Dear Friends,
I am currently stuck with a project that we are doing for a portion of Gas Processing Plant and would need your help.
Attached is a BFD for the particular part of the plant which we are evaluating.
Problem Description:
Whenever there is a malfunction in the Gas Chiller (Propane system failure, Low Propane Level in the chiller etc.), the plant observes a lot of Gas condensate in the Fuel Gas Scrubber, GR-V-003A and the level keeps on increasing. They have to drain this condensate in an open pit which is hazardous and not allowable as per the HSE regulations.
In order to resolve this issue, the project proposes to use an existing Slug Catcher, GR-V-002 to separate any Gas Condensate coming through Stream 340A (which then can be routed through an existing line from GR-V-002 to the Closed Drain System).
The gas coming at the inlet of LTS (V-0640) has about 20% (by wt) liquid, however all the liquid gets separated in the LTS (V-0640). Even if there is any liquid carryover, this liquid should get separated at MP Fuel Gas KO drum (V-0653).
Still the Plant observes Gas Condensate in the Fuel Gas Scrubber (This may be due to Malfunction in Chiller or there may be a different reason which I might not be aware of).
I am trying to simulate the malfunction scenario (using HYSYS) but somehow, I am unable to see any condensate in Fuel Gas Scrubber. I did the Carryover calculations for the Vessels as well but even that didn't help. Could you please help me understand what other possibilities are there that might lead to Gas Condensate in the Fuel Gas Scrubber.
I am sure I might be missing on something (due to lack of sufficient experience).
What might be other reasons that would contribute to the incoming of Gas Condensate in Fuel Gas Scrubber?
Does this problem needs to be thought in a different way?
Is a Dynamic simulation really necessary to understand the problem?
I hope that I was able to describe the problem though I may not have provided all the details. In case if any further information is required, I would be more than happy to provide.
Any help would be really appreciated. Thanks a lot in advance.
Regards,
Ganesh