The Significance of Reliable Pressure Control in Oilfield ...

1 White Paper D352440X012. September 2016 Burner Fuel gas system The Significance of Reliable Pressure Control in Oilfield Burner Systems P1913_1. Burners play an integral role in oil and gas production. ground enter the burner skid (commonly referred to They generate the heat necessary for separating the as burner fuel train) at a high Pressure and hence they oil, gas and water mixture and to keep the gases in need to be Pressure controlled for use in burners. their vapor phase during transportation through This paper discusses some of the challenges facing pipelines. Burners typically use a portion of the gas the burner industry and the importance of Pressure coming out of the ground as the fuel to produce Control in burner fuel trains.

2 The flame for heating. The gases extracted from the White Paper D352440X012. September 2016 Page 2 Burner Fuel gas system Introduction to Oilfield Burners Burners are gas-fired combustors used by oil and gas producers to generate the heat required for process applications. There are three major classifications: Separator Burners, which provide heat to Stack Arrestor separation units such as heater treaters Inline Burners, which provide heat to maintain temperature within pipes and to prevent Turbolators hydrate formation Tank Burners, which provide heat to maintain storage tank temperatures Flame Arrestor Flange Fire Tube Main Burner Burners typically operate continuously and play a significant role in upstream oil and gas Ignition Mode Pilot Burner and Igniter processing operations.

3 P2098_1. Figure 1. Typical Fire Tube Burner Traditional Methods of Burner Ignition Technology and innovation have drastically improved many aspects of safety and production in the Oil & Gas industry. Yet, for igniting a burner, much of the field is using antiquated methods where a worker will use a long stick with a burning rag at the end. This is not only dangerous, but also increases unnecessary downtime as the worker has to manually discover when the burner flame is extinguished. Moreover, when the burner is reignited by the worker, it will typically run continuously, often needlessly due to the absence of automation that modulates the flame intensity based on the temperature of process fluid.

4 P1997_1. White Paper D352440X012. September 2016 Page 3 Burner Fuel gas system Safer, Automated Method - Burner Management system The potential safety and operational issues with BURNER MANAGEMENT. traditional burners is driving the industry towards a safer system . and automated method through the use of a Burner Management system (BMS). A BMS is an electronic panel (see Figure 2) that ensures a safer method for Control START STOP ACK. and monitoring of burner units. The BMS operates as the brain of the burner systems as it: Ensures safe burner startup once proper PAGE. CONFIG SCROLL. conditions are met and initiates shutdown if EXIT.

5 Unsafe conditions occur CALIB. SELECT. ITEM. PASSWORD. Reignites the burner flame automatically in a OPERATOR. REQUIRED ACCESSIBLE. controlled routine in the event that it has been extinguished Monitors and ensures that the burner and pilot P2099_1. flame is lit Modulates the burner flame intensity based on ACCESSIBLE. OPERATOR. REQUIRED. PASSWORD. temperature needed for the application ITEM. SELECT CALIB. Allows user to monitor flame status, change Figure 2. Burner Management system (BMS). EXIT. SCROLL. PAGE. CONFIG. temperature set points and even shut down from a remote location When the crude oil mixture is over-heated in the Challenges facing industry today treater, the intermediates vaporize and get vented ACK.

6 STOP START. Although there are many benefits of using a BMS, there into the atmosphere or get flared. When the crude oil are also challenges related to effectively managing mixture is under-heated, water is carried over along system . the burner systems used in upstream Oil & Gas field with crude due to poor separation. The water has no BURNER MANAGEMENT. applications. These are varied among the different value and hence reduces the quality of the crude being end applications. Detailed below are challenges when transported. Both these cases result in revenue loss for burners are used in heater treater applications: the producer.

7 Operational Challenges Safety Challenges The crude oil mixture extracted from the ground is The burners that are used in heater treater applications transported along with several useful intermediates will need to Control flame intensity so that the (such as ethane, propane etc.) to the refineries where process fluid is heated, stored and transported at an they are refined, processed and sold separately. These optimum temperature. The Unites States Department intermediates, which have high volatility, add more of Transportation (DOT) regulations require that the value and revenue to the crude being transported. crude oil mixture transported by rail be maintained at a vapor Pressure rating of or lower and temperature of 110 F.

8 *. S. White Paper D352440X012. September 2016 Page 4 LPSD. #1 S S. HPSD. #1. Burner Fuel gas system 67C LOADING Pressure . SERIES REGULATOR 119EZ. SOLENOID SERIES. S VALVE SOLENOID. S. VALVE. *. S. MAIN BURNER. REGULATOR LPSD HPSD. #1 #1. FUEL GAS. YS MAIN BURNER MAIN BURNER. VALVE. EMERGENCY. SHUTDOWN. VALVE. PILOT. 627 TYPE SOLENOID. SERIES 119 VALVE. START STOP. S PILOT BURNER. PAGE. CONFIG SCROLL. EXIT. PILOT BURNER CALIB. SELECT. ITEM. REGULATOR PASSWORD. REQUIRED. OPERATOR. ACCESSIBLE. 67C. SERIES. BURNER MANAGEMENT. P2101_1. HIGH Pressure START STOP ACK. MEDIUM / LOW Pressure . LOADING Pressure PAGE. CONFIG SCROLL.

9 EXIT. CALIB. SELECT. ITEM. * Optional PASSWORD. REQUIRED. OPERATOR. ACCESSIBLE. HIGH Pressure . MEDIUM / LOW Pressure . LOADING Pressure . Figure 3. Burner Fuel Train Setup * Optional When the crude oil mixture is under-heated in the operation. These gases are typically at high Pressure treater, the VOCs (Volatile Organic Compounds) and hence will need to be controlled and regulated are poorly separated from the oil. This leads to before being fed to the main and pilot head of the transportation of crude oil that carries an increased burner. There is a series of Pressure regulators used in risk of boiling when exposed to atmospheric Pressure controlling the Pressure of fuel gas and maintaining at ambient temperature, resulting in Pressure buildup the burner flame intensity.

10 Careful selection from inside the rail car. The excessive Pressure buildup could a wide range of Pressure regulators is essential for potentially lead to rupture. On the other hand, when optimal fuel train performance. It is important to make the crude oil mixture is over-heated in the treater, the sure that the regulator's maximum operating Pressure lighter gases evaporate, resulting in flaring if sufficient rating suits the operating pressures to be encountered infrastructure is not available to contain them. The at the intended location of the burner train. Properly environmental implications posed by flaring have selected and installed Reliable Pressure Control driven several states to enforce bans or place severe elements along with a simplified fuel train should restrictions on it.