Gas Processing

1
GAS PROCESSING
Training Manual

PETROCONSULT PROJECT Company Doc. No.:
GAS PROCESSING Contractor Job Cod :
Training Manual Contractor Doc. No.:
2

Information provided in this manual is designed to address the most commonly raised issues in the
workplace relevant to the Gas Plant Mellitah
The Manual will be reviewed at regular interval with the inclusion of all necessary amendments.

Copyright Petroconsult SRL, Ploiesti, Str. Diligentei No. 18, Code 100575
www.petroconsult.ro
All rights reserved
ISBN 973-740-028-3
ISBN 978-973-740-028-4

Redacted,
Eng. Radu Gratian PEPENE
Verified,
Technical Manager Dr.Eng. Vasile SOMOGY

Aproved,
General Manager,
Eng. Mircea LABA

This Manual is legally property of Petroconsult S.r.l., and can not be reproduced partial or total
and distributed without written assent of Petroconsult SRL.

3

CONTENT

INTRODUCTION

1. CONDENSATE STABILIZATION & OFF-GAS COMPRESSION UNIT 210
1.1 General
1.2 Unit 210 Condensate Stabilization, Off - gas Compression and Off Specs. Storage
1.2.1 Main Equipments
1.2.2 Off gas compression train
1.2.2.1 Main equipments of the Off-gas compression train
1.2.2.2 Gas compressor auxiliaries
1.3 Condensate Stabilization & Off-gas Compression Process Description
1.3.1 Off-gas compression
1.3.2 Off-specs. Storage
1.4 Routine Operating Procedures
1.4.1 Process Variables
1.4.1.1 Stabilizer main process variables
1.4.1.2 Off-gas compression section main process variables
1.5 Control system Main process control loop
1.6 Start-Up procedures.
1.6.1 Start the 1
st
train of condensate stabilization
1.6.2 Start the Off-gas compression system
1.7 Shut Down procedures
1.8 Common troubleshooting

2. GAS HC DEW POINT CONTROL UNIT 340
2.1 General
2.1.1 Hydrocarbon dew point
2.1.2 Gas Dew Point Control Purpose and application
2.1.3 Main procedures
2.1.4 Propane characteristics, properties and combustion
2.2 Gas dew point control using propane refrigeration
2.3 Propane Refrigeration Unit description of the package
4

2.4 Gas Hydrocarbons Dew Point Control Process description.
2.4.1 Process Variables.
2.5 Start-Up of the 1
st
train of Gas HC Dew Point Control
2.7 Troubleshooting

3. NGL FRACTIONATION UNIT 320
3.1 General.
3.2 Unit 320 General process description
3.2.1 Main equipments of the NGL Fractionation Plant.
3.2.2 Detailed process description
3.2.3 Process Variables
3.2.4 Control system
3.3 Start Up of the NGL Fractionation plant
3.5 Common troubleshooting

5

INTRODUCTION

Mellitah Plant treats Raw Gas and Unstabilized Condensate feedstock received from Sabratha
Platform by two subsea pipelines of 36 and 10 respectively.
The hourly feed rate of gas and liquid to be treated in the plant through the two pipelines to
produce 6.66 Billion Sm
3
/year of Sales gas (including 1.1 swing factor) are the following:

Raw Gas (36 pipeline): 1003.02 tons/h; 1.006 MMSm
3
/h

Unstabilised Cond. (10 pipeline): 109.30 tons/h; 156.1 Sm
3
/h

The above figures are referred to the scenario foreseen in winter season after 11 years of plant
operation.
For summer season of year 2 the hourly feed rate of gas and liquid to be treated in the plant
through the two pipelines are the following:

Raw Gas from 36 pipeline: 1017.10 tons/h; 1.018 MSm
3
/h

Unstabilised Condensate from 10 pipeline: 143.48 tons/h; 203.3 Sm
3
/h

Mellitah Plant produces 6.0 Billions/year standard cubic meters of sales gas (excluding swing
factor) to be delivered to Mellitah Gas Compression Station (MGCS) and Local gas
Compression Station (LGCS).
The process units foreseen to treat the Raw Gas include Gas Sweetening, Gas Dehydration
and Gas HC Dew Point Control.
The Acid Gas from Gas Sweetening Unit is treated in Sulphur Recovery Units (SRU) to
produce liquid Sulphur.
The Sulphur Recovery Plant treats the Amine Acid Gas coming from Gas Sweetening units
and the Sour Water from Gas Dehydration units and converts the H
2
S contained, into
elemental sulphur. The resulting Tail Gases will be thermally oxidised in the Incinerator Unit
along with the Flash Gas and Regeneration Fuel Gas coming from Gas Dehydration and LPG
Dehydration (WAFA) respectively.
Mellitah Plant also includes units which produce Stabilized Condensate from the Unstabilized
Condensate coming from the pipeline and NGL Fractionation Units which produce LPG,
stabilized condensate and fuel gas.
The stabilized condensate is stored in dedicated storage tanks.
The LPG is sent to C3/C4 splitter in WAFA Coastal Plant.
Fuel Gas is sent to WAFA Coastal Plant to be used as fuel for internal consumption.
Above is presented the Block Flow Diagram which shows the interconnection of the units
6

50-210 Condensate Stabilization(trains 1&2 ), Off-gas compression , 50-340 Gas Hc Dew
Point Control ( trains 1;2;3), 50-320 NGL Fractionation (trains 1&2) with other units
located on Mellitah platform.

7

The raw(sour) gas delivered to the plant is a complex mixture of hundreds of different
compounds of hydrogen and carbon, all with different densities, vapour pressures and other
physical characteristics. As this mixture flows towards the plant, gases evolve from the
liquids, water vapour condenses and some of the well stream changes in character from
liquid to bubbles, mist and free gas.
After the inlet production/field separators designed to separate and remove undesirable
components and to separate the gas from the free liquids such as crude oil, hydrocarbon
condensate, water and entrained solids, in gas plant trains there are a series of plants which
separates the valuables products within trade requirements.
Some theoretical considerations are necessary to be presents in followings paragraphs.
Gas/liquid separation is an operation which main purpose is to separate liquid particles
from a gaseous stream.
The forces imposed on particles in mechanical separators are gravity, drag and inertial forces.
Gravity forces act vertically downward. Inertial forces are a result of particle circular
motion. Drag forces are resistive forces.
The methods used for reducing liquid particles in a gaseous stream are:
a) Reduction of velocity of the gas; this enables the droplets to settle out by gravity.
Gravity can act to remove larger droplets (d>250 microns). Into vertical separators the
mechanism for particle separation from a gas stream is governed by the drag force
generated by the relative motion between particle and surrounding fluid. The drag
force F is directly proportional to droplet diameter, gas density and to the settling
velocity. A particle falling will accelerate until the drag force balances the
gravitational forces. Thereafter, the particle falls at constant velocity called settling
velocity.
Gravity settling: Liquid droplets will settle out from gas phase if the gravitational force
acting on the droplet is greater than drag force of the gas flowing around the droplets.
b) Impingement of the droplets on special devices. Impingement separation allows
particles to strike some type of surface in order to be removed. Separation
depends primarily on the coalescing of droplets on an impingement surface,
from which the enlarged droplets fall when the gravity force upon them exceeds
the combined forces of vapour momentum and interfacial tension.
Coalescing: Very small droplets such as fog or mist cannot be separated practically by
gravity. These droplets can be coalesced to form larger droplets that will be settled by
gravity. Coalescing devices in separator force gas to follow a tortuous path. The
momentum of the droplets causes them to collide with other droplets or the coalescing
medium forming larger droplets. These larger droplets can than settle out of the gas
phase by gravity. Wire mesh screens and filter cartridges are typical examples of
coalescing devices.
Momentum: Fluid phases with different densities will have different momentum which
corresponds to mass x time x velocity. If a two phase system changes direction sharply,
greater momentum will not allow the particles of heavier phase to turn as rapidly as the
lighter fluid.

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Some types of internals are used, such as:

Straightening vanes (see Figure 3)
Mist pad (See Figure 2)
Typical impingement separators internals are represented in Figure1
Vane elements have a 97 to 99% efficiency for removal of liquid particles. The pad serves as
the impingement surface for liquid separation and removes particles down to 5 m. A
typical wire-mesh mist eliminator is constructed from 0.0 11 inches wire at a density of 144
kg/m
. Such a mist pad can collect entrained mist and spray from a gas stream at 99%
efficiency or better for droplets diameters larger than 6 microns. The term mist
designates droplets diameters less than 10 microns. Spray refers to droplets greater than
10 microns.
The mechanisms of interception and inertial impact are the most important ones for the two
types of separators previously named.

Interception occurs, in general, with droplets
approximately the same dimensions as the
target or larger. For example, a wire filament
0.011 inch (280 microns diameter) intercepts
droplets roughly 280 microns or larger.

Inertial impact occurs when a gas is forced
to change direction around an object. The
inertia of a droplet causes it to continue in the
same direction. Collision with the object then
causes the droplet to collect on the objects
surface. Inertial impacting is clearly the
predominant mechanism of droplet capture for
a wire-mesh mist eliminator.

Separators Internals

9

Figure 2 - Typical Mist Pad Separator
Figure3 - Typical vane separator

Stabilization of condensate is an attractive proposition for certain types of feed composition.

Table 1 - Components in natural gasoline before and after stabilization

Components
Before
Stabilization,
mole%
Stabilizer
Bottoms,
mole%
Stabilizer
Overhead,
mole%
Methane 25 - 42.7
Ethane 10 - 14.8
Propane 24 0.2 41.5
Butane 18 41.7 1.0
Pentane 11 27.6 -
Hexane Plus 12 30.5 -
10

Table reports a typical composition of a condensate before and after stabilization.
The removal of the methane, ethane, and propane from the stream and the reduction of butane content
increases the production of sales gas, as shown in the table In addition, stabilization reduces the
vapour pressure of the finished condensate and makes it suitable for storage, blending
and transportation purposes. Moreover, it sweetens the raw liquids entering the plant by removing the
hydrogen sulphide and carbon dioxide contents.

Stabilization of condensate streams can be accomplished through either flash vaporization or
fractionation.

Flash Vaporization. Many gas plants stabilize the recovered condensate by flash
vaporization or simply by flashing. This process is based on the equilibrium principles
between the vapour and liquid. Equilibrium vaporization occurs when the vapour and liquid
phases are in equilibrium at the final temperature and pressure of separation. In practice, the
liquid, with some gas in solution, flows into the constant pressure flash tanks and methane and
ethane are released.

Stabilization by fractionation is a detailed process, very popular in the industry and precise
enough to produce liquids of suitable vapour pressure. During the operation, the methane-
ethane-propane and most of the butanes are removed and recovered. The finished product
from the bottom of the column is composed mainly of pentanes and heavier hydrocarbons,
with small amounts of butane. The process actually makes a cut between the lightest liquid
component (pentane) and the heaviest gas (butane). The bottom product is thus a liquid free of
all gaseous components able to be stored safely at atmospheric pressure.
Stabilization by fractionation is a modern operation and economically attractive next to flash
vaporization. It is a single tower process since only one specification product is required. in
Fig.4 the raw condensate from the inlet separator and other sources flows to the feed drum
where its pressure is drastically lowered to a level depending on the grade of gasoline desired.

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Figure 4 - Common Stabilizer System

In the feed (flash) drum, the water carried in from the field, is dropped out and collected in the
water leg in the bottom of the tank. When the level is high it is withdrawn, on level control, to
suitable locations.
The pressure-temperature conditions in the flash drum vary with the plant design. In the
process shown in Fig.4 the pressure is controlled with a back pressure controller (PIC). At
this pressure some light ends are vaporized and pass on to the low pressure gas sweetening
contactor at about 10
0
C.
Figure 4 reports a typical stabilizer system that is not exactly the system used at Mellitah
Plant but similar.
The condensate level in the flash drum is controlled by a level controller and is usually
recorded on a control room recorder. The condensate leaves the flash drum at about 10C,
flows through the stabilizer feed bottom heat exchanger where its temperature is increased to
90 to 120C. It enters the stabilizer tower next, at the appropriate feed tray depending on the
design, and flows downwards mixing with the hot vapours generated in the reboiler. An
alternate feed point, as shown in Fig. 4 is also provided to accommodate varying feed
compositions.
In the stabilizer, the liquid is stripped of the light ends as it flows downwards to the bottom of
the tower. It overflows from the bottom tray and runs into a seal chamber in the enlarged
lower section of the tower. This section is the reservoir for the reboiler circulating pump. The
adjacent pump well provides suction to the finished product pump which forces the gasoline
through the heat exchanger, through another cooler, and on to storage.
The reboiler pump discharges liquid to the reboiler where part of the liquid is vaporized. The
vapour-liquid mixture from the reboiler returns to the stabilizer above the seal chamber in the
bottom of the tower. The reboiled liquid falls into the seal chamber while the ascending
vapour is mixed with the descending feed in the tower.
The chamber arrangement at the lower section of the stabilizer prevents the loss of suction at
the reboiler pump. Also, the level control in the adjacent pump well excludes the possibility of
12

blowing hot, high-pressure vapour into the condensate product storage tank. Vapour from the
top of the tower is cooled and partially condensed in the stabilizer overhead condenser. The
condenser outlet mixture is separated in the reflux accumulator and the liquid is pumped back
to the top of the tower as reflux under level control.
The overhead vapours from the reflux drum are preheated to prevent formation of liquid
hydrocarbons and then flow through a back pressure controller to the low-pressure contactor
for sweetening. A connection is usually provided to flare the vapour from the accumulator if
such a necessity arises. A water drain in the tank is provided to drain any water that may have
accumulated there.

Product Characteristics

The tables which follows, contains the quality requirements for the
products of Mellitah gas plant, excepting the section for removing the hydrogen sulphide and
other contaminants, and consequently the sulphur recovery. So, it may see the sales gas
quality specification, stabilized condensate specification, LPG expected composition, and fuel
off-gas from deethanizer.

Sales Gas Specification

13

Stabilized Condensate Specification

LPG
Specification
C3 + C4: 99.0% mol
C2-: 0.5% mol

Table LPG Expected Composition

14

Fuel Off-Gas Deethanizer

Specification
C3+: 7.5% mol

Table Fuel Off-gas Deethanizer Expected Composition

15

Products Conditions

In the following, have to show the contents and the objects of the three chapter that deals
with the processes of condensate stabilization, gas hydrocarbons dew point control and NGL
fractionation.

The Chapter 1 presents Unit 210 Condensate Stabilization, Off -gas Compression and
the Off-specs. Storage. The above mentioned unit consists of two parallel trains, unit 51-210
and 52-210, plus common facilities unit 50-210, for Off-gas Compression and off-
specs.storage.
The Off-gas Compression unit has three independent lines, each equipped with compressor,
driver, drums, exchangers, piping and instrumentation-control systems. During normal
operations one compression is in running while two are in stand-by mode. A second train will
be started when receiving gas from Bouri platform.
There are presented the technical characteristics and the functionality details for the main
equipments of the Unit 210 and for the gas compressor auxiliaries (scrubbers / K.O. drum,
inter-coolers and after-coolers). It is explained the role and functionality of the Off-specs
Condensate Storage Tank.
The process variable are described pointing out the main process variable of the Stabilizer and
for off-gas Compressors, follow by the Control system with its components: Control loops. So
it may see the Condensate from pipeline to surge drum flow control, Condensate Cooling
Control, Stabilizer reboiler temperature control, Stabilizer feed bottom exchanger flow and
temperature Control, Off-gas Compressor capacity Control.
In the final part of the Chapter 1 are provided the procedures for Start-up (restart after first
start-up or after general plant shut down) of the 1
st
condensate stabilization train and of the
off-gas compression system as well as are provided the procedures for shut down of entire
unit 210. Common troubleshooting are presented finally by short.

The Chapter 2 is dedicated to Gas Hydrocarbons Dew Point Control Unit 340 which is
designed to separate the heavier condensable hydrocarbons from the dry gas arriving from
Unit 311( Gas Drying Unit), in order to avoid further condensation in the sales gas pipelines.
Three parallel trains, each designed for 33.3 % of the total capacity forms unit 340.
Taking in account the specific technologies of this unit, the training manual follows the same
pattern like in the previous chapter of this work.
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In the general overview, at the beginning of the chapter, some theoretical considerations about
hydrocarbons dew point and a diagram P-T for dew point are provided to the trainees in order
to facilitate the understanding of this term. Are explained in same time the scope of this plant
for reducing the condensable hydrocarbons, condensation of the liquid creates major problems
in export pipeline, in metering, in safely operating of equipments. Small amount of water or
condensate can reduce the efficiency of gas transportation lines, cause corrosion, forms
hydrates, liquid slugs, could damage compressors, can cause serious safety hazards. This
determines the gas transportation and distribution companies to request rigorously dew point
analysis.
The condensation curves of a natural gas separated at 0
0
C and 70 bar g , with cricondenbar
and cricondentherm points allows to know with certain accuracy the temperature of
condensation at the various pressure or to find the pressure at which the condensation
temperature is highest (cricondentherm). It is known that heavier hydrocarbons even in
minimal percentages influenced dew point temperature.
Are overviewed the main procedures for obtaining the lower dew point: LTS( Low
Temperature Separation, the Joule-Thompson effect to refrigerate the gas); Absorption by
glycol (when only water dew point has to be controlled); Dry bed adsorption(
simultaneously removing of water and heavier hydrocarbons); Mechanical refrigeration (
often using mechanical propane refrigeration plant with glycol injection); Turbo-expansion
(Cryogenic plant) the simultaneous expansion and refrigeration of the gas stream by means
of the a turbo-expander permits to condense all the condensable hydrocarbons.
Refrigeration systems using propane can be apply to chill gas to - 40
0
C.
Before accomplish a description of the Gas Point Control using propane refrigeration are gave
the characteristics and properties of the propane.
The Propane Refrigeration Unit existing in Gas Dew Point Control Unit 210, consists of a
closed loop in which the propane is flashed in 2 steps, vaporized, recompressed and
condensed. The first flash step is the economizer system, which split the main stream in to a
liquid phase (used to refrigerate second flash step) and a gas phase that is routed to the
Refrigeration Compressors.
Description of the package of unit 51-340-XX-001(Propane Refrigeration Unit) is together
with the corresponding process flow diagram.
Description of the process which takes place in the Unit 340 is completed with useful details
and technical characteristics of the main equipments.
The main process variable as the temperature of chilled gas that is controlled in cascade with
level of evaporating propane in propane chiller is presented together sales gas analysis, which
depends directly by the temperature of the chilled gas.
At the end of chapter 2 are includes the recommended operations for start-up and shut-down
of the unit taking in account the interconnections with another plants on Mellitah platform.
Finally are mentioned some troubleshooting possible to arise while running the plant.

The Chapter 3 entitled NGL Fractionation Unit 320, treats the process of separation from
the condensate of Unit 340 the LPG (Liquefied Petroleum Gas) and the NGL (Natural Gas
Liquid). NGL is sent to storage while LPG is sent to Wafa Coastal Unit C3/C4 Splitter. At
beginning in this chapter are reviewed the general notion about fractionation principle and
equipment used.
The Unit 320 has two identical parallel trains, the NGL Fractionation is designed for a 50%
turndown referred to the design case, as shows in General Process Description.
17

The plant comprises two essential sections: Deethanization and Debutanization where takes
place the splitting of the NGL coming from Gas HC Dew Point Control Unit 340 mainly in
valuables fraction LPG and C5+. Are described in details the technological streams pointed
out the major variation of the parameters with its consequences.
Main equipment existing in the plant are presented detailed together their construction types
and their operating parameters. Complete operating parameters together Process Flow
Diagram of the Unit 320 are gave in the paragraphs referring to Detailed Process Description.
The main process variables as: the reflux rate, the reboiler heat input, the fractionator
pressure, the feed rate and temperature are commented focusing directly to the both section:
deethanizer and debutanizer being follow by apllicated control system in these cases.
The final part of the Chapter 3 contains the start-up and shut down procedures of the NGL
Fractionation unit and a detailed paragraph concerning to common troubleshooting.

18

GAS HC DEW POINT CONTROL UNIT 340 Contractor Job Cod :
19

1. CONDENSATE STABILIZATION & OFF-GAS

COMPRESSION - UNIT 210

20

1.1 General

Raw gas and unstabilised condensate, coming from Sabratha Platform by means of two
different submarine pipelines, are received and sent to the treatments facilities.
Condensate is sent to two identical condensate stabilization units. The produced stabilized
condensate is delivered to the storage, while the off-gas also produced at the stabilization unit
is joined with the raw gas stream coming from pipeline.
The gas from the pipeline, jointly with the off-gas, is sent to three identical gas treatments
trains. Each of them is composed by a sweetening unit, a dehydration unit and a hydrocarbon
dew point control unit.
In the sweetening unit, the CO
2
and H
2
S contained in the gas are completely removed and sent
to SRU where H
2
S is converted to liquid sulphur. The sweetened gas is sent to a molecular
sieves dehydration unit, where water is removed, and then to hydrocarbon dew point control,
where, by means of external refrigeration, heavy HC are condensed and separated in order to
match the sales gas characteristics.
The recovered NGL from the dew point control unit is sent to two identical NGL fractionation
units.
More light components (C1, C2) are stripped out from NGL and sent to the fuel gas network.
The liquid is then splitted into a LPG stream that is routed to WAFA Coastal Plant for C3/C4
production, and into a C5+ cut which is sent to storage.

1.2 - Unit 210 - Condensate Stabilization, Off- gas Compression and Off-Specs Storage

The Unit 210 is composed of the following sections:

Condensate Stabilization Surge Drum and Feed Pumps.

Stabilizer Feed/Bottom Exchangers.

Stabilizer.

Off-gas Compression

Off Spec Tank.

The Condensate Stabilization Unit consists of two parallel identical trains, Units 51-210 and
52-210, plus common facilities Unit 50-210, for Off gas Compression and Off-Specs storage.
The Off-gas Compression unit arrangement is on three independent lines, each equipped with
compressor, driver, drums, exchangers, piping and instrumentation/control system.
During normal operations one compression is running while two are in stand-by mode. A
21

second train is started when receiving gas from Bouri Platform
Facilities to operate a partial unit by-pass are available. On this occasion part of the
condensate is sent to Off- spec storage, under level control, while the balance of condensate is
treated in the unit and consequently directed to product storage facilities from the stabilizer
bottom.
In case stabilizer column is in shut-down, but the surge drum is operating, condensate is
passed through the vessel, as a first degassing stage (with vapour recovery) and then routed to
tank for atmospheric flash. Only in case the Surge Drum is also out of service the condensate
from pipeline and Slug Catcher will be diverted to Off-Spec Tank. Motorized valves are
provided to operate the above mentioned deviation and the DCS is equipped with facilities to
switch the Surge Drum level control to the relative valve on the line to off spec storage.
In case of off-spec condensate detection, it can be diverted to the Off- Specs Condensate and
stored for reprocessing. In this case, motorized valves are able to operate diversion
downstream the level control valve.
In case of an emergency occurring onshore, whereby unstabilized condensate is not possible
to be processed in any of the Condensate stabilization units, the feed from the pipeline can be
directed to Off-Spec storage. If such an emergency lasts for more than 12 hours the Marine
Platform has to be shut down too.
The following description is relevant to Units 50-210 (common facilities) and Unit 51-210
(same description of 51-210 is applicable also for Unit 52-210).

1.2.1 - Main Equipments.

Degassing Boot 50-210-VA-004
Condensate Surge 50-210-VA-001
Stabilizer Column 51-210-VE-001
Stabilizer Feed/Bottom Exchangers 51-210-HA-001
Condensate Trim Cooler 51-210-HA-003
Stabilizer Reboilers 51-210-HA-002
Off-specs. Condensate Pumps 51-210-PH-001A/B
Off-specs. Condensate Tank 50-210-TA-001

Inside the Degassing Boot 50-210-VA-004 the condensate is flashed to LP Flare pressure
(about 1.4 bara) in order to eliminate most of the light hydrocarbons, which may be cause of
fixed roof damaging in case of direct flash in the tank. The Degassing Boot is a vertical vessel
measuring 1400 mm dia. and about 9100 mm height. It operates at about 1.4 bara.

Condensate Surge Drum 51-210-VA-001 - operates at a temperature of about 29C and at a
pressure of about 8.5 barg. Overall dimensions of the Surge Drum are 3000 mm dia. and 9000
mm length, with the boot of 800 mm dia. and 900 mm height.

22

Condensate stabilization column

The stabilizer tower is a vertical vessel designed to provide the necessary space, time, and
means for the countercurrent contact between the ascending vapor and descending liquids. A
typical stabilizer tower is shown in Figure 1.1
The column is divided into two sections, the top or the rectifying section, which includes all
the trays above the feed tray; and the lower or stripping section, which contains all the trays
below the feed. In some cases the stripping section is enlarged to accommodate the reboiler
pump well and provide a surge space for the bottom product pumps.
The stabilizer can be a "packed tower", packed with a specific design of packing material or
tray design using bubble cap, valve, or sieve trays.
Tray types are a more common design, built with up to 40 trays in some units. Spacing of the
trays depends on the design and height of the unit, but 45 cm to 50 cm distance is considered
common.

The Stabilizer Column 51-210-VE-001 operates at a temperature varying from about 32C
(top) to 155C (bottom) and at a pressure of about 5.5 barg. Overall dimensions of the
Stabilizer are 900 x 2000 mm dia. and 20,830 mm height. Stabilizer Reboiler 51-210-HA-002
feed is foreseen at 112C/5.8 barg, outlet 155C/5.8 barg.

Figure 1.1 - Condensate Stabilizer Tower

Stabilizer Feed /Bottom Exchangers 51-210-HA-001 is of the shell-and-tube type, with the
stabilized condensate flowing through the shell side and the unstabilized condensate gas
flowing through the tube side. The inlet temperature of the unstabilized condensate is 23.6C
and the pressure 18 barg, while outlet temperature will be 68C and the pressure 17.6 barg.
For the treated condensate is foreseen an inlet temperature of 155C and a pressure of 5.8
barg, while at the outlet the temperature will be 125C and the pressure 5.3 barg.

23

Condensate Trim Cooler 51-210-HA-003 is of the shell-and-tube type, with the stabilized
condensate flowing through the shell side and the cooling water flowing through the tube side.
The inlet temperature of the unstabilized condensate is 55C and the pressure 4.8 barg, while
outlet temperature will be 40C and the pressure 4.1 barg. For the cooling water the
temperatures are 32/44C

Figure 1.2 - Common type shell and tube exchanger

Stabilizer Reboilers 51-210-HA-002 is a shell-and-tube type Kettle reboiler. The internal
diameter is 1.35 m, the length is 4.8 m . The reboiler service is to supply the
additional heat to stabilizer by means of the MP steam condensation. The hydrocarbon
flowing through the shell (114990 kg/h), is heated up from 112C to 155C, at a pressure of
about 5.8 barg, while the MP steam, flowing through the tubes (11200 kg/h), is condensed and
cooled down from 235C to 165C.

Figure 1.3 - Steam reboiler Kettle type

24

Off-specs Condensate Pumps 50-210-PH-001A/B are vertical centrifugal pumps, electric
motor driven with a rated capacity of 39 m
3
/h and a head of 16 barg.

Figure 1.4 - Typical vertical pump

Off-Specs Condensate Tank 50-210-TA-001 has a working capacity of 2280m3, a diameter
of 15m and a height of 14.4.m. The tank is provided with three vacuum relief valves, with
level and pressure indicators, level transmitter, breathing valve, venting control valve on a 8"
line towards low-low pressure flare (fail closed type),
It is blanketed with fuel gas to prevent entering of air. Two blanketing control valves of the
fail open type on a 3" line bringing fuel gas to the tank will ensure a working pressure range
from a minimum of 20 mm H
2
O to a maximum of 4000 mm H
2
O.
Besides three sampling lines, at different height, and local temperature indicators are provided
also fire fighting facilities.

25

Figure 1.5 - Typical fixed roof tank with instrumentation

1.2.2 - Off gas Compression Train

The three off gas compression trains are shown in Figure 1.7 . Each train contains all the
elements described previously as typical for the compression trains. Considering the A train,
its components are reported hereafter:

1.2.2.1 - Main equipments of the Off-gas Compression Train :

First stage K.O. Drum 50-210-VA-001
Off-gas compressor first stage 50-210-KB-001A
First stage discharge cooler 50-210-HC-001A
First stage discharge drum 50-210-VA-002A
Off-gas compressor second stage 50-210-KB-002A
Second stage discharge cooler 50-210-HA-001A
Second stage discharge drum 50-210-VA-003A

50-210-VA001A First stage KO Drum: is an inlet separator/scrubber, 2.1 m3 capacity
operating at a pressure of 4.5 bar and a temperature of about 37 C. The overall dimensions
are 0.9 m diameter and 3 m height. It is provided with gas inlet distributor, wire mesh
26

demister and vortex breaker.
50-210-KB001A Off gas compressor first stage: is the first stage of a reciprocating
compressor, electrical motor driven, which duty is to compress 6940 Nm3/h gas from 4.5 bar
to 15 bar. The absorbed power for both stages is about 700 KW. The estimated
compressibility factor is about 0.947.
50-210-HC001A First stage discharge cooler: is an intercooler (air cooled), type, 0.22 MW
capacity, operating at a pressure of 15 bar and a temperature of about 102 C (hot side). Air
temperature considered to be 55 C. The cooler is provided with two fans, electric motor
driven. One motor is single speed the other is double speed type.
50-210-VA002A First stage discharge drum: is a separator/scrubber, 1.2 m3 capacity
operating at a pressure of 14.5 bar and a temperature of about 55 C. The overall dimensions
are 0.7 m diameter and 3 m height. It is provided with gas inlet distributor, wire mesh
50-210-KB002A Off gas compressor second stage: is the second stage of a reciprocating
compressor, electrical motor driven, which duty is to compress 6940 Nm3/h gas from 15 bar
to 44 bar. The estimated compressibility factor is about 0.917.
50-210-HA001A Second stage discharge cooler: is an aftercooler (water cooled), shell and
tube type, 0.53 MW capacity, operating at a pressure of 44 bar and a temperature of about
133C (hot side) and 4bar and 32C (cold side).
50-210-VA003A Second stage discharge Drum: is a separator/scrubber, 1 m3 capacity
operating at a pressure of 43.5 bar and a temperature of about 50C. The overall dimensions
are 0.6m diameter and 3.5m height. It is provided with gas inlet distributor, wire mesh
The oldest, and probably the best known, of the positive displacement machines is the
reciprocating compressor that is the type used to compress the off-gas. It is a highly flexible
machine, being readily adaptable to ratio changes and capacity changes within wide limits for
any one particular machine. This machine works like a positive displacement pump. A piston
is drawn back in the cylinder and the cylinder is filled with gas; then the piston is moved
forward and the gas is forced out. The cylinder must be equipped with intake and discharge
valves to control the flow of gas entering and leaving.
Reciprocating compressors can be used on wide ratios of compression. In gas work they will
normally be found operating from 1.1 - 1 to 5 - 1. They have a relatively high efficiency (72%
in our case), the major efficiency loss being the pressure loss through the valves. As ratios
increase this valve loss has less and less effect on efficiency.
With the single-acting type, compression takes place at one end of the cylinder only;
therefore, there is only one compression stroke for every crankshaft or flywheel revolution.
With the double-acting type, compression takes place alternately at both ends of the cylinder,
and therefore there are two compression strokes per revolution. A two stage compressor is
illustrated in Figure 1.6

27

Figure 1.6 - Two- stage Compressor

1.2.2.2 - Gas Compressor Auxiliaries

Scrubbers / KO Drums

Before the flow stream from the pipeline is compressed to a higher pressure, it enters into
vessels commonly called "scrubbers" or KO drums. These are located in close proximity to
the compressors on the suction or intake header. The purpose of the scrubber is to remove all
free liquids and any suspended solid from the gas stream.
These liquids may be crude oil, hydrocarbon condensate, water, lubricating oil, drilling mud,
acid and pipeline dirt. This material is displaced from low places in the gathering system or it
may be entrained with the gas. The scrubber must have adequate storage and discharge
capacity to accommodate large volumes of liquid. The scrubbers are usually equipped with
mist extractors particularly on the high pressure stages, or they may contain just an angle
baffle or wear plate below the gas entrance. In addition to this equipment, the scrubber is
generally equipped with a liquid-level control and an automatic dump valve. Simultaneously
28

with the functioning of this valve an automatic alarm is given. In the event of a further rise in
level, an automatic shut-off will shut down the compressors.
The liquid or condensate in the scrubber may be disposed off in several ways:

a) Blown from it to the desired vessel or other location, if under pressure.
b) Pumped from it.

The back pressure valve is a valve used to prevent excessive pressure. If the pressure exceeds
design, the back pressure valve opens to flare so the compressor will not be overloaded. If the
pressure falls too low, the back pressure valve does not function. In such cases, a compressor
may be removed from service.
Back pressure regulators in the field are also used to maintain constant back pressure. They
act similarly to a relief valve. That is, if the pressure becomes too great, the regulators release
gas to the downstream side. Some systems are not even equipped with regulators between the
well and the plant. The absence of regulators can only be tolerated, however, when
connections are provided directly to the well and not to the separator.
From the scrubber, the charge flows into the header. The header is simply a pipe, generally
laid in horizontal position, from which extend a number of outlets or outlet pipes. The size of
the intake header at some installations has been observed to be as large as 1 m. In travelling
through the header, the gas may flow through the center outlet; it may flow through end-
outlets, or it may flow through all of these on its entry into the compressor. The main
objective in appropriately routing the flow of gas through the header is to insure the delivery
of fairly equal quantities of the gas to each compressor.

Intercoolers and Aftercoolers
These are usually shell and tube type heat exchangers and may be arranged to have water
flowing through the tubes and gas passing over the tubes or they may be arranged with gas
flowing through water surrounded tubes. Intercooling involves cooling the gas between stages
of compression, to reduce temperature, to reduce the volume to be compressed in the
succeeding stage, to liquefy condensable vapours and to save power. An aftercooler is the
heat exchanger on the discharge of the compressor following the completion of compression.

The reasons for cooling the gas are as follows:

a) To remove water vapour and oil vapour from the stream between
compression stages and after the last stage. When the gas is cooled, the
water and oil vapours will condense and may then be drained from the
bottom of the coolers. If the oil vapour is not condensed and removed, it
will have a detrimental effect on the transmission efficiency. If water
vapour is not removed from the gas, then it may collect in pipelines and
cause hydrates or damage from freezing.

b) In the case of an intercooler, another purpose is to decrease the amount of
power required to compress the gas. Iso-cooling or cooling between stages,
is most efficient when gas temperatures within the compressor approach
200C. In fact, the use of an intercooler between stages of compression will
reduce the power required for compression by 15%. For this same reason,
in addition to using intercoolers, compressors are usually water jacketed in
29

order to aid in removing the heat of compression and so approach
isothermal compression.

c) Other purposes in reducing the gas temperature by means of coolers are: to
make cylinder lubrication more effective, to reduce weakening of parts due
to high temperatures, and to reduce the possibility of explosions of oil
vapour mixed with air.

Intercoolers and aftercoolers may be either air-cooled or water-cooled. The air-cooled type is
normally used when the compressor itself is air-cooled and it consists of a finned pipe through
which the compressed gas passes.
The water-cooled type, as mentioned previously, is of shell and tube construction with either
the cooling water passing through tubes, or the compressed gas passing through water-
surrounded tubes. Intercoolers should be provided with a safety valve, pressure gages and
thermometers on the compressed gas side and also thermometers on the cooling water side.
Fig. 1.8 shows an aftercooler in which the compressed gas flows through the tubes and the
cooling water flows around the tubes. The usual direction of water flow is counter or opposite
to the gas flow, so cooling water would enter at the bottom of the aftercooler and exit at the
top. As the gas discharges from the aftercooler, it passes through a separator, where moisture
and other particles are removed from the stream.
Aftercoolers, like intercoolers, are fitted with pressure gages and thermometers and, if there is
a shutoff valve between the aftercooler and the receiver, the aftercooler must also be fitted
with a safety valve. Aftercoolers should always be equipped with separators which should be
installed as close to the aftercooler as possible.

30

Figure 1.7 - Off-gas compression train

31
Figure 1.8 After-cooler

Figure 1.9 - Vertical Scrubber

32

1.3 - Condensate Stabilization & Off-gas compression Process description

The feed of Unit 51-210 is collected into the Condensate Surge Drum 51-210-VA-001,
which receives a combined stream formed by condensates from:

Condensate pipeline

Slug Catcher 50-190-VQ-001 and KO Drums 50-190-VA-001/002
Off gas Compressor 1
st
and 2
nd
stage Discharge Drums 50-210-VA-
002A/B and 50-210-VA-003A/B

Condensates from Unit 330 Gas Sweetening

Off Specs Condensate from Off-Specs Condensate Pump 50-210-PA-001

Each one of these streams is split upstream of the Surge Drums so that each train is fed with
required flow rates.
The ways to perform the splitting are described below:

the condensate from pipeline is split into two streams, each one with a
separate flow controller placed at the inlet of the surge drum; upstream the
splitting, on the combined feed, a pressure controller gives the set point to the
flow controllers. The ratio of the two flow rates is adjustable by a hand Bias
function. High level in the surge drum will act limiting the set point of the flow
controller;
the condensate from the Slug Catcher boot is controlled by means of two
flow controllers.
the condensates from Off gas Compression and from Unit 330, being small
in quantity, are sent to either train 1 or 2;
the Off Specs Condensate from Off gas Condensate Pump 50-210-PA-001,
being an intermittent flow rate, is sent either to train 1 or 2. Motorized valves
are provided to operate selection.

The Condensate Surge Drum is equipped with a water disengaging pot. The separated water is
collected into the pot and sent to waste water treatment or to sour water stripper under
interface level control.
The separated gas is sent to Off gas Compression under pressure control.
The condensate from the Surge Drum is sent by the Condensate Feed Pump to the Condensate
Filter, in order to remove any fines particles carried from the pipeline. On pump discharge a
connection is provided to route the condensate to the Degassing Boot and Off Specs
Condensate Tank. The design intention is that, in case stabilizer column is in shut down, but
the surge drum is operating, condensate is passed through the vessel, as a first degassing
stage (with vapour recovery) and then routed to tank for atmospheric flash.
Only in case the Surge Drum is also out of service the condensate from pipeline and Slug
33

Catcher will be diverted to Off Spec Tank. Motorized valves are provided to operate the
above described diversions and facilities are provided in DCS to switch the Surge Drum level
control to the valve on the line to off spec storage.
Downstream the Condensate Filter, the stabilizer feed is split in two streams: the first stream
is preheated in the Stabilizer Feed/Bottom Exchanger and fed to an intermediate tray of the
Stabilizer column, and the second stream is sent to the top tray of the Stabilizer.
The reason of the double column feed is to provide, without need of creating a reflux stream,
a rectifying section in the column.
Overhead vapours leave the column under pressure control and are sent, after joining with gas
separated in the Surge Drum, to Off Gas Compression.
The heat to the Stabilizer Column is supplied by medium pressure steam through a Stabilizer
Reboiler, kettle type.
The Stabilized Condensate is sent to storage from the stabilizer bottom under level control
after having been cooled down in the following exchangers:

Stabilizer Feed/Bottom Exchanger

Condensate Air Cooler

Analyser is provided at the line to storage to check product quality.
In case of detection of off-spec condensate, it can be diverted to the Off Specs Condensate
and stored for reprocessing. In this case, motorized valves are provided to operate diversion
downstream level control valve.
Facilities to operate a partial unit bypass are also provided. In this situation part of the
condensate is sent to Off Spec storage under a partialised level control signal from Surge
Drum, meanwhile the balance of condensate is treated in the unit and sent to product storage
from stabilizer bottom.

1.3.1 - Off gas Compression

The Off gas Compression unit is formed by three independent lines, each one complete with
compressors, drivers, drums, exchangers, piping and instrumentation/control system. During
normal operations one compression train is operating and two are in stand-by mode. A second
train is started while receiving gas from Bouri Platform
The Off Gas Compressors are two stage reciprocating compressors. The Off gas from the
Stabilizer Overhead, together with the Condensate Surge Drum Off gas (Trains 1 and 2) is
sent to the Off gas Compressor 1
st
Stage KO Drum (Trains A, B and C).
The Liquid separated in the drum (not normally expected) is sent to closed drain.
The Off gas from the K.O. Drum enters the Off gas Compressor 1
st
Stage. At its outlet it is
cooled in the Off gas compressor 1
st
Stage Discharge Cooler and sent to the Off gas
Compressor 1
st
Stage Discharge Drum.
The Condensate separated in the drum is sent to the Condensate Surge Drums.
The Off gas from the 1
st
Stage Discharge Drum feeds the Off gas Compressor 2
nd
Stage. At its
outlet it is cooled in the Off gas Compressor 2
nd
Stage Discharge Cooler (water cooled) and
34

sent to the Off gas Compressor 2
nd
Stage Discharge Drum.
The condensate separated in the drum is sent to the Condensate Surge Drums.
This Off gas is sent to Unit 190 for further processing together with raw gas.

The compressor control system includes:

1
st
stage Suction pressure control, acting on compressor valve unloader
and on recycle bypass control valve

Discharge high pressure control, operating on vent valves to LF flare.

1.3.2 - Off - Specs Storage

An Off-Specs Condensate Storage Tank 50-210-TA-001 is provided to serve the following
purposes:

to store the Unstabilized Condensate received from platform when one of
the two Trains is out of order for maintenance

to store the Off Specs Condensate from Condensate Stabilization (Unit
210) or from NGL Fractionation (Unit 320).

to collect recovered hydrocarbons from closed drains

The condensate diverted to Off-specs storage first enters a Degassing Boot 50-210-VA-004 in
which the condensate is flashed to LLP flare pressure (about 1.4 bara) in order to eliminate
most of the light hydrocarbons, which may be cause of fixed roof damaging in case of direct
flash in the tank because of a sudden high pressure.
The vapours from tank are sent to the LLP flare KO Drum through a dedicated line in order to
have minimum back pressure in the tank. The degassed condensate flows to the Off-Specs
Condensate Tank 50-210-TA-001. One Off-Specs Condensate Pump is used to deliver
condensate to the desired train (51-210 or 52-210) for processing and/or reprocessing.
In case of an emergency occurring onshore, so unstabilized condensate is not possible to be
processed in any of the Condensate stabilization units, the feed from the pipeline can be
diverted to Off-Spec storage. In case of longer than 12 hours of such emergency, the platform
will also have to shut down. The condensate pipeline design allows for a sudden closure at
onshore plant inlet. However, this should be avoided if possible. Here below closure sequence
will be followed as an operating procedure:

throttling the condensate flow from the pipeline to 10-15% of design flow
(and send an alarm to platform for information)

35

stabilization during a few minutes (approx. 5 minimum)

complete closure of the condensate flow

Such a sequence allows shut down without any water-hammer in the pipeline, resulting in
improved safety and could be implemented in case of shut down for process upset.
Emergency shut down, as in case of fire, will be dealt by ESD with an immediate valve
closure.

1.4 - Routine Operating Procedures

Normal operation is defined as the operation of the plant under steady state conditions.
However, under the heading "normal operation" certain process adjustments are required to
meet variations in feed, temperature, pressure, component content.
Remember that the everyday activity in the control room is supported by an amount of
information produced by DCS, by laboratory and last but not least by various reports from the
field inspection.

1.4.1 - Process Variables

Efficient fractionation will depend on one or more of the following factors: top (overhead)
temperature, tower bottom temperature, the tower operating pressure, the components present
in the tower feed, rate of reflux and temperature of tower feed.

- Top Temperature

The top temperature of a fractionator is the temperature of the liquid on the top tray. It is the
dew point temperature of the overhead product and depends on the composition of the
overhead product(s). The top temperature is the lowest temperature in the tower and is limited
by the amount of cooling that can be accomplished by the reflux.

The top temperature is an indication of the overhead product quality and composition. A
change in top temperature is also an indication of a change in tower feed. The top temperature
is set just high enough to completely vaporize the overhead product. If the top temperature is
controlled too low, there will be a loss of recovered overhead product.

- Tower Bottom Temperature

The bottom temperature is controlled to maintain the quality of the bottom product. If the
bottom product contains too much overhead product, the bottom temperature is raised.
Raising the bottom temperature will cause more heating fluid to flow through the reboiler and
36

increase the expense of operating the unit. The bottom temperature of the tower should be
maintained at the lowest point that produces a bottom product of acceptable quality.

- Tower Pressure

The ease with which the overhead and bottom product can be separated in the fractionator
depends on the relative vapour pressure of the two streams. The relative vapour pressure is
determined by:

Relative vapour pressure = vapour pressure of top product / vapour pressure of bottom
product.

The higher the relative vapour pressure, the easier it is to fractionate the two streams. The
relative vapour pressure of liquid hydrocarbons is greater at low temperatures.
The operating pressure of the fractionator is determined by the vapour pressure of the
overhead product at its condensing temperature. Suppose the reflux temperature is limited to a
maximum of 40C by the condensing water temperature. If, for example, the overhead product
is propane, its vapour pressure will be found to be approximately 1260 kPa(g) at 40C.
The minimum operating pressure of the fractionator must be 1260 kPa(g), because below that
pressure the overhead propane product will not condense. For economical, effective operation
a fractionator should operate at the lowest possible pressure.
When the tower pressure is changed, the top and bottom temperatures must also be changed.
If the pressure is increased, both temperatures must be increased to maintain the quality of the
overhead and bottom products. If the tower pressure is lowered, then both temperatures must
be lowered. It may be necessary to operate the fractionator at a higher pressure to maintain
high flow rates.

Figure 1.10 - Reflux Condenser Water Control

37

- Components in the Feed

The quality of the feed to the tower determines the quality of the overhead and bottom
products. For example, if it is desired to split a mixture of propane and butane into two
finished products and the feed contains appreciable amounts of ethane, the propane product
will not meet the specifications.

- Rate of Reflux

Whenever reflux is increased to the tower, the heat input must also be increased. It logically
follows that the reflux rate should be as low as possible while maintaining the quality of both
the overhead and bottom products.

The procedure for determining the minimum reflux flow is to lower the reflux flow until
either the overhead or bottom product quality just meets the specifications. After the
minimum reflux rate is determined, the reflux ratio should be calculated as follows:
Reflux ratio = reflux flow rate / overhead product flow rate

The reflux ratio will be different for each fractionator, but generally it will be between two
and four. If the overhead product flow changes, the reflux rate must also be changed to
maintain the product quality and efficient tower operation. This may be changed manually by
the operator or accomplished by automatic controls.

- Temperature of Tower Feed

The feed stream to the tower should be partly vaporized. If the feed contains 40% overhead
product, then 40% of the feed should be vaporized by the heat contained in the feed.
The operator has no way of knowing what percent of the feed is vaporized, so the feed
temperature should be controlled at the same temperature as the temperature on the tray where
the feed is entering. If the temperature of the feed cannot be changed, then the feed should
enter the tower where the temperature is the same or close to the feed temperature. If the feed
temperature is too high, extra vaporizing will occur and the top of the tower will be
overloaded.

1.4.1.1 - Stabilizer main process variables :

- Tray 14 -Temperature set at 100C by temperature controller 51-210-TIC-0176 in
cascade with 51-210-FIC-009 that controls the steam flow to Stabilizer Reboiler 51-
210-HA-002. An increase of this temperature, without changing other parameters,
results in higher vapour rate through the Tray and a transfer of heavy component from
the bottom to the top of the column. The main effect is decreasing the stabilised
bottom flow and a major off-gas flow; on the contrary lowering this temperature light
component may remain in the bottom liquid of the stabilizer and consequently the
product is not stabilised.
-
38

- Stabilizer bottom pressure set at 5.8 barg by 51-210-PIC-013, operating the pressure
valve on stabilizer vapour line. Increasing this pressure light component remain in the
bottom liquid of stabilizer and as result the bottom product will increase and it is not
stabilised; on the contrary lower pressure allows that some heavy components are
transferred to top of stabilizer in this case the off gas will increase and it is out of
specification due to heavy component.
- Stabilizer feed bottom temperature set at 68C by 51-210-TIC-006, by-passing the
Stabilizer Feed/Bottom Exchanger; increasing this temperature increase the
vaporisation of feed on Tray 6 and consequently more vapours travels up to top of
column and as result off-gas may be out of specification due to heavy component.

Ratio between stabilizer feed to Tray 6 and feed to top Tray is carried out through 51-210-
HIC-0027; the normal ratio is 4.65. Increasing this ratio more cold condensate is fed to top
Tray that
means lower top temperature and lower flow rate; meantime the bottom flow rate will
increase
and therefore the stabilised bottom liquid may result out of specification.

1.4.1.2 - Main process variable of the off gas compression section:

Pressure on Off Gas Compressor 1
st
Stage K.O. Drum (50-210-VA-001A) set at 4.5 barg by
pressure controller 50-210-PIC-0228 operating on:

- master pressure controller

- pressure recirculating valve from delivery of 2nd stage

- the load of compressor.

Increasing this pressure within the range allowed by stabilizer, more gas as final result is
recycled to suction from delivery of 2
nd
stage; on contrary lowering the suction pressure the
compressor will be overloaded.
Temperature outlet Off Gas Compressor 2
nd
Stage Discharge Cooler (50-210-HA-001A) is set
at 50C by 50-210-TIC-023 that controls the cooling water flow. An increase of the said
temperature diminishes the amount of condensate separated in the 2
nd
Stage Discharge Drum
50-210-VA-003A; the contrary effect is obtained decreasing the temperature. Delivery
Pressure of 2
nd
Stage Off Gas Compressor is 43.5 bar.
1
st
Stage Off Gas Compressor Delivery Pressure and Temperature. Delivery Pressure of 1
st
Stage Off Gas Compressor is 15 bar and the temperature on Off Gas 1st discharge Drum 50-
210VA002A is 50C due to cooling of gas in the Off Gas 1
st
discharge Cooler 50-
210HC001A; this temperature and pressure allow the condensation of part of heavy
components.
39

Table 1.1 - Main local indicators

Variable Equipment/Service Instrument tag Range Normal Op.
Value/Set Point
Flow Condensate from 50-190-
VR-002
51-210-FI-003A 0-150 Sm
3
/hr 97.6 Sm
3
/hr
VA-001
51-210-PI-305/307 0-20 barg 18.6 barg
Pressure Gas from 51-210-VA-001 50-210-PI-005A/B 0-15 barg 11 barg
Level 51-210-VA-001 51-210-LG-301 0-100%(106-
2600 mm)
50%(1350 mm)
CL-001A/B
51-210-FI-006A 0-150 Sm
3
/hr 103.26 Sm
3
/hr
Flow MP Steam to 51-210-HA-
002
51-210-FI-009A 0-17,000 kg/hr 11,200 kg/hr
Temperature 51-210-VE-001 51-210-TI-312 0-100
0
C 32
0
C
0
C 155
0
C
0
C 94
0
C
Pressure 50-210-PH-001A/B 50-210-PI-314A/B 0-15 barg 12 barg
Pressure Off-gas to 50-210-KB-
001A
50-210-PI-324 0-6 barg 4.4 barg
Level 50-210-VA-001 51-210-LI-013A 0-100%(106-
2600 mm)
50%(1350 mm)
Pressure Off-gas to Header 50-210-PI-318 0-50 barg 44 barg

40

Table 1.2 Stabilized Condensate Analysis

Table1.3Stabilized Overhead Gas Analysis

Analysis

Method

Frequency
i C
4
ASTM D 2597 daily
C
4
/ C
5
ASTM D 2597 daily
i C
5
ASTM D 2597 daily
C
6
/ C
7
ASTM D 2597 daily
C7+ ASTM D 2597 daily
Distillation ASTM D 86 daily
Water UOP 481 daily
Salt Content ASTM D 3230 daily
H
2
S UOP 163 daily
RVP
Specific Gravity
ASTM D 323
ASTM D 1298
daily
daily

Analysis Method Frequency
C1 C6 ASTM D 1945 weekly
C3 ASTM D 1945 weekly
i C4 ASTM D 1945 weekly
C7+ ASTM D 1945 weekly
H2S UOP 212 or ASTM D 1945 weekly
Mercaptans UOP 212 weekly
Water ASTM D 5454 weekly
41

1.5 - Control System Main Process Control Loop of Condensate Stabilization & Off-gas
Compression Unit 210

a) - Condensate from Pipeline to Surge Drum Flow Control

Reference P&ID: G-65-D-O-1021-01 Unit 51-210 Condensate Stabilization Inlet Common
Header
G-65-D-O-1021-02 Unit 51-210 Condensate Stabilization Surge Drum
Condensate from 50-190-VR002 is sent to the units 51-210 (condensate surge drum 51-210-
VA001) and 52-210 (condensate surge drum 52-210-VA001). The 50-160-PIC053 signal feed
the set point adjuster 50-160-PY053. The scope of the set point adjuster is to control the ratio
between the signals to the two trains and to maintain the total of the two outlets equal to the
inlet signal.

Figure 1.11 - Condensate from Pipeline to Surge Drum Flow Control

This means the 100% of 50-160-PIC053 output will be splitted in two signals, but in any case
the sum of the two ratio will be 100% (e.g. 50% to unit 51-210 and 50% to unit 52-210, or
60% to unit 51-210 and 40% to unit 52-210 etc.).
42

The low signal selector 51-210-FY003A receives the signals from 50-160-PY053 and high
level constraint controller 51-210-LIC002 and select the lower one (normally is the pressure
signal) and fixes the set point of 51-210-FIC003.
The 51-210-FIC003 opens valve 51-210-FV003 when the pressure rises over the SP value and
closes valve when pressure falls under SP value. In case the lower signal is coming from 51-
210-LIC002 (52-210-LIC002), the 51-210-FIC003 opens valve when level is lower than the
SP value and closes valve when level is higher than SP value. Activation of interlock 51-210-
I5007 will drive 51-210-FIC003 to manual mode and output null by 51-210-XS007.

b) - Condensate Cooling Control

Reference P&ID: G-65-D-O-1021-03 Unit 51-210 Condensate Stabilization Stabilizer Feed
/ Bottom Exchanger
The controller 51-210-TIC-011 opens valve 51-210-TV-011 when temperature rises over the
SP value and close valve when temperature falls under the SP value.

Figure 1.12 - Condensate cooling control

43

c) - Stabilizer Reboiler Temperature Control

Reference P&ID: G-65-D-O-1021-04 Unit 51-210 Condensate Stabilization Stabilizer Feed/
Bottom Exchanger
When temperature rises over 51-210-TIC017 set point, 51-210-TIC017 output signal will
decrease the set point of 51-210-FIC009 in order to close valve 51-210-FV009.If the
temperature is below the set point, 51-210-TIC017 output signal will increase the set point of
51-210-FIC009 in order to open valve 51-210-FV009.
Activation of interlock 51-210-I5005 will cut the air supply to control valve 51-210-FV009 by
action on solenoid valve 51-210-FY009A. In the same time and for same reasons 51-210-
XS005 drives 51-210-FIC009 to manual mode and output null.

Figure 1.13 - Stabilizer Reboiler Temperature Control

d) - Stabilizer Feed Bottom Exchanger Flow Control and Temperature

Reference P&ID: G-65-D-O-1021-02 Unit 51-210 Condensate Stabilization Surge Drum
G-65-D-O-1021-03, G-65-D-O-1021-04 Unit 51-210 Condensate Stabilization Stabilizer
Feed/Bottom Exchanger
G-65-D-O-1021-05 Unit 51-210 Condensate Stabilization Outlet Header

44

Feed Temperature on Tray 6. The stabilizer feed temperature is automatically controlled at
68C. It determines the degree of condensate vaporisation on feed Tray and supplies heat to
liquid/vapour equilibrium of Tray 6.

Stabilizer Feed Rate on Top Tray. The Stabilizer Feed Rate on top Tray (reflux) is a ratio of
the feed rate and it is adjusted to maintain 32C on top temperature of stabilizer; the increase
of top temperature allows that higher boiling component will contaminate the off gas fed to
compression section.
51-210-LIC001 is a split range controller. The first portion of the output signal (0-60%) is
sent to the signal multiplier 51-210-LY001B, which can adjust the ratio between the signals to
the two column feed (51-210-FIC006 & 51-210-FIC007) by means of 51-210-HIC002 located
in the DCS (i.e. 60-40 or 70-30 or other combination depending from operating conditions).
The low signal selectors 51-210-FY006 (51-210-FY007) receives the signal from 51-210-
LY001 and from high flow constraint controller 51-210-HIC003 (51-210-HIC004) and select
the lower one (normally the lower signal is from the level controller) and fixes the set point of
51-210-FIC006 (51-210-FIC007). The 51-210-FIC006 (51-210-FIC007) opens valve 51-210-
FV006 (51-210-FV007) when the level rises over the SP value and closes valve when level
falls under the SP value.
The second portion of the output signal of 51-210-LIC001 (60-100) is sent directly to 51-210-
LV001, in order to open valve when level rises over SP value and close when level falls under
the SP value. Activation of interlocks 51-210-I5001/002 drives 51-210-LIC001, 51-210-
FIC006 and 51-210-FIC007 to manual mode and output null by 51-210-XS001 and 51-210-
XS002.
The temperature of the condensate from the heart exchanger 51-210-HA-001 is controlled by
51-210-TIC-005 which operates the by-pass control valves 51-210-TV-006.

Figure 1.14 - Stabilizer Feed Bottom Exchanger Flow Control
45

Figure 1.15 - Stabilizer Feed Bottom Exchanger Temperature Control

e) - Off-gas Compressor Capacity Control

Reference P&ID: G-65-D-O-1021-08 Unit 50-210 Condensate Stabilization Off Gas
Compr. 1
st
Stage A K.O. Drum
G-65-D-O-1021-14 Unit 50-210 Condensate Stabilization Off Gas Compr. 1
st
and 2
nd
Stage
A
st
Stage B
K.O. Drum
G-65-D-O-1021-15 Unit 50-210 Condensate Stabilization Off Gas Compr.1
st
and 2
nd
Stage
B
st
Stage C
K.O. Drum
st
and 2
nd
Stage
C

Note: hereafter is described the capacity control only for KB001A/002A; KB001B/002B and
KB001C/002C capacity controls are identical.

46

Figure 1.16 - Off gas Compressor Capacity Control

Compressor control capacity shall be Automatic or Manual (Auto/Man selector 50-210-
HSKB001A-2) by steps (0-50-75-100%).
Even if the compressor load/unload step changing is done by operator from DCS, the recycle
valve control will remain in any case under master pressure control (50-210-PIC022).
For each step signal from master pressure controller 50-210-PIC022 acts on compressor
recycle valve and on compressors valve unloader as described below.

Suction pressure decrease:

Compressor Condition: Running 100% Load
With recycle valve 50210PV022 in control condition, master pressure controller
50210PIC022 start to open the recycle valve 50210PV022. Once 50% (1) of the output signal
is reached, than a digital output signal (XS003A=0), is sent to compressor PLC in order to
reduce compressor capacity control from 100% to 75% (2). The master pressure controller
will now operate with the new working condition on recycle valve 50210PV022.

50210PIC022 start to open the recycle valve 50210PV022. Once 50% (1) of the output signal
reduce compressor capacity control from 75% to 50% (2). The master pressure controller will
now operate with the new working condition on recycle valve 50210PV022.
47

50210PIC022 start to open the recycle valve 50210PV022. Once 100% (1) of the output
signal is reached, than a digital output signal (XS001A=0), is sent to compressor PLC in order
to reduce compressor capacity control from 50% to 0% (2). The master pressure controller

Suction pressure increase:

50210PIC022 start to close the recycle valve 50210PV022. Once 0% (1) of the output signal
increase compressor capacity control from 0% to 50% (2). The master pressure controller will
now operate with the new working condition on recycle valve 50210PV022.

increase compressor capacity control from 50% to 75% (2). The master pressure controller

increase compressor capacity control from 75% to 100% (2). The master pressure controller

1.6 - Start-Up Procedures

Restart after first start-up or after Plant General PSD
The plant at restart condition (after the first start up) is in the following status:

Each unit is pressurized at its operating pressure.

All manual isolating valve between unit or upstream and downstream
SDV, MOV, EBV, UV, are open.

All manual isolating valves on control valves are open.

Cooling water to all cooler is open.

48

Instrument air supply is available.

Locked Open and Locked Closed valves are in their normal operating
positions.

All safety devices are ready for operation.

Electrical trace heating is energised;

All instruments are ready for operation.

All instrument vent/drain valves are SHUT.

All MOV, BDV and SDV valves are in position shown on the P&ID.

Acid and LP flare system are ready for operation.

Acid and LP flare system are ready for operation.

All process controllers are set at its normal operating value and the
relevant control valves have the position according to the set, excluding
those forced in manual mode with output zero through XS signal.

The raw gas and condensate incoming pipeline are isolated.

All process controllers are set at its normal operating value and the
relevant control valves have the position according to the set, excluding
those forced in manual mode with output zero through XS signal.

The raw gas and condensate incoming pipeline are isolated.

1.6.1 - Start the 1
st
train of condensate stabilization

Check the pressure drop across 50-190-SDV-002A; if it is less than 3 bar,
reset 50-190-SDV-002A; if the pressure drop is higher, reset 50-190-
SDV
002B.

Open 50-190-SDV-003 and 51-210-SDV-003.

Start to feed the Condensate Surge Drum opening gradually 51-210-FV-
003;
condensate will flow to Condensate Surge Drum 51-210-VA-001; check
the
flow on 51-210-FIC-003 and check the level rising on 51-210-LIC-001
and
51-210-LIC-002.
49

When the level on Condensate Surge Drum 51-210-VA-001 reaches the
50%
then open 51-210-EBV-004, start Condensate Feed Pump 51-210-PA-
001,
verify that minimum flow 51-210-FIC-005 works properly; start to feed
gradually the stabilizer column operating through 51-210-FIC-006, check
the
level increase on bottom of stabilizer column (51-210-LIC-006).

As soon as the level on bottom of stabilizer column is detect, (51-210-LIC
006) commission the reboiler 51-210-HA-002; gradually open the steam
operating 51-210 FIC-009; check the temperature increase on 51-210-
TIC
017; when 94C are detected, then put the instrument in cascade.

Check the profile of temperature on stabilizer column; when the top
temperature start to increase, then start the reflux, (feed to try 1)
operating
through 51-210-FIC-007 to maintain 38C at vapour line of column (51-
210
TI-013); the off gas is sent to LP flare by operation of 51-210-PIC-008.

Check the pressure drop across the column.

When the level on bottom of stabilizer reach the 50% the product start to
flow to off-spec condensate storage tank.

Slowly increase the flow rate to reach 50% of design capacity of this
train;
51-210-FIC-006 and maintaining the some ratio increase the flow rate on
51
210-FIC-007; at these new conditions, adjust the other operating condition
such as feed temperature 51-210-TIC-006, temperature on try 14 51-210-
TIC
017 in cascade with steam flow controller 51-210-FIC-009, pressure on
vapour line maintained by 51-210-PIC-008 sending off gas to LF flare,
level
on bottom of stabilizer 51-210-LIC-006, the product is sent to off spec
condensate storage tank; check the pressure drop across the column,
vapour
line temperature, temperature of product to storage.

When the feed rate to stabilized have been increased, also the flow rate to
Condensate Surge drum will be automatically increased; check the
operating
conditions on this vessel such as levels of condensate; 51-210-LIC-001
and
50

002, level of interface in water pot 51-210-LDIC-004, pressure on
Condensate Surge drum maintained by 51-210-PIC-027 sending off gas
to
LP flare, minimum flow of condensate feed pump 51-210-FIC-005.

Commission the analyser 51-210-AA-002 on stabilized condensate to
storage
tank and when the condensate meet the specifications, operate 51-210-HS
005 to position A in order to have the following MOV in the indicated
position:

51-210-MOV-007 to feed condensate to stabilizer column remain
open;

51-210-MOV-008 condensate from delivery of 51-210-PA-001
unstabilized condensate to off specs tank remain closed;

51-210-MOV-009 stabilized condensate to off specs tank is closed;

51-210-MOV-010 stabilized condensate to storage tank is open and
stabilized condensate will flow to appropriate condensate storage
tank.

Increase the stabilizer flow rate to reach the design capacity then proceed
with the start up of 2nd train of stabilization.

During stabilizer feed flow rate increase, check the flow rate of off gas
sent
to LP flare from stabilizer vapour line 51-210-FI-008 and when the flow
is
steady, the off gas compression system will be started up.

1.6.2 - Start the Stabilization Off Gas Compression System

Slowly increase the set point of 51-210-PIC-008 and decrease the set
point of
51-210-PIC-013 so that the off-gas sent to LF flare is diverted to off gas
compressor.

Commission the off gas compressor according to the manufacturer
recommendation then start compressor operating 50-210-HSKB-001A-1;
the
MPC (Master Pressure Controller) by means of 50-210-PIC-022
automatically load the compressor or open the recirculation line from
51

delivery of second stage to maintain the suction pressure of compressor.

With the compressor running check all operating parameters in the unit.

1.7 - Shut-down Procedures

Condensate Stabilization, Off-gas Compression and Off-Specs Storage

As reported previously there are two parallel trains, each designed for 66.6% of total capacity,
for condensate stabilization.
Recompression of OVHD stabilizer column gas to be recycled to gas sweetening unit is
accomplished by means of a 1x100% capacity two stage reciprocating compressor (50 -
210KB001A/002 A, common for two lines). 1x100% capacity identical compressor (50 -
210KB001B/002B) is installed as stand-by. The third identical compressor (50 -
210KB001C/002C) is foreseen in the unit, as common spare compressor for the two
compressors A and B, when both running (Bouri case).
The off-specs condensate tank 50-210-TA-001 will provide a sufficient storage capacity to
store unstabilized condensate of one train for about 24 hours. This tank will serve to divert the
unstabilized condensate from off-shore in case of an emergency in the downstream
stabilization unit, thus avoiding to stop gas production.
The arrangement described previously and the stand-by philosophy are good reasons to
consider only the shut down of one condensate stabilization train. The relevant procedure
consists in the following steps:

1) Start to reduce slowly the NGL condensate feed to the Stabilizer Column
51-210VE-001 (52-210VE-001) down to 50% of the plant capacity,
reducing manually 51-210FIC003 (52-210FIC003) following the
procedure

described in the general shutdown of the unit

2) In the same time, increase the condensate feed flow rate in the running
condensate stabilization train to the maximum allowed capacity, i.e.
66.6%

3) Reduce accordingly the load of the Off Gas Compressor (of the three)
50-210KB001/002 A or B or C which is running, to match the new load
conditions of the condensate stabilization trains.

4) Stop the train when the capacity reached 50%, following the procedure
described in the general shutdown of the unit.
52

1.8 - Common Troubleshooting

There is a possibility of slugs of heavy liquids coming into the plant along with the inlet feed
stream. This heavy liquid will flow through the feed drum to the stabilizer and out through the
bottom with the condensate.
Since these slugs should be intermittent, it will be necessary to be aware of this situation and
adjust the operating conditions to compensate for the presence of the heavy material. All
changes in the bottom temperature controller must be made slowly to allow the tower to
stabilize (lineout) after each small change. A low bottom level alarm is also provided to warn
the operating personnel of forthcoming erratic conditions.
Figure 1.17 reports some probable upsets that may occur in the unit during normal operation
together with the relevant operator action.

Figure 1.17 - Troubleshooting

53

54

55

2. GAS HC DEW POINT CONTROL - Unit 340

56

2.1.1 Hydrocarbon dew point

The condensation temperature of heavy hydrocarbon components in gas - commonly
known as the hydrocarbon dew point - is a complex and difficult parameter to
measure.Traditionally, this measurement has been made using a manual optical technique
based on the cooling of a mirrored surface in contact with the hydrocarbon gas mixture.
Whilst it is possible, with experience and application, to obtain repeatable results with a
manual dew-point hygrometer, the subjective nature of this technique yields it ever less
applicable in today's de-regulated gas markets where continuous and precise
measurement of this critical parameter are demanded.
Natural gas is made up of a large number of discrete components, from hydrogen to
complex long chain hydrocarbons. Each component will have its own particular dew
point, effectively defined by its concentration and vapour pressure. Therefore, as a
sample of natural gas is cooled, each component will begin to condense as it becomes
saturated at a particular temperature. Heavy hydrocarbons will be the first to condense,
but in small quantity as they are normally the trace components in the gas mixture.
Therefore, unlike for instance water dew point in an air system, the hydrocarbon dew
point in natural gas is a non-distinct parameter that can be changed dramatically by small
changes in gas composition or pressure. To complicate matters further, component
molecules can interact and even form weak bonds together at higher pressures and
therefore the phase relationship of natural gas follows a completely different pattern to
that of simple gas mixtures. Indeed, the phase envelope folds back on itself at higher
pressures, so effectively the hydrocarbon dew point reaches a peak (normally at about 27
bar g) and then reduces.

57

A final physical point of note is that hydrocarbon condensates have an extremely low
surface tension compared, for example, to that of water. Therefore, as condensation forms
on a surface, it will tend to form a film rather than discrete droplets, rendering detection
by traditional optical means far more difficult than the detection of water dew points.It is
therefore vital that any technology used for the measurement of the effective hydrocarbon
dew point of natural gas is extremely sensitive, repeatable and able to operate over a
range of system pressures. Sensitivity of the order of 1ppm (molar) of condensate enables
the analyser to detect the almost invisible films of condensate that are characteristic of
hydrocarbon gases at dew point, due to their low surface tension.
In order to achieve maximum accuracy in this difficult measurement, a flow de-coupling
method is used. Discrete measurement cycles, at user definable intervals, lock a fixed
sample of the hydrocarbon gas mixture into the measurement cell. As the optical surface
is cooled, sequential condensation of hydrocarbon components occurs until the pre-
selected optical trip level is reached that signals the effective hydrocarbon dew point
temperature of the gas. The fixed sample means that there is representative condensation
of all the hydrocarbon components and prevents preferential condensation of heavy ends
that might occur with a flowing sample - this could lead to a falsely high indication of the
hydrocarbon

Figure 2.1 Diagram P-T for HC Dew point

.

58

2.1.2 Gas Dew Point Control - Purpose and application.
The Gas HC Dew Point Control Unit has the duty to reduce drastically the condensable
hydrocarbons (heavier HC), still present in the sweet and dried gas, so that condensation of
hydrocarbons in the export pipeline is avoided.
Condensation of liquid is a problem in metering, pressure drop and safe operation.
Condensation of liquid can also be a major problem with two-phase flow and
liquid slugging.
To prevent the formation of liquids in the system, it is necessary to control the
hydrocarbon dew point below the pipeline operating conditions. Since the pipeline
operating conditions are usually fixed by design and environmental consideration,
single-phase flow can only be assured by removal of the heavier hydrocarbons from the
gas.
Small amounts of water or condensate can impair the efficiency of gas transportation
lines, cause corrosion, form hydrates and, in time may form liquid slugs that could
damage compressors and burners and cause serious safety hazards.
For this reason gas transportation and distribution companies specify, for the gas they
have to transport, the maximum dew point temperatures (the temperature at which the
liquids, water or hydrocarbons, will starts condensing).

Figure2.2 A typical Hydrocarbon Dew Point Control Unit - a number of process
components are added/modified/remove to suit the requirements of each individual
application.
59

While the water condensation curve has a positive slope (condensation occurs either reducing
the temperature or increasing the pressure), this slope of a multicomponent hydrocarbon
condensation curve is negative (or retrograde). The hydrocarbons condense when the
pressure is reduced. Retrograde condensation occurs even with very lean gases ( e.g. 99.5 %
methane) that have an appreciable long tail of heavy components, and is observed down to
pressure of 15/30 barg. In order to know with a certain accuracy the temperature of
condensation at the various pressures or to find the pressure at which the condensation
temperature is highest ( cricondentherm) it is necessary either to have an experimental
condensation curve or, a representative detailed gas composition up to at least C13. The
heavier hydrocarbons even in minimal percentages have a great influence on the dew point
temperature.

Figure 2.3 Condensation curves of a natural gas separated at 0
0
C and 70 barg

60

2.1.3 - Main procedures
In order to obtain the lower dew point it may use one from following procedures:
- LTS ( Low Temperature Separation). When high pressure gas is available,
the expansion of the gas stream can be used to refrigerate the gas (Joule-
Thompson effect) and condense heavy hydrocarbons and water that can be
removed as liquids.(Figure2.6)
Figure 2.4 - Horizontal low temperature separator
Figure 2.5 Vertical low temperature separator

61

Figure 2.6 LTS Low Temperature Separator

Figure 2.7 - % of hydrocarbons recovery in a low temperature separator

62

Absorption by glycol. When only water dew point has to be controlled a
simple process is the absorption of water by glycols.

Dry bed adsorption.( Figure 2.8) By running the gas stream through adequate
adsorbing dry beds, water and heavier hydrocarbons can be removed
simultaneously. Generally no LPG is recovered.

Figure 2.8 - Three tower Dew Point Control Plant Adsorption Type

Commercial amorphous adsorbents are materials treated in order to develop a
high porosity and a very large surface area per unit volume. Activated carbon,
alumina, activated alumina gel, silicagel, are commercial adsorbents, marketed
under several trade names. Their porosity is of de order of 50% and is made of
a great number of interconnected capillary channels of various diameters that
develop an enormous surface (of the order of 500 m
2
/g). They are suitable to
adsorb molecules of various nature, specially polar, that fit in their pores. The
most commonly used adsorbent for simultaneous water and hydrocarbon dew
point control is silicagel. Molecular sieves are synthetic crystalline zeolites
having pores of constant diameter ( e.g. 3, 4, 5, 10 A
0
), ideal for adsorbing
selectively small size molecules like H
2
O, CO
2
, H
2
S, Mercaptans, but too small
63

for adsorbing heavy hydrocarbons. When the removal of hydrocarbons is not
wanted, molecular sieves, rather than silicagel, can be used. Molecular sieves
can obtain very low water dew points and are indicated when followed by
cryogenic plants or when s is protected by graduated layers of inert ceramic
balls.
Mechanical refrigeration.(Figure2.9) By cooling the gas stream to low
temperature by means of a refrigeration unit (e.g. with propane refrigerant),
and removing the condensed NGL (the higher the pressure the lower must be
the temperature). Refrigeration of a gas stream causes condensation of both
water and hydrocarbons and therefore can be used to reduce the dew point of
the gas. However at high pressure and low temperature liquid water form
hydrates and may plug valves and exchangers of the plant. In order to prevent
hydrates formation it is necessary either to previously dehydrate the gas stream
or to inject hydrate preventers like methanol, ethylene glycol or di-ethylene
glycol. Methanol is used only in emergency or at start-up because it is mostly
lost with the gas stream. Glycols (mono and di-ethylene) are preferred since
they can be easily regenerated and recycled. It is adopted when sizeable
amounts of condensate are expected (gasoline plant). The process may lead to
the recovery of LPG. In the figure 1.9 it can see the gas runs first through a
filter separator to remove all the liquid droplets, is then pre-cooled by the
outgoing treated gas and finally chilled by means of a mechanical propane
refrigeration plant.
Before the gas being cooled reaches the hydrate formation temperature a
solution of glycol is sprayed into the gas stream to prevent the formation of
hydrates. More glycol is injected at the chiller inlet. The condensates are
separated from the gas stream in the low temperature separator. While the
hydrocarbons are sent to the cold feed stabilizer and from there to storage, the
diluted glycol is regenerated and recycled. The most expansive and complex
part of the plant is the mechanical refrigeration unit.

Figure 2.9 Flow diagram of a refrigeration Dew Point Control Plant with glycol
64

Turbo-expansion (Cryogenic plants).(Fig.2.10) The simultaneous expansion
and refrigeration of the gas stream by means of a turbo-expander brings the gas
to very low temperatures and permits to condense all the condensable
hydrocarbons. With the turbo-expansion unlike the lamination through a valve,
the gas stream produces work subtracting calories from the stream, and can
reach much lower temperatures. The gas can thus be separated at a more
convenient pressure and the work generated can be used to partially re-
compress the gas after separation of the NGLs. This process leads also to the
recovery of gasoline, butanes, propane and ethane. Their fractionation is
generally integrated with the dew point plant. Since at these low temperature
the water would form hydrates, and the glycols would become too viscous and
might clog the exchangers, this process requires a previous deep dehydration
of the gas by means of molecular sieves adsorption. A dew point control plant
is not necessarily economically justified by the recovery of NGL, sometimes
it is necessary to meet the gas transportation or distribution company
specifications.

65

Figure 2.10 Conceptual Diagram of a Cryogenic Plant

A cryogenic plant has four functional sections:
- Dehydration to remove moisture from the gas
- Chilling and expansion to liquefy part of the gas
- Demethanizing to remove the methan which liquefies.
- Compression to boost gas pressure to sales gas pipeline pressure.
Obviously, a pre-treatment stage is necessary in case of presence in the inlet gas
of hydrogen sulphide and/or carbon dioxide.

The chilling section is the heart of the cryogenic plant. Gas can be chill by following
procedures:
a) Heat exchange with cold gas
b) Refrigeration
c) Pressure reduction
d) Removing energy from the gas as in an Expander
Refrigeration systems using propane can be apply to chill gas to -40
0
C. At temperature below
this, ethane or ethylene is used for refrigerant, but the system is very expensive.
Another means of lowering gas temperature is simply to reduce its pressure across a pressure
reducing valve. The temperature will drop approximately 1
0
C for each 125 kPa drop in
pressure,( 1
0
F for each 10 psi drop in pressure). Pressure reduction requires recompression, so
its cost is high.
66

2.1.4 Propane - Characteristics, Properties and Combustion
Propane is a liquefied petroleum gas that comes out of both oil and gas wells. Propane does
not occur naturally though. Raw crude oil or raw natural gas is refined to make different types
of petroleum products, one of which is propane. Following it's refinement, propane is stored
as a liquid under pressure until utilized, at which point it becomes a gas.
Propane Properties
Propane Boiling Point - 44
0
C
Weight of 1 Gallon Liquid Propane at 60
0
F 4.24 Lbs
Specific Gravity of Propane Gas at 60
0
F 1.52
Specific Gravity of Liquid Propane at 60
0
F 0.51

Propane Boiling Point - Water boils at 212F meaning that it becomes a gas at this
temperature whereas water is still a liquid at 200F. Propane is a liquid at -50F and boils at -
44F. In other words, at 10 degrees below zero, propane is well past its boiling point. It means
that propane is cold enough freeze your skin (and tissue underneath) to the point of severe
damage.
Specific Gravity of Propane Gas - One cubic foot of propane weighs .1162 lbs. and one
cubic foot of air weighs .07655. Dividing .1162 by .07655 equals 1.52. What does this mean?
Propane is heavier seek the lowest space available.
Specific Gravity of Liquid Propane - One gallon of propane weighs 4.24 lbs. One gallon of
water weighs 8.33 lbs. Dividing 4.24 by 8.33 equals .51. This means propane is less dense
than water (lighter than water) and will not sink in water, so to speak.
Propane Limits of Flammability - The lower and upper limits of flammability are the
percentages of propane that must be present in an propane/air mixture. This means that
between 2.15 and 9.6% of the total propane/air mixture must be propane in order for it to be
combustible. If the mixture is 2% propane and 98% air, there will not be combustion. If the
mixture 10% propane and 90% air, combustion will not occur. Any percentage of propane in a
propane/air mixture between 2.15% and 9.6% will be sufficient for propane to burn. However,
an improper air/gas mixture can produce CO (carbon monoxide) that is a deadly product of
incomplete combustion.
Flash Point - The flash point is the minimum temperature at which propane will burn on its
own after having been ignited. This number states that below -156F, propane will stop
burning on it's own. In other words, if the outside air temperature is -155F, propane will burn
on it's own. If the outside air temperature falls to -157F, propane will no longer burn on it's
own. However, if a source of continuous ignition is present, propane will burn below - 156F.
Ignition Temperate in Air - This number states that propane will ignite if it reaches a
temperature between 920-1020F. If propane is heated up to a temperature between 920 and
1020F, it will ignite without needing a spark or flame.
Maximum Flame Temperature - A propane flame will not burn hotter than 3595F
Before propane is used, it exists in one of two forms, liquid or vapor. Both liquid propane and
vapor are usable but cannot be used interchangeably. In other words, a propane system
67

designed to use vapor can't utilize propane in its liquid form and vice-versa. Additionally, the
characteristics of propane liquid and propane vapor are so different that the primary properties
we are concerned with are as different as night and day. With propane liquid, temperature is
the primary factor whereas weight is the main concern regarding propane vapor. Think of it
this way, water is liquid and steam is water vapor. The same holds true for propane and is
explained in detail below.
Propane Liquid
Propane exists in its liquid form at or below its boiling point (-44F) as well as when it stored
under pressure. To further explain, if the temperature outside is -45F, propane will be a
liquid and you would be able to pour it out of a bucket. But as soon as the temperature rises to
-44F, the propane begins to boil and thus give off vapor. If the temperature outside is colder
than -44F, propane exists as a liquid. It's still propane but it looks a lot like water while at
this cold temperature. It's colorless, odorless and tasteless...but who would take a drink of a
any liquid that is 45 degrees below zero? Who would stick their finger in a glass of anything
that is 45 degrees below zero? Holding a handful of ice can be quite uncomfortable (or
painful) after some time but think how painful it would be if that handful of ice was almost 75
degrees colder.
Because propane boils at a temperature that is over 70 degrees lower than the freezing point
of water, it has the ability to freeze skin tissue in a very short period of time (severe frostbite).
The temperature properties of liquid propane are such that being aware of possible danger
when dealing with propane in its liquid state is extremely important.

Propane Vapour . Propane becomes a vapor at temperatures above -44F. Similar to water
when it boils and gives off steam, propane gives off vapor when it boils. One may refer to
propane vapor as "flammable steam" for simplicity. However, for the propane vapor to be
ignited, there must be the right mix of air and vapor. Propane vapor is heavier than air and
will sink to and collect in the lowest point it can find. If propane is vented to the outside air, it
will quickly dissipate with the slightest movement of air. Conversely, if propane is vented into
an air tight structure with no air movement, the propane vapor will collect on the floor and
rise vertically if more propane is vented into the structure.
This is extremely important to know because if there is a propane leak in a house or building,
the propane vapor will seek the lowest possible point where it will collect. Keep in mind that
one gallon of propane will produce over 36 cubic feet of vapor and this vapor will settle in the
lowest possible place. If the propane vapor level continues to rise, it may ignite if finds a
source of ignition. The weight of propane vapor being heavier than that of air is a
characteristic of propane gas that needs to be understood by all LP Gas users, not just propane

2.2. - Gas Dew Point Control using Propane Refrigeration
The Propane Refrigeration Unit consists of a closed loop in which the propane is flashed in 2
steps, vaporized, recompressed and condensed. The first step flash is the economizer system,
which splits the main stream in to a liquid phase (used to refrigerate second flash step) and a
gas phase that is routed to the Refrigeration Compressors.
68

The refrigerant medium used is propane product. The propane refrigerant make-up is stored in
the Propane Refrigerant Storage Unit.
The composition of the propane refrigerant, which was considered for the design of the unit,
is:
Ethane: 1.55 %mol
Propane: 96.54 %mol
I-Butane: 1.51 %mol
Butane: 0.45 %mol

For the initial fill of the system, the propane refrigerant is from road tankers. The quality of
this fill followed the specifications, imposed to the onshore plant Propane product, which are
summarized in Table 2.1 below.

Table 2.1 - Propane Composition

Propane refrigeration is well suited to gas plant applications where chilling to
between -12C and -40C is required. Boiling points of propane are -42C at 101.35 kPa
and 38C at 1310 kPa. The propane refrigerant cycle can be thought of as heat pumping.
Composition, liquide
volume %

Methane
Ethane
Propane
Butanes
Pentanes +

Max 1 ppm vol
Max. 2.0
Min. 95.0
Max. 3.0
Max 15 ppm vol

ASTM D-2163

Corrosive Compounds,
Copper Strip

Max. No.1 ASTM D-1838
Total sulphur ppm (wt)

Max. 15

ASTM D-2784
Hydrogen Sulphide content

Negative

ASTM D-2420
Vapour pressure @ 100F,
psig (kPa(g))
Max. 200 ( 1380)

ASTM D-1267
Water Content, ppm (wt)
Residues
Residues number
Oil number
Oily residue, ppm(wt)
Max.10

Max.10
Pass test
20
ASTM E-700

ASTM D-2158

69

Heat is brought into the system at a low-temperature level and "pumped up" to be
discarded through the condenser to a high-temperature heat sink. Propane is the heat
carrier.
Propane as a refrigerant in externally refrigerated processes is effective when large rates of
heat removal are required from the gas streams. It is readily available in large plants and
has excellent thermodynamic qualities. Propane possesses much greater refrigerating
effect than other refrigerants such as freon, ammonia and carbon dioxide.
The boiling point of propane at atmospheric pressure is fairly low and requires large
amounts of heat to convert it from a liquid to a gas in the chillers. When in vapour form after
compression, it requires a low pressure to condense it for use a liquid in another cycle. It has
no offensive odour and is not of poisonous or toxic nature. Further, propane is not corrosive to
metals and can be safely stored in properly designed vessels.
The biggest drawback of propane, however, is that it is inflammable and explosive when
mixed with air. Great care is required to handle it and all safety precautions should be
adhered to when charging the system initially, periodically or during any maintenance work
in the system.
Propane refrigeration systems require centrifugal compressors, condensers, surge tanks,
economizers and evaporators or chillers to produce the required cold.
The Refrigerant Compressors are two stage centrifugal compressors, driven by a fixed speed
electrical motor and are configured as 2x 50% ( two in operation/none in stand-by).So in the
event of only one compressor working, most of flow enters to the other compressor. Because
of flow rate and suction pressure increasing, compressor load increases; so for the period
required, operation is possible, only reducing flow rate to the working compressor. Each
compressor has two inlets and one outlet. An anti-surge controller caters for the protection of
each Refrigerant Compressor. Hot propane vapour from the Refrigerant Compressor
discharge is recycled through

+ The centrifugal compressor is used to raise the condensing
temperature of the propane refrigerant above the temperature of
the available cooling medium in the condenser.
+ The condenser is used to cool and condense the discharged
propane vapour from the compressor back to its original liquid form
+ The economizer is designed to lower the temperature of the liquid
refrigerant by flashing or heat exchange and improves the
refrigeration cycle efficiency.
+ The evaporators or chillers accomplish the transfer of heat from
the gas stream to the boiling refrigerant thus lowering the
temperature of the incoming gas.

Generally the entire refrigeration process depends upon two facts:
That propane refrigerant has a low boiling point and will boil as
soon as it contacts the warm gas.
That the boiling point varies with the pressure of the refrigerant.
70

Referring to the general flow diagram in Figure 2.11 the cooling is accomplished in the
chillers by passing the inlet gas through the tubes, while maintaining a level of liquid
propane at the proper pressure around the tubes in the chiller shell.
The heat exchange surface or outside area of the tubes in the chiller, may be designed for a
five degree approach, which means that the gas leaving the chillers will be five degrees
warmer than the liquid propane in the chiller shell. Therefore, cooling the gas to -37C
requires that the propane be maintained at -42C.
Any pure liquid will have a specific boiling temperature corresponding to the pressure being
exerted against it. For instance, water boils at 100C when under atmospheric pressure at sea
level. If the pressure is lowered or a vacuum pulled on the water, the boiling temperature is
also lowered until it will boil at a room temperature of 26C under a 736 mm vacuum.
When the liquid boils, it absorbs heat from some source such as, in the case of a pan of
boiling water, the flame below it. In the plant chillers, the propane will boil at -42C if the
pressure on it is held at atmospheric level and the boiling liquid will absorb heat from the
gas in the tubes.
For each kilogram of propane vaporized a definite amount of heat will be absorbed from the
gas. Thus, heat is removed until the temperature of the gas has decreased to the desired level
of -37C. To cool the design volume of gas to -37C, it will be necessary to vaporize 4,041
kg per minute of propane.

Figure 2.11 - Typical Propane Refrigeration System

71

To hold the pressure in the shell of the chillers down to atmospheric pressure and to
provide a continuous supply of propane to replace that which has vaporized, it is necessary to
withdraw the vaporized propane from the chiller, compress it, to cool it until it is again a
liquid and to reinject it into the chillers. Just as there is a definite boiling point for a pure
liquid at any given pressure, so is there also a definite temperature at which the vapours will
condense into a liquid for any pressure. In fact, they are the same temperature; that is, a
pure fluid (which is either liquid or vapour) will boil or condense at the same temperature, if
the pressure is held constant, depending on whether heat is added or withdrawn.
The pressure to which the propane must be compressed then, is determined by the temperature
to which it can be cooled. Since the propane condenser was designed with the same 5C
approach as the chillers and the design cooling water temperature is 22C, the propane will
leave the condenser shell at 50C. To condense at 50C, the propane must be at 928 kPa to
allow pressure losses in the line and condenser, the compressor is designed for a
discharge pressure of 966 kPa. From the condenser, the liquid propane flows to a surge tank
which allows for minor upsets and changes in operating conditions. In flowing from the surge
tank where the temperature is 50C to the shell of the chillers where the temperature is -
42C, the propane loses much of its cooling capacity in cooling itself. The power used in
compressing the propane which has vaporized, only to cool the remaining liquid, is lost in as
much as it has not been used in cooling gas. To minimize this loss and increase the efficiency
of the cycle, the pressure on the liquid is reduced in some steps. At the two intermediate steps,
the liquid is allowed to boil or flash in vessels called flash tanks or open flash economizers,
thus cooling itself to a temperature corresponding to the pressure level. The resulting vapour
must then only be compressed from that pressure level to 966 kPa instead of from 7 to 966
kPa. This results in considerable savings in power.

2.3 - Propane Refrigeration Unit 51-340-XX-001 - description of the package.

The propane vapour coming from the process Propane Chiller, 51-340-HA-002, arrives at
the battery limit of the Propane Refrigeration Unit, enters the Compressor Suction KO Drum
and afterwards feeds the Propane Refrigeration Compressors (two in operation, one in
stand-by).
The suction pressure of compressor will be controlled by acting on its load capacity, which
shall be able to vary from 0 to 100%. This pressure control is in turn fixing the operating
pressure in the Propane Chiller. The compressed propane gas, which might have been
contaminated by compressor oil, passes through the Compressor Discharge Oil Separator.
Then, the propane is condensed in the Propane Condenser, using cooling water. The
condensed liquid propane from the condenser enters the Propane Receiver. The Propane
Receiver is sized for total hold-up of the Package Unit. Connection will be provided here for
filling the Unit with propane from the production units (41/42-320) in Wafa Coastal Plant.
From the Receiver, the liquid is sent on level control to the Economiser, 51-340-HA-005 that
produces the cold refrigerant. A part of the liquid propane is flashed on the shell side of the
Economizer. The liquid on the tube side gets cooled down to 5C. The propane flashed gas is
72

sent to the intermediate stage of the compressor.
From the Economiser, the liquid propane arrives to the battery limit of the Propane
Refrigeration Package at a temperature of 5C maximum. The propane gets vaporized in the
Propane Chiller at a temperature of 39C. The vapour propane is delivered back to the
battery limit of the Propane Refrigeration Unit for compression. The Propane Chiller is
provided with a bottom boot collect the oil coming along with propane. This oil is sent back
to the Propane Refrigeration Unit for feeding into the Compressor Oil System
The temperature controller on the gas leaving the chiller operates in cascade on the propane
side level controller in the propane chiller which acts on the liquid propane supply valve.

Figure 2.12 Propane chiller level control

When the temperature rises over the set point value, 51-340-TIC-007 output will increase set
point of 51-340-LIC-002 in order to open valve 51-340-LV-002, when temperature falls under
the set point value, 51-340-TIC-007 output will decrease set point of 51-340-LIC-002 in order
to close valve 51-340-LV-002.
73

Figure 2.13 Propane Refrigeration package 51-340-XX-001

74

2.4. - Gas HC Dew Point Control Process Description

Unit 340 is designed to separate the heavier condensable hydrocarbons from the dry gas
arriving from Unit 311 in order to avoid any further condensation in the export gas pipeline.
The Unit 340 is split over three parallel trains, each sized for 33,3% of the total capacity.
The following description is relative to Train 1 but Trains 2 and 3 are identical to Train 1.
The Unit 340 is composed of the following sections:

Pre-cooling.

Cooling.

Separation of NGL condensate.

Propane refrigeration system.
The Gas HC Dew Point Control is designed for a 50% turndown referred to the design
case; the propane refrigeration system has a capacity that goes from 0 to 100% meaning that
the system is able to operate continuously.
The Gas HC Dew Point Control Unit has been designed to cool 12081.6 kmol/h of dry gas
(considering Year 2 summer case).
The Unit is designed to process a stream of dry gas, coming from unit 311, having a B.L.
pressure of 35.7 barg and a temperature of 38.6C in the summer time.
The propane chilling system is a fully automatic system; normally two compressors are
running while the third one in stand-by. The start-up of the two running compressors shall
be done manually by a local push button. The stand-by compressor starts automatically in
case of failure of one of the operating ones; a dedicated control panel (PLC based) is foreseen
for each compressor, to avoid that a single machine failure causing the shutdown of the Unit
and consequently of the whole plant.

The main equipment necessary to complete the above mentioned task is the following:

Raw Gas/Treated Gas Exchangers 51-340-HA-001AF
Propane Chiller 51-340-HA-002
NGL Condensate Separator 51-340-VA-001.
Propane Refrigeration Unit 51-340-XX-001

The dry gas from Unit 51-311 reaches the unit 340 through a 20" line (see Figure 2.17 ) on
75

which is located a shutdown valve provided with a by-pass also isolated by a shutdown
valve. The latter is designed to equalize main valve upstream/downstream pressures.
Opening of the main shutdown valve is allowed only when the differential pressure is less
than 3 barg.
Downstream the shutdown valves are located pressure and temperature indicators, and
transmitters with indication at DCS.

The Raw Gas/Treated Gas Exchangers 51-340-HA-001AF are of the shell-and-tube type,
with the dry gas flowing through the shell side and the treated chilled gas flowing through
the tube side.
At the conditions foreseen for summer of year 2, the inlet temperature of the dry gas will be
38.6C and the pressure 34.7 barg, while outlet temperature will be 14C and the pressure
34.2 barg. For the treated chilled gas is foreseen an inlet temperature of 31C and a pressure
of 32.6 barg, while at the outlet the temperature will be 34.6C and the pressure 32.0 barg,
that are the export gas characteristics.
The 20" line is provided with sample connection, temperature, pressure and flow indicators
and transmitters with indication and alarm at DCS, the pressure control valve driven by a
controller located on the outlet of the condensate separator 51-340-VA-001
There is also a shutdown valve and its by-pass provided with another shutdown valve. The latter
is designed to equalize main valve upstream/downstream pressures because opening of the
main shutdown valve is allowed only when the differential pressure is less than 3 barg.

Figure 2.14 - Common Shell and Tube Heat Exchanger

The treated pre-cooled gas from the shell of 51-340-HA-001AF flows, through a 20" line to
the Propane Chiller 51-340-HA-002 where it is further cooled to -31C by vaporising liquid
propane supplied from the Propane Refrigeration Unit 51-340-XX-001

Chillers are heat exchangers used to lower the temperature of a fluid below that which could
be achieved either using circulating water or atmospheric air. They are part of a refrigeration
system that uses a boiling refrigerant such as propane or freon to obtain the desired cooling.
Chillers (Figure 2.15 ) are generally kettle type shell and tube exchangers. The refrigerant is
76

on the shell side and the tubes are maintained completely submerged in the refrigerant. The
fluid to be cooled is circulated through the tubes, giving up heat, causing the refrigerant to
boil (vaporize).
The vaporized refrigerant is then compressed and condensed back into a liquid and
recirculated to the chiller.
One disadvantage of these units is the heat transfer surface which must be kept and free of any
compressor oil or other fouling substances. Heavy oil deposits on the tubes surface turn
viscous at lower temperatures, coating the tubes and reducing the effectiveness of heat
transfer.
Chillers are often provided with liquid refrigerant cleaning equipment called reclaimers or
blow cases. They commonly receive a batch of heavy bottoms from the chiller boiling off the
refrigerant and dump the heavy oil residue to a drainage system.
Figure 2.15 Propane Chiller

The Propane chiller 51-340-HA-002 has a capacity of 3.22MW, the gas (238,322 Kg/h)
enters at a temperature of 14C to leave the chiller at 31C. The propane flowrate is 33177
Kg/h.
The Propane Chiller 51-340-HA-002 is a heat exchanger of the kettle type, provided with a
boot. The treated pre-cooled gas flows through the tube bundle immersed in the liquid
propane coming from the Propane Refrigeration Unit 51-340-XX-001. The liquid propane
absorbs heat from the treated pre-cooled gas, and vaporizes. Propane vapour gathers on the
top of the shell and leaves the kettle through the 24" line to return to the Propane
Refrigeration Unit 51-340-XX-001, while the compressor oil comes along with propane
settles on the boot to be sent back to the Propane Unit. The temperature of the chilled gas is
controlled by regulating the level of the liquid propane in the kettle: the temperature
controller monitoring the chilled gas temperature operates the propane level controller
which control the propane level control valve.
The level of the oil in the boot is controlled through the interlock which closes the isolation
valve on the 2" oil line and gives an alarm at DCS. Boot drain and level stacks drain may be
77

directed to open drain system, while level vents are directed to the cold flare
The mixed phase of gas and NGL condensed in the Raw Gas/Treated Gas Exchanger and in
the Propane Chiller enters the NGL Condensate Separator 51-340-VA-001.

The NGL Condensate Separator 51-340-VA-001 is a vertical vessel with a diameter of
3200 mm and a height of 6000 mm, provided with a distributor for the incoming chilled gas
and a wire mesh pad demister. Heavier hydrocarbons settle to the bottom and exits through a
breaker and a 6" line, under level control.

Figure 2.16 Vertical 2-phase separator

The NGL Condensate Separator 51-340-VA-001 is a vertical vessel where heavier
hydrocarbons settle to the bottom and exits through a breaker and a 6" line, under level
control.
A 3" line, leading to cold drain or to open drain systems, is foreseen for the vessel bottom
drain and for level instrument drains. Level instrument vents are directed to cold flare.
The vessel 51-340-VA-001 is also provided with the pressure safety valves discharging to
78

the cold flare, and with the blow down valve controlled by the interlock 51-340-I2001, also
leading to the cold flare. The 20" line from the vessel 51-340-VA-001 conveying the chilled
exchangers 51-340-HA-001AF is provided with sample connection, pressure and
temperature indicators and transmitters.
The 6" line from the bottom of 51-340-VA-001 is provided with the isolation valve controlled
by the interlock and with an analyzer for C3/C4/IC4 detection.
Hydrocarbon liquids separated in the NGL Condensate Separator are sent, under level control,
to the NGL Fractionation Units - Unit 320, after mixing with the corresponding streams from
Trains 2 and 3. A minimum pressure drop is required for control valve to avoid flashing of the
liquid. C3/C4 analyzer is provided to check NGL quality.
Large hold up has been provided for NGL Condensate Drum to assure Plant flexibility. In
case one of the two downstream NGL fractionation units shut down, two operation are
possible:
1) The NGL Fractionation Unit that is in service is brought to its maximum capacity. If the
DPCU's are kept to their normal operating chiller temperature (-31C), this unit will be able
to treat the NGL from two of the three gas treating trains. The third train must be stopped with
consequent loss of production.
2) The DPCU's chiller temperature is increased to 5C in all the three gas treating trains. In
this condition the produced gas is still on spec for hydrocarbon dew point. The amount of
produced NGL decreases and can be treated by one single unit if brought at its maximum
capacity.
Adequate time to perform any of the two operations is assured by vessel hold up. The treated
gas from the NGL Condensate Separator is sent to the Raw Gas/Treated Gas Exchanger, it is
mixed with the corresponding streams from Trains 2 and 3 and then joined with sales gas
from Wafa pipeline before delivery to MGCS or LGCS.
Before exiting the Dew Point Control Unit the outlet gas is analyzed in the analyzer to
monitor Wobbe Index and GHV, and it is measured and totalized by the flow totalizer. In case
of MGCS/LGCS temporary shut down the excess gas will be immediately flared.

79

Figure 2.17 - Gas HC Dew Point Control process flow diagram

2.4.1 - Process Variable

The main process variable on Gas HC Dew Point Control is the temperature of
chilled gas that is controlled at 31C by 51-340-TIC-007 in cascade with 51-340-
LIC-002 evaporating propane in propane chiller. This temperature has effect on
condensation of light components; increasing this temperature some light component
is not condensed and on contrary decreasing this temperature lighter component are
condensed.
The dry gas from the Gas Dryer Unit is first pre-cooled in a feed/effluent heat
exchanger from a temperature of 38C to 13C, and the treated gas is cooled in the
Propane Chiller where the gas gets cooled to minus 31C for base case.
In the Propane Chiller, the cooling is achieved by commercial propane evaporating
on the shell side at a pressure of 1.2 bara at the corresponding temperature of -37C
for base case.
The outlet temperature of dry gas from chiller is automatically controlled at -31C at
a pressure of 34.2 bar.

Conclusion: During routine inspection operation keep an eye on the
instrumentation/parameters reported in Table 2.2
Table 2.3 reports the analysis of sales gas that may be extremely important for the operator of
this unit.
80

Table 2.2 - Main local indicators

Variable Equipment/Service Instrument Tag Range Normal
Value /Point
Temperature Propane to 51-340-HA-
002
51-340-TI-308
-8020
0
C
-37
0
C
Temperature Chilled Gas to 51-340-
VA-001
51-340-TI-308
-8020
0
C
-31
0
C
Level 51-340-HA-002 51-340-LI-004A 0100%(0-
1650mm)
55%(900mm)
Pressure Treated Gas to Fiscal
Metering
51-340-PI-302 040 barg 32.0 barg

Table 2.3 - Sales Gas Analysis

C1 C3 ASTM D 1945 daily
i C4 ASTM D 1945 daily
C4 ASTM D 1945 daily
i C5 ASTM D 1945 daily
C5/C8 ASTM D 1945 daily
C7+ ASTM D 1945 daily
CO2 ASTM D 1945 daily
N2 ASTM D 1945 daily

2.5 - Start-up of 1
st
Train of Gas HC Dew Point Control

Line up the propane vapour to/from Propane Refrigeration Unit 51-340-XX-001.

Open slowly 51-340-LV-002 propane to Propane Chiller 51-340-HA-022; build up
the propane level and when 50% level is reached, the put 51-340-LIC-002 in
automatic at this value.

Commission 51-340-LIC-009 condensate from NGL Condensate Separator 51-340-
VA-001 to NGL fractionation; commission the relevant control valve on feed line.

Commission 51-340-PIC-004 and relevant control valve; treated gas from battery
limit of unit 340 to H.P. Flare; set PIC at 33 bar in auto mode.

81

Put 51-340-PIC-010 in automatic set at 32.5 bar.

The dry gas from unit 311 is flared to HP flare by operation of 51-311-PIC-052;
increase the set point of this instrument to feed the dry gas to Gas HC Dew Point
Control

Check the temperature decrease on 51-340-TIC-007; when temperature reaches -
31C, put the instrument in automatic at this value; the instrument in cascade will
operate the 51-340-LIC-002.

Check the level increase on NGL Condensate Separator 51-340-VA-001 and when
the level reaches 50%, the NGL will be fed to unit 320 NGL Fractionation.

Check the level increase of oil on separation pot of NGL Condensate Separator 51-
340-VA-001 and when the level reaches 50%, the oil will be transferred manually
to Propane Refrigeration Unit 51-340-XX-001 after reset 51-340-EBV-002 located
on outlet nozzle of separation pot of NGL Condensate Separator 51-340-VA-001.

2.6 - Shut down procedures

As reported previously three parallel trains each designed for 33.3% of total capacity are
foreseen for gas HC dew point control. Each train is directly connected with the
corresponding upstream trains of Unit 330 gas sweetening and Unit 311-Gas Dehydration.
This means that when a single train 51, 52 or 53 of Unit 340 scheduled to shut down, the
corresponding train 51, 52 or 53 of the unit 311 is to be shut down too, or kept running with
dry gas discharged to HF through PV052 at unit outlet line.

Remarks: If the train is scheduled to remain shut for a long period, it shall be better to also
shut down one train of the downstream Unit 320-NGL Fractionation, taking care to increase
the feed rate to the other train at 100% capacity. If the shut down is of short duration, keep
both trains of NGL Fractionation running at lower capacity, say 33.3% for each train.

Proceed as follows:

1) Start to increase slowly the temperature of the chilled gas at outlet of
Propane Chiller 340HA002, by acting from DCS on TIC007, which in
turns operates in cascade on the chiller level controller LIC002 to
reduce propane flow rate

2) Shut SDV002/A and SDV002/B on treated gas line to fiscal metering
when it is supposed that chilled gas is out of specification, and
contemporarily control the unit pressure by PIC004, discharging treated
gas to HF

82

3) Shut the condensate outlet valves SDV007 and SDV010 from NGL
Condensate Separator 340VAOQI, when no liquid level appears to
increase anymore.

4) Reduce accordingly the duty of the propane refrigeration unit, following
the instructions of the package unit supplier

5) Shut completely the liquid propane to the chiller, and close manually
LV002 from DCS

6) Depressurize the train to H.P. flare through PV004, then close the valve
when pressure is balanced with the flare.
2.7 - Troubleshooting
Beginning with the refrigerant compressors, especially on start up periods, the
worst problem faced is the possible accumulation of liquid propane in the suction
line. This problem will occur if the pressure and temperature conditions between the
chillers and compressors are allowed to equalize and propane vapour condenses. To
prevent this, all suction lines, liquid traps and drains should always be checked before
the unit is started, particularly if the flow of propane to the chillers has not been blocked
off.
High discharge head conditions is encountered particularly in reciprocating
compressors due to erratic operation of the condenser. Propane contaminated with oil
picked up from the compressors is another problem in gas plants. This problem can be
minimized by passing the compressed propane vapour through the oil separators
(usually of cyclone type), separating the oil which is drained away later. The blow case
(reclaimer) mentioned earlier is another means of removing the oil from the propane if
this unit is properly operated.
Excess liquid level build up in the suction scrubber and inter-stage bottles should be
catched carefully. Some liquid may have to be returned back to the surge drum or
dumped to the closed hydrocarbon drain system if levels become excessively high.
Figure 2.18 reports some probable upsets that may occur in the unit during
normal operation together with the relevant operator action.

83

Figure 2.18 - Unit 340 Troubleshooting

84

NGL FRACTIONATION UNIT 320 Contractor Job Cod :
85

3. NGL FRACTIONATION - UNIT 320

86

3.1 General

Fractionation is a unit operation utilized to separate mixtures into individual products.
Fractionation involves separating components by relative volatility. The difficulty of a
separation is directly related to the relative volatility of the components and the required
purity of the product streams.
Heat is introduced to the reboiler to produce stripping vapours. The vapour rises through the
column contacting the descending liquid. The vapour leaving the top of the column enters the
condenser where heat is removed by cooling medium. Liquid is returned to the column as
reflux to limit the loss of heavy components overhead.
Internals such as trays or packing promote the contact between the liquid and vapour streams
in the column. Intimate contact of the vapour and liquid phases is required for efficient
separation.
Vapour entering a separation stage will be cooled which results in some condensation of
heavier components.
The liquid phase will be heated which results in some vaporization of the lighter components.
Thus, the heavier components are concentrated in the liquid phase and eventually become the
bottom product. The vapour phase is continually enriched in the light components which will
make up the overhead product.
The vapour leaving the top of the column may be totally or partially condensed.
A tray-type fractionator (Figure 3.1) is a vertical, steel cylindrical vessel divided into a
number of horizontal sections by metal trays. The top section contains the rectifying trays and
is called the rectifying section. The centre section is called the feeding section and the bottom
is called the stripping section.
Most large fractionators use trays or plates instead of packing because they are easier to
maintain and are not as subject to fouling as are packed towers. Products can be taken off at
different levels (trays) if specific products are required. Trays are the most efficient method of
fractionating liquid hydrocarbons.
The action on the trays performs the following:

- Strips the vapors from the descending liquid to produce an acceptable bottom product.

- Condenses the liquids from the ascending vapor to produce an acceptable overhead
product.

The number of trays required for a vessel will depend on such factors as:

-If the products have a high relative vapor pressure, the products will be easier to separate
and fewer trays will be required.
87

-The purity required of the overhead and bottom products.

-The efficiency of the action on the trays.

Fractionator trays are named according to their function and location in the tower:

- Top tray is the highest tray in the tower.

- Reflux tray is the tray where reflux enters the tower.

- Intermediate trays are the trays below the reflux tray where the overhead product is
enriched.

- Feed trays are where the raw product enters the tower.

- Stripping trays are the trays where the bottom product is stripped of overhead fractions.
- Seal pan is used to seal the bottom tray.

- Chimney tray is used for liquid draw off or to maintain a liquid head to the reboiler.

Figure 3.2 shows a typical fractionator tray. The bolts around the circumference are used to
install the tray to brackets welded to the vessel wall. The centre section of the tray can be
removed without disturbing the main part of the tray so the vessel can be inspected or
maintained. The weir on the right side of the tray maintains a liquid level on the tray.

Figure 3.1 - Fractionator

88

Figure 3.2 - Fractionator tray

Installation of Trays. Trays are generally bolted into the fractionator so they can be removed
for repairs, replacement, or for inspection of the vessel. They must be firmly installed to
prevent surges from lifting the trays from their supports.
Regardless of which type of tray or packing is used, the purpose is to provide intimate contact
between the descending liquid and the rising vapor. Economics, product purity, cleanliness of
the feed, operating pressures and temperatures, as well as other considerations enter into the
choice of contacting equipment used in fractionators.
Tray Spacing. Tray spacing is based on the mechanical design of the trays, the viscosity of
the products, velocity of the rising vapor, and accessibility. The spacing must allow enough
time and height for the entrained liquid droplets to disengage from the rising vapor. The most
common spacing for trays is 60 cm.
Flooding. Flooding takes place when the down-comers cannot carry away the liquid from the
trays, causing a high level on the trays and products that are off specification. Flooding can be
caused by high pressure drops, which in turn can be initiated by entrainment. Entrainment is a
condition where the rapidly rising vapor stream carries liquid droplets from one tray to the
tray above.
Blowing. Blowing is the opposite of flooding. The rising vapor blows the liquid from the tray
in a fine spray, leaving the tray essentially dry. The lack of contact between liquid and vapor
greatly reduces the efficiency of the trays and off specification product results.
Bubble caps. Bubble caps are very efficient and provide uniform distribution and action on
each tray. Bubble caps provide intimate contact between the descending liquid and the
ascending vapor. Although bubble cap trays provide effective fractionation, they have been
replaced to a great extent by valve trays. Bubble cap trays provide an excellent means of
explaining the action that takes place in a fractionator, as shown in figure 3.3

89

Figure 3.3 Fractionator in action

NGL Supply to Mellitah.

Raw gas and unstabilized condensate, coming from Sabratha Platform by means of two
different submarine pipelines, are received and sent to the treatments facilities.
Condensate is sent to two identical condensate stabilization units. The produced stabilized
condensate is delivered to the storage, while the off-gas also produced at the stabilization unit
is joined with the raw gas stream coming from pipeline.
The gas from the pipeline, jointly with the off-gas, is sent to three identical gas treatments
trains. Each of them is composed by a sweetening unit, a dehydration unit and a hydrocarbon
dew point control unit.
In the sweetening unit, the CO
2
and H
2
S contained in the gas are completely removed and sent
to SRU where H
2
S is converted to liquid sulphur. The sweetened gas is sent to a molecular
sieves dehydration unit, where water is removed, and then to hydrocarbon dew point control,
where, by means of external refrigeration, heavy HC are condensed and separated in order to
match the sales gas characteristics.
The recovered NGL from the dew point control unit is sent to two identical NGL fractionation
units.
More light components (C1, C2) are stripped out from NGL and sent to the fuel gas network.
The liquid is then splitted into a LPG stream that is routed to WAFA Coastal Plant for C3/C4
production, and into a C5+ cut which is sent to storage.

90

3.2 - Unit 320 General process description

Unit 320 is designed to separate from the condensate of Unit 340 the Liquefied Petroleum Gas
(LPG) and the Natural Gas Liquid (NGL). NGL is sent to storage while LPG is sent to Wafa
Coastal Unit C3/C4 Splitter. Lighter hydrocarbons are routed to Fuel Gas System Unit 420.
Last but not least Off-spec NGL condensate, if any, is sent to Unit 210.
The Unit 320 is split over two parallel Trains. The following description is relative to Train 1.
Train 2 is identical to Train 1.
The NGL Fractionation is designed for a 50% turndown referred to the design case. NGL
capacities lower than said turndown may affect the distillation operation carried out in the
NGL Fractionation due to a too low tray load. The Unit has enough capacity to treat on each
line 618.9 kmol/h of NGL condensate (considering Year 2 summer case).
The Unit is able to process a NGL feed having a B.L. pressure of 26 barg and a temperature of
-33.3C.
The NGL from the two dedicated header collecting liquid streams from Unit 340 is feeding
Trains 1 and 2.
NGL is fed to the top tray of the Deethanizer 51-320-VE-001. The overhead vapour is sent to
the LPG Subcooler 51-320-HA-004, where it is heated with the LPG from Debutanizer 51-
320-VE-002. It is then sent to the Fuel gas network. The deethanizer pressure controller
operates on a control valve placed on the gas line to the Fuel Gas network, downstream of the
LPG Subcooler. A pressure blow-off valve discharging to HP flare is installed for start-up
purpose and upset conditions.
The LP Steam flow to the Deethanizer Reboiler 51-320-HA-001 (kettle type) is regulated by
a flow controller on the LP Steam inlet, acting on a valve on the LP Steam Condensate outlet
and cascaded by a temperature controller placed on the sensitive tray of the column.
The Deethanizer bottom product is fed to the Debutanizer 51-320-VE-002 under flow control,
cascaded by the Deethanizer bottom level controller.
The Debutanizer bottom product is sent under level control to the Debutanizer Bottom
Cooler 51-320-HA-005, wherein it is cooled by cooling water. The cooled product is
delivered to storage after mixing with stabilized condensate from Unit 210 or to off spec tank
in case of bad quality.
Analyser to monitor condensate composition/TVP is provided at cooler outlet.
The MP Steam flow to the Debutanizer Reboiler 51-320-HA-002 is controlled with a flow
controller on the MP Steam inlet, acting on a valve on the MP Steam Condensate outlet and
cascaded by a temperature controller placed on the sensitive tray of the column.
The Debutanizer overhead vapour is sent to the Debutanizer Condenser 51-320-HA-003,
and then to the Debutanizer Reflux Drum 51-320-VA-001.
The pressure controller on the Debutanizer operates on the hot bypass of the Debutanizer
Condenser. The condenser operates partially flooded. In case from debutanizer is producing a
vapour amount larger than condensing capacity, pressure increases in the column. The valve
on hot by-pass reacts closing. This increasing differential pressure between inlet of condenser
and reflux drum. Liquid is pushed out from exchanger until the increased surface available for
condensation balances vapour production. In case of pressure in excess over the normal one
due to not condensable in the Reflux Drum, a pressure control valve is provided venting to the
HP Cold Flare.

91

The liquid from the Debutanizer Reflux Drum is pumped by the Debutanizer Reflux Pump
51-320-PA-001A/B and split into two streams: Debutanizer Reflux and LPG product. Reflux
is flow-controlled while LPG is sent, under flow control cascaded by Debutanizer Reflux
Drum level control, to the LPG Subcooler where it is cooled down by means the Deethanizer
Overhead gas.
The LPG Subcooler outlet temperature controller operates on the control valve placed on the
subcooler bypass, Deethanizer overhead gas side.
The subcooled LPG is then mixed with the corresponding stream from Train 2. This
combined LPG stream is sent to Wafa Coastal Plant (Mellitah) for splitting in propane/butane
products.

3.2.1 Main Equipments of NGL Fractionation Plant

Deethanizer 51-320-VE-001

LPG Cooler 51-320-HA-004

Deethanizer Reboiler 51-320-HA-001

Debutanizer 51-320-VE-002
Debutanizer Reboiler 51-320-HA-002

Debutanizer Reflux Pumps 51-320-PA-001A/B

Debutanizer Condenser 51-320-HA-003,
Debutanizer Bottom Cooler 51-320-HA-005

The Deethanizer 51-320-VE-001 is a fractionating column with the diameter of 1700/2100
mm and the height of 31110 mm. It operates at 1/140C (top/bottom) and 25 barg.

The Debutanizer 51-320-VE-002 is a fractionating column with the diameter of 1700/2200
mm and the height of 35000 mm. It operates at 96/191C (top/bottom) and 21 barg.

Debutanizer Condenser 51-320-HA-003 is of the shell-and-tube type, with the LPG flowing
through the shell side and the cooling water flowing through the tube side. The inlet
temperature of LPG is 97C and the pressure 21 barg, while outlet temperature will be 38C
and the pressure 19.5 barg. For the cooling water the temperatures are 32/44C .

LPG Sub-cooler 51-320-HA-004 is a shell-and-tube exchanger, with the deethanizer
overhead

92

gas flowing through the tubes and the LPG flowing through the shell. LPG is cooled down
from 38C to 26C, with a pressure drop from 31 barg to 27 barg, while the Deethanizer
Overhead gas is warmed up from 1C to 28C with a pressure drop from 25 to 24.5 barg.

Debutanizer Bottom Cooler 51-320-HA-005 is of the shell-and-tube type, with the NGL
flowing through the tube side and the cooling water flowing through the shell tube side. The
inlet temperature of NGL is 190C and the pressure 21 barg, while outlet temperature will be
40C and the pressure 19 barg. For the cooling water the temperatures are 32/44C .

Figure 3.4 Common Shell and Tube Heat Exchanger

Deethanizer Reboiler 51-320-HA-001 is a shell-and-tube type Kettle reboiler. The internal
diameter is 1.27 m, the length is 6.8 m . The reboiler service is to supply the additional heat to
deethanizer by means of the LP steam condensation. The hydrocarbon flowing through the
shell (76590 kg/h), is heated up from 118C to 137C, at a pressure of about 25.3 barg, while
the LP steam, flowing through the tubes (6500kg/h), is condensed and cooled down from
170C to 150C.

Debutanizer Reboiler 51-320-HA-002 is a shell-and-tube type Kettle reboiler. The internal
diameter is 0.9 m, the length is 4.8 m . The reboiler service is to supply the additional heat to
debutanizer by means of the MP steam condensation. The hydrocarbon flowing through the
shell (85758 kg/h), is heated up from 182C to 190C, at a pressure of about 21.3 barg, while
the MP steam, flowing through the tubes (7477 kg/h), is condensed and cooled down from
235C
to165
0
C .

Debutanizer Reflux Pumps 51-320-PA-001A/B are horizontal centrifugal type, electric
motor driven, with a design capacity of 110 m
3
/h each and a delivery pressure of barg. They
operate at a temperature of 48C.

93

Figure 3.5 Kettle Type Reboiler

Figure3.6 A typical arrangement for using a Kettle-type reboiler

The location of each item is visible in Figure 3. 7

3.2.2 - Detailed Process Description

As reported previously the header collecting liquid streams within Unit 340, (op. parameters
32C and 27.5 barg), is split into two streams feeding the above mentioned Trains 1 and 2.
The splitting is controlled by the level controller cascaded on the two flow controllers (one
for each branch).
The 8" line directed to train 1, provided with isolation and drain facilities, is fed to the top tray
of the Deethanizer 51-320-VE-001 .
It is important to control the temperature and the pressure of the column.
The Deethanizer operates at 25 barg. The column pressure controller, operates a control valve
94

located on the gas line to the Fuel Gas network (downstream the LPG Sub-cooler 51-320-HA-
004). The pressure blow-off valve operated by another pressure controller may discharge to
HP Flare for start-up purpose and during upset conditions.
The overhead vapour (1C and 25 barg), is sent to the LPG Sub-cooler 51-320-HA-004,
where it is heated up to 28C by the LPG from Debutanizer 51-320-VE-002.
The flow of Deethanizer overhead gas through tube bundle of the LPG Sub-cooler 51-320-
HA-004 is controlled modulating the temperature of the LPG flowing through the shell side.
The LPG temperature monitoring is performed by a temperature controller driving in split
range two control valves (the first one being placed on the by-pass of the exchanger.
As previously said, the deethanizing process requires external heat that is supplied by the
Deethanizer Reboiler 51-320-HA-001 heated with low steam and returns pressure steam.
The stream of the Deethanizer product, at 118C, is withdrawn from the chimney tray (by
means of a 10" line) and flows to the Reboiler, gets partly vaporized absorbing heat from the
steam and returns to the Deethanizer through a 12" line at 137C. The flow of LP Steam is
controlled by the controller set by a tray temperature controller.
The remainder flows back to the bottom of the Deethanizer at the same temperature.
The Deethanizer bottom product flows to the Debutanizer 51-320-VE-002, at 136C and
25.3 barg, through a 8" line, under flow control.
The Debutanizer 51-320-VE-002 is a fractionating column operating at 1/140C
(top/bottom) and 25 barg. The Debutanizer bottom product, at 191C and 21 barg, flows,
through a line under level control to the Debutanizer Bottom Cooler 51-320-HA-005, where
it is cooled (by cooling water) down to 40C. The cooled product is delivered to storage
facilities or to off- spec tank in case of bad quality. On the line of NGL to storage are installed
isolation facilities. The analyzer 51-320-AT-002A/B provides condensate composition/RVP
monitoring at cooler outlet. Pressure and temperature indicators and transmitters are installed
at the battery limit.
The debutanizing process requires also external heat, in this case supplied in the Debutanizer
Reboiler 51-320-HA-002 by medium pressure steam. A stream of the Debutanizer product,
withdrawn from the chimney tray at 182C and 21 barg, by means of a 10" line flows to the
Reboiler, gets vaporized (partially) absorbing heat from the steam and returns, at 190C, to
the Debutanizer by means of a 12" line.
The remainder flows back to the bottom of the Debutanizer through a 6" line. The MP Steam
flow is controlled by the flow controller, reset by tray temperature controller.

The Debutanizer overhead vapour, at 97C and 21 barg, flows to the Debutanizer Condenser
51-320-HA-003, and further on to the Debutanizer Reflux Drum 51-320-VA-001. The 10"
overhead line from the debutanizer is provided with temperature and pressure instrumentation
and depressurization facilities. The Debutanizer Condenser 51-320-HA-003 operates at
97/38C (inlet/outlet) and 21 barg, while the Debutanizer Reflux Drum 51-320-VA-001
operates at 38C and 20.8 barg.
The Debutanizer Condenser 51-320-HA-003 is a shell-and-tube exchanger, with the LPG
vapour flowing through the shell and the cooling water flowing through the tubes.
The pressure controller on the Debutanizer located at the centre of the column, operates on the
hot 4" bypass of the Debutanizer Condenser acting on the control valve. The condenser
operates partially flooded. If from debutanizer is flowing a vapour amount larger than
condensing capacity, the pressure in the column will increase and the valve on hot by-pass
tends to close. This increases the differential pressure between inlet of condenser and reflux
drum thus pushing liquid out from condenser until the increased surface available for
95

condensation balances vapour production. In case of pressure in excess, over the normal value
due to not condensable in the Reflux Drum, the pressure control valve, operated by the
pressure controller of the Reflux Drum, provides venting to the cold flare, of the excess gas.
The Debutanizer Reflux Drum 51-320-VA-001 is protected by the two pressure safety valves
discharging to the cold flare. Also discharging to the cold flare, but through a restriction
orifice, there is a blow-down valve, operated by an interlock.
The liquid from the Debutanizer Reflux Drum is pumped by the Debutanizer Reflux Pumps
51-320-PA-001A/B and split into two streams:

Debutanizer Reflux
LPG product

The Debutanizer Reflux Pumps 51-320-PA-001A/B are horizontal centrifugal type, electric
motor driven, with a design capacity of 110 m3/h each.
Debutanizer Reflux flow is controlled by means of a flow control valve, 51-320-FV-009,
when flowing to the head of the column. LPG is directed, under flow control to the LPG Sub-
cooler 51-320-HA-004 where it is cooled-down by the Deethanizer Overhead gas as
previously explained.
The LPG Sub-cooler 51-320-HA-004 is a shell-and-tube exchanger, with the deethanizer
overhead gas flowing through the tubes and the LPG flowing through the shell.
LPG is cooled down from 38C to 26C, with a pressure drop from 31 barg to 27 barg, while
the Deethanizer Overhead gas is warmed up from 1C to 28C with a pressure drop from 25
to 24.5 barg.
The LPG Sub-cooler 51-320-HA-004 outlet temperature controller operates on the control
valve placed on the sub-cooler by-pass (Deethanizer overhead gas side).
The sub-cooled LPG is mixed with the corresponding stream from Train 2. The combined
LPG stream finally is directed to Wafa Coastal Plant (Mellitah) for splitting into
propane/butane products.

96

Figure 3.7 - NGL Fractionation-unit 320 Process flow diagram

97

3.2.3 - Process Variables

In order to produce products that meet the required specifications the following variables must
be controlled:

The reflux rate.

The reboiler heat input.

The fractionator pressure.

The feed rate.

The feed temperature.

The Deethanizer bottom operating pressure is automatically controlled and kept at 25.3 bar;
this pressure combined with Tray 17 temperature automatically controlled meet the required
deethanized NGL condensate that is fed to debutanizer.

The Debutanizer operating pressure is automatically controlled and kept at 21.3 bar; this
pressure combined with the Tray 29 temperature automatically controlled meet the required
debutanized NGL that is sent to storage.

a) The main process variable on deethanizer section are:

Temperature of Tray 17 set at 52C by 51-320-TIC-003(18) in cascade with 51-320-FIC-
003 that controls the steam flow to Deethanizer Reboiler 51-320-HA-001. An increase of the
said temperature without changing other parameters will increase the vapour rate through the
Tray and will transfer heavy component from bottom to top of column. This results in
diminishing the deethanized bottom flow and in more off-gas; a contrary effect is obtained
lowering this temperature; light component is supposed to remain into the bottom liquid of
deethanizer meaning the product is not deethanized.

Deethanizer bottom pressure is set at 25.3 barg by 51-320-PIC-005(19) operating the
pressure valve on deethanizer vapour line. Increasing this pressure light component remain in
the bottom liquid of deethanizer and as result the bottom product will increase and it is not
deethanizer; on contrary lower pressure allows that some heavy components are transferred to
top of deethanizer, in this case the off gas will increase and it is out of specification due to
heavy component.

98

b) The main process variable on debutanizer section are:

Temperature of Tray 29 controlled at 148C by 51-320-TIC-021 in cascade with 51-320-
FIC-008 that operate the steam flow to Debutanizer Reboiler 51-320-HA-002. An increase of
this temperature without changing other parameters, increase the vapour rate through the Tray
and transfer heavy component from bottom to top of column the principal effect is on
debutanizer bottom flow that decrease and the overhead product (LPG) flow that will increase
and out of specification due to heavy components; the contrary is obtained lowering this
temperature; light component remain in the bottom liquid of debutanizer and as result the
product is not debutanized.
Pressure on bottom of debutanizer is controlled at 21.3 barg by 51-320-PIC-013 operating
the hot by-pass valve of debutanizer condenser. Increasing this pressure together with the
pressure of debutanizer overhead accumulator allows that light component can remain in the
bottom liquid of debutanizer and as result the bottom product will increase and it is not
debutanized; on contrary lowering pressures allows that some heavy components are
transferred to top of debutanizer, in this case the LPG product will increase and it is out of
specification due to heavy component.
Conclusion: During routine inspection keep an eye on the instrumentation/parameters
reported in Table 3.1. Table 3.2. reports the analysis of NGL that may be very important for
the operator of this unit.
.

Table 3.1 Main local indicators

Variable

Equipment/service

Instrument tag

Range
Normal
op.value/Set
point
Level 51-320-VE-001 51-320-LG-301 0-100%(380-
6280 mm)
46%
(3100 mm)
Temperature 51-320-VE-001 51-320-TI-321 - 30 60
0
C 0.0
0
C
Temperature 51-320-VE-001 51-320-TI-319 0 60
0
C 39
0
C
Pressure FG to FG Unit 51-320-PI-305 0 40 barg 26 barg
Pressure FG to FG Unit 51-320-PI-305 0 40 barg 25 barg
Pressure LPG from 51-320-PA-
001A/B

51-320-PI-306

0 60 barg

30.6 barg
Pressure LPG to 41/42-320-
XX001

51-320-PI-316

0 40 barg

27 barg
Table 3.2 NGL Condensate Analysis

C4 ASTM D 2597 weekly

99

3.2.4 - Control System

Deethanizer Temperature and Pressure Control

Reference P&ID: G-65-D-O-103201 UNIT 51-320 NGL FRACTIONATION
DEETHANIZER

Flow of LP Steam is controlled by the controller 51-320-FIC-003, reset by sensitive tray
temperature controller 51-320-TIC-003 and controlled by the interlock 51-320-I5001, driving
the control valve 51-320-FV-003 placed on the steam condensate outlet. The deethanizer
pressure is controlled by 51-320-PIC-005. The Deethanizer bottom product flows to the
Debutanizer 51-320-VE-002, at 136C and 25.3 barg, through a 8" line under flow control
operated by 51-320-FIC-004, cascaded by the Deethanizer bottom level controller 51-320-
LIC-001.

Figure 3.8 Deethanizer Control

Debuthanizer Temperature and Pressure Control

Reference P&ID: G-65-D-O-103203 Unit 51-320 NGL FRACTIONATION
DEBUTHANIZER

Flow of MP Steam is controlled by the controller 51-320-FIC-008, reset by sensitive tray
temperature controller 51-320-TIC-021 and controlled by the interlock 51-320-I5001, driving
the control valve 51-320-FV-008 placed on the steam condensate outlet.

100

Figure 3.9 Debuthanizer Control

3.3 - Start up of NGL fractionation

Check the level increase on bottom of deethanizer; gradually open 51-
320-FV-003 located on SC condensate from deethanizer reboiler

Check the temperature and pressure increase; the gas will be flared by
operation of 51-320-PIC-002.

When the temperature on tray 16 reaches 100C put 51-320-TIC-003 in
cascade with 51-320-FIC-003, in auto mode.

When the level on bottom of deethanizer is about 50%, NGL is fed to
debutanizer by operation of LIC.

When the operating conditions of deethanizer are steady, then increase the
set point of 51-320-PIC-002 so that the gas is not flared and sent to fuel
gas system by operation of 51-320-PIC-005.

Check the level increase on bottom of debutanizer and as soon as level is
detected, gradually open 51-320-FV-008 condensate from Debutanizer
Reboiler 51-320-HA-002

Check the temperature and pressure increase; check the operation of hot
by-pass of 51-320-HA-003 and operation of 51-320-PIC-017; excess of
gas will be flared by this controller.

Check the debutanizer temperature and when the temperature on tray 29
101

reaches 160C put 51-320-TIC-021 in cascade with 51-320-FIC-008 in
auto mode.

Check the pressure on bottom of debutanizer; put 51-320-PIC-013 (hot
by-pass in auto at 21 bar.

Check the level increase on Debutanizer Reflux Drum 51-320-VA-001
and as soon as level is detected, start Debutanizer Reflux Pump 51-320-
PA-001 and operating 51-320-FIC-009 reflux the liquid to top try of
debutanizer.

When the level on bottom of debutanizer is near 50%, the product is sent
to send off spec NGL to 50-210-VA-004 Degassing Boot.

When the level on Debutanizer Reflux Drum 51-320-VA-001 is near
50%, LPG is sent to fed unit 41.

Adjust the operating conditions of debutanizer to meet the NGL
condensate on spec then open 51-320-MOV-004 to send on spec NGL
to storage and close 51-320-MOV-002 off spec NGL to 50-210-VA-
004 Degassing Boot.

3.4 - Shut Down Procedure

A reported previously two parallel trains (51 and 52), each designed for 66.6% of total
capacity, are foreseen for NGL Fractionation.
If the train is scheduled to remain shut for a long period, it shall be better to also shut down
one train of the upstream Unit 340 Gas Dehydration. In any case, the feed rate to the running
train has to be increased at 100% capacity of the train, to match the production capacity of the
two running trains of Unit 340.
If the shut down is of short duration, keep the three trains of Unit 340 running at lower
capacity, say 16.6% of total plant capacity, corresponding to 50% capacity of each train.
Proceed as follows:

1) Start to reduce slowly the NGL condensate feed to the deethanizer
column down to 50%, by reducing manually FIC303/304 on 340VA001
outlet line; in the transitory phase, the excess NGL condensate in
340VA001 may be drained to CB in order to maintain the level in
340VA001
102

2) Gradually shut the steam to the deethanizer reboiler HA001 and to the
debutanizer reboiler HA002 by acting on the relevant steam flow rate
controllers.

3) Shut the relevant steam condensate outlet on off valves SDV010 and
SDV011.

4) Shut the NGL condensate feed to the deethanizer column on valves
SDV001/A and SDV001/B

5) Stop the debutanizer reflux pumps PA001A/B and shut the discharge
valve

6) Shut the LPG flow control valve FV006 to Wafa Coastal Unit C3/C4
splitter

7) Keep running the circulation of cooling water in the debutanizer
condenser HA003 till the column is cooled at ambient temperature.

3.5 Common Troubleshooting

There are four problems associated with fractionators and each must be treated so as to solve
the problem and not the symptom.

There is too much bottom product in the top product.

There is too much top product in the bottom product.

Both products are bad.

The tower is carrying over.

When the top product contains too much bottom product, the top temperature will go up
because the bottom product has a higher boiling temperature than the top product.
When the bottom product contains too much top product, the bottom temperature will drop
because the top product has a lower boiling temperature.
Before any change is made to a fractionator that is producing off specification product, the
other product must also be checked. If there is too much bottom product in the overhead
103

product, check the bottom product also to see what is happening in the tower.

Temperature Change Cause of change Effect of Purity
Top goes up Temperature More bottom product in top
product
Top product less pure
Top goes down Temperature Less bottom product in top
product
Top product purer
Bottom goes down Temperature Less top product in bottom
product
Bottom product purer
Bottom goes down Temperature More top product in bottom
product
Bottom product less
purer

Table 3.3 - Product purity and change in temperature

The following checks should be made:

Check all instruments, thermometers, pressure gauges, and flow meters to
ensure they are giving accurate readings.

Check the feed temperature, if it is not within a few degrees of the
temperature of the feed tray, adjust the feed temperature.

Ensure that the pressure controller is maintaining the tower pressure
within 2% of the set point. If not, have the instrument adjusted.

Check that the reflux ratio controller is maintaining the desired reflux
ratio on units so equipped.

Check both products to confirm that one or both products are off
specification.

Ensure that the tower is not being fed in slugs. A level control on another
fractionator or the fractionator feed tank may be cycling and causing
the problem. Have the defective level controller adjusted or repaired.

Observe the flow of heating fluid to the reboiler. If the flow is cycling
have the controller adjusted or repaired.

Check the overhead condenser. If it is water cooled there should be a
difference in water temperature through the exchanger. A high pressure
drop on the water side indicates fouling of the tubes and the exchanger
may have to be cleaned. Check the fan speed and blade pitch, and for
dirt or an obstruction if it is an aerial cooler.

Check the reflux pump, if it is cavitating there may be insufficient reflux

104

Water in a fractionator. In some operations it is possible for slugs of water to enter the
fractionator feed. It is often the case that the bottom temperature of the tower is above the
boiling point of water so it will not flow out of the tower with the bottom product. The top
temperature may be below the condensing temperature of water so the water is trapped on a
few trays near the centre of the tower which is the same as removing the trays from service.
The symptoms of water in the tower are that both products are off specification and no
improvement can be made by changing the reflux rate or heat input to the reboiler. Some
towers are equipped with a dewatering system so the water can be drained but if the
dewatering facilities are not installed, it may be necessary to shut down and drain the tower.
When problems exist with a fractionator, make one adjustment at a time. Make the
adjustment small and allow time for it to produce the desired results. A good fractionator
operator must have patience and not expect immediate results.

Fractionator Instrumentation. The pressures and temperatures in a fractionator must be
controlled within very close limits. The instrumentation must therefore be sensitive enough,
and maintained in a condition to meet the exacting requirements.

Figure 3.10 - Unit 320
Troubleshooting

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