PART III.

PRACTISE ON DYNAMIC SIMULATOR

I.

GAS PROCESSING PLANT

II. GAS DEHYRATION UNIT

1/169

I. GAS PROCESSING PLANT ON

DYNAMIC SIMULATOR

1. Process description
2. Simulation PFD
3. Start up procedure on dynamic simulator
4. Shutdown procedure on dynamic simulator
5. Malfunction exercises

2/169

1. Process description
Slug catcher

GPP Deethanizer

GPP Dehydration

Gas Stripper

Regeneration

Stabilizer

GPP Condensate Process C3/C4 Splitter

Gas chill down & Rectifier

Metering for pipeline

Storage tank and pumps

3/169

1. Process description
Slug catcher (SC-01)

Separate condensate and Free-water from the gas at 109 BarA, 25oC
Piping type
The volume should be sufficient to receive liquid slug coming from
the battery limit

4/169

1. Process description
GPP Dehydration (V-06A/B)

Feed stock: The natural gas stream at 29oC and 109 BarA

Remove water included in the gas

Two absorber: one on-line, the other is standby
The dry natural gas exits the on-line adsorber and then treated by
dehydration After filter (F-01A) for removal of adsorbent dust.

5/169

1. Process description
Regeneration

The absorbents will become saturated with water for 8 hours with
condition of water saturated at inlet (29oC and 109 BarA) and
need to be regenerated.
Suppose V-06A is on standby for dehydration and V-06B need to
be regenerated.

6/169

Regeneration (Desorption)

6 steps:
1. Adsorber Switch-over
2. Depressurization
3. Heating
4. Cooling
5. Pressurization
6. Standby

7/169

a. Adsorber Switch-over
For a short time both adsorbers are operated in parallel to:

Minimize gas composition changes

Minimize carry over of liquid hydrocarbons that accumulated

in inlet pipe-work during pressurization.

Avoid gas flow interruption
The adsorber to be regenerated is then isolated.

8/169

b. Depressurization
The adsorber is depressurized, after isolated at both gas in

& out, from the gas pressure (109 BarA) to the regeneration
gas pressure (35 BarA).

Depressurization is limited by a restriction orifice and can be

controlled by a manual control valve so as to obtain an over

all depressurization time of 30 minutes (not simulated)

9/169

c. Heating
Heating with dry regeneration gas which originates from suction

of the compressor of Tubro-Expander Compressor (CC-01).

The regeneration gas (14NM3/Hr) is heated by hot oil to 230oC
Regeration gas flow is counter-current to adsorption
The progress of heating can be monitored by T indicators installed
on adsorbent bed (TI0551A/B).

10/169

d. Cooling
The adsorbent bed is cooled with the same regeneration

gas as for heating except that the Dehydration Gas

Heater is bypassed.

The adsorbent bed will be monitored by temperature

indicators.

11/169

e. Pressurization
The adsorber is pressurized in a down flow direction

with dry product natural gas (typically 109BarA).

The rate of pressurization limited by a restriction orifice and

can be controlled by a manial control valve so as to obtain

an overall pressurization time of 30 minutes (not simulated).

12/169

f. Standby
The adsorber will be maintained at the natural gas
pressure (109BarA) using the pressurization line.
During this period some of the liquid hydrocarbons in the
inlet pipe work will evaporate due to the ambient
temperature.

13/169

1. Process description
GPP Condensate Process
The liquid and gas from the Slug Catcher Liquid Flash Drum (V-03)
are sent to the Gas Stripper (C-04) and 2nd Stage overhead Gas
Compressor (K-03).
Pressure of the Slug Catcher Liquid Flash Drum (V-03) is controlled

at 75 BarA
A purpose of sending the gas to K-03 suction: water included in the
gas stream can be removed by Dehydration Adsorber the gas

can be compressed by the K-03 and mixed with the feed gas before
the dehydration Regeneration gas for Dehydration will not
include water any more.

14/169

1. Process description
Gas chill down & Rectifier
Around 1/3 of the dried gas (60 NM3/HR) is sent to Cold Gas/Gas
Exchanger (E-14) to be chilled down from 26oC -35oC by the cold
gas from top of Rectifier (C-05) of -42.5oC
The Toutlet (-36oC) is rather important factor in the gas processing:
If it is higher than specific value a recovery of liquids cannot
be obtained
If it lower hydrate could form at downstream

15/169

1. Process description
Gas chill down & Rectifier
Another 2/3 (134NM3/HR) is sent to the Turbo Expander (CE-01), in
which the gas is expanded from 109 Bar to 33.5 Bar to result in
lower temperature as -18oC.
In the Rectifier:
Top product: Sale gas (methane, ethane), T = -43oC
Bottom product: heavier component such as C3, C4; T = -20oC

16/169

1. Process description
GPP Deethanizer (C-01)

Has 2 feeds:

The liquid from the Gas Stripper after heated up from 40 86 oC

in the Condensate Cross Exchange (E-04) on the 20th tray
The Rectifier bottom liquid of -23oC on top tray which includes
95 mole% of liquid and provides external reflux for distillation
Poperating = 29 BarA
T = 14 and 109 oC at the top and bottom respectively.
Cold reflux fluid is not available.
Includes total 32 valve type trays inside

17/169

1. Process description
Gas Stripper (C-04)

The normal operation pressure: 47 BarA

Temperatures are 44 and 40oC at the top and bottom respectively.

Includes total 6 valve type trays

18/169

1. Process description
Stabilizer (C-02)

Operating pressure is controlled at 11 BarA

LPG component (C3 and C4) is separated from the feed condensate.
The top LPG vapor from the column is totally condensed at 43 oC
One Kettle type reboiler is installed at its bottom to provide reboiling
heat by hot oil at 154 oC
Condensate is stored in a float-roof tank TK-21

19/169

1. Process description
C3/C4 Splitter (C-03)
Operating pressure is controlled at 16 BarA

Including total 30 valve type trays

Propane and butane are separated
The propane vapor from the column top is totally condensed at
46oC in Splitter Condenser (E-11) of air cooled type exchanger
One Kettle type reboilers are installed at its bottom (Splitter
Reboiler E-10) to provide reboiling heat by hot oil at 97 oC

20/169

1. Process description
Metering for pipeline

Three liquid pipelines are installed to transfer the liquid products

of condensate, propane and butane from the Gas Plant to a LPG

terminal.
In normal operation of the Gas Plant, the liquid products will be
transferred directly to the LPG terminal through these three
pipeline.

21/169

1. Process description
Storage tank and pumps

Three LPG Bullets and a condensate Day Tank in the Plant will

be used as buffer for abnormal situation of the LPG terminal.

The bullets are used also for truck loading of LPG for domestic
use.
Condensate Day Tank (TK-21) of internal floating cone roof type
with 13m diameter and 15.6m high have a capacity of 2,000 m3
which is equivalent to three days production for a condensate
transfer tanker travel.

22/169

1. Process description
Storage tank and pumps

Stored Condensate Tranfer Pumps (P-23A/B):

30 m3/H capacity
133 m head
Driven by 30kw motor

One standby
Deliver the condensate product in the tank to the condensate
pipeline

Single stage centrifulgal pumps

The head is designed based on requirement of 8 BarA at pipeline
inlet.

23/169

1. Process description
Storage tank and pumps
Three LPG Bullets (V-21A/B/C):

3,35 m diameter
54,61 m long horizontal vessel
Provided for liquid products storage of 540 m3 capacity
A for propane, B for butane, and C for off specification product basically
A and B can store of specification also
Mechanically these three bullets are identical
The design pressure of 17.5 Barg is equivalent of propane vapor
pressure at 50oC any one of them can be used as propane storage.

24/169

2. Simulation PFD

25/169

2. Simulation PFD

Slug Catcher SC-01

26/169

2. Simulation PFD

Slug Catcher Liquid

Flash Drum V-03

27/169

Regeneration
2. Simulation PFD

GPP
Dehydration

Adsorber Switch-over
Depressurization

28/169

2. Simulation PFD
Regeneration

Heating
Cooling

29/169

2.Regeneration
Simulation PFD

Pressurization
Stanby

30/169

2. Simulation PFD

31/169

2. Simulation PFD

Gas chill down

& Rectifier

32/169

Gas chill down

& Rectifier

2. Simulation PFD

33/169

2. Simulation PFD

GPP Deethanizer

34/169

2. Simulation PFD
GPP Compression

35/169

2. Simulation PFD

Stabilizer C-02

Splitter C-03

36/169

Three LPG Bullets (V-21A/B/C)

37/169

3. Start up procedure on dynamic

simulator
Recommended sequence of operations and demonstrates the
interaction of each section of the model during startup.
Criteria:
Operator must deminstrate an understanding of the startup
procedure
Operator must follow the correct sequence
Operator must start up smoothly

38/169

4. Shutdown procedure on dynamic

simulator
Recommended sequence of operations for a normal shutdown
and demonstrates the interaction of each section of the model
during shutdown.

39/169

5. Malfunction exercises
Blockage slug catcher downstream
Compressor K-02 trip
V03 Level transmitter LT0302 drift high
FV1201 fails close
SDV1101 fails close CC01 trip
C04 gas stripper pressure transmitter PT1801B drift high
C01 transmitter LT1302 drift low
E01A Deethanizer reboiler fouling
Loss of hot oil
Electrcal power failure

40/169

5. Malfunction exercises
Blockage slug catcher downstream
Compressor K-02 trip

V03 Level transmitter LT0302 drift high

FV1201 fails close
SDV1101 fails close CC01 trip
C04 gas stripper pressure transmitter PT1801B drift high
C01 transmitter LT1302 drift low
E01A Deethanizer reboiler fouling
Loss of hot oil
Electrical power failure

41/169

II. GAS DEHYRATION ON DYNAMIC SIMULATOR

1. Process description
2. Simulation PFD

3. Start- up and shutdown

42/169

1. Process description
The Gas Dehydration consists of the following major equipment:
a. Glycol Contactor Inlet Cooler 24HH001
b. Glycol Contactor Inlet Scrubber 24VG101
c. Glycol Contactor 24VB001

43/169

a. Glycol Contactor Inlet Cooler 24HH001

Suction Cooler 23HBI02 is a compact type exchanger. Gas side
design pressure and temperature is 50.5 barg/ I55oC and the
cooling medium side design pressure and temperature is I6 barg /
I55oC. Design heat duty of the exchanger is 9749 kW.
The cooling medium is taken from the closed loop circulating
system (see section 3.I2). Control of the gas exit temperature is
by modulation of a temperature control valve on the cooling
medium return line, the temperature being measured on the inlet
to the Inlet Scrubber 24VGI0I by 24TCI009.

44/169

a. Glycol Contactor Inlet Cooler 24HH001

Gas is mixed upstream of Inlet Cooler 24HH00I that has originated from:
The discharge of the 2nd Stage Recompressor 23KA002 via
23EV0002
The Test Separator 20VA004 via 20EV00I0 (with 20EV00II in
parallel)
The HP Separator 20VAI0I via 20EVI00I (with 20EVI002 in parallel)
The anti-surge system of the Export Compressor 26KA00I

45/169

a. Glycol Contactor Inlet Cooler 24HH001

NOTE: There are no specific Isolation Valves for the Dehydration
System as closing all of the above valves isolates the system.
24PDTI006 measure the differential pressure across the gas side
of the cooler.
Methanol injection upstream of the Inlet Cooler is provided for the
prevention of Hydrate formation. A 2" electrically operated valve,
42HV000I, controls the flow.
Gas then enters the Inlet Scrubber 24VGI0I where any entrained
liquid is removed.

46/169

b. Inlet Scrubber 24VG101

Contactor Inlet Scrubber 24VG101 is a vertical gas/liquid separator
with a design P of 50.5 barg and a T of I55oC. The vessel has an
internal diameter of 0.99 metres with a height of 5.56 metres.
Liquids which are disengaged are returned, under control of
24LCI007 modulating a level control valve to either the inlet of the
MP Separator 20VA202 via 4" hydraulically operated shutdown valve
24EVI005 or to the 2nd Stage Recompressor via 4" hydraulically
operated shutdown valve 24EVI0I0. 4" hydraulically operated
shutdown valve 24EVI005 will open automatically on 2nd Stage
Recompressor trip.

47/169

b. Inlet Scrubber 24VG101

NOTE: The level controller is pulsed to Manual Mode and 0% output
when respective EV or XV valve is closed.
The gas is then routed to the inlet of the Glycol Contactor 24VB00I or
it can be routed through a I4" Contactor Bypass line. The manual
valves on this line are interlocked to prevent the isolation valves
being

closed

if

the

bypass

valve

is

closed.

Safeguarding

Instrumentation is provided by High and Low Level trip switch

24LSTI008.
The Inlet Scrubber can be depressurised to the HP Flare via a 3"

hydraulically operated blowdown valve 24BDVI00I. A restriction

orifice downstream of the blowdown valve limits the rate of
depressurisation.

48/169

c. Glycol Contactor 24VBOOl

Glycol Contactor 24VB00I is a vertical vessel with a design pressure
of 50.5 barg and a temperature of I55oC. The vessel has an internal

diameter of 1.67 metres with a height of I0.76 metres.

A separate compartment in the base of the vessel collects any
condensate and returns it, under the control of 24LC0007

modulating a control valve, to either:

The inlet of the MP Separator 20VA202 via 4" hydraulically
operated shutdown valve 24EVI005 or to
The 2nd Stage Recompressor via 4" hydraulically operated
shutdown valve 24EVI0I0.

49/169

c. Glycol Contactor 24VBOOl

NOTE: The level controller is pulsed to Manual Mode and 0%
output when respective EV or XV valve is closed.
The gas rises through the packed bed where it has intimate
contact with the lean glycol from the regeneration unit supplied
via 2" hydraulically operated shutdown valve 24XV2003 located
on the dry glycol inlet line. The glycol absorbs any water from the
gas and the, now wet, glycol is returned under the control of
24LC0006 modulating a control valve, to the inlet of the Glycol
Regeneration System (See section 3.II).

50/169

c. Glycol Contactor 24VBOOl

NOTE: The level controller is pulsed to Manual Mode and 0%
output when respective EV or XV valve is closed.
The dry gas exits the top of the contactor where it is monitored by
dewpoint analyser 24AT0010. A slipstream from this vapour line
is taken to supply the Glycol Regeneration System with make-up
and stripping gas via 2" hydraulically operated shutdown valve
24XV2001. The main vapour route continues to the inlet of the
Gas Export System. Safeguarding Instrumentation is provided by
Low Level trip switch 24LST0009 on the condensate side and by
High and Low Level trip switch 24LST0008 on the wet glycol side.

51/169

c. Glycol Contactor 24VBOOl

Gas Blowby is prevented by 2" hydraulically operated shutdown
valve 24XV0005 located on the condensate outlet line and by 2"
hydraulically operated shutdown valve 24XV0004 located on the
wet glycol outlet line.
The Glycol Contactor can be depressurised to the HP Flare via a
2" hydraulically operated blowdown valve 24BDV0001. A
restriction orifice downstream of the blowdown valve limits the
rate of depressurisation.
A 14" lean, dry gas then passes to the suction side of the Gas
Export Compressor 27KA001.

52/169

Cooler 24HH001
Scrubber 24VG101

53/169

Glycol Contactor
24VB001

54/169

Glycol Regeneration
Reboiler & Surge Drum

55/169

Glycol Regeneration
Filter & Glycol/Glycol HX

56/169

GLYCOL REGENERATION PACKAGE

Flash drum

57/169

GLYCOL REGENERATION PACKAGE

Pumps & Glycol Trim Cooler

58/169

GLYCOL REGENERATION PACKAGE

AquaStripper C

59/169

3. Start- up and shutdown

The first step of the glycol dehydration plant start-up procedure is
to drain all the water from the system
During start-up, the workers establish glycol circulation before
adding glycol to the reboiler
After the glycol dehydration unit has been started-up for about 4
hours, the sales gas dew point is checked to make sure water is
being adequately removed from the gas
The pH of the glycol can be controlled with Buffer chemicals
When the pH of glycol above 8.5, it becomes Foamy
When the pH of glycol drops below 7, it becomes Acidic

60/169

 If the solids present in the rich glycol are not removed, they
could damage the glycol pump.

More solids in the lean glycol steam indicates there are more
solids in The reboiler
The first step of the glycol dehydration plant shutdown

procedure is shutting off the heat source

If the suspended solids content in the glycol is above the 400
to 500 ppm range, the workers probably need to Change the

filters more frequently

The presence of finely divided black solids in the glycol is
often an indication of Hydrocarbon contamination

61/169

3. Start- up and shutdown

62/169

3. Start- up and shutdown

63/169

3. Start- up and shutdown

64/169

3. Start- up and shutdown

65/169

3. Start- up and shutdown

66/169

THANK YOU

www.pvmtc.com.vn

67/169