PPA Platform BGEPIL, India Section 2.

BG EXPLORATION AND PRODUCTION INDIA LTD

PPA PLATFORM

OPERATION & MAINTENANCE MANUAL

SECTION: 2.5

GLYCOL DEHYDRATION SYSTEM

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Contents

2.5 GLYCOL DEHYDRATION SYSTEM

ISSUE AND AMENDMENT RECORD

ABBREVIATIONS
UNITS OF MEASUREMENT

2.5.1 GENERAL DESCRIPTION

2.5.2 DESIGN BASIS
2.5.3 PROCESS DESCRIPTION
2.5.4 SYSTEM START-UP
2.5.4.1 NORMAL START UP
2.5.4.2 NORMAL OPERATING CONDITIONS
2.5.5 NORMAL SHUTDOWN
2.5.6 EMERGENCY SHUTDOWN
2.5.7 TROUBLE SHOOTING
2.5.8 Annex
2.5.8.1 PROCESS FLOW DIAGRAM
2.5.8.2 HEAT & MASS BALANCE
2.5.8.3 P&IDs
2.5.8.4 EQUIPMENT LIST
2.5.8.5 ELECTRICAL MOTOR LIST
2.5.8.6 INSTRUMENT LIST
2.5.8.7 ALARM & SHUTDOWN LIST/LOGIC DIAGRAM
2.5.8.8 TRAINING AND COMPETENCIES

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ISSUE AND AMENDMENT RECORD

Chapter Pages Amendment description Rev.No Date Revised Approved

No. Amended . by by
All All New Manual Rev A 12-05-03 KPGI
2.5.2, All More details on design Rev B 11-06-03 KPGI
2.5.3, basis, training and
2.5.9.8 competencies added
2.5.2, All More details on Rev 0 23-06-03 KPGI
2.5.3 Regenerator added
All All Updated for Rev A1 17 -05-06 AKPG
incorporating changes
of Panna Capacity
Enhancement Project
All All Final Issue-Updated for Rev 1 8 -09-06 AKPG
incorporating changes
of Panna Capacity
Enhancement Project
All All Updated for Rev 1C 04-03-13 WP
incorporating changes
of ESD Migration
Project
All All Updated for Rev D 30-12-14 WP
incorporating changes
of ESD Migration
Project

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ABBREVIATIONS

BGEPIL B G Exploration and Production India Limited

BDV Blow Down Valve
B/V Block Valve
CV Control valve
D/S Downstream
ESD Emergency Shutdown
FE Flow Element
FQI Flow Quantity Indicator
FRP Fibreglass Reinforced Plastic
FV Full Vacuum
KPGI Kvaerner Powergas India Pvt Ltd
LC Level Controller
LP Low Pressure
LTS Low Temperature Separator
MMSCFD Million Standard Cubic Feet per Day
NRV Non Return Valve
ONGC Oil and Natural Gas Commission
PCV Pressure Control Valve
PDI Pressure Differential Indicator
PPA Panna Production Platform
PS Pressure Switch
PSE Pressure Safety Bursting Disc
PSH Pressure Switch High
PSL Pressure Switch Low
PSV Pressure safety Valve
PFD Process Flow Diagram
PSV Process Safety Valve
RV Relief Valve
RVP Reid Vapour Pressure
SDV Shut Down Valve
SAFE Chart Safety Analysis Functional Evaluation Chart
SOP Standard Operating Procedure
TAH Temperature Alarm High
TAL Temperature Alarm Low
TI Temperature Indicator
TEG Tri Ethylene Glycol
U/S Upstream

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UNITS OF MEASUREMENT

Sr.no Parameter Unit Alternative

1 Dimension m, mm In, ft
2 Area m2 Ft2
3 Volume m3 Ft3
4 Time h, s
5 Pressure(absolute) kPa (abs) psia, bara
6 Pressure(gauge) kPag psig, barg
7 Liquid head m In
8 Pressure loss/unit length kPa/m Mm Hg
9 Static pressure mm water
10 Temperature o
C, k
11 Mass flow rate kg/h Lb/h
12 Gas volumetric flow rate(standard conditions) sm3/h MMscfd
13 Liquid volumetric flow rate m3/h Bpd
14 Liquid volumetric flow rate(stock tank conditions) m3/h st bpd
15 Actual flow rate m3/hr
16 Amount of substance kmole
17 Density kg/m3 lb/ft3
18 Dynamic viscosity cP
19 Kinematic viscosity cSt
20 Weight kg
21 Thermal conductivity W/m.oC
22 Fouling factor m2oC/kW m2oC h/kcal
23 Velocity m/s
24 Surface tension mN/m Dyne/cm
25 Speed rpm
26 Particle size mm Micron
27 Solid/sediment concentration g/l
28 Contaminant concentration(mass) mg/kg ppm(w)
29 Contaminant concentration(volume) mg/l ppm(v)
30 Heat kW Kcal
31 Latent heat kJ/kg Kcal/kg
32 Specific heat kj/kgoC kcal/kgoC
34 Heat transfer coefficient kW/m2oC kcal/h-m-2oC
35 Heating value(liquid) MJ/kg kcal/kg
36 Heating value (gas) MJ/sm3 kcal/sm3
37 Power kW Hp
38 Noise dB(A)

Note that
Standard conditions Defined at 15.6o C and 101.3 kPa abs)
Normal conditions Defined at 0o C and 101.3 kPa (abs)

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2.5 GLYCOL DEHYDRATION SYSTEM

2.5.1 GENERAL DESCRIPTION

B G Exploration and production India Limited (BGEPIL) operates Panna

Production Platform (PPA). PPA is designed to process Oil and Gas
produced from Panna and Mukta Oil fields and dispatch the same to ONGC’s
Hazira Terminal via sub-sea Departing Export Pipeline.

PPA has a design capacity of processing 240 MMSCFD gas. The gas
produced from the platform is totally saturated with water. Wet gas, if
transported as such, can partly condense in sub-sea pipeline resulting in
undesirable two-phase flow. To avoid this, gas is dehydrated on PPA using
Trio-ethylene Glycol (TEG) in a contactor. Water content in the dehydrated
gas is maintained below 6 lbs / MMSCF.

Rich TEG from Dehydrator containing water is regenerated in TEG-

Regeneration unit and reused in dehydrator.

Dehydrated gas at a pressure of 1000 psig and temperature of 100 oF is sent

to third stage of the compressor where the pressure is raised maximum upto
1350 psig. Dehydrated gas after third stage of the compressor is split into
two streams. The main stream is metered and exported to Hazira by sub-
sea pipeline. The second stream is used for Fuel and Lift Gas and can vary
from 2.5 to 25 MMSCFD.

Dehydrated gas has H2S content in the range of 350 to 500 ppm. This meets
the mainstream gas consumer’s specification and supplied as such. Fuel Gas
/ Lift Gas H2S spec is 10 ppm. To achieve this, stream is sent for sweetening
/ H2S removal to Amine scrubbing unit where H 2S content is reduced to 10
ppm.

Dehydrated gas sent to Amine Scrubber for the removal of H 2S again

becomes saturated with water and therefore treated again in the second
glycol contactor, which is known as fuel/lift gas contactor for water removal.

The scope of this manual is to provide information for start-up, normal

operation, emergencies in the plant, emergency shut down, monitoring of the
plant and handing over the equipment to maintenance for repairs.

This section of the plant includes the following major equipment

 CONTACTOR INLET SCRUBBER, MBF – 1100.

 CONTACTOR INLET FILTER SEPARATOR , MAK – 1110
 BULK GLYCOL CONTACTOR, MAF – 1120
 BULK GAS FILTER SEPARATOR, MAF – MAK-9390
 FUEL / LIFT GAS GLYCOL CONTACTOR, MAF – 1170.
 GLYCOL HYDROARBON SEPARATOR, MBD-1260
 GLYCOL SOCK FILTER, MAJ-1270.
 CHARCOAL FILTER, MAJ-1280.
 GLYCOL REGENERATION SKID, ZZZ – 8710
 GLYCOL VAPOUR CONDENSER, HAL-4330/4330A

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The procedures given in this manual are guidelines only and must be
considered as such. Before using any procedure, make sure it is safe in the
given conditions and process variables at the time of use.

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2.5.2 DESIGN BASIS

The design capacity of Gas Dehydration System at PPA platform facility is

240 MMSCFD.

The system consists of two Glycol towers, one flash gas separator and one
Glycol Regeneration System. The system is designed to dehydrate the gas
to contain water below 6 lb / MMSCF. Tri-ethylene Glycol is used as a
dehydrating medium. As per design, 3 gallons of lean glycol needs to be
circulated for every lb of water removed from the wet gas. Water content of
wet gas depends upon the temperature and pressure at the inlet of contactor.
The flow of lean Glycol is adjusted to get desired quality of gas at the outlet
of the contactors. Following graphs depict the effect of various parameters on
the dehydration mechanism.
a) Water Content of Hydrocarbon Gas
b) Dew Point of Natural Gas
c) Equilibrium Water Dew Points with Various Concentrations of
TEG

The dehydrated gas is split into two streams. The main stream is metered
and exported to Hazira by subsea pipeline. The second stream is used for
fuel and lift gas. The flow of the fuel/lift gas can vary from 2.5 MMSCFD to 25
MMSCFD. It is further treated in Amine contactor to remove H 2S. The off
gas from the Amine Contactor is water saturated and therefore it is again
dehydrated to get the water content below 6 lb/MMSCF.

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The design parameters for the major equipment of the dehydration system are given below:

BULK GLYCOL CONTACTOR MAF-1120

Sr.No. Parameters Details

1) Type Vertical glycol contactor
2) Dimensions 1676 mm ID x 7620 mm Height
3) Design Pressure 1380 psi (95.15 bar) at 130F (54C)
4) Design code ASME Section VIII, Division 1 Code
design
5) Operating pressure 1000 psig (68.95 barg) at 100F
(38C)
6) Process Design Data Liquid rate = 14184 lb/hr
Density = 69.07
(Tray #2) lb/cu.ft.
Surface Tension = 41.58
dyne/cm
Viscosity = 15.10 cP
Vapour rate = 557800 lb/hr
Density = 4.699
lb/cu.ft.
Flood = 49%
Pressure Drop = 0.68 mm Hg
Liquid hold up = 1.67%
7) Internals  SS316/SS316L FLEXIPAC 2Y
HC structured packing.
 SS316/SS316L structured
packing grid.
 Evenflow HE.
 Mesh type agglomerator
 1 off spiral flow cyclones deck.
 Glycol distributor
 Internals supports
 Interface bolting-SS316
 Interface gasket-PTFE

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FUEL / LIFT GAS GLYCOL CONTACTOR MAF-1170

Sr.No. Parameters Details

1) Type Vertical glycol contactor
2) Dimensions 762 mm ID x 6096 mm
3) Design Pressure 1380 Psig (95.15 barg) at 170F
(77C)
4) Design code ASME Section VIII, Division 1 Code
design
5) Operating pressure 1100 psig (75.85 barg) at 120F (49C)
6) Process Design Data Liquid rate = 2375 lb/hr
Density = 68.44 lb/cu.ft.
(Tray #2) Surface Tension = 40.57
dyne/cm
Viscosity = 11.15 cP
Vapour rate = 59977 lb/hr
Density = 5.243 lb/cu.ft.
Flood = 31%
Pressure Drop = 0.21 mm Hg
Liquid hold up = 1.46%
7) Internals  11’-9” 316L SS Structured packing
(Montz B1-200, 0.005” thickness,
7.8” thick, 18 Units)
 316L SS inlet gas distributor
 MTS-109 Multipan 2-stage liquid
distributor. 12 GA 316L SS
sectionalized pan, 3” deep, Slotted
drop tubes, 9 points/sq.ft.
 RKP predistributor.
 316L SS packing support grid
(SPS-101 support grid, 12 Ga
316L SS, 3” high on 3” centres)
 16” thick composite density
demister, 4” thick topped with 12”
thick stranded Dacron yarn,
reinforced with SS wire, 316L SS
top/bottom grids, segmental
construction, 6 pieces total.

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GLYCOL REGENERATION SKID, ZZZ – 8710

There is a wide difference in boiling points of water and TEG and this
simplifies the regeneration process of glycol. In the regenerator, reboiling of
the glycol is carried out at atmospheric pressure. The design temperature of
395 o F in the reboiler can achieve the concentration of 99.2 weight % of
TEG. It is essential that the temperature of regenerator does not exceed the
recommended temperature. At higher temperature, decomposition of glycol
occurs and lower glycols get formed. Degradation of glycol also lowers the
pH and increases the potential of corrosion. To overcome the temperature
limitation, provision of gas stripping is made. Gas stripping helps achieve the
required TEG concentration without exceeding the recommended
temperature. It is also essential that the system is designed to avoid
carryover of hydrocarbons and water. Carryover of heavy hydrocarbons
results in a black tarry solution, increase in viscosity and foaming of the
solution. Inorganic salts carried over along with water can deposit on the
reboiler tubes causing fouling and high metal temperature and tube failure.

Sr.No. Parameters Details

1) Type Single barrel Reboiler with surge tank
2) Dimensions 1372 mm ID * 7620 mm height
3) Design Pressure 10 Psig (0.69 barg) at 450 F (232C)
4) Design code ASME Section VIII, Division 1 Code
design
5) Operating pressure Atmospheric at 395 F
6) Major components
Glycol Reboiler 2.5 MMBTU/hr Rating
Surge Tank 1200 USG normal operating volume
Still Column 610 mm OD * 3658 mm , 3048 mm
packed section with 40 mm SS 316 pall
ring packings
Inlet Glycol Orifice Type
Distributor

Design data for other equipment is given in section 2.5.9.4

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2.5.3 PROCESS DESCRIPTION

The Glycol system consists of two Glycol Towers, one Flash Gas Separator
and one Glycol Regeneration System.

CONTACTOR INLET SCRUBBER MBF – 1100 :

(Refer to P& I D No. BGEP-LNTA-P121-PPAX-PR-11-158-4113-D)

The gas stream at 100oF and 970 psig nominal pressure (During minimum
ambient temperature 971 psig & during maximum ambient temperature 966
psig ) enters the Contactor Inlet Scrubber MBF–1100 where free liquid, if
any, is separated from the gas. The gas exits the scrubber through a high
efficient vane pack, where the residual droplets in the stream are coalesced.
The liquid separated in the vane pack is piped to the bottom of the scrubber
and mixes with the free liquid. The liquid goes back to the crude oil header.

 LC–1101 controls the level in the Scrubber by operating control valve

LV–1101.
 The Scrubber is equipped with low and high level alarms to alert the
operator if the level gets out of range.
 A Low Low Pressure Transmitter PT-1101B (3 out of 4)voting
alongwith PT-1121A,PT-1451C &PT-7501B) will trip at 850 425 psig
(decreasing).
 Bursting Disc PSE–1101 is in series with Pressure Safety Valve
PSV–1101. Both are set at 1380 psig which protect the Scrubber
from over pressurising.
 A 2” by-pass around the Safety valve allows the Scrubber to be
depressurised manually.
 Pressure Transmitter High PT-1101A,, set at 10 psig will sound an
alarm at the Control Panel if there is a leak in the disc.

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CONTACTOR INLET FILTER SEPARATOR MAK – 1110 :

(Refer to P& I D No. BGEP-LNTA-P121-PPAX-PR-11-158-4113-D)

The gas stream from the Contactor Gas Separator enters the Contactor Inlet
Filter Separator MAK–1110, where any carry over in the gas stream is
removed. The Separator is divided into two sections. The first section
removes the free carry-over liquid. In the second section at the top, finer
entrapped liquid droplets are separated when the gas passes through eleven
Apex Porous media coalescing filter elements.
The Contactor inlet filter/separator can be bypassed, blocked in, and
depressurised to change the elements, if they are plugged.

 LC–1111, controls the liquid level, a snap action level controller that
operates the LV–1111, level control valve.
 The gas then passes through eleven (11) Apex Porous Media
Coalescing Filter Elements in top section.
 Level Controller LC-1112, A snap action controller, operating LV–
1112 controls the level in the second section.
 Outlet from both Level control valves go back to the Crude oil
header.
 Differential Pressure meter PDI–1111 installed across Filter
Separator indicates the fouling of the filters. Filter elements should
be changed when delta-P is between 12 to 15 psig.
 Bursting Disc PSE-1111 and a Pressure Safety Valve, PSV–1111
both set at 1380 psig protect the Filter Separator from over
pressurising.
 Pressure Transmitter PT-1111A will give pressure alarm high at 10
psig in control panel if there is leak in the bursting disk.
 A 1” line provided around the relief valve to flare is used to de-
pressurise the filter.

The Separator must be isolated and fully depressurised before opening of top
cover head. Failure to depressurise the Separator before opening can result
in serious injury or damage.

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BULK GLYCOL CONTACTOR MAF – 1120 :

(Refer to P& I D No. BGEP-LNTA-P121-PPAX-PR-11-158-4114D)

The Bulk Glycol Contactor, MAF-1120, is packed with SS316/SS316L struc-

tured packing.
Lean glycol prior to entering the Contactor, enters the Bulk Gas/Glycol Ex-
changer HBG–4070, where it is cooled by the outlet gas from the Contactor.
The Gas /Glycol heat Exchanger HBG-4070, is shell tube type heat ex-
changer, installed down stream of TEG Contactor MAF-1120, to cool the lean
TEG. This ensures that the Glycol does not enter the contactor at an elev-
ated temperature. A high glycol return temperature may lead to significant
heat transfer at the top of the tower and elevate the dry gas temperature
which would lead to the following.
 Increased vapour pressure of the water at the top of the
column.
 Poor dehydration performance.

A low glycol return temperature may result in hydrocarbon condensation

within the column and poor performance due to foaming of the condensed
hydrocarbons. TEG is cooled against the dry gas leaving the Contactor.

A glycol distributor is provided at the top of the structured packing. It

spreads the incoming glycol evenly over the top surface of the packing.

The gas stream enters the Bulk Glycol Contactor below the structured pack-
ing section of the tower and flows upward through the packing where the gas
and lean glycol are contacted in counter-current direction. TEG comes in
close contact with water saturated as. TEG has a high affinity for water and
dehydrates the gas. Glycol absorbs the water from gas thereby reducing wa-
ter below 6 lbs per MMSCF. Dry gas comes out of the top of the contactor
and water laden rich glycol comes off from the bottom of the tower.
 FE-1121 / FQI-1121 measure Glycol flow to the Contactor and con-
trolled by flow controller FC-1121 operating flow control valve FV-
1121.
 At 240 MMSCFD gas rate, glycol circulation is 25USGPM of 99.2
weight % glycol. The gas stream from the Filter Separator enters the
Bulk Glycol Contactor MAF–1120 below the structured packing sec-
tion of the tower, flows upward through the packing where the gas
and lean glycol are contacted counter–current. Water laden rich
glycol comes to the bottom of Contactor.
 Level Controller LC–1121 controls the bottom level of the column by
operating the control valve LV–1121 with a proportional action to
keep the liquid flowing smoothly to regeneration. LT-1121A trips on
high high LSHH-1121A & low low LSLL-1121A to alert HH & LL
Level.
 The Choke FO–1121 is located down stream of level control valve is
to prevent the washing out of SDV-1121 due to the high pressure
drop.
 Valve SDV–1121 located on the line to shut off the line in the event
of an emergency.
 Low Low pressure transmitter (PT-1121A) PSLL-1121A, set at 850
445 psig will activate based on 3 out of 4 voting alongwith PT-
1101B, PT-7501B and PT-1451 C.A 2” by-pass around the PSV for
manual flaring or depressurising.
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 Valve BDV-1121 is located on the HP flare line.
 TAH-7003 set at 120 oF is provided at the inlet line of bulk glycol
contactor.
 TI-7003 is provided on inlet line of Bulk Glycol Contactor for
temperature indication.

BULK GAS FILTER SEPARATOR MAK – 9390 :

(Refer to P& I D No. BGEP-LNTA-P121-PPAX-PR-11-158-4114D)

Dry gas from the Bulk Glycol Contactor is compressed in third stage of Pro-
cess Gas Compressor. In PGC pressure is raised from 1000 psig to 1350
psig. Due to increase in pressure, heavier components in the gas get partially
condensed, as the compressed gas is cooled to remove the heat of compres-
sion, in the compression section. The compressed and cooled gas is then
sent to the Bulk gas Filter Separator MAK–9390. In Bulk gas Filter a distrib-
utor is provided in gas inlet line for evenly distribution of the gas entering.
The liquid separated at bottom gets knocked out and its level is controlled by
LC-1131 with the operation of control valve LV-1131. For removal of mist in
gas, the gas flows to down stream filter media, made of glass fibre + nylon.
Here mist is condensed and separates in form of fine liquid droplets. The
droplets gets collected at the bottom of the separator.

 PDI-1131 measures differential pressure across the filter. The filter

elements should be changed when the differential pressure reaches
12 to 15 psig.
 The separator can be by-passed, blocked / isolated / drained /
depressurised to change the filter elements.
 PSV-1131 A/B set at 2000 psig., protects the vessel from over
pressurising.
 A 1” line to flare around the PSV to depressurise the unit.


The Separator must be isolated and fully depressurised before opening

of top closure head. Failure to depressurise the Separator before
opening can result in serious injury or damage.

The gas dehydrated to 6 lbs. H2O / MMSCF and filtered in MAK-1130 is split
into two streams. The main stream is metered at the sales gas meter station
and dispatched from the Platform to ONGC terminal at Hazira.

The second stream is used for Fuel and Lift Gas. Its flow can vary from 25
MMSCFD (When the Lift System is in operation) to 2.5 MMSCFD. (When
only Fuel Gas system is being processed)

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DEHYDRATION OF GAS AFTER REMOVAL OF HYDROGEN SULPHIDE

IN AMINE CONTACTOR

The process gas contains 1070 ppm H2S. Fuel / Lift gas specifications are 10
ppm H2S. This stream is sweetened in an Amine Contactor located in Amine
unit. In this unit H2S content of the gas is reduced from 1070ppm to 10 ppm
but it becomes fully saturated with water. Water saturated gas is dehydrated
again to attain water content of 6 lbs. per MMSCF. Outlet gas from Amine
Contactor at 137o F is cooled to 120oF in Amine Contactor. outlet gas Cooler.

The cooled gas stream then flows through either of the two Amine Contactor
Filter Separators MAK–1150 or MAK–1160. One Unit remains on line,
second unit remains stand-by; either of the two can handle the entire flow.
The cooled gas stream enters the bottom of the filter separator. Amine
Contactor outlet filter separator is divided in two sections. The free liquid is
removed in the first section. The Level controller LC–1151/1161, controls the
level of the knocked out liquid in the vessel. In the second section, the gas
stream then flows through two Apex Porous Media Coalescing Filters. The
fine liquid droplets are removed and collected at the bottom of this section.
Liquid so recovered by the separators is returned to the Amine Flash
Separator.
 Level control LC –1151 / 1161 operates the control valves LV–1151 /
1161 to maintain the level in the bottom section.
 If the level gets too high, the high level alarm LAH 1151A/1161A will
alarm at the control panel.
 Level control LC–1151 / 1161 operate level control valves LV–1151 /
1161 to control the liquid level in top section.
 Level control LC –1152 / 1162 operates the control valves LV–1152 /
1162 to maintain the level in the second section.
 Separators are protected from over pressurising by a Bursting Disc in
series with PSV, The Bursting Discs PSE–1151 / 1161 are set at
1380 psig.
 Pressure Relief Valves, PSV–1151 / 1161 are set at 1380 psig. If
there is a leak in the Bursting Disc the pressure to PSV rises to 10
psig, pressure Transmitter PT-1151 A/1161A will send a High High
alarm to control panel.
 The separator can be by-passed, blocked / isolated to change the
filter elements. The filter elements should be changed when the
differential pressure on PDI–1151/1161 reads 12 to 15 psig across
the elements.

The Separator must be isolated and fully depressurised before opening of top
closure head. Failure to depressurise the Separator before opening can
result in serious injury or damage.

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FUEL / LIFT GAS GLYCOL CONTACTOR MAF – 1170 :

(Refer to P& I D No. BGEP-LNTA-P121-PPAX-PR-11-158-4116-D)

The Glycol Contactor, MAF-1170, tower is packed with structured packing.

Lean Glycol stream prior to entering Glycol Contactor is first cooled in gas /
glycol exchanger HBG-4090, by outgoing gases from the Contactor.

The Gas /Glycol heat Exchanger HBG-4090, is shell tube type heat ex-
changer, installed down stream of TEG Contactor MAF-1170, to cool the lean
TEG.

This ensures that the Glycol does not enter the contactor at an elevated tem-
perature. A high glycol return temperature may lead to significant heat trans-
fer at the top of the tower and elevate of the dry gas temperature this would
lead to the following.

 Increased vapour pressure of the water at the top of the

column.
 Leads to poor dehydration performance.

A low glycol return temperature may result in hydrocarbon condensation with

in the column and poor performance due to foaming of the condensed hydro-
carbons. TEG is cooled against the dry gas leaving the Contactor.

The cooled glycol flows to three tier stainless steel distribution section and
spreads evenly over the packing and flow downward absorbing water from
the wet gas moving upwards.

The outlet from Filter Separator MAK–1150 or MAK–1160 enters the Fuel /
Lift gas Glycol Contactor MAF-1170 below the structured packing section of
the tower, flows upward through the packing where the gas and lean glycol
is contacted counter-currently. The dry gas coming out from the top of the
Contactor and water rich glycol coming off from the bottom of the tower. Ef -
fluent gas from the top of the contactor flows through the Gas / Glycol ex-
changer HBG–4090 to the high pressure fuel gas scrubber and power gas
accumulators.

At 24 MMSCFD of gas, the Glycol circulation is 5.3 US GPM of 98.9%

 Glycol flow to the Contactor is measured at FL–1171 / FQ–1171 and

controlled by flow controller FC–1171, operating flow control valve
FV–1171.
 LC-1171 located at bottom of the tower controls the tower bottom
level by operating LV-1171 control valve with a proportional action
and the liquid flows to the Regeneration equipment.
 A Choke FO-1171, located downstream of the level control prevents
high pressure drop from washing out the valve.
 Valve SDV-1171 is located on the line to shut-off the line in case of
Emergency.
 Level transmitter(LT-1171A) with Low Low and high high level trip
LSLL-1171A and LSHH-1171A signal the ESD if the level in the
tower goes out of range.

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 Pressure transmitter (PT-1171A) with Low Low pressure trip PSLL-
1171A, set at 850Psig sends trip signal in case tower pressure goes
below the range.

 PSV-1171 is set at 1380 psig to protect from over pressuring. A 2”

by-pass is provided around the PSV for manual flaring or
depressurising of the tower.

GLYCOL REGENERATION SYSTEM :

(Refer to P & ID No: BGEP-LNTA-P121-PPAX-PR-11-158-4122-D)

Water Rich Glycol from Bulk Contactor MAF-1120 and from Fuel/lift Glycol
Contactor MAF-1170 jointly flow as coolant through the reflux condenser at
the top of still column. Glycol is further heated in Glycol/Glycol Pre-heater
HBG-4150 to 210F and then it enters the Glycol Flash Drum.

GLYCOL HYDROCARBON SEPARATOR :

Hot, water rich Glycol at 210F and a pressure of 1350 psig flashes in Glycol
Flash Drum to a pressure between 50 to 60 psig. Dissolved gaseous and
entrained liquid hydrocarbon droplets are removed in Glycol Flash drum. The
dissolved vapours are flashed off. Typically these vapours are about 1
SCF/gallon of Glycol. Partial heating of the Glycol stream reduces the
foaming tendency in flash tank. Entrained droplets of hydrocarbon liquid rise
to the surface of the liquid Glycol, where they accumulate as hydrocarbon
layer. This layer is skimmed off by raising the vessel level until the liquid
spills into the skim bucket in side the separator.
 Level in skim section can be seen can be seen in level gauge LI-
1261.
 Level Controller LC-1261 controls the level of skim section by
operating control valve LV-1261. The liquid is drained to a closed
drain system.
 Low Low level trip LSLL-1261A of LT-1261A initiates from ESD if
level drops beyond limit.
 High high & low low level trip LSHH/LSLL-1262A of LT-1262A
initiates from ESD if level drops/goes beyond limit.
 Pressure Controller PCV-1261 set at 60 psig releases the gas to LP
flares in case pressure increases.
 Pressure Controller PCV-1262 set at 50 psig make-up gas from Fuel
Gas System when ever pressure drops.
 Pressure transmitter (PT-1261A) with Low Low and High High
Pressure trips PSLL-1261A and PSHH-1261A set at 43 40 psig and
69 135 psig respectively send alarm to ESD in case pressure goes
beyond the limits.
 Bursting Disc PSE-1261 set at 150 psig, and a pressure Relief Valve
PSV-1261 set at 150 psig protect the system against over
pressurising.
 Separator level is controlled by LC-1262 by operating control valve
LV-1262, located down stream of Glycol Sock Filter, MAJ-1270 and
Charcoal Filter MAJ-1280.

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GLYCOL FILTERATION :
(Refer to P & ID No: BGEP-LNTA-P121-PPAX-PR-11-158-4122-D)

Having removed dissolved gaseous and entrained liquid hydrocarbon

droplets in Glycol Flash Drum, the Residual Solid Impurities are removed by
filtration, first in Glycol Sock Filter MAJ-1270 and thereafter in Charcoal Filter
MAJ-1280. Entire Glycol stream is filtered in the Glycol Sock Filter. Filter
uses eleven (11) number Peco Filtertex 25 micron elements. The unit can be
by-passed, Blocked /Isolated a depressurised and drained for maintenance.

 Pressure Drop across the filter is measured by Pressure differential

Indicator PDI-1271.
 The elements should be replaced when differential pressure reaches
12 to 15 psig.
 PSV-1271 set at 150 psig protects the system from over
pressurising. After the Sock Filter glycol is treated in the full flow
Charcoal Filter MAJ-1280 to remove trace hydrocarbon from the
stream. Filter can be By-passed, Blocked/Isolated, drained /
depressurised for maintenance.
 PSV-1281 set at 150 psig protects the vessel from over Pressurising.
 Differential Pressure Meter across the filter indicate plugging. The
Unit is By-passed and Isolated if the pressure increases 10 psig over
the start-up pressure.

GLYCOL REGENERATION SKID ZZZ – 8710 :

(Refer to P & ID No: BGEP-LNTA-P121-PPAX-PR-11-158-4120/4121-D)

Glycol Separator liquid level control valve is located down stream of Charcoal
Filter MAJ-1280. Filtered Glycol is heated from 2100F to 310F in Glycol /
Glycol exchanger HBG-4160 before it enters the Still Column for
regeneration. Regeneration column is a simple packed distillation column.
Regenerator operates at atmospheric Pressure and re-boiler of Glycol
Regenerator is designed to operate at a temperature of 395F. Under these
conditions Glycol Thermally Regenerates to a concentration of 99.2 weight
%.

The separation of water vapours from Glycol takes place in the distillation
column. Vapours from the overhead of the column are partially condensed by
cooling coil / condenser HAL-4330/4330A. Both the Glycol Vapour Condens-
ers, operates in parallel are designed for thermal rating 0.6 MMBTU/HR
each. The condensed vapours from both the vapour condensers are drained
to overhead accumulator MBL-1560 and generate reflux for the column.
Pumps PBE-6550 / 6560, pump water from overhead accumulator MBL-1560
to closed drain. 25% of the overhead vapours are condensed and fall back
as reflux, which maintains desired temperature profile of the column.

 Flow Indicator FI-2011 is provided on a Gas Stripping Line. Gas is

not normally required to attain a concentration of 99.2 weight%.
 Temperature Controller TIC-2011 controls the reboiler temperature
by operating FV-2011 controlling the heat medium through the
reboiler.
 High high & low low level LSHH/LSLL-1561A of LT-1561A initiates
from ESD if level exceeds limit.
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 PPA Platform BGEPIL, India Section 2.5
 Level Transmitter LT-1561A located on the drum start and stop the
Pumps PBE-6550/6560, pumping water to the disposal system.

Regenerated hot lean solution overflows to Glycol reboiler surge tank BBC-
2010 from the reboiler. Submergence of the overflow pipe isolates the surge
tank from the wet reboiler vapours. From here the hot lean solution flows
from the surge tank where it exchanges heat in heat-exchanger, HBG-4160,
with incoming water rich Glycol, and flows to the suction inlet of glycol
circulation pumps, PBA-6110/6120 .

 High High pressure trip PSHH-6111A/6121A of PT-6111A/6121A set

at 1265 1350 psig.
 Low Low pressure trip PSLL-6111A/6121A of PT-6111A/6121A set
at 935 650 psig to signal ESD in case of pump problem.
 PSV-6111/6121 set at 1380 psig protect the pumps from over
pressurising.
 A Lean Glycol flow of 25 USGPM to the bulk contactor and 5
USGPM going to fuel/lift contactor is measured and controlled. In
case total flow is less than 30 USGPM a pressure controller PIC-
1127 set at 1200 psig will recycle the excess glycol back to the
pump suction through pressure control valve PV-1121.
 Flow choke FO-1121 located downstream of PV-1121 minimises
wear in the control valve.

A simple visual inspection of the TEG sample can provide clues for identifying many common
glycol problems. The following conditions can indicate major operating problems.

* A black viscous TEG solution (compared with clean TEG from a supply drum) may
be the result of heavy hydrocarbon contamination or glycol polymerisation due to
thermal breakdown or interaction with hydrocarbons.

* A sweet aromatic odour is an indicator of thermal degradation of the TEG.

* The presence of two liquid phases indicates the hydrocarbon contamination of the
TEG indicate the poor separation in the Flash Drum (MBA-1260)
.
* The presence of finely divided black precipitate is the result of iron corrosion.

The foaming tendency of the TEG can be can be checked by sparging air through a sample
in a test tube, The formation of a stable bubble or foam on the TEG surface (stable for
greater than 10 seconds) indicates the foaming character of the Glycol. In case the foaming
is detected, anti foam chemical should be added to the TEG and checked again if foaming
tendency remains.

The pH of the TEG should be approximately 7.0. However it should be noted that thermal
degradation of TEG will result in the formation of acid and the pH of the TEG will fall. A pH of
6 or less will result in poor dehydration and increased corrosion. The pH should be modified
by the batch addition of base i. e. DEA or Sodium Acetate. A pH above 9 is also not desirable
because it leads to emulsification in the presence of hydrocarbons and foaming in the
contactor.

DP type Level transmitter (LT-2011A/2012A) with high high (LSHH-2011A/2012A) and low
low (LSLL-2011A/2012A) on Glycol Reboiler/Surge tank (BBC-2010) are provided.
Document No. BGEP-LNTA-P121-POXX- Rev.1DC Page 21 of 55
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2.5.4 SYSTEM START-UP

2.5.4.1 NORMAL START UP

Normal start-up means the start-up after short shutdown.

ANNEXURE - START-UP CHECK-LIST - 1

STATUS OF VALVES ON THE PROCESS LINES AND

INSTRUMENTS ON EACH EQUIPMENT

This Check List is to be filled-up/used before restarting the unit which

has stopped for a short period only and the following conditions are
fulfilled.

1) Running plant is stopped for a short duration due to some

minor problem.
2) The problem is duly identified.
3) The cause of stoppage corrected.
4) All the utilities are available.
5) The time between shutting plant and restarting is reasonably
short.
6) System is still close to operating Pressure and Temperature
conditions.
7) Various vessels are still holding Liquid levels.
8) All the safe shut down actions on the panel are completed
(valves are manually taken in safe shutdown mode)
9) Gas cloud / liquid hydrocarbon spillage, if any, during the
stoppage is cleared.
10) No major isolation of equipments and/or instruments is
carried out during stoppage.
11) No major change is carried out in the Process line-up of the
Unit. The crew is fully aware of changes done in process
line-up.

MAF-1120 : BULK GLYCOL CONTACTOR

1) All the instruments, measuring Temperature, Pressure, Level

and Flow are operational. No sensor is isolated.
2) Alarm and Tripping system is healthy.
3) SVD-1121 Emergency shut off valve is open.
4) Choke valve FO-1121 is operationally OK.
5) Relief Valve PSV-1121 A/B is commissioned.
6) LC-1121 isolation valves are open and C/V is closed
manually from panel.
7) FC-1121 isolation valves are open and C/V is closed
manually from panel.
8) Check TAH-7003 to be set at correct set point and
functioning correctly.

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 PPA Platform BGEPIL, India Section 2.5

MAF- 1170 : FUEL / LIFT GAS GLYCOL CONTACTOR

1) All the instruments, measuring Temperature, Pressure, Level

and Flow are operational. No sensor is isolated.
2) Alarm and Tripping system is healthy.
3) SDV-1171 Emergency shut off valve is open.
4) Choke valve FO-1171 is operationally O.K

5) Relief Valve PSV-1171 is commissioned.

6) LC-1171 isolation valves are open and C/V is closed
manually from panel.
7) FC-1171 isolation valves are open and C/V is closed
manually from panel.

MBD-1260 : GLYCOL / HYDROCARBON SEPARATOR

1) All the instruments, measuring Temperature, Pressure, Level

and Flow are operational. No sensor is isolated.
2) Alarm and Tripping system is healthy.
3) SDV-1261 Emergency shut off valve on make-up line is
open.
4) PCV-1262, on make-up line is set at 50 psig and
commissioned.
5) PCV-1261, on pressure release line to flare, is set at 60 psig
and commissioned.
6) Relief Valve PSV-1261 is commissioned.
7) Rupture disc, PSE-1261 is installed and healthy
8) LC-1261, on skimming line, isolation valves are open and
C/V is closed manually from panel.
9) LC-1262, on glycol outlet line, isolation valves are open and
C/V is closed manually from panel.

MAJ-1270 : GLYCOL SOCK FILTER

1) PDI-1271, Differential pressure across filter on full load was

below 12 Psig. filter elements do not need any change.
2) Relief Valve, PSV-1271 is commissioned.
3) Sock Filter is on line and by-pass is shut.

MAJ-1280 : GLYCOL CHARCOAL FILTER

1) PDI-1281, Differential pressure across filter on full load was

below 10 psig. filter elements do not need any change.
2) Relief Valve, PSV-1281 is commissioned.
3) Charcoal Filter is on line and by-pass is shut.

ZZZ-8710 : GLYCOL REGENERATOR

1) All the instruments, measuring Temperature, Pressure, Level

and Flow are operational. No sensor is isolated.
2) Alarm and Tripping system is healthy.
3) Relief Valve PVSV-2011 is commissioned.

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PR-12-158-0001-D
 PPA Platform BGEPIL, India Section 2.5
4) Heater, HBG-4180, TIC-2011, isolation valve is closed and
TV-2011 closed from the panel.
5) Purge stream PCV-2011 isolation valve is closed and

MBL-1560 : GLYCOL REGENERATOR REFLUX DRUM

1) All the instruments, measuring Temperature, Pressure, Level

and Flow are operational, no sensor is isolated,
2) Alarm and Tripping system is healthy
3) Glycol vapour Condenser, HAL-4330/4330A, fans are in
operation.

4) Glycol overhead accumulator pumps PBE-6550/6560 are

fully operational.

PBA-6110, PBA-6120 : GLYCOL CIRCULATION PUMPS

1) All the instruments, measuring Temperature, Pressure, Level

and Flow are operational. No sensor is isolated.
2) Alarm and Tripping system is healthy
3) Glycol Circulation Pumps PBA-6110, PBA-6120 are
operationally ready.
4) Relief Valves PSV-6111/6121 are commissioned

BULK GAS FILTER SEPARATOR

1) All the instruments, measuring temperature, pressure, level

and flow are operational. No sensor is isolated.
2) Alarm & tripping system is healthy.
3) SDV-7004, Emergency shut-off valve is open.
4) Relief valve PSV-1131 A/B is commissioned.
5) LV-1131 isolation valve are open and LV-1131 is closed
from panel.

ESTABLISHING GLYCOL CIRCULATION :

Glycol Circulation System involves the following Equipment and all

the Instrumentation installed on them.
1) Glycol Regenerator ZZZ-8710
2) Glycol Regenerator Re-boiler HBG-4180.
3) Glycol /Glycol Exchanger HBG-4160
4) Glycol Pumps PBA-6110 and PBA-6120
5) Glycol Preheater HBG-4150
6) Bulk Contactor MAF-1120.
7) Glycol gas Exchanger HBG-4070
8) Fuel/Lift Gas Glycol Contactor MAF-1170
9) Fuel lift gas glycol exchanger HAL- 409010)
10) Glycol Flash tank MBD-1260.
11) Glycol Sock Filter MAJ-1270.
12) Glycol Charcoal Filter MAJ-1280.
13) Glycol / Glycol heater HBG-4160

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 PPA Platform BGEPIL, India Section 2.5
It is assumed that all the equipment associated with glycol
Regeneration system are pressure tested, leaks if any, attended, and
system is ready in every respect to receive hydrocarbons.
Carry out final check for the line-up of the equipment for the process
flow, vents/drains opening, instruments commissioning,

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PR-12-158-0001-D
 PPA Platform BGEPIL, India Section 2.5

START-UP

TEG CIRCULATION SYSTEM START-UP :

1) All the Equipment in Tri-ethylene Glycol system, Connecting

Pipelines, Instrumentation, Controls, Relief System, are
meticulously checked and logged-in prior to the start-up as
per the Annexure –Checklist
Plant is lined-up for start-up mode.

2) System is thoroughly purged with inert gas. Please refer

Annexure - for purging of the system.
3) System is pressure tested and all the leaks rectified.
4) Following Utilities are ready and operational
a) Flare System
b) Instrument Air
c) Power Supply
d) Cooling Water System
e) Heating System
f) Inert Gas System
g) Fuel Gas System
h) Lift gas System
i) Sea Water System
5) Tri-ethylene Glycol stocks are available in requisite quantity
6) All the Control Valves are stroke checked for proper opening
and found OK.
7) All the Relief Valves certified tested in shop and installed in
field.
8) Rupture Discs of designated pressure ratings are properly
installed.
9) All the Control Valves are stroke checked for proper opening
and found OK.

PRESSURISING THE UNIT WITH HYDROCARBONS :

Initial pressurising the unit with hydrocarbon is the Most Critical Step
in plant start-up. Utmost care must be taken to ensue that the
operation is completed smoothly with out any mishap.
Main threat is uncontrolled leaks in the system. This operation
becomes all the more critical because of the presence of H 2S in
Lethal quantity in the process gas.

The personnel working in the plant must be thoroughly conversant

with the hazards involved in H2S handling and use of the Personnel
Protective Equipment like airline masks. Availability of protective
equipment must be ensured in the plant before the plant start-up.

PRESSURISING MAF-1120, BULK GLYCOL CONTACTOR :

Slowly admit gas into the Absorber, checking the leaks until the
pressure in vessel reaches the line pressure. Close the inlet valve.

CHARGING TRI-ETHYLENE GLYCOL IN ZZZ-8710, GLYCOL

REGENERATOR :

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 PPA Platform BGEPIL, India Section 2.5
1) Check pumps packing, which is shipped loose in plunger
compartment, is installed, pump oil level, belt tension
checked and pumps are ready to start functionally.
2) Charge Pulsation dampeners of Glycol pumps with Nitrogen.
(Follow instructions given in manufacturer’s literature on
Pulsation dampeners).
3) Start Glycol make up pump and charge Glycol Regenerator
reboiler and accumulator with glycol, check, reboiler and
accumulator glycol levels individually in their respective level
indicators.
4) Once glycol regenerator accumulator level has come-up,
start glycol circulation pump, PBA-6110 or PBA-6120 as per
the procedure given by the manufacturer.

CHARGING TRI-ETHYLENE GLYCOL TO MAF-1120, BULK

CONTACTOR :

1) Check and ensure dump valves LCV-1121 and its by-pass

on bulk contactor to regenerator are CLOSED.
2) Manually open FQI-1121 C/V, FV-1121 to control glycol flow
to bulk contactor MAF-1120.
3) Watch level build up in MAF-1120 bottom level indicator, LI-
1121.
4) As the glycol level in Glycol regenerator / accumulator drops
make-up more glycol in it.
5) Maintain 50% levels at the bottom of MAF-1120, bulk
contactor.
6) Check the unit for any leaks / dripping.

CHARGING TRI-ETHYLENE GLYCOL TO MAF-1170, FUEL/LIFT

GAS CONTACTOR:

1) Check and ensure dump valve LCV-1171 and its by-pass on

V-1171, lift / fuel contactor to regenerator are CLOSED.
2) Manually open FQI-1171 C/V, FV-1171, to control glycol flow
to fuel gas/ lift gas Contactor MAF-1170.
3) Watch level build up in MAF-1170 bottom gauge glass, LI-
1171.
4) As the glycol level in Glycol regenerator / accumulator drops
make-up more glycol in it.
5) Maintain 50% levels at the bottom of MAF-1170, bulk
contactor.
6) Check the unit for any leaks / dripping.

Stop glycol circulation pump and glycol make-up in Glycol

Regenerator as the levels in Glycol Regenerator, Bulk Contactor and
Fuel / Lift Contactor stabilises.

UNIT ON INITIAL START-UP BY-PASS MODE :

Initially in Start-up By-pass made of the unit

1) Isolate MAJ-1280, Charcoal Filter and keep its by-pass

open.
2) Isolate MAJ-1270, Sock Filter and keep its by-pass open.
Document No. BGEP-LNTA-P121-POXX- Rev.1DC Page 28 of 55
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 PPA Platform BGEPIL, India Section 2.5

PRESSURISING MAF-1120, BULK GLYCOL CONTACTOR AND

MAF-1170, FUEL GAS/LIFT GAS GLYCOL CONTACTOR :

Slowly admit gas into the contactors, checking the leaks until the
pressure in vessels reaches the line pressure. Close the inlet valve.

PRESSURISING MBD-1260 - GLYCOL/HYDROCARBON

SEPARATOR:

1) Open SDV-1261, emergency shut off valve on Fuel gas/lift

gas makeup to MBD-1260.
2) Keep PCV-1262 at a set point of 50 psig. (C/V goes wide
open).
3) Slowly open 1" block valve on the make-up line admitting gas
to the separator and watch separator pressure comes up
gradually to 50 psig.
4) Fully open the block valve, after PCV-1262 takes over and
start closing at a pressure of 50 psig.
5) Commission PCV-1261 and set it at a pressure of 60 psig.

STARTING AND STABILISING TRI-ETHYLENE GLYCOL

CIRCULATION:
Before starting TEG circulation following operations are completed.
1) Glycol levels are available in
a) ZZZ-8710, Glycol / hydrocarbon separator.
b) MAF-1120, Bulk Contactor
c) MAF -1170, Fuel gas/Lift gas Contactor
2) MBD-1260, Glycol / hydrocarbon separator is at a pressure
of 50 psig.

3) MAF-1120 and MAF-1170 are at a pressure more than 50

psig.
4) Glycol circulation pumps PBA-6110, PBA-6120 are fully
operationally.
5) Instrumentation on equipment involved in Glycol circulation
system is fully commissioned and operationally.
* Take FQI-1120 and FQI-1170 on manual and minimum
opening.
* Take PIC-1121 on manual, with minimum opening
* Start Glycol circulation pump, PBA-6110 or PBA-6120,
* Open 1/2" bleed valve on high-pressure discharge side
of the pump to determine if pump has primed and
discharging glycol.
* If O.K, continue the pump operation otherwise prime
pump or check suction line from accumulator. (See
pump catalogue for additional information)
* As the glycol pump discharge pressure increases open
PIC-1121 manually and then take it on Auto set at 1200
psig.
* Slowly open FQI-1121 C/V and increase the flow to 25
USGPM and transfer the control to Auto. (Flow to Bulk
Contactor).
* Slowly open FQI-1171 C/V and increase the flow to 5
USGPM and transfer the control to Auto. (Flow to Fuel
gas/Lift gas Contactor).

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* Commission LC-1121on Auto and maintain 40 to 50%
level in the
MAF-1120, Bulk Glycol Contactor.
* Commission LC-1171 on Auto and maintain 40% level in
the MAF-1170, Fuel / Lift gas Glycol Contactor.
* Commission LC-1262 on Auto and maintain 40% level in
the MBD-1260 Glycol / hydrocarbon separator.
* Commission LC -1261 on Auto and maintain 40% level
in the skimming section of MBD-1260, Glycol /
hydrocarbon separator.

HEATING THE CIRCULATING TEG :

1) Commencement of heating in Regeneration system:

* Check heating system is available for use.
* Open valve (3") at regenerator heater, HBG-4180
heating media outlet line.
* Commission and manually open TIC-2011 C/V on
heating media inlet line and bring up separator
temperature to 390F and take TIC-2011 on Auto.

2) As some glycol is locked up as circulating inventory, the level

in glycol regenerator accumulator drops, make up, more
glycol from the storage. Stop make-up as level is restored to
50%.

3) Sample circulating Tri-ethylene Glycol for,

a) Water content
b) Boiling Point
c) pH Analysis
d) Hydrocarbon Content & other foreign substances.
e) Inorganic salts.

4) Commission Charcoal Filter, MAJ-1280, and keep its by-

pass shut. Commission Sock Filter, MAJ-1270 and keep its
by-pass shut.

GLYCOL DEHYDRATOR / REGENERATOR SYSTEM IS READY

FOR CUTTING IN GAS :

Commissioning Gas to System :

Slowly open gas to MAF-1120 and MAF-1170.

Check water content in gas coming out of

1) Bulk Contactor
2) Fuel/Lift Gas Contactor.

2.5.5.3 NORMAL OPERATING CONDITIONS

After stabilising the Glycol dehydration plant for liquid circulation, gas
can be introduced. Before introduction of the gas into Glycol
dehydration system, it is essential to ensure that the relevant
upstream and downstream process units are in ready condition. The

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overall start of the facility is covered in Section 4.0 (Facility Start-up
Procedure).

During the normal operation, the process conditions are monitored

and controlled to achieve the desired quality of the gas.
Instrumentation and controls are provided for automatic and safe
operation of the unit. Please refer section 2.5.8.6 for instrument list,
where the values for normal operation are also given. Any deviation
from the normal values will give alarm for the critical parameters. The
corrective actions needs to be taken by the operating staff in case of
process deviation. Section 2.5.7 gives the guidelines for Trouble
shooting.

2.5.6 NORMAL SHUTDOWN

SHUT DOWN PROCEDURE

Unit may be required to be stopped because of a variety of reasons like,

1) Production requirement.
2) Planned maintenance.
3) Equipment Failure.
4) Failure of an essential utility.
5) Hydrocarbon leakage to the atmosphere.

In order to carry out the safe shutting down of the unit it is essential to carry
out various steps in proper sequence. The guiding principal for carrying out
the safe shut down is as follows.

1) Prevention of hydrocarbon leak / spillage in the atmosphere

2) Prevention of over pressurising of any section / equipment of the unit
and releasing the excessive gas in controlled way.
3) Avoiding excessive rise of temperature beyond the safe design limits
of the system, by closing heat input to the system.
4) Minimising the loss of gaseous hydrocarbon inventory in the flare.
5) Preventing the damage to the rotating equipment, by stopping them
as per the laid down procedure.
6) Conserving the inventory of the Circulating fluid, Glycol.
7) Keeping the relief / flare system in healthy condition.

Shutting down of Dehydration System involves,

1) Isolating gas inlet to system,

2) Stopping dry gas flowing from third stage of the compressor.
3) Closing gas from third stage discharge to system and to the
consumers.
4) Cutting of hot media supply to Glycol Regenerator reboiler.
5) To continue with cold glycol circulation, if plant is closed for a shorter
duration, otherwise stop glycol circulation and pump out glycol
inventory to glycol storage tank.
6) Hold the system under gaseous hydrocarbon pressure.

Sequential Action in case of stoppage

(Assumption; power to Instruments and Instrument Air is available)

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Actions from Panel :

1) Close TIC-2011, glycol regenerator heater, heating medium inlet

valve TV-2011 from the panel (Control Room)
2) Reduce glycol flow to both the Contactors, MAF-1120/1170, by
closing FC-1120 and FC-1170 C/Vs FV-1120/1170 from.local
controllers. Stop the flow totally after stopping gas flow to the
Contactors in the field. Stop glycol pump.
3) Close Emergency shut off valve, SDV-1261 on fuel gas make up to
MBD-1260, Glycol /hydrocarbon Separator.
4) Close the following Level Control Valves on from the panel to hold
glycol level in the respective vessel. Isolate respective block valves.
a) LC-1121 (MAF-1120)
b) LC-1171 (MAF-1170)
c) LC-1262 (MBD-1260)
5) In case of persistent loss of glycol level in MAF-1120/1170 close
emergency shut off valves, SDV-1121/1171, from the panel
6) Close Emergency shut off valve, SDV-7004 on knock out liquid outlet
to bulk oil header.

Actions in the Field :

Gaseous hydrocarbon flow:

1) Check the compressor has stopped and not restarting immediately.
2) Close isolation block valves on heating medium to glycol regenerator
heater, HBG-4180.
3) Close gas inlet to MAF-1120, Bulk Contactor.
4) Close dry gas flow from Bulk Contactor/Glycol ex-changer HBG-4070
to compressor third stage suction.
5) Close valve at compressor third stage discharge to MAK-1130, Bulk
Filter separator, inlet.
6) Close valve on line to metering station.
7) Close valve at MAK-1150/1160, Amine Contactor Filter Separator to
MAF-1170, Fuel/Lift Contactor.
8) Close valves on MAF-1170, Fuel/Lift Contactor outlet to
a) HP Fuel Gas Scrubber
b) Power Gas Accumulator

TRI-ETHYLENE GLYCOL CIRCULATION :

1) Close the isolation valves on following level control valves in the field
to hold glycol level in the respective vessel.
a) LV-1121 (MAF-1120)
b) LV-1170 (MAF-1170)
c) LV-1262 (MBD-1260)
2) Stop HAL-4330, glycol vapour condenser, cooling fan.
3) Isolate Glycol Sock Filter, MAJ-1270 and Charcoal Filter, MAJ-1280.

2.5.7 EMERGENCY SHUTDOWN

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As discussed and agreed upon, this section will be finalised later.

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2.5.8 TROUBLE SHOOTING

A) As detected by the measuring Instruments

MAF-1120, Bulk Glycol Contactor :

Detection Set Point Trouble & possible Remedy
cause
PSLL- 850 445 psig System Pressure Low Low
1121A(Bulk (dec) 1) Compressor Trip/ 1) Stabilise compressor,
Contactor Upset in case of Trip,
Low/Low Low 2) Uncontrolled h/c leak carryout plant shut
Pressure) 3) Rupture disc burst down.
4) RV Lifting /passing at 2) Isolate leaky
pressure lower than equipment, if possible.
set pr. 3) Shut isolation Valve. If
5) Well gas supply cut- RD ruptures / RV
off/compressor lifting / passing / RV
recycles are not able not resetting at low
to maintain the pressure & maintain
pressure. system pr. manually
on by-pass.
4) Shut unit in case of
pressure drop is
unmanageable.
PSV-1121 1380 psig System pressure High 1) Investigate cause of
(Bulk High blocked & rectify.
Contactor RV 1) Forward flow blocked 2) Stabilise compressor
Lifting ) 2) Compressor upset 3) Check pressure, if
4) RV malfunction /Lifting lower than RV reset
at pressure lower than pr. & RV not resetting,
set pr./not setting back isolate RV & manually
at pr. lower than control pr. till RV is
design. rectified & reinstalled.
LSHH 1121A 14"213mm High High Level
(Bulk 1) L/V-1121 C/V not fully 1) Open L/C by-pass,
Contactor (from bottom opening. check if level drops.
High High seam) 2) SDV-1121 not open / 2) Stroke LV-1121,
Level) partially open ensure it is fully open.
3) Obstruction in the 3) Remove obstruction
choke. 4) Check & ensure that
4) Isolation valves in the all the valves on the
line not fully open. line are open.
5) Level indication erratic. 5) Check Level indicator
6) Blocked in the line match its level with
level in gauge glass

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MAF-1120, Bulk Glycol Contactor :

Detection Set Point Trouble & possible Remedy
cause
LSLL-1121A -3"152mm Low Low Level
(Bulk Glycol (from the 1) L/V-1121 C/V Open / 1) Close L/C by-pass, if
Contactor Low bottom seam) not closing properly. open, check if level
Low Level) 2) LC-1121, By-pass drops.
valve open/passing. 2) Stroke LV-1121, check
3) Level indication erratic its travel, ensure it
closes fully
3) Check Level indicator
match its level with
level in gauge glass

MAK-9390, Bulk Gas Filter Separator:

Detection Set Point Trouble & possible Remedy
cause
PSV-1131 A/B 2000 psig System pressure High
(Bulk Gas 1) Forward flow blocked 1) Investigate cause of
Filter 2) Compressor upset blocked & rectify.
Separator RV 3) RV malfunction /Lifting 2) Stabilise compressor
Lifting) at pressure lower than 3) Check pressure, if
set pr./not setting back lower than RV reset
at pr. Lower than pr. & RV not resetting,
design. isolate RV & manually
control pr. Till RV is
rectified & reinstalled.
LSL-1131 4” (From Low Level
(Bulk Filter bottom seam) 1) LV-1131 C/V Open / 1) Close LV-1131 by-
Separator Low not closing properly. pass, if open, check if
Low Level) 2) LV-1131, By-pass level drops.
valve open/passing. 2) Stroke LV-1131, check
3) Level indication erratic its travel, ensure it
closes fully
3) Check Level indicator
match its level with
level in gauge glass

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MAF-1170, Fuel Gas / Lift Gas Glycol Contactor :

Detection Set Point Trouble & possible Remedy
cause
PSLL-1171A 850 psig System Press. Low Low
(Fuel / Lift 1) Compressor Trip/ 1) Stabiliise compressor,
Gas Glycol Upset in case of Trip,
Contactor low 2) Uncontrolled h/c leak carryout plant shut
Low pressure) 3) Rupture disc burst down.
4) RV Lifting /passing at 2) Isolate leaky
pressure lower than equipment, if possible.
set pr. 3) Shut isolation valve. if
5) Well gas supply cut- RD ruptures / RV
off/compressor lifting /passing /RV not
recycles are not able resetting at low
to maintain the pressure & maintain
pressure. system pr. Manually
on by-pass.
4) Shut unit in case of
pressure drop is
unmanageable.
PSV-1171 1380 psig System pressure High
(Fuel / Lift 1) Forward flow blocked 1) Investigate cause of
Gas Contactor 2) Compressor upset blocked & rectify.
RV Lifting ) 3) 2) Stabilise compressor
4) RV malfunction / 3
Lifting at pressure 4) Check pressure, if
lower than set pr./not lower than RV reset
setting back at pr. pr. & RV not resetting,
lower than design. isolate RV & manually
control pr. till RV is
rectified & reinstalled.
LSHH-1171A- 22"399mm High High level
1171 (from the 1) L/V-1171 C/V not fully 1) Open the L/C by-pass,
(Fuel/Lift Gas bottom seam) opening. check if level drops.
Contactor 2) SDV-1171 not open / 2) Stroke LV-1171, check
High High partially open its travel, ensure it is
Level) 3) Obstruction in the fully open.
choke 3) SDV-1171, operate
4) Isolation valves in the and see its travel in
line not fully open. the field.
5) Level indication erratic. 4) Remove obstruction
6) Blocked in the line 5) Check & ensure that
all the valves on the
line are open.
6) Check, Level indicator
match its level with
level in gauge glass

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MAF-1170, Fuel Gas / Lift Gas Glycol Contactor :

Detection Set Point Trouble & possible Remedy
cause
LSLL-1171A 5"-305mm Low Low Level
(Fuel/Lift Gas (from the 1) L/V-1171 C/V Open / 1) Close L/C by-pass, if
Contactor bottom seam) not closing properly. open, check if level
High High 2) LC-1171, By-pass increases
Level) valve open/passing. 2) Stroke LV-1171, check
3) Level indication erratic its travel, ensure it
closes fully
3) Check, Level indicator
match its level with
level in gauge glass

MBD-1260, Glycol Hydrocarbon Separator :

Detection Set Point Trouble & possible Remedy
cause
PSLL-1261A 4043 psig System Pressure Low Low
Glycol 1) PCV-1262, controller 1) Stroke, & check PCV-
Hydrocarbon faulty/C/V not opening 1262, travel, ensure
Separator Low proportionally. full opening.
Low pressure 2) Valve (1") on PCV- 2) Check valve (1") on
1261, make-up line PCV-1261, make-up
close. line is open.
3) SDV-1261 close / 3) Stroke & check SDV-
partly open 1261 is fully open
4) PCV-1261, controller 4) Stroke & check, PCV-
faulty/C/V not opening 1261, C/V is opening
proportionally. proportionally / fully
5) PSV-1261, RV, 5) Close PSE-1261 (RD)
passing/ Lifting. isolation valve &
6) PSE-1261, RD, check if pressure
leak/burst improves, re-
7) LC-1261,controller commission
faulty, C/V open fully / 6) Close (RV) PSV -1261
partly isolation valve & check
if pr. improve, re-
commission
7) Check liquid level in
LI-1261, if no level
shut LV-1261 B/V,
check if pr. improve,
re-commission
PSHH-1261A 69 135 psig System Pressure High
(Glycol 1) PCV-1261, control 1) Stroke & check, PCV-
Hydrocarbon Malfunctioning 1261, C/V is opening
Separator 2) Two nos. valve (2") on proportionally / fully
High High PCV-1261, flare line 2) Check & ensure two
pressure) close. no. valve (2") on PCV-
1261, flare line are
open.

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MBD-1260, Glycol Hydrocarbon Separator :

Detection Set Point Trouble & possible Remedy
cause
LSHH-1262A 28"839mm High High Level in 1) Open LV-1262 by-
(Glycol (from bottom Separator pass, check if level
Hydrocarbon of vessel) 1) LC-1262 controller reduces
Separator faulty / C/V not 2) Check & ensure LV-
High High opening proportionally, 1262, isolation valves,
Level) 2) LV-1262, isolation fully open.
valves closed/partly 3) Stroke LV-1262, check
open. its travel, ensure, it
3) Level indication erratic opens fully
4) Down stream isolation 4) Check Level indicator
valves for match its level with
Sock/Charcoal Filters level in gauge glass LI-
partly/fully closed. 1262
5) Down stream system 5) Check & ensure down
high back pressure. stream system
isolation valves on for
Sock/Charcoal Filters
partly/fully open.
6) Check PDI across
Sock/ Charcoal filters.
if high change filters.

LSLL-1261A 10"25502 mm Low Low Level in 1) Close, LV-1262 by-

(Glycol (from bottom Separator pass, if open.
Hydrocarbon of vessel) 1) LC-1261 controller 2) Close LV-1262,
Separator Low faulty / C/V not closing isolation valves, if level
Low Level) proportionally, improves, attend C/V
2) LV-1262, by-pass & re-commission
valves open / partly 3) Stroke LV-1262, check
open. its travel, ensure, it
3) Level indication erratic. opens fully
4) Check Level indicator
match its level with
level in gauge glass LI-
1262

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MAJ-1270 / MAJ-1280, Glycol Sock / Charcoal Filter :

Detection Set Point Trouble & possible Remedy
cause
PDI-1271 12 to 15 psig 1) Filter fouled 1) Check PDI
2) Faulty PDI 2) By-pass, isolate,
depressurise & change
filters.
PDI-1281 10 psig 1) Filter fouled 1) Check PDI
2) Faulty PDI 2) By-pass, isolate,
depressurise & change
filters.
PSV-1271 150 psig 1) System Pressure High 1) Same as for MBD-
Sock Filter RV 2) Defective RV setting 1260, Separator, high
lifting pressure.
2) Check, if system pr.
less than RV re-set pr.
isolate RV, rectify,
install & commission.
PSV-1281 150 psig 1) System Pressure High 1) Same as for MBD-
Charcoal 2) Defective RV setting 1260, Separator, high
Filter RV lifting pressure.
2) Check, if system pr.
Less than RV re-set
pr. isolate RV, rectify,
install & commission.

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ZZZ-8710, Glycol Regeneration Skid :

Detection Set Point Trouble & possible Remedy
cause
TAH-2011 425F System Temperature High 1) Check TIC-2011
1) TIC-2011 indication / indication
(Glycol control erratic 2) Stroke, & check TV-
Regeneration 2) TIC-2011 C/V by-pass 2011 travel, check,
Skid high open proportional opening &
temperature) full closing.
3) Check & ensure TIC-
2011 by-pass is shut

LSHH-2011A 39"902mm Bottom Accumulator 1) Increase Lean Glycol

(Glycol (From bottom Compartment High High flows FQI-1121/1171,
Regeneration of vessel) Level if low. Check operation
Skid 1) FQI-1121 flow low & of FC
Accumulator FC-1121 malfunction. 2) Increase Lean Glycol
high 2) FQI-1171 flow low & flows FQI-1121/1171,
Highlevel) FC-1171 malfunction. if low, Check operation
3) FQI-1121/1171, of FC
FC-1121/FC-1171
indication erratic 3) Check FQI-1121/1171
4) High circulating TEG indications.
inventory in the 4) Check & stop TEG
system. make-up to system.
5)Transfer to storage .
LSLL-2011A 34"267mm Bottom Accumulator 1) Decrease Lean Glycol
(Glycol (From bottom Compartment Low Low flows FQI-1121/1171,
Regeneration of vessel) Level if high.
Skid 1) FQI-1121 flow high & 2) Lower LC-1121/ LC-
Accumulator FC-1121 high flow. 1171 levels if high.,
Low Low 2) FQI-1171 flow high & reduce flow FQI-1171
level) LC-1171 high level. 3) Check FQI-1121/1171
3) FQI-1121/1171, LC- indications.
1121/LC-1171 4) Check, LC-1121/ LC-
indication erratic 1171 levels
4) Low circulating TEG 5) Start TEG make-up to
inventory in the system.
system.

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ZZZ-8710, Glycol Regeneration Skid :

Detection Set Point Trouble & possible Remedy
cause
LSLL-2012A 34"559mm Re-boiler Compartment 1) Check level build-up in
(Glycol (From bottom Low Low Level MBD-1260, MAF-
Regeneration of vessel) 1) Reduction or stoppage 1120, MAF-1170 take
Skid Re-boiler of water rich Glycol corrective action to
compartment feed to Regenerator. bring down level as
Low Low 2) Level build-up in MBD- mentioned earlier in
level) 1260, MAF-1120, respective Equipment
MAF-1170. Trouble Shooting.
3) Re-boiler drain to 2) Check & ensure re-
closed header open boiler drain is close.
LSHH-1561A 29" 988mm Over-head 1) Check & rectify,
(Glycol (from bottom Accumulator high High Switch LT-1561A.
Regeneration seam) level 2) Check & rectify if
Skid o/h 1) LT-1561 defective pumps' PBE-6550/
accumulator 2) PBE-6550, PBE-6560 6560 not starting.
high High not starting / not 3) Check & rectify if
level) pumping. pumps' PBE-6550/
6560 not pumping.
PVSV-2011 10 Psig. System pressure High 1) Restore cooling
(Glycol 4 Oz Vac. 1) Loss of cooling capacity of HAL-4330,
Regeneration capacity of HAL-4330, check fan is on.
Skid R/V water vapours not 2) Check level in LI-1561,
Lifting.) condensing o/h accumulator take
2) MBL-1560 o/h corrective action to
accumulator full of bring down level as
water mentioned earlier in
3) LSH-1561high level respective Equipment
alarm is active Trouble Shooting.

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PBA-6110/6120 Glycol Pumps :

Detection Set Point Trouble & possible Remedy
cause
PSHH- 1265 1350 1) PBA-6110/6120, Pump 1) Check
6111A/ 6121A psig High High discharge PSHH-6111A/6121A
pressure. indications.
2) PIC-1121 Sensing / 2) Check PIC-1121
control erratic 3) Check & ensure (2")
3) Choke FO-1122 valve on PCV-1121,
obstruction line is open.
4) Valve on PIC-1121 line remove obstruction
closed/partly open. 5) Rectify PSHH-
5) PSH-6111/ 6121 6111A/6121A
indication erratic.
PSLL- 935 650 psig PBA-6110/6120, Pump 1) Check PSLL
6111A/6121A Low Low Discharge -6111A/6121A
Pressure. indications.
1) PIC-1121 indication/2) Stroke & check, PCV-
sensing erratic. 1261, C/V is closing
2) Recycle valve PV- proportionally / fully
1121 not closing fully. 3) Check & ensure that
3) PIC-1121 by-pass PIC-1121 by-pass
valve partly / fully open valve is closed.
4) PSV-6111/6121 R/V4) Check PSV-6111/6121
passing / lifting at R/V if passing / lifting
pressure lower than at pressure lower than
set pressure. set pressure, change
5) Excessive flow through pump / attend passing
FQI-1121/1171 R/V,
5) Check FQI-1121/1171
for excess flow, bring
flow to correct level.
PSV- 1380 psig 1) System Pressure 1) Take corrective action
6111/6121 High. to control system
Pump PBA- 2) R/V setting, changed pressure as mentioned
6110/6121 above
R/V Lifting 2) Check system
pressure, if lower than
set pressure, rectify
R/V setting.

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B) Process related effects

Effect Cause Checks/Remedy

1. Exit dew  Insufficient glycol circulation rate, as  Check suction
point of gas indication by, FC-1121 and FC-1171 strainers of pumps,
is high for MAF-1120 & MAF-1170 PRA-6110/6120
respectively.

 Poor glycol regeneration (lean glycol  Check for the passing

concentration to be checked, minimum of PSV-6111/6121
concentration of 99.5%, must be
maintained)

 Low purity of lean glycol  Low level in TEG

Regenerator

 Improper separation in the flash drum,  Check the check

MBD-1260 valve at the inlet of
TEG contactors for
full opening.
 Low temperature of TEG at TI-
4071/4991

 High differential pressure across TEG  Check the vapour

contactors. lock in the pump
head.

 TEG distributor not working / choked  Low temperature in

the reboiler,

 Low stripping/ no
stripping gas through
the packed column of
the reboiler,

 Heating medium low

temperature

 Rich glycol leaking

into lean glycol in
glycol heat exchanger

 Check carbon and

particulate filter drain
lines for passing.

 Over loading capacity

of reboiler

 Fouling of the tubes

in reboiler

 Glycol foaming in still

column.

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Effect Cause Checks/Remedy

 Dirty and broken

packing in still column

 Flooding of still
column

 High still column

pressure.

 Improper separation
in the flash drum,
BMD-1260

 Check the drain

valves for
passing/open
condition valves

 Excessive circulation
(low residence time)
 Contactors’ LIC-
1121/1171
malfunction/valve
closed
 Check gas distributor
inlet/internals
 Excessive gas
flowrate
 Plugged packing and
demister pads.
 Fouling on packing
 Channelling in
packing
 Glycol foaming
2. High glycol The common symptom of many problems  Carry over due to
losses is excess glycol loss. This loss is due to Excessive foaming.
(Maximum one, or a combination of the following:
glycol losses
to be 0.1
gal/mmscf) Foaming, Degradation, Salt plugging the  Mist extractor
regenerator still column, inadequate mist plugged or
extraction, Lean glycol absorber is too hot, channelling/damage.
spillage of glycol or pump leakage.
 Lean glycol entering
 Loss from contactor contactor too hot.

 Loss from still column  Excessive gas

velocity/fluctuation
 Loss from flash separator.  Check pH of TEG

 Excessive stripping
gas

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Effect Cause Checks/Remedy
 Flash separator
passing condensate
 Packing in still
column is broken,
dirty plugged

 Insufficient reflux
cooling at top of still

 Temperature at top of
still is too high.

 Glycol dumped with

the hydrocarbons.

 Passing drains valves

of the vessel.

 Leaks and spills.

 Check the piping,

fittings, valves and
gaskets.

 Check the pump

gland and the
leakage rates.
3.Glycol  Carryover of oils (compressor lube  Check for the
contamination oils) well treating chemicals and contaminants in TEG.
corrosion scales etc from inlet
separator.  Check pH.
Inadequate pH
 Oxygen leaks into glycol storage control (low pH)
tanks. increases corrosion.
And enhances
 Overheating of glycol in the reboiler degradation.
due to excessive temperature or hot
spots in the fire tube.  Build up of salt, dust,
scales on the fire
 Improper filtration, plugged filters, tubes.
bypassing of the filters.
 Deposition of coke,
 Contamination by foreign acids and Tar formed by glycol
detergents. overheating and/or
hydrocarbon
decomposition

4.Low glycol  Check Glycol circulation pump  Check for routine

circulation - operation problems on pumps.
Glycol pump
 Plugged suction
strainer of the pump.

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Effect Cause Checks/Remedy

 Vapour lock of the

discharge lines

 Excessive packing
gland leakage

 Contactor pressure
too high.

5. High  Inadequate reflux  Observe the trend of

Temperature local Field mounted
Glycol  Still column flooded. instrument only)
Regenerator.
 Glycol foaming.  Adjust the manual
valve bypassing the
 Carryover of light HC in rich glycol. reflux condenser

 Low flow through reflux Condenser.

6.Low  High flow through the reflux  Check and adjust the
Temperature condenser. bypass valve of reflux
-Glycol condenser.
Regenerator  Low reboiler temperature.
 Increase the
 Packing choked. temperature of
reboiler.

 Check reboiler
pressures compare
for any abnormal rise.
7.High  Packing in the still column is broken
Pressure - and/or plugged with tar, dirt
Glycol
Regenerator  Restricted vent line not sloped.
reboiler.
 Still column is flooded by excessive
boil up rates and/or excessive reflux
cooling.

 Slug of HC enters stripper, Vaporiser

on reaching reboiler, and blows liquid
out of the still.

2.5.9 ANNEX

2.5.9.1 PROCESS FLOW DIAGRAM

Sr.No. Description Drawing No.

01 HP Gas Separation and Dehydration 4003
02 Glycol, Relief and closed blowdown 4007

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2.5.9.2 HEAT & MASS BALANCE

Sr.No. Description Drawing No.

01 Stream Data – Separation, Dehydration 4004

2.5.9.3 P&IDs

Sr.No. Description Drawing No.

01 Contactor Inlet Scrubber and Filter BGEP-LNTA-P121-
Separator PPAX-PR-11-158-
4113-D
02 Bulk Glycol Contactor & Bulk Filter BGEP-LNTA-P121-
Separator PPAX-PR-11-158-
4114-D
03 Fuel/Lift Gas Filter & Glycol Contactor BGEP-LNTA-P121-
PPAX-PR-11-158-
4116-D
04 Glycol Reboiler & Exchanger BGEP-LNTA-P121-
PPAX-PR-11-158-
4120-D
05 Glycol Pumps & Vapour System BGEP-LNTA-P121-
PPAX-PR-11-158-
4121-D
06 Glycol Separator & Filters BGEP-LNTA-P121-
PPAX-PR-11-158-
4122-D

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2.5.9.4 EQUIPMENT LIST

Tag Title Description Design Operating Gas

No. (dimensions) Capacity
Pressu Tem Pressu Tem MMSCFD
re p. re p
psig O
F psig O
F
MBF- Contactor 36" OD x 6'-0" 1380 130 1000 120 180
1100 I/L S/S316/316Ldua
Scrubber l stamped SS
MAF- Bulk Glycol 66"IDX25.0"SS 1380 130 1000 100 180
1120 Contactor CS NACE
HBG- Lean Glycol Shell & tube CS 1380 170/ 1000 125/ -
4070 Heater 700 MBTU/Hr. 250 200
MAK- Bulk Gas 31.5"IDx5'- 9" 2000 150 1350 120 227
9390 Filter/ T/T
Separator
MAF- Fuel/Lift gas 30" ID x 20'-0" 1380 170 1100 120 25
1170 Glycol S/S CS
Contactor
HBG- Fuel/Lift gas Shell &Tube CS - - - - -
4090 / 91 MBTU / HR
Glycol
Exchanger
HAL- Glycol Air Cooler 0.6 150 300 0.5 225 -
4330/ Vapour MMBTU/hr
4330A Condenser each.
HBG- Glycol Hairpin CS 150 450 - - -
4150 Preheater NACE Shell /
316L SS Tube
13 MMBTU/hr.
MBD- Glycol/ 48"OD x15- 150 230 60 210 -
1260 Hydro- 0"S/SCS
carbon
Separator
MAJ- Glycol Sock 14"OD x 46 5/8" 150 230 60 210 -
1270 Filter S/S CS NACE
MAJ- Glycol 48"ODx54"S/ 150 230 55 210 -
1280 Charcoal SCS NACE
Filter.
HBG- Glycol/ Hairpin 150 450 - - -
4160 Glycol CSNACE
Exchanger Shell/316L SS
Tube 550
MMBTU/hr.
ZZZ- Glycol - - - - - -
8710 Regenerat-
ion Skid

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Tag Title Description Design Operating Gas

No. (dimensions) Capacity
MMSCFD
Pressu Tem Pressu Tem
re p. re p
psig O
F psig O
F
HBG- Glycol Flanged Multi- 300250 600 - - -
4180 Reboiler tube Heat
Heat Bundle Bundle
25MMBTU/hr.
MBL- Glycol 24" 150 150 050.5 120
1560 Overhead ODx7'5ODx7'6"
Accumulator S/S
PBE- Glycol Centrifugal - - 50gpm@40TD -
6550 Accumulator 3"x4" 10" 8" H
Pump No.1 impeller 7.5HP
@ 1500RPM
PBE- Glycol Centrifugal 50gpm@40TD
6560 Accumulator 3"x4" 10" 8" H
Pump No.2 impeller 7.5HP
@ 1500RPM

2.5.9.5 ELECTRICAL MOTOR LIST

1) PBA-6110 Glycol Circulation pump no.1 - Motor

2) PBA-6120 Glycol Circulation pump no. 2 - Motor
3) PBE-6550 Glycol overhead accumulator pump - Motor
4) PBE-6560 Glycol overhead accumulator pump - Motor
5) XSH-4331 HAL-4330, Glycol vapour condenser - Fan Motor.
6) XSH-4331A HAL-4330A, Glycol vapour condenser - Fan Motor.

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2.5.9.6 INSTRUMENT LIST

Item Tag No. Values

Normal Alarm Trip
MAF-1120, Bulk Contactor :
Pressure PSLL -1121A 1000 psig 850 445 850 445
PSIG(dec)
PSV-1121A/B 1000 psig - 1380psig (RD)
PI-1121 1000 psig - -
PI-4071 1000 psig - -
Temperature TI-1121 100F - -
TI-4071 - -
TI-4072 - -
TI-4073 - -
TI-4074 - -
TI-7003 0-200F
TAH-7003 120F
Level LC-1121 - 4" - -
(from bottom LSLL -1121A - -152 mm- 3" -- 3”152mm
seam or top of LSHH -1121A - -213mm+ 14" + 14”-213mm
baffle plate)
Flow FQI-1121 25USGPM - -
MAK-9390, Bulk Gas Filter Separator:
Pressure PSV-1131A/B 1380 psig. - 2000 psig
(RD)
PI-1131 1350 psig. - -
PI-1132 1350 psig. - -
PDI-1131 12 to 15 psig
Temperature - - - -

Level LC-1131 16" - -

(from bottom LI-1131 45.36" Center to - -
seam or top of Center
baffle plate) LSL -1131 4” - -
- -
Flow - - - -
MAF-1170, Fuel/Lift Gas glycol Contactor :
Pressure PSLL-1171A - 850 PSIG 850 psig
PSV-1171 1350 - 1380Psig (RD)
PI-1171 1350 - -
PI-4181 1350 - -
Temperature TI-1171 - -
TI-4091 - -
TI-4092 - -
TI-4093 - -
TI-4094 - -
Level LC-1171 12" - -
(from bottom LSHH-1171A - 399mm22" 399mm22”
seam or top of LSLL-1171A - -305mm5" -305mm5”
baffle plate)
Flow FC-1171 5USGPM - -

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Item Tag No. Values

Normal Alarm Trip
MBD-1260, Glycol Hydrocarbon Separator :
Pressure PSLL-1261A 40 psig43 4340 psig
(Low)
PSHH-1261A 135 69135 psig
psig69Psig
(High)
PI-1261 - -
PSV-1261 150 psig (RV)
PSE-1261 150 psig (RD)
PCV-1261 60 psig
PCV-1262 50 psig.
Temperature TI-1261
Level LI-1261 20" - -
(Set points LI-1262 18" - -
from bottom of LC-1261 20" - -
vessel) LC-1262 18" - -
LSHH-1262A - 28"839mm 28”839mm
LSLL-1261A/ - 202/255mm10 202/255mm10
1262A ” ”
Flow - - - -
MAJ-1270 / MAJ-1280,Glycol Sock Filter / Glycol charcoal Filter :
Pressure PDI-1271 Less than 15 Psig - -
PSV-1271 - - 150 psig.(RV)
PDI-1281 - -
PSV-1281 150 psig.(RV)
Temperature - - - -
Level - - - -
Flow - - -

ZZZ-8710, Glycol Regenerator :

Pressure PCV-2011 5 psig (Purge gas)
PI-2011 5 psig - -
PVSV - - 10 psig, 4 Oz
Vacc (RV)
Temperature TIC-2111 390F - -
TI-2011 390F - -
TI-4151 - -
HBG-4150
TI-4152 - -
HBG-4150
TI-4153 - -
HBG-4150
TI-4161 - -
HBG-4160
TI-4162 - -
HBG-4160
TAH-2O11 - 425F
Level LI-2011 - - -
(from bottom of LSHH-2011A - 39”902mm -
vessel) LSLL-2011A - 267mm34"
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LI-2012 - - -
LSLL-2012A - 559mm34" -
Flow FI-2011 - - (Purge
gas)

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Item Tag No. Values

Normal Alarm Trip
MBL-1560, Glycol Regenerator Overhead Accumulator :
Pressure PI-1561 PI-6551 Pump, PBE-
6550 /
PBE-6560
Temperature TI-1561 - -
TI-4331 - -
Level LI-1561
from (bottom LSHH-1561A 988mm29 “ 988mm29” 988mm29 “
seam) LS-1561 17"
LS-1562 11"
LSLL -1561A 379mm11” 379mm11” 379mm11”
Flow - - - -
PRAPBA-6110 and PBAPRA-6120 Glycol Pump :
Pressure PI-6111 - -
PSHH-6111A 1265 psig 1265psig
PSLL-6111A - 935 psig 935 psig
PSV-6111 - - 1380Psig (RV)

PI-6121 - -

PSHH 6121A - 1265 1350 12651350 psig

psig
PSLL-6121A - 650935 psig 650 psig935
PSV-6121 - - 1380Psig (RV)
PIC-1121 1200 psig - -

2.5.9.7 ALARM & SHUTDOWN LIST/LOGIC DIAGRAM

Safety Flow Diagrams

Sr.No. Description Drawing No.

01 SFD-Gas Production and Treating 4014
02 SFD-Glycol Regeneration 4016
03 SFD-Lift and Fuel Gas System 4017
04 Cause and Effect Function Chart –Process Functions Image
P001273A
05 SAFE Chart (Bulk Contactor, Inlet scrubber, Filter Image
separator, Exchanger P001285A
06 SAFE Chart (Fuel Gas Glycol Contactor) Image
P001286A

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2.5.9.8 TRAINING AND COMPETENCIES

Requirement Description Remarks

Qualification Engineering background in Chemical /

Petrochemical petroleum /Mechanical

Experience Adequate experience in Oil & Gas/ Petrochemical /

Refinery / chemical / LNG / Power Industry

Skill Set * Should be conversant and proficient with

- plant control System
- - Gas Separation Technologies

* Should have practical knowledge in Basic

Engineering

* Should have the working knowledge of offshore

oil & gas operation

* Should have exposure to HSE Management

Systems, Emergency Response plan, HAZOP &
HAZID studies, Risk assessment.

* Should have working knowledge of MS office

* Should possess good communication skill,

observation skill and report Writing skill.
Competencies * Ability to access understand, interpret, check,
practice and implement
- The basic process
- Basic engineering / equipment details
- Operating parameters.
- P & ID
- Vendor drawings
- Instrument loop diagrams
- control logic and interconnecting diagrams.
- start-up / shut-down procedures
- cause and effect Logic

* Ability to :
- Detect the deviation
- Continuously and patiently monitor the
operations
- communicate to the group involved in the
process
- trouble shooting
- Take corrective action
- Report the deviation
- Follow SOP's

* HSE: Ability to identify, understand, interpret and

implement
- potential hazardous situation

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Requirement Description Remarks

- mitigate the Risk

- Emergency response Procedure
- Adhere to HSE procedures
- Adhere to PTW

Training * Technical
- Plant Control System

* Non Technical
- Report writing skills
- Communication skills

* HSE
- HSE Management

* IT
- MS Office

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