MALVINAS GAS PLANT

OPERATOR TRAINING

PARAGON ENGINEERING SERVICES, INC.

HOUSTON, TEXAS

Prepared By
H. G. Winningham
September 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OVERVIEW

 FUNDAMENTALS OF NATURAL GAS PROCESSING

 REVIEW OF MALVINAS PROCESS FLOW DIAGRAMS
 THE PURPOSE / FUNCTION OF EACH PROCESS SYSTEM
 SYSTEM OPERATING CHARTS AND GUIDELINES
 MANAGING PLANT PERFORMANCE
 GAS & NGL PRODUCT SPECIFICATIONS
 IMPACTS TO TGP AND PISCO
 “KEY” OPERATING GOALS & OBJECTIVES
 PLANT SAFETY

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

FUNDAMENTALS OF NATURAL GAS PROCESSING

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

GAS PROCESSING FUNDAMENTALS

BLOCK DIAGRAM

Sales Gas

NGL Recovery/Gas Rejection

Inject Gas Gas Compression Residue Gas

Water
Vapor Reflux
“Wet”
Gas Expander
Chill-Down
Feed Gas Slug Catcher Dehydration
Heat Exchange

DEETHANIZER
Recovered
“Wet” Vapors
HP Condensate Cond
Flash NGL
Vapors Reboiler
Vapor
Recovery Stabilizer
Vapors

Condensate Condensate NGL Product

Separation / Dehyd Stabilization
High VP Product Storage
Condensate
To Pisco
Condensate Product & Shipping
Water

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

GAS PROCESSING FUNDAMENTALS

MALVINAS GAS PROCESSING FACILITY PRODUCTION CAPACITY

 GAS PROCESSING CAPACITY FOR 440 MMSCFD

 Two – 220 MMscfd Turbo Expander Cryo Trains
 One – Condensate Stabilization Train
 CRYO PLANT NOMINAL PROPANE RECOVERY @ 440 MMSCFD
 GSP (J-T) 40%
 SCORE (J-T) 38%
 GSP (Expander) 89.2%
 SCORE (Expander) 99.6%
 NGL PRODUCTION @ 440 MMSCFD
 GSP (J-T) 28,240 B/D
 SCORE (J-T) 26,750 B/D
 GSP (Expander) 33,850 B/D
 SCORE (Expander) 35,100 B/D

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

GAS PROCESSING FUNDAMENTALS

MALVINAS GAS PROCESSING FACILITY PRODUCTION CAPACITY (Cont.)

CRYO PLANT (Train 1 & 2) PRODUCTION B/D @ 440 MMscfd

PRODUCT GSP (J-T) GSP (EXP) SCORE (J-T) SCORE(EXP)

C3 4,320 9,420 3,940 10,570

i-C4 1,360 1,610 1,020 1,660

n-C4 2,610 2,830 2,050 2,870

i-C5+ 4,800 4,840 4,590 4,850

TOTAL 13,090 18,700 11,600 19,950

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

GAS PROCESSING FUNDAMENTALS

MALVINAS GAS PROCESSING FACILITY PRODUCTION CAPACITY (Cont.)

CONDENSATE STABILIZER PRODUCTION B/D @ 440 MMscfd

PRODUCT STABILIZER

C3 1,040

i-C4 380

n-C4 880

i-C5+ 12,850

TOTAL 15,150

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

GAS PROCESSING FUNDAMENTALS

MALVINAS GAS PROCESSING FACILITY PRODUCTION CAPACITY (Cont.)

TOTAL PLANT PRODUCTION B/D @ 440 MMscfd

PRODUCT GSP (J-T) GSP (EXP) SCORE (J-T) SCORE(EXP)

C3 5,360 10,460 4,980 11,610

i-C4 1,740 1,990 1,400 2,040

n-C4 3,490 3,710 2,930 3,750

i-C5+ 17,650 17,690 17,440 17,700

TOTAL 28,240 33,850 26,750 35,100

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAMS

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING
MALVINAS PROCESS FLOW DIAGRAM
CONDENSATE STABILIZATION AND VAPOR RECOVERY SYSTEM
F 1,285 psig
1,400 psig “WET” GAS
PIC PIC PIC
TRAIN #1
TO INLET
FILTER
SEPARATOR
COMPRESSOR 1,265 psig
“WET” GAS HEADER STABILIZER OVHD TRAIN #2
SKIDS (3 UNITS) PIC “WET” GAS
COMPRESSORS

190 psig
FROM FIELD 110oF 2nd 1st F
GATHERING 1,300 psig 94oF PIC
5.7 MMscfd
S
INLET GAS
PIC 107oF
95oF 3.4 MMscfd
1,300 psig 175 psig
LIC
SLUG CATCHER
PIC 485 psig

STABILIZER
“WET” HP CONDENSATE FIC 250 psig 235 psig
F
500 psig F

PIC PIC PIC

180 psig
22,280 B/D 82oF 76oF
SAND 485 psig 8.0 MMscfd 235 psig 2.3 MMscfd TIC
FILTER CONDENSATE CONDENSATE 300oF
LC LIC STABILIZER
SEPARATOR FLASH DRUM LIC
BOTTOMS/FEED
LC EXCHANGER
S FIC
100oF Hot Oil
WATER 17,020 B/D
CONDENSATE TIC
500 B/D STABILIZER
FILTER
CD REBOILERS
TIC
110oF

S
CONDENSATE
STABILIZER 14,860 B/D
PRODUCT COOLER TO STORAGE

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAM

INLET GAS DEHYDRATION AND MOLE SIEVE REGENERATION (TRAIN #1 OR #2)
INLET FILTER GLYCOL INLET GAS DEHYDRATORS Adsorb: 24 Hrs (1,265 psig)
SEPARATOR CONTACTOR COALESCER FILTER (MOLE SEIVE BEDS) Regen: 12 Hrs (450 psig)
TRAIN #1 <2psi (Clean)
95oF
10psi (Dirty)
220 MMscfd PDI
“WET” GAS <2psi (Clean)
10psi (Dirty) 30 gpm
FROM SLUG PDI
CATCHER FI
LC Adsorption Adsorption

5-8 psi
LC
PDI
LC LC
TO CONDENSATE LC
SEPARATOR Normally Regen
450oF
“WET” COND No Normally No Flow
5 MMscfd Flow
FIC

REGEN GAS
470 psig 5 gpm
FIC
TO RESIDUE GAS <2psi (Clean)
COMPRESSORS PDI 10psi (Dirty)
TIC
REGEN GAS 450oF 1,255 psig
Water Vapor/Stripping Gas REGEN GAS COMPRESSORS
To Warm Flare GLYCOL “DRY” GAS
CONTACTOR REGEN GAS
F
490 psig SCRUBBER
110oF DRY GAS DUST TO CRYO UNIT
LIC Hot Oil
470 psig FILTERS
Lean Glycol TIC110oF 5 MMscfd
TEG 440 psig REGEN GAS
99.5 wt%
REGENERATION REGENERATION
SYSTEM 35 gpm LIC FROM BOOSTER COMPRESSOR
GAS HEATER
REGEN GAS DISCH COOLER
COOLER
Rich Glycol
Water
CD
SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAM

GLYCOL REGENERATION SYSTEM (TRAIN #1 OR #2)

Blanket Gas
Set @ 0.5 psig
From Fuel
Gas Header
Set @ 5 psig
GLYCOL OVHD
FROM COOLER
F
GLYCOL CONTACTOR 209 F
o

AND
REGEN GAS GLYCOL CONTACTOR 110oF
112oF GLYCOL REFLUX COIL
RICH TEG LC LC

128oF
GLYCOL Hydrocarbon
Set @ 50 psig REGENERATION Skim Liquid
Blanket Gas STILL Water To
From Fuel
Disposal
Gas Header CD
GLYCOL FILL & TIC
GLYCOL FLASH Set @ 60 psig MAKE-UP 400oF
TANK GLYCOL REBOILER
F
LG
Hot Oil
128oF
60 psig
Stripping Gas FI
LC LC From Fuel Gas Header

400oF 85 to 90 Mscfd (~2 scf/gallon TEG Circ Rate)

<2psi (Clean)
10psi (Dirty)
RICH / LEAN GLYCOL
PDI PDI PDI 300oF EXCHANGER TO
Hydrocarbon
Skim Liquid GLYCOL CONTACTOR
AND
CD
128oF REGEN GAS GLYCOL CONTACTOR
234oF TIC
110oF
GLYCOL SOCK GLYCOL CARBON GLYCOL SOCK LEAN TEG
FILTER FILTER FILTER 35 gpm
99.5Wt% TEG
LEAN GLYCOL
COOLER

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEMS (GSP w/ J-T)
FFIC
Set @ 495
PIC psig
F
BOOSTER COMPRESSOR
S DISCH. COOLER
RESIDUE GAS GAS / GAS REFLUX
FIC
470 psig EXCHANGER CONDENSER
PIC C
TO RESIDUE -41oF
COMPRESSORS VVVVVVVV--VVVVVVVV
90oF O
Residue
BOOSTER VVVVVVV VVVVVVVV
Compressor
COMPRESSOR -40oF -97oF
Speed Control DEETHANIZER
(Bypassed)
45MMscfd EXPANDER
92%
26 F
o 21% C Inlet PC or FC
<
FROM DRY GAS SIC Signal
DUST FILTERS O
FIC
Warm Gas Bypass Set @ FFC C C
“DRY” GAS +5oF 168MMscfd 1225psig J-T VALVE
S
96 F
o
TIC 79%
1,255 psig DEETHANIZER DEETHANIZER SIDE
FEED PREHEATER LIQ / GAS EXCHANGE LIC
219.8 MMscfd FIC
26oF
DEETHANIZER
VVVVVVVV--VVVVVVVV REFLUX FFIC
8% 26oF
LIC ACCUMULATOR
VVVVVVV VVVVVVVV COLD FIC
SEPARATOR DEETHANIZER 480 psig
REFLUX PUMPS
HS TIC -2oF DEETHANIZER
C Pump Min Flow Recycle REBOILER
90oF

TIC LIC

TIC
277oF
TO PRODUCT
STORAGE PROPANE RECOVERY 110oF TIC
38%
NGL PROD
S
PRODUCT
SEPTEMBER 2004 COOLER
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEMS (GSP w/ EXPANDER)
FFIC
Set @ 495
PIC psig
F
BOOSTER COMPRESSOR
S DISCH. COOLER
RESIDUE GAS GAS / GAS REFLUX
FIC
470 psig EXCHANGER CONDENSER
TO RESIDUE PIC C -78oF
COMPRESSORS VVVVVVVV--VVVVVVVV
90oF O
Residue
BOOSTER 345 psig VVVVVVV VVVVVVVV
Compressor
COMPRESSOR -76oF -131oF
Speed Control DEETHANIZER
45MMscfd EXPANDER
87%
18 F
o 21% C Inlet PC or FC
<
FROM DRY GAS SIC Signal
DUST FILTERS O
FIC
Warm Gas Bypass Set @ FFC C C
“DRY” GAS +5oF 166MMscfd 1225psig J-T VALVE
S
96 F
o
TIC 79%
1,255 psig DEETHANIZER DEETHANIZER SIDE
FEED PREHEATER LIQ / GAS EXCHANGE LIC
219.8 MMscfd FIC
19oF
DEETHANIZER
VVVVVVVV--VVVVVVVV REFLUX FFIC
13% 30oF
LIC ACCUMULATOR
VVVVVVV VVVVVVVV COLD FIC
SEPARATOR DEETHANIZER 365 psig
REFLUX PUMPS
HS TIC -19oF DEETHANIZER
C Pump Min Flow Recycle REBOILER
90oF

TIC LIC

TIC
209oF
TO PRODUCT
STORAGE PROPANE RECOVERY 110oF TIC
88%
NGL PROD
S
PRODUCT
SEPTEMBER 2004 COOLER
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEMS (SCORE w/ J-T)
FFIC
Set @ 495
PIC psig
F
BOOSTER COMPRESSOR
DISCH. COOLER 10% Of Inlet Rate
RESIDUE GAS GAS / GAS REFLUX 22MMscfd
FIC
470 psig EXCHANGER CONDENSER
TO RESIDUE PIC
-24oF
COMPRESSORS VVVVVVVV--VVVVVVVV
Residue 90oF
BOOSTER 470 psig VVVVVVV VVVVVVVV
Compressor
COMPRESSOR -23oF
Speed Control DEETHANIZER
(Bypassed) 19oF C EXPANDER
86% Inlet PC or FC
30 F
o
O Signal
<
FROM DRY GAS SIC
DUST FILTERS C
FIC
Warm Gas Bypass Set @ FFC O O
“DRY” GAS +5oF 213MMscfd 1225psig -23oF
J-T VALVE
96oF TIC C
1,255 psig DEETHANIZER DEETHANIZER SIDE
219.8 MMscfd FEED PREHEATER LIQ / GAS EXCHANGE 473psig 0%
28oF LIC FIC
0gpm
VVVVVVVV--VVVVVVVV DEETHANIZER FFIC
14% 16oF
REFLUX
LIC
VVVVVVV VVVVVVVV COLD ACCUMULATOR FIC
SEPARATOR DEETHANIZER 100% 480 psig
Set @ 208gpm
HS TIC -19oF REFLUX PUMPS 230 gpm DEETHANIZER
O Pump Min Flow Recycle REBOILER

TIC LIC
71oF

TIC
277oF
TO PRODUCT
STORAGE PROPANE RECOVERY 110oF TIC
36%
NGL PROD

PRODUCT
SEPTEMBER 2004 COOLER
 MALVINAS GAS PLANT
OPERATOR TRAINING

MALVINAS PROCESS FLOW DIAGRAM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEMS (SCORE w/ EXPANDER)
FFIC
Set @ 495
PIC psig
F
BOOSTER COMPRESSOR
DISCH. COOLER 21% Of Inlet Rate
RESIDUE GAS GAS / GAS REFLUX 45 MMscfd
FIC
470 psig EXCHANGER CONDENSER
TO RESIDUE PIC
-95oF
COMPRESSORS VVVVVVVV--VVVVVVVV
Residue 90oF
BOOSTER 325 psig VVVVVVV VVVVVVVV
Compressor
COMPRESSOR -75oF -75oF
Speed Control DEETHANIZER
-17oF C EXPANDER
86% Inlet PC or FC
22 F
o
O Signal
<
FROM DRY GAS SIC
DUST FILTERS C
FIC
Warm Gas Bypass Set @ FFC O O
“DRY” GAS +5oF -84oF
208MMscfd 1225psig J-T VALVE
96oF TIC 50%
1,255 psig DEETHANIZER DEETHANIZER SIDE 197gpm
219.8 MMscfd FEED PREHEATER LIQ / GAS EXCHANGE 333psig LIC FIC
12oF
VVVVVVVV--VVVVVVVV DEETHANIZER FFIC
14% -34oF
REFLUX
LIC
VVVVVVV VVVVVVVV COLD ACCUMULATOR FIC
SEPARATOR DEETHANIZER 50% 340 psig
Set @ 197gpm
HS TIC -30oF REFLUX PUMPS 230 gpm DEETHANIZER
O Pump Min Flow Recycle REBOILER

LIC
-40oF TIC

TIC
68oF 196oF
TO PRODUCT
STORAGE PROPANE RECOVERY 110oF TIC
99.6%
NGL PROD

PRODUCT
SEPTEMBER 2004 COOLER
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH

PROCESS SYSTEM

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

CONDENSATE STBILIZATION AND VAPOR RECOVERY

 Slug Catcher: Separate and collect slugs of liquid from the inlet gas delivered
to the plant from the gathering system. Act as a large feed surge tank for the
Condensate Separator, Condensate Flash Drum, and Stabilizer. Liquids should
be feed at a constant, stable rate from the Slug Catcher to the Condensate
Separator.
 Sand Filter: Filters out sand and particulate from the condensate.
 Condensate Separator: Separate water and flash gas from the condensate.
 Condensate Filter: Coalesce and filter out small water droplets and
particulates from the condensate.
 Condensate Flash Drum: Second stage flash to separate gas from the
condensate before being processed in the Stabilizer.
 Stabilizer Bottoms/Feed Exchanger : Pre-heats Stabilizer feed condensate
and cools Stabilizer bottom condensate product.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

CONDENSATE STBILIZATION AND VAPOR RECOVERY (Cont.)

 Stabilizer: A trayed tower designed to retain C3+ in the bottom product and
reject C2 and C1 overhead.
 Stabilizer Reboiler: Add heat to the condensate to boil off and reject C1/C2
from bottom product. Operating temperature of reboiler controls the C2/C3
ratio in the stabilized bottom product (Max 2.0LV% C2/C3 “Spec”).
 Stabilized Product Cooler: Cool the stabilized condensate product before
sending to storage. Cooling eliminates product flashing in the storage bullets.
 Stabilizer Ovhd Compressors: Collects, recovers and compresses flash gas
from the Condensate Separator, Condensate Flash Drum, and Stabilizer. The
compressed flash gas is subsequently dehydrated and processed for NGL
recovery in the cryo Plant.
 Inlet Scrubbers: Receives the combined gas stream from the Slug Catcher
outlet and the Stabilizer Ovhd Compressors. Separates any carry-over or
entrained liquids from the recombined gas stream prior to entering the Inlet Gas
Dehydration System.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

INLET GAS DEHYDRATION AND MOLE SIEVE REGENERATION SYSTEM

 Inlet Filter Separator: Coalesce and separate entrained liquids (if any) from the “wet”
gas from the Inlet Scrubbers outlet before entering the Glycol Contactor. Filters out any
particulate from the gas down to 3 micron.
 Glycol Contactor: Contacts the “wet” gas with lean glycol. The glycol absorbs water
vapor from the gas reducing the water content of the gas to less than 7 lbs water per
MMscf of gas which acts to reduces water loading and size of the mole sieve beds required
for dehydration to cryogenic dew point specs.
 Inlet Gas Coalescer Filter: Coalesces and separates from the gas any glycol that may be
entrained in the gas stream leaving the Glycol Contactor. Filters out glycol mist droplets
from the gas down to 0.3 microns. Glycol liquid will reduce or permanently damage the
adsorption capacity of the mole sieves if allowed to enter the Dehydrators.
 Dehydrators (Adsorption Mode): Removes essentially all of the remaining water vapor
from the gas as required to lower the gas water dew point temperature below cryogenic
processing temperatures in the plant. This prevents freezing and ice build-up within the
processing equipment. Two of the three Dehydrators in each train are in Adsorption
service. The Adsorption cycle duration is 24 hours.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

INLET GAS DEHYDRATION AND MOLE SIEVE REGENERATION SYSTEM (Cont.)

 Dry Gas Dust Filters: Filters to remove mole sieve dust particles larger than 1
micron from the “bone dry” gas before it inters the brazed aluminum plate fin
heat exchanger units. If not filtered from the gas, mole sieve dust can
accumulate in and eventually plug the plate fined exchanger units which will
adversely effect plant performance.
 Dehydrators (Regeneration Mode) : At the end of the adsorption cycle, the
Dehydrator is depressured and heated by “hot” (450 oF) gas to “drive off” and
remove water from the mole sieve that was adsorbed into the mole sieve during
the Adsorption mode. The Regeneration cycle duration is 12 hours (8.0 hrs
heating, 3.5 hrs cooling, and 0.5 hrs depressure/repressure.
 Regeneration Gas Heater: Heats the regeneration gas from approximately
110oF to 450oF before the gas enters the Dehydrator selected for Regeneration
Mode.
 Regen Gas Cooler: Cools the hot, wet regeneration gas exiting the
Dehydrator selected for Regeneration Mode. This cooling causes water vapor to
condense from the regeneration gas.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

INLET GAS DEHYDRATION AND MOLE SIEVE REGENERATION SYSTEM (Cont.)

 Regen Gas Scrubber: Separates condensed water from the cooled

regeneration gas.
 Regeneration Gas Compressors : Compresses the scrubbed regeneration
gas by approximately 50 psi. This added pressure allows the regeneration gas
to flow through the Regeneration Gas Glycol Contactor and back into the main
gas stream at the suction side of the Residue Gas Compressors.
 Regen Gas Glycol Contactor : Contacts the “wet” regeneration gas with lean
glycol. The glycol absorbs water vapor from the gas reducing the water content
of the gas to less than 7 lbs water per MMscf of gas before it is returned to the
main sales gas stream.
 TEG Regeneration System: Provides a recirculated source of lean glycol
(99.5Wt% TEG) for the glycol contactors by processing and removing water
from the rich glycol exiting from the bottom of the glycol contactors.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

GLYCOL REGENERATION SYSTEM

 Glycol Flash Tank: Separates flash gas and skims hydrocarbon liquids from
.the rich glycol.
 Glycol Sock Filters: Filters particulate and solids larger than 25 microns from
the rich glycol. Particulate, if not removed, will cause sludge build-up in the
Contactors and other equipment resulting in fouling and plugging problems.
 Glycol Carbon Filter: Activated charcoal filters removes degraded products
from the glycol to maintain glycol purity and quality. Products of degraded
glycol can be corrosive and will lead to accelerated corrosion of equipment if not
removed from the system.
 Rich/Lean Glycol Exchanger: Pre-heats the rich glycol before entering the
Glycol Regeneration Still column by cross exchange with the “hot” lean glycol
from the Glycol Reboiler. This exchanger recovers energy from the glycol and
acts to cool the glycol from 400oF to 234oF before feeding the Glycol Circulation
Pumps.
 Glycol Regeneration Still: Separates water vapor from the glycol, generates
reflux, and reduces glycol losses in the overhead vent stream.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

GLYCOL REGENERATION SYSTEM (Cont.)

 Glycol Reboiler: Heats the glycol to a temperature required to regenerate the

glycol (400oF). Stripping Gas is injected through a sparger at the bottom of the
Glycol Reboiler and bubble through the hot glycol to help “strip out” water from
the glycol. Water vapor, stripping gas and some vaporized glycol flow from the
Glycol Reboiler into the bottom of the Glycol Regeneration Still column while rich
glycol flow down the Glycol Regeneration Still and into the Reboiler effectively
distilling the water from the glycol stream. A stripping gas ratio of 2 scf / gallon
of glycol circulation will yield a 99.5Wt% TEG lean glycol when regenerated at
400oF near atmospheric pressure.
 Glycol Circulation Pumps: Provide lean glycol circulation to the Contactors
and boosts the pressure of the glycol to a pressure of approximately 1300 psig.
 Lean Glycol Cooler: Cools the lean glycol to 110oF before entering the
contactors.
 Glycol Ovhd Cooler: Cools the overhead vapor stream from the Glycol
Regeneration Still column condensing water vapor, BETX and other VOC’s from
the gas stream.
 Glycol Ovhd Separator: Separates liquid water and BETX from the overhead
gas stream before being vented / flared.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEM

 Gas/Gas Exchanger: Recovers refrigeration from the cold residue gas and
chills a portion of the dry inlet gas upstream of the Cold Separator.
 Deethanizer Feed Pre-Heater : Recovers refrigeration from the Cold
Separator liquids after flashing and chills a portion of the dry inlet gas upstream
of the Cold Separator.
 Cold Separator: Receives the combined chilled inlet gas streams from the
Gas/Gas Exchanger and the Deethanizer Feed Pre-Heater and separates
condensed hydrocarbon liquids from the chilled gas.
 Warm Gas Bypass: Keeps the Cold Separator from getting too cold. The Cold
Separator is a carbon steel vessel with a minimum design temperature of -20 oF.
 Reflux Condenser: Condenses liquid for refluxing the Deethanizer using the
cold Deethanizer overhead residue gas as a refrigeration source. In the GSP
Mode, a portion of the high pressure gas from the Cold Separator outlet is
condensed and used as reflux. In the SCORE Mode, a side vapor draw from the
top mid section (rich in C1 and C2) is condensed and used as reflux.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEM (Cont.)

 Deethanizer Side Liq / Gas Exchanger : In the GSP Mode, the exchanger
performs no function. In the SCORE Mode, the exchanger recovers refrigeration
from a liquid side draw from the Deethanizer mid section chimney tray. The
recovered refrigeration chills a portion of the inlet gas flowing from the
Deethanizer Feed Pre-Heater. The extraction of refrigeration from the side
liquid stream acts to heat and partially reboil the liquid before being returned to
the Deethanizer mid section.
 Expander / Booster Compressor : Removes energy from chilled inlet gas
flowing from the Cold Separator as the pressure is reduced across the Expander
as it is fed to the top of the Deethanizer mid section. Removal of energy from
the gas stream acts to refrigerate the gas. Energy recovered by the Expander is
transferred by a direct shaft connected the Booster Compressor which uses the
energy to compress the residue gas stream. Inlet vanes are provided within the
Expander which serve as a throttle controlling the flow of gas through the unit.
The unit is equipped with a speed control that will limit flow of gas through the
Expander as required to prevent the unit for over speed.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEM (Cont.)

 Deethanizer Reflux Accumulator : Serves no function in the GSP Mode. In

the SCORE Mode, the unit separates condensed liquids from the outlet stream of
the Reflux Condenser and serves as surge tank for the Deethanizer Reflux
Pumps.
 Deethanizer Reflux Pumps: Serves no function in the GSP Mode. In the
SCORE Mode, the pumps provide pressure boost to the reflux liquid as needed
to flow the liquid back to the Deethanizer as reflux overcoming head loss and
losses through the control valves and piping.
 Deethanizer: Separates the condensed C1 and C2 from the NGL product as
required to produce a NGL product having a C2/C3 ratio < 2.0 %LV.
 Deethanizer Reboiler: Provides heat to the bottom of the Deethanizer to
generate boil-up vapor making the Deethanizer function. Temperature control
of the Deethanizer Reboiler return temperature is used to maintain the C2/C3
ratio in compliance with the spec.
 Product Cooler: Cools the NGL product leaving the bottom of the Deethanizer
to 110oF before entering product storage. This prevent the NGL Product from
flashing off vapor within the storage tanks.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PURPOSE / FUNCTION OF EACH PROCESS SYSTEM

GAS CHILLDOWN & LIQUIDS RECOVERY SYSTEM (Cont.)

 Booster Compressor Discharge Cooler : Cools the discharge gas from the
Booster Compressor before being sent to the Residue Compressor suction
scrubbers. Heat of compression must be remove to prevent subsequent
compression from excessive discharge temperatures.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

CONDENSATE STABILIZER

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

STABILIZER REBOILER TIC
NOTES: PFD
1. Stabilizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Stabilizer Pressure 180 psig.
3. Stabilizer Feed Temperature 100oF

330
Stabilizer Btms Temp - DegF

320
SLUG CATCHER TEMP

110oF
310

100oF
300
295oF
90oF

290
80oF
1250 psig
280
1050 1100 1150 1200 1250 1300 1350
Slug Catcher Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

STABILIZER REBOILER TIC
NOTES: PFD
1. Stabilizer Pressure 180 psig.
2. Stabilizer Feed Temperature 100oF
3. Slug Catcher Pressure 1,300 psig

320
Stabilizer Btms Temp - DegF

SLUG CATCHER TEMP

310
110

300 100

295oF
290 90

80
280
0.0 1.0 2.0 3.0 4.0 5.0 6.0
C2/C3 Ratio LV% In Stabilized Product

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

GAS DEHYDRATION SYSTEM

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

GLYCOL DEHYDRATION
PFD

100
99.9
99
98
% Water Removed From Gas

99.5
97 96.5%
96
95 99.0
94
93
98.5
92
Lean TEG Wt%
91
90
89
88
3.0
87
86
1 2 3 4 5 6
TEG Contactor Circulation Rate - gal TEG/lb Water Removed

GPSA Engineering Data Book, 1998

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

GLYCOL REGENERATION
PFD

100.0
Glycol Still Top Pressure = 2 psig
99.9
Wt% TEG From Reboiler @ 400 oF

99.8
99.73%
99.7

99.6

99.5

99.4

99.3
99.2

99.1
2.0 scf / gal
99.0
0 1 2 3 4 5 6
Stripping Gas, scf/gal. TEG

GPSA Engineering Data Book, 1998

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

DEETHANIZER
GSP CONFIGURATION (w/ J-T)

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

PROPANE RECOVERY CHART (GSP w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Temp, 95oF. Cryo Train Feed = 220 MMscfd
3. Reflux: 21% Cold Sep Gas To Reflux Condenser

60 Higher Slug Catcher

Pressure INCREASES
C3 Recovery.
50
SLUG CATCHER
% Propane Recovery

45% PRESSURE, psig

1300
40
1250

30 1200

20 1150
16%

460 psig
1100
10
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig
Lower Deethanizer
Pressure INCREASES
SEPTEMBER 2004 C3 Recovery.
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER REBOILER TIC (GSP w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux: 21% Cold Sep Gas To Reflux Condenser

310
SLUG CATCHER TEMP
300 110oF
TIC-4230/4430 Set Point F

290
o

280 100oF

270
90oF
261oF
260
80oF
250

240
230

220
460 psig
210
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER FEED PREHEATER TIC (GSP w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux: 21% Cold Sep Gas To Reflux Condenser

110
SLUG CATCHER TEMP
110oF
TIC-4110/4310 Set Point F
o

100

100oF

90
86oF
90oF

80
80oF

460 psig
70
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

DEETHANIZER
GSP CONFIGURATION (w/ EXPANDER)

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

PROPANE RECOVERY CHART (GSP w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Temp, 95oF. Cryo Train Feed = 220 MMscfd
3. Reflux: 21% Cold Sep Gas To Reflux Condenser

95

90
% Propane Recovery

89.2%
SLUG CATCHER
PRESSURE, psig
85
84.5% 1300
1250
Higher Slug Catcher
80 1200
Pressure INCREASES
C3 Recovery. 1150

75 1100

340 psig

70
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig
Lower Deethanizer
Pressure INCREASES
SEPTEMBER 2004 C3 Recovery.
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER REBOILER TIC (GSP w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux: 21% Cold Sep Gas To Reflux Condenser

240

SLUG CATCHER TEMP

230
TIC-4230/4430 Set Point F
o

110oF
100oF
220 90oF
80oF

210

199oF
200

190

340 psig
180
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER FEED PREHEATER TIC (GSP w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux: 21% Cold Sep Gas To Reflux Condenser

110
SLUG CATCHER TEMP
110oF
TIC-4110/4310 Set Point F
o

100

100oF

90
85oF 90oF

80
80oF

460 psig
70
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

DEETHANIZER
SCORE CONFIGURATION (w/ J-T)

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

PROPANE RECOVERY CHART (SCORE w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Temp, 95oF. Cryo Train Feed = 220 MMscfd
3. Reflux Split: 0% Top 100% Mid Section

50 Higher Slug Catcher

Pressure INCREASES
C3 Recovery.

SLUG CATCHER
% Propane Recovery

PRESSURE, psig
40
39% 1300
1250

1200
30

1150

24% 1100
460 psig
20
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig
Lower Deethanizer
Pressure INCREASES
SEPTEMBER 2004 C3 Recovery.
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER REBOILER TIC (SCORE w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux Split: 0% Top 100% Mid Section

300
SLUG CATCHER TEMP

290 110oF
TIC-4230/4430 Set Point
F

280
o

100oF

270 90oF
266oF
80oF
260

250

240

230
460 psig
220
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER SIDE LIQ / GAS EXCHANGER TIC (SCORE w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux Split: 0% Top 100% Mid Section

110

SLUG CATCHER TEMP

100
TIC-4116/4316 Set Point F

110oF
o

90

80
100oF

70
65oF
90oF
60 80oF

460 psig
50
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

DEETHANIZER
SCORE CONFIGURATION (w/ EXPANDER)

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

PROPANE RECOVERY CHART (SCORE w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Temp, 95oF. Cryo Train Feed = 220 MMscfd
3. Reflux Split: 50% Top 50% Mid Section

100
99.6% SLUG CATCHER
99
PRESSURE, psig
98
97
1300
% Propane Recovery

96
95.3%
95
1250
94
93 Higher Slug Catcher
92 Pressure INCREASES
C3 Recovery. 1200
91
90
89
88
1150
87
86 340 psig
1100
85
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig
Lower Deethanizer
Pressure INCREASES
SEPTEMBER 2004 C3 Recovery.
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

PROPANE RECOVERY CHART (SCORE w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure, 1265 psig. Cryo Train Feed = 220 MMscfd
3. Reflux Split: 50% Top 50% Mid Section

100
99.6% SLUG CATCHER TEMP
99
80oF
98
97 90oF
% Propane Recovery

96
95
100oF
94
93
92
91 110oF
90
89
Lower Slug Catcher
Temperature INCREASES
88
C3 Recovery.
87
86 340 psig

85
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig
Lower Deethanizer
Pressure INCREASES
SEPTEMBER 2004 C3 Recovery.
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER REBOILER TIC (SCORE w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux Split: 50% Top 50% Mid Section

230
SLUG CATCHER TEMP
110oF
220
TIC-4230/4430 Set Point F
o

100oF
90oF
80oF
210

200
195oF

190

180

340 psig
170
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER SIDE LIQ / GAS EXCHANGER TIC (SCORE w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher Pressure 1265 psig.
3. Reflux Split: 50% Top 50% Mid Section

0
SLUG CATCHER TEMP

-10 110oF
TIC-4116/4316 Set Point F
o

100oF
-20

90oF
-30
80oF
-40
-44oF

-50

-60
340 psig
-70
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

DEETHANIZER REBOILER TIC (SCORE vs J-T)
NOTES:
1. Slug Catcher 1300 psig and 90oF.
2. Reflux: w/Expander 50% Top and 50% Mid-Section
w/ J-T 0% Top and 100% Mid-Section

300
290
Stabilizer Btms Temp - DegF

280
270
266oF SCORE (J-T)
260
DeC2 460 psig
250
240
IF EXPANDER GOES DOWN, OPERATOR MUST
230
MAKE ADJUSTMENT TO DEETHANIZER
220 REBOILER TIC TO KEEP PRODUCT ON “SPEC”.
210
200
195oF SCORE (EXP)
190
DeC2 340 psig
180
0.0 1.0 2.0 3.0 4.0 5.0 6.0
C2/C3 Ratio LV% In Stabilized Product

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING CHARTS & GUIDELINES

RESIDUE GAS COMPRESSION CAPACITY

LIMITATION

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

RESIDUE GAS COMPRESSION (w/ J-T)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher 95oF and 1,250 psig
3. Reflux: 21% Cold Sep Gas To Reflux Condenser
4. 100% Reinjected @ 4000 psig

34000

33000
Power Available
Residue Gas Compression HP

28,660 hp @ Site
32000
Conditions
31000
Inlet Gas Rate
30000 MMscfd

29000 220

28000
210
27000
200
26000

25000 190

24000
360 370 380 390 400 410 420 430 440 450 460 470 480
Deethanizer Pressure psig

Lower Deethanizer Pressure INCREASES

Residue Compression HP
SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

SYSTEM OPERATING CHARTS & GUIDELINES

RESIDUE GAS COMPRESSION (w/ EXPANDER)
NOTES: PFD
1. Deethanizer making 2.0 LV% C2/C3 Ratio In Bottom Product.
2. Slug Catcher 95oF and 1,250 psig
3. Reflux: 21% Cold Sep Gas To Reflux Condenser
4. 100% Reinjected @ 4000 psig

34000

33000
Power Available
Residue Gas Compression HP

28,660 hp @ Site
32000
Conditions
31000
Inlet Gas Rate
30000
MMscfd

240
29000

28000 230

27000 220
26000
210
25000
200
24000
290 300 310 320 330 340 350 360 370 380 390 400 410
Deethanizer Pressure psig

Lower Deethanizer Pressure INCREASES

Residue Compression HP
SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MANAGING PLANT PERFORMANCE

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MANAGING PLANT PERFORMANCE

 COLLECT/REPORT ACCURATE PROCESSING & PRODUCTION DATA

 Check Calibration of Metering & Instrumentation Monthly
 Check Chromatograph Accuracy and Calibrate w/ Standard Samples Once Weekly
 Calculate and Report Overall % Product Recovery Performance Daily
 Monthly Production Review and Reports
 MAINTAIN EQUIPMENT DOWNTIME AND MAINTENANCE RECORDS
 Rotating Equipment
 Log Causes For Downtime
 Schedule Preventive Maintenance On Major Equipment
 MAINTAIN GOOD COMMUNICATIONS
 Field to Plant Operations
 Plant to Pipeline
 Plant to Pisco
 Shift Logs and Hand Off Between Shifts
 FOSTER GOOD OPERATING TECHNIQUES
 Make Process Changes Slowly, Observe Results and Allow Plant To Stabilize
 Refer to Operating Manuals When Unsure Of Operating Parameters

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MANAGING PLANT PERFORMANCE

MAXIMIZING PROPANE RECOVERY

 J-T OPERATING MODE

 Avoid Prolonged Operation In the J-T Mode.
 If Prolonged J-T Mode Operation Is Required, Use GSP Configuration
 GSP J-T Operation Yields Slightly Higher C3 Recovery Than SCORE J-T
Operation
 See GSP J-T C3 Recovery Curve
 See SCORE J-T C3 Recovery Curve
 Residue Compressors
 Operate Residue Compressors At Max Speed To Lower Deethanizer Pressure.
 Lower Deethanizer Pressure Increases C3 Recovery
 Slug Catcher
 Operate Slug Catcher Pressure as High As Possible But Not Greater Than 1300 psig
 Higher Pressure In the Slug Catcher Increases C3 Recovery
 If High Slug Catcher Pressure Limits Field Production, Then Operate At Slightly Lower Pressure
 Deethanizer
 Use Operating Charts (Deethanizer Reboiler and Deethanizer Feed Pre-Heater)
 Keep Product “On Spec”. Calculate C2/C3 Ratio of Bottoms Product Using Chromatograph Data
 Cryo Train Gas Flow Distribution
 Send Maximum Inlet Gas Flow (220 MMscfd) To Cryo Train That Has Expander In Service
 Send Remainder Of Inlet Gas Flow To Cryo Train Operating In J-T Mode.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

MANAGING PLANT PERFORMANCE

MAXIMIZING PROPANE RECOVERY

 EXPANDER OPERATING MODE

 Use SCORE Configuration
 SCORE Achieves Higher C3 Recovery Than GSP
 See GSP C3 Recovery Curves
 See SCORE C3 Recovery Curves
 Residue Compressors
 Operate Compressors At Speed Required To Maintain Deethanizer Pressure at 330 to 340 psig.
 Lower Deethanizer Pressure Increases C3 Recovery
 Slug Catcher
 Operate Slug Catcher Pressure as High As Possible But Not Greater Than 1300 psig
 Higher Pressure In the Slug Catcher Increases C3 Recovery
 If High Slug Catcher Pressure Limits Field Production, Then Operate At Slightly Lower Pressure
 Deethanizer
 Use Operating Charts (Deethanizer Reboiler and Deethanizer Side Liq/Inlet Gas Exchanger)
 Keep Product “On Spec”. Calculate C2/C3 Ratio of Bottoms Product Using Chromatograph Data
 Deethanizer Reflux
 Side Vapor Draw From Deethanizer To Reflux Condenser At Rate Equal To 20% Inlet Gas Rate
 Send 50% Of Reflux Liquid to Top and 50% To Mid Section

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

GAS & NGL PRODUCT SPECIFICATIONS

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PRODUCT SPECIFICATIONS
RESIDUE GAS

• Maximum Water Content lbs. / MMscf 4.0

• Maximum CO2 Content, Mole % 2.0
• Maximum Total Inerts (N2 + CO2), Mole % 4.0
• Maximum Total Sulfur, grains / 100 scf 0.655
• Dew Point 25oF @ 798 psia
• Maximum Oxygen, Mole % 0.2
• Minimum Gross Heating Value, Btu/scf 989
• Maximum Gross Heating Value, Btu/scf 1,157
• Maximum Delivery Temperature, oF 110
• Minimum Gas Delivery Pressure From Cryo Plant, psig 470
• Maximum Gas Delivery Pressure To Sales Pipeline, psig 2,120 @ 110oF
• Maximum Gas Delivery Pressure For Injection, psig 4,000 @ 110oF

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PRODUCT SPECIFICATIONS
CRYO PLANT NGL AND STABILIZED CONDENSATE PRODUCT MIX

• Max. Water Content Pisco C3 To Pass GPA Propane Dryness Test or D-2713-86
• Max. CO2 Content, Mole % (Not Specified)
• Corrosion Pisco C3 To Pass No.1 Copper Strip Test
• Max. C2/C3 Ratio, LV% 2.0 (Pisco C3 Must Meet HD5 Spec)
• Max. Design Pressure Of Storage, psig 250 psig @ 125oF
• Normal Storage Op. Pressure, psig 70 psig @ 100oF
• Max. Delivery Temperature To Storage, oF 110
• Max. Delivery Pressure To Pipeline, psig 400
• Max. Design Pressure Of Pumps, psig 450 @ 130oF

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PRODUCT SPECIFICATIONS
MAINTAINING STABILIZED CONDENSATE ON “SPEC”
PFD
 SLUG CATCHER
 Operate at 1300 psig
 Feed Liquids To Condensate Separator at Steady Rate
 Service Sand Filter As Required To Keep Solids Out of the Condensate
 CONDENSATE SEPARATOR
 Operate at 485 psig
 Maintain Water/Condensate Interface In Boot On Automatic Level Control
 Maintain Condensate Liquid Level At Approximately 65-75% to Assure Residence Time For Water
Separation
 CONDENSATE FLASH DRUM
 Operate at 235 psig
 Feed Liquids from Condensate Flash Drum on FIC w/ LIC resetting FIC
 Maintain Liquid Level At Approximately 50-60%
 STABILIZER BOTTOMS/FEED EXCHANGER
 Maintain Feed To Stabilizer At 100oF
 STABILIZER AND REBOILER
 Maintain Reboiler Outlet Temperature Between 295 to 315 oF
 Calculate Stabilized Condensate C2/C3 Ratio Using Data From Chromatograph
 Adjust Reboiler Temperature As Required to Maintain C2/C3 Ratio < 2.0 LV%
 Use Stabilizer Reboiler Chart As A Guideline For Reboiler Temperature.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING
PRODUCT SPECIFICATIONS
MAINTAINING CRYO PLANT NGL PRODUCT ON “SPEC” PFD (SCORE)

PFD (GSP)
 DEETHANIZER
 Use Deethanizer Reboiler Charts (GSP J-T, GSP Expander, SCORE J-T, SCORE Expander)
 Calculate C2/C3 Ratio Of Deethanizer Bottom Product Using Data From Chromatograph
 Adjust Deethanizer Reboiler TIC as Required To Maintain C2/C3 Ratio < 2.0 LV%

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

IMPACTS ON TGP AND PISCO

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

IMPACTS ON TGP AND PISCO

 PRODUCT COMPOSITION SHIPPED TO PISCO

OBJECTIVE: Send Consistent Product Composition To Pisco
 Fluctuating Product Composition Can Cause Upsets/Off Spec Products At Pisco.
 Mix Condensate Product with NGL Product At Malvinas Before Sending To Storage
 Mixing Products Upstream Of Malvinas Storage Help Reduce Fluctuating Compositions In The
Storage Bullets.
 Promptly Notify Pisco Operations Of Significant Product Composition
Changes When They Occur At Malvinas.
 Pisco Cannot Handle C2 In Excess Of The 2.0LV% Spec.
 No Deethanizer At Pisco
 Excess C2 In Malvinas Product Must Be Vented and Flared At Pisco
 Almost 50% of the C3 Is Lost When Pisco Must Vent/Flare Excess C2
 WATER IN PRODUCT SHIPPED TO PISCO
OBJECTIVE: Send “Dry” Product To Pisco
 Potential For Hydrate Plugging Of Pipeline
 Potential For Hydrates and Plugging In The C3 and C4 Storage At Pisco.
 Monitor Condensate Separator Interface Level Control Of Water Boot
 Keep Condensate Filters In Good Operating Condition.
 Frequently Check Malvinas NGL Storage For Water and Drain Off Any Water That May
Accumulate In Storage Before Shipping To Pisco.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

IMPACTS ON TGP AND PISCO (Cont.)

 PRODUCT SHIPPING RATE TO PISCO

OBJECTIVE: Ship Product At The Same Rate It Is Produced
 Control Shipping Flow Rate As Required To Balance Production Rate With Shipping Rate.
 Monitor Inventory Levels
 Maintain Malvinas NGL Product Inventory At Relatively Low Level.
 If TGP Interrupts Takes, Storage Capacity Will Then Be Available To Continue Production
Operation At Malvinas For A Period Until Storage Is Full.

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

“KEY” OPERATING GOALS & OBJECTIVES

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

OPERATING GOALS & OBJECTIVES

 SET AGGRESSIVE GOALS & OBJECTIVES

 Unscheduled Plant Downtime: Less Than 3% Annually
 Scheduled Plant Downtime: Less Than 5% Annually
 Plant Gas Capacity Utilization: Greater Than 95% Net Of Scheduled Downtime
 Propane Recovery In Cryo Units: 99.0 to 99.5% When On-Line Using SCORE
 No Gas Flaring
 No Lost Time Accidents
 PRODUCTION GOALS
 Inlet Gas Production 435 to 440 MMscfd
 Daily Production Averaged Annually
 C3 11,000 B/D
 C4 5,500 B/D
 C5+ 17,300 B/D
 Total 33,800 B/D

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

PLANT SAFETY
 ESD SYSTEM
 Check calibration of instruments periodically
 Test shutdown devices annually to assure proper function and protection
 PSVs and OTHER PRIMARY PRESSURE RELIEF DEVICES
 Block valves Around PSVs Should Be “Car Sealed Open”
 Breaking Seals and Closing Such Valves Can Result In Overpressure and Failure Of Equipment. This
Should Be Only Done Under The Supervision Of An Engineer or Plant Supervisory Personnel Trained
In this Activity.
 PSVs Should Be Tested Annually To Check Pressure Relief Setting and adjusted as needed to
maintain proper protection for the equipment. This activity should be carefully documented and
records kept for future reference.
 OPERATING SAFETY IS EVERYONES JOB
 Conduct Regularly Schedule Plant Safety Meetings and Programs
 Conduct Periodic Fire Drills and Response Practices To Simulated Emergency Conditions
 Wear Personnel Safety Equipment Including Hard Hats, Eye Protection, Ear Protection, and Steel
Toed Shoes/Boots.
 Train Personnel On “Lock-Out” and “Tag-Out” Procedures.
 Train Personnel On Handling Hazardous Materials and Products Found In the Plant.
 Follow All Safety Procedures and Instruction Issued By Pluspetrol Operating Management
 Report To Your Supervisor Any Situation or Equipment Defect That Could Lead To An Unsafe
Condition

SEPTEMBER 2004
 MALVINAS GAS PLANT
OPERATOR TRAINING

Thank You For Your Help and Participation....

OPERATE SAFELY !

SEPTEMBER 2004