Prepared By: Ahmed Mohamed Elshora Under The Supervision Of: U-104 Process Team

Gulf of Suez Petroleum Company (GUPCO)
Gas Operations
R/Sh Gas Plant U-104
Process Dept.
Prepared by:
Ahmed Mohamed Elshora
Under the supervision of :
U-104 Process team
April
2014
U-104 Gas gathering station Gulf of Suez Petroleum Company (GUPCO)
Acknowledgements
I appreciate the patience and assistance of the process team in U-104 .Special thanks to
people who read the early versions of this report and made recommendations to improve the
final text .I am grateful to team members who provided me with the technical resources in
order to make the report appears in this appropriate image .
Abstract
This report aims to describe the treatment operations of natural gas and how we apply it in U-104 in order to
produce LPG within required specification. The main equipment used to achieve this operation also will be
discussed and its theory of work. The treatment operations mentioned in report include separation
,dehydration, sweetening and compression of natural gas . The control of each process will be also discussed
briefly .
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Table of Contents
Table of Figures...................................................................................................................................................... 3
1-Introduction ........................................................................................................................................................ 4
1-1-What Is Natural Gas? ................................................................................................................................. 4
1-2-What is LPG?................................................................................................................................................ 4
1-3- U-104 Gas plant ........................................................................................................................................... 5
2-Inlet Area ............................................................................................................................................................. 6
2-1-Satellite stations ............................................................................................................................................ 7
2-2-Pipelines ........................................................................................................................................................ 7
2-3-Inlet separators ............................................................................................................................................. 8
2-3-1-Advantages and Disadvantages of Horizontal Separator ............................................................... 10
2-3-2-Process Description ............................................................................................................................ 10
2-3-3-The Control system of inlet separators : .......................................................................................... 12
3-Compression Area ............................................................................................................................................ 12
3-1-Centrifugal compressor .............................................................................................................................. 13
3-2-Surge and Choke ........................................................................................................................................ 16
3-3-Compressors process description ............................................................................................................... 18
3-4-Compressors efficiency ............................................................................................................................... 19
3-5-Compression ratio....................................................................................................................................... 20
3-6-Control of compressors .............................................................................................................................. 20
4-Drying & sweating area ................................................................................................................................... 22
4-1-Control of Dryers ........................................................................................................................................ 23
5-Gas Cooling and Expansion ............................................................................................................................. 25
5-1-Normal operation of Chilling area ............................................................................................................ 25
5-2-Control of Expanders ................................................................................................................................. 27
6-Fractionation ..................................................................................................................................................... 29
5-1-Normal operation of Fractionation .......................................................................................................... 30
5-2-Control of Fractionation .......................................................................................................................... 31
6-Booster Compressors ........................................................................................................................................ 34
6-1-Normal operation of Booster...................................................................................................................... 34
6-2-Control of Boosters ..................................................................................................................................... 35
7-References.......................................................................................................................................................... 37
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Table of Figures
FIGURE 1: SIMPLE FLOW DIAGRAM OF U-104 .............................................................................................. 5

FIGURE 2: GUPCO DISTRICT FLOW DIAGRAM ............................................................................................. 6
FIGURE 3: SIMPLE FLOW DIAGRAM OF U-103 .............................................................................................. 7
FIGURE 4: PIPELINES AND PIG TRAPS AT INLET AREA .................................................................................. 8
FIGURE 5: CROSS SECTION AT HORIZONTAL SEPARATOR ............................................................................. 9
FIGURE 6: SIMPLE FLOW DIAGRAM OF 4-V101 .......................................................................................... 11
FIGURE 7: DETAILED COMPONENTS OF THE CENTRIFUGAL COMPRESSOR. ................................................. 13
FIGURE 8:CLASSIFICATION OF COMPRESSORS TYPES ................................................................................. 14
FIGURE 9: CENTRIFUGAL COMPRESSOR ..................................................................................................... 14
FIGURE 10:TYPES OF ROTORS ................................................................................................................... 15
FIGURE 11: STAGES OF COMPRESSORS ...................................................................................................... 15
FIGURE 12: COMPRESSOR CHART (CONSTANT SPEED ) .............................................................................. 17
FIGURE 13: SIMPLE FLOW DIAGRAM OF COMPRESSION AREA .................................................................... 18
Table of tables
TABLE 1: OPERATING CONDITIONS OF INLET SEPARATORS ........................................................................ 11

TABLE 2:OPERATING CONDITIONS OF THE TWO STAGES COMPRESSORS .................................................... 16
TABLE 3:ADVANTAGES &DISADVANTAGES OF CENTRIFUGAL COMPRESSORS ........................................... 16
TABLE 4: POLYTROPIC EFFICIENCY OF MAIN COMPRESSORS. .................................................................... 19
TABLE 5: PROPERTIES OF SOLID DESICCANTS . .......................................................................................... 23
TABLE 6 : MOLECULAR SIEVE OPERATION PROGRAM ................................................................................ 24
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1-Introduction
1-1-What Is Natural Gas?
Natural gas is a subcategory of petroleum that is a naturally occurring, complex mixture of hydrocarbons,
with a minor amount of inorganic compounds. Geologists and chemists agree that petroleum originates from
plants and animal remains that accumulate on the sea/lake floor along with the sediments that form
sedimentary rocks. The processes by which the parent organic material is converted into petroleum are not
understood. The contributing factors are thought to be bacterial action; shearing pressure during compaction,
heat, and natural distillation at depth; possible addition of hydrogen from deep-seated sources; presence of
catalysts; and time (Allison and Palmer 1980).
Table 1-1 shows composition of a typical natural gas (ex : Gas feed to U 104 ). It indicates that methane is a
major component of the gas mixture. The inorganic compounds nitrogen, carbon dioxide, and hydrogen sulfide
are not desirable because they are not combustible and cause corrosion and other problems in gas production
and processing systems. Depending upon gas composition, especially the content of inorganic compounds, the
heating value of natural gas usually varies from 700 Btu/Scf to 1,600 Btu/Scf.
1-2-What is LPG?
LPG is the normal abbreviation used to describe Liquefied Petroleum Gas which is itself the term used to
describe a group of hydrocarbons existing as vapors under ambient conditions of temperature and pressure,
but which can be liquefied by the application of moderate pressure and/or refrigeration. Such liquefaction is
always accompanied by a considerable decrease in the volume occupied by the vapor so that the liquid formed
requires much less storage space. The material is therefore normally stored and distributed in the liquid phase,
in pressurized containers and systems, and is finally allowed to revert to the vapor phase before the point of
eventual consumption. This property is the basis of one of the principal advantages of LPG as a convenient
premium energy source
.
Liquefied petroleum gases originate from two main sources. LPGs are found at the oil and/or gas fields where
they are removed as condensable products from natural gas (such LPGs are often referred to as Natural Gas
Liquids NGLs), and LPGs are also removed from crude oils during the stabilization process applied in
order to reduce the vapor pressure prior to shipment.
The second normal source of LPGs is found at the refineries where the crude oil is processed. LPGs are
produced by many refinery activities, but the actual composition and quality varies considerably, being
determined by the process involved and the type of crude oil or feed-stock being used. Large quantities of LPG
are used by oil refineries, particularly butane which is added to gasoline to improve the volatility. LPGs are
also used as feedstock for petrochemical production
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1-3- U-104 Gas plant
U-104 gas gathering station is natural gas processing plant was established on two stages the first was in 1982
" phase I " with a capacity of 80 MMSCFD and the second "phase II " in 1986 with a capacity of 90 MMSCFD
. The associated gas feed of the plant came from others sisters companies and GUPCO satellite stations. The
plant products are Sales gas ,LPG and Naphtha
Natural gas feed entering the station composes mainly from saturated hydrocarbons "parrafins" within a range
from C1 to C7+ and some impurities which are mainly hydrogen sulfide "H2S" water vapor "H2O" and carbon
dioxide CO2.
The associated gas feed is separated in inlet area and then compressed as necessary for the LPG recovery .the
compressed gases are dried ,desulfurized and then cooled . The remaining gas is expanded to recover further
liquid and to generate refrigeration for cooling the incoming gas .The lean gas leaving the heat exchanger is
recompressed by a compressor driven by the expander and by booster compressors . The recovered liquids are
fractionated in depropanizer and debutanizer , to produce specified LPG and naphtha as by product .
The sales gas from booster compressors is recompressed by sales gas compressor and flowed to EBGDCO, to
recover the propane from the sales gas and return the remaining gas to GASCO network . All of these
processes take place in the plant in different areas as shown in Fig 1 , all of these areas will be discussed
briefly in this report .
Figure 1: Simple flow diagram of U-104
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2-Inlet Area
The Inlet area at U104 consist of Inlet Separators and pipelines that connect the plant with the others sisters
companies(Amal,Suco,Ashrafi,Ebgedco,Oapco) and the Gupco satellite stations (U102,U103,U108,Saqara) .
All the gas came to the plant from Gupco satellite stations are from offshore production, many wells are tied
back to a platform, and then gas from multiple platforms are tied together into large pipelines that go to the
gas satellite stations .
July,Ramadan and Morjan 1 send their production to U103 Max 54 MMSCF .

Badri send its production to U108 25-30MMSCF.
Shoab Ali, Sedky and Helal 80MMSCF Ashrafi and Oapco 14MMSCF to U102.
Saqara platform To Sqara station 60MMSCF
October 135 MMSCF to Trans Gulf and we send or receive from T.G depend on operations conditions .
Figure 2: GUPCO district flow diagram
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2-1-Satellite stations
In addition to compression which its main function , satellite stations have inlet slug catcher and dehydration
unit .
Slug catcher is a separator designed to separate bulk liquid- gas flow streams which are surging or slugging. There are
two types of slug catcher inlet vessels and manifoldedpiping. Inlet vessels is that we use , commonly called inlet
receivers, are simply gas -liquid separators that combine slug catching with liquid storage. They are usually employed
where operating pressures are relatively low or where space is a problem. Horizontal vessels are preferred, unless area is
limited (as on offshore platforms), because they provide the highest liquid surface area. Usually two or three vessels are
manifolded together to permit larger volumes and to allow servicing of one vessel without plant disruption.
In U-103 and U-102 they used Glycol dehydration unit, U-108 make dehydration by refrigeration using
propane chiller. The purposes of dehydration of the gas stream before it enters U-104 are to prevent formation
of hydrates in transmission lines and to prevent corrosion in acid gas streams.
Each satellite station 4has its centrifugal compressors .In addition to compressing the gas to move it into the
gas plant, the stations usually have inlet suction separators (scrubbers) to
remove condensed liquids.
Figure 3: Simple flow diagram of U-103
2-2-Pipelines
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Pipelines in inlet area are equipped with pig launcher or pig receiver. Pigging is the process of forcing a solid
object through a pipeline. The process involves inserting the pig, via a pig launcher, into the pipelines and
removing it by use of a pig receiver. Pigging is used to perform any of the following functions:
1. Provide a barrier between liquid products that use the same pipeline
2. Check wall thickness and find damaged sections of lines
3. Remove dirt and wax from lines
4. Provide a known volume for calibrating flow meters
5. Coat inner pipe walls with inhibitors
6. Remove condensed hydrocarbon liquids and water in two phase pipelines
Field operations must follow a rigorous pigging schedule prevent the plant from being hit by large slugs of
liquid that would flood inlet receiving and carry liquids into the gas-processing units. Gas released venting,
before emptying of the catcher goes to flare.
Figure 4: Pipelines and pig traps at inlet area
2-3-Inlet separators
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The gas after it gathered at one 24 header, splits into two main pipelines one for Ph I and one for Ph II ,each
line enter separators 4-V1 and 4-V101. A typical gas well stream is a high velocity, turbulent, constantly
expanding mixture of gases and hydrocarbon liquids, intimately mixed with water vapor, free water, and
sometimes solids.
A separator is normally constructed in such a way that it has the following features and basic functions :
cause a primary-phase separation of the mostly liquid hydrocarbons from the gas stream .
refine the separation by further removing the entrained gas from the liquid stream ( Secondary
separation section).
it is equipped with a mist extractor or eliminator near the gas outlet to coalesce small particles of liquid
that do not settle out by gravity(Mist Extraction section )
it provides a large settling section of sufficient height or length to allow liquid droplets to settle out of the
gas stream with adequate surge room for slugs of liquid (Liquid accumulation section).
discharge the separated gas and liquid from the vessel and ensure that no reentrainment of one into the
other occurs.
it allows adequate controls consisting of level control, liquid dump valve, gas backpressure valve, safety
relief valve, pressure gauge, gauge glass, instrument gas regulator, and piping.
Figure 5: Cross section at horizontal separator
Primary Separation Section:
In the primary separation section, the bulk of the liquid is removed from the inlet stream. It is desirable remove
slugs and large droplets of liquid quickly from the gas stream to minimize re entrainment of liquid particles in
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the gas.
Secondary Separation Section

In the secondary separation section the smaller liquid droplets are removed. The major separation principle in
this section is gravity settling of liquid droplets from the gas stream.
Mist Extraction Section:

In the mist extraction section tiny liquid droplets, still in the gas stream after passing through the primary and
secondary separation sections, will be removed.
Liquid Accumulation Section:

In the liquid accumulation section liquids are collected as described above. Also any gas bubbles still entrained
in the liquid have the opportunity to rise and join the gas stream.
4-V1and 4-V101 are classified as horizontal 3 phase separators. The number of phases refers to the number of
streams that leave the vessel, and not the number of phases that are in the inlet stream.
2-3-1-Advantages and Disadvantages of Horizontal Separator
Advantages
Handle larger volumes of gas.

More successful in handling foaming crudes because of the large interface area in relation to the liquid
volume and that will also help to make good separation
When the gas capacity is a design criterion, the horizontal vessel is more economical
in high-pressure separators.
the first choice because of their low costs.
Horizontal separators are easier to skid-mount and service, and require less piping for field connections.
For a given size, more area is available for settling in the liquid phase. Thus, the horizontal conforms to
three phase operation better than does a vertical.
If heating coils or sand jets are required, horizontal configuration is more adaptable.
Disadvantages
Difficult to clean. Provisions should be made for cleaning the separator during shutdowns, and if
necessary during operations, by installation of water jets and additional drains.
Require more floor space.
Limited liquid surge capacity .Since the gas travels horizontally over the liquid a rise in liquid level will
immediately reduce the gas space and consequently create an increase in gas velocity resulting in lower
efficiency.
Liquid level control more critical.
2-3-2-Process Description
The process of separation will be described based on 4-V101 as shown in fig 5, the process at 4-V1 differs
slightly but main concepts are the same . The feed gas after it enters the separator, separated into 3 phases wet
gas, condensate and water .Stream no 8 the gas splits into two streams to main compressors of PH II at
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compression area . Stream no 11 the water sends to Lablar tank and from it to Knock out drum of the flare and
then to retention bond. Stream no 12 the condensate is collected at the Knock out drum of the flare .
Stream no 1; when the pressure inside 4-V101 over 8 KG/Cm2 the PSV will open and send the gas to flare.
Stream no 2 Stream no 3; represent the gas after it separated at TCU 4-V201 is send back to the separator.
Stream no 4; will be discussed in the control section of the separation. Stream no 5; the gas from upper section
of 4-V109 send back to the main header of gas outlet from the separator. Stream no 6; Stream no 7; vent of
LPG tank 4-V12 return back to the main header of gas outlet. Stream no 9; this line will transfer the outlet gas
from 4-V1 to main header of if the main compressors of PH I are shut down. Stream no 10 ; is a branch taken
from both outlet gas header , to be used as a fuel gas when only both PH I and PH II are shut down.
5 6
7
2
4
8
1
3 10 9
11
12
Figure 6: Simple flow diagram of 4-V101
TOperating POperating TDesign PDesign Flow Rate

o o
4-V1 38 C 5 KG/Cm2 68 C 7 KG/Cm 2
80MMSCF
o o
4-V101 38 C 6 KG/Cm2 70 C 8KG/Cm 2
90MMSCF
Table 1: Operating conditions of inlet separators
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2-3-3-The Control system of inlet separators
A-The split control loop by 2PIC-301:
The split control loop of 2PIC-301 is provided to control the main compressors for various feed gas flow rate .
The suction pressure of the main compressors is controlled constantly by 2PIC301 split control system on 4V1,
4V101. The output signal of 2PIC 301 (3-15) psig is connected to 2PV-301 pressure control valve on flare line,
and 2SIC1001 gas turbine governor control instruments (Inlet guide vane).
With Increasing of 2PIC-301 output signal from 3 psig to 9 psig (4-12 mA),the 2SIC1001 set point and gas
turbine speed will also increase and vice versa.
To control the excess gas in order to keep 4-V101 operates under the max design pressure, 2PIC-301 output
signal will increase from 9 psig to 15 psig (12-20 mA) so 2PV-301 will open and the excess gas is flared .
Note: Now days,the gas turbine speed is controlled either local from the turbine itself in the site or from the
DCS,that is mean that the 2PIC-301 is now working only in the output signal range from 9-15 psig.
B-Liquid Level control:

2LIC-702 control the water level inside the vessel, when the water level is high the control opens and send the
water to lablar tank .
2LIC-701 control the condensate level inside the vessel, when the water level is high the control opens and
send the condensate to Knock out drum of the flare.
3-Compression Area
This area contains 4 parallel centrifugal main compressors driven by gas turbine4-C1A&B for PH I and
4-C101 A&B for PH II. The purpose of compression process is to increase the pressure of the gas so when it
arrives to the expanders at later stage the P will be high, that will lead to increase the LPG recovery from the
gas. The compressors are designed to handle at each 50% of the expansion unit feed, with a maximum capacity
of 75% when one of existing main compressors stops, by other mean 4-C1A&B at max capacity will handle
120 MMSCF and 135 MMSCF for mean 4-C101A&B. The 4-C101A/B and 4-C1A& are classified as
dynamic centrifugal compressors, Vertically split construction, also called (barrel ) construction.
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Figure 7: Detailed components of the centrifugal compressor.
3-1-Centrifugal compressor
Dynamic compressors are classified as either centrifugal or axial flow. Both types operate by changing the
velocity of gas and converting energy to pressure. centrifugal compressors are ideal for high flowrate and low
to high head situations. Unlike reciprocating compressors, centrifugal compressors are steady-flow devices
hence they are subjected to less vibration and noise. In addition, the ability of a centrifugal compressor to
handle changing conditions (pressures, temperature, molecular weight) may be limited.
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Figure 8:Classification of compressors types
Figure 8 shows the working principle of a centrifugal compressor. As shown in the figure, low-pressure gas
enters the compressor through the eye of the impeller is accelerated radially by moving impellers. The impeller
consists of a number of blades, which flow passages formed by the impeller blades, which rotate at very high
speed. As the gas flows through the blade passages towards the tip of the impeller, it gains momentum and its
static pressure also increases. From the tip of the impeller, the gas flows into a stationary diffuser.
In the diffuser, the gas is decelerated and as a result the dynamic pressure drop is converted into static pressure
rise, thus increasing the static pressure further. The vapor from the diffuser enters the volute casing, where
further conversion of velocity into static pressure takes place due to the divergent shape of the volute. Finally,
the pressurized gas leaves the compressor from the volute casing.
Figure 9: Centrifugal compressor
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The rotor (impeller) can be open or close on one or both sides. A survey of literature from compressor
manufacturers indicates that most compressors for natural gas service are shielded on both sides (i.e., closed).
Like other compressors, exit temperature limits the pressure ratio in centrifugal compressors. The Engineering
Data Book (2004a) recommends a maximum discharge temperature of 400F (200C).
Figure 10:Types of rotors

Centrifugal compressors can be single-stage or multistage,4-C101A/B and4-C1A/B are double stage . Single-
stage compressors compress the gas once, whereas multistage compressors deliver the discharge of one stage
to the suction of another stage. Single-stage centrifugal compressors are designed for high gas flow rates and
low discharge pressures; multistage compressors are designed for high gas flow rates and high discharge
pressures. In gas processing, they are usually powered by either a gas turbine or a turbo expander but can be
steam or electrically driven.
Figure 11: Stages of compressors
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4-C101 4-C1
Inlet conditions Outlet conditions Inlet conditions Outlet conditions
P = 6-7 kg/cm2 P =18.5-19 kg/cm2 P =5.1-6 kg/cm2 P =18 kg/cm2

First stage
T = 29c T = 115-120c T=20c T=103c
P = 18 kg/cm2 P = 45-46 kg/cm2
P = 18 kg/cm2 P = 50 kg/cm2
Second stage T = 32c T = 129c
T = 32c T = 220-225c
Table 2:Operating conditions of the two stages compressors
Advantages Disadvantages
High horsepower per unit of space and weight. Lower compressor efficiency.
Turbine drive easily adapted to waste-heat Limited flexibility for capacity.
recovery for high fuel efficiency. Turbine drives have higher fuel rate than
Easily automated for remote operations. reciprocating units.
Can be skid mounted, self -contained. Large horsepower units mean that outage has
Low initial cost. large effect on process
Low maintenance and operating cost. or pipeline capabilities.
High availability factor.
Large capacity available per unit.
Table 3:Advantages &disadvantages of centrifugal compressors
3-2-Surge and Choke
If downstream pressure becomes too high (or inlet pressure becomes too low), the compressor cannot push the
gas out and backflow occurs, which results in a drop in the discharge pressure. Then, the compressor raises the
discharge pressure only to go into backflow again. This cyclic process is called surge. In other words, the
impeller is no longer able to maintain the pressure rise necessary to move gas into the receiving system at the
compressor discharge. At surge, the receiving system pressure is temporarily greater than the compressor
discharge pressure and a flow reversal occurs in the compressor.
This in turn leads to a temporary drop in the receiving system pressure which allows the compressor to again
move gas forward until another flow reversal takes place. If the cause of the surge is not eliminated, a series of
flow oscillations occur - forwards, backwards, forwards, etc. The frequency of these oscillations depends on
the compressor size, piping configuration, placement of non-return valve etc., but can be less than a second.
This induces vibration that can damage internal bearings. a rapid temperature rise in the compressor and in
severe cases, catastrophic compressor failure. Surge occurs at low flow conditions. A single compressor
impeller may surge at 50-60% of design flow, but in multistage compressors the surge point may be 70-80% of
design flow.
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The most common method of preventing surge is to ensure at all times that the inlet flow to the compressor is
greater than the flow rate at which the compressor surges. This is typically done by recycling flow from the
compressor discharge back to the compressor section. This recycle system, which is automated using
sophisticated instrumentation, is referred to as a surge control or anti-surge system such as FV103A/B anti
surge control for PH II FV 101A/B for PH I in our plant which will be discussed later in this report .
A stonewall or choked flow condition occurs when sonic velocity is reached at the exit of a compressor
wheel. When this point is reached, flow through the compressor cannot be increased even with further increase
in suction pressure. At choke, the compressor cannot handle any additional inlet flow regardless of the
compressor head.
If this occurs, the suction pressure will rise, Operation in this region will cause excessive use of horsepower,
occasionally to the point of overload, and frequent flaring. If higher flow rates are desired, modifications to the
impeller must be made.
This condition is generally causedby the limiting flow rate of the gas through the "eye" of the first impeller.
This flow is always higher than design and usually should not occur below 115-120% of rated capacity. The
maximum velocity is limited by the speed of sound of the gas. Theoretically, the choke effect would occur at
this value, but usual practice is to limit design to 0.85-0.90 of sonic velocity. At choke, the compressor cannot
handleany additional inlet flow regardless of the compressor head.
Figure 12: Compressor chart (constant speed )
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3-3-Compressors process description

The process of compression will be described through Fig 12, note that the compressor shown in Fig 12 is for
PH II but the differences between PH I & II will be discussed through description. The stream no 1 represent
the incoming gas from inlet separators, the gas enter 4-V102A (comp suction drum) to separate any condesate
associated with the gas that didnt separated at inlet separators. Stream no 2, gas will be compressed at 1st stage
from 6 kg /cm 2 to 18-19 kg /cm 2 .
Stream no 3 the exit gas which temperature increase from 29c to 115 due to compression will pass through
inter air cooler 4-A102 before it enter4-V103A ( inter separator ), at PH I the inter cooling take place by water
cooler 4-E1A. Stream no 4, the gas compressed at 2nd stage from 18-19 kg /cm 2 to 50 kg/cm2. Stream no 5
condensate formed due to compression is separated and recycled to 4-V102A for more separation .Stream no 6
;the exit gas from the 2nd stage is cooling by two after cooler 4-A102B air cooler and 4-E102A and then enter
4-V104A(after separators ) , at PH I there is only one after cooler 4-E2A (water cooler ).
Stream no 7, the outlet gas from 4-V104A will transfer to the drying area to be dehydrated and sweetened .
Stream no 8,the condensates at the bottom of 4-V104A transfer to inlet of inter separator. All condensates are
gathered at the bottom of 4-V102A and pumped by 4-P157 to total condensate unit as shown in stream no 10 .
Stream no 9 represent anti surge line which protect the compressor from surge problem as will be discussed
briefly in compressor control section in this report.
2 4
1 3
10
Figure 13: Simple flow diagram of compression area
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3-4-Compressors efficiency
The other commonly used efficiency, especially with centrifugal compressors, is the polytropic efficiency, P,
defined as:
where k is the empirically determined polytropic constant
The value of y is both temperature and composition dependent. Molar gas mixture heat capacities are
computed by:
and CVM is computed the same way.
4-C1A 4-C1B 4-C101A 4-C101B
P % 78.3 72.1 80 79
Table 4: Polytropic efficiency of main compressors.
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3-5-Compression ratio
Compression ratio is defined as the ratio of discharge pressure (psia) to suction pressure (psia). Frequently, the desired
discharge pressure is very high, over 100 times that of the inlet pressure. When a gas is compressed, the temperature of
the gas increases. If a gas was compressed in one stage to a pressure 100 times that of the inlet pressure, the gas
temperature would be extremely high. Multistage compressors, with cooling between stages,
are used to develop high pressures to allow for the heat of compression.
The compression ratio normally runs in the 3 to 4 range, with the same approximate compression ratio in each stage. For
example, if the desired discharge pressure is 1,500 psia, a 4-stage compressor with a 3.2 compression in each stage might
st nd rd
be used. The pressure at the discharge of each stage would be: 1 = 47 psia, 2 =150.5 psia, 3 = 481.7,
th
4 = 1,541.4 psia.
The simple calculation used to calculate the pressure increase on each stage is:
Stage One 14.7 psia * 3.2 = 47.04 psia

Stage Two 47.04 psia * 3.2 = 150.528 psia
Stage Three 150.528 psia * 3.2= 481.689 psia
Stage Four 481.689 psia * 3.2 = 1541.407 psia
3-6-Control of compressors
A-Split control loop by 2PIC-301:
The split control loop of 2PIC-301 is provided to control the main compressors for various feed gas flow
rate.The suction pressure of the main compressors is controlled constantly by 2PIC301 split control system on
4-V1, 4V101. The output signal of 2PIC 301 (3-15) psig is connected to 2PV-301 pressure control valve on
flare line, and 2SIC1001 gas turbine governor control instruments (Inlet guide vane).
With Increasing of 2PIC-301 output signal from 3 psig to 9 psig (4-12 mA),the 2SIC1001 set point and gas
turbine speed will also increase and vice versa.
To control the excess gas in order to keep 4-V101 operates under the max design pressure, 2PIC-301 output
signal will increase from 9 psig to 15 psig(12-20 mA) so 2PV-301 will open and the excess gas is flared .
Note: Now days,the gas turbine speed is controlled either local from the turbine itself in the site or from the
DCS,that is mean that the 2PIC-301 is now working only in the output signal range from 9-15 psig.
B- Auto start /Stop sequence of main compressor:
4-C101 A/B compressor panels have a function of auto start / stop sequence. The sequence controls suction/discharge
sectionalizing valves (2SDV-1903/1905), system pressurizing valve (2SDV-1904), de pressure valves (2SDV-
1942/1906) and anti-surge valve (2FV-103).
In case of 4-C101 startup, purge and pressurize operation of 4-C101 system are performed automatically. When 4-W101
gas turbine reaches the minimum speed, anti-surge valve is set to auto position by pushing the load button on compressor
panel. In case of 4-C101 shut down, sectionalize and depressurize operation of 4-C101 system is performed
automatically .
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C- Anti-surge control system
As discussed previously surge is an unstable region where flow reversal occurs inside the compressor.The only
way to prevent surge is to recycle or blow-off a portion of the flow to keep the compressor away from its
surge limit. Blow-off is not feasible in natural gas compression so recycle is the most common anti surge
method.
As discussed earlier, recycle is inefficient and expensive. A well designed antisurge system will protect the
compressor from surge but not recycle excessive amounts of flow.
We will take the anti-surge control system of 4-C101A as an example to illustrate on it . The operation of the
system is as follows. The volumetric suction flow rate is measured by 2FE-103A, generating a differential
pressure which is translated into a standard signal by 2FT-103 differential transmitters.
The compressor differential pressure between suction and discharge is measured by 2PDT-305A which output represents
a standard signal. The output of both transmitters serves as input for 2FY-103A in which the dividing takes place. The
output of 2FY-103A serves as input for the flow controller, which in turn controls 2FV-103A anti surge control valve.
The operation of the controller is discontinuous. In normal compressor operation, the suction flow rate is well above the
surge line. Only when the flow rate begins to drop in the surge region (10% surge margin region), the controller needs to
act
D-Flow measurement of feed gas (2FR-101A/B)
The suction flow rate is measured with 2FE-101A/B flow instruments which have the compensative function with
pressure (2PT-301) and temperature (2TT-501). The measured flow rate is indicated as normal state (0C, 1 atm). The
plant capacity is the sum of 2FR-101a and 2FR-101B
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4-Drying & sweating area
The compressed gas from compression area is dried and simultaneously sweetened by Driers of PH I and PH
II in parallel to prevent freezing in the chilling and turbo expander area and remove H2S to meet the LPG and
sales gas to consumers specifications. There are essentially four methods in current dehydration gases
processes
1. Absorption using liquid desiccants.
2. Absorption using solid desiccants.
3. Injection of hydrate point depressants.
4. Expansion refrigeration.
Liquid water and water vapor are removed from natural gas for several reasons:
To prevent formation of hydrates in transmission lines. The primary conditions promoting hydration
formation are the following:
1-Gas must be at or below its water (dew) point with free water present. 2-Low temperature.
3. High pressure.
To meet a water dew point requirement of a sales gas contract

To prevent corrosion in acid gas streams.
In U -104 we are applying adsorption method using solid desiccant ,adsorption process is the removal of water
vapor by making the flow through a bed of granular solids that have an affinity for water. The two types of
adsorption are physical adsorption and chemisorption. In physical adsorption, the bonding between the
adsorbed species and the solid phase is called van der Waals forces, the attractive and repulsive forces that hold
liquids and solids together and give them their structure. In chemisorption, a much stronger chemical bonding
occurs between the surface and the adsorbed molecules. The most used adsorption system in natural gas
dehydration is the physical adsorption, and all references to adsorption mean physical adsorption
Solid desiccants have very large surface areas per unit weight to take advantage of these surface forces. The
most common solid adsorbents used today are silica (SiO2), alumina (Al2O3), and certain silicates known as
molecular sieves. Dehydration plants can remove practically all water from natural gas using solid desiccants.
Because of their great drying ability, solid desiccants are employed where higher efficiencies are required.
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Table 5: Properties of solid desiccants .
The advantages of solid-desiccant dehydration include:
lower dew point, essentially dry gas (water content less than 1.0 Ib/MMcf) can be produced
higher contact temperatures can be tolerated with some adsorbents
higher tolerance to sudden load changes, especially on startup
quick startup after a shutdown
high adaptability for recovery of certain liquid hydrocarbons in addition to dehydration functions
The unit includes sex molecular sieve beds 4-D101A/B/C and 4-D1A/B/C , are regenerated and cooled in a
closed loop. The regeneration gas is treated in the DEA Unit ,and now is being saturated with water so it
recycled back to be treated with incoming feed gas to the dryers.Regeneration gas is available from either
dehydrators (existing or expansion) and is normally taken from the existing dehydrators. The acid gas from the existing
DEA unit is flared. Tie-in lines are provided between the existing and expansion unit, both upstream and downstream of
the molecular sieve beds.
4-1-Control of Dryers
A-Ratio control of after separator gas distribution (2PIC-307)
The after separator gas from 4-V104 A/B is mixed with existing 4-C1A/B discharge gas. The total after
separator gas is distributed to existing and expansion dryer units by 2PIC-307 ratio control system on 4-V143
inlet line. 2PIC-307 output signal is connected to 2FIC-108 set point through 2PY-307-1 ratio controller and
2FIC-107 set point. in this control loop, the pressure fluctuation signal with flow rate fluctuation is used to
adjust the ratio of existing and expansion side flow rate.
For any 2PIC-307 fluctuation signal, the ratio of 2FIC-107 and 2FIC-108 set value is constant as each control
valve (2FV-107 or 2FV-108) is controlled to adjust the flow rate to the set value, the flow ratio of existing
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stream and expansion stream is usually kept constant. The flow rate ratio is able to change by using 2PY-308-1
ratio controller
B-Molecular sieve control sequence:
Molecular sieve control sequence is modified to the combined system for existing and expansion molecular
sieve units. The below chart shows the new control system operation chart by stepping programmer. Where A
adsorption (down flow rate, 4+4 hr.), H heating (up flow, 2hr.)and C are and cooling (down flow, 2hr) cycle,
respectively.
Process 1 2 2 4 5 6
Step
Time 0-2 2-4 4-6 6-8 8-10 10-12
Process
Adsorption A A A A
4-D1A
Regeneration H C
Adsorption A A A A
4-D1B
Regeneration H C
Adsorption A A A A
4-D1C
Regeneration C H
Adsorption A A A A
4-D101A
Regeneration H C
Adsorption A A A A
4-D101B
Regeneration H C
Adsorption A A A A
4-D101C
Regeneration H C
FV-4003,2FV-
OPEN CLOSE OPEN CLOSE OPEN CLOSE
4015,2FV4018,2FV4020
FV-4004,2FV-
CLOSE OPEN CLOSE OPEN CLOSE OPEN
4016,2FV4017,2FV4019
Table 6 : Molecular sieve operation program
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5-Gas Cooling and Expansion

The dried gas is split to two parallel trains by each hand control valve on 4-E104 and 4-E105 flow lines, and
cooled.in Gas/Gas Exchangers 4-E104, Gas/Liquid Exchanger 4-E105 and. Gas Chiller 4-E106, and the
condensed liquid is separated in High pressure. Separator 4-V107.The liquid is throttled and exchanged the heat
with the incoming gas in 4-E105 and goes to the depropanizer as main feed. The gas from the high pressure
separator is expanded in turbo-expander 4-C103.
H.P. separator gas from 4-V107A/B is expanded by 4-C103A/B expanders. Then, the temperature of the gas is
decreased and the butane component is recovered into L.P. separator liquid.The shaft powers from expanders are
used for compressing the lean gas in 4-C103A/B recompressors.
The expander effluent is separated in Low Pressure Separator 4-V108. The liquid from 4-V108 is pumped to the
upper tray of the depropanizer. The lean gas from 4-V108 is used to cool the incoming gas in 4-E106 and 4-
E104. The lean gas leaving 4-E104 is recompressed in a compressor driven by the expander. This whole section
of the plant is provided as two parallel 50% trains.
A balancing line between existing and expansion recompressors, as tie-in connection, is provided so that the
excess depropanizer overhead gas can be split into existing recompressors when expansion depropanizer is
processing excess liquids from existing plant.
Methanol can be injected at the upstream of 4-E104, 4-E105 and 4-C103 to prevent traces of water from freezing
in the exchangers or in the turboexpander.
A recycle line is provided from the recompressors discharge line to the main compression suction line through a
hand control valve. If the quantity of associated feed gas to the plant decreases, for instance because of a
shutdown of one of the gas supplying stations, this line will be used to make up the feed gas. This is necessary to
keep the expander load.
5-1-Normal operation of Chilling area

The dried sweetened gas from molecular sieve unit is chilled in heat exchangers and 4-C103A/B expanders, to
separate the butane component, into the hydrocarbon liquid.
A) Split flow ratio
The optimum split flow ratio of 4-E104A/B tube side to 4-E105A/B tube side, for obtaining the minimum
temperature at 4-V107A/B, varies with plant feed gas composition.
1)When the plant feed gas is lean, L.P. separator gas from 4-V108A/B is increased. Then, increase the flow
rate into A-F104A/B tube side by closing 2HV-1102A/B control valves.
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2)When the plant feed gas is rich, H.P. separator liquid from 4-V107A/B is increased. Then, increase the
flow rate into 4-E105A/B tube side by opening 2HV-1102A/B control valves. Periodically check the
inlet/outlet temperatures of 4-E104A/B, 4-E105A/B and 4-E106A/B. It is important to maintain the
minimum temperature of 4-V107A/B, for obtaining the good butane recovery rate.
B) Chilling train feed rate
The feed flow rate into existing and expansion chilling trains is automatically controlled by the ratio control
system between 2PIC-308 and 2FIC-109A/B, FIC-102A/B. Periodically check that the flow rate ratio of
existing chilling train to expansion chilling train is proportional to each plant load.
When the plant feed gas flow rate of expansion plant not reached to 100 % if required, adjust the split flow rate
by resetting the ratio value of 2PY-308-1. Then the values is set the ratio of existing plant feed rate to
expansion feed rate (2FR-101A + 2FR-101B).
B) Hydrate formation
When the hydrate formation in the process piping equipment is found-out, inject the methanol to melt the
hydrate. If the hydrate causes in heat exchanger's tube and it doesn't melt after injection of the methanol,
gradually open the bypass valve for heat exchanger. Then, the temperature of heat exchanger's tube raises and
the hydrate will be melted.
D) Liquid levels in 4-V107A/B
Take care that the liquid levels in 4-V107A/B don't become high. Then, 4-C103A/B expanders/recompressors
are shut down.
E) Liquid levels in 4-V108A/B
Take care that the liquid, levels in 4-V08A/B don't become high. Then, 4-C104A/B and 4-C4A/B/C booster
compressors are shut down. When the liquid level becomes high, immediately start 4-P112C standby pump
after checking the operating conditions of the expander liquid pump.
F) Distribution of depropanizer OVHD gas
Periodically check the distributed flow rate 2F1-113A/B of depropanizer OVHD gas. When the flow rates are
not same, adjust them by 2HIC-1103A/B.
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G )Temperature, of 4-V108A/B
Periodically check the temperature 2TR-510A/B of 4-V108A/B. It, is important to maintain the minimum
temperature of 4-V108A/B, for obtaining the maximum butane recovery rate. The temperature of expander is
dependent upon the efficiency the expander process. Therefore, it is necessary to monitor the -system pressure
profiles, carefully.
H ) J.T. operation
When 4-C103A/B expander/recompressors are stopped by any trouble, expansion plant can continue the
operation by using 2FV-109A/B J.T.valves. Then, the operating condition is automatically shifted to J.T.
operation with the partial control system of expander. 2PV-315A and the bypass-valve of recompressor are fully
opened and the downstream pressure of J.T. valve is balanced to the suction pressure of booster compressors,
with line pressure drop. In this case, the butane recovery rate at 4-V108 is decreased. So, after completion of
repair, immediately start the expander/recompressor .
I ) Recycle operation by 2HV-1104
If the flow rate 2FI-113A/B from 4-V109 depropanizer OVHD accumulator is decreasing in condition of
depropanizer normal operation, it is considered that the suction pressures . 2PI-416A/B of 4-C103A/B
recompressors are raised. Check the operating conditions of 4-C103A/B expander/recampressors. If the expander
load is under 70 %, gradually increase the load by opening 2HV-1104 recycle valve.
5-2-Control of Expanders
Automatic control system in this section is as follow:
A) Partial control system for expander and J.T. valve:
A pressure controller on the common feed gas line is provided to ensure the LPG recovery in the existing and
expansion high pressure separators. The pressure controller resets the flow controller set va1ue on each cooling
train inlet line .The flow controllers control all for expander guide vanes
The partial control system is provided to switch J.T. valve operation to expander operation, smoothly.
4-C103A/B expander guide vanes and 2FV-109A/B J.T. valves are controlled with partial control systems. The
control system is composed of 2FV-C103A-1 low limiter, 2FY-C103A-2 low selector, 2FY-C103A-3
pneumatic calculator and solenoid valves; etc. The low limiter maintains the minimum opening of guide vane
for preventing the damage of expander due to quickly close of the guide vane in case of instrument signal failure.
The low selector, pneumatic calculator and 2H1C-1105A controller, which is mounted on ROTOFLOW local
panel, are used to gradually close 2FV-109A J.T. valve with increasing. speed up of 4-C103A expander, for
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start-up operation. When 2HIC-1105A output signal is 3 psig, 2FIC-109A signal controls 2FV-109A J.T. valve.
Then, expander guide vane keeps minimum vane opening. When 2HIC-1105A output signal value is larger than
, 2FIC-109A output signal value, 2FIC-109A signal. controls, 4-C103A expander guide vane. Then 2FV-109A
J.T. valve is fully closed. During normal operation, 2HIC-1105A output signal is fixed at 15 psig.
The solenoid valves in partial control system is used to shift the expander operation to J.T. valve operation in
condition of expander shut down. At that time 2PV-315 control valve on4-V108A outlet line is fully opened to
maintain the fuel gas pressure constant, because 4-C103A recompressor is shut down, and the gas flows through
2SDV-1912A recompressr bypass valve.
B) Anti-surge control system of recompressor
Anti-surge recycle control system is provided on expander/compressor. If the compressor operation point
approaches the surge limit, the discharge gas will be recycled to the suction. 4-C103A recompressor has an anti-
surge control system to avoid the surge operation. The system is mainly composed of 2PDT-312A pressure
differential transmitter, 2PY-312A ratio instrument and 2F1C-114A flow controller. 2FIC-114A is reset by
2PDT-312A output signal through 2PY-312A to maintain the minimum suction flow rate (10% surge margin
flow rate) of recompressor.
2FIC-114A is controlled 2FV-114A anti-surge valve with adjusting the recompressor suction flow rate to-the set
value. As 2FV-114A anti-surge valve has an antiwind-up switch, the valve is fully closed in anti-surge region,
included normal operation point.
C) Cascade control of H.P. separator liquid
The H.P. separator liquid from 4-V107A/B is controlled by 2FIC-112A/B cascade control loop. 2FIC-112A set
value is changed by 2LIC-710A output signal. 2FV-112A control valve operates to adjust 2FT-112A flow rate
to the set value. In this control loop, 2LIC-710A controller continuously changes 2FIC-112A set value with the
liquid level fluctuation in 4-V107A. This control system is useful for stable operation of depropanizer, because
the liquid levels of 4-V107A/B are comparatively stable at normal operation condition.
D) Recycle flow control
2HV-1104 control valve on recompressor discharge line is used for plant recycle operation. If plant load
decreases and 4-C103A/B expander/recompressor's efficiency falls, the value is manually opened and the
handling gas flow rate is increased.
E) Control of split flow rate (2HIC-1101AJB and 2HIC-1102A
The flow rate to 4-E104A/B and 4-E105A/B is adjusted by 2HIC1101A/B and 2HIC-1102A/B. This split ratio
is important to achieve the high butane recovery rate. The best adjustment is that the temperature of 4-V107A/B
becomes minimum , without hydrate formation in 4-E104A/B, 4-E105A/B and 4-E106A/B
F) Control of split flow rate (2HIC-1103A/B)
The depropanizer OVHD gas to 4-E104A/B shell side is adjustable equally by 2HIC-1103A/B.
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6-Fractionation
Depropanizer 4-T101 removes excess propane and lighter components from the recovered hydrocarbon liquids. Two
feed sources are provided for depropanizer. The cold condensate from the low pressure separators 4-V108A/B is fed to
No.5 tray, and the hot condensate from the high pressure separators and the main compressor suction drums 4-V102A/B
are normally fed to No.17 tray. Two (2) spare feed nozzles are provided for the hot condensate at No.13, 21 tray to
ensure proper performance of the column for different feed composition .Methanol can be injected into the depropanizer
overhead line, necessary, to avoid freezing in the overhead condenser.
An auxiliary refrigeration system is provided for the cooling in the overhead condenser 4-E109 and the existing
depropanizer condenser 4-E123. The refrigerant pressure, and hence, its temperature is reset by level controller on reflux
drum 4-V109 to maintain the liquid level in 4-V109. The depropanizer is reboiled by a heating oil circulation system.
In the existing unit, depropanizer Overhead Condensers 4-E9A&B are presently cooled by the cold expander vapour. In
addition to this, the new refrigeration package is used to supply the required refrigerant. This will lead to
1) better fractionation in the existing depropanizer.
2) more available cooling to the incoming gas in the chilling train.
3) increase of butane recovery.
Note: If one of the compressors in the refrigeration unit is shutdown, the expansion depropanizer will be operated with
the refrigeration package, while the existing depropanizer will be operated with the cold expander gas to generate the
reflux.
Tie-in lines between the existing depropanizer feeds and the expansion depropanizer feeds are provided.so that a part of
the recovered liquid in the existing plant may be fractionated in the expansion fractionation section. The depropanizer
and associated equipment are designed with enough capacity to handle the recovered liquid hydrocarbons, to recycle
some off-spec LPG and to handle a part of the recovered liquids in the existing plant.
The pressure of the column is controlled by the pressure control valve on outlet line of depropanizer overhead
accumulator 4-V109. The recycle line is provided between upstream of the pressure control valve and main compressor
suction line for mainly handling. the excess overhead depropanizer gas during the shut-down of both expanders. The
circulation operation is controlled by hand indicate control valve.
Debutanizer 4-T102 fractionates the depropanizer bottom liquid into LPG and naphtha which are sent to existing storage
facilities. As the pressure of the column is controlled by-the pressure control valve on the debutanizer OVHD trim-cooler
outlet line.
The pressure of the debutanizer OVHD accumulator is controlled by ,the condenser hot by-pass valve and the flare by-
pass valve. Reboiling is done by heating oil circulation. Vapour pressure of the bottom product is calculated to be
slightly below atmosphere at 38C. Three feed inlets are provided. The raw LPG is normally fed to No.21 tray, and the
spare inlets are provided at No. 17 and. No.25 tray like for depropanizer. The column and associated equipment are
sized. to handle the recovered liquid hydrocarbons and recycle some off-spec LPG.
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6-1-Normal operation of Fractionation
The depropanizer 4-T101 removes excess, propane and lighter components from the recovered hydrocarbon liquids.
6-1-1-Vapor pressure of LPG product
Vapor pressure of LPG product is dependent upon the butane/propane ratio at 4-T101 depropanizer bottom. Periodically
take the sample of LPG product. If the vapor pressure is abnormal, adjust the reflux flow rate 2FIC-123 of 4-T101.
A) If the vapor pressure is low, increase the reflux flaw rate. Then, the propane component in the bottom product of
4-T101 is increased. The hot oil flow rate is automatically increased by 2TIC-517, for keeping the reboiler
temperature constant.
B)If the vapor pressure is high, decrease the reflux flow rate. Then, the propane component in the bottom product of
4-T101 is decreased. In this case, take care that the butane loss from the top is not increased.
6-1-2- Water in 4-V109 boot
Periodically check the interface level in 4-V109 boot. When the level is high, drain the water into the closed drain line.
In this operation, take care that the valve port is not. choked up with ice. In this case, as there are two valves on the line,
close another valve to stop the flow.
6-1-3-Hydrate formation
When the hydrate formation in 4-E109 tube is found out inject the methanol to melt the hydrate.
6-1-4- Liquid level in 4-V109
Periodically check the liquid level in 4-V109. If the liquid level is abnormal, check the cascade control system between
2LT-718 and 2PIC-324.
6-1-5- J.T. valve operation case
In case of J.T valve operation, the depropanizer OVHD gas doesn't f lows to chilling trains. Because 2PV7315A/B is
fully opened and the pressure of 4-V108A/B is raised. In this case ,close 2HV-1103 A/B and gradually open 2HV-1108.
Then, the gas recycles from 4-V109 to V-101 outlet line.
The debutanizer 4-T102 fractionates the depropanizer bottom product into LPG and stabilized Naphtha product.
6-1-6-C5+ heavier in LPG product
Periodically take the sample of LPG product. If the heavier hydrocarbons are increased in the product, increase the reflux
flow rate.
A) Gradually open 2FV-126 and increase the hot oil flow rate into 4-E113 debutanizer reboiler with watching the
temperature of No. 32 tray.
B)Then, the reflux flew rate is increasing to keep the top temperature constant. Check the indications of 2TIC-
518 and 2FIC-126.
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6-1-7- Top pressure of 4-T102
If the top pressure of 4-T102 is abnormal, check the hot bypass. control system .2PIC-338- and 2PIC-326).Especially
take care that there is no liquid in 4-E112. Then, the hot bypass control system. doesnt work normally .When the outlet,
temperature (2TUI-500-20) of 4-E112 is not normal, adjust sea water flow rate.
6-1-8- Temperature of-Naphtha product
If the outlet temperature. (2TUI-500-21) of 4-E114 is -not normal, adjust the seawater flow rate.
6-1-9- Non-condensing gas in 4-V110
If there is non-condensing gas in 4-V110, Purge it into the flare line through 2PV-326A bypass valve. Take care that the
pressure of 4-V110 dont fluctuate.
6-2-Control of Fractionation
6-2-1-Control of depropanizer bottom temperature
The bottom temperature of depropanizer is controlled by 2TIC-517 temperature controller, varying the hot-oil flow rate
and tower load. The control is important to adjust the. propane/butane ratio in LPG product.
6-2-2 Split control of depropanizer top pressure
The pressure of depropanizer top is controlled by 2PIC-323 split control system on 4-V109. 2PIC-323 output signal (
3-15psig) is connected to 2PV-323B and 2PV-323A (flare line) control valve. 2PV-323B control valve is opening with
increasing 2P1C-323 output signal to 9 psig. And, 2PV-323A control valve is opening with increasing 2PIC-323 output
signal from 9 psig to 15 psig. Then, the depropanizer OVHD gas flows to flare header.
6-2-3-Control Of depropanizer reflux flow rate
The reflux flow is controlled constantly by 2FIC-123 set value. If the tower load is changed, the set value of 2FIC-123 is
reset by manual according to the tower load .
6-2-4Control of depropanizer OVHD accumulator :
The condensate flow from 4-E109 is variable as OVHD gas flow. Because the refrigerant flow to 4-E109 is variable to
OVHD gas flow for maintaining the constant liquid level in 4-E109 and the pressure of the refrigerant is controlled
constantly by 2PIC-324 to the variable refrigerant vapor. In the consequently, the liquid level of 4-V109 is variable as the
condensate flaw. Following control system is provided for achieving constant liquid level to variable OVHD gas flow.
The vapor load fluctuation of depropanizer top is adsorbed by 2LIC-717 liquid level controller on 4-E109 and 2PIC-324
pressure controller, which set point is connected to 2LT-718 level transmitter on 4-V109. For large vapor. load, the
propane evaporation speed in 4-E109 shell is increasing and the propane liquid level is decreasing. Then, 2LV-717
control valve is opening by 2LIC-717 and the balanced Propane Liquid flows into 4-E109 shell. At that time, the -
pressure in 4-E109 is kept constant by 2PIC-324 pressure controller.
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If the vapor load-is-very large or small and the liquid-in 4-V109 is decreasing or increasing, 2LT-718/2PIC7324 cascade
control system is activated. 2LT-718 output signal.is transported to 2PY-324-5 high/low selector through 2PY-324-3
and 2PY-324-4.
2PY-324-5 output signal is composed of three characteristic straight lines, which change the set point of 2PIC-324
pressure controller. 2PY-324-5 output signal is constant, which is changed by 2HIC-324 manual controller, during some
liquid level range around NLL in 4-V109. Then, the pressure in 4-E109 shell is controlled constant and the Propane
liquid temperature in it is kept constant.
If the liquid level -in 4-V109 decreases under the minimum point of the level range,2PY-324-5 outppt signal is
decreasing with decreasing of 21T-718 output signal. Then, the pressure in 4-E109 shell is decreased and the propane
liquid temperature is decreased. As the result, the condensed rate of tower top vapor increases and the liquid level in 4-
V109 increases. If the liquid level in 4-V109 increases over the maximum point of the level range; the control is in a
reverse action.
6-2-5- Bypass control of depropanizer OVHD gas
2HV-1107 control valve on 4-T101 top line is a load down valve for 4-E109 depropanizer OVHD condenser. The valve
is used during start-up operation.
6-2-6- Recycle flow control by 2HIC-1108
In case of OVHD gas flaring, i.e. J.T. valve operation of the chilling trains, the OVHD gas can be recycled to main
compressor suction line by the opening of 2HV-1108 on 4-V109 vapor line for saving of the gas loss.
6-2-7-Control of debutanizer bottom temperature
The temperature of debutanizer is controlled by 2FIC-125 which supplies the constant hot oil flow to 4-E113
debutanizer reboiler. If the debutanizer feed is changed, the set value of 2FIC-125 is reset by manual for maintaining the
tower bottom temperature.
6-2-8- Control of debutanizer top pressure
The pressure of debutanizer top is controlled by hot bypass control system. The system is composed of 2PIC-338 press
controller, 2TIC-560 temperature controller and 2PIC-326 press controller. 2PIC-326 on 4-V 110 is a split control
system and the output signal is connected to 2PV-326B bypass valve through 2HSV-326B and 2PV-326A flare line
valve. 2PV-326B control valve is closing with increasing 2PIC-326 output signal to 9 psig.
And 2PV -326A control valve is opening with increasing 2PIC-326 output signal from 9 psig to 15 psig. Then, the
debutanizer OVHD gas flows to flare header. Normally, 2PIC-326 output signal is under 9 psig. The hot vapor of 4-T102
top flows into 4-V110 through 2PV-326B, and the down stream pressure of 2PV-338 control valve is kept constant. The
hot vapor is condensed at the liquid surface in 4-V110, because the liquid is a sub cooled state. 2HSV-326B is switched
to2HIC-326B during start-up operation.
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2PIC-338 pressure controller and the heat transfer surface in 4-E112 are main control loop of hot bypass control system.
If the tower load increases, the pressure of 4-T102 top raises. Then, 2PIC-338 output signal increases and 2PV-338
control valve is opened. As the downstream pressure of 2PV-338 is constant, which is controlled by 2PIC-326 split
control system on 4-V110, the flow rate through 2PV-338 valve increases. After that, the liquid level in 4-E112 decreases
and the condensing heat transfer area is increased. As the result, the condensing speed of tower top vapor in 4-E112 is
increased and the top pressure returns to normal value.
In addition, 2TIC-560 output signal is connected to variable pitch fun's controller of 4-A112. The control loop is used to
avoid an ambient temperature fluctuation from hot bypass control system.
6-2-9- Control of debutanizer reflux flow rate
The reflux flow rate is controlled by 2FIC-126 cascade control loop. 2FIC-126 set value is changed by 2TIC-518 output
signal. 2FV-126 control valve operates to adjust 2FT-126 reflux flow rate to the set value. In this control loop, 2TIC-
518 controller continuously changes 2FIC-126 set value with the top temperature fluctuation of 4-T102. This control
system is important to adjust the pentane component in LPG product.
6-2-10-Flow measurement of LPG product
LPG product flow rate is measured with 2FE-127 flow instrument which has the compensative function (density) with
temperature 2TT-519 The measured flow rate is indicted as the liquid volume at 15.6C.
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Page | 33
7-Booster Compressors
The lean gas leaving the expander/compressor is boosted to obtain the pressure needed for the gas transmission pipeline
to EBGDCO .This operation takes place in Booster Compressors 4-C104A&B.
To have the operation flexibility, two 50% units are provided parallel to three 50% units in the existing plant. Each
compressor is provided with Booster Inter Cooler 4-A107, Booster Inter Separator 4-V116 and Booster After Cooler 4-
A108. Tie-in connection between the compressor suctions are provided so that one of the existing compressors may be
used as a spare to the expansion Compressors.
The compressors ire driven by gas turbines. The compressor speed is controlled by a pressure controller on the suction
line. In this way, the booster compressors maintain the discharge pressure of the expander compressors. Also, the gas
load is distributed equally for the booster compressors. Split range pressure Control is provided to flare the excess gas
when the gas rate over compressor capacity flows to the suction.
Each compressor has a recycle line which is activated at reduced load on the booster compressor to prevent surging. The
control scheme is the same as one for the main compressor. The booster compressor is normally operated at the
discharge pressure of 60 kg/cm2 , and is able to raise the discharge pressure to 90.0 kg/cm2 . Turbine driver has output
power for this duty at site rated condition.
7-1-Normal operation of Booster
The lean gas leaving 4-C103A/B recompressors is boosted to the pressure needed for transmission to.
7-1-1 Suction pressure control
4-C104A/B booster compression are automatically controlled by the split control system 2PIC-317 between 2PV-317
and2SIC-1004A/B governor controllers. 4-C4A/B/C existing booster compressors-will be controlled automatically by
the suction pressure controller PIG-317 too.
When both suction headers of existing and expansion booster compressors are combined (fully open 16" valve near tie-in
point 12), it is necessary to adjust the set points of 2PIC-317 and PIC-317 to same value. If the set points are not same,
the load balance between existing and expansion booster compressors is not established. Therefore to close 16" valve is
a desirable operation, except 4-C4 stand-by booster compressor's operation case.
7-1-2-Discharge pressure
When 4-C105 .sales gas compressor is not operated, the discharge pressure of booster compressors is dependent upon;
the pipeline pressure (i.e- sales gas: flow rate). If the sales gas rate required from-Suez area is stable, set .2PIC-328 to
auto mode. Then, the discharge pressure is kept constant by 2PIC-328.
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Page | 34
7-1-3-Load balance
If the load balance between 4-C104A/B and existing 4-C4A/B booster compressors is not correct, it can be adjusted
with, resetting the ratio values of 2PY-317A/B-1 manual loaders. It is desirable to adjust the ratio value of expansion
booster compressor's handled flow rate to existing one into the plant capacity ratio.
7-1-4-Liquid level in -V107A/B
Take care that the liquid levels in 4V116A/B ,dont become high. Then 4-C104A/B booster compressors are shut down.
7-1-5-Outlet temperatures 4-A107A/B and 4-A108A/B
Periodically check the outlet temperatures of 4-A107A /B and 4-A108A/B. And adjust the temperatures by 2HIC-
A107A/B. and 2HIC-A108A/B manual controllers.
7-1-6- J.T. valve operation case
When 4-C103A/B expander/ recompressors are stopped by any trouble, J.T. valves, are automatically opened and
controlled. In this case, L.P. separator gas flow rate (i.e. the suction flow rate of booster compressors) is rapidly
increasing. Take care that the operating conditions of booster compressors dont fluctuate. If the fluctuation doesn't
become small, cut the split control signals between 2PIC-317 and 2PY-317A/B-1. Then, the speeds of 4-W104A/B are
manually controlled by 2PY-317A/B-1 manual loaders.
7-2-Control of Boosters
7-2-1 Control of main booster compressor
A) Split control by 2PIC-317
The suction pressure of 4-C104A/B booster compressors is controlled by 2PIC-317 split control system on -the suction
line.2PIC-317 output signal (3 - 15 psig) is connected to control valve (on flare line) and 2SIC-1004A/B gas turbine
governor control instruments.2 SIC-1004A/B set points and 4-W104A/B gas turbine speeds are increasing with
increasing 2PIC-317 output signal from psig to 9 psig .
2PV-317 control valve is opening with increasing 2PIC-317 output signal from 9 psig to 15 psig. The pressure
fluctuation of 4-C104A/B suction is normally controlled by cascade control of 2PIC-317 and 2SIC-1004A/B. If the
pressure increasing rate for large pressure fluctuation exceeds the compressor speed increasing rate, which decreases the
suction pressure, 2PIC-317 output signal becomes over 9 psig and the compressor suction gas flows to flare header
through 2PV-317. 2PY-317A/B-1 ratio instruments are used for adjustment of each compressor performance's
difference.
B) Auto start/stop sequence of booster compressor
4-C104 compressor panel has a function of auto start/stop sequence. The sequence controls suction/discharge
sectionalizing valves (2SDV-1919/1921), system pressurizin valve (2SDV-1920), depressure valve (2SDV-1922) and
anti-surge valve (2FV-118). In case of 4-C104 start-up, purge and pressurize operation of 4-C104 system are performed,
________________________________________________________________________________________
Page | 35
automatically. And, when 4-W104 gas turbine reaches the minimum speed, anti-surge valve is set to auto position by
pushing the load button on compressor panel. In case of 4-C104 shut down, sectionalize and depressurize operation of 4-
C104 system is performed, automatically.
C) Anti-surge control system
4-C104 booster compressor ,has an anti-surge control system to avoid the surge operation . The operation of the system
is as follows .The volumetric suction flow rate is measured by 2FE-1I8A, generating a differential pressure which is
translated into a standard signal by 2FT-118A differential transmitter. The compressor differential pressure between
suction "and discharge is measured by 2PDT-320A which output represents a standard signal.
The output of both transmitters serves as input for 2FY-118A in which the dividing takes place. The output of 2FY-118A
serves as input for the flow controller, which in turn controls 2FV-118A anti-surge control valve.The operation of the
controller is discontinuous. In normal compressor operation, the suction flow rate is well above the surge line. Only
when the flow rate begins to drop in the surge region (10% surge margine region), the controller needs to act.
7-2-2-Flow measurement of sales gas
The flow instrument, 2FE-119, is installed on 4-C104A/B discharge line to measure the sales gas flow rate. The
instrument's loop has a compensative function with pressure (2PT-322) and temperature (2TT-516). Then, the measured
flow rate is indicated as normal state (0C, 1 atm).2FT-119A and 2FT-119B flow transmitter loop are used for under
33% and over 33% of 2FE-119 design flow rate, respectively. The integrated total flow rate is calculated as the sum of
2FQ1-119A/119B
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Page | 36
8-References
Arthur J. Kidnay &William R. Parrish , Fundamentals Of Natural Gas Processing, Taylor And
Francis ,Ohio,2006.
Boyun Guo & Aii Ghalambor, Natural Gas Engineering Hand Book, Gulf Publishing Company,
Houston ,2005.
Charles E. Thomas, Process Technology Equipment And Systems, Third Edition, Ny ,Delmar 2011.
GPSA Engineering Data Book , Eleventh Edition, Gas Processors Suppliers Association, Oklahoma
,1996.
Happy Training Manual , Gulf Of Suez Petroleum Company (GUPCO) ,1999.
Ken Arnold & Maurice Stewart ,Surface Production Operations ,Volume 2 , Second Edition , Elsevier,
Houston ,1999
Plant Operation Manual For Gulf Of Suez Gas Plant Expansion Main Process Area (Phase Il), Hitachi
Zosen, November 1986.
Reports Of Other Process Team Members.
Saeid Mokhatab, William A. Poe & James G. Speight ,Handbook Of Natural Gas Transmission And
Processing , Burlington, Elsevier,2006.
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Page | 37

Prepared By: Ahmed Mohamed Elshora Under The Supervision Of: U-104 Process Team

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Gulf of Suez Petroleum Company (GUPCO)

FIGURE 1: SIMPLE FLOW DIAGRAM OF U-104 .............................................................................................. 5

TABLE 1: OPERATING CONDITIONS OF INLET SEPARATORS ........................................................................ 11

1-3- U-104 Gas plant

Figure 1: Simple flow diagram of U-104

July,Ramadan and Morjan 1 send their production to U103 Max 54 MMSCF .

Figure 2: GUPCO district flow diagram

Figure 3: Simple flow diagram of U-103

Figure 4: Pipelines and pig traps at inlet area

Figure 5: Cross section at horizontal separator

Primary Separation Section:

Secondary Separation Section

Mist Extraction Section:

Liquid Accumulation Section:

2-3-1-Advantages and Disadvantages of Horizontal Separator

Handle larger volumes of gas.

Figure 6: Simple flow diagram of 4-V101

TOperating POperating TDesign PDesign Flow Rate

Table 1: Operating conditions of inlet separators

2-3-3-The Control system of inlet separators

A-The split control loop by 2PIC-301:

B-Liquid Level control:

Figure 7: Detailed components of the centrifugal compressor.

Figure 8:Classification of compressors types

Figure 9: Centrifugal compressor

Figure 10:Types of rotors

Figure 11: Stages of compressors

Inlet conditions Outlet conditions Inlet conditions Outlet conditions

P = 6-7 kg/cm2 P =18.5-19 kg/cm2 P =5.1-6 kg/cm2 P =18 kg/cm2

Table 3:Advantages &disadvantages of centrifugal compressors

3-2-Surge and Choke

Figure 12: Compressor chart (constant speed )

3-3-Compressors process description

Figure 13: Simple flow diagram of compression area

where k is the empirically determined polytropic constant

and CVM is computed the same way.

4-C1A 4-C1B 4-C101A 4-C101B

Table 4: Polytropic efficiency of main compressors.

Stage One 14.7 psia * 3.2 = 47.04 psia

A-Split control loop by 2PIC-301:

B- Auto start /Stop sequence of main compressor:

D-Flow measurement of feed gas (2FR-101A/B)

4-Drying & sweating area

1. Absorption using liquid desiccants.

2. Absorption using solid desiccants.

3. Injection of hydrate point depressants.

To meet a water dew point requirement of a sales gas contract

Table 5: Properties of solid desiccants .

The advantages of solid-desiccant dehydration include:

A-Ratio control of after separator gas distribution (2PIC-307)

B-Molecular sieve control sequence:

Table 6 : Molecular sieve operation program

5-Gas Cooling and Expansion

5-1-Normal operation of Chilling area

A) Split flow ratio

B) Chilling train feed rate

D) Liquid levels in 4-V107A/B

E) Liquid levels in 4-V108A/B

F) Distribution of depropanizer OVHD gas

I ) Recycle operation by 2HV-1104

Automatic control system in this section is as follow:

A) Partial control system for expander and J.T. valve:

B) Anti-surge control system of recompressor