Hydrate and Dehydration

Gas Dehydration System
Suryas Year 2003 PMP Diversity Action Plan Agreement
ChevronTexaco Indonesian Business Unit

PT. Caltex Pacific Indonesia
Bekasap Operation GO&RT Team
August 2003

References: 1. John M. Cambells Gas Conditioning and Processing and Processing, Vol.2: The Equipment
Modules
2.
Maurice Stewards and Ken Arnolds Surface Production Operations Design of Gas Handling Systems and Facilities, 2nd Edition. E.Dendy Sloan, Jrs Hydrate Engineering, Monograph Volume 21 SPE Hendry L.Doherty Series
3.
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PT. Caltex Pacific Indonesia Bekasap GO&RT Typical Gas Plants
August 2003

Typical Gas Plant
METERING SKID
GLYCOL REGENERATION SYSTEM HP HEADER GLYCOL CONTACTOR HP-GAS SEPARATOR COOLER
MP HEADER
MP-GAS SEPARATOR
MP-GAS COMPRESSOR
August 2003

Typical Gas Plant
G/G HE INLET GAS 3 PHASE SEPARATOR CHILLER STEAM
REFRIGERANT
HC VAPOR
TO BUYER COND. FLASH TANK
RICH GLYCOL COMPRESSOR LEAN-RICH EXCHANGER REBOILER
FILTER LEAN GLYCOL
SURGE TANK
PUMP
August 2003

What factors influence gas quality?
Gas quality closely relates to the following parameters: 1. Saturated water content in lb/MMscfd 2. Free liquid content 3. Heat value in Btu/Scf 4. CO2 content in mol 5. Inert substance content in mol 6. H2S content in ppm 7. Oxygen content in %
August 2003
Hydrate and Dehydration
August 2003

Hydrate is solid water compound developed on a process flow
Hydrate forms in two fundamental ways:

1. 2. Slow cooling of a fluid as in a pipeline, or Rapid cooling caused by depressurization across valves or through a turbo expander
Three conditions promote hydrate formation in process:

1. 2. 3. Presence of free water from reservoir or pipeline condensation and natural gas components. Presence of sufficiently low temperature on the process stream Presence of sufficiently high pressure on the process steam
August 2003

Hydrate formation prevention can be accomplished through: 1. Water removal.
Separation will remove free water from gas stream.
2.
3. 4.
Maintaining of process high temperature

Pipe insulation and bundling, or steam or electrical heating process
System Pressure Decreasing

High temperature system pressure drops design through line choking.
Alcohol Inhibitors injection

Acting as antifreezes, alcohols will decrease hydrate formation temperature below operating temperature
5.
6.
Kinetic (Polymer dissolved in solvent) Inhibitors

It will bond on the hydrate surface to prevent crystal growth.
Antiagglomerants
This dispersants will cause water phase be suspended as small droplets in oil or condensate.
August 2003

Hydrate formation can be found on the following section of gas system: 1. Gas wells.
High reservoir temperature will prevent hydrate formation. However, abnormalities may arise during drilling, testing or shut-in/startup of a well.
2.
Gas pipelines
Pipeline maintained pressure above hydrate formation pressure and temperature below hydrate formation temperature will prevent hydration formation.
3.
Gas Processing Facilities

There are three reasons why we need gas processing facilities: 3.1. Requirement for water, gas and oil separation 3.2. Dehydrate gas into acceptable water content 3.3. Compression of gas for transportation. It is important to notice that water separation and gas dehydration are vital for hydrate prevention as they will help maintain insufficient water content on the gas for hydration formation.
August 2003

In gas processing facilities, Hydrate formation can be found on the following sections: 1. Low lying equipment points
such as pipeline lying under a roadway
2.
3. 4.
Points of gas expansion

Downstream of valves, expanders and other similar equipment
Points of flow obstruction

such as screens preceding heat exchangers
Points of Change in flow direction

such as pipe elbows
As a rule of thumb, Hydrate will form in a natural gas system in free water
is available and system pressure is above 166 psig at 39 oF, which indicates: 1. Gas drying or inhibitor is required for temperature approaching 39 oF 2. A more accurate hydrate estimation procedure is required
August 2003

Hydrate Formation Points
PC C B Dehydrator or Inhibitor Injection D
PC GATHERING SYSTEM E F Fuel to heater or Engine
A well GAS
Dehydrator or Inhibitor Injection
J Valve
Compressor PROCESSING PLANT
Chiller Condensate
August 2003

When we have a pipeline partial or complete blockage, questions arisen,
among others, are (1) where is the plug? (2) is the blockage composed of hydrates, paraffin, scale, sand or some combination of these?
Indication of blockage composition can be found through combination of

separators contents and pigs returns, which can provide line solids information such as hydrates, wax, scale and sand.
How to detect pipeline blockage? 1. Pigging returns can indicate implicit hydrate as hydrate can flow with
oil/condensate.
2. 3. 4. 5.
Lack of hydrate blockage does not mean lack of hydrate! Always examine pigging returns for the best hydrate indication! Changes in fluid rates or composition at separator - Separator water arrival decline indicates separators upstream hydrate Line Differential Pressure Increase indicates Line Hydration Formation Thermo-camera Gamma-ray Densitometer with Temperature Sensor
August 2003

Hydrate Formation Conditions by Gas-Gravity Methods
Gas Molecule weight ratio can be used to determine hydrate formation temperature and pressure. (from page 11 of SPE book, figure 2.8)
Knowing gas gravity and the lowest temperature of the process/pipeline, we can read the hydrate formation pressure at the gas gravity and temperature. To the left of every line, hydrates form with a gas of that gravity, while for pressure and temperature to the right of the line, system is hydrate-free.
August 2003

Hydrate Formation Conditions by Gas-Gravity Methods, an example
Find the pressure are which a gas composed of 92.67 mol% metahen, 5.29% ethane, 1.38% propane, 0.182% I-butane, 0.338% n-butane, and 0.14% pentane froms hydrate with free water at 50oF Solusion: Gas gravity is 0.603 = Mg (gas mole weight) / M air = 17.47/28.96 = 0.603 From the gas gravity table, gas gravity 0.603 in temperature of 50oF, hydrate pressure is around 450 psig.
Gas Gravity Chart

Molecule Mole Fraction yi 0.9267 0.0529 0.0138 0.0018 0.0034 0.0014 1.0000 Fraction Molecular Molecular Weight Weight in M Mixture yiM 16.0430 14.8670 30.0700 1.5907 44.0970 0.6085 58.1240 0.1058 58.1240 0.1965 72.1510 0.1010 Average Molecular Weight is 17.4700
Methane Ethane Prophane I-butane n-butane Pentane Total
A thing to remember is that the value is only approximation. However, it can be used to determine whether hydrate is potential to form or not in a system based on the data.
August 2003

Will hydrate form in my pipeline?
Knowing composition of the stream, hydrate formation temperature can be predicted using hydrate equilibrium constants in which, SUM(Yn/Kn) = 1 Where
Yn = mol fraction of hydrocarbon component n Kn = vapor solid equilibrium of component n
Kn itself can be derived from Kn = (Yn/Xn)

Xn = mol fraction of hydrocarbon component in the solid Kn value of various gas components can be taken from the charts of the following slides
Steps for determining hydrate temperature at a give pressure can be summarized; 1. Assume a hydrate formation temperature 2. Determine Kn for each component 3. Calculate Yn/Kn for each component and sum them 4. Repeat step 1-3 with other assumed temperature until getting total Yn/Kn value = 1
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Condensation of Water Vapor
Temperature at which water condenses from natural gas is called its dew point. If a gas is saturated with water vapor, it is, then, at its dew point. Amount of water vapor saturated in a gas can be checked from the next page chart. For example, at 150 oF and 3000 psi, saturated gas will contain approximately 105 lb of water vapor per MMscf of gas. If there is less water vapor, the gas is not saturated and its temperature can be reduced without water condensing. If the gas is saturated at a higher temperature and ten cooled to 150 oF, water will condense until there are only 105 lb of water vapor left on the gas.
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Water content
T e m p
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pressure

Dehydration is the of removing water from a gas and/or liquid to
eliminate free water on the process system. Inhibition is the process of adding chemical to the condensed water to stimulate hydrate formation.
Why should water be removed from the system?

Because free water can form hydrate and stimulate corrosion
Natural gas is dehydrated in one of the following methods: 1. Absorption Glycol dehydration
usually used to meet pipeline specification and field requirement
2. Adsorption
Mol Sieve, Silica Gel or Activated Alumina
used to obtain very low water content in NGL extraction and LNG plant
3. Condensation Refrigeration with Glycol or Methanol injection

usually used in transportation pipeline
August 2003

Four types of glycol are used for dehydration and/or inhibition
1. 2. 3. 4. Monoethilene glycol (MEG or EG) Diethylene glycol (DEG) Triethylene glycol (TEG) Tetraethylene glycol (TREG)
Glycol to be used in absorption must satisfy the following requirements:

1. 2. 3. 4. 5. 6. Hygroscopic, having an affinity to water Non corrosive Non-volatile, Easily regenerated to high concentrations, Insoluble in liquid hydrocarbons Non-reactive with hydrocarbon, CO2 and sulfur compounds
August 2003

Distinguishable parameters among glycol types
Ethylene Glycol
Molecular Weight Specific Gravity @ 77 F Boiling point @ 1 atm, F Freezing Point, F Viscosity, cP, @ 77 F Specific Heat @ 77 F Vapor pressure, psia @77 F Decomposition temperature, F 62.07 1.110 387.3 7.9 16.9 0.58 < 0.1 329
Diethylene Glycol
106.12 1.111 473.8 16.4 25.3 0.55 < 0.01 328
Triethylene Glycol
150.17 1.120 550.0 19 39.4 0.52 < 0.01 404
August 2003
Glycol Dehydration System
August 2003

TC DRY GAS OUT WATER VAPOR & OFF-GAS TO ATM OR INCINERATOR
TC LC
OUTLET SCRUBBER
LEAN TEG COOLER TEG PUMP TO TEG SUMP LEAN TEG SURGE TANK LEAN/RICH TEG EXCHANGER FLASHED VAPOR TO FUEL OR FLARE (LEAN TEG) REBOILER
GLYCOL CONTACTOR
PC
LC
FLASH DRUM
LC
WET GAS IN
LC
TO HC DRAIN
LC INLET SEPARATOR CARBON FILTERS SOCK FILTERS TO HC DRAIN
August 2003
Typical Glycol Regeneration System
(RICH TEG)

Wet gas, free of liquid water, enters bottom of contactor and flows countercurrent to glycol. Glycol-gas contacts occurs on trays or packing where glycol absorbs water from gas, leaving the dried gas flow upward to the top of the contactor while the lean glycol enriched with absorbed water leaves the contactor through the bottom line of the contactor.
Rich glycol, leaving the contractor will flow to a reflux condenser at the top of the still column and, then, to a flash tank where the entrained and soluble (volatile) components are vaporized.
Leaving the flash drum, the rich glycol will flow through glycol carbon filters before being heated in lean-rich exchanger from which it flows to still column for water distillation. The distillation process in still column and reboiler is the true glycol re-concentration media, i.e, the parts where rich glycol be turned to rich glycol.
August 2003

To properly absorbs gas water content in contactor (knowing how much water to absorb from incoming gas), gas system personnel needs to know:
1. Minimum concentration of lean glycol entering the contactor 2. Lean glycol rate required to pick up water from the gas
The higher glycol concentration, the higher water removal rate be The higher glycol circulation rate, the higher water removal rate be
As the concentration of lean glycol entering the contactor is a predefined value, then, things to calculate is only the lean glycol rate required to pick up water from gas. Approximation of the glycol circulation rate can be obtained by knowing (1)
lean glycol concentration, (2) entering gas water content and (3) outgoing gas water content
Combined with the use of the following approximation chart to get the circulation rate in liters TEG/kg water or in gallon TEG/ lb water.
August 2003
August 2003

Example: Find circulation rate of 98.7 wt % lean TEG required to dry 106 std m3/d (35.4 MMscfd) of gas at 7 Mpa (1000 psia) and 40 oC (104 oF) to achieve an exit gas water content of 117 kg/ 106 std m3(7 lbm/MMscf) if the incoming gas water content is 110 kg/ 106 std m3(68.5 lbm/MMscf) Solution#1 Water removal = (Win-Wout)/Win = (1100-117)/1100 = 0.894 From the chart, at 98.7 wt % TEG, the rate is around 35 liters TEG/kg
water
Solution#2 Water removal = (Win-Wout)/Win = (68.5-7)/68.5 = 0.898 From the chart, at 98.7 wt % TEG, the rate is around 4.4 gal TEG/lb water
August 2003
TEG Regeneration
August 2003

TC DRY GAS OUT WATER VAPOR & OFF-GAS TO ATM OR INCINERATOR
TC LC
OUTLET SCRUBBER
LEAN TEG COOLER TEG PUMP TO TEG SUMP LEAN TEG SURGE TANK LEAN/RICH TEG EXCHANGER FLASHED VAPOR TO FUEL OR FLARE (LEAN TEG) REBOILER
GLYCOL CONTACTOR
PC
LC
FLASH DRUM
LC
WET GAS IN
LC
TO HC DRAIN
LC INLET SEPARATOR CARBON FILTERS SOCK FILTERS TO HC DRAIN
August 2003
Typical Glycol Regeneration System
(RICH TEG)

Regeneration system consists of a reboiler, still column and a gas stripping column. Lean glycol concentration is controlled with adjustment of reboiler temperature, pressure and possible use of a stripping gas, while Concentration of rich glycol leaving a contactor can be calculated with : %wt of rich TEG = (j.(%wt of lean TEG))/(j + (1/CR))
Where is equal to 1.12 kg/lt or 9.3 lb/gal
One thing to notice is that, whatever rich glycol concentration flown to an atmospheric pressure glycol regeneration system, in no stripping gas, the lean glycol concentration will be: * 98.1 wt % if the reboiler temperature is maintained 128 oC or 360 oF * 98.4 wt % if the reboiler temperature is maintained 193 oC or 380 oF * 98.7 wt % if the reboiler temperature is maintained 204 oC or 400 oF. One other thing to notice is than 20 oF reboiler increase of decrease will cause the lean glycol wt % increase or decrease by 0.3 wt %, however NEVER let temperature exceeds 400 oF.
For stripping gas usage, the lean glycol wt % can be approximated with the following chart (figure 18.12 JMC page 359)
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Still column is the fractionator portion of the regenerator in which rich glycol is fractionated to some portions of water vapour, and lean glycol fractions. Flash Drum is used to remove light hydrocarbons, CO2 and/or H2S absorbed or entrained with glycol, and to separate liquid hydrocarbons from glycol to prevent it from entering the reboiler and causing fouling and foaming. Notwithstanding that flash drum should not contain liquid hydrocarbon, sometimes, we may find it there. Consequently, it is wise to have some kinds of skimmer to separate liquid condensate from rich glycol. Filters in the regeneration system is used to reduce solids from rich glycol
to about 100 ppm which will reduce corrosion, plugging and solid deposits in the reboiler and may reduce foaming losses.
Filters effectiveness can be checked through differential pressure inspection. As it reaches 25 psi, it needs replacement.
August 2003

Lean-Rich Glycol Heat Exchanger is designed to have lean glycol exchanger outgoing temperature of around 60 65 oC. Reboiler is the actual location of regeneration kitchen in which heat source, such as hot oil, steam or electrical resistance heater, is usually direct fired with fire tubes immersed in a glycol bath. Surge tank is installed in regeneration system to give at least 20 minutes retention times between pumpings with sufficient volume to accept glycol drained from the reboiler to allow repair or inspection of fire tube or heating coil. Glycol Circulating Pump is installed to provide flexibility to increase glycol circulation rate to meet dew-point requirements Types of pumps to use in this function can be reciprocating multiplex type with conservative slow piston speed. Lean Glycol Cooler is designed to have temperature of the lean glycol entering the top of contactor be within 5-10 oC.
August 2003

One thing that must be made sure in glycol dehydration system is that whatever gas fed to the contactor should have been free of liquid hydrocarbons, liquid water, solids, corrosion inhibitor, etc, i.e, gas must be sufficiently clean and free of liquid before dehydrated. It is wise to make sure that gas planned to be glycol dehydrated be flown to a separator or to a slug catcher before being flown to contactor.
Other important thing to remember is that glycol must be free of nonvolatile contaminant such as salt or hydrocarbon. Salt can cause plugging which increases pressure drops and flow rate in regeneration parts such as reboiler, still column and exchangers. In addition to causing things caused by salt, hydrocarbon can stimulate foaming in contactor and cause filters damage.
August 2003
How much glycol is required?
August 2003

Estimation of Hydrate Inhibitors Needed in Free-Water phase
Gas gravity chart described before may be combined with Hammerschmidth equation to estimate hydrate depression temperature for several inhibitors: dT = CIWI /(MI (100-WI)) Where dT = hydrate depression, (Teq Top), oF at the pressure CI = constant for particular inhibitor (2 for MEG) WI = weight % of inhibitor in the liquid MI = molecular weight of inhibitor (62 for MEG)
This equation is usable to determine amount of inhibitor to prevent hydrate formation with great accuracy
August 2003

Estimation of Hydrate Inhibitors Needed in Pipeline
Three considerations must be analyzed before injecting inhibitors to pipelines 1. Amount of inhibitors in free-water phase 2. Amount of inhibitor lost to gas phase 3. Amount of inhibitor lost to condensate phase Rule of thumb : For long pipelines approaching ocean, bottom temperature of 39 oF, the lowest water content can be tabulated
Gas Water Content at 39 oF
Pipe pressure, psia water content, lbm/MMscfd 500 15 1000 9 1500 7 2000 5.5
Rule of thumb : At 39 oF, and pressure greater than 1000 psia, the maximum amount of MEG lost to the gas is 0.02 lbm/MMscfd.
August 2003
Rules of Thumb
August 2003

1. At 39 oF, hydrates will form in anural gas system if free water is available and the pressure is greater than 166 psig.
2.
3.
It is always better to expand a dehydrated gas than a moist gas to prevent hydrate formation
Where drying is not a possibility, it is always better to take a large pressure drop at a process condition where the inlet temperature is high. Hydrate blockages occur owing to abnormal operating conditions such as well tests with water, loss of inhibitor injection, dehydration malfunction, startup and shut-in.
4.
5.
In gas/water systems, hydrates tend to form on the pie wall. In gas.condensate or gas/oil systems, hydrates frequently form from free water as particles that agglomerate and bridge as larger masses in the bulk stream.
August 2003

6. A lack of hydrate blockages does not indicate a lack of hydrates. Frequently, hydrates form but flow with an oil/condensate (e.g., in an oil with a natural dispersant present) so they can be detected in pigging returns. Attempts to blow the plug out of the line by increasing pressure differentials result in more hydrate formation because higher pressure place the system farther into the hydrate-formation region. When a hydrate blockage is experienced, for safety reason, the first step is to inject inhibitor from any access point. As gas is cooled from reservoir temperature, the amount of water vapor contained in the gas will decrease. That is water will condense
7.
8.
August 2003
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August 2003

Hydrate and Dehydration

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Gas Dehydration System

Suryas Year 2003 PMP Diversity Action Plan Agreement

ChevronTexaco Indonesian Business Unit

Gas Dehydration System

Gas Dehydration System

PT. Caltex Pacific Indonesia Bekasap GO&RT Typical Gas Plants

Gas Dehydration System

GLYCOL REGENERATION SYSTEM HP HEADER GLYCOL CONTACTOR HP-GAS SEPARATOR COOLER

Gas Dehydration System

TO BUYER COND. FLASH TANK

RICH GLYCOL COMPRESSOR LEAN-RICH EXCHANGER REBOILER

FILTER LEAN GLYCOL

Gas Dehydration System

Gas Dehydration System