Technical Note

Cold Box issues Issues, remedial actions and prediction for future performance
Prepared by: Brijesh Goel (Process Engg Superintendent), with Field Inputs from Carey
Swanson (BGP Operations Superintendent)
Date: 26th April 2009
Cold Box Issues:
Cold Box has 2 main issues: Icing and Mercury. In this note, icing related issue is
discussed since it was the cause of recent BGP shutdown/increasing trend of downtime
as highlighted by our partner, Petronas (email dt 15 th April 10 from Pak Rahizan Ahmad
to Mr. RSK Mohan). Mercury issue is a separate issue for which separate short term and
long term action plan has been prepared/in progress.
Icing Issue: Chronology of events and actions taken.
15th Jan 2010 In the molecular sieves regeneration system, it was detected that the sequencing valve
695-KV-158 was passing. This resulted in regeneration gas from the Waste Heat
Recovery Unit (WHRU) to bypass Mol Sieve towers causing 'end of heating'
temperatures to be lower than normal.
17th Jan 2010 - Removed 695-KV-158 to repair leak. To avoid a BGP Facility shutdown, Operations Dept
had to manually adjust the Absorption timer for the Mol Sieve tower from 1020 minutes
to 1200 minutes. It is suspected this is when the initial moisture breakthrough occurred.
25th Jan 2010 It was noted that the pressure differential (dP) across the Cold Box pass# 7 was slowly
increasing (from 20 psi to 40 psi) which typically indicates increasing icing/hydrate
deposits in the affected pass. It was decided to lower the Absorption Timer in Mol sieve
system from 1020 min to 960 min.
Moisture analyzer not working for three months already due to unavailability of probe
which has been on order.
8th Feb 2010 - Shutdown the NGL Recovery Unit for 5 hours to flow hot gas through Pass #7 to thaw the
ice build-up. The thaw job was successful. Still waiting for moisture analyzer probe.
13th Feb 2010 - Cold Box Pass #7 showed low dP's until BGP Operations introduced NG sales gas into
BGPs molecular sieve system. (Note - NG sales gas was routinely introduced to BGP
mol sieve system prior to icing issue, for enhanced liquid recovery from NG sales gas).
Due to flow of an extra 15 MMscfd NG gas to BGPs 135 MMscfd gas (designed to
handle 133 MMscfd gas), it is possible that the molecular sieve system was overloaded
resulting in icing in pass#7 of cold box once again, higher dP was observed (up to 50
psi). Absorption Timer was still at 960 minutes. (960 minutes is design).

Feb 26 2010 - In order to prevent production total plant shutdown to clean the cold box, an online
cleaning of icing was attempted. The NGL Recovery Unit was switched to JT Mode by
closing the C3 to Pass #4 to warm the cold box. Production from 14 gas wells was shut

down due to high GHV of Sales gas. NGL Recovery System was warm but did not help to
thaw the ice. Methanol injection was also tried but did not help, probably due to normal
operating pressure of 600 psi on Pass #7 was not low enough to remove hydrates from
the system. The online cleaning plan was abandoned and it was decided to shut down
BGP to clean pass#7. In addition, it was also agreed to install isolation valve around pass
# 7 so that in future, methanol dumping and hot fuel gas could be introduced without total
plant shutdown.
Moisture analyzer probe was changed with a new one.
Engineering drawings were prepared, material procured and procedures written to
implement the proposed modifications.
29th Mar 2010 - BGP Facility was shutdown for 30 hours to install isolation valve downstream of Pass
#7. All production was shutdown to decrease flare header pressure. Theoretically, the
hydrate melts at pressure below 50 psig and Operations brought the operating pressure
around the pass #& to almost atmospheric pressure prior to re-starting the plant. Upon
plant re-start, it was noted that the cold box dP was still high and required to be cleaned
again.
See attached P&ID (As Built) for modifications implemented during BGP shut down.
14th April 2010 With the isolation valves in place, online cleaning of the pass#7 was attempted. BGP
production was decreased by 75 MMscfd to keep sales gas GHV within spec after mixing
with NG gas. Pass #7 was isolated and depressurized for 3 hours during which 18 barrels
of absolute methanol were dumped into the pass and allowed to soak for one hour. Also,
the Absorption timer was adjusted to 810 minutes. Plant was re-started and it was noted
that the Cold box dP had reduced to 5 psi.
Since then to date, Cold Box Pass #7 dP is low (5 psi) and steady.

ROOT CAUSE of icing issue:

Moisture ingress into cold box pass # 7 from molecular sieve system. Possible reasons;
1. Inefficient operation/performance of Filter Coalescer 615-F-104 A/B upstream of molecular sieve
beds. It is suspected that free liquid carryover is taking place from these coalescer vessels to the
mol sieve beds resulting in damage to the bed absorbents (which are sensitive to any free liquid
or water). The bed damage results in caking of the absorbents and then channeling of gas
through the beds. This can result in moisture break-through from beds towards the end of
absorption cycle. It is shortly planned to test performance of these filters using a specialist testing
agency. Results would help to analyze if any action is required or not and if the existing
Coalescers can be modified to improve efficiency or require to be changed to prevent damage to
bed media.
2. Faulty moisture analyzer probe at the outlet of molecular sieve beds resulted in inaccurate
moisture level content of feed gas to the cold box. The probe has since been changed. Another
moisture analyzer (relocated from Condensate Stripper bottom) will be shortly installed in parallel
to provide comparative real time data. Instrumentation engineer also studying a more accurate

Optical technology based moisture analyzer design to replace the existing aluminum oxide
ceramic capsule type probe.
3. Degradation of mol sieve (in part due to 1) for which absorption cycle times has been
progressively reduced to prevent break-through. There is virtually no standby time left after
regeneration cycle and further reduction in absorption cycle time could require bed media
change-out or reduction in plant throughput. Moisture breakthrough is being closely monitored
now. Steps also being taken to order fresh charge of bed absorbent to be changed-out during
planned BGP shutdown in 1Q-2011.
Based on above, it is clear that cold box icing issue is more due to problem in the upstream
equipment, i.e. the molecular sieve dryer system which needs to be fixed effectively to keep cold box
operating efficiently.

END.