GAS DEHYDRATION

10.0

Troubleshooting Check-list

Troubleshooting Gas Dehydration Operational Problems

The most obvious indication of a glycol dehydrator malfunction is high water content
(dewpoint) of the outgoing gas stream.
In the majority of cases this is brought about by insufficient glycol circulation or by
insufficient reconcentration of the glycol. These two factors can be caused by a
variety of contributing causes as indicated below.
In addition to mechanical causes, high dewpoints may be found due to existing
operating conditions for which the equipment was not designed for. These
conditions can sometimes be at least partially alleviated by both changes in process
condition and mechanical operation.

FAULT
1. High Dewpoints

POSSIBLE CAUSES
l

Insufficient Glycol Circulation

CORRECTIVE ACTIONS
l

Check Glycol Circulation pump

for proper operation, may be
stroking but not pumping. Call
Maintenance to check the valves
to see if they are seating
properly.

Check pump suction and

discharge valves to see if they
are in proper position.

Call Maintenance to check pump

suction strainer for blockage.

OR

OR

OR

OR
l

Check pumping system for air or

gas lock.
OR

Insufficient Reconcentration

Check Surge Drum glycol level is

sufficiently high.

Verify reboiler temperature with a

test thermometer and ensure set
at maximum allowable operating
setpoint (380/400 F for TEG).
OR

Check glycol to glycol heat

exchanger for leakage of wet
(rich) glycol into the dry (lean)
glycol.
OR

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Check Stripping or sweep gas, to

be sure there is a positive flow of
gas and set at specified rate.

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GAS DEHYDRATION

Troubleshooting Check-list

FAULT

POSSIBLE CAUSES

CORRECTIVE ACTIONS

Contd
1. High Dewpoints

Insufficient Reconcentration

Check Reboiler for high

pressure.
a) Ensure steam is not
backflowing into the Surge
Tank from the reboiler. If so,
call Maintenance to check Still
Column packing for possible
blockage and if needed to
clean.

OR

b) Ensure Surge Tank breather

pipe is not blocked and there
is a positive flow of steam.
l

Operating Conditions Different

from Design.

Check the absorber pressure,

increase if required. This should
be done in gradual steps.
OR

OR

Check gas temperature. If high

reduce.
OR

Low Gas Flow Rates

Check glycol circulation rate.

Increase if possible.

Call Maintenance to blank off a

portion of the bubble caps.
OR

Add external cooling to the dry

glycol and increase circulation.

Change out absorber to smaller

one designed for the lower rate.

OR

OR
l

Reduce glycol circulation to

optimum rate.
Note: When a glycol/gas cooler
is used and a glycol circulation
rate is maintained unnecessarily
high, a higher contact
temperature may result with
possible increase of the
dewpoint of the outlet gas.

Production & Export Admin. Division

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GAS DEHYDRATION

Troubleshooting Check-list

FAULT
2. Glycol Losses

POSSIBLE CAUSES
l

Foaming

CORRECTIVE ACTIONS
l

Glycol foaming problems

usually appear in two types,
Chemical foaming or
Mechanical foaming.

A. Loss of
Glycol from
Absorber

Chemical foaming is often

caused by contamination of
glycol with salt, hydrocarbons,
dust, mud or corrosion inhibitor.
This can be cured by removing
source of contamination. If
glycol is badly contaminated,
recharge the system with new
glycol and add anti-foam
chemical.
OR

OR

Excessive Velocity in Absorber

Mechanical foaming is caused by

turbulence, like high gas
velocities through the absorber.
Reduce gas flowrate to prevent
this.

Decrease gas flowrate through

the Absorber.
OR

Note: The gas velocity will

increase when the absorber
pressure is lowered below the
design pressure. This results to
increased pressure drop and
increased of the glycol losses.

OR

Trays Plugged with Mud,

Sludge, etc.

Plugged trays and/or

downcomers usually results in
inability of liquid to flow down the
tower with any appreciable gas
flow. Call Maintenance to check.
If the tower is coated with
gummy deposits, it then needs
manual cleaning and/or chemical
cleaning.

Higher pressure drops in

absorber will tear up the demister
and sharply increase glycol
losses. Higher pressure drop is
caused by either high gas
flowrate, low pressure or plugged
trays in the absorber. High gas
pressure drop can be prevented
by reducing the flowrate through
the Absorber and low pressure
condition by increasing the
Absorber back pressure. For
plugged trays in the Absorber call
Maintenance to effect cleaning.

OR

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A Damaged Absorber Demister

Pad

Increase pressure on absorber, if

low.

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GAS DEHYDRATION

Troubleshooting Check-list

FAULT

POSSIBLE CAUSES

CORRECTIVE ACTIONS

Contd
A. Loss of Glycol
from Absorber

B. Loss of
Glycol out of
Stripping
Column

Lean Glycol Temperature

Low/High

The lean glycol temperature

should enter the absorber about
10-15 F hotter than the
incoming wet gas. If the lean
glycol enters at higher
temperatures, the glycol losses
by vaporization sharply
increases. And if the lean glycol
entering the absorber is colder
than the incoming process gas,
the gas will tend to cool and this
can create hydrocarbon
condensation and resultant
foaming.

Stripping Gas Flowrate

Abnormal

Be sure the stripping or sweep

gas valve is open and there is a
positive flow at a specified rate.
High stripping gas rate can flood
the Still Column and blow the
glycol out from the top.

Be sure the surge tank is vented

to atmosphere and there is
positive flow.

Determine if free water is

entering the Absorber with the
gas stream, this may overload
the reconcentrator (reboiler).
Check the operating conditions
at the Absorber end ie. incoming
gas temperature, inlet glycol
temperature or signs of free
water presence.

Call Maintenance to clean or

replace the Still Column packing,
if fouled. The packing in the Still
Column can easily get plugged if
glycol is not clean and can
possibly prevent the glycol to
flow through to the Reboiler.

Adjust the temperature of the

condenser to 212-215 F to
prevent glycol vaporization
losses. The Still Column has a
reflux coil with automatic
temperature bypass control valve
(TCV). Adjustment can be made
using this valve.

OR

High Pressure in Surge Tank

OR

Free Water or Hydrocarbon

Liquids Entering Absorber

OR

Still Column packing is plugged.

OR
l

Production & Export Admin. Division

High Temperature at the Still

Column

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GAS DEHYDRATION

Troubleshooting Check-list

FAULT

POSSIBLE CAUSES

CORRECTIVE ACTIONS

Contd
B. Loss of Glycol
out of
Stripping
Column

Still Column Temperature Low

Note: The condensed water if

not prevented may fall back into
the column packing and washed
back into the reboiler. In the
reboiler this water may vaporize
and overpressure the reboiler
and forces the glycol blown out
through the top of the Still
Column.

OR

Liquid Hydrocarbons Carryover

into Reboiler

When liquid hydrocarbons get

into the reboiler and come into
contact with the hot glycol will
normally flash out and vent
through the Still Column carrying
large quantities of glycol with
them. Check for the source of
liquid hydrocarbons carryover
and rectify.

Leaks at the glycol circulation

pumps can contribute to serious
glycol losses. Call Maintenance
to check for possible worn or
clogged check valves, damaged
O-rings or choked strainers.
Frequent maintenance of
strainers and filters is essential to
good pump operation. Also
ensure the designed operating
pressure and temperature of the
pump is not exceeded.

Some excessive glycol losses

are sometimes caused by human
or operator mistakes. Ensure to
add clean and proper glycol from
tight sealed drums never re-use
contaminated or decomposed
glycol. Do not add excessive
defoamers and pH stabilizers
into the glycol system, this can
contribute to increased glycol
losses.

The downcomer could get

plugged and prevent the glycol to
enter the Surge Drum. This may
result to overfilling the reboiler
and glycol blow out may result
through the top of the Still
Column.

OR

Mechanical Losses (ie. through

pump glands, pipe joints, leak
flanges, etc).

OR

Human Errors

OR

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Downcomer between Reboiler

and Surge Drum is plugged

Adjust the condenser

temperature to 212-215 F to
prevent the water vapour leaving
the top of the Still Column to be
recondensed.

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GAS DEHYDRATION

Troubleshooting Check-list

FAULT
3. Glycol
Decomposed
or Degraded

POSSIBLE CAUSES
l

Reboiler Temperature Too High

CORRECTIVE ACTIONS
l

Check the reboiler temperature

and lower to normal operating
range. Change out glycol if
necessary.

Check and ensure glycol

atmospheric process vessels are
always gas blanketed (where
applicable) to prevent oxidation.

OR
l

Glycol Oxidized and Corrosive

Note: The glycol will oxidize
readily in presence of air and
form corrosive organic acids.
Operating under these
conditions and at higher
regeneration temperature may
accelerate corrosion process in
the equipment. Low pH value
of the glycol may indicate that
corrosion is taking place (pH is

OR
l

Replace glycol if heavily

oxidized.
OR

a measure of the acid content of

the glycol solution) .

Add MEA chemical at

recommended dosage to raise
the pH of the glycol.
OR

4. Glycol
Contaminated

Poor filtration in glycol filters

(cartridges/charcoal filters).

Take glycol samples for chemical

analysis to determine cause of
corrosiveness, could be: presence of salts
- presence of H2S

Change filter elements when the

pressure drop (Delta P) exceeds
1.5 Bar (20-21 Psid).
AND/OR

Take glycol samples from

various points for analysis (color
check, chromatographic
composition, turbidity, etc) to
determine the impurities and
sources. Implement remedial
actions as recommended by your
superiors.
Note: Could be paraffin
problem. Paraffin is usually
carried in the gas stream in the
vapour phase. If the paraffin
gets into the glycol system that
operates at high temperatures, it
solidifies (paraffin solidifies at
150 F). When paraffin is
solidified, it contaminates the
glycol, plugs in-line filters and
other process equipment.

Production & Export Admin. Division

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GAS DEHYDRATION

Troubleshooting Check-list

HOW CAN TELL THE GLYCOL NEEDS

CHANGING
1. When the glycol is densely discolored with dark particles. This is a sign of
thermally decomposed glycol or filtration problem.

2. When face with frequent Filters blockage (Delta P as high as 20 21 Psid).

3. When the glycol is heavily saturated or entrained with hydrocarbon liquids

and beyond regeneration capability. Symptoms excessive foaming in the
Absorber.

4. When Lean and Rich TEG Water content is equal during circulation sign
of decomposed glycol or insufficient reconcentration.

5. When chemical analysis of glycol for Salt content shows Salt content in the
region of one weight percent in glycol. High salt content in the glycol
generally restricts heat transfer, cause degradation of glycol and frequent
firetube failures.

6. When Lab Test indicates Glycol is laden with excessive corrosive acids due
to excessive Oxygen and H2S presence in process gas stream. Oxygen
oxidizes the glycol and forms corrosive acids while H2S lowers the glycol pH
value and turns the glycol black.

7. When glycol remains unused in a Reboiler/Surge drum for a period of over

six months and exposed to air/oxygen environment unprotected with gas or
nitrogen blanketing. Glycol oxidizes in the presence of air and forms
corrosive organic acids.

Production & Export Admin. Division

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