Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

TABLE OF CONTENTS
Section Description Section Page
Ref.

1.0 Purpose 1
2.0 Pre-Requisites 2
3.0 Procedures Steps 2-10
4.0 Training & Implementation 10

Approvals

Prepared G.Sureh 22/01/2020

By:
Date

Checked By: B.Maduike 29/01/2020

Date
Ravindranath.Gutta
Checked By:
24/02/2020 Date

Approved by:
Date

Approved by:
Date

Revision
Rev. Changed Prepared Changed
Date Approved
No. Section By By
0
1
2

Document No: GPP1-01 Revision No: 1 Sheet: 1 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

1. 0 Purpose

The purpose of this Procedure is to describe the tasks, activities and preparation of
dehydration unit which comprises of Dehydration absorbers, Regeneration
compressor, lube oil pump, and lube oil coolers, hot oil heater and dehydration dust
filters. This document shall be used during the Startup/shutdown/Operation of the
dehydration unit

2.0 Pre-Requisites Information

a) All maintenance has been completed on the C-111/ E-211 and dust filters
F-416/417 & Fin fan coolers A-311A/B.
The Maintenance Supervisor ensures that no further jobs are scheduled or
on-going signifying that start-up can be performed.
b) All Permits (Hot and Cold) related to the all equipment’s and motors are
closed. Closed permits are located in the Permit Controller office in the
permit rack.
c) De-Isolation & De-blinding has been done and Isolation & Blinds Lists signed
off.
d) All Tags removed returned as per the Procedure.
e) Maintenance handed over all equipment after maintenance to Operations.
f) Disturbed Flange list has been signed off after the leak test.

3.0 Procedure Steps

3.1 Process Description
The Dehydration system receives gas from the inlet gas system. The
dehydration system is used to remove the moisture from the inlet (feed) gas.
It consists of three bed molecular Sieve System. Once molecular sieves are
saturated with water, they must be regenerated by passing hot gas through
the molecular sieve beds. That can be done by using Regeneration
Compressor C-111.The heat drives the water off the molecular sieves and the
gas stream carries the desorbed the water out of bed. Each vessel is sized for
half the design inlet gas flow. This allows two of the vessels to be on stream
for water adsorption while the third vessel is being regenerated.

Document No: GPP1-01 Revision No: 1 Sheet: 2 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

The system is time controlled to switch beds every 16 hours. At design conditions
two beds are in adsorption at all times while the third bed is in regeneration. The
regeneration cycles last 8 hours and required 10.88KNm3/hr (mmscf/d) of
regeneration gas to regenerate the bed. The regeneration gas is taken from the
dehydration dust filters F-416/417.
During heating cycle, the heated regeneration gas routed to the bottom of the
dehydration adsorbers to regenerate the beds. During cooling cycle, the
regeneration gas heater is bypassed and cool regeneration gas routed to the
bottom of the dehydration adsorber to cool the bed. During both heating and
cooling mode regeneration gas goes through the V-418. V-418 helps remove the
moisture stripped from the bed during regeneration

3.2 List of Equipment

S/no. Equipment number Equipment Description

1 F-412 Dehydration inlet filter/Coalescer

2 F-416/417 Dehydration Dust Filter

3 V-413/414/415 Dehydration Adsorbers

4 V-418 Regeneration Gas Scrubber

5 A-311 Regeneration Gas Cooler

6 C-111 Regeneration Gas Compressor

7 F-411 Regeneration Seal Gas Filter/Coalescer

8 E-211 Regeneration Gas Heater

Document No: GPP1-01 Revision No: 1 Sheet: 3 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

4.0 INITIAL VALVE POSITIONS

INITIAL VALVES POSITION

S/no. Description Signature

Dehydration Dust Filters F-416/417

1.0 Ensure the following Dehydration Dust filter,
F-416/417 valves are OPEN

1 1.1. D8RF-H2 , 1559 F-416 outlet valve

1.2. D8RF-H2, 1548, F-417 outlet valve
1.3. D8RF-H2, 1551 F-416 inlet valve
1.4. D8RF-H2, 1541 F-417 inlet valve
2.0 Ensure the following Dehydration Dust filter,
F-416/417 Valves are CLOSED

2.1. U2TR- H2, 1545, 0.5” F-416 vent valve

2.2. U2TR- H2, 1555, 0.5” F-417 vent valve
2 2.3. U2TR- H2, 1558, 0.5 F-416 drain valve
2.4. U2TR- H2, 1549 0.5 F-417 drain valve
2.5 X4S-H2 , 1540 1" F-417 main inlet
bypass valve
2.6. X4S-H2 , 1550 1" F-416 main inlet
bypass valve

3 3.0 Ensure crack open 1" main inlet bypass valves of

F-416/417 for pressurization. Once system is
pressurized then close the main inlet bypass valve of
F-416/417 and open the inlet valves of F-416/417

Document No: GPP1-01 Revision No: 1 Sheet: 4 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

Regeneration Gas Heater E-211 valve

4.0 Ensure the following E-211 vent and drain valves are
CLOSED
4.1. 1734, 0.5 " PSV-211 vent
4.2. 1747, 0.75” E-211 Tube side inlet vent
4 4.3. 1748, 0.75 “ E -211 Tube side outlet drain
4.4. 1739, 0.75" E-211 Shell side inlet low point
drain
4.5. 1735, 0.5 " E-211 Shell side outlet vent

5.0 Ensure the following E-211 Tube side inlet are

5 OPEN.
5.1. 1737, 6" E-211 Tube side outlet valve is open
6.0. Ensure the following TCV-211 Hot oil shell side isolation
valves are OPEN
6.1. 1742, 4“ TCV-211 upstream isolation valve
6 6.2. 1740, 4" TCV-211 downstream isolation valve
6.3. 1736, 4" E-211 downstream isolation valve

7.0. Ensure the following TCV-211 hot oil bypass / drain

valves are CLOSED
7 7.1. 1741, 3” TCV-211 bypass
7.2. 1743, 0.75" TCV-211 drain

Regeneration Suction Scrubber V-418

8.0 Ensure the following LCV-418 Valves are CLOSED
8 8.1. 1732, 1" LCV-418 bypass
8.2. 1729, 3/4" LCV-418 drain

9.0. Ensure the following LCV-418 isolation valves are

OPEN
9 9.1. 1728, 1" LCV-418 inlet
9.2. 1731, 1" LCV-418 outlet

Document No: GPP1-01 Revision No: 1 Sheet: 5 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

Regeneration Compressor C-111 Seal Gas System

10.0 Ensure seal gas coalescer/filter (F-411) drain/vent
valves are CLOSED
10
10.1 Ensure seal gas coalescer inlet and outlet
Valves are OPENED

Regeneration Compressor C-111

11.0 Ensure the compressor casing drain
(1/2"U2TR-H2-1778) is CLOSED
Ensure the following FCV-111 valves are CLOSED
11.1. 1715, 4" FCV--111 bypass
11.2. 1713, 3/4" FCV-111 drain
11 11.3. 1745, 6" FCV-111 outlet to flare
Ensure the following Regeneration gas
Compressor, C-111 valves are OPEN
11.4. 1703, 6" Main Suction valve
11.5. 1705, 1/2" PI-111 outlet valve
11.6. 1707, 6" Main discharge valve

4.1 Normal Start up

S/no. Description Signature

Ensure inlet gas system is running as per inlet gas system

1 procedure.

Ensure entire dehydration loop is moisture free ( should be purge

2 with nitrogen ).

All valve position in Dehydration and Regeneration Compressor

3 loop should be as per initial valve position list

Ensure V-413/414/415 Pressurized by using inlet bypass isolation

4 valves X1SR-H2 1626/1627/1628 respectively. After pressurizing
monitor pressures at PT-413B/414B/415B then CLOSE inlet
bypass isolation valves

Document No: GPP1-01 Revision No: 1 Sheet: 6 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

Ensure all drive motors of C-111, lube oil pump, lube oil cooler
5 fan are in energized condition at the MCC.

Ensure hot oil system H-768 is in service in accordance with the

6 hot oil system procedure.

Keep Regeneration cooler fans A-311 in Auto mode and start one
7 or both fans as necessary.

8 Keep V-418, LIC -418 in auto mode with set point 40%

Ensure E-211 hot oil supply inlet and outlet manual valves are in
9 open position. And TCV-211 in AUTO mode with set point
262.67oC
10 Continuously 2 beds in service mode for 16 hours & 1 bed
regeneration mode for 8 hours’ period. Every 8 hours, one bed
begins its 16-hour adsorption cycle, another bed half way through
its 16 hour adsorption cycle and third bed is starting its
regeneration cycle. The regeneration cycle as following steps.
Step 1 – Time (00) – Close V-413 Process Valves (Close XV-
413A & XV-413B Process Gas, XV-413C & XV-413D Regen Gas,
11 XV-211A Regen Gas to Heater & Open XV-211B Regen Heater
Bypass).

12 Step 2 – Time (2 min) – Open V-413 Regen Valves & XV-211A

(Open XV-413C & XV-413D Regen Gas, XV211A) (XV-413 A&B,
XV-211B in the same position as in Step 1)
13 Step 3 – Time (2 min 30 secs) – Close XV-211B Regen Heater
Bypass (Close XV-211B other Valves in the same position as in
Step 2)
14 Step 4 – Time (3 min) – Start Regen Gas Compressor, C-111 &
Regen Heater E-211 & Open TCV-211 Hot Oil to Regen Heater
(Valves in the same position as in Step 3). Heating Cycle of V-413
starts.
15 Step 5 – Time (4 hrs 3min) – Close TCV-211. Heating Cycle
completes. (All Valves in the same position as in Step 4)

16 Step 6 – Time (4 hrs 3 min 30 secs) – Open XV-211B Regen

Heater Bypass. Cooling Cycle of V-413 starts. (Open VX-211B &
other valves in the same position as in Step 5)

Document No: GPP1-01 Revision No: 1 Sheet: 7 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

17 Step 7 – Time (4 hrs 4 min) – Close XV-211A Regen Gas to

Heater (Close XV-211A & all other Valves in the same position as
in Step 6)
18 Step 8 – Time (7 hrs 57 min 30 sec) – Cooling Cycle
completes. Close V-413 Regen Valves & Stop C-111.
Regeneration Cycle of V-413 completes. V-413 Bed idle. (Close
XV-413A & XV-413B, XV-413C & XV-413D, XV-211A, Open XV-
211B, Stop C-111).
19 Step 9 – Time (7 hrs 58 min) – Open V-413 Process Gas
Valves. V-413 ready for Adsorption Cycle (Open XV-413A & XV-
413B, XV-211B, Close XV-413C & XV-413D, XV-211A).
20 The above explains the steps involved in the Regeneration Cycle
for V-413. The steps involved for the beds V-414 / V-415 for
Regeneration Cycles is the same, only the valve tags changes.
21 Check dehydration sequencing matrix to see whether the
Regeneration Gas compressor C-111 will be running when the
dehydration sequencing timer is started in one of the following
steps.
If C-111 will not be running when the dehydration sequencing
22 timer is restarted, place C-111 in Auto mode.

Keep FIC-111 in manual position with about FIC-111 50% open.

23 Ensure C-111 suction and discharge manual valves are open
position
In the Heating Cycle (Step#4), Start C-111 Regen Compressor’s
24 Oil Pre lube Pump and Oil Cooler. When PSL-111 clears start a 15
to 30 seconds timer. When the timer times out start the
Compressor C-111 main motor. Start a 30 second timer and
when it times out stop the Oil Pre lube Pump.
Establish flow through FIC-111 above min flow and compressor
25 parameters are normal switch FIC-111 in AUTO mode with set
point 9.6 MMSCF/D (11300 KNm3/hr).
NOTE: During plant normal running condition, if regeneration
compressor C-111 tripped due to any ESD activated related to
Regen gas loop, then IMMEDIATELY do following steps.
26 Open C-111 discharge to flare valve D2RR-H2-1745
Open 4” C-111 bypass valve D2RR-H2-1709
Close C-111 suction isolation valve D8RR-H2-1703
Close C-111 discharge isolation valve going to F-412
(D8RR-H2-1744)

Document No: GPP1-01 Revision No: 1 Sheet: 8 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

4.2 Normal Shutdown

S/no. Description Signature

1 Stop the Dehydration sequencing timer.

Stop Regeneration compressor C-111 and leaves HOA switch in

2 OFF mode.

Ensure Auxiliary lube oil pump running for 15minutes period

3 once C-111 stop command receives

4 Verify the TCV-211, hot oil supply to regen gas heater E-211
closes.

5 Shutdown the regen gas cooler A-311A/B and leave the HOA
switch in OFF mode.

Ensure monitor the all temperatures, pressures, liquid levels

6 during the shutdown period.

NOTE: Block in applicable control valves (close main inlet and outlet isolation valves)

CAUTION: DO not expose to molecular sieves to air. Flammable materials deposits on

the molecular sieves during normal operation may ignite resulting in fire in dehydration
absorbers

4.3 Emergency Shutdown

S/no. Description Signature

Document No: GPP1-01 Revision No: 1 Sheet: 9 of 10

Issue Date: 22-Jan-2020
 Alacrity Production Systems Ltd

Dehydration Unit Start up and Shutdown procedure

Group: GPP1 Operations Document No. AHL -01

Department: Operations Revision: 1

Emergency shutdown initiated by any of the following 3 causes

Fire Detection
1 Combustible gas detection
Manual initiation
Whenever ESD occurs, vessels in the dehydration system
2 should not blocked nor vented.

3 Get all the workers to assembly point or Muster point.

4 Ensure dehydration and regeneration loop all XVs are closed.

Ensure Regen gas compressor C-111, lube oil pump, lube oil
5 cooler are shutdown.

6 Ensure hot oil heater E-211,TCV-211 are in close position

NOTE: Due to ESD activation if required start depressurizing the loop from C-111
discharge to flare or C-111 suction side PRV's bypass to flare.

5.0 Training & Implementation

 Training required for field operators are; how to start/shutdown of C-111.

 Training required for operators on how to handle Emergency’s i.e. Fire/ gas leaks
 F-416/417 online handover to mechanical for filter elements cleaning or
replacement.
 Hot work/ confined space/ line break permit training required for field operators.
 Handling DCP/CO2 and Foam, Fire hose nozzles operating training for field
operators.

Document No: GPP1-01 Revision No: 1 Sheet: 10 of 10

Issue Date: 22-Jan-2020