Lean TEG Quality Control Procedure
Lean TEG Quality Control Procedure
REVISION
TABLE OF CONTENTS
1 PURPOSE ...................................................................................................................................... 4
2 SCOPE ........................................................................................................................................... 4
3 RESPONSIBILITIES .................................................................................................................... 4
4 REFERRENCES ............................................................................................................................ 4
5 DEFINITIONS ............................................................................................................................... 4
6 SAFETY/ENVIRONMENT .......................................................................................................... 5
7 TASK/ PROCEDURES ................................................................................................................. 6
7.1 General Information of TEG Regeneration System. ............................................................... 6
7.2 Daily required task/activities to control TEG quality ............................................................. 7
7.3 Operating problem and troubleshooting................................................................................ 10
1 PURPOSE
The purpose of this Operating Procedure is to describe operational requirements and steps to
be taken to ensure the quality of lean TEG is maintained for natural gas dehydration purpose.
2 SCOPE
This procedure shall apply to daily operations of the TEG re-generation package in the gas
dehydration system on FPSO Ruby II.
The scope will cover required tasks to control the quality of lean TEG including TEG sample
test method, sampling frequency and the testing specifications required. It is also used to
troubleshoot some related problem.
3 RESPONSIBILITIES
The TEG quality control is generally under scope of work of Production Department. In
maintenance activities requirements, the Maintenance Department will normally assign for
the job together with Production Department.
4 REFERRENCES
Documents reference:
J07183-DPSM-00-P-KA-002 Operating Procedure Manual (Topsides)
J07183-DPSD-35-0-MA-0101 Installation Operation Manual Glycol Dehydration
Package
PRB-PRN-PR26 Change over and cleaning element of Glycol particulate
filter Procedure
PRB-PRN-PR27 Changing Glycol Carbon filter elements S-3502
Procedure
PRB-PRN-PR28 Glycol Flash vessel skimming the condensate
Procedure
Process latest P&ID drawings:
J07183-DPSM-30-P-XB-0351 Gas Dehydration Unit Interface
J07183-DPSD-35-P-XB-0001 Glycol Contactor Column
J07183-DPSD-35-P-XB-0002 Glycol Re-Boiler System
J07183-DPSD-35-P-XB-0003 Glycol Flash Drum
J07183-DPSD-35-P-XB-0004 Lean-Rich Glycol Heater Exchanger E-3504
J07183-DPSD-35-P-XB-0005 Surge Tank and Pumps
J07183-DPSD-35-P-XB-0006 Gas Dehydration Glycol Filters
J07183-DPSM-85-P-XB-0852 Piping and Instrument Diagram Chemical Injection
Skid 2 (Module 6)
J07813-DPSM-85-P-XB-0854 Piping and Instrument Diagram Chemical Injection
Skid 1 (Module 6)
5 DEFINITIONS
CCR Central Control Room
CRO Control Room Operator
DP Differential Temperature
DT Differential Temperature
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Lean TEG quality control Procedure Code: PRB-PRN-PR25
6.11 No waste or TEG spill discharged overboard is permitted at all-time operations; personnel
involved must follow waste management procedure for onboard waste segregation.
6.12 All activities shall be logged in the CCR Log Book by the CCR Operator.
6.13 Communication between personnel involved (field operator and CCR operator)/ line
supervisors must be well established, the conversation should be clear, precise and
understandable during these operations.
7 TASK/ PROCEDURES
7.1 General Information of TEG Regeneration System.
The flash drum C-3504 is a three phase separator is used to remove all free liquid condensate
and gas from the glycol. It operates at 1.8barg and this pressure is controlled by regulating
valve PCV-3513. The system relies on dissolved gases flashing off from the rich glycol to
maintain the pressure. In the event that the dissolved gases cannot maintain sufficient
pressure, PCV-3511 allows blanket fuel gas into the system to make up the shortfall,
otherwise there would not be enough pressure driving force to push liquid glycol around the
system. Sufficient residence time is provided in the flash drum for liquid hydrocarbons to
build up and float on top of the glycol layer. And then liquid hydrocarbon is collected in a
hydrocarbon skim bucket inside the vessel. The level of skimmed hydrocarbon is controlled
by LICA-3516 where its modulate LCV-3513 for accumulated hydrocarbon removal to
closed drain. The glycol leaves the flash drum to the filters under the glycol level control
LCV-3514 which is controlled by LICA-3517.
Rich glycol form the flash drum flows to one of the two glycol cartridge particulate filters.
Solid particles present in the glycol are removed by the 5 micron filter elements. Filter
element condition is monitored by PDG-3511A/B and filters should be replaced at a DP of
100kpa max. Refer to Change over and cleaning element of Glycol particulate filter
Procedure PRB-PRN-PR26.
Rich glycol from cartridge filters passes through the activated carbon filter (S-3502). The
carbon filter works by adsorption and will remove dissolved gases and coloured matter (in
particular aromatics) from the glycol. Filter elements condition is monitored by PDG-3512
and elements should be replaced at a DP of 140kpa. Refer to Changing Glycol Carbon filter
elements S-3502 Procedure PRB-PRN-PR27.
Rich glycol exiting the carbon filter passes through Hot lean/rich glycol heat exchanger (E-
3504) where it is heated by hot lean glycol at about 200˚C leaving the stripping column C-
3503. The heated rich glycol leaving E-3504 enters the glycol still column C-3502.
The heated rich glycol leaving E-3504 enters the glycol still column C-3502 mounted on top
of the Re-boiler (V-3501). This column is packed with stainless steel pall rings and insulated.
Rich glycol flow downward across the packing, in counter-current contact with the lean
glycol vapour and stripping gas, water is stripped from the rich glycol by the vapour lean
vapour phase. Vapour rising through the still column is partially condensed by the reflux
condenser (E-3503). The partly regenerated glycol leaving the bottom of the still column
enters the front end of the glycol re-boiler for completion of the regeneration.
The re-boiler (V-3501) is heated using one electric heater bundle E-3502. Rich glycol enters
the re-boiler by the still column and heats it up to 204˚C. In case the temperature is higher
than 206 ˚C, which cause decomposition of TEG. Lower temperatures have proven to
increase the water content considerably. Glycol flows across the re-boiler and enters the
integral Stripping Column C-3503 where heated fuel gas from the re-boiler heating coil
passes into the bottom of the stripping column. The stripping gas reduces the partial pressure
of water in the glycol and allows more water vapour to be removed. It is expected that
stripping gas used to obtain glycol purity 99.4% in order to get gas outlet water content is
6lb/mmscf (meet specification). The stripping gas flow rate must be at 26MSCFD and it is
controlled by PCV-3512.
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Lean TEG quality control Procedure Code: PRB-PRN-PR25
Lean glycol leaving the stripping column and passing through glycol lean/rich glycol heat
exchanger (E-3504) once again before go to Surge drum (V-3502). The Surge drum allows
for changes in glycol working volume resulting from the glycol losses and allows for makeup
and storage of working inventory from the contactor. The surge drum has a gas blanket to
minimize the effect of glycol volume changes on the vessel pressure.
Glycol Pumps (P-3501A/B) are positive displacement type operating at a normal discharge
pressure of approximately 27barg. These pumps are provided to boost pressure of regenerated
glycol before glycol comes to Contactor.
Glycol cooler (E-3501) cools the lean glycol, which pumped from surge drum, from 105˚C to
about 56 ˚C via cooling seawater. This is to ensure that the glycol leaving the exchanger is at
least 5 ˚C above the temperature of the gas leaving the glycol contactor. Temperature control
is affected by comparing temperature signals from two transmitters, TIT-3512 on the glycol
outlet from the glycol cooler and TIT-3511 on the gas inlet to the contactor C-3501.
The glycol PH level should be maintained slightly on the alkaline side, from 7 to 8.5 in order
to avoid the system corrosion as well as foam formation in the system. So that chemical
injection has been provided in the form of a storage tank for PH modifier chemicals (T- 8503)
with a PH modifier chemical injection pump (P-8505) and a storage tank of Anti foam (T-
8508) with an Antifoam chemical injection pump (P-8516). These are used on a batch basis,
as determined by Lab testing results. The chemicals are directly injected in Surge drum.
The chemical injection equipment does not have alarms or trip, and so must have on-going
operator supervision when in use.
7.2 Daily required task/activities to control TEG quality
7.2.1 On daily work shift, both CCR operator and field operator are required to monitor and
maintain the system operating parameters referring to required parameters as follows:
Parameters to be monitor
Equipment Specifications
Tag name Description
Design pressure:
Pressure differential
PDIT-3511 H alarm = 1.7barg
indicating transmitter
HH alarm = 2barg
H alarm=2464 mm
LG-3513 Glycol Level Gauge Set point= 2388mm
L alarm=2311 mm
Glycol
Contactor H alarm= 80%
C-3501 Glycol Level Indicating
LIT-3513 Set point= 50%
Control Alarm
L alarm= 20%
HH alarm=2540 mm
LG-3514 Glycol Level Gauge
LL alarm= 2235 mm
H alarm= 898 mm
LG-3512 Condensate Level Gauge Set point= 746mm
L alarm= 593 mm
H alarm = 80%
Condensate Level
LIT-3512 Set point= 50%
Indicating Control Alarm
L alarm= 20%
HH alarm= 1051mm
LG-3511 Condensate Level Gauge
LL alarm= 441 mm
H alarm= 1828 mm
LG-3517 Glycol side level gauge
L alarm=1626 mm
HH alarm= 2134 mm
LG-3519 Flash drum level gauge
Flash drum LL alarm=1549 mm
C-3504 HH alarm= 80%
Flash drum level trip
LZIT-3519
indicating transmitter LL alarm= 20%
H alarm= 1524 mm
LG-3516 Condensate level gauge
L alarm= 1219 mm
Design Temp:230 ºC
TG-3527 Lean glycol to surge drum
Operating Temp:90 ºC
H alarm= 204 ºC
TIT-3513 Temp Indicating transmitter
L alarm= 185 ºC
Re-Boiler
V-3501 Re-boiler temperature trip HH alarm=206 ºC
TZIT-3514
And indicating transmitter LL alarm= 170ºC
Stripping
Column LG-3516 Re-boiler level gauge LL alarm= 406 mm
C-3503
Re-boiler temperature trip
LZIT-3516 LL alarm= 56%
indicating transmitter
HH alarm= 458mm
LG-3518 Surge Drum Level gauge
LL alarm= 153 mm
Surge Drum
Surge vessel level trip HH alarm=75%
V-3502 LZIT-3518
indicating transmitter LL alarm=25%
7.2.2 On daily work shift, both CCR operator and field operator are required to skim condensate
from Flash Drum to Closed drain system (Refer to PRB-PRN-PR28 Glycol Flash vessel
skimming the condensate Procedure).
7.2.3 End of each day, CCR operator and field operator are required manually calculate the glycol
consumption. The method is to measure glycol volume in the level gauge of Surge drum and
compare the reduction with the previous day level to identify the quantity consumption. This
glycol loss is updated into daily production report.
7.3 Operating problem and troubleshooting
It is the responsibility of the production operator to quickly identify and if possible, eliminate
an operating problem. There are many indication of abnormal glycol quality appears in the
gas dehydration system during normal operation which helps us to evaluate and control TEG
quality efficiently.
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Lean TEG quality control Procedure Code: PRB-PRN-PR25
The Lean TEG quality is normally affected by high condensate content, total suspended solid,
iron and high water content as the Lean TEG Quality Control chart below:
temp,…
Fuel gas:
Contactor Flash drum Carbon filter Fuel gas: less flow rate
DT is out of Inability to Inability to Gas contains
range 5-10oC separate remove much liquid
condensate hydrocarbon hydrocarbon
The differential temperature is limited at 10oC for minimum ideal value to prevent glycol
loss in the compressed gas. If the differential temperature increases to the higher value at
10oC, the TCV-3511, which take signal from TDIC-3511, on seawater return will open wider
to maintain the differential temperature. Field operator should check status of TCV-3015. If
the differential temperature is still high, the glycol cooler will be considered to clean in order
to increase performance of the cooler.
b) Flash Drum C-3504
During normal operation condition, if a large amount of condensate separated from glycol in
flash drum could not remove completely by observing LG-3519 and LG-3517, it will indicate
that LIT-3517 or LIC-3517 is malfunction.
The poor condensate separation of flash drum causes TEG glycol impurity and makes carbon
filter overload. In this case:
Field operator should liaise with CRO to carry out the condensate skimming operation
immediately (refer PRB-PRN-PR28 Glycol Flash Drum Skimming the Condensate).
The production team liaises with E&I team in order to test function of LIC-3157 and
inspect LIT-3517 to ensure flash drum is functional.
c) Activated carbon filter S-3502
In case differential pressure of rich glycol between inner side and outer side of filter elements
in activated carbon filter approaches 140kpa, it will be suspected that high condensate content
is existing in filter elements.
This problem makes condensate separating performance of carbon filter S-3502 decreasing
and more condensate circulates throughout the GDU system.
The pressure differential gauge PDG -3512 was equipped for the filter to monitor filter
element. Field operator should regularly check pressure value on PDG-3512 and in case the
differential pressure is higher than 140kpa, the filter elements should be replaced by the new
elements to ensure separating performance (refer to PRB-PRN-PR27 Changing Glycol
Carbon Filter elements S-3502).
d) Fuel gas supply
Fuel gas will be supplied as stripping gas in stripping column to help separate the water from
glycol. If the fuel gas contains high liquid hydrocarbon. It will cause contaminant the glycol
directly.
In case a large amount of condensate content is observed in water vapour from LP flare
header though all parameters of GDU system is maintained as requirement. It can be
suspected that fuel gas supply contained a lot of liquid hydrocarbon.
During normal operation, field operator should check condensate content in the water vapor
and drain out the liquid hydrocarbon in fuel gas regularly by drain valve at the bottom of Fuel
gas supper heater E-4501A/B to avoid liquid hydrocarbon entrained with fuel gas supply for
GDU system.
7.3.2 High Water Content in TEG
The high water content in lean TEG may be caused by poor performance of these devices as
below:
a) Lean/ Rich heat exchanger E-3504
The rich glycol is heated up by hot regenerated glycol from stripping column C-3503 before
it goes into still column for further water separation. The desired operating temperature of
heated rich glycol is about 145oC when rich glycol comes out E-3504. If the decreasing
temperature is lower than the desired value at 145oC, it will cause over load capacity for heat
re-boiler and excessive water content in regenerated glycol. The potential causes of poor
performance of L/R heat exchanger as follow:
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Lean TEG quality control Procedure Code: PRB-PRN-PR25
It is suspected that tube side of exchanger is fouled by hydrocarbon and it needed to be
cleaned by chemical circulation.
It is suspected that leakage of wet glycol into regenerated glycol. The heat exchanger E-
3504 is considered to carry out leaking test and rectify the leakages if it happens.
b) Still column C-3502
The normal operating temperature of steam outlet to LP flare header is approximate 98oC.
If the increasing of temperature on steam outlet to LP flare header approaches the high alarm
temperature value at 110oC, it will indicate that TEG flooding occurs in still column.
This phenomenon causes backpressure in re-boiler so separated water from TEG is reduced.
Absolutely, the TEG quality is decreased.
In this case, CRO liaise with field operator immediately to open the flooding valve in order to
eliminate back pressure in re-boiler and regulate the flow rate of Glycol pump P-3501A/B to
normal operating at 16 LPM.
c) Re-boiler V-3501
The ideal operating temperature in re-boiler is approximately 204oC. In case the normal
operating temperature is much lower than 204oC during a long time, this problem could be
made by the inefficient performance of heating bundle of re-boiler.
It will cause an insufficient heat to separate absorbed water in rich glycol completely and
affect to quality of regenerated TEG directly. Production team should inform to E&I team in
order to check capacity of heating bundle at control panel in E-house. E&I team should
inspect cables connection of Re-boiler at site and cross check accuracy of Temperature
transmitter TIT-3513 also.
d) Fuel gas Flow rate
The flow rate of fuel gas providing for GDU system is 26MSCFD (as per design) and the fuel
supply for stripping column is monitored by flow meter FG-3511 with normal flow rate is
8MSCFD. In case the gas flow rate is not sufficient by observing FG-3511, this problem
could be caused by not sufficient fuel gas supply from Fuel gas system or the malfunction of
PCV-3512, PCV-3511 or flow meter FG-3511.
The purity of glycol cannot regain to 99.4% after pass through stripping column C-3503.
Then field operator should check PCV-3512/PCV-3511 to ensure sufficient fuel gas go
through re-boiler. The stripping column is considered to open up for cleaning structure
packing in order to make good contact between fuel gas and regenerated glycol.
7.3.3 Total Suspended Solid, Iron
The total suspended solid, iron in the lean TEG glycol can be caused by some factors as
below:
a) Particulate filter S-3501A/B
In case differential pressure of rich glycol between filter element section and outer filter
element section in particulate filter approaches 100kpa, it will be suspected that high solid
particles content is existing in filter element and other equipment also.
The large amount of solid particles is contained in GDU system result in foaming in contactor
or fouling on surface of heat exchanger or settling down at the bottom of re boiler, surge
drum, Hence, glycol quality is effected also.
The pressure differential gauge PDG -3511A/B was equipped for the filter to monitor filter
element. Field operator should regularly check pressure value on PDG-3511A/B and if the
differential pressure is higher than 100kpa, it indicates that filter element should be replaced
by the new one to prevent solid particle accumulate in the GDU system. The glycol sample of
rich glycol outlet contactor could be sent to ashore for Total suspended solid analysis if
required.
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Lean TEG quality control Procedure Code: PRB-PRN-PR25
b) Low PH level
By daily testing PH level of lean TEG in GDU system. If the PH level is lower than 6, it will
indicate that potential corrosion can be attributed to the presence of oxygen in the system or
the re-boiler operated at over range of operating temperature.
This results in the formation of peroxides, aldehydes and organic acids such as formic and
acetic acids. These acids, along with any acid picked up from the natural gas stream will
cause severe corrosion.
If the temperature in the Re-boiler is higher than 206oC, the TEG will start to rapidly
decompose and the acid products of decomposition affect the PH of the glycol quite rapidly
causing corrosion problems in the regeneration.
In these cases, PH modifier chemical will be inject to Surge drum V-3502 to maintain PH
level in ideal range 7 to 8.5.
7.3.4 Depending on the purpose for sample collection, different sampling points will be used
as per the following table:
Expected
Sampling for Sample point Method test Test Frequency
result
PH paper/ PH kit
or Daily or on
Test PH Surge Drum V-3502 7.0-8.5
request
ASTM D1293-12
ASTM E2409-13
Every 03 monthly
Glycol Purity Surge Drum V-3502 or depend on lab 99.4%
or on request
standards
Solid post
filter Upstream LCV-
Weekly or on
3514 ¾” Drain Centrifuge Visually
request
Hydrocarbons valve
post-filter
Daily or on
Lean glycol outlet request
Glycol cooler E- Or whenever PH
Foam Visually Visually
3501 ¾” Drain band is higher
valve than 8.5 by PH
test