Technology Roundup

With the need for ever-more infrastructure, the midstream industry has been hard pressed to make new projects available on time and on budget. Shale plays, now recognized as the catalyst for this construction renaissance, have undergone a transformation in drilling practices through the advent of hydraulic fracturing. No less important, the innovations and technologies of the year have also made a large impact on the midstream industry. Here, from metering technology to new pipeline materials, are a few of the most modern technologies available on the market today.

Oil-water separators

The Corella inclined parallel plate coalescer is the newest edition to Highland Tank & Manufacturing Co. Inc. patented oil-water separators product line. It combines the features of both a flat plate coalescer and a corrugated plate coalescer into a new self-cleaning design that performs more efficiently than traditional plate separators.

Highland's Corella separators greatly reduce the level of oil, grease and oily coated solids discharged by produced water-treatment facilities throughout the Marcellus shale play. Highland separators meet the new Underwriters Laboratories Inc. SU2215 design, construction and performance standards for engineered oil-water separators rated at 10 parts per million oil and grease.

Highland separators are durable and simple to operate. The selection of the appropriate type of separator depends on the amount of wastewater to be treated, its physical and chemical characteristics and the treatment objectives. It can be constructed from either stainless steel or carbon steel protected with a variety of coating systems for fresh or brine-water treatment.

The oil-water separator is provided with a metal catwalk with railings for operator safety during operation and maintenance of the unit. Oil and wastewater pumps and controls are offered as well as reliable insulation and heating systems.

Superior separator performance can be achieved with the addition of Highland's Advanced Filtration Systems (AHFS). AHFS contain oleophobic filters that use a patented hydrocarbon removal technology that instantly bonds hydrocarbons to the filter media, making them hydrophobic and viscoelastic, thus removing them completely from the water. The addition of Highland's AHFS to the high-performance Corella oil-water separators greatly reduces an industrial facility's levels of dissolved hydrocarbons, solvents, volatile organic compounds and organically bound metals prior to wastewater discharge.

Metering technology

The Smith Meter Positive Displacement (PD) Meter is one of the most recent products from FMC Technologies Inc. available on the market.

To help reduce operating costs, the large 10-inch to 16-inch PD meters contain features to enhance longevity in difficult applications. The Smith Meter PD product line also includes the Genesis Meter. This meter, designed for smaller line sizes, offers both a direct electronic pulse output and enhanced range-ability in a compact design with no mechanical gearing or packing gland.

By employing the multi-viscosity (MV) series helical turbine meter along with viscosity compensation using the Universal Performance Curve Compensator preamplifier and the new FMC Viscosity Sensing Unit, customers can now choose economical turbine meter measurement systems for multi-viscosity crude oil systems.

FMC also offers the Ultra Series Liquid Ultrasonic Meter. The Ultra Series is available in a six-path configuration for custody transfer applications and a four-path configuration for high accuracy applications, including line balance and leak detection. Including features such as remote diagnostic capability, full networkability through a 10/100 megabits per second Ethernet port and an advanced signal detection algorithm, the Ultra Series offers non-intrusive flow measurement applications.

Flow meter

Krohne Inc. recently introduced the Altosonic V12 gas flow meter for custody transfer applications. With 12 measuring chords, two of which are solely dedicated to diagnostic functions, it continuously checks operating status. The positioning of the chords in five horizontal parallel planes compensates for swirl and provides reliable measurements, even with highly distorted flow profiles. The diagnostics in the V12 can reliably assess deposits, contamination or changes in wall roughness, so that maintenance can be scheduled according to actual needs.

In the development of the Altosonic V12, Krohne focused on two significant problems that customers encounter and which cannot be satisfactorily addressed by existing ultrasonic flow meters. The first involves how to transfer the calibration curve obtained under ideal conditions in the high-pressure test rig to the real-life measuring station with its headers, strainers and bent pipes, among others. Hundreds of flow profiles in all kinds of applications were analyzed and the result is that the Altosonic V12 is now the first ultrasonic flow meter capable of complying with the ISO17089 and AGA9 standards having five pipe-diameter straight inlet requirements without using a flow straightener.

The second problem involved self-monitoring of the flow meter during operation, with regard to defining accuracy of billing after a certain period of operation. Applying the proven reflecting technique, the meter is able to detect changes in the flow profile as well as changes in the cross sectional area. The V12 is capable of assessing process changes that existing ultrasonic flow meters cannot detect.

The Altosonic V12 meter is available in sizes from 4-inch to 24-inch, an installation length of three pipe-diameter and a maximum operating pressure of 2,200 pounds per square inch (psi). It is compatible with commonly used protocols and can be seamlessly integrated into any existing infrastructure.

Modular catalytic converters

Johnson Matthey Public Limited Co. modular converters contain platinum oxidation catalysts and are specifically designed for use in reducing hazardous air pollutants (HAP) from gas and diesel engines. A large number of these engines are operating in the Marcellus shale in midstream processes such as gas drilling, fracking and gas compression. Diesel engines are used to power drill rigs and to pump fracking slurries. Gas engines are used to gather natural gas and to transport the natural gas from a processing plant to a gas pipeline.

The Johnson Matthey modular catalytic converters reduce carbon monoxide (CO) to comply with the emission limits established by the 2010 National Emission Standards for Hazardous Air Pollutants for Reciprocating Internal Combustion Engines (RICE NESHAP) regulation. The EPA chose CO as a surrogate for a variety of HAP including formaldehyde, acetaldehyde, acrolein, methanol and benzene. Owners and operators of diesel engines in the Marcellus must comply by April 2013 and gas engines by October 2013.

The Johnson Matthey modular converters are equipped with a hatch that allows easy access to clean or replace the catalyst element. The Johnson Matthey modular converters will be in stock for the most popular diesel and gas engine models. The company offers RICE NESHAP information, education and assistance. In addition, Johnson Matthey provides on-site evaluations, standard and custom catalytic converter designs, guaranteed performance and competitive pricing.

Online fuel auction platform

Pricelock Inc., the online leader in energy solutions for U.S. businesses, recently launched Pricelock Marketplace, the first customized, online energy-auction platform that allows companies to conduct fast-paced, real-time auctions for natural gas and motor fuels.

The platform is designed to handle the specialized needs of utilities, electricity generators, government, commercial and industrial, and other large buyers. These needs include large volumes, complex delivery requirements and custom terms and conditions. Pricelock Marketplace's platform is customized to support the unique features of each commodity, including fixed and index pricing as well as peak and weather contingent options.

Pricelock debuted its platform with a live auction of natural gas for CenterPoint Energy Inc.'s natural gas operations business unit that serves more than 3.2 million metered customers in six states. More than 25 major energy sellers participated in the auction for more than 700,000 million Btu (MMbtu) per day of base load and peak and weather contingent options.

By creating a more efficient market for energy and fuel, Pricelock Marketplace saves both buyers and suppliers money, time and paperwork. For buyers, having a large and diverse network of marquee suppliers who compete ensures the best price available. The ease of the process to set up and award business through live or sealed-bid auctions improves the buyers' overall efficiency and the transparency while the audit trail embedded in the electronic platform reduces the administrative burden.

For sellers, participating in Pricelock Marketplace offers a convenient hub for acquiring customers easily and efficiently. Since sellers are notified of business opportunities and bidding for energy or contracts online, it eliminates the need for additional sales personnel or a staffing infrastructure to prepare and submit bid documents. Pricelock says it is in active discussions with other large utilities and electricity generators and expects to expand this service into electricity and other energy products.

Tier 4A generators

To help its portable equipment customers meet today's Tier 4A emission standards, Atlas Copco Group is introducing a range of Tier 4A generators in the power category above 150 kilo volt amperes. The QAS 150 JD T4a, QAS 250 JD T4a and QAS 330 JD T4a models offer minimized energy use, noise levels and environmental impact.

The QAS 150 JD T4a, QAS 250 JD T4a and QAS 330 JD T4a are powered by fully Tier 4A-compliant John Deere engines with variable geometry turbocharger technology. The three generators offer low noise levels and a significant increase in energy efficiency. One tank of diesel lasts up to 24 hours at full load.

The generators have a containment base to prevent leakage, offering customers significant environmental benefits. As a result, customers no longer have to be concerned with soil contamination. In addition, local production allows the company to offer shorter delivery times.

In January 2011, Tier 4A emission regulations for 130-560 kW off-road diesel engines went into effect. The standards require a reduction of particulate matter by no less than 90% and of nitrogen oxide emission levels by 50% compared to previous standards. The new standards apply to both variable and constant speed engines, affecting all larger compressors, as well as generators. The introduction of the QAS 150 JD T4a, QAS 250 JD T4a and QAS 330 reflects Atlas Copco's commitment to offer full Tier 4A compliance throughout its entire range of large compressors and generators.

Electromagnetic surveying techniques

In response to a release of produced water in Texas, Titan Engineering Inc., a division of Apex Co. LLC completed assessment and remediation to reduce the salinity of the affected soil to restore normal productivity. The produced water had affected a field cultivated with Sudan grass, which is characterized as mildly tolerant. Comprehensive analytical suites were completed, including saturated paste electrical conductivity (EC), exchangeable sodium percentage (ESP), cation exchange capacity and sodium adsorption ratio. Pelletized gypsum was initially applied to reduce the ESP. Subsequently, organic matter was applied and tilled into the soil to manage the excess salt.

To expeditiously delineate the remaining areas of elevated EC, Titan completed an electromagnetic (EM) survey using a Geonics EM-38 DD instrument. The integrated horizontal and vertical dipoles of the instrument measure apparent conductivity at effective depths of two and a half and five feet. The instrument is valuable for evaluating salt in agricultural soil because it can provide depth-weighted readings to simulate the way plants remove water. Subsequent to the EM survey, additional soil samples were collected to correlate the instrument readings to laboratory results.

The EM-38DD survey provides a rapid assessment of remaining salt in soil allowing closely targeted and cost-effective remediation. Based on the EM and analytical data, elemental sulfur and hay were applied to the remaining affected soil and the sulfur was allowed to oxidize. After the reaction period, ground-weathered hay was incorporated into the soil to serve as a sink for any remaining excess salt. Re-sampling of soil to confirm conditions is presently underway to assure it is returned to a productive state.

Gear lubricant

Reciprocating pumps are regularly used throughout the gas industry. These pumps are exposed to extreme temperatures and operate in remote areas where performing repairs can be difficult. Therefore, keeping these pumps running is critical for the midstream industry.

Because these pumps are heavily loaded and can operate in excess of 10,000 psi, they need high performance lubricants to provide maximum protection in this harsh environment. Castrol Ltd. has produced the Castrol Optigear Synthetic X, a gear lubricant that represents breakthrough technology that will help reciprocating pumps remain at maximum reliability with reduced maintenance and repairs.

Castrol Optigear Synthetic X combines a fully synthetic fluid with high-performance additives to maximize anti-wear and extreme pressure protection to gears, bearings and crossheads. This can result in pumps being put under full load faster than with mineral oils.

Other features of Optigear Synthetic X include high load-carrying capacity, superior micro-pitting protection, excellent friction reduction, prevention of sludging, extends oil service life for three to five years, superior wear protection at high temperatures, remains fluid at cold startup temperatures and maximum uptime with reduced repair costs.

Survey mapping and reporting tool

Dewberry, an architectural, engineering and management consulting firm headquartered in Fairfax, Virginia, has developed a system for linear projects that integrates field and office technologies to optimize project outcomes. The Survey Mapping and Reporting Tool (SMART) is a web-based, geospatial information system for end-to-end managing and reporting of project activity to improve safety and product delivery.

SMART performs multiple real-time actions that helps surveyors in the field integrate with client safety and security structure and protocols. SMART also delivers safety and security notifications via an internal team emergency-alert broadcast system, as well as precise display of local emergency facilities, such as hospitals, law enforcement and ranger stations. Other real-time user and management options include field-personnel location, weather radar and fire warnings, and scheduling and tracking of day-to-day field and office operations.

Dewberry's SMART simplifies project processes by delivering real-time project maps and pertinent project data, such as project alignments and assets; project-control locations and data sheets; survey field notes; record plats and exhibits; and right-of-way and easement documents.

Dewberry offers this tool on complex projects, because the real-time data enables flexible, proactive decision-making, while lessons-learned are implemented more quickly using tracked progress, measured results, and integrated project data. The tool supports redundancy checks by integrating with client and other team-member project databases and public information sources.

Filter design

One of the largest natural gas suppliers in the Appalachian basin recently installed Shawndra Products Inc.'s newest technology, SparksTM R100 coalescing pipeline filters at five coal-bed methane operations in Virginia and West Virginia. The first two of these filter units have now been in continuous, service-free operation for six months.

One unit processes 7 MMcf of natural gas, filtered at the manifold-head of ten gas wells, to remove water, liquid mist, coal dust and sand to protect two downstream Caterpillar engines and two compressors. R-Series filters remove the solid particles and liquids from natural gas, using multi-stage filtration technology, vastly reducing maintenance service and downtime to compressors, engines, turbines and other gas-fired equipment.

This same pipeline filter replaced a competitive unit that required seven four-inch by 36-inch elements. The new Sparks Series R100 filter, with only three elements, had operated continuously for six months without needing any service, saving this coal-bed methane producer 75 hours of remote field maintenance and about $20,000 in replacement filter elements.

After six months of service, the coal-bed methane producer opened the vessel and pulled its elements for inspection. Although soiled, the elements were quickly washed and placed back in service. Obviously, a substantial amount of contaminant is removed prior to the filter elements prolonging element life. The sump area was drained, the elements were reinstalled and the vessels have been placed back in service. To date, this same vessel has been in service-free operation for an additional five months. All of the other R100 filters in service have similar or better results. Options available include separate sump tank, platforms, ladders, all valves and gages.

Fiberspar linepipe

Fiberspar LinePipe LLC has introduced to the midstream market a patented, spoolable, high-strength, fiber-reinforced pipeline for gathering, injection and transmission applications, and remediation of existing lines. This new solution, LinePipe, provides lower capital and operating costs and improved pipe integrity and field performance over conventional jointed-line pipe.

Fiberspar LinePipe's design uses a filament-wound glass-reinforced structural layer similar to existing stick fiberglass pipe, but with the addition of a thermoplastic liner, which acts as both the manufacturing mandrel and fluid barrier. The entire structure is bonded together.

The product is appropriate for flowline applications due to its availability in long, continuous lengths with few connectors, rapid deployment from strategic centers throughout North America, nearly 75% faster installation than stick fiberglass or welded steel with fewer people and less equipment. It is suitable for sour or sweet in-field crude oil or natural gas gathering and transmission, high-pressure water, and carbon dioxide injection applications, and pipeline remediation, and is availabile in two-inch to six and a half-inch nominal sizes. The product is engineered and certified for operating pressures from 300 psi to 2,500 psi and temperature ratings from –34°C (–29°F) to 60°C (140°F), or 82°C (180°F) continuous operation.

Furthermore, LinePipe is API 15 HR monogrammed and meets all industry regulatory standards and quality requirements, including ISO 9001. It can be deployed and installed in North America for about 25% less than welded steel. In addition, it lowers capital and operating costs by eliminating all corrosion-related maintenance costs over the life of the field.

Savings to a North American field with a 20-year drilling program where 80 wells are drilled per year is an estimated $45 million net present value from installation and operating cost reductions if LinePipe was used exclusively in place of steel.

Vapor recovery unit

To meet the production equipment demands of one of the fastest growing oil and gas plays in North America, Exterran Holdings Inc. has been developing new products specifically designed for the high API-gravity condensate and sour gas prevalent in the Eagle Ford and other shale plays.

Two new products have been designed specifically for the high API gravity condensate and sour gas of the Eagle Ford. Partnering with an industry leader to offer vapor recovery technology, the Exterran Vapor Recovery Unit (VRU) captures valuable natural gas that would otherwise be vented or flared into the atmosphere. The pre-engineered, customizable package features programmable logic controller-based precision pressure regulation, automatic tank pressure sensors, oxygen monitoring of compressed vapors and a compressor with variable speed drive.

Employing compression to recover vapors from condensate and natural gas liquids storage tanks, stock VRUs can recover between 22,000 to 400,000 cubic feet of natural gas per day. The unit consists of a direct-drive compressor, water-cooled engine, fuel-gas and water knock-out tanks, oil coolers and a precision pressure controller mounted on a containment skid. The unit can be outfitted with a rotary screw, piston or scroll compressor, powered with either an electric or natural-gas certified (according to EPA standards) engine. This standard product can be easily customized to meet client needs.

To improve worker safety, extend the life of client assets and to meet hydrogen sulfide pipeline specifications, Exterran is launching a new Hydrogen Sulfide Eliminator (H2SE) designed to remove hydrogen sulfide from the natural gas stream. The H2SE uses a triazene solution to remove hydrogen sulfide from natural gas. The spent triazene solution can be safely disposed with produced water.

The H2SE consists of a structured packed contactor tower with stainless-steel packing, solar-powered H2S monitor, natural gas-powered pump, optional after-scrubber, optional heater, optional standby pump and optional flash-gas separator. The triazene solution circulation is controlled by the H2S monitor to ensure pipeline specification is consistently met.