DEPARTMENT FOR THE PREPARATION AND DELIVERY OF OIL AND GAS
INSTRUCTIONS
FOR LABOR HEALTH AND INDUSTRIAL SAFETY DURING OPERATION OF TRACK HEATERS PP-1.6; 0.8; 0.63
Office for the preparation and delivery of oil and gas
INSTRUCTIONS
on labor protection and industrial safety during the operation of track heaters PP-1.6; 0.8; 0.63
1. General requirements for labor protection and industrial safety.
1.1. Automated block furnaces PP-1.6, 0.8; 0.63 are designed for heating crude oil.
PP -0.63 - line heater with a heat output of 0.63 Gcal/h
PP - 0.8 - line heater with a heat output of 0.8 Gcal / h
PP -1.6 - line heater with a heat output of 1.6 Gcal/hour
1.2. Operation of PP-1.6, 0.8; 0.63 must be produced by qualified personnel with certain experience and knowledge of the design of furnaces.
1.3. For independent work on the operation of PP-0.63; 0.8; 1.6 Persons under the age of 18 are allowed who have undergone primary instructing at the workplace in their main profession, fire safety and electrical safety, an internship, an initial test of knowledge in their main profession, fire safety and electrical safety with a mark in the certificate.
1.4. The next test of knowledge is carried out annually, according to the approved schedule.
1.5. Maintenance personnel must have 1 electrical safety qualification group for non-electrical personnel.
1.6. When introducing new types of equipment and mechanisms, new technological processes, as well as when new rules and instructions for labor protection are put into effect, service personnel must undergo additional training and instruction.
1.7. An extraordinary test of knowledge of safety regulations for maintenance personnel must pass:
After training, the introduction of new types and equipment and mechanisms, changes in the technological process, the introduction of new rules and instructions for labor protection,
In case of violations of the rules and instructions on labor protection, at the request or order of the heads of the enterprise or state supervision bodies.
1.8. Oil heater PP-1.6; 0.63; 0.8 is a cylindrical horizontal vessel with flat bottoms, in the inner cavity of which two furnaces and two coils are installed. Furnaces are equipped with gas burners with igniters, chimneys, Argus-3 automation system. Outside the vessel, automation control devices, a gas collector, pipelines for supplying and discharging oil, sediment drainage, a water level indicator, a service platform, an expansion barrel for inspecting and filling the vessel with water are mounted.
1.9. When fuel gas is burned in the furnace, the coolant (water) is heated to a temperature of 90°C-95°C. The heat transfer medium transfers the heat of the crude oil passing through the coil. Oil is heated from 25°C to 70°C.
1.10. Line oil heater PP-1.6; 0.63; 0.8 is equipped with a monitoring, control and automatic regulation device providing:
Technological control of pressure, temperature, coolant level inside the vessel;
The pressure of the fuel gas in front of the burner and the igniter is regulated by the RDUK installed on the fuel gas line.
1.11.Argus-3 automation system provides:
1.11.1.automatic shutdown of the fuel supply to the burners with interpretation and memorization of the root cause in case of:
Increasing the pressure of the fuel gas in front of the burners;
Extinction of torches of burners;
Increasing the temperature of the coolant;
Increasing pressure in the coil;
Lowering of the water level.
The specified parameters are controlled:
Manometers showing, signaling;
Converters of ultraviolet radiation - PUI.
1.11.2. Automatic transition from the ignition mode to the mode of automatic control of technological parameters.
1.12. Maintenance personnel must strictly comply with the requirements of the instructions for the mode of operation, safe maintenance, timely check the serviceability of fittings, instrumentation, and equipment.
1.13. Gas pulsation and condensate injection into the gas supply pipeline to the burner is not allowed.
1.14. When stopping the line heater for more than 12 hours at negative ambient temperatures, in order to avoid freezing, it is necessary to drain the water.
In the absence of traction in the furnace;
Without purging the gas manifold;
Without furnace ventilation;
In the absence of liquid in the vessel;
Valve leaks on the gas manifold.
2 .Requirements for labor protection and industrial safety
before starting work.
2.1. Before the launch of the furnace PP-1.6; 0.63; 0.8 in operation, the furnace coil and gas manifold should be tested for density and strength.
2.2. Adjust the pressure regulator (RDUK) on the gas supply line to the burners to a pressure equal to 0.7 kg / cm 2.
2.3. Make settings:
Indicating, signaling manometer;
The indicating, signaling thermometer on the top limits of operation on temperature and pressure.
Certificate of Conformity No. ROSS RU. AB28. H05762. Rostekhnadzor permission РRS 414-0196
Line heater PP-1,6(AM) (automated block gas furnace with water heat carrier) is designed for heating dehydrated oil emulsions, viscous oils during transportation through pipelines, as well as water for various technological purposes.
Main technical data
|
Useful fuel capacity, MW (Gcal/h), no more |
|
|
Productivity for the heated product, kg/s (t/day): |
|
|
Product coil pressure, MPa (kg/cm2): Working, no more Estimated Trial hydraulic |
6,3 (63) 6,3(63) 8,2 (82) |
|
Pressure drop in the coil, MPa (kgf/smg), no more |
|
|
Temperature, K (°C): At the product inlet to the heater, within. Product heating, no pain. Intermediate heat carrier heating, no more. Average of the coldest five-day period, no less. Absolute minimum ambient air, no less |
278…232 (5…50) 343 (70) |
|
Intermediate coolant |
Fresh water |
|
Heated medium - oil, oil emulsion, reservoir water, content, % mol, not more than: .Hydrogen sulfide (H2S) Carbon dioxide (CO2) |
|
|
Fuel - natural, associated petroleum gas, with parameters: Heat of combustion, MJ/nm, within Pressure at the inlet to the fuel preparation unit, MPa (kgf/cm2). within Pressure in front of the burner, MPa (kgf/cm*), within Fuel gas consumption, m3/h, no more |
35…60 0,002 0,3…1,2 (3,0…12,0) 0,07…0,15 (0,7…1,5) 180 |
|
Efficiency, %, not less than |
|
|
Overall dimensions (length, width, height), no more |
|
|
Heater weight without intermediate coolant, kg, max |
|
|
Reliability indicators: .Average service life, lay down |
Note:
* Assuming the calorific value of the fuel gas is 40.3 MJ/m (9625 kcal/m).
* * At low ambient temperatures, it is possible to heat the combustion air with electric heaters with a power of 10 kW. The heater consists of the following main parts: heating unit, fuel preparation unit, ventilation unit unit, automation system.
*** Upon request, a heater for operation on fuel gas with HjS content up to 5% can be manufactured.
The heater consists of the following main parts: a vessel, two coils, a sleigh, two furnaces, two burners, a platform and a ladder, two brownie chimneys.
It is standardly equipped with the BChK-4X automation system (with on-off control), which is designed for remote control of ignition, automatic protection with fuel cut-off, sound signal, decoding and storing the root cause in case of unacceptable deviations of technological parameters from the specified norms, power failure and communication lines break with sensors that control the limit parameters, issuing a notification signal about the stop or operation of the furnace to the control room (to the highest level), as well as communication with the upper level machine via the RS-232/485 interface, using standard industrial protocols.
LINE HEATERS WITH INTERMEDIATE COOLANT.
They provide "soft" heating due to the presence of an intermediate heat carrier and can be used to heat oil emulsion, oil, gas, gas condensate, water, heat carriers at oil production, transportation and primary treatment facilities.
Fresh water (mineralization not more than 1 g/l), as well as any non-flammable non-viscous heat carriers (water solutions of ethylene glycol, propylene glycol, antifreeze, antifreeze, etc.) can be used as an intermediate heat carrier.
When using ethylene glycol solutions as a heat carrier, it is necessary to indicate this in the questionnaire, because they require the use of one-piece gaskets on the flanged connections of the tank-coil, tank-firebox, without adhesive seams.
It is possible to manufacture without a coil, for heating water for technological or heating purposes.
Line heater coils are manufactured for a design pressure of 6.3 MPa; if a lower pressure is indicated in the questionnaire, the measurement limits of the supplied instrumentation and control systems change, the coil design does not change.
When using gas that does not meet the requirements of GOST 5542-2014 as a fuel, it is necessary to indicate the composition, paying attention to the content of hydrogen sulfide and other sulfur-containing components, ballast gases (CO2 and N2), and the presence of a droplet fraction.
The line heaters are designed for a stable, without sharp fluctuations, gas pressure at the inlet from 0.2 to 0.4 MPa, in case of a different pressure or the likelihood of sharp fluctuations, it must be specified when ordering. If there are requirements for manufacturers or brands of instrumentation used - specify when ordering. Line heaters are technological devices that use open fire in the process, and therefore do not require the use of explosion-proof equipment.
If there are requirements for the completion of explosion-proof instrumentation and automation - indicate in the questionnaire, preferably with a breakdown of the reasons for installing explosion-proof instrumentation and automation (company standard, the need to meet the requirements for climatic performance, etc.), while taking into account that burners, igniters, spark ignition units does not exist in an explosion-proof version.
Standard supply of a line heater: line heater, complete instrumentation, automation system, terminal boxes. If it is necessary to supply without automation and instrumentation - specify specifically when ordering. If it is necessary to supply a line heater with factory thermal insulation, please specify it when ordering. If it is necessary to supply cable products - specify specifically when ordering, indicating the distances.
The line heaters are supplied without site lighting, ATS, gas control systems, fire alarms, fire extinguishing systems, steam curtains, top-level metering units for the heated product and fuel (SCADA systems). If you need to supply the above components - you must specify this separately when ordering.
Automation systems BUK-5PUR, BUK-4.X3.APN are supplied without BKA (blocks of switching devices) and insulated cabinets. In the presence of blast burners, instead of the BKA, a control unit for the ventilation unit is supplied.
The need to supply these automation systems with BKA or in insulated cabinets with electric heating is specified when ordering. ALL of the following heaters can be manufactured to operate on gas, liquid or combined (gas-liquid) fuels, to operate on associated petroleum gas with a high content of hydrogen sulfide, to operate with high-viscosity oils.
The selection of the track heater should be carried out according to the thermal power. Performance is given approximately, for the initial selection of the heater.
Track heating PPT-0.2.
The marking may contain the letters G, K, Zh, GZh. The letters mean:
G - the heater is equipped with a gas burner;
G - the heater is equipped with a liquid burner;
ГЖ - the heater is equipped with a combined burner;
K - the heater is designed to work with high-viscosity oils.
PPT-0.2 line heaters are equipped with automation systems SA-PNG.M (by default), BUK-5PUR, BUK-4.X3.APN (at the request of the customer or selection according to the questionnaire).
As a fuel, operation is implemented on gas (natural, associated petroleum, process gas), liquids (oil, diesel fuel, heating oil, stable gas condensate) or a combined gas-liquid version.
Available with burners:
- IGK 1-15 (injection Kazantsev, the main version);
- NUS-01 (injection specially designed, version for operation on associated petroleum gas with the presence of a drop fraction, do not go out when the drop fraction is thrown into the burner nozzle);
- IGK 4-50 (for track heaters of increased power - up to 0.3 Gcal / h, reduce the efficiency of the track heater);
- GGV-25 (blowing, a fan unit is required);
- GGV-50 (for track heaters of increased power - up to 0.3 Gcal/h, they reduce the efficiency of the track heater, blast heaters, a fan unit is required);
- non-precision supercafitting mechanical nozzle (blowing, requires the presence of a BPZhT or a pump unit to create pressure in front of the nozzle, they work on any type of fuel, including oil);
- block burners Ekoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences, a BPZHT or a pumping unit is not required, unsuitable for oil operation).
- GGV-25, GV-50 with a non-precision super-cafitting mechanical nozzle (blast burners, a fan unit is required).
The marking may contain the letters A, AJ, AM, AC, D
The letters mean:
A - the heater is supplied complete with an automation system (of any type);
AM - the heater is supplied complete with a microprocessor-based automation system (PLC-based);
АЖ - the heater is supplied complete with an automation system (of any type) and a liquid or combined burner;
AC - the heater is supplied complete with an automation system (of any type) for operation on gas with a high content of hydrogen sulfide (up to 5% and more);
D - the heater is supplied complete with an automation system (of any type) and a two-flow coil.
Track heaters PP-0.63A and PP-1.6A are equipped with automation systems SA-PNG.M (by default), BUK-5PUR, BUK-4.X3.APN (at the request of the customer or selection according to the questionnaire).
Available with burners:
- PP-0.63.04.00.000 (special design for associated petroleum gas injection) - the main option;
- IGK 4-50 (Kazantsev's injection burner, for line heaters of reduced power);
- IGK 4-100 (Kazantsev's injection burner);
- GGV-100, GV-100 (blast burners, a fan unit is required);
- block burners Ecoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences).
- non-precision supercafitting mechanical injector (requires the presence of a BPZhT or a pump unit to create pressure in front of the injector, they work on any type of fuel, including oil);
- block burners Ecoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences, the presence of a BPZhT or a pumping unit is not required, unsuitable for oil operation);
- GGV-100, GV-100 with a non-precision super-cafitting mechanical nozzle (blast burners, a fan unit is required)
The marking may contain the letters M, MK, M-KS. The letters mean:
M - the heater is supplied complete with an automation system (of any type);
MK - the heater is supplied complete with an automation system (of any type) and a liquid or combined burner;
M-KS - the heater is supplied complete with an automation system (of any type) for operation on gas with a high content of hydrogen sulfide (up to 5% and more);
Path heaters PBT-1.6 are equipped with automation systems SA-PNG.M (by default), BUK-5PUR, BUK-4.X3.APN (at the request of the customer or selection according to the questionnaire).
Gas (natural, associated petroleum, process gas), liquid fuel (oil, diesel fuel, heating oil, stable gas condensate) or gas and liquid fuel (combined gas-liquid) are produced for use as fuel.
Available with burners:
- GGV-200 (basic version);
- foreign-made block burners Ecoflam, Unigas, Lamborghini (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences);
- with a non-precision supercafitting mechanical nozzle (blowing, requires the presence of a BPZhT or a pump unit to create pressure in front of the nozzle, they work on any type of fuel, including oil);
- block burners Ecoflam, Unigas, Lamborghini of foreign production (only with the SA-PNG.M automation system, a shelter is required to protect the burner from climatic influences, the presence of a BPZhT or a pumping unit is not required, unsuitable for oil operation).
- GGV-200, GV-200 with a non-precision supercaficating mechanical nozzle (blast burners, a fan unit is required).
Line heater PP-1.6 (A) AZH designed for heating oil products, oil emulsions, viscous oil during transportation through pipelines, in oil fields and oil treatment plants. The PP-1.6 line heater consists of a cylindrical vessel, inside which there are two coils and two combustion chambers equipped with burners with igniters and chimneys. The vessel of the line heater is installed on the base of the welded structure. Outside, on the vessel, there are automatic control devices, a fuel piping, an oil supply and discharge pipeline, a ladder, a service platform, an expansion tank, and a water level indicator. The line heater PP-1.6 is produced in two versions that differ in the type of fuel used: PP-1.6A (gas) uses natural or associated petroleum gas as fuel; PP-1,6AZh (liquid) uses oil from the fuel system or from the field network, which is subjected to preliminary purification and reduction using the BPZhT liquid fuel preparation unit. To ensure safe working conditions, the PP-1.6 heater is equipped with the SA-PNG-I (AB-2G-3) control and automation system, which allows remote ignition of nozzles, regulates the parameters of the oil heating process, performs the functions of working and emergency alarms and automatic protection in case of deviation of technological parameters.
The automation system provides for automatic control of the oil heating temperature
- in case of flame failure of the main and pilot burners
- when the fuel pressure in front of the combustion chambers deviates below the operating values
- when the oil heating temperature rises above 70ºС
- when the level of the intermediate coolant drops below the working one
- with an increase in the pressure of the heated product above 6.3 MPa
The operating and alarm signaling system notifies the operating personnel about the normal operation of the burners of the combustion chambers and the failure of their flame, about cutting off the fuel supply when the parameters of the oil heating process deviate from the specified values.
Device and principle of operation
:
The track heater consists of the following main parts:
- - heating unit (designed to transfer heat from combustion products to the heated product);
- - fuel preparation unit BPZhT;
- - automation and security system.
Oil from the field network through a valve enters the product coil of the heater (heating unit), heats up from the intermediate coolant (water), and then is removed from the heater. The fuel is burned in the heater furnace, giving off heat to the intermediate heat carrier, the cooled combustion products are discharged from the heater furnace into the atmosphere by means of a chimney.
Specifications
During the combustion of fuel gas in the furnace, the heat carrier is heated to a temperature of 90 - 95°C. The heat transfer fluid transfers heat to the oil passing through the coil. Oil is heated by 25°C.
Fig.12.1. Oil heater type PP-1.6
Gas is supplied to the pilot burner from a cylinder.
Oil for the heater is taken from the fuel system or from the field network, which, after cleaning, is fed to the nozzle, burned in the heater furnace, giving off heat to the intermediate coolant.
The cooled combustion products are discharged from the heater furnace into the atmosphere by means of a chimney.
Oil from the field network enters the product coil of the heater, is heated from the intermediate heat carrier, and then is removed from the heater.
Track heater PBT – 1.6M/MZH/MK
The track heater PBT-1.6M / MZH / MK is designed for heating oil emulsions, oil, gas, formation water during transportation, at oil treatment plants.
Advantages of PBT-1.6M
The PBT-1.6M heater is a development of design and engineering services of PG "Generation", its use provides significant advantages.
The fuel can be natural or associated petroleum gas, dried fuel gas, commercial oil, which makes it possible to use the resources of the deposit as fuel.
A heater with an intermediate heat carrier with a compacted coil and a combustion device with a developed heating surface provides a highly economical "soft" mode of heating oils of various compositions. At the same time, fluctuations in product consumption and the size of the gas phase do not affect the reliability of the product.
The heater PBT-16M / MZH / MK with equal thermal power compares favorably with the heater PP-1.6 and heaters of other Russian and foreign manufacturers, being more economical and having reduced overall weight indicators. This reduces the cost of installation and operation of the heater PBT-1.6M/MZH/MK.
12.5. Description of the construction of PBT-1.6M:
The PBT-1.6M heater consists of the following components: heating unit, fuel preparation unit, ventilation unit unit, automation system.
The technological process of heating the product is carried out as follows: the product from the field network enters the heater coil, is heated from the intermediate heat carrier, and then is removed from the heater. The gas to feed the burners is heated in the heating unit and enters the fuel preparation unit.
After purification and reduction, the fuel gas is supplied to the pilot and main burners, burned in the heater furnace, giving off heat to the intermediate coolant (fresh water).
The cooled combustion products are discharged from the heater furnace into the atmosphere through the chimney.
The heating unit is designed to transfer heat from the combustion products of the fuel gas to the heated product. The heating unit is a container mounted on a base frame and filled with an intermediate coolant (fresh water). A furnace and product coils are placed in the tank. It is made as a monoblock, which can be transported by any mode of transport.
The fuel preparation unit is designed to accommodate devices for cleaning, reducing and controlling the fuel supply to burners. The devices are mounted in an insulated cabinet.
The unit of the ventilation unit is an insulated shelter, in which a radial fan with an electric motor with a power of 4 kW.
The heater is equipped with an automation system.
SPECIFICATIONS
| Name | PP-1.6 | PP-1,6-1 | |
| Rated thermal power of the combustion device, no more | MW (Gcal/h) | 1,86 (1,6) | 1,86 (1,6) |
| Productivity for oil emulsion when heated to 25°C, water cut 30%, no more | t/day | ||
| Pressure in the product coil, no more | MPa (kgf / cm 2) | 6,3 (63) | 6,3 (63) |
| Pressure drop in the coil, no more | MPa (kgf / cm 2) | 0,55 (5,5) | 0,55 (5,5) |
| Temperature: | |||
| product heating, no more | °C | ||
| heating of the intermediate heat carrier (fresh water), not more than | °C | ||
| Heated medium (oil, oil emulsion, formation water) containing acid gases: | |||
| hydrogen sulfide (H2S), no more | mol % | 0,01 | 0,01 |
| carbon dioxide (СО2), no more | mol % | 1,0 | 1,0 |
| Fuel with parameters: | natural or associated petroleum gas | oil, oil emulsion | |
| calorific value within | MJ / nm 3 | 35–60 | 39,8 |
| hydrogen sulfide content, no more | mol % | 0,002 | 0,01 |
| preheater inlet pressure | MPa (kgf / cm 2) | 0,3 (3) – 0,6 (6) | 3,5–4,4 (35–44) |
| pressure in front of the burner, within | MPa (kgf / cm 2) | 0,07 (0,7) – 0,15 (1,5) | 3,5 (35) |
| Rated fuel consumption: | |||
| per burner, no more | m 3 / h | 90* | |
| general, no more | m 3 / h (kg / h) | 180* | 100–200 |
| Power supply of devices of the control system, signaling, protection from the AC mains: | |||
| tension | IN | ||
| frequency | Hz | ||
| Furnace overall dimensions (length x width x height), no more than | m | 18.36 x 4.78 x 7.4 | 16.0 x 4.78 x 7.4 |
| Weight, not more than: | |||
| dry | T | 39,8 | 39,8 |
| filled with water | T | 125,2 | 125,2 |
| Climatic version of the heater | "U", category 1 according to GOST 1515069 |
Fig.12.2. Scheme of the track heater PBT-1.6M
SPECIFICATIONS
| Name | PBT-1.6M | PBT-1,6MZh | PBT-1,6MK |
| Useful thermal power, no more, MW (Gcal) | 1,86 (1,6)* | 1,86 (1,6)* | 1,86 (1,6)* |
| Productivity for the heated product, within, kg/s(t/day) | 11,6–18,5 (1000–1600) | 11,6–18,5 (1000–1600) | 11,6–18,5 (1000–1600) |
| Product coil pressure: | |||
| working, no more | 6,3 (63) | 6,3 (63) | 6,3 (63) |
| estimated | 6,3 (63) | 6,3 (63) | 6,3 (63) |
| Temperature: | |||
| at the product inlet to the heater, not less than | 278 (5) | 278 (5) | 278 (5) |
| product heating, no more | 343 (70)* | 343 (70)* | 343 (70)* |
| heating of the intermediate heat carrier (fresh water), no more than, K (°C) | 368 (95) | 368 (95) | 368 (95) |
| Heated medium | oil, oil emulsion, formation water containing: hydrogen sulfide, not more than 0.01% mol., carbon dioxide, not more than 1.0% mol. | ||
| Efficiency, not less, % | |||
| Consumed electric power, kW, no more | 5,0*** | 12*** | 12*** |
