ICDL Module 1 (IT) lec (1)

Concepts of Information Technology (IT)

1.1 General Concepts
1.1.1 Hardware, Software, Information Technology
1.1.1.1 Understand the terms hardware, software, Information Technology (IT).
Hardware
• The term hardware refers to the physical components of your computer such as the
system unit, mouse, keyboard, monitor etc.
Software
• The software is the collection of instructions which makes the computer work. For
instance, when you type in words via the keyboard, the software is responsible for
displaying the correct letters, in the correct place on the screen. Software is held either
on your computer’s hard disk, CD-ROM, DVD or on a diskette (floppy disk) and is loaded
(i.e. copied) from the disk into the computers RAM (Random Access Memory), as and
when required.
Information Technology (IT)
• This is a general term which relates to the use of computers as an aid to creating and
maintaining data, i.e. information. IT is related to all aspects of managing and processing
information, especially within a large organisation. Computers are critical to managing
information, and computer departments within large organisations are often called IT
departments. Alternative phrases are IS departments (Information Services) or MIS
departments (Management Information Services). People working with computers within
large companies will often refer to their job, as “working in IT”.

1.1.2 Types of Computer
1.1.2.1 Understand and distinguish between mainframe computer,
network computer, personal computer, laptop, personal digital assistant
(PDA) in terms of capacity, speed, cost, and typical users.
What is a mainframe computer?
• Mainframe computers are the big, powerful, expensive computers used in the
background by most large organisations. The power of the mainframe can be distributed
amongst many people accessing the mainframe via their own PC. Organisations such as
large insurance companies would use the mainframe to keep track of their policyholders
and send out renewal notices.
What is a PC?
• IBM invented the PC (Personal Computer) way back in 1981. All PCs released since
then are in many ways compatible with the original design, though many extensions
have been made. The term PC compatible relates to PCs manufactured by companies
other than IBM which are compatible with the traditional PC specification. In the early
days, most PCs ran an operating system called DOS (Disk Operating System). These
days most PCs will be running a version of Microsoft Windows.
What is a Mac?
• The Apple Mac is a computer, but NOT a PC. It uses a different operating system, and
requires special versions of application programs (such as word-processors or
spreadsheets). Even the hardware add-ons have to be customised to some extent to be
able to be connected to a Mac. In the early days the thing which really distinguished the
Mac over the PC was the GUI (Graphical User Interface), or in plain English the way you
could use the mouse to drive the computer. In the early days of the PC, you really had to
be a bit of an expert to use and maintain your PC. Recently the differences between the
PC and the Mac have blurred, with Microsoft buying a stake in Apple.
What is a networked computer?
• A network allows you to connect two or more computers together. This allows data
stored on one PC to be retrieved by other PCs connected to the network. It also allows
the sharing of resources. Thus instead of each PC requiring its own printer to be directly
connected to it, you can have a single printer shared amongst many networked PCs. In
the early days, to network PCs together was a complicated task, only to be attempted by
qualified professionals. These days most people with a good working knowledge of
Microsoft Windows can install and configure a Windows based network. However to get
the best out of your network, in terms of performance and security, still requires a
qualified, experienced technician.
What are laptop & palmtop computers?
• Laptop computers, as the name implies, are small portable computers which can run on
batteries as well as mains power. They use special screens, rather than the traditional
bulky VDUs (Visual Display Units), which allows for longer battery life as well as
portability. A newer term, “Notebooks”, simply indicates a VERY small laptop. These are
especially popular with salespersons on the move or people giving presentations. While
they tend to still be more expensive than an equivalent Desktop computer, they can now
match the power of a Desktop computer. Palmtops are even smaller computers which
can literally fit into the palm of your hand.
What is a Personal Digital Assistant (PDA)?
• These devices use a special pen, rather than a keyboard and can be used for storing
and retrieving information. Like most computer devices, many can connect to the
Internet. They are extremely compact.
Types of computer - Mainframe
• Capacity: Very powerful computers often connected to many individual PCs over a network.
Speed: Much faster than PCs used for processing large amounts of data such as mail-shots, salaries, tax
etc.
Costs: Very, very expensive, only affordable by large companies.
Typical Users: Only used by large companies including banks, building societies etc.
Types of computer - PC
• Capacity: Large hard disks combined with a work working memory (RAM)
Speed: Fast. Normally measured in GHz.
Costs: Getting cheaper by the day.
Typical Users: Home users, large and small offer users. Education, Doctors. In fact just about everyone
needs to know how to operate a PC these days.
Types of computer - Networked PC
• Capacity: Large hard disks combined with a work working memory (RAM)
Speed: Fast. Normally measured in GHz.
Costs: A PC only requires an inexpensive card to be added to it to connect it to a network.
Typical Users: Due to ease of networking a PC these days just about anyone can network PCs together.
Types of computer - Laptop
• Capacity: Large hard disks combined with a work working memory (RAM) – Often less powerful than for a
PC of equivalent price.
Speed: Fast. Normally measured in GHz. Often speed specifications are less than for a PC of equivalent
price.
Costs: Components need to be much more compact, so there is a price overhead when compared to a PC
of equivalent power.
Typical Users: Business users, people on the move, educational users.
Types of computer - Palmtop
• Capacity: Much smaller storage capacity compared to a PC.
Speed: Much less than a PC unless you pay a lot extra.
Costs: In relative terms expensive when compares to a PC.
Typical Users: Mostly business users.
Types of computer - PDA (Personal Digital Assistant)
• Capacity: Much smaller storage capacity compared to a PC.
Speed: Much less than a PC unless you pay a lot extra.
Costs: In relative terms expensive when compares to a PC.
Typical Users: Mostly business users.
1.1.3 Main Parts of a Personal Computer
1.1.3.1 Know the main parts of a personal computer such as: central
processing unit (CPU), hard disk, common input or output devices, types
of memory. Understand the term peripheral device.
The System Unit
• The "system unit" is the name given to the main PC box which houses the various
elements which go together to make up the PC. For instance within the system unit is the
computer system's motherboard, which contains all the main components, such as the
CPU. The system unit also houses items such as the hard disk, the floppy disk and CDROM
drives etc. System units come in two basic varieties, the tower version, as
illustrated, or a desktop version, which is designed to sit on your desk with your monitor
on top of the system unit.
The System (Mother) Board
• The system (mother) board is contained within your system unit and all the vital
computer systems plug directly into the system board. The CPU is normally housed on
your system board along with all the other electronic components. Other items such as
the hard disk are attached to the system board, either directly or via cables. These
boards are getting smaller and smaller as the components become more integrated. If
you open up a modern system you will find that it is mainly full of air.
The CPU
• The CPU (Central Processing Unit) is normally an Intel Pentium (or equivalent) and it is
one of the most important components within your computer. It determines how fast your
computer will run and is measured by its MHz or GHz speed. Thus, a 2 GHz Pentium is
much faster than say a 1 GHz Pentium CPU. It is the CPU which performs all the
calculations within the computer, when running programs such as word-processors,
spreadsheets and databases. See page 16 for more information.
Memory (RAM)
• The RAM (Random Access Memory) within your computer is where the operating system
is loaded to when you switch on your computer and also where your applications are
copied to when you start an application, such as a word processor or database program.
When you create data, (e.g. letters and pictures), these are initially created and held in
RAM and then copied to disk when you save the data. As a rule of thumb, the more RAM
you have installed in your computer the better. These days you will commonly find over
128 Megabytes of RAM installed.
ROM-BIOS
• The ROM-BIOS (Read Only Memory - Basic Input Output System) chip is a special chip
held on your computer's system (mother) board. It contains software which is required to
make your computer work with your operating system, for instance it is responsible for
copying your operating system into RAM when you switch on your computer.
Serial Port
• The serial port is a socket located at the back of your computer which enables you to
connect items to the computer, such as a modem. They are commonly labelled as
COM1 or COM2.
Parallel Port
• The parallel port is a socket located at the back of your computer which enables you to
connect items to the computer, such as a printer. It is commonly labelled as LPT1 or
LPT2.
Universal Serial Bus (USB)
• The Universal Serial Bus is a relatively new item within the PC. You will see one or more
USB sockets at the back of the system unit, allowing you to plug in devices designed for
the USB. These devices include printers, scanners and digital cameras.
What are input devices?
• Input devices allow you to input information to the computer and include things such as
the keyboard and mouse.
What are output devices?
• Output devices allow you to output information from the computer and include the printer
and the monitor.
What is a peripheral device?
• A peripheral device is any device which you can attach to your computer. Thus, you
could attach a scanner or modem to the back of your system unit.
The Keyboard
• An Input device. The keyboard allows you to type information into the computer. It has
evolved over the years and many people now use a Microsoft style keyboard, which has
additional keys designed to make Microsoft Windows easier to use.
The Mouse
• An Input device. When using an operating system, such as Microsoft Windows, you use
the mouse to select drop down menus, to point and click on items, to select items and to
drag and drop items from one place to another.
CD
• Most computers are now supplied with a CD-ROM (Compact Disc - Read Only Memory)
drive. CD-ROM discs look exactly like music CDs but contain computer data instead of
music. The advantage of a CD-ROM is that it can hold a vast amount of data (equivalent
to the storage capacity of over 450 floppy disks). The other big advantage of CD-ROMs
is that they are interchangeable. This means that you can own a range of different CDROMs
and choose which one to insert into your CD-ROM drive.
DVD Drives
• Short for "Digital Versatile Disk”. Similar to CD-ROM drives but allows you to use DVD
disks, which contain vastly more information than a traditional CD-ROM disk. These also
transfer the data from the disk to the computer far faster, allowing you to watch movies
on your computer screen. A CD-ROM can store 650 MB of data, while a single-layer,
single-sided DVD can store 4.7 GB of data. The two-layer DVD standard allows a
capacity of 8.5 GB. A double-sided DVD increases the storage capacity to 17 GB (or
over 25 times the data storage capacity of a CD-ROM).
Floppy disk
• Floppy disks are also known as diskettes. They are very slow compared to hard disks or
CD-ROMs, and hold relatively small amounts of data (1.44 Mbytes). Sometimes people
will backup (i.e. copy) important data from their hard disk to floppy disks. However, as
diskettes are notoriously unreliable this is not the best way of backing up valuable data
(but is better than nothing).
Zip Disc
• A Zip disk is like a bigger version of the floppy disk, the main difference being that a
single Zip disk can hold up to 250 Mbytes of data. They also offer increased speed
compared to the old floppy disk.
Hard (Fixed) Disk
• Hard disks are the main, large data storage area within your computer. Hard disks are
used to store your operating system, your application programs (i.e. your word
processor, games etc) and your data. They are much faster than CD-ROMs and floppy
disks and can also hold much more data. The picture shows the inside of a hard disk
(which you would not normally see). Hard disks are installed within the system unit of
your computer.
The Monitor
• An output device. The monitor is the TV type screen on which you view your programs.
They are supplied in different sizes, common sizes range from 15" to 21" screens. You
should be aware that poor quality or badly maintained monitors could harm your
eyesight.
Additional items or cards
• Many 'extra' components can easily be fitted to your computer, which has the advantage
of making the computer 'upgradeable' as newer and better hardware comes along.
Sound cards and speakers
• Many computers are now supplied with sound cards and speakers which means that
when you run 'multi-media' programs, you can listen to sounds which are played back via
your computer. If you have a microphone and suitable software, you can also record
sounds. You can even purchase special software which will allow you to talk to your
computer and get the computer to type the words you have spoken on your screen. In
time, this type of software may replace the keyboard.
Modems
• A modem is a device which is used to attach your computer to the telephone system.
The modem converts data into sound which is sent over the telephone line, the receiving
modem turns the sounds back into data. If you wish to connect to the Internet, you will
need a modem (or equivalent device). Modems used to be large boxes that you had to
plug into the computer, but now modems boxes have become very small and in many
cases the modem is actually inside the computer. If you are using ISDN or broadband
then you will use another device similar to a modem.
Printers
• Most data is printed once you have created it and there are a vast number of different
printers available to accomplish this. Most common are ink jet and laser printers both of
which can now produce coloured output (at a cost).
Scanners
• Scanners allow you to scan printed materials into your computer, which can then be
stored within the computer. These pictures can then be altered, resized and printed as
Recordable CDs
• CD-ROMs are read-only devices, but increasingly people are purchasing a special type
of CD drive unit which allows you to record data, music or video to your own CDs. These
devices require the purchase of special CDs to which you can write, called CD-R
(Compact Disc – Recordable).
Tape backup
• A tape backup unit allows for regular backing up of your data. These tapes can store a
vast amount of data at a low cost. DAT (Digital Audio Tape) devices are commonly used
for backups. The DAT tapes which are used can backup enormous amounts of data (i.e.
over 4 GBytes per tape). The devices are also fast and reliable.
What is PCMCIA?
• Portables by their very nature are very compact and require smaller than standard parts
such as hard disks and CD-ROM drives. Many portables are supplied with special
adaptor sockets which enable what are called PCMCIA compatible hardware to be
connected to them. PCMCIA components tend to be more expensive than standard
computer parts which are designed for more bulky desktop computers.
More information: http://www.pcmcia.org
1.1.4 Computer Performance
1.1.4.1 Know some of the factors which impact on a computer’s
performance, such as: CPU speed, RAM size, the number of applications
running.
Factors affecting performance
• CPU Clock speed: The computer clock speed governs how fast the CPU will run. The
higher the clock speed the faster the computer will work for you. The clock speed is
given in megahertz (MHz). The original IBM PC ran at 4.77 MHz whereas modern PCs
will run at over 2000 MHz, which gives you an idea of how far things have progressed.
The higher the MHz speed the faster the computer.
RAM size: As a rule the more memory you have the faster the PC will appear to operate.
Windows also uses the hard disk a lot, so logically the faster the hard disk can operate
Hard disk speed and storage: Hard disks are also measured by their speed, defined by
the disk access time, which is measured in milliseconds. The smaller this access time
the faster the hard disk will store or retrieve data. The data storage capacity of hard disks
continues to increase as new products are released. The disk storage capacity is
measured in Gigabytes (GBytes). 1 GByte is equivalent to 1024 Mbytes.
Free Hard Disk Space: To get the most out of your Windows based PC, you not only
need a fast hard disk but also a large hard disk with plenty of "spare space". This is due
to the fact Windows is constantly moving data between the hard disk and RAM (Random
Access Memory). Microsoft Windows will create many so-called “temporary files” which it
uses for managing your programs. In fact, if you have very little free hard disk space you
may find that Microsoft Windows will not be able to run your programs at all.
De-fragmenting Files: If you are running Windows you may find that if you click on the
Start menu, select Programs, and then select the Accessories / System tools group,
there is a de-fragmentation program. Running this periodically may noticeably speed up
the operation of your PC. When you use a PC, over a period of time the files get broken
up into separate pieces which are spread all over the hard disk. De-fragmentation means
taking all the broken up pieces and joining them back together again.
Multitasking considerations: Windows is a multitasking system, which means that it
can run more than one program at a time. However the more programs which are
running at the same time, the slower each one will run. To some extent this slowing
effect depends on what each program is doing. Editing a large, full colour picture for
instance can take up a lot of CPU time.
1.2 Hardware
1.2.1 Central Processing Unit
1.2.1.1 Understand some of the functions of the CPU in terms of
calculations, logic control, immediate access memory. Know that the
speed of the CPU is measured in megahertz (MHz) or gigahertz (GHz).
The CPU (Central Processing Unit)
• The CPU is the brains within your computer. It performs most of the calculations within
the computer and is responsible for the smooth running of your operating system
(Microsoft Windows) as well as your application programs, such as word-processors,
spreadsheets and databases. There is a small amount of memory associated with the
CPU, which it uses to perform these operations. It also accesses and uses the main
memory (RAM - Random Access Memory) within your computer. In many ways, the CPU
is the single most important item within your computer which governs the overall speed
of your computer. The CPU's speed is measured in MHz. This relates to the frequency at
which the CPU runs and the higher the MHz rating of your CPU the faster your computer
will run. To give you some indication of how PCs have advanced over the years, the
original IBM PC released in 1981 ran at less than 5 MHz while modern PCs can run at
speeds well in excess of 2000 MHz (2 GHz). Note that 1000 MHz is the same a 1 GHz.
More information:
Intel: http://www.intel.com
AMD: http://www.amd.com
Cyrix: http://www.viatech.com
1.2.2 Memory
What is computer memory?
• You can store data on your hard disk, while data which is being processed is stored in
RAM (Random Access Memory). Data which is stored on a hard disk can be permanent,
while data in RAM is only temporary. Normally when people talk about memory in
relation to a PC, they are talking about RAM.
1.2.2.1 Understand different types of computer memory such as: RAM
(random-access memory), ROM (read-only memory) and distinguish
between them.
What is RAM?
• Random Access Memory (RAM) is the main 'working' memory used by the computer.
When the operating system loads from disk when you first switch on the computer, it is
copied into RAM. The original IBM PC could only use up to 640 KB of memory (just over
half a megabyte), whereas a modern computer can effectively house as much RAM as
you can afford to buy. Commonly modern computers are supplied with over 128 MB of
RAM. As a rough rule, a Microsoft Windows based computer will operate faster if you
install more RAM. When adverts refer to a computer having 128 Mbytes of memory, it is
this RAM which they are talking about. Data and programs stored in RAM are volatile
(i.e. the information is lost when you switch off the computer).
What is ROM?
• Read Only Memory (ROM) as the name suggests is a special type of memory chip which
holds software which can be read but not written to. A good example is the ROM-BIOS
chip, which contains read-only software. Often network cards and video cards also
contain ROM chips.
What is the ROM-BIOS?
• The 'Read Only Memory Basic Input Output System' chip is a chip located on the
computer's system (mother) board, which contains software. This software performs a
variety of tasks. When you first switch on the computer the ROM-BIOS software
performs a self-diagnostic to check that the computer is working OK. This software then
loads your operating system from the disk into the RAM.
What is flash BIOS?
• Most modern computers are actually supplied with a flash BIOS rather than a ROMBIOS.
This chip contains exactly the same type of in-built software, but has the
advantage that the software on the chip can be upgraded. This upgrade is achieved by
simply running a small program supplied by the computer manufacturer.
What is video (graphics) memory?
• The picture which you see on your screen is a form of data and this data has to be
stored somewhere. The on-screen pictures are held in special memory chips called
video memory chips; these chips are usually located on the video card. A modern
computer will be supplied with several Megabytes of video memory.
1.2.2.2 Know how computer memory is measured; (bit, byte, KB, MB, GB,
TB). Relate computer memory measurements to characters, files and
directories/folders.
• It is important to understand the following terminology:
Basic Units of Data Storage: It is important to realise that the term digital computer
refers to the fact that ultimately the computer works in what is called binary. Humans
work in tens (because we have 10 fingers). To use the jargon humans work in base 10.
A digital computer uses the numbers 0 and 1 (or on and off if you prefer). When we talk
about computer storage, either the amount of memory (RAM) or the hard disk capacity
we are talking about numbers which are multiples of 0 or 1.
Bit: All computers work on a binary numbering system, i.e. they process data in ones or
zeros. This 1 or 0 level of storage is called a bit. Often hardware is specified as a 32-bit
computer, which means that the hardware can process 32 bits at a time. Software is also
described as 16 bit, 32 bit or 64 bit software.
Byte: A byte consists of eight bits.
Kilobyte: A kilobyte (KB) consists of 1024 bytes.
Megabyte: A megabyte (MB) consists of 1024 kilobytes, approximately 1,000,000 bytes.
Gigabyte: A gigabyte (GB) consists of 1024 megabytes, approximately 1,000,000,000
bytes.
Terabyte: A terabyte (TB) consists of approximately 1,000,000,000,000 bytes.
Files: Data and programs are stored on your disk as files. There are different types of
files, such as the files in which you store your data, the files which contain your programs
and also files used to store your operating system (such as Microsoft Windows).
Directories (folders): Directories or folders are used to group files with a similar theme
together. For example, you could have a folder called “Accounts” containing all your
accounting related files, or a folder called “Customers” containing correspondence with
your customers. Folders can also contain sub-folders to further divide files. The
uppermost level folder is often referred to as the “root” folder (or directory). Sometimes
you may see a diagrammatic representation of folders, as illustrated below.
In this example, we have the root folder at the top. Below this are three sub-folders
called Data, Programs and Games.
Records: A record is a collection of data held within a file. It is the sort of storage unit
used by a database. For more information, please see the ECDL module concerned with
databases.
1.2.3 Input Devices
1.2.3.1 Identify some of the main devices for inputting data into a
computer such as: mouse, keyboard, trackball, scanner, touchpad, light
pen, joystick, digital camera, microphone.
The Mouse
• The mouse came into common use on a PC with the introduction of the Microsoft
Windows operating system. Before this, the operating system (DOS) would normally be
controlled via the keyboard. These days it is vital to be a competent mouse user. There
are many different types of mice, a commonly used model now has a small wheel on it
which when combined with the correct software allows additional functionality and fine
control over the use of your applications.
The Keyboard
• The keyboard is still the commonest way of entering information into a computer. There
are a number of different types, including those specially designed for use with Microsoft
Windows. The quality of the keyboard is often overlooked when buying a PC; it should
be robust and easy to use.
Tracker Balls
• A tracker ball is an alternative to the traditional mouse and favoured by graphic
designers. Tracker balls often give much finer control over the movement of the items on
the screen. They may take a while to get used to if you are used to the traditional mouse,
but offer a lot in terms of added flexibility.
Scanners
• A scanner allows you to scan printed material and convert it into a file format which may
be used within the PC. You can scan pictures and then manipulate these inside the PC
using a graphics application of your choice. In addition, you can scan printed text and
convert this not just to a picture of the text but also to, actual text which can be
manipulated and edited as text within your word-processor. There are a number of
specialist programs, generically called OCR (Optical Character Recognition) programs
which are specifically designed for converting printed text into editable text within your
applications.

Touch Pads
• A touch pad is a desktop device and responds to pressure. Used in conjunction with a
special pen they can be used by graphic artists wishing to create original, digital artwork.
Light Pens
• A light pen is used to allow users to point to areas on a screen and is often used to
select menu choices.
Joysticks
• Many games require a joystick for the proper playing of the game. There are many
different types, the more sophisticated respond to movement in 3 axis directions, as well
as having a number of configurable buttons. Like most things in life you get what you pay
for with joysticks and it is worth investing in a good, strongly constructed model,
especially bearing in mind that children will hammer these devices whilst playing games.
Voice input for PCs (microphones)
• Early voice recognition systems offered very poor results, due to the limitations of the
software combined with hardware limitations. It takes an awful lot of CPU processing
power to convert the spoken word into text which appears on the screen. Things are
changing rapidly however and recent systems allow you to talk to a PC and see text
appear on the screen. Most of these systems require an initial training period, where you
train the software to respond to your particular voice. Whilst still not perfect this is a key
technology of the future.
Web Cams
• Ever since it was invented, the Web has become increasingly interactive. You can now
use a small digital movie camera (a Web cam) mounted on the PC monitor to allow twoway
communication involving not just text communication but sound and video
communication as well. While not yet considered a standard piece of PC kit, it is only a

Digital Cameras
• A digital camera can be used in the same way a traditional camera can, but instead of
storing images on rolls of film which require developing, the images are stored digitally in
memory housed within the camera. These pictures can easily be transferred to your
computer and then manipulated within any graphics programs which you have installed
on your computer. Currently they are limited by the quality of the image recorded and the
number of pictures which you may store within the camera.
1.2.4 Output Devices
1.2.4.1 Identify common output devices for displaying the results of
processing carried out by a computer, such as: monitors, screens,
printers, plotters, speakers. Know where these devices are used.
The VDU (computer monitor or screen)
• The VDU (Visual Display Unit) is the computer screen used for outputting information in
an understandable format for humans. Remember that at the end of the day the
computer works in binary code (a series of on/off impulses). It is hard to realise that the
original electronic computers did not have a screen.
Flat screen monitors
• Traditional computer monitors are based on the same sort of technology which is used
within a television screen.
More recently, flat screen computer monitors have become available. These take up a lot
less room on a desk and use less energy than the traditional, more bulky monitors.

Screen size
• You should be aware that often if you specify a screen of a certain size, say a 17-inch
screen, this is the size measured diagonally, not horizontally across the screen. If you
are upgrading you should also ask for the "visible viewing area" of the screen.
Graphics for games
• Many games require very advanced graphics cards (boards) to be installed within your
computer to make them run. These advanced graphics cards contain their own CPU
which is dedicated purely to displaying the graphics on your screen. You should find that
a recent PC has this advanced graphics capability built-in whereas PCs from only 2-3
years ago may not.
Computer presentation projection devices
• These are projection devices which can be attached to your computer and are useful for
displaying presentations to a group of people. They are best used in combination with
presentation programs, such as Microsoft PowerPoint. They are used within education
and are also very popular for sales presentations. The price of these devices has
dropped dramatically recently. When purchasing one of these devices the two things to
look out for are the resolution (go for a minimum of XGA) and the brightness of the lamp
(the brighter the better). Other factors to be aware of are the quietness (or otherwise) of
the device, as well as the cost of replacement bulbs.
Different types of printer
• There are many different types of printers. In large organisations, laser printers are most
commonly used because they can print very fast and give a very high quality output. In
most organisations, the printers are connected to the computers via a network. This
means that each person with a computer does not require his or her own printer. Each
computer connected to the network can print using a particular shared printer.

Laser printers
• Laser printers produce high print quality at high speed. They are called "laser printers"
due to the fact that they contain a small laser within them. There is a wide range of laser
printer manufacturers and one buzzword to be aware of is Postscript, a type of printer
which is designed to give very high quality reproduction of pictures.
Colour laser printers
• Originally, most laser printers would only print in black and white (mono). More recently
colour laser printers have dropped in price and are entering wide spread use. While
many of these produce excellent results, you should be aware of the fact that the "price
per page", especially if you are using a lot of colour on a page can be very high
compared to the cost of printing in black and white.
Inkjet printers
• Inkjet printers work by using tiny jets to spray ink onto the paper. Inkjet printers are very
quiet in operation and produce print quality comparable to that of laser printers, though
laser printers still have the edge in terms of speed. Inkjet printers are ideal for low
volume printing where high quality print is required and speed is not a high priority, e.g.
printing letters in a small office or in the home.
Dot Matrix printers
• Dot matrix printers work by firing a row of pins through an ink ribbon onto the paper. The
more pins the print head has the higher the quality of the print, most modern dot matrix
printers have 24 pins. Unfortunately, dot matrix printers can generate a lot of noise and
do not produce a very high quality of print, especially when printing graphics. As a result,
the inkjet printer has now largely replaced the dot matrix printer. Dot matrix printers are
used for high volume / low quality printing, e.g. printing company pay slips.
Printer Memory
• It is important to realise that most printers have their own memory chips, in the same
way that each computer has its own memory. If you are printing very large graphics (i.e.
pictures), and want the best quality output from your printer then you should consider
adding more memory to your printer. This must only be done by a qualified person, and
has the benefit of really speeding up the rate at which you can print pages in many
cases.

Cost of running a printer
• When you buy a printer, one of the things the salesperson will not necessarily stress is
how much it will cost to keep that printer running. Laser printers do not use ink; they use
something called toner which is normally supplied in a sealed unit called a toner
cartridge. Each toner cartridge will allow you to print a certain amount of pages and when
the toner is used up it needs to be replaced. In some cases the costs of these toner
cartridges is very high. Ink jet printers can work out even more expensive to run.
Plotters
• A plotter is an output device similar to a printer, but normally allows you to print larger
images. Their use is common in the design and research sector.
Speakers
• Most computers are sold with the capability to add a pair of speakers to your system unit.
In fact, in some cases, the monitor may have speakers built directly into the unit. This
enhances the value of educational and presentation products and can now be
considered a standard PC component.
Speech synthesizers
• A recent development is the ability not only to display text on a monitor but also to read
the text to you. Thus, you could receive a text email from a colleague and the system
could read that email to you. This is of enormous benefit to the visually impaired when
using a computer. On the flip side, it is now possible to use a microphone to talk to the
computer and for the computer to directly convert the spoken word into text which will be
displayed within say your word-processor. Whilst these systems are far from foolproof
they are getting better as more advanced software is being made available.
1.2.5 Input/Output Devices
1.2.5.1 Understand some devices are both input/output devices such as:
modems, touch screens.
Input/Output devices
• Some devices are both input and output devices. A modem can be used for downloading
information from web sites and receiving emails. It can also be used for uploading and
sending emails. A touch screen can display a menu system (output device), and accept
input when people touch the menus displayed on the screen.
1.2.6 Storage Devices

1.2.6.1 Compare the main types of memory storage devices in terms of
speed, cost and capacity such as: diskette, Zip disk, data cartridges, CDROM,
internal, external hard disk.
Internal hard disks
• Speed: Very fast. The speed of a hard disk is often quoted as "average access time"
speed, measured in milliseconds. The smaller this number, the faster the disk is.
• Capacity: Enormous. Measured in Gigabytes. A Gigabyte is equivalent to 1024
Megabytes.
• Cost: Hard disks costs are falling rapidly and normally represent the cheapest way of
storing data.
External hard disks
• Speed: Normally slower than internal disks, but more expensive versions offer the same
performance as internal hard disks.
• Capacity: Same as internal disks.
• Cost: More expensive than internal disks.
Zip drives
• You can install a Zip drive into your computer and then you can insert Zip disks into that
drive. The great thing about these disks is that you can remove one disk and replace it
with another, in exactly the same way that you can place different diskettes in your
diskette drive. They are great for backing up data and exchanging data between nonnetworked
computers.
• Speed: Slower than normal hard disks but ideal for backups.
• Capacity: 100 or 250 Megabytes.
• Cost: You have to consider both the cost of the drive, plus the cost of each disk which
you wish to use in the drive. Often suppliers will sell the drive plus a pack of 5 disks at a
bundled discount price.
Jaz drives
• A Jaz drive is similar in concept to a Zip drive. The main difference between them is that
a Jaz drive can hold a lot more data. Alas, the disks are not the same as used in a Zip
drive and as a result, you cannot use a Zip disk in a Jaz drive or a Jaz disk in a Zip drive.

• Capacity: Around 2 Gigabytes (2048 Megabytes).
• Cost: You have to consider both the cost of the drive, plus the cost of each disk which
you wish to use in the drive. Often suppliers will sell the drive plus a pack of 5 disks at a
bundled discount price.
• More information: http://www.iomega.com
Diskettes (floppy disks)
• Speed: Very slow.
• Capacity: Normally 1.44 Mbytes.
• Cost: Very cheap.
CD Disks
• Speed: Much slower than hard disks. The original CD-ROM specification is now given a
value of 1x speed, and later, faster CD-ROMs are quoted as a multiple of this value.
Thus, a 50x CD-ROM is 50 times as fast as the original 1x speed CD-ROM specification.
• Capacity: Around 650 Mbytes.
• Cost: CD drives are becoming very inexpensive. The disks themselves are so cheap
that they are often given away when they contain samples or demo software (i.e. free
versions).
DVD Drives
• Speed: Much faster than CD drives but not as fast as hard disks.
• Capacity: Up to 17 GBytes.
• Cost: Slightly higher than CD drives.
What is the difference between internal and external hard disks?
• Internal hard disks are located inside your main computer unit, while external hard disks
are joined to the main computer unit via a lead which you plug into the back of your
computer unit. Some external hard disks will plug into the USB port (connector) located
at the back of your computer. Other external hard disks require the installation of a
special card within your computer which allows the connection of the external hard disk
to the computer unit.

Why format a disk?
• Originally when you purchased a pack of floppy disks (diskettes), you had to format them
prior to use. Today, most floppy disks are supplied pre-formatted.
Formatting a disk is like putting lines on a blank sheet of paper, so that you can write on
that paper. Formatting allows the operating system (i.e. Windows) to read information
stored on the disk and also to store information on the disk.
The manufacturer will have formatted your hard disk for you prior to delivering the PC to
you. You should be very careful about formatting a disk, as any data on the disk will be
lost after re-formatting. You would not normally format a hard disk, this should only be
done by a qualified person. You do not even need to know how to format a hard disk!

1.3 Software
1.3.1 Types of Software
1.3.1.1 Distinguish between operating systems software and
applications software. Understand the reasons for software versions.
What is an Operating System?
• The operating system is a special type of program which loads automatically when you
start your computer. The operating system allows you to use the advanced features of a
modern computer without having to learn all the details of how the hardware works.
What is an Application Program?
• An application program is the type of program which you use once the operating system
has been loaded into memory (RAM). Examples include word processing programs (for
producing letters, memos etc), spreadsheets (for doing accounts and working with
numbers), databases (for organising large amounts of information), games and graphics
programs (for producing pictures, advertisements, manuals etc).
Why are new versions of software released year after year?
• A cynic might say 'so that the companies which manufacture software can continue to
make money each year'. Another cynic may say ' so that you can pay to have the
unfinished version you bought last year patched up a little, so there are less bugs in it
this year'. The software manufactures claim that each new release has less bugs,
greater flexibility and more features. Often if you wish to see the version of software you
are using, you can click on the product’s Help drop down menu, and then click on the
About (or similar) command.
1.3.2 Operating System Software
1.3.2.1 Describe the main functions of an operating system and name
some common operating systems.
What is an Operating System?
• The operating system is a special type of program which loads automatically when you
start your computer. The operating system allows you to use the advanced features of a
modern computer without having to learn all the details of how the hardware works.
There are a number of different types of operating system in common use. The IBM PC
(Personal Computer) was introduced way back in 1981 and was originally supplied with
an operating system called DOS (Disk Operating System). This operating system was
very basic, and you had to be a bit of a computer expert just to understand how to use it.

It was NOT user-friendly. Later on, Microsoft introduced Windows and this is the
operating system which is most widely used on PCs today.
• To complicate matters further, there are a number of different types of Windows. The first
widely used version of Windows was called Windows 3.1. This was more powerful than
DOS and far easier to use. It had a Graphical User Interface (GUI), i.e. you could 'drive' it
using a mouse and drop down menus. Later, different releases of Windows were
introduced. The good news is that later versions of Microsoft Windows look almost
identical to each other and are all much easier to use than Windows 3.1.
• IBM produced an operating system called OS/2 but this was largely ignored and is only
used by a few companies.
• UNIX and Linux are other examples of operating systems which may be run on PCs.
• Other types of computers, such as those manufactured by Apple have a completely
different operating system.
Microsoft Windows: Microsoft: http://www.microsoft.com
IBM OS/2: http://www.ibm.com/software/os/warp
Linux: http://www.www.linux.com
Linux: http://www.www.linux.org
UNIX: http://www.www.unix.org
1.3.3 Applications Software
1.3.3.1 List some common software applications such as: word
processing, spreadsheet, database, Web browsing, desktop publishing,
accounting, together with their uses.
What is an application program?
• An application program is the type of program which you use once the operating system
has been loaded. Examples include word-processing programs (for producing letters,
memos etc), spreadsheets (for doing accounts and working with numbers), databases
(for organising large amounts of information), games programs and graphics programs
(for producing pictures, advertisements, manuals etc).
Word processing
• A word processing program (such as Microsoft Word) allows you to produce letters,
memos, etc., easily. You can easily mail merge a list of names and addresses to
produce mass mailers, individually addressed to customers or subscribers.
Microsoft Word http://www.microsoft.com/office/word/default.htm
Lotus Word Pro http://www.lotus.com/home.nsf/welcome/wordpro
WordPerfect http://www.corel.com/Office2000

Spreadsheets
• A spreadsheet program (such as Microsoft Excel) allows you to work out a company’s
income, expenditure and then calculate the balance. It enables you to make 'what if' type
projections of how the company will fair in the future and to forecast how changes in
prices will affect profits.
Microsoft Excel http://www.microsoft.com/office/excel
Lotus 123 http://www.lotus.com/home.nsf/welcome/lotus123
Databases
• A database program (such as Microsoft Access) allows you to compile information and
then to search this information to extract just the information you require. For instance, if
you have a database of all the equipment housed within an office you can very simply
produce a report listing only the equipment above a certain value.
Microsoft Access http://www.microsoft.com/office/access
Lotus Approach http://www.lotus.com/home.nsf/welcome/approach
Presentation
• A presentation program (such as Microsoft PowerPoint) allows you to produce
professional looking presentations, which can be printed out directly onto slides for use
with an overhead projector. Alternatively, you can display your presentations directly on
a computer screen or via a computerised projector.
Microsoft PowerPoint http://www.microsoft.com/office/powerpoint
Lotus Freelance http://www.lotus.com/home.nsf/welcome/freelance
Accounts / Payroll
• In most large organisations, the accounts are maintained by a computerised system.
Due to the repetitive nature of accounts, a computer system is ideally suited to this task
and accuracy is guaranteed.
Sage software http://www.sage.com
Web browsing
• Applications used to view and interact with the World Wide Web (WWW).
Microsoft Internet Explorer http://www.microsoft.com/ie
Netscape Navigator http://www.netscape.com
Mozilla Firefox http://www.mozilla.org/products/firefox
Web authoring
• These applications allow almost anyone to create a web site, quickly and easily.

1.3.4 Graphical User Interface (GUI)
1.3.4.1 Understand the term Graphical User Interface (GUI).
What is a Graphical User Interface?
• A Graphical User Interface (GUI) is simply an additional part of the operating system
which displays windows and drop down menus, and also enables you to drive your
computer using a mouse. Examples of operating system which use a GUI include
Windows and IBM's OS/2.
If you used an old operating system like the original version of DOS, there was no GUI
and the screen would look like this.
As you can see there are no menus, no icons and nothing for the mouse to click on. You
had to know a special language which you then typed into the computer to make it do
anything!
The advantages of using a GUI (Graphical User Interface)
• All programs look similar and when you switch from a program supplied by one
manufacturer to a different program supplied by another manufacturer, you will find the
transition very easy.

• Application programs work in the same way as the underlying operating system, and
also look very similar, which means that they are easier to learn and use.
• The GUI also allows programmers to easily write consistent looking programs.
1.3.5 Systems Development
What is systems development?
• This is a general term used to describe the way new software is specified, written by
programmers, tested and then delivered to the user.
1.3.5.1 Understand how computer-based systems are developed. Know
about the process of analysis, design, programming and testing often
used in developing computer-based systems.
What is a systems development cycle?
• Most IT projects work in cycles. First, the needs of the computer users must be
analysed. This task is often performed by a professional called a 'Systems Analysts' who
will ask the users exactly what they would like the system to do, and then draw up plans
on how this can be implemented on a real, computer based, system.
• The programmer will take the specifications from the Systems Analyst and then convert
the broad brushstrokes into actual computer programs. Ideally at this point there should
be testing and input from the users so that what is produced by the programmers is
actually what they asked for.
• Finally, there is the implementation process, during which all users are introduced to the
new systems, which often involves an element of training.
• Once the users start using the new system, they will often suggest new improvements
and the whole process is started all over again. These are methodologies for defining a
systems development cycle and often you will see four key stages, as detailed below.
- Analysis
- Design
- Programming
- Testing

Chapter 6: Corrosion and Erosion



Corrosion
Corrosion is defined as destruction of a metal by chemical or electrochemical reaction with its environment.’ It is reported that 80% of failures in production and pipeline operations are caused by corrosion.
 Corrosion may be apparent by metal loss, strength loss by cracking and solids problems
caused by formation of corrosion by-products. One of the first decisions in well completion design is the selection of the proper casing and tubing. Corrosion will not alter calculation of the tensile, burst and collapse, but it may dictate the selection of the grade of material necessary to satisfy these requirements. Corrosion is common in almost all hydrocarbon-producing environments and costs hundreds of millions of dollars throughout the industry every year.3 In addition, the economic problems are intensified through loss of revenues due to down time and deferred production. For corrosion to occur, there must be a circuit produced through which electrical current can flow. The circuit is called the corrosion cell and the electrical current produced by the process, although very small, can do enormous damage to metal systems. The basic cause of corrosion is instability of metal in its refined form. Because of the free energy relationship, the metals tend to revert to their natural state through the process of corrosion. Pure metals rarely exist in the natural world. To obtain a pure metal, a salt of the metal (the ore) is refined (energy added). This energy input is stored in the metal and serves as a source of potential (voltage) for the corrosion circuit. Since different metals require varying amounts of energy to refine, there are variations
in the amount of voltage available for the circuit. The following table from Patton5 is included to show the tendencies of metal to corrode. The half-cell potentials, which were reported by Peabody, were measured with a hydrogen reference electrode in a solution of the metal salt.


Galvanic corrosion occurs when the dissimilar metals are coupled in an electrolyte. The attack is from current flow within the simple “battery” formed by the metals and the water. Metals that are widely separated in the previous galvanic series will show the highest level of corrosion. Coatings on the metal surface, such as iron carbonates, block the galvanic current and lessen corrosion.
In any steel, the important sources of galvanic cell potential difference are:8
1. The various states of heat treatment of the steel, such as:
a. weld metal deposits,
b. the junction of weld and base metal,
c. tubing end heat treatment prior to upset (joint) manufacture
2. Cold Work and residual stress that result in anodes.
The Corrosion Circuit
The corrosion circuit requires an anode (the site of corrosion on the metal), a cathode, a metal connection between the anode and the cathode, and an electrolyte (liquid) surrounding the anode and the cathode.
Chemical Reaction
In acid solutions (pH e 7), reduction of hydrogen ions to hydrogen gas can be the dominant reaction in the absence of H2S gas. In neutral or basic soluiions (pH 17), reduction of oxygen is the dominate reaction. When gases such as CO2 and H2S are present, the reactions are modified by the gases. Presence of CO2 in neutral solutions can cause direct reaction of bicarbonate or carbonate ion with the steel. This can deposit a beneficial protective films such as iron carbonate. H2S on the metal surface stops the formation of hydrogen gas from hydrogen ions and permits a large percentage of the cathodic hydrogen ions to enter the steeL7 This is the start of one of the hydrogen embrittlements; cracking in hard steels or blistering in soft steels. As the metal corrodes, it dissolves at the anode and enters the solution as ions. It is an oxidation reaction since the iron leaves in an state. The electrons flow toward the cathode, where hydrogen gas is evolved. The schematic of the corrosion cell is shown in Figure 6.1 .5 The anode reactions are:



This reaction is for corrosion produced in neutral, agitated salt water.5 The actual location of the anode and cathode may vary with the inhomogeneities in the metal and attack may be localized or may occur over a very wide area. The rate of reaction is dependent upon many factors, including the salinity of the water, flow velocity, temperature, pH, metal alloy characteristics, and dissolved gases such as oxygen, carbon dioxide and hydrogen sulfide.
The overall corrosion process results in weight loss at the anode caused by the loss of iron and hydrogen embrittlement of high strength and highly stressed steels by penetration of the atomic hydrogen. The corrosion reaction is most severe where pits are formed. The intensity of the pitting is affected by the manufacturing, handling and production factors. In these areas, abnormalities such as large grains, poor heat treating, improper stress relief, mill marks, pipe wrench nicks, damage during running, and other factors contribute heavily to the location of electrochemical attack that causes pits. Endean summarized the common sources of metal corrosion as:*
1. Hydrogen sulfide - causes both pitting and general attack. The reaction product is a black, usually shiny mass and may be in the form of a hard scale or a finely divided solid dispersed in the water.
2. Carbon dioxide - attack is through pitting with brown or black reaction product. Pits produced in CO2 attack are frequently in a line and resemble a large cavity. The remainder of the pipe may be unaffected.
3. High concentration chloride brines with a pH of 6-7 produce shallow wide spread pitting attack similar to acids but much less severe.
4. HCI - mineral acid attack produces severe general pitting with frequent occurrence of deep channels and deep pits.
5. Sulfate reducing bacteria - SRBs produce a localized corrosion by trapping their own low pH waste product and protecting the corrosion from inhibitor contact. The location of the corrosion is usually under the bacteria colony.
6. Erosion damage - high velocity contact by fluids, gases containing mists and droplets, or fluids containing solids generates a smooth surface with frequent shallow channels, plateaus, and sharply defined transition areas, especially around the area of highest fluid velocity and directly across from perforation.
The amount of corrosion is often expressed as a mils (or thousandths of an inch) per year, MPY. This means of expressing corrosion is only usable when the corrosion rate is an even attack on the surface of the steel. Where pits occur, an MPY value is useless: generation of even a few deep pits can ruin a piece of equipment without loosing but the smallest fraction of a percent of the total metal mass. Rate of pit growth varies with the depth and size of the pit and the rate of penetration of the pit will actually increase with depth of the pit.2 As the pit is growing, the very bottom of the pit is the anode. This area becomes smaller with pit depth as the pit forms a V shape. The smaller bottom area looses metal at a faster rate to satisfy the current flow of the corrosion circuit. This is the reason for pin hole leaks in an
otherwise solid piece of equipment.
Acid Gases
The special case of production of hydrogen sulfide gas, H2S, carbon dioxide gas, CO2, or a mixture of the two is the area of acid gas technology.’O The corrosion produces one or more types of Hydrogen Embrittlement, HE, in the steel. Hydrogen embrittlement reduces the toughness of steel (a loss of ductility) and is most prevalent around existing defects (micro or macroscopic) in the steel. The steels most susceptible to hydrogen embrittlement problems are those with a yield strength of 80,000 psi, or greater (N-80 and higher alloys). In lower strength steels, hydrogen blistering is occasionally found. The corrosion caused by acid gasses is influenced by the pH and by pressure, temperature, the corrosion
resistance of the metal and the passive corrosion films formed on the surface of the metal.
Several forms of hydrogen embrittlements, HE, have been described including stress corrosion cracking
and stress sulfide cracking.’&’’
All forms of hydrogen embrittlement are brittle failures of a metal at a stress level below its yield
strength as a result of their exposure to atomic hydrogen.’’ The atomic hydrogen is generated on
metal surfaces by corrosion rea~t ion. ’T~h e hydrogen is diffused into the metal and causes a reduction
in the ductility of the metal. Sour gas increases the corrosion of HE by:‘’ (1) low pH of fluids that
contain H2S, (2) sulfide causes a greater percentage of the hydrogen created at the surface to enter
the metal, and (3) the anodic portion of the corrosion reaction tends to be localized, which helps
cracks initiate. The result of these actions is extremely rapid failure of some metals in sour fluids.
HE is generally associated with high strength steel and is common with H2S wells. The factors controlling
HE are:*
1. Steel yield strength - steel with yield strengths of 90,000 psi or lower (C-90, N-80, L-80, C-75,
etc.) are usually less susceptible to hydrogen embrittlement.
2. Hardness - Maximum hardness should be a Rockwell “C” scale of 22 or lower (the hard steels
are much more prone to attack from HE).
3. Stress level - At low stresses HE failures are lessened. In HE susceptible steels there is a
threshold below which HE will not occur. This threshold value is lowered for higher strength
steels.
4. Internal stress - The internal stress, which includes stored tensile stress produced by welding,
bending or surface damage is a common initiator for corrosion.
5. Hydrogen concentration - The time to failure of any high strength steel is a function of the concentration
of hydrogen.
6. Temperature - HE failures usually do not occur above 150°F. (A special exception to this is the
case of stress corrosion cracking7)
Two special cases of HE are sulfide corrosion cracking and stress sulfide cracking. Sulfide corrosion
cracking, SCC, causes a brittle failure of metals by the action of localized corrosion and stress.lg SCC
is normally encountered near the bottom of wells and in hotter environments than other forms of HE.7
In sour gas systems, SCC causes failure of high strength steels, all types of stainless, and many low
alloy nickel-based alloys.lg SCC will also occur in production of hot brines (chloride rich). SCC is common
in stainless alloys and materials. Alloys containing about 8% nickel are the most ~usceptible.~
Alloys with over about 42% nickel are usually immune to SCC.7 These alloys include Inconel, Incoloy,
Monel and Hasteloy. Other immune alloys may include cobalt-cromium-nickel-molybedenum alloys,
nickel-free low alloys, and nickel-free martensitic stainless steels.
There is a relationship between the environment and the metal to cause SCC; only certain metals will
crack in given environments at the critical stress level. SCC is considered to be an anodic process in
which a crack is initiated (usually by HE) and reaction progresses inside the crack. The dissolution of
metal at the tip of the crack controls the process. The environment inside the crack may be very different
from that on the surface of the casing due to the large area of metal and the protected environment.
The pH of the produced fluids, for example, may be between 4 and 6, while inside the crack, pH
may be between 1 and 2 (highly acid) because of higher concentration of chloride ions, which
increase the local corrosion rate.lg The overall corrosion rate of a material that is undergoing SCC
may be low and outer appearance may be good. However, the detrimental SCC corrosion in the crack
occurs as the result of the localized, often unseen, attack.
Stress sulfide cracking, SSC, occurs in high strength (high hardness) steels exposed to sour gas production.
It is also known as hydrogen stress cracking and hydrogen embrittlement cracking.20 SSC is
cracking that results from hydrogen charging (large volume entrance of hydrogen) of high strength
and/or high hardness steels. Most SSC occurs at lower temperatures and is prevalent in the upper
parts of the well. It may accelerate during periods of shutin or cool down, requiring only a reduction in
temperature to become active. SSC is a form of hydrogen embrittlement and is a bulk alteration of the
metal surrounding the surface areas.
Most corrosion rates increase with an increase in temperature up to about 140 to 150°F. At this point,
several forms of corrosion are lessened and some corrosion inhibiting films begin to form. Although an
increase in temperature renders the steel more susceptible to attack by SCC, an increase in temperature
decreases the rate of stress sulfide cracking, SSC. At higher temperatures, the atomic hydrogen
that contributes to the initiation of the crack by embrittlement is able to diffuse out of the steel. Temperature
thresholds exist for SSC and above these limits, SSC does not occur. The limits for hydrogen
sulfide content and temperature are indicated in Figures 6.2 and 6-3. Figure 6.3 shows that the temperature
threshold for SSC free behavior is dependent upon the grade of steel. SSC can be controlled
with use of lower strength alloys.
Controlling Corrosion
Approaching corrosion control from a well completion position may involve selection of corrosionresistant
alloy,i1~i2*19*2’-24 films and coatings,2532 liquid
device^.'^^^-^^ The least expensive route will depend on the produced or injected fluids, completion
design and the level of protection required in the operation.

Modifying the produced fluid by changing pH or removing water or dissolved gasses such as oxygen,
CO2, or H2S are usually only available for use in pipelines and injection systems. Gas removal systems
such as gas stripping, degeneration and chemical treating may all be used to remove or reduce
the content of gases. Changing the character of the produced fluids is usually achieved by changing
operating conditions to control the separation of the condensing phase.

Coatings are a relatively simple and inexpensive way to isolate the metal (the anode and cathode)
from the electrolyte liquid. Permanent coatings include plastic, tars, cement and paint. Coatings are
usually chosen for a protection against a particular liquid. The plastic coatings, for example, include
resins and polymers that are resistant to low pH waters, oxygen, COs, or salts. Coatings are not resistant
to all influences however: acids, alcohols, and other materials will destroy some coatings. Care
must be taken in working over wells with coated tubing to avoid damage to the surface of the coating.
Abrasive action such as wireline action or coiled tubing are very detrimental. Damage to coated surfaces
offer sites for very localized, intense corrosion.
Liquid corrosion inhibitors act as temporary coatings or films on the surface and are effective in providing
a passive film or a coating if they are replenished on a regular basis. Selection and application
of inhibitors are critical elements in the corrosion control program of a well. There are literally hundreds
of chemical inhibitors for control of dozens of different corrosion problems on various types of
steels. The inhibitor for a particular application must be selected from lab or field tests at the conditions
where the corrosion will be active. Normally, these selection tests are started in the lab and completed
in the field with field trials on test metal coupons.
Complete reviews and comparisons of the methods of applying corrosion inhibitors are rare, but a few
case histories do exist. Houghton and We ~ t e rma r kh~av~e provided data on some corrosion problems
in the North Sea and compared the methods for application of corrosion inhibitors. In the wells that
were used for a database, average workover life was approximately 60-1 20 days. CO2 corrosion and
erosion were present in these wells’. Erosion was determined to have a significant influence on the
rate of corrosion and CO2 corrosion/erosion was found to be the normal mechanism of attack on these
wells.
During the study, the rate of corrosion for these wells was determined to be exponential rather than
linear. Once the corrosion started, very rapid increases in the corrosion rate were common. The most
prevalent place for attack of the corrosion/erosion was at changes in diameter or direction of the fluid
flow. The paper pointed out that sweet corrosion was prevalent in these wells even though there was
less than 14% formation water in the total produced fluids.
Ekofisk wells in the study that had a high GOR showed increased corrosion; probably by providing
greater volumes of CO2 and by increasing the flaw velocities of the produced fluids. The GOR has
also been shown to be a factor in corrosion in other studies. Even in gas wells, a change in flowing
fluid composition because of condensation of C-3+ hydrocarbons can result in a change in corrosion
intensity or location.40 The most common corrosion site depth was in the mid-range from 4000-
7000 ft. The mid-range location on these wells corresponds with gas breakout and increased turbulence
from suspended gas that is rapidly expanding due to the lowering of hydrostatic head.
In all cases of wells deviated more than 20°, a preferential attack along the low side of the tubing was
spotted. This attack reportedly resulted in troughs 1 in. wide that tracked along the inside of the low
side of the tubing.
This “pipe trough” development has also been though to be the result of a low oil wetting tendency of
the Ekofisk crude, which would result in a water wetted pipe. If the fluid velocity in these flowing wells
is below 2.5 to 3 ft/sec, the approximate minimum velocity for water entrainment in the oil, a free water
layer would exist at the lowest point due to gravity separation and increased corrosion could occur.8
The corrosion/erosion attack location was identified using casing calipers. Corrosion in caliper tracks
has also been observed. The cause may be that early caliper surveys were not followed with inhibitor
treatment to repair damaged protective films.
In the higher volume wells, preferential attack occurred on the pin-end shoulder on the coupling. The
shoulder seems to cause additional turbulence and pitting is a byproduct of the turbulence.
The paper reported a comparison of inhibitor treatment types, in terms of both economically application
and performance. Formation squeezes with inhibitor, continuous injection, and tubing displacements
were all examined. Continuous injection was found to be the least expensive in almost all flow
rates studied.
A second case study, and one that covers economics of chemical inhibitor usage was provided by
Akram and Butler.41 This work showed that the cost of the successful inhibitor protection program was
about $29,000 per well per year, compared with a super alloy tubular cost (for passive control) of
about 1.25 million. The cost of carbon steel tubulars for the same well was $271,000 (all dollar values
are 1982 U.S. dollars). The economic impact of the successful inhibitor program was significant;
34 years of inhibitor operation to equal the simple difference of super alloy and carbon steel tubular
cost. Obviously, the successful control of corrosion using either method depended upon good design
and strict application. All inhibitor films have to be replaced on a regular basis. While this addition is
relatively easy in injection wells by surface addition to injected fluids, it is more difficult in producing
wells. The inhibitor must be circulated into position and allowed to film on a clean surface without
being disturbed by action of other surfactants, inhibitors or solvents. Most inhibitors must be placed as
a dispersed phase in a non reactive fluid without the aid of surfactants. The application of these materials
may range from simple “dump” jobs down the back side (low pressure injection into the annulus
at the surface in a well without a packer) to periodic workovers requiring the well to be shutin while
inhibitor is injected down the tubing. Some wells are completed with a small string of tubing (1/4 in. to
1 in. diameter) down the outside or inside of the tubulars where the inhibitor and other treating chemicals
can be injected continuously.
Some naturally passive films (a reaction product of the metal and the wetting fluid) provide a barrier
surface that reduces the potential produced in the corrosion circuit by altering the reactivity of surface.
The film may be a metal oxide laye?5v27 or other reaction by-product that is not easily attacked by produced
fluid. These films are recognized as major corrosion controlling mechanisms. Corrosion of low
alloy steels at temperatures below 140°F, increase with the partial pressure of CO2 in the gas phase.
Above 140°F the corrosion decreases with temperature because of the formation of iron carbonate
and iron oxide films. The films are destroyed by acidizing or erosion during high velocity flow. In certain
cases, passivity is designed into the alloy by combining chromium and nickel with iron. Whether
these iron-chromium and iron-chromium-nickel alloys are active or passive depends upon the alloy
composition and the electrolyte. For example, in CO2 rich environments, 13% chrome alloys are successful
in preventing corrosion that destroys other alloys.25
Cathodic protection using sacrificial anodes or impressed current to offset the current of the corrosion
cell, can be applied to the outside of casing and pipelines and to the insides of production processing
vessels where a continuous water phase exists. It cannot be used internally in most production tubing
or inside pipelines.
Materials for Sour Service
The following description of materials for Sour Service is from Wilhelm and Kanelg and represents
generalized guidelines on selection of tubular components for hydrogen sulfide and carbon dioxide
service.
High strength tubular steel grades, often containing chromium and molybdenum designated for use in
H2S service include C75, L80, C90, and some specially processed C95. These materials exhibit necessary
resistance to SSC under some specific conditions for use in sour gas operations.
In general, the higher the yield strength of a material, the more susceptible it is to SSC. There are no
recognized carbon or low alloy steel compositions suitable for sour service at ambient temperatures
with yield strength in excess of 11 0,000 psi. The most widely used criterion for selection of materials
for sour service is hardness. NACE requirement MR-01-75 specifies that for steels to be considered,
they must have a hardness value below HRC-22 (some exceptions to HRC-26).4
Stainless steel casing (greater than 12% chromium) are used when superior resistance to general corrosion
is necessary. Table 2 shows composition of several of the high nickel alloy materials. The
steels increase in cost as corrosion resistance is increased.
The following paragraphs, also from Wilhelm and Kane,lg describe the general classifications of the
high strength alloys available for use in corrosive environments. Stainless steel is a generic term for a
group of steels having a chromium content of over 12%. Most metallurgists refer to the stainless steels
with the more widely based term “corrosion resistant alloy,” or CRA. The general classes of the alloys
are listed in order of increasing resistance to SCC and SSC (also increasing cost).
1.
2.
3.
4.
5.
6.
7.
Martensitic stainless steels, (11 -1 8% chromium) have applications in wellheads and tubing
where high yield strengths are not required.
Precipitation hardened stainless steels (12-1 8% chromium and 6-1 2% nickel) are useful for
downhole equipment or tools that require non-cold-worked, high yield strength materials. Some
of these materials, depending on composition, may be susceptible to SCC and SSC.
Duplex stainless steels (22-28% chromium and 5-7% nickel) have a resistance to chloride cracking
that exceeds the resistance of low alloy austenitic stainless steels, but they may be susceptible
to SSC or SCC in the presence of H2S.
Low alloy austentinic stainless steels (1 8% chromium and 10% nickel) offer better resistance to
SSC than martensitic stainless steels, but yield strengths are limited. These alloys are susceptible
to SCC and pitting by chlorides.
High alloy austentinic stainless steels contain 20-30% chromium and 20-35% nickel. They
achieve strength through cold work and offer the best combination of corrosion resistance and
mechanical properties of all the CRAs. The cost for these alloys is high.
Nickel-based super alloys such as C-276, 71 8, and MP35N (cobaltlnickel-based) have better
resistance to H2S than most other types of commercial alloys but may be extremely expensive.
They do have the advantage of very high yield strengths.
Titanium alloys are slowly being introduced to the industry although the use is rare at the present
time.
CO2 Corrosion
CO2, one of the acid gases, is a very common contaminate in gas, oil and water production, even in
sweet reservoirs. CO2 corrosion of steel is usually a localized corrosion that takes the form of pits of
various sizes. Liquid water is necessary for CO2 corrosion to take place.43 The typical corrosion product
of the CO2 reaction is ferrous carbonate.a Dissolved carbon dioxide content is a function of pressure
and temperature and pH is much less important. Corrosion increases for increasing carbon
dioxide content.
Pitting produces severe penetration. Outside of the affected areas, the corrosion rate might be limited
and the transition from an affected to an unaffected area can be very abrupt. The action of CO2 attack
has been described as both chemical and physical through e r o ~ i o nE.ro~s~ion~ c~an~ a ccelerate the
overall corrosion rate by a hundredfold or more by removal of protective scales, oxides and corrosion
inhibitor films. Even for CO2, however, the increase in rates usually is in the area of five to ten
The addition of CO2 gas to water can reduce the pH to a value below 4, promoting acid attack. CO2
corrosion from chemical attack has been generally effectively controlled through the use of 13%
chrome tubulars.
Although CO2 corrosion and stress sulfide cracking have nothing in common when both corrosion factors
are present in a well, control of both forms of corrosion may be accomplished by using a corrosion-
resistant alloy to block CO2 attack and a reduced hardness to prevent SSC. Choosing a 13%
chromium steel that has a hardness below 22 Rockwell hardness-C, (LSO tubing), should also be
effective.
One severe drawback to using the 13% chromium steels is that they exhibit very limited resistance to
pitting during storage where air and chloride are present (seacoasts). This type of corrosion can much
more significant inside the pipe, particularly if condensation inside the pipe forms standing puddles.24
In the well, control of pitting corrosion of the 13% chrome steels relies on the deaeration of water.
The second type of severe corrosional effect produced by CO2 is largely physical -the erosional effect
produced by changes in fluid flow direction or an effect often described as ~ a v i t a t i o n . ~E~ro*si~on~ is* ~ ~
the increase in the rate of metal deterioration from the abrasive effects of a fluid flowing into or
through a pipe. Other sources of erosion may include entrained gas in liquids, liquid droplets in gas,
solids in any fluid, very high flow rates, or any restriction in the completion strings that causes a drastic
change in the flow velocity of the produced fluids. Erosion may often lead to a removal of the effective
inhibitor, corrosion film, or reactant film. Severe cases can be identified by grooves or rounded
pits or holes that are usually smooth and lie along the direction of flow. Removal of a protective inhibitor
or corrosion oxide film takes place when the strain on the film or corrosion oxide layer exceeds the
strain for the failure of the film. Erosion by solids and droplets may also affect the tenacity of the film
on an exposed surface. The failure of a corrosion oxide layer takes considerably longer than the failure
for most film-forming materials.
Squeezing or continuous injection of inhibitors may not be cost effective if the completion string ID is
smaller than the minimum ID required to prevent erosion. If this principle is violated, the film may be
continuously stripped off, even at high loading rates. Not all inhibitor films react in the same manner to
stripping by erosion; a few products offer very good performance in high velocity applications.
Other Factors
The presence of oxygen either as dissolved or entrained gas substantially increases the corrosion,
Figure 6.4.2 In almost all fluid handling systems, oxygen must be removed prior to injection of water or
shipment of the fluids by pipeline.
The pH of the water and the velocity of the water influence the corrosion attack. The chart in
Figure 6.5 illustrates the relative corrosion of flowing and nonflowing fluids versus the fluid pH. The
velocities shown in the graph are for water velocities of 3 to 7 ft per second. Below 3 FPS, corrosion is
reduced at pHs above 7. Notice for the flowing case that there is very little corrosion in waters with a
pH above 7 (basic). In these high pH waters, iron is almost insoluble, so the byproducts of a corrosion
reaction cannot be swept away from the corrosion site and the corrosion reaction is stopped.
The amount of water in the production is also a factor in corrosion. Water cuts below 25% are likely to
cause less corrosion than water cuts above 45%, especially at pHs below 7. As water cut increases,
the tendency for a steel surface to be oil wet decreases. Corrosion is very low for most oil wet surfaces
and very high for most water wet surfaces. Since most wells are at least very slightly deviated,
the water caused corrosion damage may be confined to a trench in the low side of the pipe. In wells
where the flow rate in the tubing is not high enough to keep all the liquids moving at near the same
velocity, the water may reflux (up and down with gas rate changes) in the low side, creating a serious
corrosion trench even at very low water cuts. Inspection with caliper or electromagnetic surveys (measures
metal loss through field generation and interruption techniques) can usually spot the trench if
one exists. Water can be produced and carried as an emulsion (entrained water) at flow velocities of
3-1/2 to 5 fps.

Corrosion by Stimulation Acids
The use of stimulation acids such as HCI and HCVHF create severe problems in the specialty tubulars.
Special problems of selective effects of inhibitor^,^^ pitting and intergranular attack,47 detrimental
influence of added organics,48i49 and increased corrosion of the fluoride ion,50 require special inhibitors
and special inhibition techniques for the high allow steels. The primary attack of the steels by acid
is severe pitting and intergranular attack that is difficult to control with inhibitors. Localized pitting may
be severe enough to ruin a section of the string.
Acid inhibitors work in the same manner as other corrosion inhibitors; by filming and passivating the
surface. The HCI and HCVHF acids are much more severe environments than other types of corrosion
and the inhibitors for these uses are specially blended and have much shorter effective life spans.
Also, presence of mutual solvents, alcohols,
destroy the effectiveness of some inhibitors.
oil solvents and surfactants in the acid may alter or
Some of the expensive super alloys, such as the 13-chrome materials, may be especially sensitive to
HCVHF acid attack and special inhibitors are required.
Destruction of Elastomers
The steels used in the tubulars and well equipment are not the only materials susceptible to corrosion.
The elastomers (plastics and rubbers) used in the seals are also affected by the well fluids and must
be carefully selected to avoid problems. The attack on elastomers by gas is usually by swelling or blistering,
5’ both involve invasion of the elastomer by the gas. Rapid release of the pressure around a
gas permeated seal will likely cause explosive decompression and destruction of at least the outer
layer, the sealing edge, of the seal. Surprisingly, although gas permeation of a seal can destroy the
seal when pressure is released, the seal may function adequately before pressure release. Reaction
of various liquids to elastomer seals depends on seal type and position, temperature, liquid type, pressure,
previous seal contamination and the presence of some lubricants used for tool assembly.52 In
general, nitrile seals are used for most general purpose applications where oil contact is necessary.
Other compounds such as the fluorinated elastomers (e.g., Viton) are available for contact with aromatic
solvents (xylene and toluene). Other specialty compounds are available for specific, highly corrosive
conditions or contact with powerful solvents; however, seal cost increases quickly with the more
exotic elastomer compounds. Some metal-to-metal seals are being offered where elastomer destruction
is most severe.53
Microbial Corrosion
Microbiologically influenced corrosion (MIC) active corrosive influence of the attached (sessile) bacteria
c o l o n i e ~ . ’T~h*e~ p~ro blems are two fold; the colonies cover areas of steel, blocking corrosion
inhibitors from reaching the pipe surface, and the waste products of the colonies are often very corrosive
in the protected areas under a colony. The sulfate reducing bacteria, SRBs, are the most detrimental,
with the capability of souring wellbores and parts of reservoirs with H2S. Bacteria are
controlled by cleaning the water and treating with bactericides.
Nonmetallic Tubulars
As an alternative to steel casing with its problems with corrosion, fiberglass casing, tubing and rods
are being applied in some ~ e l l sTh. e~ ad~va~nta~ge~s o f the plastic materials are excellent resistance
to most forms of water related corrosion and some scale and paraffin deposition. Most applications
have been in shallow, low pressure wells, where high strength is not needed; however, new placement
techniques and plastic formulations are stretching limits of application.
Predictive Techniques and Inspection Devices
Monitoring the rate of corrosion is of critical importance to determine when to repair or replace equipment
and to judge the effectiveness of corrosion control techniques on well e q ~ i p m e n t .A~ s~y-s~te~m -
atic examination of the produced fluid chemistry, operating conditions and failures can describe the
potential for further failure.55 Monitoring of corrosion in the well uses several logging techniques to
monitor abrasion (and other wear), pitting and surface corrosion.
The data from produced fluid analysis includes ion analysis, pH, gas type and content. It can be used
with computed based predictive models to establish a general potential for corrosion in the well. Corrosion
coupons inserted into the well stream can verify the predictive results and help evaluate the
effect of an inhibitor. Sections of test pipe are also used, normally in surface piping, to evaluate
selected metals.
When a corrosion related failure occurs, it is most important that the cause of the failure be determined.
The analysis of corrosion products and the characteristic corrosion pattern can usually determine
the type of corrosion that caused the failure. Hardness tests, microscopic examination, and
chemical analysis of the failed and unaffected surfaces are also tools of identifi~ation.~~
To monitor the corrosion rate and general condition of the tubulars in the well, a set of instruments are
used that provide data for comparisons with earlier readings to arrive at a corrosion or erosion rate.
These tools include multifingered c a l i p e r ~p,r~ob~e s for measuring anodic activity,57 induction tools to
measure pipe mass,58 magnetic devices,59 sonic tools that measure pipe thickness,60 and some
experimental tools that locate cracks in the pipe.60 These tools will establish a rate of corrosion or
wear when the results from several regular runs are compared.
Erosion
Surface erosion from solid particles in a high velocity produced fluid stream is normally associated
with unstable formations such as unconsolidated sands. Other occurrences of erosion include cases
of choke and tree loss following rapid back flow of wells after fracturing. The common denominator is
the high flow velocity.
Maximum velocities that can be tolerated in a situation will depend on the flowing fluid and other factors
including foaming or emulsifying tendency, solids and entrained gas. Mechanical limitations in the
piping design or metering apparatus may also influence the maximum permissible flow rate.
Although some information exists that a corrosion inhibitor film is removable by high velocity flow,2i61
other authors offer evidence of successful inhibitor film performance at mass velocities of up to
100 Wsec with abrasion where inhibitor was continuously present.62 In any design where flow rates
will be high, a testing program should be used to identify the best method of corrosion protection.
The concept of critical velocity for flow of fluids with no solids in sizing of piping is covered in API RP-
14E.63 In general, the limits for dry crude flow velocity in pipe is about 30 to 35 fps (ft per second) and
for wet crude, the maximum velocity is 20 to 25 fps. At faster flow rates, some steel may be lost to
abrasion from the clean liquids. In some inhibitor protected systems, the limit of fluid velocity is often
much higher than set by the API equation.

The erosion rate of any metal surface is strongly controlled by the presence and hardness of naturally
occurring (but metal-composition related) oxide or sulfide film. This film, which depending on composition,
can be much harder than the pure metal surface, is one of the main factors that reduce erosion
(and some forms of chemical corrosion).

Presence of mist droplets in the stream can destroy the natural or added inhibitor barriers and rapidly
increase corrosion. Actual abrasive induced failures of the pipe depend on the entrained droplets or
solids in the gas as well as the density of the gas. Estimates of the densities and good design velocities
are contained in Figure 6.6. For further information, refer to the “Oil Field Corrosion Detection and
Control Handbook,” by Endean, available from Champion Chemicals Inc., Houston.

The API RP-14E equation is a quasi-rigorous attempt to determine critical velocity for general purpose
projects. Craig 68 proposed flow ranges for a modification of the RP-14E equation, proposed by Griffith
and Rabinowicx (1985), where the C factor was calculated. The calculated value of C was based
on actual well conditions. The equation was only very slightly different:

but the C was dependent on flowing fluid and pipe metallurgy, rather than a range of operating constants.
When using chemical resistant alloys such as stainless and some nickel based materials
(especially those containing Chromium), the stable range of the C factor in the equation would be in
the range of 160 to 300. The 160 to 300 range for CRA tubulars is well proven infield performance for
long lived projects.
The ultimate value of C is then dependent on alloy composition, oxide or sulfide layer composition,
and flowing fluid composition (H2S, CO2, etc.). The layer composition and fluid resistance would also
change with temperature and impact resistance. Craig proposed a further modification of the equation
to allow input of the oxide hardness layer

where P is the measured hardness of the oxide layer in kg/mm2 and p is fluid density in Ib/ft3. The use
of such an equation for calculations is limited at the present time by available data on hardness, P.
Craig offers the following explanation: “for Ti alloys, using a hardness of 1,000 kglmm2 for titanium
dioxide (Ti02) film formed on the alloy, the C factor would be 189. However, if aluminum oxide (aI2O3)
were incorporated into the oxide of any alloy so it was the predominate film, then P E 200 kg/mm2 and
C = 255. Conversely, if a SS or Ni-based alloy containing Cr is exposed to a high H2S environment,
then the film could be predominately Cr2S3, with P - 480 kg/mm2 and C would drop to 138l (with data
from A.A. Ivan’ko - Handbook of Hardness),
Impingement of particle laden fluids on a screen, casing wall, choke, or other surface in the well will
result in some erosion, regardless of the velocity flow. Erosion is usually only severe however, when
the fluid flow velocity is high enough to impact the solid particles on the surface with enough force to
abrade the metal or the natural or man-made coating on the metal surface.
Well completion decisions in wells with solids erosion problems may take one or more of three routines:
(1) decrease the flowing liquid velocity with larger perforations, larger wellbores and larger tubing,
(2) use hardened blast joints to slow the rate of erosion, and (3) control the solids with gravel
packs and screens.
If the erosion problem is slight, blast joints represent the cheapest methods of control. If erosion is
severe, the producing pays are usually gravel packed.
The erosion rate of any surface exposed to fluids that contain solids depends on the size, roundness,
and composition of the solids, the amount of solids in the flow stream, the velocity of the flowing fluid,
the shape of the flow path and the hardness of the metal layer exposed to the fluid. The worst erosion
conditions are created when sand grain sized (0.01 to O.l”), particles of high density materials rapidly
strike the metal surface at angles of about 45” to 95”. If the energy of the impact is sufficient to dislodge
or break the oxide layer, then erosion and some forms of corrosion will be accelerated.

UOP OLEFLEX PROCESS FOR LIGHT OLEFIN PRODUCTION


INTRODUCTION
The UOP* Oleflex* process is catalytic dehydrogenation technology for the production
of light olefins from their corresponding paraffin. An Oleflex unit can dehydrogenate
propane, isobutane, normal butane, or isopentane feedstocks separately or as mixtures
spanning two consecutive carbon numbers. This process was commercialized in 1990,
and by 2002 more than 1,250,000 metric tons per year (MTA) of propylene and more
than 2,800,000 MTA of isobutylene were produced from Oleflex units located throughout
the world.
PROCESS DESCRIPTION
The UOP Oleflex process is best described by separating the technology into three different
sections:
● Reactor section
● Product recovery section
● Catalyst regeneration section

Reactor Section


Hydrocarbon feed is mixed with hydrogen-rich recycle gas (Fig. 5.1.1). This combined
feed is heated to the desired reactor inlet temperature and converted at high monoolefin
selectivity in the reactors.

The reactor section consists of several radial-flow reactors, charge and interstage
heaters, and a reactor feed-effluent heat exchanger. The diagram shows a unit with four
reactors, which would be typical for a unit processing propane feed. Three reactors are
used for butane or isopentane dehydrogenation. Three reactors are also used for blends of
C3-C4 or C4-C5 feeds.
Because the reaction is endothermic, conversion is maintained by supplying heat
through interstage heaters. The effluent leaves the last reactor, exchanges heat with the
combined feed, and is sent to the product recovery section.
Product Recovery Section
A simplified product recovery section is also shown in Fig. 5.1.1. The reactor effluent
is cooled, compressed, dried, and sent to a cryogenic separation system. The dryers
serve two functions: (1) to remove trace amounts of water formed from the catalyst
regeneration and (2) to remove hydrogen sulfide. The treated effluent is partially condensed
in the cold separation system and directed to a separator.
Two products come from the Oleflex product recovery section: separator gas and separator
liquid. The gas from the cold high-pressure separator is expanded and divided into
two streams: recycle gas and net gas. The net gas is recovered at 90 to 93 mol % hydrogen
purity. The impurities in the hydrogen product consist primarily of methane and ethane.
The separator liquid, which consists primarily of the olefin product and unconverted paraffin,
is sent downstream for processing.
Catalyst Regeneration Section
The regeneration section, shown in Fig. 5.1.2, is similar to the CCR* unit used in the
UOP Platforming* process. The CCR unit performs four functions:
● Burns the coke off the catalyst
● Redistributes the platinum
● Removes the excess moisture
● Reduces the catalyst prior to returning to the reactors
The slowly moving bed of catalyst circulates in a loop through the reactors and the
regenerator. The cycle time around the loop can be adjusted within broad limits but is typically
anywhere from 5 to 10 days, depending on the severity of the Oleflex operation and
the need for regeneration. The regeneration section can be stored for a time without interrupting
the catalytic dehydrogenation process in the reactor and recovery sections.


DEHYDROGENATION PLANTS
Propylene Plant
Oleflex process units typically operate in conjunction with fractionators and other
process units within a production plant. In a propylene plant (Figure 5.1.3), a propanerich
liquefied petroleum gas (LPG) feedstock is sent to a depropanizer to reject butanes
and heavier hydrocarbons. The depropanizer overhead is then directed to the Oleflex
unit. The once-through conversion of propane is approximately 40 percent, which
closely approaches the equilibrium value defined by the Oleflex process conditions.
Approximately 90 percent of the propane conversion reactions are selective to propylene
and hydrogen; the result is a propylene mass selectivity in excess of 85 wt %. Two
product streams are created within the C3 Oleflex unit: a hydrogen-rich vapor product
and a liquid product rich in propane and propylene.
Trace levels of methyl acetylene and propadiene are removed from the Oleflex liquid
product by selective hydrogenation. The selective diolefin and acetylene hydrogenation
step is accomplished with the Hüls SHP process, which is available for license through
UOP. The SHP process selectively saturates diolefins and acetylenes to monoolefins
without saturating propylene. The process consists of a single liquid-phase reactor. The
diolefins plus acetylene content of the propylene product is less than 5 wt ppm.
Ethane and lighter material enter the propylene plant in the fresh feed and are also created
by nonselective reactions within the Oleflex unit. These light ends are rejected from
the complex by a deethanizer column. The deethanizer bottoms are then directed to a
propane-propylene (P-P) splitter. The splitter produces high-purity propylene as the overhead
product. Typical propylene purity ranges between 99.5 and 99.8 wt %. Unconverted
propane from the Oleflex unit concentrates in the splitter bottoms and is returned to the
depropanizer for recycle to the Oleflex unit.


Ether Complex
A typical etherification complex configuration is shown in Fig. 5.1.4 for the production
of methyl tertiary butyl ether (MTBE) from butanes and methanol. Ethanol can be substituted
for methanol to make ethyl tertiary butyl ether (ETBE) with the same process
configuration. Furthermore, isopentane may be used in addition to or instead of field
butanes to make tertiary amyl methyl ether (TAME) or tertiary amyl ethyl ether
(TAEE). The complex configuration for a C5 dehydrogenation complex varies according
to the feedstock composition and processing objectives.
Three primary catalytic processes are used in an MTBE complex:
● Paraffin isomerization to convert normal butane into isobutane
● Dehydrogenation to convert isobutane into isobutylene
● Etherification to react isobutylene with methanol to make MTBE
Field butanes, a mixture of normal butane and isobutane obtained from natural gas condensate,
are fed to a deisobutanizer (DIB) column. The DIB column prepares an isobutane
overhead product, rejects any pentane or heavier material in the DIB bottoms, and makes
a normal butane sidecut for feed to the paraffin isomerization unit.
The DIB overhead is directed to the Oleflex unit. The once-through conversion of
isobutane is approximately 50 percent. About 91 percent of the isobutane conversion reactions
are selective to isobutylene and hydrogen. On a mass basis, the isobutylene selectivity
is 88 wt %. Two product streams are created within the C4 Oleflex unit: a hydrogen-rich
vapor product and a liquid product rich in isobutane and isobutylene.
The C4 Oleflex liquid product is sent to an etherification unit, where methanol reacts
with isobutylene to make MTBE. Isobutylene conversion is greater than 99 percent, and
the MTBE selectivity is greater than 99.5 percent. Raffinate from the etherification unit is
depropanized to remove propane and lighter material. The depropanizer bottoms are then
dried, saturated, and returned to the DIB column.


PROPYLENE PRODUCTION ECONOMICS
A plant producing 350,000 MTA of propylene is chosen to illustrate process economics.
Given the more favorable C4 and C5 olefin equilibrium, butylene and amylene production
costs are lower per unit of olefin when adjusted for any differential in feedstock
value. The basis used for economic calculations is shown in Table 5.1.1. This basis is
typical for U.S. Gulf Coast prices prevailing in mid-2002 and can be used to show that
the pretax return on investment for such a plant is approximately 24 percent.
Material Balance
The LPG feedstock is the largest cost component of propylene production. The quantity of
propane consumed per unit of propylene product is primarily determined by the selectivity
of the Oleflex unit because fractionation losses throughout the propylene plant are small.
The Oleflex selectivity to propylene is 90 mol % (85 wt %), and the production of 1.0 metric
ton (MT) of propylene requires approximately 1.2 MT of propane.
An overall mass balance for the production of polymer-grade propylene from C3 LPG
is shown in Table 5.1.2 for a polymer-grade propylene plant producing 350,000 MTA,
based on 8000 operating hours per year. The fresh LPG feedstock is assumed to be 94 LV %
propane with 3 LV % ethane and 3 LV % butane. The native ethane in the feed is rejected in
the deethanizer along with light ends produced in the Oleflex unit and used as process fuel.
The butanes are rejected from the depropanizer bottoms. This small butane-rich

stream could be used as either a by-product or as fuel. In this example, the depropanizer
bottoms were used as fuel within the plant.
The Oleflex process coproduces high-quality hydrogen. Project economics benefit
when a hydrogen consumer is available in the vicinity of the propylene plant. If chemical
hydrogen cannot be exported, then hydrogen is used as process fuel. This evaluation
assumes that hydrogen is used as fuel within the plant.
Utility Requirements
Utility requirements for a plant producing 350,000 MTA of propylene are summarized
in Table 5.1.3. These estimates are based on the use of an extracting steam turbine to
drive the Oleflex reactor effluent compressor. A water-cooled surface condenser is used
on the steam turbine exhaust. A condensing steam driver was chosen in this example for
the propane-propylene splitter heat-pump compressor.
Propylene Production Costs
Representative costs for producing 350,000 MTA of polymer-grade propylene using the
Oleflex process are shown in Table 5.1.4. These costs are based on feed and product

values defined in Table 5.1.1. The fixed expenses in Table 5.1.4 consist of estimated
labor costs and maintenance costs and include an allowance for local taxes, insurance,
and interest on working capital.
Capital Requirements
The ISBL erected cost for an Oleflex unit producing 350,000 MTA of polymer-grade
propylene is approximately $145 million (U.S. Gulf Coast, mid-2002 erected cost).
This figure includes the reactor and product recovery sections, a modular CCR unit, a
Hüls SHP unit, and a fractionation section consisting of a depropanizer, deethanizer,
and heat-pumped P-P splitter. The costs are based on an extracting steam turbine driver
for the reactor effluent compressor and a steam-driven heat pump. Capital costs are
highly dependent on many factors, such as location, cost of labor, and the relative workload
of equipment suppliers.
Total project costs include ISBL and OSBL erected costs and all owner’s costs. This
example assumes an inclusive mid-2002 total project cost of $215 million including:
● ISBL erected costs for all process units
● OSBL erected costs (off-site utilities, tankage, laboratory, warehouse, for example)
● Initial catalyst and absorbant loadings
● Technology fees
● Project development including site procurement and preparation
Overall Economics
Because the feedstock represents such a large portion of the total production cost, the
economics for the Oleflex process are largely dependent on the price differential
between propane and propylene. Assuming the values of $180/MT for propane and
$420/MT for propylene, or a differential price of $240/MT, the pretax return on investment
is approximately 24 percent for a plant producing 350,000 MTA of propylene.