American Petroleum Institute Programs In Learning Operating Techniques Glycol Dehydration 1585WBProgram developed for API Production Department by: Author: API Content Specialist: Field validation provided through the cooperation of: Howell Training Company 13831 Northwest Freeway, Suite 520 Houston, Texas 77040-5215 John M. Wagner Norman Balliviero Chevron U.S.A., Inc. Arco Oil and Gas Company Harkins and Company Marathon Oil Company Operators inc. Philips Petroleum Company Sun Exploration and Production Company Texaco inc Union Pacific Resources Company Special Acknowledgement Preparation guidance and review of the manual was accomplished by the API Committee on Programed Learning under the auspices of the AP! Executive Committee on Training and Development, Dan B. Johnson, Tenneco Oil Exploration and Production Company, Chairman. Members of the Programed Learning Committee were: John Mitchell, Conoco Inc., Chairmai Jack R. Blann, Exon Production Research Co.; L. R. Kennedy, Shell Oil Company; Kennith Knoll, Standard Oil Production Company; George A. Heil, Mobil Exploration and Production U.S.A.; 80b Maglitto, Sun Exploration and Production Company: Darryl L. Sullivan, Arco Oil and Gas Company; Patty S. Thomas, Oxy/Cities Service Oil and Gas Corporation; and W. G. White, Chevron U.S.A. LD pros © Howell Training Company 1987 Reprinted March 1986 This program may not be reproduced in whole or in part without the express permission of Howell Training Company. All translation rights are reserved by the publisher.GLYCOL DEHYDRATION This program provides an overview of the glycol dehydration process ‘and the operating techniques for efficient drying of natural gas. Specific topics covered include dehydration methods, dew point calculations, equipment and process flow, adjusting glycol circulation rates, maintaining glycol purity, troubleshooting, and start-up and shutdown procedures. NOTICE: Some glycol dehydration units have the potential to emit benzene and other aromatics from the Teboiler stack. Some units in some areas may require ‘emission controls. Consult your supervisor.INSTRUCTIONS This is a programed learning course. Programed learning gives information in a series of steps called frames. Each frame gives some information and asks you to make use of it. Here is how it works. First, cover the response column at the right with @ mask. Read this frame and use the information it gives to fill in the blank. ‘A micrometer is an instrument designed to measure in thousandths of an inch. A micrometer is a good tool for meesuring very differences in size small Move the mask down to uncover the word at the right of the frame. if you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. ‘The drawing of @ micrometer provides information thet will help you fill in the next blanks. OBJECT TO BE MEASURED ‘Seven major parts are shown in the drawing, but only the _____and the contact anvil; spindle the object to be measured.The next frame calls for 2 choice. Circle or underline the appropriate word. Of the two parts that contact the object, only the (anvil / spindle ) moves. A program is a series of frames that work like the ones you have just done. Read the frame. Use the information to fill in the blanks or make a choice. Move the mask down and check the response column. Go on to the next frame. Remember to cover the response column with @ mask before you begin each page. Notice that the left-hand pages from here on are printed upside down, The program is designed so that you will go through all the fight-hand pages first, and then turn the book upside dwn and go through the other pages. Before starting the program, remove the Exhibit Booklet from the center of this workbook and lay it aside. Refer to the exhibits as they are mentioned in the self-teaching frames.GLYCOL DEHYDRATION Introduction 1. Natural gas as it comes from the ground consists of a number of hydrocarbon gases. NATURAL GAS Ethane ‘These gases have desirable properties which allow us to them as products. 2, Most of the propane, butane, and pentane is removed from the natural gas before it is used. These components are ‘more valuable in other products like gasoline and petrochemical feedstocks. ‘So the natural gas that pipeline companies distribute contains mostly. and 3. In addition to hydrocarbons, raw natural gas usually contains ‘some undesirable components. OTHER COMPONENTS IN NATURAL GAS Water Vapor Hydrogen Sulfide ‘Carbon Dioxide Well Treating Chemicals Liquid Hydrocarbons ‘These contaminants or impurities reduce the quality and marketability of the natural gas, so they must be to contract specifications before the gas is sold. 4. Water vapor is the most common impurity found in natural gas and can cause several different problems, When condensed, it can form ice-lke crystals called hydrates that build up inside gas transmission lines and can eventually them. use, or sell methane; ethane removed, or reduced block, or plug5. Or, the water may combine with acid gases like carbon dioxide or hydrogen sulfide to form a liquid that (is / is not) very corrosive to metal pipes. is 6. At high flow velocities, water mixed with solids can erode pipes, fittings, and vaives. This erosion of metal can eventually lead to equipment failure, or breakdown 7. Finally, the compressors which move natural gas are not designed to handle any liquid. Therefore, any free water that is present in the gas must be removed with separation ‘equipment. Condensed water in the gas can damage compressors and ( decreases / increases ) pipeline efficiencies. decreases Water Vapor Content in Natural Gas 8. The amount of water vapor that natural gas can hold depends on the temperature and pressure of the ges. AT ATMOSPHERIC PRESSURE 14.7 PSIA ‘Pounds of Water per Gas Temperature. Million ‘Cubic Feet of Gas 10°F 120 60 700 According to this chart, natural gas can hold much more water vapor at ( 10°F / 60°F ). 60°F 8. When the temperature is reduced, the amount of water vapor in the gas ( decreases / increases ). decreases 10. This is because, at lower temperatures, some of the water vapor in the natural gas condenses to liquid, or water 11. So one way to remove water vapor from natural gas is simply to ( cool / heat ) it. cool 12. Natural gas can hold more water vapor at ( low / high ) high temperatures.13 14 15. 16. 7. 18, 19. Now consider how pressure affects the ability of natural gas to hold water vapor. NATURAL GAS AT 60°F igtural ‘Pounds of Water per Gas Pressure Millon Cubic Feet of Gas 500 PSIA 30 100 PSIA At 500 PSIA, natural gas holds ( less / more ) water vapor than at 100 PSIA. ‘The higher the pressure of the natural gas, the water vapor it can hold. Natural gas can hold more water vapor at ( lower / higher ) pressures. Water vapor will condense out of natural gas when the pressure is . ‘The amount of water vapor in natural gas depends on both the —___ and of the gas. Natural gas can hold more water vapor at ( low / high ) pressures and (low / high ) temperatures. You can reduce the amount of water vapor in natural gas by the temperature or by the pressure. Water Vapor Removal 20. 21. 22. 23. When something loses water or moisture, it is said to be dehydrated You become dehydrated when your body loses an excessive amount of - Removing water vapor from gas is called gas Gas dehydration means removing from gas. vepor ‘There are several ways to dehydrate gas. You have learned that we can remove water vapor by simply reducing the ( temperature / pressure ) of the gas. less lower increased Pressure; temperature low high reducing increasing water, or fluid dehydration water natural temperature24. 28. 27. 28. 30. Dry materials called desiccants can also be used to absorb water vapor from gas. You've probably seen small packets of these materials in shipping containers where they're used to absorb Water vapor can aiso be removed with chemicals like calcium chloride, which is a salt Calcium chloride absorbs water vapor from gas and forms @ liquid micure of Another way to remove water vapor from natural gas is with a liquid desiccant called glycol. Glycol has a natural affinity for water which means it readily absorbs water vapor, forming a liquid solution of and An advantage of glycol dehydration is that after the water is absorbed it can be separated from the glycol by heating the mixture. The boiling point of glycol is above 400°F, while water boils at 22°F, ‘So when we heat a water-giycol mixture to above 212°F but below 400°F, the water sway leaving the glycol. ‘The dry or lean glycol can then be recycled and used to absord more vapor. Glycol that is essentially free of water is said to be (lean / rich ). Giycol that has absorbed water vapor from natural gas is said to be There are several types of glycol on the market today. The most widely used glycol for gas dehycration is triethylene glycol. MAX, ALLOWABLE TEMP. Triethyiene glyco! has excellent drying characteristics and can be used more economically than any of the other glycols as long as it is not subjected to temperatures above __°F. moisture saltwater water; glyco! boils water lean rich 400GLYCOL DEHYDRATION PROCESS Inlet Scrubber Refer to Exhibit 1 32. Exhibit 1 shows the main components of a typical glycol dehydration unit. Let's follow the flow of natural gas and glycol through the unit to see how the system works. The first piece of equipment that the natural gas enters is the inlet scrubber 33. The purpose of this vessel is to remove all contaminants that are entrained or being carried by the incoming stream. gas 34, These contaminants (ike oil, saltwater, scale, and sand) contaminate the glyco! and can damage the equipment. ‘These contaminants must be removed from the gas stream ( before / after ) it is dehydrated. before 35. Here is a more detailed drawing of one type of inlet gas scrubber. DIFFERENTIAL GAS Gas ms, PRESSURE GAGE GAS. FILTER ELEMENTS Cr CONDENSATE AND WATER OUTLET INLET GAS SCRUBBER Gas containing small amounts of water, solids and condensed hydrocarbons (condensate) enter at the gas inlet 36. The gas then flows through a series of filter elements.37. While flowing through these elements, the fine particles of liquid join together or coalesce to form Particles. 38. These larger particles of liquid then fall to the bottom of the unit where the ang are removed. 38. Before the gas leaves the vessel, it passes through @ extractor. 40. The mist extractor coalesces small droplets of that were not removed by the filter elements. 41. So the gas that leaves the scrubber is essentially of all entrained contaminants. 42. The scrubber is equipped with a gage that measures the in pressure between the inlet anc outlet sides of the filter. 43. As the filter elements collect solids, it becomes more ifficult for the gas to flow through the elements and the Pressure builds up on the ( inlet / outlet ) side of the filter. 44. AS @ result, the pressure drop across the filter 45. If the filter elements remain clean, however, the pressure drop (remains the same / increase ). 48. Therefore, an increase in the differential pressure across a filter is a good indication of 47. When the differential pressure rises to a certain point, the filter elements need to be as recommended by the manufacturer. Contact Tower Refer Again to Exhibit 1 48. 43. When the natural gas leaves the scrubber, it should be basically free of all entrained contaminants. However, the gas still contains water The scrubber ( does / does not ) remove water vapor from natural gas. larger water; condensate mist liguic free, or scrubbed difference inlet increases remains the same plugging, or fouling replaced, or changed vapor does not50. 51 52. 53. ‘The scrubber only removes water and condensate that is in the ( vapor / liquid ) state. liquid Because the gas at this point is still saturated with water vapor, it is called ( wet / dry ) gas. wet From the scrubber the wet gas flows into a vessel called a tower. contact Here is 2 more detailed view of a typical contact tower. This one is equipped with an optional internal gas scrubber. ABSORBER TRAY IN | -DOWNCOMER |__ SuBBLE ‘CAPS GiycoL IN OUT, a CHIMNEY TRAY Mist EXTRACTOR Gas INLET = DIVERTER, ‘SCRUBBER PLATE ‘SECTION ‘The gas enters the ( scrubber / absorber } section of scrubber the tower.55. 56. 87. 61 62. 63. 65. 66. In the scrubber section, the gas hitsa_____ plate. ‘The civerter plate breaks up the gas flow which knocks out any last traces of in the gas. ‘The gas then passes through a mist extractor to any final tiny droplets that remain. The liquid—free gas then flows up 2 into the upper section of the tower. tray ‘The upper part of the tower is called the section. ‘The absorber section is where the gas is actually In the contact tower shown in our illustration, there are four separate . This number may vary from tower to tower. On each tray there are several caps. Lean glycol enters at the top of the tower. The glycol flows across the top tray and then down through a to the next lower tray. ‘The natural gas flows upward and makes contact with the glycol as it passes through the on each tray. ‘The alycol absorbs water vapor from the gas that it on each tray. As the glycol flows down the column, it absorbs (less / more ) water vapor and becomes (leaner / richer ). es ‘The gas, on the other hand, becomes it flows up the tower. diverter liquia remove chimney absorber dried, or dehydrated trays. bubble downcomer bubbie caps contacts more; richer drier67. Contact towers may also be designed like this. DOWNCOMER ~_| GLYCOL our With this design, the contact tower does not have a ( srubber / absorber) section. scrubber 68. Let's take a closer look at how a bubble cap promotes good contact between the natural gas and the glycol. GLYCOL, SLOTS BUBBLE CAPS As the gas flows up into the bubble cap, it is forced to its direction of flow. change69. It then passes through____in the base of the bubble cap before contacting the glycol. 70. The fiow reversal and the slots in the bubble cap cause the 988 to break into many tiny as it passes, through the glycol. 71. These tiny bubbles ( decrease / increase ) the surface area for contact between the glycol and gas. 72. The better this contact, the more efficiently the glycot will the water vapor. 73. So the purpose of the bubble caps is to increase the ——_____ for more intimate between the glycol and gas. 74. For efficient operation, the liquid level on each tray must always be above the slots in the bubble cap. WEIR DOWNCOMER: If the level is below the slots, the gas will not make with the liquid as it passes through the bubble cap. 75. The proper level on each tray is maintained by a which functions like a dam. 76. The weir holds back enough liquid so that the slots of the bubble cap are always covered by 77. The glycol which flows over the weir passes down a ——__ 10 the next lower tray. 10 slots bubbies increase absorb surface area contact contact weir Qlycol, oF liquid downcomer78. at. 82. 83. Now look at this detaied drawing of the top portion of a contact tower. Mist EXTRACTOR GLYCOL our TBF HEAT GLYCOL IN At the very top of the tower is enothier ae aassee acer This mist extractor is designed to separate { Gas our out any Fowaa Sag that is entrained with the upward flowing gas. GS. the gas flows out the top of the tower, it passes through the ( inside / outside ) pipe of an external heat ‘exchanger, Glyeol coming into the tower passes through the ———__ pie. The natural gas is considerably cooler than the incoming glycol so it absorbs from the glycol as it passes through the pipe. in our example, this exchange of heat causes the temperature of the glycol to drop from 160°F to Fomum 5, Naturally, these temperatures will vary from unit to unit. To prevent liquids from condensing out of the 92s, the Teop erature of the incoming glycol should be about 10 to 15°F warmer than the incoming gas. Zhe heat exchanger ( cools / warms ) the glyco! to within this desired range, 1" EXCHANGER mist extractor glycol, or liquid outside inside heat 115 cools85. 86. 87. 89. 90. st ‘The function of the natural gas in this heat exchanger is to. (absorb / release ) heat. ‘Some units utilize an internal heat exchanger to cool the incoming glycol. our Mist EXTRACTOR GLYCOL —<— INLET 160°F GLYCOL, | —_—— OUTLET INTERNAL Wt COOLING COL (= tee With this setup, the natural gas flows across an internal ‘The glycol fiows through the coil ( absorbing / releasing ) heat to the cooler natural gas. As a result of this heat exchange, the glycol enters the column at a temperature slightly ( below / above ) the temperature of the incoming natural gas. To prevent liquid from condensing out of the gas, the temperature of the incoming glycol should be to ___°F warmer than the incoming gas. oF After leaving the contact tower the gas can be used for fuel ‘oF gas lift operations Or, the gas can be __to a pipeline ‘company. At this point the gas should be essentially which means it has a water vapor content at or below contract specifications. 12 absorb cooling coil releasing above 10 15 sold dry, or dehydratedPacked Towers 92. Some contact towers do not utilize trays. LIQUID IN Liquip DISTRIBUTOR PACKING RESTRAINER RANDOM TOWER PACKING SHELL. Liquip REDISTRIBUTOR PACKING ‘SUPPORT| GAS IN LQUID out PACKED TOWER Instead they are filed with a____ material. packing 83. As the glycol flows downward through the packing, it comes into contact with the upward flowing gases, or vapors 1396. 96. ‘The packing material increases the surface area for contact. This type of tower provides sufficient drying as long as there is an even distribution of glycol and natural gas across all the packing, Deposits on the packing, however, can cause these flows to become or channeled. When this occurs, the contact between the glycol and gas will be ( poor / good ). Glycol Regeneration/Reconcentration Refer Again to Exhibit 1 97. 98. 99. 100. 101. 102. 103. 104, 105. 106. 107. The glycol that leaves the bottom of the contact tower is rich in . The rich glycol also contains some entrained gas and small amounts of hydrocarbons absorbed from the gas stream. ‘These impurities must be removed before the glycol can be The majority of the water is removed by the reboiler/stil This is accomplished by heating the glycol-water solution 10 @ temperature that vaporizes the water but leaves the glycol in @ (vapor / liquid ) state. Most of the other impurities are removed in a vessel called @ gas-condensate-glycol Let's follow the flow of glycol as it leaves the contact tower. First, the glycol flows through a high pressure ~type filter. In some systems this will be a Y-screen. This filter removes any ‘materials that are Present in the glycol. If these solids are not removed, they could damage the ext piece of equipment in our illustration, which is the gtycol From the pump, the rich glycol flows through a reflux coil in the column, Here the cool, rich glycol absorbs heat from hot rising vapors that are generated by the ‘The glycol then passes through a__ where it absorbs more heat from hot lean glycol leaving the reboiler. ‘Then the rich glycol enters the —__ (GCG) separator. 14 gas; glycot uneven poor water reused liquid separator sock solid pump still reboiler heat exchanger gas condensate glyco!GCG Separator 108. Here is a detail of a typical GCG separator. FUEL Gas ‘SUPPLY INLET DIVERTER, —>— | GLYCOL INLET y) CONDENSATE — ESS —— — WET. GLYCOL, GAS CONDENSATE GLYCOL SEPARATOR ‘The rich glycol entering this vessel has already been warmed by heat exchange so any entrained gas will tend to (remain in / break out of ) the glycol. 108. This gas is recovered and can be used as. , OF may be used as stripping gas. 110. Any hydrocarbons that have condensed to liquid form what we call 111. This condensate is lighter than glycol, so it floats on top and (can / cannot ) be removed as a separate stream. 112. The glycol which leaves the GOG separator is for the most part free of and Refer again to Exhibit 1 113. After leaving the GCG separator, the rich glycol passes. through a series of 114. The first sock fiter is used to remove solid 115. The charcoal in the second filter readily absorbs entrained hydrocarbons so it will remove any traces of ( condensate / solids ). 116. The final sock filter is used to catch any Particles that may have entered the glycol as it passed through the second fitter. 15 break out of fuel condensate can gas; condensate fitters Particles, or materials condensate charcoal117, The glycol then passes through another heat exchanger where it absorbs more heat from the hot, or lean glycol leaving the reboiler. 118. From here the hot, rich glyco! flows into the column, stil Still Column 118. Still columns will vary in design from unit to unit. Regardless of design, however, the purpose of every still column is to ‘separate the water/glycol solution. WATER VAPORS. TEMPERATURE CONTROLLER STILL, COLUMN TOP TEMPERATURE 212-215°F REFLUX COIL RICH GLYCOL —+E INLET PACKING REBOILER When the hot, rich glycol enters the column, it is distributed over 2 material. packing 120. Hot vapors moving upward from the reboiler make contact with the water-rich glycol which is moving «by gravity. 16 downwardEXHIBIT BOOK GLYCOL DEHYDRATION This center section contains the exhibits. It may be pulled out of the book for easy reference without upsetting the frame sequence. © 1987, Howell Training CompanyGlycol Dehydration EXHIBIT 1 Process Flows wagaNuOs LAINE ypooreys = 40 48h YOO = 4S WSONVHOXA V3H woLvuvaas Sa1vs OL 100A 19=diVENSGNOO-svo| g a M ° 4 4 3 v 4 N 9 3 UBONVHOXT 13H, SuOdvA,4 6 @ 7 0 ° -10 “50-49-90 -20 80 100 110 120 190 140 150 160 170 180 190 200 210 220 290 240 EXHIBIT 2 Water Content Chart a A : SHEGeS § of | Sesess¢ eof | feorpe tg Le NN : XEN SN Pec SEO 2 6 NNT AT acs fu 2 i |) cH io GLYCOL LEAN @LycoL Tostonace = cous Hor t FUEL FUEL HOT AS GAS LEAN GLYCOL TO PUMP ACCUMULATOR The accumulator is basically @ vessel storage that maintains a reservoir of glycol for the contact tower. 185. This vessel is designed to promote further ( cooling / heating ) of the hot, lean glyco! cooling 188. For example, the accumulator is not insulated which allows some heat 10 escape to the outside air, oF atmosphere 187. Oftentimes, there is @ heat exchange coil for heat to the rich glycol entering the transferring reboiler. 158. And there may be a heat exchange coil for heating up the fuel gas 188. All these methods of heat exchange function to ( reduce / __ increase ) the temperature of the outgoing lean ghwol, reduce 20Refer Again to Exhibit 1 160. After leaving the accumulator, the lean glycol is passed through a finel_______ filter to capture any sock impurities, 161. To complete the cycle, the lean glycol is pumped through either an internal or external heat exchanger at the contact tower. Here the lean glycol temperature is further by an exchange of heat with the reduced cooler dry gas. Gas-Glycol Pump 182. For glycol to circulate throughout the system, a source of energy is needed to move the liquid. This energy may be provided by the glycol to drive a pump 163. One of the most common pumps in glycol dehydration is the gas-glycol pump. This pump has two pistons. PILOT PISTON PUMP PISTON One is called the piston and the other pilot is the Piston. pump 2164, 165. 166. 167. Fich glycol at contact tower pressure, along with some fatural 98S, Provides the force which both pistons. Here's how the pump works. On each piston there is a device called a which moves back and forth as the piston strokes, In this position, the D-slide is covering ports 5 and 6, aitowing high pressure glycol to only flow through port When the piston strokes, the D-slide moves to the left, Now ports 4 and 6 are and high pressure glycol can only flow through port . 22 moves, or powers closed168. 169. 170. 171, 172. The D-slide shifts back and forth opening and closing ports each time a completes a stroke piston This drawing shows the D-slide on the pilot piston. D-SUIDE PILOT PISTON ‘The piston is grooved in a way that each time it strokes, it moves the along D-slide with it. ‘The pump piston works on a similar principle. POSITION RING There is an that contacts and moves actuator the D-slide. The actuator is moved by a position ring attached to the piston shaft. When the piston strokes to the right, the position ring Contacts the actuator causing the D-slide to open port 23