Glycol Dehydration Systems

Prepared for:
Dr. S. M. Anisuzzaman
Lecturer
Safety, Environmental Impact & Risk Management (KOG 11203)
Master of Engineering (Oil & Gas)
Universiti Malaysia Sabah
GAS AND GLYCOL DEHYDRATION SYSTEMS
OCTOBER 2015
Prepared by:
R B KENNEDY ENIS (MK1422074T)
Student
Master of Engineering (Oil & Gas)
Universiti Malaysia Sabah
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION
1.0
1.1
1.2
General Overview ................................................................................................................. C1-1

Petinent Legislation and Regulatory Requirements .............................................................. C1-2
1.1.1 Environmenta Quality Act, 1974 .............................................................................. C1-2
1.1.2 Occupational Safety and Health Act, 1994 ............................................................... C1-2
1.1.3 Factories and Machineries Act, 1967. ....................................................................... C1-2
Glycol Dehydration Systems ................................................................................................ C1-3
1.2.1 Types of Glycol ....................................................................................................... C1-3
1.2.2 Components of Dehydration Systems ...................................................................... C1-5
1.2.2.1 Glycol Contractor (Absorption Column) ................................................................. C1-6
1.2.2.2 Flash Drum .............................................................................................................. C1-7
1.2.2.3 Glycol Regeneration Unit ......................................................................................... C1-7
1.2.2.4 Reboiler ..................................................................................................................... C1-7
1.2.2.5 Condenser..C1-8
1.2.2.6 Reflux Drum.C1-8
CHAPTER 2 SAFETY ISSUES AND CHALLEGES

2.1
BTEX Emission .................................................................................................................... C2-9
CHAPTER 3 SAFETY AND HEALTH MANAGEMENT

3.1
3.2
3.3
Introduction ......................................................................................................................... C3-10

Risk Assessment Management Process .............................................................................. C3-10
3.2.1 Hazards Identification ............................................................................................. C3-11
3.2.2 Risk Analysis .......................................................................................................... C3-12
3.2.2.1 Consequence. .......................................................................................................... C3-12
3.2.2.2 Frequency. ............................................................................................................... C3-12
3.2.2.3 Risk Ranking........................................................................................................... C3-14
3.2.3 Risk Mitigating / Risk Control . .............................................................................. C3-15
Glycol Dehydration Systems Risk Assessment .................................................................. C3-16
3.3.1 Identified Hazards ................................................................................................... C3-16
3.3.2.1 Toxic Gasses Release to Atmosphere. .................................................................... C3-16
3.3.2.2 Contacted with TEG. .............................................................................................. C3-16
3.3.2.3 Fire or Explosion Due to Ignition of TEG. ............................................................. C3-17
3.3.2.4 TEG Spill / Leak . ................................................................................................... C3-17
CHAPTER 4 MITIGATION AND RECOMMENDATION

4.1
Mitigation and Recommendation ........................................................................................ C4-19
CHAPTER 5 CASE STUDY

5.1
TEG Fire at Gas Dehydration Unit ..................................................................................... C5-20

5.1.1 Incident Information ............................................................................................... C5-20
5.1.2 Incident Detail ......................................................................................................... C5-20
5.1.3 Incident Root Cause ................................................................................................ C5-20
5.1.3 Corrective Action and Recommendation ................................................................ C5-21
GAS AND GLYCOL DEHYDRATION SYSTEM
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CHAPTER 1
1.0
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INTRODUCTION
General Overview
This assignment title Gas and Glycol Dehydration System were prepared, presented and
submitted by the writer as a Universitys requirement for course subject Safety,
Environmental Impact & Risk Management (KOG11303) of Master of Engineering (Oil
& Gas) programme.
Firstly, safety is defined as the prevention of accidents through the use of appropriate
technologies to identify the hazards of particular activities to be carried out or equipment/
instrumentation and eliminate or control the identified hazards before an accident occurs.
Natural gases are found beneath the earth that was formed through the process of
organics cooking (organic theory) underneath the earth millions years ago and become
a valuable resources to the nations economy such as Malaysia. Productions of natural
gases are complex due to its properties that need several refining process so that it can be
legally utilised by the consumer or industry since a water content shall be indicated in the
agreement contract between supplier and buyer.
Gas dehydration system is one of the initial processes that shall be carried out before it
can be transported, refined and utilised. The system is a technology of plant that created
or inverted to separate gases from water vapour. Gas dehydration system is a system or
unit to remove water content that mixed with the natural gases and normally this
operation is carried out in the upstream stage of oil and gas.
There are several technics to remove water from gases that which by (1) absorption,
using the liquid desiccants, (2) absorption, using solid desiccants and (3) cooling/
condensation below the dew point.
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1.1
Pertinent Legislation and Regulation Requirements
1.1.1
Environmental Quality Act, 1974
C1-2 of 8
The Environmental Quality Act (EQA), 1974 [Act 127] (Incorporating latest amendment
Act A1441/2012) is an Act relating to the prevention, abatement, control of pollution
and enhancement of the environment, and for purposes connected therewith. EQA 1974
forms the main frame for the environmental legal requirements in Malaysia which cover
matters enumerated within the Federal List of the Constitution.
1.1.2
Occupational Safety and Health Act, 1994
The Occupational Safety and Health Act (OSHA), 1994 [Act 514] (Incorporating all
amendments up to 1st January 2006) is an Act to make further provisions for securing
the safety, health and welfare of persons at work, for protecting others against risks to
safety or health in connection with the activities of person at work, to establish the
National Council for Occupational Safety and Health, and for matters connected
therewith. OSHA 1994 applies throughout Malaysia to the industries as specified in the
First & Third Schedules.
The Act provides a framework for self-regulations to ensure safety and health at work lies
with those who create the risks and those who work with the risks, by emphasising on the
prevention of accidents, ill health and injury. The Act supersedes and is complementary
to any other written law relating occupational safety and health. Salient provisions of the
Act include the establishment of a Safety Policy, Safety and Health Committee,
employment of a competent safety officer, and the notification of accidents, dangerous
occurrence, occupational poisoning and occupational diseases to the Department of
Safety and Health (DOSH).
1.1.3
Factories and Machinery Act, 1967
The Factories and Machinery Act (FMA), 1967 [Act 139] (Incorporating all amendments
up to 1st January 2006) is an act to provide for control of factories with respect to
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matters relating to the safety, health and welfare of person therein, the registration and
inspection of machinery and for matters connected therewith.
FMA 1967 provides a framework for the control of factories and machinery, through the
supervision of the Inspectors by the powers provisioned to them by the Act, with respect
to matters relating to the safety, health and welfare of persons, and the registration and
inspection of the machinery.
1.2
Glycol Dehydration Systems
Glycol Dehydration Systems is the most commonly used in oil and gas industry (which is
up to 90%) to remove water vapour from natural gas. Natural gas must be dehydrated
(remove water vapour) to prevent hydrates formation (an icy solid-formed of due to
combination of 10% hydrocarbon and 90% water vapour) that could lead to plugging/
blocking of pipes function, to prevent corrosion of metal (degradation of metal due to
exposing with water vapour) and requirements of downstream processing (water may
react with same catalyst in downstream processing).
1.2.1
Types of Glycol
Glycol is a chemical substance used in Glycol Dehydration Systems because of its

properties of having lower vapour pressure and does not evaporated into the vapour
phase. It is also less soluble in liquid hydrocarbons than methanol. Glycol is
economically because of it could be recovered and reused for the treatment, reduces the
operating costs as compared to the others chemical substances.
There are three types of glycols used: ethylene glycol (EG), diethylene glycol (DEG) and
triethelyne (TEG) (see Table 1.2-1 for its physical properties). The following specific
applications are recommended:-
a. For natural gas transmission lines, where hydrate protection is of importance, EG

is the best choice (see Figure 1.2-1). It provides the highest hydrate depression,
although this will be at the expense of its recovery of its high vapour pressure.
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b. EG is used to protect vessels or equipment handling hydrocarbon compounds,

because of its low solubility in multicomponent hydrocarbons (see Figure 1.2-2).
c. For situations were vaporization losses are appreciable, DEG or TEG should be
used, because of their lower vapour pressure (see Figure 1.2-3).
Figure 1.2-1: Chemical compositions of ethylene glycol (EG)
Figure 1.2-2: Chemical compositions dithylene glycol (DEG)
Figure 1.2-3: Chemical compositions of triethelyne glycol (TEG)

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It is of importance to mention that when hydrate inhibitors in general are injected in gas
flow lines or gas gathering networks, installation of high-pressure free-water knockout at
the wellhead is of value in the operation. Removing of the free water from the gas stream
ahead of the injection point will cause a significant savings in the amount of the inhibitor
used.
Table 1.2-1: Physical Properties of EG, DEG and TEG
1.2.2 Components of Glycol Dehydration Systems
Glycol Dehydration System is the most common solvent used in dehydration unit in oil
and gas industry due to its economic as shown in Figure 1.2-4 and Figure 1.2-5. The
systems act as an absorber of water vapour in natural gas i.e. absorption, which is defines
as the transfer of a component from the gas phase to liquid phase, is more favourable at a
lower temperature and higher pressure.
Figure 1.2-4: Glycol Dehydration Systems

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1.2.2.1 Glycol Contractor (Absorption Column)
The wet natural gas enters the absorption column near its bottom and flows upward
through the bottom tray to the top tray and out at the top of column. Usually six to eight
trays are used. Lean (dry) glycol is fed at the top of the column and it flows down from
tray to tray, absorbing water vapour from the natural gas. The rich (wet) glycol leaves
from the bottom of the column to the glycol regeneration unit. The dry natural gas passes
through mist mesh to the sales line (see Figure 1.2-6 for water dew point with
concentration of TEG).
Figure 1.2-5: Schematic of Glycol Dehydration Systems
Figure 1.2-6: Water Dew Point with Various Concentration of TEG
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1.2.2.2 Flash Drum
The wet glycol leaves the bottom of the absorber, flows through a pressure control
valve, (Pressure Let-down valve, PLV) then into a flash drum. In the flash drum the
wet glycol pressure is reduced to enable light hydrocarbons, mainly methane to escape
from the solution (Glycol, water and hydrocarbons) as vapour. This process is termed as
flash evaporation.
Pressure in the flash drum is generally less than 5 bars and requires a typical holdup time
of 15-30 minutes. After leaving the flash drum the rich glycol is heated in a heat
exchanger to replace the heat lost during the flash process and ensure that it has the same
temperature as the stripper before entering it
1.2.2.3 Glycol Regeneration Unit
The glycol regeneration unit is composed of a re-boiler where steam is generated from
the water in the glycol. The steam is circulated through the packed section to strip the
water from glycol. Stripped water and any lost hydrocarbons are vented at the top of the
stripping column. The hydrocarbon losses are usually benzene, toluene, xylene, and ethyl
benzene (BTXE) and it is important to minimize these emissions. The rich glycol is
preheated in heat exchangers, using the hot lean glycol, before it enters the still column of
the glycol re-boiler. This cools down the lean glycol to the desired temperature and saves
the energy required for heating the rich glycol in the reboiler.
1.2.2.4 Reboiler
At the bottom, a reboiler is installed. This acts like a heat exchanger and provides the heat
required to separate the glycol from water in the stripper. The temperature is mostly
based on the degradation temperature of the glycol type being used. For TEG the
recommended maximum temperature is 206C. Steam is used as the heating medium and
exits as condensate (water). The lean glycol is taken from the reboiler and recycled
back into the absorber. Before it enters the absorber, the lean glycol goes through a heat
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exchanger and a pump to ensure that the temperature and pressures are equal or close to
that in the absorber.
1.2.2.5 Condenser
After the vapour leaves the still column, it is routed through a cooling water condenser,
which condenses the glycol vapour.
1.2.2.6 Reflux Drum
The reflux drum acts as a distribution point and stores the condensed glycol allowing
water vapour to exit. It is mostly used to ensure that the condensed glycol enters the
stripper under controlled standards thus ensuring that the right amount of glycol is
returned back into the Stripper with the help of control devices. It is also equipped with a
pump to manage flow rates.
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GLYCOL DEHYDRATION SYSTEMS
CHAPTER 2
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SAFETY ISSUES AND CHALLENGES
BTEX Emission
TEG Dehydration Systems emit several billion cubic feet of toxins annually.
Emissions include hazardous air pollutants (HAPs), volatile organic compounds
(VOCs) which are highly flammable, and BTEX which consists of benzene, toluene,
ethyl benzene and xylenes, which are lethal carcinogens (cause cancer to human).
Benzene, toluene, ethyl benzene and xylene (BTEX) is a problem because of

environmental concerns. BTEX is removed from the gas during glycol dehydration, a
smaller amount BTEX may also be removed during gas sweetening. When the glycol
is regenerated the BTEX will be removed with the water, and thereby be
vented to the atmosphere. BTEX are also a problem in cryogenic gas treatment
because they can freeze like water. BTEX cannot be removed from the gas before
the dehydration.
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SAFETY, ENVIRONMENTAL IMPACT & MANAGEMENT
CHAPTER 3
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SAFETY AND HEALTH MANAGEMENT
Introduction
This section describes overall concept and risk assessment of the TEG Dehydration
Systems.
A risk is the potential for a hazard to cause a specified harm to someone or something,
i.e. it is a product of both the magnitude (scale of consequences) and the likelihood
(frequency) of it occurring. Therefore, to identify the risks associated with a TEG
Dehydration Systems, the assessment process needs to identify systematically the
hazards, causes and consequences, which may occur or arise from the operation of
TEG Dehydration System.
In compliance with normal practice, the level of acceptability for each particular risk
is the ALARP level, where ALARP is the level below which the costs to reduce the
risk even lower (in terms of both time and effort as well as money) would be greatly
disproportionate to the reduction in the risk that could be achieved. Typically, the
relationship between the ALARP risk acceptability level, and the frequency and
consequence
magnitude
of
hazardous
incident
occurring
is
illustrated
diagrammatically in Figure 3.1-1 below.
3.2
Risk Assessment Management Process
The processes of risk assessment management process are as following steps:-
Step 1 Identify Hazards;

Step 2 Assess Risks; and
Step 3 Specify Risk Control Options.
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Figure 3.1-2 illustrates the risk management process. It comprises a considered,

systematic risk planning, identification, analysis, evaluation and treatment/ mitigation
process that is supported by appropriate monitoring, review and recording of the
CONSEQUENCE
identified risks.
C5
Catastrophic
C4
Major
C3
Moderate
C2
Minor
C1
Insignificant
INTOLERABLE
AL
AR
P
ACCEPTABLE
Rare
F1
Unlikely
F2
Possible
F3
Likely
F4
Frequent
F5
FREQUENCY
Figure 3.1-1: The ALARP Risk Acceptability Level and its Relationship to the
Frequency and Consequence Magnitude of a Hazardous Incident
Occurring
3.2.1 Hazards Identification
Hazards identification is a process of determining the area of concerns that are present
and relevant which could induce risks. The aim is to identify where, when, why and
how events could prevent, degrade or delay the achievement of objectives with the
focus on the 'overall picture'.
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3.2.2 Risk Analysis
Risk analysis is a process of measuring the relative level of risk exposure that the
identified hazards pose. The level of risk exposure is considered as a product of the
likelihood of the risk event occurring and the consequence should it occur.
Figure 3.2-1: Risk Management Process

3.2.2.1 Consequence
The severity of the identified hazards is assessed against the consequence definitions
that are specific to the potential impacts as presented in Table 3.2-1.
3.2.2.2 Frequency
The likelihood of the identified hazards is assessed against the frequency definition as
listed in Table 3.2-2.
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Table 3.2-1: Consequence Ranking

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Table 3.2-1: Frequency Ranking
3.2.2.3 Risk Ranking
Risk ranking is a simplistic technique for an initial sorting of identified area of

concerns into categories according to their perceived level of seriousness, to allow
them to receive the appropriate level of attention. Risk is defined as the seriousness of
an initiating event and is the product of the frequency of occurrence of a scenario and
the severity of its consequences. The risk matrix presented in Table 3.2-3.
Table 3.2-3: Risk Ranking
The following risk rating criteria was adopted for the assessment:
Low risk: 1 6, Risk is acceptable and can be managed by routine

procedures; however, specific application of resources may not be required.
Medium risk: 8 10, Risk is acceptable on condition and on-going

monitoring or routine procedures have to be in place to ensure level of risk
does not increase.
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High risk: 12 25, Risk is unacceptable and senior management attention is

required; action plans must be developed with clear assignment of individual
responsibilities and timeframes to mitigate risk.
3.2.3 Risk Mitigating / Risk Control
Selection of preferred risk mitigations is typically a cost-benefit decision, with

preference given to treatments that provide the best all round benefit to or create
opportunity for the development. For any particular risk, a number of mitigating
measures may be considered, and applied either individually or in combination. The
additional mitigation measures will be implemented by the responsible party to reduce
the risk to the As Low As Reasonably Practicable (ALARP) level.
The risk factors must be identified and respective initiating events, consequences,
existing control and mitigation measures as well as need to implement additional
mitigation measures. Table 3.2-2 shows the risk mitigation/ risk control pyramid.
Figure 3.2-2: Risk Control Pyramid
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Glycol Dehydration Systems Risk Assessment
The hazards and risk assessment of Glycol Dehydration Systems are explained in
Paragraph 3.3.1 and Table 3.3-1 below.
3.3.1 Identified Hazards
3.3.1.1 Toxic Gasses Release to Atmosphere
Toxic gasses of Hazardous Air Pollutants (HAPs), Volatile Organic Compound

(VOC) and Benzene, Toluene, Ethyl-benzene and Xylene (BTEX) are gasses that
released to the atmosphere during process of regeneration of TEG.
This happens due to the process of absorption that taking place in the TEG absorption
column (Contractor) by TEG desiccant. During the process, wet methane gas is
supplied at bottom of the column while TEG liquid at top of the column, the process
of absorption occur when wet gasses and TEG is contacted inside the column.
The TEG act as an absorber to water vapour in the wet gas, however, other impurities
such as HAPs, VOC and BTEX are also absorbed by TEG liquid. These gasses are to
be harmful to human if inhaled and BTEX could be carcinogen (cause cancer).
In operation, all of these gasses are flowed to the flare and burned (converting to less
hazardous gas i.e. carbon monoxide, carbon dioxide) before releasing to the
atmosphere. Toxic gasses release to atmosphere is considered due to leaking.
3.3.1.2 Contacted with TEG
The effects of TEG when physically contacted to human are tabulated in Table 3.3-1
below.
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Table 3.3-1: Effect of TEG when Contacted

Human Part / Category
Inhalation
Eye
Skin
Ingestion
Description
Short term harmful effects are not expected from
vapour generated at ambient temperatures.
Splashing in eye causes irritation with transitory
disturbances of corneal epithelium. Vapours are not
irritating.
Prolonged exposure may cause skin irritation.
Abdominal discomfort, nausea and vomiting may
occur.
3.3.1.3 Fire or Explosion Due to Ignition of TEG
TEG is colourless, low volatility and water-soluble liquid that mostly used in
dehydrator for natural gas. Due to it volatile characteristic, TEG can be a fire hazard
when exposed to extreme temperature of 176oC (TEG Flash Point) and auto-ignition
at temperature of 371oC.
3.3.1.4 TEG Spill / Leak
TED spill / leak are considered as a safety hazard to human.
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TEG spill / leak
Unlikely
Unlikely
Minor
Major
Unlikely
Unlikely
Major
Minor
Likelihood
Consequence
Potential Hazard
Toxic gasses release and inhaled by the operator/
workers i.e. Hazardous Air Pollutants (HAPs),
Volatile Organic Compound (VOC) and Benzene,
Toluene, Ethyl-benzene and Xylene (BTEX)
resulting in health illness.
Contacted with TEG solvent
Fire or explosion due to ignition of TEG resulting
in injury and properties damages.
Table 3.3-1: Risk Assessment of Glycol Dehydration Systems
Very Low
Moderate
Very Low
Moderate
Risk
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MITIGATION AND RECOMMENDATION
The risk assessment of Glycol Dehydration Systems is summarised in Chapter 3. The

risk results that assessed of moderate to high risk must be controlled and reduced to
As Low As Reasonably Practicable (ALARP).
4.1
Mitigation and Recommendation
While Glycol Dehydration Systems has been assessed without high risk of identified
hazard, safety precaution or preventive action shall be formulated for all identified
hazards. Therefore, the following recommendations have been raised to ensure the
risk of Glycol dehydration System is kept at a minimum.
4.1.1 Toxic Gasses Releasing to Atmosphere
Toxic gasses of HAPs, VOC and BTEX must be engineered control by burning its
(flare) to become less hazardous gas i.e. carbon monoxide and carbon dioxide.
4.1.2 Fire or Explosion Due to Ignition of Glycol
All sources of ignition must be identified and controlled. No any activity is permitted
within the hazardous zone of Glycol Dehydration Systems without concern
permission by the authority.
4.1.3 Develop Safe Work Procedure (SWP) and Emergency Response Plan (ERP)
A comprehensive SWP and ERP must be established for Glycol Dehydration

Systems.
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CASE STUDY
5.1
TEG Fire at Gas Dehydration Unit
5.1.1
Incident Information
Country
Location
Incident date
Type of Activity
Type of Injury
5.1.2
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Spain
Onshore
15 May 2013
Maintenance, inspection and testing
Explosions or burns
Incident Detail
After a TEG (Triethylene glycol) low level alarm at the natural gas dehydration unit,
the unit was stopped and the operator waited 2 hours before opening the TEG inlet. A
fire occurred when the TEG vapours, coming from inside the accumulator tank,
reached the exhaust stack during the TEG refilling operation. The burner zone has
restrictions for operator escape, although on this occasion the operator reached the
TEG inlet cap from outside the zone and was not caught by the fire. The fire detector
produced a level 1 emergency shut down and the fire was put out by the internal fire
brigade without significant consequences (see Figure 5.1-1).
5.1.3 Incident Root Cause
TEG inlet aiming to a hot spot is considered to be an error in design, causing

that TEG vapour is directed to a hot spot when the inlet cap in opened.
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Deficient inspection and maintenance plan: the periodic inspection of exhaust

pipe for burners was not included in plan.
5.1.4 Corrective Action and Recommendation
The TEG inlet must be checked/ modified to ensure that vapours are
evacuated to a safe place.
A technical instruction shall be prepared to describe TEG refilling operation.
Include the inspection of exhaust pipe for all the units with burner in the
inspection and maintenance plan.
Figure 5.1-1: Site Incident Photo
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REFERENCES
1.
Abdel-aal H.K., Aggout, M. and Fahim, M.A., 2003. Petroleum and Gas Field
Processing. Marcel Dekker, Inc. Dharan, Saudi Arabia.
2.
Christensen, D. L. 2009. Thermodynamic Simulation of the Water/ Glycol Mixture.

Aalbog University. Denmark.
3.
Hansen, P., Chiriac, A., Incoom, N. and Olsen, A. 2013. Design of TEG Dehydration
Train Model Using the Glycol Property Package in HYSYS. Aalbog
University. Denmark.
4.
Moore, Jr., 1999. Glycol Refining (Patent No. 5,882,486). United States Patent, USA.
5.
National Research and Development, Research Triangle Park. 1996. Methane

Emission from Natural Gas, Volume 14: Glycol Dehydrator. United States
Environmental Protection Agency.
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SAFETY, ENVIRONMENTAL IMPACT & RISK MANAGEMENT

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GAS AND GLYCOL DEHYDRATION SYSTEMS

General Overview ................................................................................................................. C1-1

CHAPTER 2 SAFETY ISSUES AND CHALLEGES

BTEX Emission .................................................................................................................... C2-9

CHAPTER 3 SAFETY AND HEALTH MANAGEMENT

Introduction ......................................................................................................................... C3-10

CHAPTER 4 MITIGATION AND RECOMMENDATION

Mitigation and Recommendation ........................................................................................ C4-19

CHAPTER 5 CASE STUDY

TEG Fire at Gas Dehydration Unit ..................................................................................... C5-20

GAS AND GLYCOL DEHYDRATION SYSTEM

SAFETY, ENVIRONMENT IMPACT & RISK MANAGEMENT

GAS AND GLYCOL DEHYDRATION SYSTEM

Pertinent Legislation and Regulation Requirements

Environmental Quality Act, 1974

Occupational Safety and Health Act, 1994

Factories and Machinery Act, 1967

SAFETY, ENVIRONMENT IMPACT & RISK MANAGEMENT

GAS AND GLYCOL DEHYDRATION SYSTEM