WRITTEN TEST

PROCESS ENGINEER POSITION

(7+ years experiences)

ANSWER – Part 1
Problem solution number 1. Determining the specs break.

Initial knowledge you need to know:

You have to remember the ANSI pressure-temperature class rating, at least the yellow marked below.
Assume material is carbon steel class 1.1 as per ASME B16.5 with Maximum temp is 300 – 400 F.

Temp, 0F MAWP
150 300 400 600 900 1500 2500
-20 to 100 285 740 990 1480 2220 3705 6170
200 260 675 900 1350 2025 3375 5625
300 230 655 875 1315 1970 3280 5470
400 635 745 1270 1900 3170 5280

Another knowledge you need to know is, how to develop specs break. Herewith to refresh what
assumption has to be made in designing specs break:

1. Check valve is always passing or fail open/close in such so there is possibility a blockage fluid flow
from higher to lower pressure system.
2. Control valve, include self-contain regulator, may open or close, in such so that create a condition
that there is a part of pipe may contain of a maximum-pressure fluid.
3. Manual valve may open or close, that may support the occurrence of high pressure condition.
Lock open or lock close valve should keep valve position as is, if locking management is robust.
Process Hazard Analysis shall be done to assess whether this type of protection is acceptable. For
this application – it is recommended not to be taken into account (for determining specs break)
as valve passing is common phenomena in production facility.
4. Pressure Safety High (PSH) is assumed will not provide adequate protection, with HIPPS mode as
exception. However, HIPPS type selection shall follow thorough review, including reviewing other
alternative.
5. Pressure Safety Valve and Rupture disk are assumed always work. Designed case for PSV or RD is
block discharge case.

Now we ready to develop specs break.

We start from PT setting – set at 290 psig. The downstream facility pressure rating should higher than 290
psig, and it won’t be ANSI 150# (285 psig). Minimum is ANSI 300# (740 psig). This valid for upstream
compressor up to downstream of PCV/Anti-surge valve. Note: Upstream/downstream here means in
context of flow direction.
Specs break is also will be implemented on downstream of LCVs and BDV as fluid will go to the lower
pressure system. In here, we down from higher pressure rating to ANSI 150#. For 2 LCVs – the specs break
would be from ANSI 300# to ANSI 150#. For BDV? Will be answered later on.

If we go through along the line from outlet suction scrubber to suction of the compressor, specs break
should also apply from ANSI 300# to MAWP of the compressor – say 2000 psig. On discharge side, specs
break is applied again - from compressor’s MAWP (2000 psig) to X ANSI rating. How to determine this X
ANSI rating?

By logic – it should be higher than ANSI 300#, it could be either ANSI 400 (990 psig) or ANSI 600 (1480
psig).

There are two clue to determine this thing. First is information about cooler’s MAWP (which is 1000 psig)
and secondly from compressor maximum discharge pressure (which is 1100 psig). So, the right decision is
to select ANSI 600.

Therefore, on compressor casing outlet, there will be specs break between compressor MAWP (2000 psig)
and ANSI 600#. This ANSI 600# will be apply along the discharge side to export line and further, up to BDV,
and up to anti-surge valve.

For BDV – the specs break will be from ANSI 600# to ANSI 150#

For anti-surge valve – the specs break will be from ANSI 600# to ANSI 300#.

What else? On PSV and PCV outlet.

All PSVs and PCV outlet ANSI rating would be ANSI 150# as all fluid from those instrumentation goes to
the flare system, which is lower pressure system.
 WRITTEN TEST
PROCESS ENGINEER POSITION
(7+ years experiences)

ANSWER – Part 2
Problem solution number 2. Determining the set points for PCV, PSHH, and PSVs.
On separator section, you see a PCV, named PCV-1 is installed. The purpose of the PCV is to maintain
process stability by flaring the incoming process gas. This normally occurred during compressor start-up,
where process gas is already flow from wells while compressor system is still in process to achieve it
stability to compress gas. Also, when anti-surge valve opens due to compressor operating envelop is close
to surge line.

What is the best setting for the PCV-1? Well, it is adjustable. In fact, this is something that internal
operation can adjust the set point without have to raise formal Management of Change or MOC. The case
will different for changing PSHH or PSV set point.

The mainly setting point connection of PCV-1 is PT set point (suction compressor set point). With giving
allowance, the suction pressure setting may up to, say 20 psig (from 290 to 310 psig) plus possible add
pressure drop from PCV to suction compressor (assumed 10 psig), then the PCV-1 setting would be 320
psig.

So, when operator starts the compressor for the first time or after shutdown, where the anti-surge valve
is still open due to: compressor is still on the ‘ready to load’ condition and not inject gas to pipeline yet
for export, or compressor system not stable yet for any reason, then process stability is maintained by
flaring gas to flare system from the PCV-1.

While compressor system is gradually stable (as indicated by gradually closing of anti-surge valve), then
discharge pressure is gradually increasing as well and now gas gradually flows to export line. This is
followed by closing of the PCV-1.

Now what is setting point for PSHH and PSV-1 at the separator then? If the PCV-1 will be set at 320 psig,
then setting point of the PSHH and PSV-1 (as well as vessel MAWP’s) – will follow table below. I have
taken the table from one of my guru – Dr. Maurice Steward on his famous book – Surface Production
Operation volume 2.

For PSHH setting point- it would be 320 x 1.1 = 352 psig. I choose 360 psig.

And for PSV-1, that would be 360 x 1.05 = 378 psig. Should I choose PSV and MAWP design for 378 psig? I
think I propose to increase up to 400 psig or more to anticipate future requirement. For this purpose, I
choose 400 psig.

So PCV-1 setting is 320 psig

PSHH setting is 360 psig
PSV-1 setting is 400 psig
Vessel’s MAWP is 400 psig.

You can argue that the PSV-1 setting point can be higher than that as per API RP-520 for fire case.
However, this PSV-1 for sure is designed for process/block discharge case, due to there is a credible
scenario that during compressor shutdown (which will initiate isolation of compressor system), it will
block all fluid flow from separator to compressor.

Note – I prefer to have this PSV-block discharge case installed on separator instead is installed on
incoming header/flowline. By having the PSV-1 installed on separator, when activated, it only releases
single-phase fluid (gas) to flare. If I install the PSV-1 on incoming header, the PSV will release two-phase
fluid, and may create problem on the flare header, and possibly create hammering phenomena on the
header (based on my experience).

Now we move to Suction Scrubber.

The operating pressure on suction scrubber would be vary from set point of compressor suction (290
psig) and up to settle out pressure condition. The settle out condition happens when gas in suction
pressure condition mix with gas at discharge pressure condition. So, the operating pressure would be in
between suction and discharge pressure of the compressor (between 310 and 1100 psig. Noted: I choose
310 instead 290 psig for conservatism). It wouldn’t be the average between 310 and 1100 psig as volume
on both suction and discharge side shall be taken into account. For this purpose – the operating pressure I
choose is less than ANSI 300 (740 psig). Assume the settle out pressure is 500 psig, so I choose the vessel
MAWP is 550 psig (500 x 1.1). Therefore, the PSV-2 setting on this suction scrubber would be either 550
psig or 10% above due to its design for fire case.
In general, the PSV-2 setting is the same or 10% above from suction scrubber’s MAWP.

Finally, we move to Discharge Side.

How to determine PSV-3 setting point on discharge compressor?
The weakest system on this section is cooler’s MAWP (1000 psig). Note: The piping system was designed
in ANSI 600 (1480 psig). Therefore, I can set the PSV-3 with setting 1000 psig or may be less (in order to
anticipate future de-rating requirement of the cooler).

PSV-3 design capacity.

The PSV-3 is designed based on block discharge case. How to determine the design flow for the PSV? Is it
based on gas flow of 250 MMSCFD (@ 850 psig discharge pressure) or based on gas flow at setting point?
Note: as centrifugal compressor will work to follow its parabolic curve, so the discharge flow will vary with
discharge pressure. Higher discharge pressure will produce less flow and less discharge pressure will
produce more flow..

PSV-3 setting point is assumed at 1000 psig. Then we need to check on compressor curve with the highest
possible suction pressure condition. For sure won’t be 250 MMscfd, must be less. However, how much is
it, then we need to check. If the gas rate design is significantly different so may cause orifice of designed
PSV differ, then you need to think if you still select the PSV that suite for 250 MMSCFD gas rate. It seems
conservative and safe, but, it makes the PSV-3 is overcapacity.

Overcapacity may cause PSV chatter and this may initiate mechanical damage on the PSV when it
activated. In the end may initiate compressor shutdown. This this obviously impact to gas export as
downtime is required to replace the PSV.

If a PSHH will be installed on discharge compressor, what do you think the proper setting should be?
Discharge compressor normally will be at 850 psig. According to above table, the minimum set point of
PSHH is 900 psig, however, I think we need more ‘room’ for compressor operating envelope as the
compressor still can be operated at 1100 psig discharge pressure without surge, so I will set PSHH at 950
psig.

Problem Solution number 2.

Question: If capacity of the compressor will be increased, what should I do & what checking
should be done for the entire of the system?

The answer for what should be done when compressor capacity needs to be increased by increasing its
suction pressure I think I already did in my article – The Beauty of Centrifugal Compressor – Part 2.

Question number 3:
If, for some reason, the setting of suction pressure will be reduced to 200 psig without re-
stagging the impeller of the compressor - to accommodate declining in gas well reservoir
pressure, what checking I should do as well?

I will answer this later..

Vivat Process Engineering

Cahyo Hardo
 WRITTEN TEST
PROCESS ENGINEER POSITION
(7+ years experiences)

ANSWER – Part 3
Problem solution number 3. If, for some reason, the setting of suction pressure will be reduced to
200 psig (without re-staging the impeller of the compressor), in order to accommodate the
declining in gas well reservoir pressure, what check I should do?

Answer:

Lowering operating pressure is normal in surface production facility. Lowering the operating pressure
normally happen after well flow declined over the period. By lowering the operating pressure, many wells
will response by increasing the flow. Some wells may have good response in term of flow increase,
however, other wells in moderate response, and other may only slightly response. Well curve
characteristic may give us clue what is the total gain (additional flow) will be. Assume after lowering the
operating pressure, total fluid flow will increase.

On separator section, what check should I do? Off course the PCV-1 setting, as this setting point
correlates with compressor setting point (which planned to be 200 psig). Following the previous way
when answering problem number 2, the new setting point of PCV-1 should be about 200 psig + 20 psig
(for pressure drop allowance) or 220 psig.

What other check? Separation capacity.

Lower operating pressure (from 320 to 220 psig) causes gas actual velocity inside separator increases. We
need to check the length of gas-liquid separation inside the separator, as is may not adequate. If new gas
flowrate that will passing through the separator is significantly less than per original design flow, probably
we do not need to check separator capacity. However, if it is not much different, it is a common practice
to check. Otherwise, it may end up with liquid carry over from separator into compressor suction
scrubber.

Other check is review LCV-1 capacity. Capacity a control valve is determining by pressure drop across the
valve. Higher pressure drop across, it makes capacity of control valve increase. Less pressure drop across
valve, cause reduction in capacity. Therefore, if operating pressure on separator is reduced to 200 psig,
there is chance capacity of the LCV-1 is not sufficient to handle liquid flow. If this happen, liquid level in
separator will increase even though LCV-1 has opened 100%. In the end, plant will shutdown due to high
level in separator occurred.

Still on separator section, should we adjust setting of PSHH and PSV-1? I believe you can answer this trivial
question.

Now we move to Suction Scrubber.

Capacity review should be done on this vessel, similar with upstream separator. There is a chance that
scrubber will be more wet due to increasing liquid carry over from separator. The capacity of scrubber
perhaps is adequate, however, capacity of LCV-2 probably not. From the name - scrubber – was designed
to handle small amount liquid. It is common that because the amount of liquid is small, the original design
of LCV is overcapacity. To anticipate this, instrument engineer will apply control valve that behaves like
on-off or snap acting valve. Valve will 100% close until liquid level in scrubber raise to a certain value then
open 100%. This 100% opening will continue until the level decreases to certain value, then the valve re-
close.

With new operating pressure (lower pressure), the snap acting mode for the LCV-2 may not appropriate
anymore as may initiate high level in scrubber. Therefore, a part of capacity check of the LCV itself, it also
worth to check control action of the LCV-2.

Note: If you see the detail P&ID on common centrifugal compressor configuration, it is not rare you will see a sign
like triangle on suction line of the compressor with direction toward to suction scrubber. This sign is 'message' to
mechanical and or piping engineer to design the suction compressor line to have a slope, with direction toward to
suction scrubber. This in order to facilitate a possible dropped liquid between suction scrubber and along the outlet
line of scrubber to compressor inlet, to flow back to scrubber by gravity.

Do you know what is consequence if liquid entering the compressor?

Check on Compressor system.

Reduction in suction pressure of compressor while maintaining its discharge pressure will have impact to
the raising of discharge temperature as this makes compression ratio increase. The compression ratio is
simply the ratio of the absolute stage discharge pressure to the absolute stage suction pressure. The final
compressor outlet temperature is always a concern as a high discharge temperature can lead to the
failure of internal components due to material degradation or excessive thermal expansion. This more
susceptible if compression ratio increases.

For this matter, better we involve compressor manufacture for information about new discharge
temperature. From that point, we can add safety factor, say 50F to handle any unexpected process
conditions or unexpected internal cylinder losses due to wear or fouling. This number will be new TSHH
set point on discharge compressor (I do apology as this TSHH not shown on previous P&ID).

Anything else? Compressor manufacture may suggest to adjust surge line, etc. Let just trust them to do
so..

What ELSE?
It is very common to check the adequacy of the piping system if operating pressure to be lowered.
According to the gas law, the actual velocity of the gas increases as the operating pressure decreases. The
increases in the actual velocity of the gas may exceeds the allowable erosional velocity. And if it happens
for a long time, it will cause erosion in the piping. The worst thing – it may create hole in the piping and
risk of uncontrolled gas release to atmosphere is obvious.

Someone may argue that normally production header is designed with safety factor, including to
anticipate lower operating pressure (during line sizing calculation in design stage). This correct, however,
we should not limit the checking only on the header. Production header may safe in term of erosional
velocity, however, the incoming flowlines to this header, that come from wells, needs also to be checked
– one by one, even though that all flowlines do not appear on the reference drawing (see my article for
part-1 and 2), however, a good process engineer shall have sense to do that..

Vivat Process Engineering

Cahyo Hardo
 WRITTEN TEST
PROCESS ENGINEER POSITION
(7+ years experiences)

ANSWER – Part 4
 WRITTEN TEST
PROCESS ENGINEER POSITION
(7+ years experiences)

ANSWER – Part 5
1. Refer to the above drawing. Suppose operation is facing high water content problem on the gas
export (that to be delivered to the buyer). What check should be done and how to do it - for
individual equipment on dehydration unit above?
2. On the gas side, what do we do immediately to reduce water content of export gas while we are
troubleshooting?

Note: I do apology if this problem solution is too esoteric. I try to explain in simple way, and herewith the
result for those 2 above questions.

Al-Jawab:
FYI - above drawing represents a simple system of Triethylene Glycol (TEG) that common installed at
onshore facilities. The mass transfer takes place in dehydration column/absorber where feed gas flows
from bottom while lean glycol flows from top of the column. Rich glycol (called rich due to contain more
water) will be circulated back to the system to release its water to atmosphere by distillation process in
column called still column, and the purer glycol as the product (called lean glycol – due to have minimal
water content) is recirculated to the dehydration column.

Prior to answer the question number 1, first action is – reduce gas rate until its water dew point on gas
export back to specification. This have to be done first as we have to fulfill obligation under gas sales
contract. This actually answer for question number 2.

Next then, we need to check two parts – operating condition of gas and healthiness of glycol system
itself.
Let start with operating condition of gas.

Operating pressure of gas.

As you knew, natural gas has equilibrium water content, with function of pressure and temperature.
Normally expressed in lb/MMscf. Example is below:

WATER VAPOR CONTENT OF NATURAL GAS

220
WATER CONTENT, LB/MMSCF

200
180
160
140
120 1000 PSIA
100 800 PSIA
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
TEMPERATURE, F

From the above curve, water content of 100F temperature gas @ 1000 psia is about 60 lb/Mmscf, while
at 800 psia on the same temperature will be about 75 lb/MMscf.

On that point, we can see that pressure governs the water content, and it is very possible that the glycol
system is overloaded in such cause high-water content on outlet gas due to operating pressure drops
significantly from design pressure (to hundred psia).

If operating pressure decrease, there are several way to overcome the problem of high-water content.
Note: it is not rare for glycol tower operating pressure rely on hydraulic pressure from pipeline. This design, has
inherent weakness as operating pressure varies, depends on hydraulic pressure from pipeline. Installing pressure
control on outlet glycol tower will solve this problem.
Assume we can’t do more to return operating pressure to normal condition, what we are going to do
then?
You may try to increase the glycol recirculation rate. Why? As lower operating pressure bring more gas
to the glycol system, so we need to increase glycol circulation rate to absorb that additional water load.
This is mass balance principle.

What else we can do?

You can increase reboiler temperature to increase glycol purity. This in order to make glycol has more
capability to absorb additional water vapor.

Note: if you are familiar with modified Mc-Cabe Thiele curve developed by Richard Sivalls (see on Sivalls,
Richard, “Glycol Dehydration Design Manual”, Sivalls Inc, Texas 79760), increasing purity of glycol as well
as increasing glycol circulation rate, will move ‘gradient of absorption operation line ‘ to the left of the
curve, so it will be more feasible to achieve the outlet water content specification as less number of
theoretical separation stage required (this off-course with assumption that you have sufficient glycol
recirculation rate).

See curve below for illustration:

The curve also can explain for the first action we did when facing with high-water content (we decided to
reduce the gas rate to follow mas balance principle). As you can see on below curve, the lower gas rate
will make less number of theoretical separation stage required, so the desired outlet water content in
gas can be achieved. Conversely, the higher gas rate needs more number of theoretical separation stage.
If the high-water content of outlet gas because of higher gas rate, there is a big chance that the number
of theoretical separation stage for that high gas rate can’t be provided by existing absorber/column, so
the gas will be off specs.

Assume all of actions above allow you back to original gas rate. Then, you can do that in gradual while
keep monitoring gas specification (in term of water content/water dew point).
Gas Temperature

Increasing gas temperature will increase water content of feed gas to contactor. And the impact is higher
compare to decreasing in operating pressure (see previous curve above for water content of natural
gas).

To overcome this, you may increase glycol recirculation rate – similar when operating pressure drops.
This may happen until, either up to maximum glycol pumping capacity or you face with tower hydraulic,
which is flooding limitation.

Other action is find out the way to reduce gas temperature. You can mix hot gas with low temperature
gas wells (in order to lower temperature of feed gas). If we keep high operating temperature pass
through contactor for so long, the equilibrium of TEG with water content (see bottom line in modified
Mc-Cabe Thiele curve) will shift up and this make closer with ‘operating line’. Means, you need more
number of theoretical separation stage. This may hold you to increase gas rate (back to normal) as
equilibrium line of TEG and water content limits that – regardless how maximum of glycol rate that
injected to the dehydration column.
Note: There is possibility case on high-temperature feed gas to dehydration column. It caused by the
upstream aftercooler (of compressor system) is unavailable as under maintenance (say, due to motor
vibration).

The water content of this hot gas shall not increase (compare to inlet gas condition to the compressor)
as there is no process change takes place. However, if we overlook to drain water level in inlet suction
scrubber of glycol dehydration column, there is possibility the hot gas will absorb water on that scrubber
as it directly contacts with feed gas prior to enter to the dehydration column. My guru/teacher told me
that this has happened sometime in the past somewhere…

See drawing below for clarity..

Glycol system healthiness

We have checked gas operating parameter, now we move to glycol healthiness. In general, glycol
dehydration unit does not have a wide variety of operational problem. For this purpose, first we need to
check whether the glycol recirculation pump is already sufficient.

In addition, we need to check glycol purity. If found glycol temperature setting was below as should be
or as per original design, you may increase a bit as long as is still in its safe operating limit.

In case glycol reboiler temperature has already set as per design to corresponds glycol purity (you can
run Hysys to prove that!), please to continue to check glycol purity. Why? Because, there is a case that
salt-contaminated on glycol cause deposit on glycol reboiler fire tube, and this may reduce heat transfer
effectiveness from heat-generated inside fire tube to bulk rich glycol surrounding it. And this may cause
reduction in purity of lean glycol. Reduction in lean glycol purity will have direct impact to the success
operation of glycol dehydration system. One possible action is - do top up new lean glycol to the system.
This has temporary impact to bring purity of lean glycol back. Thorough review to understand why glycol
purity decreasing must be conducted.
Note: Do you know how to determine the glycol purity? The simple one is, if you have densitometer, then
you can measure lean glycol solution specific gravity (sg). Record its sg and compare with sg of glycol
from manufacturer, and sg for water. By applying mixing rule, you can determine how pure your lean
glycol is…

Note: Salt deposit acts as insulator of fire tube. The surface temperature of the fire tube builds up to the
point of the deposit causing what is commonly known as ‘hot spots’. This, if prolong, may cause tube
burn-out and failure. For the glycol, you may smell it – a sweet sugar smell accompanied by low pH and
dark, is a signal that thermal degradation is occurring in the reboiler. Process Engineer can detect this as
early as possible if noticing this matter.

Vivat Process Engineering.

Cahyo Hardo