1、I I I I I I I I I I I I I I I I I I I GPA TITLExGUIDE 87 3824b79 0002LOb 512 GUIDE FOR PERFORMANCE TESTING OF PLANT EQUIPMENT Initial Publication 1989 GAS PROCESSORS ASSOCIATION 6526 E. 60th STREET TULSA, OK 74145 PHONE: 9181493-3872 TELEX: 91 0-845-21 91 GPA TITLE*GUIDE 89 m 3824699 0002107 459 m D
2、ISCLAIMER The Guide for Performance Testing of Plant Equipment was devel- oped by GPA Technical Section A. These data are to be taken as sug- gestions based on operating experience of Committee members. Each situation requires judgment of the individual concerned. Neither the GPA nor any member of T
3、echnical Section A makes any warranty, guaran- tee or representation, express or implied, with respect to the ac- curacy, completeness, or usefulness of the information contained in this report. i I I I 1 1 I I I I I I 1 I I I! I I I I GPA TITLE*GUIDE 89 m 3824697 0002108 395 m TABLE OF CONTENTS GEN
4、ERAL INFORMATION Disclaimer Table of Contents Acknowledgement PLANT ACCEPTANCE AND PERFORMANCE TESTS Plant Acceptance and Performance Tests TOWERS AND VESSELS Absorbers Fractionators Filters and Separators ENGINES AND TURBINES Natural Gas Fueled Reciprocating Engines Gas Fired Turbines Steam Turbine
5、s Gas Expander Turbines (Turbo Expander) COMPRESSORS, PUMPS AND BLOWERS Reciprocating Compressors Centrifugal Compressors Axial Compressors Worm/Screw Compressors Reciprocating Pumps Centrifugal Pumps Blowers and Fan HEATING AND COOLING Aerial Coolers Cooling Towers Fired Heaters and Boilers Waste H
6、eat Recovery Units Process Exchangers and Reboilers ii 1 ii iii Section Page Tab A 1 A-1 Tab B 1 B-1 2 B-9 3 B-17 Tab C 1 c-1 2 C-14 3 C-25 4 c-35 Tab D 1 D-1 2 D-14 3 D-23 4 D-27 5 D-32 6 D-38 7 D-47 Tab E 1 E-1 2 E-7 3 E-24 4 E-34 5 E-46 GPA TITLEaGUIDE 89 W 3824699 0002LO 221 ACKNOWLEDGEMENT In 1
7、982, Technical Section at the direction of then Chairman J.A. (Joe) Zanetell and endorsement of the Technical Committee undertook, as a section project, the development of a “Guide for Performance Testing of Plant Equipment,“ The Guide would compliment two check- lists that had been previously devel
8、oped by Technical Section A and published by GPA. committee with members of Section A serving as coordinators, writers and editors. The Ad hoc committee was initially chaired by John Hunt, Mobil Oil Corporation with R.A. Robinson, Tejas Gas Corporation, serv- ing as Co-chairman. In March, 1985, John
9、 Hunt retired and Joe Cloessner, Mitchell Energy Corporation, was named to chair the com- mittee. The project was organized to function as an Ad-hoc Since the projects inception in the Fall of 1982, almost every member of Section A and many associates in the GPSA industry contrib- uted of their time
10、 and talent to the development of the Guide. It is beyond the scope of this acknowledgement to name all persons who par- ticipated in the development of the Guide, however, it is appropriate here to recognize their efforts and extend the heartfelt “thanks“ of GPA. Further, it is most appropriate tha
11、t Technical Section A give special due to the people who served long and laboriously to edit the Guide in it published form. A special thanks to the EDIT REVIEW COM- MITTEES. V“rst“ Final Edit Review Committee T. J, Wheeler, Union Pacific Resources Company Chairman Technical Section A, Joe J. Cloess
12、ner, Liquid Energy Corp. Vice-chairman Technical Section A. Howard Grekel, HG Consulting Associates, Inc. J. M. Harryman, Shell Oil Company. “Final“ Final Edit Review Committee Harold L, Schnack, Warren Petroleum Co., a Div. of Chevron USA. Boyd George, Amoco Production Co. Don B. Earnst, ARCO Oil d
13、ead weight gauges and standard 7. Thermocouples and readouts. thermometers. D. Determine Test Schedule 1. Duration. 2. Maximum delay from mechanical acceptance date. 3. Maximum delay of report from end.of test. III. PRE-TEST PREPARATIONS A. Test Notifications 1. Notify gas supply operators and reque
14、st stable supply before and during test. 2. Notify maintenance personnel. a. Additional personnel required for equipment b. Revise plant preventative maintenance schedules installation and calibrations. to avoid test period. 3. Notify plant operations personnel. a. Routine operator assignments. b. E
15、xtra operators required for normally nonattended periodF and for additional monitoring assign- ments. A-3 GPA TITLE*GUIDE 89 = 3824b 0002114 699 B. Test Parameters 1. 2. 3. 4. 5. 6. 7. 8. 9. List and plan analyses of all entering and leaving gas and liquid streams-inlet, residue, product rundown and
16、 product surge vessel liquids. Prove all plant meters. Check orifice plate sizes. Record spring and temperature range, Calibrate all thermometers, gauges and analyzers. Strap all liquid product storage tanks. Read flow totalizers, Note level gauges. Pre-fill displacement fluids in sample containers,
17、 as needed. Stabilize plant operation - make necessary changes in operating conditions - pressure, temperature and flow rates to obtain desired operating conditions. Lower levels of product make tanks to permit zero make-tank deliveries if possible. Check operation of all recording meters and set co
18、r- rect chart time. Check totalizers and integrating flow meters. Confirm computer programming and design computer storage (DCS) recording, storage and retrieval capability. Check operation of all on line stream analyzers and set correct time on strip charts. IV. TEST CHECKLISTS A. Startup-Checklist
19、 1. 2. 3. 4. 5. 6. Take opening gauges and temperatures on all pro- duct storage tanks. Take opening readings for all product delivery meters. Record or mark all opening levels for process liquid surge vessels. If possible, empty all continuous sampler receiv- ing tanks and restart samplers. Change
20、all plant charts and/or mark start time on chart. Record process operating conditions and weather data not being automatically recorded. a. Visual readings by test personnel. b. Printed copy from data storage of process monitoring devices. B. Mid-Test Checklist 1. Take process operating data and wea
21、ther condi- tions at selected test intervals corresponding to the start and end of each interval and at times of each set of spot samples. 2. Take multiple spot and combined samples at selected intervals, if required. 3. Take sets of spot samples at selected times to represent at least three adjacen
22、t time periods A-4 GPA TITLEIGUIDE 89 M 3824b99 0002115 525 during the test. No test should ever be based on only one set of spot or composite analyses. 4. Monitor operation of all recording meters, ana- lyzers, samplers and data-taking devices. 5. Avoid process operating adjustments that tend to de
23、stabilize the process. 6. Delay any routine equipment shut-down until after test completion. C. Closing Checklist 1. 2. 3. 4. 5. 6. 7. Take closing gauges and temperatures on all pro- duct storage tanks at end of each test interval. Take closing readings for all product delivery meters at end of eac
24、h test. Record all test period product delivery ticket volumes. Record or mark closing levels of all process liq- uid surge vessels for each test interval. Shut-in continuous samplers and take/retrieve combined samples. Change all plant charts and/or mark closing time on chart for each test interval
25、. a. Collect and retain all non-accountable charts. b. Read, integrate, make photo copies and record all necessary data from accountable charts (charts that cannot be retained for test file). Record process operating data and weather not otherwise recorded. a. Visual readings. b. Printed copies from
26、 process monitoring devices. D. Post Checklist 1. Quick check all data for any flaws that void test results and make the approval decision more difficult. 2. Submit samples for analysis. 3. File and protect all data. could possibly or disapproval 4. Re-check calibration of all critical me-ers and/or
27、 an- 5. Calculate all test volumes corrected to standard con- alyzers. ditions. V. TEST REPORT PREPARATION A. Assemble All Data and Analytical Results. B. Determine Inlet and Outlet Streams in Common Units C. Calculate Component Volumes. D. Calculate Extraclion Efficiency by Component. (Pounds or Mo
28、ls). 1. Method a. Ratio of component total in products to com- ponent total in inlet streams. A-5 GPA TITLESGUIDE 89 D 3824699 0002LLb 4bL D b. Ratio of component total in products to com- ponent total in all residue, fuel and pro- duct streams. Adjustments for the variation in level of process surg
29、e vessels should be made. test interval the overall material balance for each component (products + fuel + residue gas as a percentage of measured total inlet streams) based on corresponding sets of rates and spot analyses for test time intervals and for the overall composite samples (if any) and ra
30、tes for the total test period. These will aid in evaluating the steadiness of the operating condi- tions and the validity of the data and results. The use of the calculated inlet composition from the sum of the products to force all material balances will not compensate for bad data. c. Calculate an
31、d include in the report for each The, “Sample Calculations“, attached as Tables I, II and III, illustrate a test with apparent metering and analytical errors. The metering er- ror(s) are shown by the methane and propane balances. Analytical errors are shown especially by the ethane, carbon dioxide a
32、nd c6 material balances. These should have been much better. Such errors could have a substantial economic ef- fect on the plant profits. This is not an ac- ceptable test. The material balances are too poor to permit valid conclusions regarding pres- ent recoveries. E. Final Test Report 1. Assemble
33、all plant data. 2. Check all calculations. 3. Prepare draft report. 4. Verify draft report results. 5. Submit final report with recommends-ions. NOTE : Modern distributed control systems can accumulate, record, manipulate and printout the various items needed for test- ing. It is necessary to confir
34、m the presence and availability of these data. Some analytical data combined with the DCS information may facilitate plant and/or equip- ment testing. Computer simulation of the equipment or plant can significantly aid in evaluating the test results. A-6 I I U I I I I I 1 1 I 1 U 1 I n GPA TITLExGUI
35、DE Q)u)mmcpomFlt-cp rlmcpomt-t-mol0 aQIoQIoQIooQIu) rl rl drl n A Y Y*. m cprloo*u)omrl12cp u)oQIooQIu) mooot-mmo d drl L. m Y -rl00rn00000 d* oooaooooo 4 12QIooooo rldrlrlrl * d O rl QI 12 * d t- io u) t- o t- 12 . - Y - CJ 12 rn u) u) rl rl C cp Co u) d Q) Co - 89 m v) 4 O B 2 n a i$ 3824699 CI H
36、H al d a a B . : Ca al k u 00 u at d u O W O a 0002117 3T8 A- 7 GPA TITLE*GUIDE 89 cv 00 o CJ 00 d rl . cjiQoCuw00000 cji o IL)ocJwmooooo o d mmm*CJ mu3 Few* ON dFd dCu O d* d d . 99. 99 m 3824699 0002118 234 m PI Cu P 00 u) . Et O to a c m B *d a O O Qo 4J a al k al 4J m m ei o 5 a O A-8 0dco000000
37、 o O d 3q c3 m a w 23 ooomma)mdocI o Io m 0000000000 o #SI rloodobmIoIoo o m m u!nt . . . . *. . . w o00ecJmooooo o w3 00cJ00000 o pl cJe000000 9 .o.*., 0du)rl000000 o O d iq E O u A- 9 JJ “ d O E + u“ O rl * O d d m c U w U a ai o GPA TITLE*GUIDE 89 3824b99 0002L20 992 TAB B - TOWERS AND VESSELS IN
38、DEX FOR ABSORBERS B1. ABSORBERS I. OBJECTIVE A. Capacity B. Absorption Efficiency C. Energy Requirements D. Operating Stability II. DEFINITIONS III. PREPARATION FOR TESTING A. Data Requirements B. Test Instruments C. Calibration of Instruments D. Placement of Test Instruments E. Sample Container Req
39、uirements F. Special Sampling Techniques G. Design Data Acquisition IV. FIELD TESTING A. Data Logging B. Sampling C. Special Instructions or Precautions V. COMPUTATIONS A. Data Accumulations B. Calculations C. Performance Compared with Requirements/Guarantees VI. REPORT A. Summary of Results B. Back
40、ground C. Discussion D. Data Presentation B- 1 GPA TITLE*GUIDE 89 3824699 0002L2L 827 = TESTING PROCEDURES FOR ABSORBERS I. OBJECTIVE An air absorber is tested to determine its ability to meet the owners requirements and/or vendors guarantee relative to: A, Capacity B. Absorption Efficiency C. Energ
41、y Requirements D. Operating Stability II. DEFINITION Gas absorption is a unit operation in which soluble components of a gas mixture are dissolved in a liquid usually called the lean solvent or simply lean oil. oil is regenerated in a desorption or stripping process and recycled to the absorber as l
42、ean oil in a continuous operation. The efficiency of the absorber is affected by the completeness of the rich oil regeneration. Normally the rich solvent or rich In gas processing, “absorber“ usually connotes the tower in which the gas stream is contacted with lean oil to remove a por- tion of the h
43、eavier hydrocarbons from the gas stream. Strictly speaking, the “contactor“ used to remove CO2 or H2S in gas treat- ing is an absorber, as is the “contactor“ used in dehydration with a glycol solution. The testing of these “absorbers“ is similar to the testing of the lean oil absorber. Note: It is a
44、ssumed the reader is familar with words and terms associated with gas processing and plant operations. III, PREPARATION FOR TESTING A. Data Requirements 1. Temperatures a. Inlet gas feed. b. Column overhead or outlet gas. c. Absorption oil inlet. d. Bottom products or rich oil. e. Sidestreams, if pr
45、esent. f. Each tray, if possible, for temperature profile. g. Ambient temperature. 2. Pressures a. Inlet gas feed. b. Column overhead or outlet gas. c. Tower bottom. d. Sidestreams, if present. B-2 I I 1 I I i i I I I I I 1 1 I 1 I I 1 I I I I I I I I I I I I I I I 1 I I I GPA TITLESGUIDE 89 3824699
46、 O002122 765 = e. Differential pressure of total column. f. Barometric pressure. 3. Flow Rates a. Inlet gas feed. b. Absorption oil or solven c. Column overhead. d. Sidestreams, if present. e. Bottom product or rich oil. 4. Composition a. Inlet gas feed. b. Absorption oil (ASTM D-86 Distillation Cur
47、ve) solvent. c. Column overhead. d. Sidestreams, if present. e. Bottom product or rich oil. 5. Levels a. Tower bottoms. b. Feed vessels. c. Product tanks. B. Test Instruments 1. Chromatograph with both liquid and vapor analyti- cal capability and services of laboratory to ana- lyze samples. the abso
48、rber. 2. Flow meters on all streams entering and exiting 3. Thermowells for thermometers or thermocouples. 4. Differential pressure transmitters and quality pres- 5. Sample cylinders for gas and liquid samples. 6. Chromatography standards with certified analyses sure gauges. approximating samples to
49、 be tested. C. Calibration of Instruments 1. Calibrate the chromatograph with previously ob- 2. Calculate all orifice coefficients. 3. Prove turbine meters. 4. Check differential pressure transmitter zero and tained gas and liquid standards. span for all orifice meters and recalibrate if outside manufacturers accuracy. 5. Calibrate mercury type thermometers and/or thermocouples. 6. Calibrate differential pressure cell transmitter for column differential by deadweight tester. 7. Check all orifice plates for proper installation, diameter, width and sharp edges, if possib
