervention programs. A pressure gauge is used to monitor the
pressure of the well. Nowadays, most of the operators often use electronic gauges
so pressure and/or temperature data can be transmitted via an electronic system for
better well monitoring.

Figure 2.10: T-Cap and Pressure Gauge

CHAPTER THREE
VALVES

3.1 What Is a Valve?

In the simplest terms, a valve is a device used to control the flow of a
medium liquid, gas or solid through a piping system. Most commonly,
valves are used to stop and start the flow of media. Some valves are also
able to control the rate of flow, these are commonly referred to as control
valves.

Because there are so many different uses for valves, they are available
in a wide range of mechanical variations. Using the appropriate valve in
a given scenario means your application will run smoothly and safely,
accomplishing the intended goal most efficiently.
3.2 Classification of valve:

3.2.1 Rotary:
Rotary valves: utilize a rotating closure component to block flow within a piping
system. Most often, this rotation is limited to 90 degrees, which is why rotary
valves are also commonly referred to as quarter-turn valves. These types of valves
are closed at 0 degrees and open at 90 degrees. Some rotary valves can operate
with a larger degree of rotation and include more than two positions. Common
examples of rotary valve types are butterfly, plug and ball.

Figure 3.1: Rotary valve

1.Ball Valves

Ball valves can be used in most applications where a fluid flow needs to be shut
off. In fact, they are the most widely used process control valve. These rotary
valves use ported spheres that swivel in the pipe stream, working to start or stop
flow. Ball valves may be more expensive than other rotary valve options, but they
offer better sealing than types such as butterfly valves.

Figure 3.2: Ball valve

2.Butterfly Valves

Butterfly valves work using a center-mounted, disc-shaped obstructer that sways

in and out of the piping system’s flow. These quarter-turn valves are frequently
used with larger pipe sizes and in wastewater plants, power plants and other
process plants where shut-off, regulation, and isolation are called for. These valves
have lower cost and smaller size. However, these common valve types are more
vulnerable to leaks and head losses than ball valves and may not work as well
against high-pressure flows.

Figure 3.3: Butterfly valve

3. Plug Valves

Plug valves are very similar to ball valves in their construction and function.
However, instead of using a ball-shaped obstructer, plug valves obstruct or allow
flow via a tapered cylinder that swings into or out of the flow stream. There are
two main types:

1.Lubricated

2.Unlubricated.

This type of rotary valve is frequently used for shut-off and as a control valve for
chemical processing industries, processing plants and wastewater treatment
facilities.
3.2.2 Linear
Linear valves: use a flow obstructer such as a disc, slat or diaphragm that moves in
a straight line to start, stop or adjust flow through a piping system. Compared to
other categories of valves, linear motion valves tend to have longer cycle times
than rotary valves. These valves can be separated into two distinct types:

1. Rising stem (Multi-turn) linear valves: work particularly well in control

applications and include globe valves, gate valves and needle valves
2. Axial valves: such as coaxial and angle seat valves, are fast-acting and used
primarily in on/off process applications.

Figure 3.4: Linear valve

1. Globe Valves
 Globe valves work by using a globe-shaped disc to block flow when closed
against a restriction orifice. These multi-turn valves are commonly used in
on/off and throttling applications. Globe valves can seal both against or with
fluid flow. Globe valves are frequently used in wastewater plants and food
processing services. Although this valve type is available in many variations,
the most prevalent is the Z-style valve.

There are two types of globe valve:

1.Two-way globe valves are recommended for precision.

2.Three-way globe valves are suitable for combining media from two inlet ports
and sending the resulting mixture through an outlet port.

Figure 3.7: 3-way globe valve Figure 3.6: 2-way(Z style) globe valve

2.Gate Valves
 Gate valves are multi-turn valves commonly used to block flow streams and
sometimes for throttling. This multi-turn valve type utilizes a plate-like barrier
to block a flow stream.

Gate valves offer lower head losses when open compared to other valve types.
Although their operation is comparable to globe valves, gate valves offer less
flow restriction and regulation capabilities.

Figure 3.7: Gate valve

3.Needle Valves

Needle valves closely resemble globe valves aside from several key factors. First,
they are smaller than globe valves and allow for more precise flow control within
smaller systems. Additionally, they consist of a cone-shaped needle as opposed to a
disc-shaped plug that moves into and out of an orifice to start and stop flow.
 3.8: Needle valve

3.2.3 Self-actuated
Unlike linear and rotary valves, self-actuated valves do not require direct input
from the operator. Instead, they use the pressure within the process line to open or
close a pressure control valve. This valve type is commonly used as a pressure
relief valve and only opens once maximum allowable pressure is reached within
the system. self-actuated valves are common safety requirements in certain
applications. Common self-actuated valves include relief valves, safety valves,
check valves.

Figure 3.9: Self-actuated valve

1.Pressure Relief Valve

A pressure safety valve is like a guardian for machines and pipes. When they feel
too much pressure or when there’s not enough air inside, these valves step in. They
let out some pressure or air when it reaches a certain limit.

Figure 3.10: Pressure relief valve

2.Safety Valves

Safety valves are used to protect equipment from excessive pressure. The valve is
used as a failsafe.
 Figure 3.11: Safety valve

3.Check Valves

Check valves are used to prevent the flow of fluids in the wrong direction. This
means they keep the flow of fluids from reversing. Usually, these are found on the
discharge end of the pump. They will automatically shut the flow off when the
pump is disengaged. This prevents the system from draining.

Figure 3.12: Check valve

3.3 Components of valves
Valves have several components such as:

1.Body 7.Stem

2.Bonnet 8.Spring

3.Ports 9.Trim

4.Actuator

5.Disc

6.Seat

Figure 3.12: Component of Globe valve

 Figure 3.13: Component of check valve

CHAPTER FOUR
SEPERATION EQUIPMENTS

4.1 Separator:
Separator works based on gravity separation and/or centrifugal separation.
separators are referred to as scrubbers, knockouts, and free liquid knockouts. These
vessels of separator are used to separate free liquids from the gas stream.

When the well flow stream emerging from the wellhead is basically a mixture of
the produced reservoir fluids of the crude oil, gas and water with possibly, some
solids such as silt/sand entered in the well stream. Depending on reservoir
characteristics, fluid properties and flowing conditions, another type of mixture,
consists mainly of oil and water forms which is referred to as an EMULSION.
Some emulsions, especially the tight ones are of complex nature and are not to be
broken out or separated by the conventional type separators.

Treating of emulsions may include one or more of the following techniques and/or
procedures:

1.Allowing settling time.

2.Applying heat

3. Injecting chemicals (Emulsifiers)

4. Using electricity

4.2 Purpose of Oil and Gas Separation:

1) To allow oil to be stored on the lease and the liquid free of gas to be sold to a
transmission line.

2) To effect a "day" gas measurement .

3) To give the producer the most dollar value from his well effluent by:

a) Making the oil gas free as possible

b) Making the gas as free as possible

 Figure 4.1: Separator

4.3 Types of Separators:

4.3.1 Basic types:

1.Two phase separators: A vessel that separates the well fluids into gas and total
liquid. A two-phase separator can be horizontal, vertical or spherical. The liquid
(oil, emulsion) leaves the vessel at the bottom through a level-control or dump
valve. The gas leaves the vessel at the top, passing through a mist extractor to
remove the small liquid droplets in the gas.
 Figure 4.2: Two phase horizontal separator

2.Three phase separators: three-phase separator uses gravity to separate

produced well fluid into gas, oil, and water phases.

Figure 4.3:Three phase horizontal separator

 These two basic types of separators should be of either one of the following
configuration designs:

1. Horizontal: Horizontal separators are versatile vessels that can be used in

applications where either gravity or gas pressure is insufficient for effective
separating.

2. Vertical: Vertical separators can handle a large range of gas and liquid flow rates.
Vertical contactors are the most popular type of separators for production service
on offshore platforms, but they can also be used in some onshore applications
where gravity is not sufficient to separate liquids from the gas stream.
 Figure 4.4: Vertical separator

3. Spherical separators: Spherical separators offer an inexpensive and compact

vessel arrangement. They can handle high vapor and liquid loads with ease. They
are particularly suited for the removal of sand and other free liquids (slug load) and
medium- and large-diameter gas streams.
 Figure 4.5: Spherical separator

CHAPTER FIVE
STORAGE EQUIPMENT

5.1 Storage:
Storage: is a container, for holding liquids (crude oil, aviation fuel, gasoline, diesel,
used engine oil, solvents and heating oil or compressed gases (gas tank). Storage
tanks are cylindrical in shape, perpendicular to the ground with flat bottoms,
design depending on the nature of the fluid contained within.

Storages are established aboveground like crude oil storages or underground like
gasoline storage in sale station. These tanks may be constructed of concrete, or
metal, with metal being the most common material of construction and now a days
metallic storage tanks are replaced by fiber Reinforced plastic(FRP).
5.2 Types of storage Tanks:

5.2.1 Atmospheric storage tanks:

These tanks are used for holding a liquid at atmospheric pressure.

The major design code for welded atmospheric tanks are API 650 (for floating roof
storage tanks) and API 620 (for fixed roof storage tanks).

Atmospheric storage tanks further classified as follows:

1. Open roof tanks

2. Fixed roof tanks

3. Floating roof tanks

1.Open roof tanks: This tank has no roof and may store or nonhazardous liquid
such as water other aqueous solution can be stored.
 Figure 5.1: Open roof tank

2.Fixed roof tanks: These tanks are most common types of tanks which are used in
industries and are used for liquid with very high flash point, (e.g fuel oil, water,
bitumen etc.) Cone roofs, dome roof and umbrella roofs are usual.

These tanks provided with breathers or vents to permit the variation in vapor
pressure of liquid with temperature and permit the change in volume of liquid with
temperature. They prevent the clogging of certain materials, wherein the heat is
provided by steam coil within the tanks.
 Figure 5.2: Fixed roof tank

3.Floating roof tanks: Floating roof tanks are broadly divided into two types:

A.Internal floating roof tanks (IFR)

B.External floating roof tanks (FR)

A.Internal floating roof tanks (IFR):

These tanks are used for liquids with low flash points (e.g. gasoline, ethanol).These
tanks are nothing but cone roof tanks with a floating roof inside which travels
upward and down along with the liquid level.

Figure 5.3: Internal floating roof tank

 B.External floating roof tank: External floating roofs do not have a fixed roof
and has floating roof only. And it is commonly used to store large quantities of
petroleum products which have medium flash point such as naphtha, kerosene,
diesel, crude oil. Expansion and contraction may happen to this tank due to
temperature changes.

Figure 5.4: External floating roof tank

5.2.2 Pressure storage tanks:

Applies to vessels designed to withstand pressures sufficient to keep liquid stored
from vaporizing. It is used for high vapor pressure liquid such as butane, propane
etc.
 Figure 5.5: Pressure storage tanks

5.2.3 Refrigerated storage tanks:

These tanks refer to low temperature or cryogenic storage. It is used for gases that
liquefy under pressure at atmospheric temperature.

In cryogenic storage the gas is at, or near to, atmospheric pressure and remains
liquid because of low temperature.

Cryogenic refers to temperature below-150°C.

 Figure 5.6: Refrigerated storage tank

CHAPTER SIX
TRANSPORTATION AND PIPE LINE EQUIPMENTS

6.1 Transportation:
Transportation is an important equipment in oil and gas industry, it ensure the
reliable and affordable flow of petroleum we all count on to fuel our cars.
Transportation of oil fluids and gas are made possible by pipelines/ ships at sea,
trucks and railways.
6.1.1 Pipeline
It is generally the case that all petroleum products flow through pipelines at some
time in their migration from the well to a refinery or gas plant, then to a terminal
and eventually to the consumer. Aboveground, underwater and underground
pipelines, varying in size from several centimeters to a meter or more in diameter,
move vast amounts of crude oil, natural gas, LHGs and liquid petroleum products.

Pipelines run throughout the world, from the frozen tundra of Alaska and Siberia to
the hot deserts of the Middle East, across rivers, lakes, seas, swamps and forests,
over and through mountains and under cities and towns. Although the initial
construction of pipelines is difficult and expensive, once they are built, properly
maintained and operated, they provide one of the safest and most economical
means of transporting these products.
 Figure 6.1: Pipeline

6.1.2 Marine Tankers and Barges

The majority of the world’s crude oil is transported by tankers from producing
areas such as the Middle East and Africa to refineries in consumer areas such as
Europe, Japan and the United States. Oil products were originally transported in
large barrels on cargo ships.

Figure 6.2: LNG tankers

6.1.3 Motor Vehicle and Railroad Transport of Petroleum Products

In oil and gas industry petroleum is transported in pressure tank cars and tank
trucks. Crude oil may also be transported by tank truck from small producing wells
to gathering tanks, and by tank truck and railroad tank car from storage tanks to
refineries or main pipelines. Packaged petroleum products in bulk bins or drums
and pallets and cases of smaller containers are carried by package truck or railroad
box car.

6.3: tank truck

6.2 Transportation equipment’s through pipelines:

6.2.1 Pumps:
pumps are essential devices required in every phase of oil and gas
operations. Basically, they help transfer process fluids from one point to
another.
For example, a pump can be used to transfer crude oil from a storage
tank to a pipeline. In oil and gas operations, process fluids can range
from easy to difficult. Depending on the nature of the substance you
want to transfer and your required flow rate, you’ll need a suitable pump
for your needs.

6.2.2 Types of Industrial Pumps Used in the Oil and Gas Industry
Various types of industrial pumps are utilized for fluid transfer in the oil
and gas industry. Pumps can be classified based on their design and
construction and generally fall into 6 major categories:

1.Centrifugal pumps

2.Reciprocating plunger pumps

3.Progressive Cavity pumps

4.Gear Pumps

5.Diaphragm pumps

6.Metering pumps

.
 Figure 6.4: Pumps

1. Centrifugal Pumps

Centrifugal pumps are the most common types of pumps used in the oil
and gas industry. Centrifugal pumps use centrifugal force through the
rotation of the pump impeller to draw fluid into the intake of the pump
and force it through the discharge section via centrifugal force. The flow
through the pump is controlled by discharge flow control valves.
 Figure 6.5: Centrifugal pump

2. Reciprocating Plunger Pumps

Plunger pumps are some of the most global industrial pumps in the oil and gas
industry. Plunger pumps use the reciprocating motion of plungers and pistons to
pressurize fluid in an enclosed cylinder to a piping system. Plunger pumps are
considered constant flow pumps since at a given speed, the flow rate is constant
despite the system pressure.

Plunger pumps require more frequent maintenance than centrifugal pumps due to
the design of the moving parts. They also have a noisier operation than centrifugal
pumps.

Figure 6.6: Reciprocating plunger pump

3. Progressive Cavity Pumps

A progressive cavity pump is a type of positive displacement pump and is also

known as an screw pump or cavity pump. It transfers fluid by means of the
progress, through the pump, of a sequence of small, fixed shape, discrete cavities,
as its rotor is turned. Progressive cavity pumps are used in high viscosity
applications or if blending of the pumped fluid is not desired. Flow rate at a given
speed is relatively constant.

Figure 6.7: Progressive cavity pump

4. Diaphragm pumps

Diaphragm pumps are one of the most versatile types of oil and gas pumps in the
industry and transfer fluid through positive displacement with a valve and
diaphragm. The working principle of this pump is that a decrease in volume causes
an increase in pressure in a vacuum and vice versa.
Diaphragm pumps are suitable for high-volume fluid transfer operations in oil
refineries. They also require much less maintenance than positive displacement
pumps due to their fewer moving parts and less friction during operation and are
available in compact designs.

5.Gear Pumps

A gear pump uses the meshing of gears to pump fluid by displacement. Gear
pumps are one of the most common types of positive displacement pumps for
transferring industrial fluids.

Gear pumps are also widely used for chemical transfer applications for high
viscosity fluids.

Figure 6.9: Gear pump

6. Metering pumps

A metering pump moves a precise volume of liquid in a specified time period

providing an accurate flow rate. Delivery of fluids in precise adjustable flow rates
is sometimes called metering.

6.2.3: Compressor:
A compressor is a device capable of increasing the pressure of a compressible fluid
while reducing its volume. They are important components in the petroleum
industry, playing a key role in the production, processing and transportation of
natural gas through a variety of equipment, including pipelines, valves, separators
and filters, by providing the necessary pressure and flow.
 Figure 6.10: Compressor

CHAPTER SEVEN
MEASUREMENT EQUIPMENT

7.1 Flow meter

A flow meter (or a flow sensor) is type of flow instrument that is used to indicate
the amount of liquid, gas, or vapor moving through a pipe or conduit by measuring
linear, non-linear, mass, or volumetric flow rates. Since flow control is often
essential, measuring the flow of liquids and gasses is a critical need for many
industrial applications – and there are many different types of flow meters that can
be utilized depending on the nature of the application.
7.2 Types of flow meters:

7.2.1 Differential Pressure Flow Meters

Differential pressure flow meters are, by far, the most common units in use today.
These meters, which boast high accuracy, calculate fluid flow by reading pressure
loss across a pipe restriction. Estimates are that over 50 percent of all liquid flow
measurement applications use this type of unit.
7.2.2 Orifice Flow Meters
Orifice flow meters are the most popular liquid flow meters in use today. An orifice
is simply a flat piece of metal with a specific-sized hole bored in it. Most orifices
in use are of the concentric type, but eccentric, conical (quadrant), and segmental
designs are also available. In practice, the orifice plat is installed in the pipe
between two flanges.

7.2.3 Venturi Flow Meters

Venturi tubes have the advantage of being able to handle large flow volumes at low
pressure drops. A venturi tube is essentially a section of pipe with a tapered
entrance and a straight throat. As liquid passes through the throat, its velocity
increases, causing a pressure differential between the inlet and outlet regions.
The flowmeters have no moving parts. They can be installed in large diameter
pipes using flanged, welded or threaded-end fittings.
7.2.4 Pitot Tube Flow Meter
Pitot tubes are generally installed by welding a coupling
on a pipe and inserting the probe through the coupling.
Use of most pitot tubes is limited to single point
measurements. The units are susceptible to plugging by
foreign material in the liquid.

7.2.5 Positive-displacement flow meter

Positive-displacement meters are good candidates for measuring the flows of
viscous liquids or for use where a simple mechanical meter system is needed.

7.2.6 Volumetric flow meter

Volumetric meters have minimum sensitivity to viscosity changes when used at
Reynolds numbers above 10,000. Most velocity-type meter housings are equipped
with flanges or fittings to permit them to be connected directly into pipelines.
7.2.7 Turbine Flow Meters
Turbine meters have found widespread use for accurate liquid measurement
applications. The unit consists of a multiple-bladed rotor mounted with a pipe,
perpendicular to the liquid flow.
7.2.8 Vortex Flow Meters
Vortex meters make use of a natural phenomenon that occurs when a liquid flows
around a bluff object.

7.3 Pressure and temperature sensors

7.3.1 Pressure sensors

are used to measure the force exerted by a fluid or gas on a surface or a container.
They are crucial for oil and gas production because they indicate the condition and
behavior of the reservoir, the well, the pipeline, and the processing equipment.
Pressure sensors help regulate the flow rate, prevent leaks, detect blockages, and
avoid over pressurization or under pressurization.

Some common types of pressure sensors are:

1.gauge

2.absolute pressure sensors

3.differential pressure sensors

7.3.2 Temperature sensors

Temperature sensors are used to measure the degree of heat or cold of a substance
or an environment. They are important for oil and gas production because they
affect the viscosity, density, and phase of the fluids and gases. Temperature sensors
help control the heating and cooling processes, prevent thermal expansion or
contraction, ensure product quality, and prevent corrosion or fire hazards.

Some common types of temperature sensors are:

1. Thermocouples
2. Resistance temperature detectors (RTDs),
3. Thermistors.
CHAPTER EIGHT
HEAT EXCHANGERS

8.1 Heat exchangers:

transfer heat from one medium to another to create cooling and heating
solutions. These machines are often the primary cooling sources
preventing heavy process equipment from overheating. Depending on
their design, they may have exchanger fans, coolants, belts, lines and
other components to improve flow and increase heating and cooling
efficiencies.
 Figure 8.1: Heat exchanger in oil industry

8.2 Heat exchangers serve many industries:

 Chemical processing
 Power plant generation
 Oil and gas industries
 Transportation
 Air conditioning and refrigeration
 Cryogenics
8.3 Types of heat exchanger in oil industry:

8.3.1 Shell and Tube Exchangers

A shell and tube heat exchanger is essentially a collection of tubes enclosed within
a pressurized outer shell. This device works by channeling one fluid (typically
from the hot process) through the smaller tubes and the other through the outer
shell to achieve heat exchange.

8.3.2 Evaporators and Boilers

These heat exchangers undergo a biphasic heat transfer process which
changes the physical state of one or more of the fluids involved.
8.3.3 Double Pipe Thermal Exchangers
The double pipe heat exchanger set up consists of two concentric pipes;
a smaller diameter pipe running within a larger one, which brings two
fluids into proximity. For maximum efficiency, the heated and cooled
fluids circulating within both pipes are driven in opposite “counter-
current” directions.

8.3.4 Plate Heat Exchangers

Plate heat exchange devices are composed of several thin plates
arranged together in stacks. These plates create channels through which
the interacting fluids can flow.

While typical plate exchangers allow for heat exchange between just two
fluid media, variation such as the plate-fin exchanger permits multiple
fluid streams through its parts. The pillow-plate exchanger variant raises
the pressure within the exchange system to improve efficiency.