SPE 154134

Gas Dehydration Offshore or Onshore, How, How Much and Design Tips
Reza Salamat, Qatar Petroleum

Copyright 2012, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE International Production and Operations Conference and Exhibition held in Doha Qatar, 14–16 May 2012.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract

Gas dehydration is a very frequent occurrence and a critical part of gas production offshore as well as onshore
and therefore all the pertinent issues such as degree of dehydration, costs, design and operating “dos and don’ts”
must be very well understood by the surface engineers as well as operators and managers. In the Middle East
gas dehydration is particularly critical because of high reservoir pressures and high H2S/CO2 (sour gas) content
and yet billions of cubic feet of gas are dried daily for gas injection or for downstream industry. But is the practice
of gas drying in Middle East technically and environmentally adequate and safe?. If the water removed is not
sufficient, liquid water is formed as pressure is dropped aiding line corrosion and upon further pressure reduction
hydrates will form potentially blocking the flow lines. On the other hand extraction of too much water will cost the
operator dearly and with the fluctuations in oil prices, revenues should be wisely used. The governing case which
determines the degree of drying is the coldest operating condition for which the process gas may be subjected
which means the degree of drying is a variable itself during the reservoir life and may be relaxed (or visa versa)
as the reservoir life progresses and these are discussed in detail in this paper. There are various correlations
used to arrive at the degree of drying and each give different results. In the proceeding paper, a range of credible
dehydration methods are summarized with special emphasis on gas dehydration by TEG method as it is widely
used and the salient points especially environmental issues related to the release of BTEXs into the atmosphere
and how to minimize them. Various sets of correlations for dew point determination are demonstrated with real
offshore case data together with unique and valuable recommendations on the design and costs optimization as
well as technical/environmental safe operation.
2 SPE 154134

List of Figures and Tables

Figure 1. Water content of natural hydrocarbons for a range of operating temperatures and pressures
Figure 2. TEG Concentration versus the corresponding dew point according to Worley and Parish correlations
Figure 3. The gas lift temperature of the choke valve and the allowable water content versus the choke pressure
Figure 4. TEG Concentration and water content of the gas versus the corresponding dew point
Figure 5. Pressure versus hydrate formation temperature for a range of dry gas specification
Figure 6. The process flow diagram for a gas dehydration and regeneration package
Figure 7. An alternative gas dehydration package including BTXs recovery

Table 1. Effect of Glycol selection on dehydration unit parameters

1. Reasons for drying the gas and dehydration methods

Water is almost always accompanied with hydrocarbons (See Figure 1) and there will always be a requirement
for dehydrating a gas or liquid to reduce the water content to an acceptable limit so that the water stays in gas
phase and thus the water phase separation that causes corrosion or line blockage by forming stable hydrates are
avoided. The acceptable limit of water content as well as the dehydration method depends on the intended use of
the gas. If the produced or treated gas is to be transmitted in transmission lines for domestic use, a water content
of 6-10 lb/MMscf (96-160kg/MMm3) giving a gas dew point of 15-29 °F (-2 to -9°C) is normally sufficient. Whereas
for a gas injection back into the reservoir in a deep cold sea and/or with a high pressure drop across the injection
choke valve, a dew point of less than -40°F (-40°C) may be found necessary to avoid separation of water phase
from the gas and hydrate formation.

Methods of gas dehydration are many and listed below are some of the popular ways in usage:

1. Adsorption - Alumina, silica gel or mol sieve are applied. This method provides extreme dryness of the
gas, well in excess of 99.9 wt% of the gas will be dry giving a very low dew point; well in excess of -40 °F (-40°C).
This package of gas dehydration is very expensive to purchase and to operate and its use is limited to gases with
high H2S or when very low dew point is required or when there is oxygen in the gas [Ref. 1].
2. Absorption – Di-ethylene glycol (DEG) or Tri-ethylene glycol (TEG) are very popular and widely used
worldwide. Drying by TEG is the most common method due to its superior properties over DEG and therefore this
is discussed in detail in the proceeding works including the coherent environmental issues. Here in a contactor
column lean TEG absorbs the water from the process gas under high pressure and low temperature which is a
favourable environment to absorb water and thus the absorbant becomes rich in water. Subsequently in the
adjacent regeneration process package, the TEG is regenerated giving up its water content in a reversal of
inventory condition, i.e., low pressure and high temperature. The available regeneration processes in absorption
method are:
2.1 Vacuum - Where a TEG concentration of 99.2 to 99.9 wt% is generated giving a possible water dew point
depression of 100-150°F (38 -66°C). The disadvantage of this method is the difficulty of holding the required
vacuum in the process.
2.2 Coldfinger – 99.9 wt% TEG is regenerated giving a maximum dew point depression of 100-150°F (38 -
66°C). Thus if the dew point of a untreated gas is say 20 °F (-7°C), using this process will theoretically depress
the gas dew point to -47°F to -99°F (-44 to -73°C).
2.3 Drizo – TEG concentration in excess of 99.99 wt% is obtained with the adherent dew point depression of
180-220°F (82-104°C). This is used when super dryness is required for process reasons and the method uses an
azeotropic distillation to achieve the target. The Drizo regeneration method is several times more expensive than
the Coldfinger method.
3. Direct cooling – Where water is separated out by dew point difference and separated out from the gas.
This is used for bulk separation or when a small depression of dew point is deemed sufficient.
SPE 154134 3

4. Chemical reaction – Methanol injection is utilized. This is normally used offshore as a back up or at start
up when the normal gas drying by TEG or absorption is not available. Its disadvantage is that methanol is toxic
and there are severe environmental constraints imposed on it in case of leaks or accidents.
5. Proprietary methods – “Drigas” or “ECOTEC” (Licensor SIIRTEC NIGL), GlyTech or available with
companies such as Shell (Twister and others).

2. Gas Drying By Glycols

There are mainly two correlations available for determining the glycol concentration required for a given dew
point; Parish and Worley. Parish is laboratory based and Worley is based on a large collection of real field data.
Parish is very conservative compared to Worley prediction although this conservatism narrows down at very low
dew points (less than -40°C). For instance, reference to Figure 2, for a dew point requirement of 5°F (-15°C), a
TEG concentration of less than 99% is required according to Worley correlation whereas Parish predicts a
requirement of TEG concentration in excess of 99.4%. It becomes exponentially more difficult to remove the last
traces of water vapour from the gas. Therefore, the difference in prediction is significant. It is the belief of the
author that Worley predictions are more realistic although the analysis should always include predictions by
Parish when the choice of regeneration package is on the border line. Figure 3 shows that the dry gas spec is a
variable during the life of the reservoir or wherever the dry gas is designated to go. This figure shows that as the
pressure drop across the injection choke valve is reduced giving a reduction in temperature drop across the
choke, the allowable water content in the injection gas is increased. This is significant in that the set point for unit
for gas injection unit shutdown should be adjusted according to the dryness demand on weekly or monthly basis
and hence unnessary shutdowns may be avoided. The specification for the dry gas in term of water content must
be fully analysed for all possible cases and real operational scenarios or for the final intent of the process gas
application. Reference to Figure 3, for a pressure differential of 50 bars across the injection whellhead choke of a
particular well with defined composition, the temperature of the main stream reduces from 28°F (-2 °C) to 23°F (-5
°C) across the choke and the allowable water content that the gas injection may carry is 2.3 lb/mmscf. Thus,
assuming the stated case is the governing (worst) case for gas dehydration, there is no need to dry the gas
beyond 2.3 lb/mmscf. This excecise should be carried out for each case of different gas injection composition.
Thus for offshore applications where space and weight are limited and the gas is brought to onshore, due
considerations should be given to dry the gas only sufficiently for transportation to onshore.

Figure 4 shows water content of natural gases at various dew points (very low dew points are achieved at low
water contents of gas) and the corresponding TEG concentration requirement using a company’s general
guidelines [Ref. 4]. For example, this graph predicts that a gas with a specification of 0.75 lb/MMscf will result in a
dew point depression of -22°F (-30°C) in the gas and the TEG concentration required to achieve this dew point is
99.8%. Based on this requirement, a suitable gas dehydration method is chosen using guidelines given in Section
1.0 above. Figure 5 show that hydrate formation temperature is pressure dependant and it generally shows that
hydrates begin to form (unstable hydrates) before dew points are reached. Therefore it is advised that always
adequate margins are added for allocating the spec for the dryness of the gas although these margins should not
be too excessive causing unnecessary design complications and added costs.

2.1 Dangerous Releases by Glycols and Environmental Considerastions

TEG picks up VOCs (volatile organic compounds) including BTEXs (benzene, toluene, ethyl benzene and xylene)
in the glycol contactor tower which is released in the glycol regeneration package and subsequently into the
atmosphere if it is not treated. BTEXs are dangerous to health and environment. Benzene is carcinogenic , and
Toluene may affect the reproductive and central nervous systems. Ethylbenzene and xylene may have
respiratory and neurological effects [8]. Therefore the release of BTEXs should be controlled. The allowable
release depends on local rules and regulations and in some parts of the world it is 25 tpy for total pollutants.
Ebling [Ref. 5] has shown that EG (ethylene glycol) and DEG (diethylene glycol) have considerably less affinity
4 SPE 154134

for VOCs than the commonly used TEG. For example, at a typical glycol circulation rate of 3 gal/lb water, the
VOC emission for a TEG system is 20-30 times higher than EG. Similarly for BTEX emission it is 5-10 times
higher in TEG system than EG. The VOCs can be reduced by the following methods especially applicable to
TEG systems:

1. Incineration of regeneration vent gases,

2. Condensing the regenerator vent. Refer to Figure 7 [Ref 7] for a flow diagram,
3. Maximizing the amount of vapour flashed upstream of the still column atop the reboiler at the lowest
pressure and highest temperature
4. Removing the BTEXs from the rich glycol in a separate BTEX stripping column
5. Decrease the glycol recirculation rate

In gases that have significant amount of pollutants (VOCs) with strict allowable releases, it is worth considering
EG and DEG. The current method of minimizing BTEX releases are rerouting of the overheads to a suitable
location within the package or condensing the regenerator overhead vapor in a partial condenser and combust
the remaining vapour. In situations when using DEG or EG achieves the required water derw point and BTEX
emissions are important, significant savings in both operating costs and expenses to treat the vent gas can be
achieved. Table 1 demonstrates the effectof glycol selection on dehydration unit parameters.

In a detailed analytical study, Moshfeghian [Ref. 8] has stated from others that the predicted absorption levels for
BTEX components vary from 5-10% for benzene to 20-30% for ethylbenzene and xylene by TEG. Moshfeghian
has noted that absorption of water and BTEXs by TEG increases with decreasing temperature and increasing
circulation ratio and has generated graphs that accurately estimate the absorption of BTEX components in a
glycol dehydration system for a given pressure, temperature and circulation ratio [Ref. 8]. Moshfeghian has further
concluded that minimization of recirculation rate is the most effective way to reduce BTEX releases.

2.2 TEG Regeneration Package - Statement of System Purpose

The Glycol Contactor (VF-001) shown in Figure 6 is designed to dry some 300 MMSCFD of wet gas containing
82 lb/MMscf at the contactor entry conditions. The wet gas is dried suitably so that no hydrate is formed at the
coolest possible operational or maintenance scenario of downstream equipment or pipelines. The dry gas in the
subsequent works is specified as 1 lb/MMSF (16 kg/MMsm3) giving a dew point of about -18 F° (-28°C) for the
gas. The dry gas is then compressed and reinjected via subsea pipelines into the injection wellheads. The glycol
regeneration package is designed to regenerate the wet glycol by giving up its water. The dry glycol is then
recirculated back into the glycol tower from the top of the column flowing counter currently with the wet gas in the
tower. In order to achieve the gas specification, 99.9 wt% glycol (TEG) purity is required. “Cold Finger
(proprietary)” process for the regeneration package is found suitable to achieve the 99.9% TEG purity.

Reference to Figure 6, the Gas Dehydration Package including the Contactor Inlet Cooler (HA-001), Dehydrator
Inlet Knock Out Drum (VD-001), a Glycol Contactor (VF-001) and a Regeneration Unit (PKG-001) is specified to
provide water dew point depression of hydrocarbon vapour prior to re-injection or gas lift use. The water content
spec is 1 lb/MMscf (16 kg/MM sm3) at the outlet of the Contactor as dry gas. The dehydration is achieved by
direct counter-current contacting of lean TEG with water containing hydrocarbon gas. Rich TEG is continuously
regenerated for removal of water and dissolved gas in a TEG Regeneration Unit.

2.3 System Description and Control

The Glycol Contactor (VF-001) portion is where the glycol absorbs water (rich glycol) and the regeneration
package is the location where the glycol gives up its water (lean glycol). From the equilibrium point of view, high
pressure and low temperature is favoured in the Glycol Contactor (VF-001) and conversely for the regeneration
package low pressure and high temperature is used. For Glycol Contactor (VF-001) a pressure range 60-70 bars
SPE 154134 5

and 68-104 °F (20-40°C) are optimum. A maximum tower temperature of 122°F (50 °C) is recommended to
prevent problems due to glycol viscosity. Figure 6 shows the process flow diagram for the glycol contactor and
the regeneration package with typical temperatures and pressures.

Wet gas enters through the tube side of the shell and tube type Contactor Inlet Cooler (HA-001) where it is cooled
down to 104°F (40 °C). The cooled gas then enters the Dehydrator Inlet Knock Out Drum (VD-001). This removes
the bulk water and condensate. Liquid carry over should not exceed 0.1 USgal/MMscf (20 litres/MMsm3)
otherwise excessive foaming and loss of glycol will be resulted. Proper and efficient separation within the Knock
Out Drum is essential for correct and trouble-free operation of the Contactor. The cooled gas with the bulk water
and condensate removed enters the Contactor from the Dehydrator Inlet Knock Out Drum (VD-001). It is vital that
the KO drum is positioned very close to the Contactor column to ensure the feeding is absolutely single phase.

Following this, the gas passes upwards and enters the structured packing bed section of the Contactor, counter-
current to the lean glycol (99.9%). Mass transfer of the water in the gas into lean glycol takes place across the
structured packing section. A pressure transmitter PDIT monitors the differential pressure across the internal
packing. The normal pressure drop across the packing is expected to be in the range of 15 to 20 kPa. An alarm is
set at 30 kPa (0.3 Bar) pressure differntial.

An increase in differential pressure across the packing is an indication of enhanced foaming causing excessive
loss of glycol. In this event anti-foaming agent should be added from the Regeneration package. Foaming used to
be a frequent problem with tray columns but the use of structured packing suppresses the foaming tendency.

Before leaving the Contactor, the gas is scrubbed by high efficiency mist extractor to remove any entrained glycol
droplets before passing out of the tower as dry gas. The maximum liquid hydrocarbon carryover in the inlet gas
stream is expected to be 0.1 USgal/MMscf (15 kg/MMsm3). The gas temperature leaving the Contactor is
continuously monitored. The normal temperature in the tower is 104 °F (40 °C). The moisture content of the gas
leaving the Contactor is measured continuously by two independent analysers. One of the analysers has a high
moisture alarm, set at 2.0 lb/MMscf (32 kg/MMsm3) or twice the dry gas spec under normal operation to alert the
operator if the dry gas is off spec. The maximum value allowable is 2.2 lb/MMscf (35.2 kg/MMsm3) under worst
conditions i.e. subsea gas lift line at minimum reported seabed temperature and the minimum choke back
pressure (i.e., maximum pressure drop across the gas lift coke at the wellhead). However, the maximum value
stated is a variable and production phase dependant. Its value may be relaxed during early life of the reservoir
when the pressures are healthy and the back pressure on the subsea choke valves are greater than the stated
minimum value and consequently lesser of a pressure drop is obtained across these valves leading to higher
temperatures downstream of the valves. The guaranteed spec for the dryness of the gas leaving the contactor is
1 lb/MMscf (16 kg/MMsm3).

Lean glycol passes down through the Contactor and accumulates as rich glycol (approximately 97%) from where
it is discharged under level control to the Regeneration Unit.

Glycol losses are usually expected to be in the order of 0.012 gal/MMscf (0.0016 m3/MMsm3) due to
vapourization and in the overheads. Total amount of losses due to leakage, vapourization and solubility may run
around 0.025 gal/MMscf (0.0033 m3/MMsm3). Glycol losses in a contactor tower filled with trays is several folds
more than structured packed towers. This is one of the advantages of packed towers over the tray type. The
quoted loss figures refer to packed towers. The maximum diameter of the contactor is recommended not to
exceed 4m in order to avoid mal distribution or excessive entrainment. If a larger diameter is required then two
trains of tower should be provided. The Contactor s recommended to be insulated to avoid gas condensation and
reduce foaming problems.

The normal operating level of glycol at the bottom section of the tower can be observed on a level gauge.
6 SPE 154134

A high/low level shutdown shall be monitored by a level transmitter which initiates shutdowns of Glycol
Regeneration Package by shutting the ESDVs of Glycol to and from the Contactor.

The rich glycol leaving the Glycol Contactor (VF-001) is reduced in pressure and then passes through a coil (heat
exchanger) in the reflux section of the Still Column where heat is exchanged with the vapours rising up the
column. The Regeneration Unit is protected from overpressure in the event of gas blow-by through level control
valve(s) located at the bottom of the contactor line carrying the rich glycol into the regeneration package, by relief
valves on the Flash Drum within the regeneration package. These level control valves control and maintain the
liquid level in the contactor tower. The blow-by will occur if these valves fail to operate and as a result liquid level
in the tower is lost and the wet gas will enter the regeneration package.

In order to provide reflux and reduce glycol losses to a minimum, the temperature of the water vapour leaving the
Still Column (at the top of the reboiler) should be controlled. In the case of this unit the temperature is 194 °F (90
°C).

Rich glycol from the Still Column reflux coil and the bypass passes through the Glycol Lean/Rich Exchanger (HA-
002). From this exchanger, the rich glycol enters the Flash Drum at 176-180 °F (80-82 °C). A temperature gauge
monitors the Lean glycol temperature at the inlet to the exchanger.

The Glycol Flash Drum (VD-002) is a horizontal vessel with an internal bucket and weir in which separated
condensate is skimmed off the surface of the glycol into the bucket, and rich glycol passes underneath the bucket
over the weir and into a separate compartment downstream of the weir.

The level of glycol in the downstream compartment can be monitored with a level gauge and the level is
controlled by a level indicator-controller (LIC) which controls glycol circulation with a control valve. This control
valve is sited downstream of the filters to prevent flashing and occurrence of gas-locks in the filters which would
reduce their effectiveness.

The selection of the operating pressure in the flash drum is based on a sufficiently low pressure to flash off as
much dissolved gas as possible, and a sufficiently high pressure to ensure adequate pressure to overcome the
line pressure drop between the Flash Drum and the inlet Glycol Still Column (VE-001) including the pressure drop
across dirty filters. In this case the operating pressure is 350 kPag (51 psig). A pressure control valve controls the
influx of LP fuel gas as blanketing gas and the former the outflow of gas into the LP flare header.

On entering the Flash Drum, dissolved gases are released from the rich glycol and any hydrocarbons present in
the glycol as liquids will start to separate, therefore there should be a considerable residence time in this drum.
Gas is vented from the Flash Drum under pressure control. Hydrocarbon liquids are skimmed off from the glycol
by a bucket and weir arrangement, and discharged under manual level control.

Rich glycol is discharged under automatic level control. Pressure is maintained in this vessel by make up gas
from the LP fuel gas system. The flash Drum is a three phase operation. Correct design and operation of this
vessel is essential to eliminate potential problems of glycol foaming, increased glycol losses, glycol degradation,
reduced glycol life and reduced Contactor efficiency due to the presence of heavy liquid hydrocarbons and any
aromatics in the inlet gas stream.

The rich glycol then passes through Glycol Filter(s) (CA-001A/B), which are designed to remove over 98% of all
extraneous materials such as solids, degraded glycol and pipe scale, greater than 5 µm. The instrumentation on
these items is simple and is limited to a differential pressure indicator PDI.
SPE 154134 7

Following this, a 10% rich glycol slipstream then passes through a Glycol Carbon Filter (CA-002) where
remaining traces of hydrocarbon well treating chemical, compressor oils and other troublesome impurities are
removed. If these impurities are not removed, the performance of the glycol is depreciated very fast. The
importance of good carbon filter design, operation and maintenance cannot be over-stressed for the same
reasons as those concerning the Glycol Flash Drum. The flow flux into the carbon filters should be as large as
practically possible.

After leaving the Glycol Interchanger (HA-003) the temperature of the rich glycol stream reaches in this case
approximately 180 °C and this indicated on a temperature indicator (TI). In the Glycol Interchanger (HA-003) the
exchange of heat takes place between the cold rich glycol downstream of the Carbon Filter and the hot lean
glycol downstream of the Glycol Interchanger (HA-003). It then enters the packed section of the Still Column
where the rich glycol is counter-current stripped with water vapour from the Reboiler. On leaving the bottom of the
Still Column the rich glycol is directed to one end of the Reboiler to improve efficiency.

The Reboiler is a horizontal vessel with electric heaters. The shell of the Reboiler is fitted with a level gauge. The
Reboiler Heater elements are electrical and 3 x 50%. One of the Heaters is controlled by a thyristor and the
remaining two by contactors arranged to stand-by each other. High temperature shutdown elements are installed
on heater elements and the respective flanges.

The operating mode of the Reboiler’s heating system may be comprised of a thyristor control:

 The thyristor controlled elements operate from 0-50% control signal

 At 50% a contactor controlled element switches in and the thyristor again starts from zero
 From 50% to 100% is again by modulation of the thyristor controlled element
 On detection of failure of a contactor controlled element the second contactor controlled element
switches in.

Thyristor controls are being substituted by better and more reliable electrical technology. The Reboiler operates
at atmospheric pressure. Local and remote (PCS) indications are available. High Pressure alarm and shutdown
are also monitored. The temperature of the glycol in the Reboiler is maintained at the required operating
temperature of 400 °F (204 °C) by temperature indicator-controller (TIC) which in turn controls the flow of
electricity to the heating elements. High temperature shutdown is provided by a separate temperature element
and transmitter. The heat vapourises water in the circulating glycol, producing lean glycol of an intermediate
concentration (up to 99.1 %). High and low temperature alarms are brought up in the PCS. On failure of the
Reboiler heaters there will be a finite amount of time before the gas will go off specification. This will be
equivalent to the inventory of the lean glycol held within the Regeneration Unit circuit at the time (mainly in the
surge drum). This is estimated to be approximately 20 minutes and this is a normal inventory for this type of
glycol regeneration.

High temperature trips for glycol temperature, heater flanges and heater elements initiate a shutdown.

The water vapour leaves the Reboiler’s vapour space and through the structured packing of the Still Column (VE-
001) and through the Glycol Condenser (HE-002) to the vent line. The water vapour is then vented off at some
distance at a location along the LP flare tower, if the environmental allows. There are two steam traps each
located along the vent route to collect any condensate formed.

The semi-lean glycol from the bottom of the Reboiler is pumped by one of 2x100% auto start Glycol Booster
Pumps (2x100%) to the top of the Glycol Stripping Column (VE-002). These pumps are protected against
minimum flow conditions by the Reboiler high high and low low liquid level trips . As a general guide, a good
glycol circulation rate in the glycol regeneration package is 3-4 gal/lb water. Fuel gas is preheated to about 356
8 SPE 154134

°F (180 °C) in an immersion coil in the Reboiler and is then passed to the bottom of the stripping column to strip
out the remaining water in the glycol, producing the final lean glycol concentration. The reboiler operating at 400
°F (204 °C) will dry the TEG to 99.1 wt%. By introducing the sparger gas (fuel gas) at a rate of several MMscf per
day into the reboiler will enhance the dryness to a maximum 99.4 wt% beyond which the increase in sparger gas
flow rate will not achieve significantly more dryness noting the cost of the sparger gas as well. The required flow
rates for sparger gas at different conditions for other plants can be found elsewhere [Ref. 1]. COLDFINGER
process is used in the reboiler to dry the TEG to the required TEG purity of 99.9%. If the lines atop the reboiler
are long and extensive, the back pressure on the reboiler will increase the boiling point of the lean glycol
therefore the target purity of lean glycol (99.1%) may not be reached by boiling in the reboiler alone.

The gases leaving atop the reboiler contain VOCs including BTXs which are picked up by the TEG in the glycol
contactor. These are harmful to the atmosphere and environment as addressed earlier in Section 2.1. There
should typically be a stream analyzer, preferably on-line, analysing the gas composition leaving the stripping or
stahl column positioned on top of the reboiler for quality monitoring purposes. If the emission levels are not
acceptable in accordance with the local rules and regulations, the vapour must be treated further by a
combination of cooling and separation before it allowed to be vented into the atmosphere.

The lean glycol then enters the bottom of the Surge Drum under gravity flow. This Surge Drum is a horizontal
vessel typically adjacent to the Reboiler separated by a partition wall with a small opening for pressure
equalisation. This vessel operates at atmospheric pressure. It acts as a surge capacity for the circulating system
and also provides the necessary head for the Glycol Circulation Pumps. The normal operating level is between
about 1/4 and 2/3 full, and it is indicated on level gauge. The low level shutdown on the level indicator (LI) is
linked to the shutdown system.

On leaving the Surge Drum the lean glycol passes through the Glycol Interchanger (HA-003) and the Lean/Rich
exchanger where it exchanges heat with the glycol from the incoming rich glycol and the glycol from the Flash
Drum, and in doing so, the temperature is decreased from 385 °F (196 °C) to approximately 136 °F (58 °C) in this
case.

The lean glycol is further cooled to 113 °F (45 °C) by the Glycol Cooler (HE-001) which uses the seawater as the
cooling medium.

The cooled lean glycol then enters the Glycol Circulation Pumps. On the discharge of the pumps are located
(2x100%) relief valves (PSVs) which relieve back into the Surge Drum. The Glycol Circulation Pumps, one
running and one standby, take suction from the Glycol Cooler (HE-001) virtually at atmospheric pressure. Suction
and Discharge pulsation dampers are provided on the pumps to provide smooth flow.

It is possible to initiate auto-changeover of the pumps from PCS without tripping any other system. The standby
pump must be brought on line before switching off the duty pump. In the case of duty pump failure, the maximum
time taken to implement a changeover before the low flow switch (FT) upstream of the Contactor trips is typically
10 seconds. This value, however, may be altered as necessary.

Before entering the top of the Glycol Contactor, the lean glycol passes through the Lean Glycol Filters. The
purpose of these filters is to absorb any impurities in the glycol stream that may clog up the fine distributor holes.

The Lean Glycol Sump Tank (TB-001) is used for storing make-up glycol to the system. It is designed to provide a
capacity (in this case around 2 m3). A due consideration should be given to sizing of the make up glycol (and
other inventores) for remote offshore operations. Since glycol is viscous, a heating element is used for warming
glycol. The pressure in this tank is atmospheric. The atmospheric vent on top of the tank is equipped with
dessicant block to absorb moisture. The glycol level in the tank can be monitored by a level gauge (LG) and the
SPE 154134 9

low level shutdown signal is supplied via a level transmitter (LT). The temperature in the tank is controlled by a
TIC at 68 °F (20 °C). The Lean Glycol Sump Tank (TB-001) Pump transfers the fresh glycol from the sump tank
to the Reboiler. The pump discharge pressure is indicated via a PI. High glycol level in the Reboiler will shutdown
the pump.

Safety shutdowns for high temperature are fitted to the Glycol Sump Tank Heater element TAHH and Flange
TAHH. A high temperature sensor (TT) is used for safety shutdown if glycol temperature goes too high.

The Lean Glycol Sump Tank (TB-001) is topped up by tote tanks laid outside the Glycol Regeneration Package.
The Glycol Charge Pump (PF-001) is used to fulfil the periodic topping up requirement. This pump is drained
each time after use.

The Chemical Dosing Tanks (TB-002A/B) are laid adjacent to the Lean Glycol Sump Tank (TB-001) which
charges the system with corrosion inhibitor/antifoam chemicals upstream of the Glycol Circulation Pumps. The
operating philosophy for chemical dosing involves the Glycol Chemical Dosing Pumps (PD-003A/B) operating at
a fixed flow rate over a timed period in order to dose the required volume of chemical based on the glycol
inventory of the package. These pumps are operated manually based on on/off control. All pumps are provided
with internal relief valves to protect against overpressure. Addition of chemicals to the system is, however,
expected to be an infrequent operation. The levels in the Chemical Dosing Tanks (TB-002A/B) are monitored via
LGs and the low level shutdown signals are supplied via LTs.

For offshore operations, where layout and space are restricted, due consideration should be made to compact the
package as much as possible leaving the maintainable parts accessible.

3.0 Start Up Procedure

3.1 Normal Start Up

Before start-up of the Glycol Regeneration Unit can be commenced the following checks must be carried out.

(a) All equipment i.e., pumps, filters and vessels are inspected and bolted up.
(b) All instrument loops are checked and tested.
(c) Low pressure and low level alarms / trips are overriden.
(d) All utilities, including Instrument Air, fuel Gas, Flare Systems (HP and LP), Maintenance and Open Drains
Systems and Seawater are to be available at the “battery limits”.
(e) The equipment has been purged by pressure cycling three times with nitrogen, and pressurised to 100
kPag.
(f) Locked, interlocked and car-sealed valves are to be in their normal operating position.
(g) Spectacle blinds and spades are to be in their normal operating position.
(h) Hand valves are to be closed unless mentioned specifically otherwise.
(i) All instrumentation is to be available with sensing line block valves open.
(j) ESD systems are to be at Shutdown status.
(k) Power Generation and distribution are to be at “normal” status.
(l) Safety detection and protection systems are to be at “normal” status.

Checklists for verification of the above shall be included for each system/subsystem. Copies of these will be used
by the operator for reference on site and for providing a permanent record that initial start-up checks have been
correctly carried out.

3.2 Unit Start-up

This procedure assumes that the recycle line will be used to circulate and warm up the glycol within the
Regeneration Unit before the glycol is circulated through the Glycol Contactor.
10 SPE 154134

a) Open make-up gas to the Flash Drum and allow the pressure to rise to the operating point, 350 kPag.

b) Start one of the two Glycol Circulation Pump. Glycol will flow around the recycle line and back to the Flash
Drum and then to the Reboiler.

c) Switch on the electric heater in the Reboiler and allow the temperature to reach 212 °F (100 °C). The
temperature increase set by the temperature controller (TIC) is recommended to be accomplished in steps to
avoid degradation of glycol. The final desired glycol temperature in the Reboiler is 400 °F (204 °C).

d) It will take a minimum of several hours for the temperature in the Surge Drum and flash Drum to reach
operating temperature.

e) Start the seawater cooling to Glycol Cooler (HE-001) heat exchanger and set TIC to auto control.

f) Set levels and pressure controller settings on the Flash Drum to give stable control.

g) Set flow through the Glycol Carbon Filter (CA-002) via (FI) to approximately 10% of total glycol flow.

h) Glycol should now be flowing around the system with the Reboiler controlling at 204 °C and the temperature
profiles close to design. The start up gas line , branched off at the Glycol Contactor (VF-001) gas outlet is used to
bring the gas train in line at start up.

i) Start opening the valve positioned on the lean glycol supply line to the contactor tower. Closely monitor the
pressures rise to the Contactor pressure. As the stripping is not available at this stage the initial dryness of the
gas will be off spec corresponding to 99.0 % glycol purity giving a gas dryness of about 7 lb/MMscf (112
kg/MMsm3) . It is to be noted that injection of methanol (if available) may be implemented if required at any stage
of production to suppress the dew point.

j) Once the fuel gas is available start stripping gas via (FI). At start-up it will be necessary to use a relatively wet
fuel gas as stripping gas. In order to achieve the necessary gas dew point a higher flowrate of wet stripping gas is
required. It is therefore recommended, at start up, to pass the highest possible rate of stripping gas and then
reducing it in stages until the desired gas water spec is met. Otherwise the minimum allowable temperature
downstream of the subsea choke valves must be relaxed to avoid hydrate formation.

k) To keep the top of the Still Column at a temperature that will allow water vapour to leave but will allow any
glycol vapour to condense back into the Reboiler, a reflux condenser is installed. To set the temperature, a by-
pass valve is located across the inlet and outlet lines of the reflux condenser. This value is manually adjusted until
a temperature of 194 °F (90 °C) is observed on (TI) which is visible from the reflux condenser.

l) Fine tune all controllers to give stable control conditions.

4.0 Normal Operation

Over the life of the plant there will be considerable variations in the gas flowrates arriving at the Glycol Contactor,
thus resulting in different dehydration loads on the system. To make allowance for this variation the Regeneration
is designed for the maximum flowrate through the system. It should not be necessary to make any changes to the
control and alarm points of the system during the normal operating conditions as there is little need for active
intervention in the operation of the Glycol Contactor. Regular checks should be made of the pressure drop across
the packed bed in the Contactor to identify any increasing trends primarily caused by an increase in foaming. The
correct functioning of the level and pressure instruments should be regularly verified.

It is important that the Contactor operating pressure is normally maintained at a steady operating pressure (in this
case 54 bars (783 psig).

The Contactor is insulated to minimise heat loss from the vessel and to avoid reducing the inside wall temperature
to below the hydrocarbon dew point of the feed gas. This approach may not be applicable to very hot climates suh
as middle east but there are cold durations on annual basis. Hydrocarbon condensation in the Contactor would
SPE 154134 11

otherwise lead to foaming and excessive carry under of condensate into the regeneration loop and carryover of
glycol into the main gas line downstream, all resulting in loss of Contactor performance.

The glycol-condensate interface level at the bottom of the contactor should be monitored regularly for build-up of
condensate. Normally, condensate should not be present as its presence can lead to foaming and a reduced
performance of the Contactor. The level of condensate should be kept to a minimum above the glycol interface. A
skimming line is provided at the interface level to enable draining of condensate.

Foam control is provided primarily by maintaining satisfactory operation of the Glycol and Carbon filters and also
by the use of an antifoam agent, typically Petrolite D-13 at 10 to 100 ppm. Specific foam promoters are salts,
heavy hydrocarbons, dust, mud and some corrosion inhibitors, particularly those not formulated specifically to
avoid foam promotion.

Corrosion inhibitor, for example Petrolite K-437, will generally be batch dosed into the system on a periodic basis
to maintain 100 ppm concentration.

A pH control chemical, such as Petrolite K-430-W, should be added as batch doses periodically to maintain the
required pH of the circulating glycol by neutralising released or generated acidic components.

The following should be observed in the design phase of the regeneration package:

1) The inlet separator/knock out drum to the glycol contactor tower should be placed as close as possible to
the tower as a single phase inlet to the tower is essential for the proper operation of the contactor.
2) The lean glycol entering atop the contactor tower should be about 5°C higher than the rich glycol leaving
to avoid condensation and excessive foaming and losses
3) Although more expensive, packed towers rather than tray type are preferred. The packed section is
normally 5m in length. The demister on top of the packing must be super efficient.
4) The residence time in the flash drum should not be less than 10-12 minutes for light gases and 20
minutes for heavy gases [Ref. 6].
5) The cleanliness of glycol is essential for optimum glycol performance therefore good filtration cannot be
overstated.
6) The minimum height of still column should be 8 feet when the reboiler duty exceeds 1 MMBtu/hr [Ref. 6].
Optimum reflux is very important and this varies on ambient temperature. So the operator has to watch out for this
variable.
7) Keep the reboiler temperature at 400°F (204°C). Do not exceed this temperature as TEG degrades.
Lower temperatures result in lower degree of glycol dryness.
8) The reboiler will boil at higher temperature if the back pressure of the vent gas line is excessive and thus
the glycol purity is negatively affected. Therefore the vent line sizes should be generous and not long routed.
9) Gas sparging in the reboiler will enhance the glycol purity from a maximum of 99.1 wt% at 400°F (204°C)
to around 99.4 wt%. Sparging does not increase the glycol purity much beyond the stated value even if the
sparging rates are increased.
10) Ensure the sparger gas does not have any oxygen (often the nitrogen produced offshore carries oxygen)
as this is detrimental to the effectiveness of the glycol and causes rapid deterioration of the glycol.
11) Ensure the flash drum is sized generously to ensure full evacuation of dissolved hydrocarbons in glycol
which gets out the BTEXs as well. The operating temperature of the flash drum should not exceed 194°F (90°C)
although the normal operating temperature is 150°F (65°C).

5.0 Shutdown and Maintenance

5.1 Normal Shutdown

12 SPE 154134

Normal shutdown of the Glycol Contactor (VF-001) and the Regeneration Unit is locally achieved by a hand
switch. This will result in closure of all the ESD valves in gas and liquid service related to the glycol system. The
gas system will settle out under pressure and will be available for quick start if desired. Alternatively the gas
inventory of the Contactor can be blown down to flare as a preliminary to maintenance operations. The liquid
inventory, glycol, will be drained to the Flash Drum to reduce losses. When the vessel inventories have been
reduced as far as possible, the vessels can be depressurised to flare and then to atmospheric vent, the spade in
the drain line opened and the remaining liquids drained via the closed drains header. Each vessel is then to be
purged with nitrogen, flushed and isolated by spading (or the removal of spools and fitting of blanks), prior to
entry. The Glycol Charge Pump (PF-001) must be drained each time after use.

5.2 Procedures for Maintenance

5.2.1 Vessel Maintenance

The Glycol Contactor (VF-001) and the vessels in the Regeneration Unit are to be opened and subjected to a
thorough visual inspection at regular intervals or at total plant shutdown whichever is sooner. Particular care and
attention should be paid in the inspection of the Contactor as it is lined. Reference should be made to the
manufacturer’s operating description on greater detail concerning the inspection and maintenance of the vessels.

If the Contactor and the Dehydrator Inlet KO Drum are lined vessels they are not suitable for steam cleaning.

Maintenance work must not be carried out on equipment within the unit while it is operating. Work can only
progress after the unit has been completely shutdown.

The procedure for unit start-up must ensure that on re-start, the air that might have been drawn into the reboiler
through vent during shutdown is moved out of the system by heating the reboiler’s content before the introduction
of the stripping gas.

5.2.2 Instrument Maintenance

In general, control valves associated with the Glycol Contactor (VF-001) and the Regeneration Unit are not able
to be maintained without shutting down the compression system positioned upstream and/or downstream of the
gas drying system. It is therefore essential that the condition of all the control valves associated with these
systems are monitored and preventive maintenance carried out to ensure that the valves will operate reliably
between scheduled maintenance periods.

No changes of control valve trim size or type shall be made without careful analysis of the effect of such changes
on relief system design.

5.3 Emergency Shutdown

In general, the initiators common to the shutdown of the glycol Regeneration Package may be summarised as
follows:

PCS Panel Manual Pushbutton

Reboiler
High-High Flange Temperature
High-High Element Temperature
High-High Temperature
High-High Pressure
High-High Level
Low-Low Level
Surge Drum
SPE 154134 13

Low-Low Level
Glycol Flash Drum

High-High Level
Low-Low Level
High-High Pressure
Low-Low Pressure

The effects resulting from a Glycol Regeneration Unit shutdown are:

Shutdown of the Reboiler Heaters

Shutdown of Glycol Circulation Pumps
Shutdown of Chemical Dosing Pumps
Shutdown of Lean glycol Sump Pump (PD-001)
Shutdown of Sump Tank Heater
Glycol Contactor (VF-001) ESDVs close (Glycol to and from Contactor)
Contactor Inlet Cooler (HA-001)’s Seawater supply and return ESDVs close

6.0 Conclusions

Dehydration of the gas offshore or onshore is essential for safe operation and delivery to the terminal point. The
amount of drying should be wisely worked out by the operators and engineers as the costs of dehydration
package escalate very rapidly with the dryness specification. Setting the exact value is difficult as different
correlations predict different results. All possible scenarios of operational constraints leading to water separation
or hydrate formation should be foreseen. The gas spec set point for gas injection unit shutdown varies throughout
the life of field and may be adjusted on weekly or monthly basis to avoid unnecessary shutdowns and this is
particularly important offshore. The graphs and works presented in this paper is considered sufficient for
prediction of dew point depression requirement and the glycol concentration required if glycol usage is preferred
for dehydration. The detailed process description and flow sheet for the popular TEG dehydration is presented in
this paper together with delicate design and practical considerations. In places where there are noticeable
amounts of BTEXs present and the environmental stakes and penalties are high, due consideration should be
given to the use of types other than TEG in the glycols family for gas drying as described in this paper.
14 SPE 154134

Figure 1. Water content of natural hydrocarbons for a range of operating temperatures and pressures
[Ref. 1]
SPE 154134 15

Figure 2. TEG Concentration versus the corresponding dew point according to Worley and Parish
correlations

3.0

Temp d/s of wellhead choke

2.5

Figure 3. The gas lift temperature of the choke valve and the allowable water content versus the choke
pressure. The figure shows the the specification for the dry gas is a variable and changes with the life of
the reservoir.
16 SPE 154134

Figure 4. TEG Concentration and water content of the gas versus the corresponding dew point [Ref. 4]

Figure 5. Pressure versus hydrate formation temperature for a range of dry gas specification [Ref.2]

Parameter EG DEG TEG

Stripping gas rate High ( 3x TEG) Intermediate Very low
BTEX Emissions Very low Intermediate High (5x EG)
Glycol Losses Very high (40x TEG) Low Very low
Reboiler Temp Intermediate Intermediate High
Reboiler Duty Intermediate Low High (25%x EG)

Table 1. Effect of Glycol selection on dehydration unit parameters

SPE 154134 17

Figure 6. The process flow diagram for a gas dehydration and regeneration package as described in
paper
18 SPE 154134

Figure 7. An alternative gas dehydration package including BTXs recovery [Ref. 7].
SPE 154134 19

References

1) Gas Processors Supplier Association, Section 20 (Dehydration), 1994/1998

2) Hydrate Curve Generation report, INFOCHEM Computer Services Ltd, Aug 98
3) Parish, W. R., “Phase behaviour of the triethylene glycol-water system and dehydration/regeneration design
for extremely low dew point requirement”, 65th Annual Convention of the GPSA, TX, 1986
4) Potterril R., Contactor Design Calculations, Brown & Root, 1999
5) Ebeling H.O., “Reduce emissions from dehydration units”, Hydrocarbon Processing, April 1999, pp 107-116
6) Manning, W. P., “Guidelines for glycol dehydrator design, parts 1 &2”, Hydrocarbon processing, January and
February 1993
7) Diba, K. Dave, Glycol Regeneration Skid Proposal, Comart/Gas Conditioners International, Sep 2009
8) Moshfeghian, M.,” Absorption of Aromatics Compounds (BTEX) in TEG Dehydration Process”, Campbell Tips
of the Month, John Campbell and Company (JMC), June 2011