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TECHNICAL DESIGN MANUAL

Document Title: TEG Package Design


Practice
Document No: 000-DP-004

One CompanyUnlimited Solutions.


TECHNICAL DESIGN MANUAL
TECHNICAL DESIGN MANUAL
Document No: 000-DP-004 Rev. C

Document Revision Status

Rev Date By Checked Approved Comments

NOV Mission Products UK Ltd, Brent Avenue, Montrose, Angus, DD10 9PB, Scotland
Tel: +44(0)1674 662200 Fax: +44(0)1674 662266

Confidential: The copyright in this work is vested in NOV Mission Products UK Ltd. The information
presented herein is considered proprietary and confidential by NOV Mission Products UK Ltd and the
recipients of this manual are asked to maintain this information as confidential and not to disclose or
publish the information contained herein without the express written consent of NOV Mission Products
UK Ltd.

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TECHNICAL DESIGN MANUAL
Document No: 000-DP-004 Rev. C

RECORD OF AMENDMENT

It is certified that the amendments listed below have been incorporated in this copy of the
publication.

Amendment
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Manual Doc No :

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Holder :

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This manual is targeted at individuals involved in the design process and contains
proprietary and confidential information. Who qualifies to receive a copy of the manual
will be decided by the manager of each facility. The manuals will be password protected
and have additional security features applied.

All Technical Design Manual updates will be controlled with a record of amendment. Any
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TECHNICAL DESIGN MANUAL
Document No: 000-DP-004 Rev. C

corrections or improvements should be forwarded to the Holder.

WARNING

This document and the information herein is the property of NOV no part of it may
be reproduced or disclosed or used for any purpose other than for which it was
issued without the written consent of NOV.

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TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................... 8
1.1 PURPOSE OF THIS MANUAL.................................................................................................... 8
1.2 PRODUCT INFORMATION ....................................................................................................... 8

2 PRODUCT DESCRIPTION .................................................................................. 8


2.1 PRINCIPLE OF OPERATION...................................................................................................... 9
2.1.1 Desanding ................................................................................................................................................ 11
2.1.2 Sand Cleaning ........................................................................................................................................... 11
2.1.3 Sand Disposal ........................................................................................................................................... 11
2.1.4 Environmental Considerations ................................................................................................................. 11
2.2 SOLID/LIQUID CYCLONES..................................................................................................... 11
2.3 JET PUMP ........................................................................................................................ 11
2.4 APPLICATIONS ................................................................................................................... 11

3 TORESCRUB PRODUCT RANGE ................................................................... 11


3.1 STANDARD OFFERING ......................................................................................................... 11
3.2 TORESCRUB VESSEL DESIGN CRITERIA................................................................................. 11
3.3 TORESCRUB STANDARD OUTLINES .................................................................................... 11
3.4 SOLID LIQUID CERAMIC CYCLONE- PRODUCT RANGE ................................................................ 12

4 PROPOSAL/CONCEPTUAL DESIGN ................................................................. 12


4.1 INFORMATION REQUIRED .................................................................................................... 12
4.1.1 Essential Information .......................................................................................................................... 12
4.1.2 Desirable Information ......................................................................................................................... 12
4.2 DESIGN OUTPUTS .............................................................................................................. 12

5 DETAILED PROCESS DESIGN .......................................................................... 12


5.1 GENERAL DESIGN .................................................................................................................. 12
5.1.1 Solid-Liquid Cyclone Sizing.................................................................................................................. 12
5.1.2 S-L Cyclone Inlet Concentration ......................................................................................................... 12
5.1.3 Jet Pump Sizing .................................................................................................................................. 12
5.1.4 Accumulator Sizing ............................................................................................................................. 12
5.1.5 Inlet /Outlet Sizing .............................................................................................................................. 13
5.1.6 Balance Line Sizing .............................................................................................................................. 13
5.2 OTHER CONSIDERATIONS .................................................................................................... 13
5.2.1 Flowrate Balancing ............................................................................................................................. 13
5.2.2 Solids Level Control ............................................................................................................................ 13
5.2.3 Tore Size........................................................................................................................................... 13
5.3 DESIGN OUTPUTS .............................................................................................................. 13

6 DETAILED MECHANICAL DESIGN.................................................................... 13


6.1 INFORMATION REQUIRED .................................................................................................... 13
6.2 GENERAL DESIGN .............................................................................................................. 13

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6.2.1 Overall Criteria .................................................................................................................................... 13


6.2.2 Safety .................................................................................................................................................. 13
6.2.3 Access ................................................................................................................................................. 13
6.2.4 Transportation/Installation/Lifting ..................................................................................................... 13
6.2.5 Cost of Construction ........................................................................................................................... 13
6.3 VESSEL DESIGN ................................................................................................................. 13
6.3.1 Design Code ........................................................................................................................................ 13
6.3.2 Nozzle Schedule .................................................................................................................................. 13
6.3.3 Vessel Openings .................................................................................................................................. 13
6.3.4 Materials ............................................................................................................................................. 13
6.3.5 Design Calculations ............................................................................................................................. 14
6.3.6 Gaskets and Seals ............................................................................................................................... 14
6.3.7 Bolting................................................................................................................................................. 14
6.4 PIPING DESIGN.................................................................................................................. 14
6.4.1 Slurry Piping ........................................................................................................................................ 14
6.4.2 Pipe Flexibility ..................................................................................................................................... 14
6.5 JET PUMP INSTALLATION REQUIREMENTS ............................................................................... 14
6.5.2 Installation .......................................................................................................................................... 14
6.5.3 Installation Precautions ...................................................................................................................... 14
6.5.4 Jet Pump Mounting Orientations ....................................................................................................... 14
6.5.5 General Recommendations ................................................................................................................ 14
6.6 DESIGN OUTPUT................................................................................................................ 14
6.7 RELEVANT SPECIFICATIONS .................................................................................................. 14

7 TORESCRUB INSTRUMENTATION & CONTROL ........................................... 14


7.1 STANDALONE UNIT WITH MANUAL CONTROLS ........................................................................ 14
7.2 AUTOMATED SYSTEMS FOR FIXED INSTALLATIONS .................................................................... 14

8 MAINTENANCE / TROUBLESHOOTING........................................................... 14
8.1 CYCLONE INSTALLATION/REMOVAL ....................................................................................... 14

9 DRAWINGS .................................................................................................... 14
9.1 PIPING AND INSTRUMENTATION DRAWINGS MANUAL & AUTOMATED ....................................... 14
9.2 TYPICAL PACKAGE GENERAL ARRANGEMENT DRAWING .............................................................. 15

10 APPENDICES ............................................................................................... 15
10.1 WORKED EXAMPLE ............................................................................................................ 15
10.2 APPENDIX A SOLID-LIQUID HYDROCYCLONE SIZING CALCULATION PC024 ................................... 15
10.3 APPENDIX B JET PUMP CALCULATION .................................................................................. 15
10.4 APPENDIX D JET PUMP DATASHEET ..................................................................................... 15
10.5 APPENDIX C TYPICAL TORESCRUB DATASHEET ..................................................................... 15

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1 INTRODUCTION
Dehydration is the process of removing water from a gas and/or liquid to ensure no condensed
water is present in the system. On the other hand, inhibition is the process of adding a certain
chemical to the condensed water so that hydrates cannot be formed.

1.1 Purpose of this Manual

1.2 Product Information

2 PRODUCT DESCRIPTION

The scope of this package is to remove water content from the wet Feed Gas to achieve a water
dew point of less than 5oC at 40 bar(a). Water is removed using Tri-Ethylene Glycol (TEG) in the
Gas Dehydration Column (3100-VE-001). The Gas Dehydration System (Unit 310) and Glycol
Regeneration System (Unit 380) are both essential systems in the dehydration process.
The process workflow for this package starts with Rich TEG flowing from the bottom of the Gas
Dehydration Column (3100-VE-001) to be pre heated in the TEG Pre Heater Coil (3800-HR-001).
The TEG Pre Heater Coil is installed at top section of the Still Column (3800-VE-001).
Consequently, the Rich TEG is heated in the TEG Heater (3800-HA-001) where the Rich TEG is
heated by heat exchanged with the hot Lean TEG from the Lean/Rich TEG Exchanger (3800-HA-
002). The hot Rich TEG is then send to the Flash Vessel (3800-VA-001) where the dissolved gas
or light ends are released and the solved liquid hydrocarbon are separated. The released gas is
sent to the Sour Gas Compression System (Unit 360), while the separated hydrocarbon liquid is
sent intermittently to the Closed Drain System (Unit 550). The Rich TEG which settles at the
bottom of the Flash Vessel (3800-VA-001) is then filtered in the TEG Cartridge Filters (3800-CL-
001-A/B), followed by TEG Charcoal Filter (3800-CN-001) and finally in the Post Filter (3800-CL-
002). Impurities such as solids can occur from corrosion within the glycol system and thus they
should be removed. As such, these filters are essential to maintain the condition of the
recirculating glycol in as clean as possible.
The clean Rich TEG will be directed to the Lean/Rich TEG Exchanger (3800-HA-002) where heat
is further exchanged with the hot Lean TEG to a temperature up to 160oC. The Rich TEG is then
flowed into the Still Column (3800-VE-001) which is installed at the top of the TEG Reboiler
(3800-VA-004). An Electrical Coil (3800-HR-001) is fitted inside the TEG Reboiler Vessel where
the Rich TEG is heated up to a temperature of 204.4oC. By boiling off the Rich TEG in the still
and reboiler to near its boiling point (TEG degrades beyond 204.4oC), the glycol virtually
releases all of the absorbed water and other components and thus regeneration is
accomplished. To further improve the purity of the glycol by removing more light ends, a
Stripping Column (3800-VE-002) is added to facilitate the function of the TEG Reboiler, utilising
Fuel Gas from Unit 420 as stripping gas. Thus, the lean TEG leaving the TEG Reboiler enters the
top section of the Stripping Column while Fuel Gas enters from the bottom of the stripper. The
top product of the stripper is recycled back into the TEG Reboiler while the bottom product of
the stripper enters the Surge Tank (3800-VA-003) via gravity flow.
The lean TEG stream is then directed to the TEG Booster Pumps (3800-PA-002-A/B), electrically
motor driven where the fluids are pumped to the Lean/Rich TEG Exchanger (3800-HA-002).

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Lean TEG enters the shell side of the exchanger where it gets cooled by exchanging heat with
the Rich TEG in the tube side of the exchanger. Thereafter, the lean TEG enters the shell side of
the TEG Heater (3800-HA-001) where it is further cooled by exchanging heat with the Rich TEG
in the tube section. The cooled Lean TEG is then sent to the Glycol Storage Vessel (3800-VA-
002). Since there will be unforeseeable losses of TEG in the system, glycol make-up is achieved
by means of an external supply of TEG fed directly to the Glycol Storage Vessel (3800-VA-002).
The Lean TEG needs to be fed back to the TEG Dehydration Column, as such the pressure of the
fluid needs to be increased by using the TEG Circulation Pumps (3800-PB-001-A/B). Before being
introduced back into the TEG Dehydration Column, the Lean TEG will be cooled in the Lean TEG
Cooler (3800-HA-004).
Evaporated water and glycol carried over in the vapour phase of the Still Column are eventually
sent to the Off Gas Condenser (3800-HA-003) where it is cooled before it is sent to the
Overhead Condenser KO Drum (3800-VN-001). Off gas is separated from liquid phase prior to
sending the gas to the Sour Gas Compression System (Unit 360) while the liquid phase is sent to
the Water Injection System (Unit 510).
The proposal of the TEG Regeneration package supplied meets all performance specification
mentioned in the package specification.

2.1 Principle of Operation


Industry practice-TEG, MEG and others. Impact/cost/application

Difference between absorption & adsorption-diagrams attached.

Dew point, water content, adverse effects on process downstream, TEG purity, use of dry gas a
fuel gas for stripping to increase purity of regen TEG.

TEG contactor.
Inputs for unisim
Internals
Diagrams from petrex

Heat exchangers (heater as still column)


Temperatuer approach
Inputs for unisim

Flash Drum
Application
Inputs for unisim

Filters
Charcoal and cartridge filters
Inputs for unisim

TEG Regeneration
Reboiler,

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Still Column
Inputs for unisim Degree of freedom, temperature degradation for TEG
Digrams, integrated stripper, removing light ends, keep heavy TEG & traces of water to increase
purity.

Booster pump
Inputs/in unisim.
Type of pump to use. -centrifugal

Heat exchanger (Lean/Rich TEG)


Converging/ inputs in unisim.

Since TEG is lost in flash drum and regen column, and dry gas need make up tank.
Inputs in unisim. (to complete mass balance).

TEG Recirculating Pump


Inputs for unisim
Recip pump
To deliver high pressure back to contacting column

High pressure > high temp


Need cooler (usually heat exchanger with dry gas outlet OR by means of Cooling medium)
Depends on supply of cooling water and demand.

Challenges in unisim. Feedback from promax.


Rule of thumb
1kg of TEG = 3 gal of water (starting point)
Stripping gas.
Different set up of TEG process-Drizo, etc
Inlet of gas contactor must be saturated
Fluid package and its impacts (use of stripper to determine water dew point).
Diagrams from petrex.

Spreadsheets Gas contactor sizing Cals (Previously done for Petronas)


Can develop one for NOV.
Should be roughly similar

-Separator sizing (Flash drum)


-Pump sizing (Spreadsheet)
-line sizing.(1-phase gas, 2 phase gas/liquid)

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2.1.1 Desanding

2.1.2 Sand Cleaning

2.1.3 Sand Disposal

2.1.4 Environmental Considerations

2.2 Solid/Liquid Cyclones

2.3 Jet Pump

2.4 Applications

3 ToreScrub Product Range

3.1 Standard Offering

3.2 ToreScrub Vessel Design Criteria


Solids Underflow

3.3 ToreScrub Standard Outlines

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3.4 Solid Liquid Ceramic Cyclone- Product Range

4 PROPOSAL/CONCEPTUAL DESIGN

4.1 Information Required

4.1.1 Essential Information

4.1.2 Desirable Information

4.2 Design Outputs

5 DETAILED PROCESS DESIGN

5.1 General Design

5.1.1 Solid-Liquid Cyclone Sizing

5.1.2 S-L Cyclone Inlet Concentration

5.1.3 Jet Pump Sizing

5.1.4 Accumulator Sizing

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5.1.5 Inlet /Outlet Sizing

5.1.6 Balance Line Sizing

5.2 Other Considerations

5.2.1 Flowrate Balancing

5.2.2 Solids Level Control

5.2.3 Tore Size

5.3 Design Outputs

6 DETAILED MECHANICAL DESIGN

6.1 Information Required

6.2 General Design

6.2.1 Overall Criteria

6.2.2 Safety

6.2.3 Access

6.2.4 Transportation/Installation/Lifting

6.2.5 Cost of Construction

6.3 Vessel Design

6.3.1 Design Code

6.3.2 Nozzle Schedule

6.3.3 Vessel Openings

6.3.4 Materials

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6.3.5 Design Calculations

6.3.6 Gaskets and Seals

6.3.7 Bolting

6.4 Piping Design

6.4.1 Slurry Piping

6.4.2 Pipe Flexibility

6.5 Jet Pump Installation Requirements

6.5.1 Unit Operation

6.5.2 Installation

6.5.3 Installation Precautions

6.5.4 Jet Pump Mounting Orientations

6.5.5 General Recommendations

6.6 Design Output

6.7 Relevant Specifications

7 TORESCRUB INSTRUMENTATION & CONTROL

7.1 Standalone Unit with Manual Controls

7.2 Automated Systems for Fixed Installations

8 MAINTENANCE / TROUBLESHOOTING

8.1 Cyclone Installation/Removal

DRAWINGS

9.1 Piping and Instrumentation Drawings Manual & Automated

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9.2 Typical Package General Arrangement Drawing

10 APPENDICES

10.1 Worked Example

10.2 Appendix A Solid-Liquid Hydrocyclone Sizing Calculation PC024

10.3 Appendix B Jet Pump Calculation

10.4 Appendix D Jet Pump Datasheet

10.5 Appendix C Typical ToreScrub Datasheet

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