PGI Product Profile Nov10

process groupI N T E R N A T I O N A L

OIL & GAS PRODUCTION

GAS PROCESSING & REFINING

CRUDE OIL STABILISATION & TREATMENT

PETROCHEMICAL

CARBON CAPTURE & GEO-SEQUESTRATION

WATER TREATMENT

SOLIDS HANDLING

DESIGN FABRICATION INSTALLATION COMMISSIONING

PROCESS GROUP INTERNATIONALCOMPANY PRODUCT PROFILE

PROCESS GROUP: Abu DhabiP.O. Box 46153Abu DhabiUnited Arab EmiratesPhone: Fax: E-Mail: Website:

+971 2 5500898+971 2 [email protected]

Based in our purpose built, 20,000m2 engineering and manufacturing centre in the Industrial City of Abu Dhabi (ICAD), Process Group International is ideally situated to cater to the bespoke process engineering and package fabrication requirements of the region.

With many years of experience in producing packages both for plants in the United Arab Emirates and for export as far afield as Equatorial Africa or the Caspian Sea, Process Group International stands ready to serve all of the region and to offer our clients the technically excellent standards of engineering and fabrication in process packages that we have become renowned for. We are also pleased to be one of the very few companies available in our field who can offer the entire engineered package from design and process guarantees through to just supplying to your project or to extending the full project offering of supply, install and commission with extended operation and maintenance if desired.

With all of the Middle East within a few days trucking distance and with the world readily accessed via the adjacent Mussafah port, we are able to not just accept fast-track or technically challenging projects but to deliver them to site on time and accompanied by a multinational commissioning team well used to getting the job done properly, no matter how arduous the environmental conditions.

We are looking forward to a long future in this prosperous, dynamic and growing Emirate and would like to invite you to benefit from our capabilities and energies.

Barry GrahamManaging Director


DESIGN FABRICATION INSTALLATION COMMISIONING

Capability & ResourcesZ.01

Introduction Introduction

Process Group is a leading supplier of process systems & com-plete process trains for a range of process industries, including:• Oil & Gas Production,• Oil Refi ning & Petrochemical,• Power Generation,• Coal Seam Methane Production,• Industrial Gas Processing,• Greenhouse Gas Abatement / Carbon Capture,• Etc.

Founded in 1978, Process Group’s success depends largely on a team of highly motivated, experienced professionals, who are committed to excellence in all aspects of project manage-ment & execution, including estimation, process, detailed engineering design, procurement, construction, fabrication & commissioning.

Process Group’s technical staff posses a wide range of specialist disciplines with a long history in their respective fi elds, which provides signifi cant depth to the organisation’s skills and capabilities.

ResourcesResources

Process DesignProcess Group uses the latest process simulation techniques to fully optimise plant process design, and to ensure correct evalu-ation of all required equipment operating parameters.

Detailed DesignDesigning complex plant is an extremely diffi cult task when combining the many requirements of plant design, operability and safety, while still ensuring perfect integration with surround-ing equipment.

Process Group’s engineers have years of experience in the de-sign and construction of complex plant, which ensures optimal plant design and performance.

Project ManagementProcess Group’s project team uses a hands-on approach to ensure that projects are closely monitored through every phase.

Procurement, Expediting & InspectionProcurement, Expediting & Inspection

Process Group recognises the value of a quality procurement system, and has established partnerships with selected suppliers with a proven track-record for delivering materials, equipment and services to consistently meet project requirements and deliv-ery schedules.

Rev 07/2010

Capability & ResourcesZ.01

Gas Processing:• LPG/NGL Recovery Systems,• Mechanical Refrigeration Plants,• Low Temperature Separation Units,• Condensate Stabilisation Units.

Industrial Gas:• Carbon Dioxide Recovery and Liquefaction,• Gas Purifi cation,• Cryogenic Vaporisers,• Gas Dehydration.

Water Treatment and Injection Systems:• Produced Water Treatment Systems,• Deoiler Hydrocyclones,• Desander Hydrocyclones,• Induced & Dissolved Gas Flotation Units,• Nut Shell Filters,• Activated Carbon Adsorption Units,• Contact Deaeration and Vacuum Deaeration,• Sea Water Injection Systems.

Solvent Recovery Systems:• Pharmaceuticals plants,• Mineral Processing,• Metals production.

Heating Systems:• Electric Immersion Heaters,• Indirect Fired Water/Glycol or Salt Bath.

Heaters:• Indirect Fired Heaters,• Plate Heat Exchangers.

Ancillary Systems:• Chemical Injection Packages,• Metering Packages,• Flare Systems,• Pressure reduction systems.

Special Systems:• Special process designs & equipment packages can

be custom made to suit specifi c project requirements.• Contact Process Group if you have any special requirements.

© Process Group Pty Ltd, 2008 – 2010.

FabricationFabrication Process Group operates a fabrication facility at its’ Aus-tralian Head-offi ce. This provides excellent monitoring, control & interfacing with all staff involved in Australian-built packaged plant & equipment.

Many of the equipment packages are also built in other countries to meet local content regulations, cost demands or client requirements. This involves extensive interfacing with remote fabricators, and clients to ensure that quality and fabrication integrity are maintained.

This is accomplished by developing relationships with re-liable fabricators, and a committed project engineering team with the skills to work in a wide range of cultural and environmental conditions.

Quality Assurance Quality Assurance

Process Group’s staff and Directors are committed to pro-viding quality plant and equipment that is designed and constructed in accordance with project specifi cations, codes, standards and sound engineering practices.Process Group has a well established track record in QA and is accredited to ISO-9001\2000 by Lloyds.

Package Equipment Range Package Equipment Range

Process Group specialises in the supply of the following range of Plant, Equipment and Packages on either a complete EPC or Supply-only basis:

Separation (Oil/Gas/Water):• HP/LP Separators • Test Separators,• Liquid/Liquid Coalescers,• Slug Catchers.

Gas Conditioning:• Scrubbers and Dry Gas fi lters,• Fuel Gas Conditioning Systems,• Pressure Reduction Systems,• Gas Sweetening Plants• Gas Dehydration Systems: i. Glycol, ii. Molecular Sieve, iii. Solid Desiccant.

Gas Dehydration- Glycol A.01

IntroductionIntroduction

The use of Glycol to dehydrate gas streams is an established method that has proven its functionality and versatility over many years.

There are 3 common types of Glycol used for Gas Dehydration:

• Mono-Ethylene Glycol (MEG)

• Di-Ethylene Glycol (DEG)

• Tri-Ethylene Glycol (TEG)

The type of Glycol used and the package design depends on several factors, and the end-users specifi c requirements and objectives for the gas stream being processed.

Each package is typically designed in close consultation with the client to ensure the best overall design is achieved.

Design Basis Design Basis

The design of TEG and MEG Dehydration Systems is unique for every requirement and the overall package design will vary to meet the specifi ed moisture content of the gas at the process conditions.

Each system is typically designed and built as a complete turn-key package with particular emphasis given to the following issues:

• Discharge gas moisture content• High gas dehydration capacity• Minimum glycol losses• Minimum power consumption• Optimum plant effi ciency & design integrity• Compliance with HSE requirements• Environmentally conscientious design

Process Description Process Description

In a typical TEG package, water saturated gas enters near the bottom of the Contactor Tower and fl ows upwards through the internal trays/packing (1). Lean Glycol enters the Contactor Tower near the top and cascades down through the Contactor internals (9), making contact with the up-fl owing gas stream. The counter-current fl ow path of the Glycol and the high contact surface area enhances water absorption into the Glycol from the gas stream.

Rev 07/2010

Gas Dehydration- Glycol A.01

Dehydrated gas fl ows out of the top of the Contactor, while the Rich Glycol fl ows out of the bottom of the Contactor and to the Glycol Regeneration Package.

The TEG Regeneration process typically involves passing the Rich Glycol through the still column to gain some heat (2) before entering the Flash Drum (3).

The Glycol is then passed through Particle Filters to remove particulates and Activated Carbon Filters to remove any dissolved hydrocarbon and/or chemical compounds (4). The Rich Glycol is heated in a cross exchanger to preheat the feed (5) to the Still Column where the Glycol present in the water vapour leaving the Reboiler is recovered (6).

Depending on the application, it may be necessary to increase the Lean Glycol concentration by using stripping gas (7), or running the Reboiler/Still Column under a slight vacuum. Lean TEG (typically >99wt%) is then cooled and pumped back to the top of the Contactor Tower (8) to repeat the process.

A ‘typical’ Glycol Dehydration Package: a number of process components are added / modifi ed / removed to suit the requirements of each individual application


Reference Clients Reference Clients

• Chevron

• Shell

• ENI Australia

• Origin Energy

• Santos Australia

• Cairn Energy

• Bahrain Petroleum

• Arrow Energy

• Anzon Australia

• Iranian Offshore Oil Co.

• Chinese National Offshore Oil Co.

• Japan-Vietnam Petroleum Co.

Hydrocarbon Dew Point ControlA.03


Hydrocarbon Dew Point Control Units (DPCUs) are designed to inhibit the formation of solid hydrates in gas streams and by default they perform a level of dehydration. This is achieved through the injection of a liquid Hydrate Inhibitor directly into the gas stream. The Hydrate Inhibitor is selected based on low viscosity and low freezing temperature rather than dehydration ability.

There are 2 common types of liquid Hydrate Inhibitor used for Dew Point Depression:

• Mono-Ethylene Glycol (MEG)• Methanol (MeOH)

The type of Hydrate Inhibitor used and the package design depends on several factors, and the end-users specifi c require-ments and objectives for the gas stream being processed. Each package is typically designed in close consultation with the client to ensure the best overall design is achieved.

Design BasisDesign Basis

The design of a DPCU follows a basic structure. However, there are a number of approaches to achieve the end means – Hydrocarbon Dew Point Depression.


• Discharge gas hydrocarbon dew point,• Discharge gas water dew point,• Minimum inhibitor losses,• Minimum power consumption,• Optimum plant effi ciency & design integrity,• Compliance with HSE requirements,• Environmentally conscientious design.

The resulting design will be infl uenced by all of these factors, and the emphasis & importance given to each particular issue.

Rev 07/2010

Hydrocarbon Dew Point Control

A.03

Process DescriptionProcess Description

In a typical MEG Injection Dew Point Control Unit (DPCU), the gas is fi rst passed through an Inlet Separator (1) where any free liquids are removed.

Just prior to entering the gas/gas exchanger pressurised Lean MEG is injected into the gas stream (2). Additional MEG is injected and the MEG-gas mixture is then further cooled through either Expansion (Joule-Thompson Valve/Orifi ce) or Refrigeration (3).

The further cooling condenses any residual water and/or hydrocarbons. A Low Temperature Separator (LTS) (4) is located downstream to remove any free liquids – now including the condensed water, condensed hy-drocarbons and injected MEG. The cooled gas with a depressed dew point is circulated back into the gas/gas exchanger for pre-cooling of the inlet gas (2).

The LTS is generally a 3-Phase Separator which allows the effective separation of not only the gas from the liquids, but also the aqueous and hydrocarbon liquid phases from one another.

The aqueous phase, containing the water and MEG is routed to the MEG Regeneration Package where the wa-ter is driven off to produce Lean MEG. The liquid hydro-carbon phase is usually mixed with the liquids from any inlet separation and either routed to storage or further processing in a Condensate Stabilisation Package.


(OPTIONAL)

CONDENSATE STABILISATION UNIT

Hydrocarbon Dew Point Control Unit

OUTLET GAS

INLET GAS1

MEG REGENERATION PACKAGE

EXPANSION2

6

REFRIGERATION

3

5

4

Carbon CaptureC.02


The capture of carbon dioxide emissions from existing industries is essential in realising global targets to decrease emissions of greenhouse gases to the atmosphere.

The Carbon Capture technology employed by Process Group can be immediately retrofi tted to virtually any exhaust gas system, including coal or gas-fi red boilers, gas turbines, blast furnaces, and cement kiln off-gas.

The process enables carbon dioxide to be selectively absorbed from fl ue gas via counter-current contact with a regenerable sol-vent. The solvent is a patented aqueous amine or amino acid solution specially designed to selectively absorb CO2 from gas streams.

Each package is designed in close consultation with the client to ensure the best overall design is achieved.

Design BasisDesign Basis

The design of Carbon Capture Systems is unique to each situ-ation with the overall package design varying to meet each client’s specifi ed process conditions.


• CO2 product purity• Minimum solvent losses• Minimum utilities consumption• Optimum plant effi ciency & design integrity• Compliance with HSE requirements• Environmentally conscientious design

Process DescriptionProcess Description

In a typical CO2 Capture package, hot fl ue gas passes through the scrubber tower, where it is cooled with cooling water (1), before being fed to the absorber tower. The gas en-ters near the bottom of the absorber tower and fl ows upwards through the internal packing (2), coming into contact with the solvent, which enters near the top of the tower, as the solvent cascades down through the tower. As the fl ue gas rises through the tower the carbon dioxide level is progressively reduced as it is absorbed by the solvent meaning the treated gas vented from the absorber (3) is virtually free of CO2.

Rev 07/2010

Carbon CaptureC.02

From the bottom of the absorber tower the CO2-rich solvent is pumped through the lean-rich exchanger (4) to pre-heat the solvent before it enters the regenerator tower. In the regenerator the solvent is heated via the reboiler (5) to reverse the absorption reaction. As the sol-vent cascades down through the tower, CO2 is gradu-ally desorbed from the solvent (6). By the time the solvent reaches the bottom of the tower virtually all the absorbed CO2 has been released and the CO2-lean solvent is cooled and pumped back to the top of the absorber tower to repeat the process (7).

The desorbed CO2 exits the regenerator tower as a pure, water saturated gas from where it is cooled (8) and then passes through the refl ux accumulator to re-move excess water (9). The pure carbon dioxide product gas is then ready for direct use or further processing.

Value Adding Value Adding

Process Group can provide expertise in processing cap-tured carbon dioxide for various applications including:

• Liquefaction for commercial use• Wastewater pH control• Enhanced oil / gas recovery• Mineral sequestration• Geo-sequestration• Enhanced agriculture

Future Technologies Future Technologies

Process Group is closely associated with The Coopera-tive Research Centre for Greenhouse Gas Technologies (CO2CRC) providing access to the latest advances in carbon capture technologies.


A ‘typical’ Amine CO2 Capture Package: A number of process components are added / modifi ed / removed to suit the requirements of

each individual application.

HydrocyclonesDeoiling D.01


Deoiler Hydrocyclones were developed for the offshore oil industry in the 1980’s and are established as the primary equipment used for recovery of oil from Produced Water streams. Deoiler Hydrocyclones exhibit the following benefi ts:

• Compact design,

• Cost effective with low OPEX costs,

• No moving parts with little maintenance required,

• Highly consistent performance,

• Proven technology,

• Suitable for use on FPSO’s, etc,

• Range of material selections.

Description Description

Process Group’s Cyclonixx® range of Deoiler Cyclones are used to recover liquid hydrocarbons from oily-water streams. These Cyclones are mostly installed in pressure vessels in a cluster, with the required number (1-400) of Cyclones Liners to match the water fl ow rate.

Cyclone Liners are made in a range of sizes, (30-70 mm diameter) and constructed from Duplex Stainless Steel, with other material options available on request.

The photo at right shows how the Deoiler Cyclone Liners are installed into the vessel by hand. Liners can be removed for inspection, or replaced with Liner Blanks by using simple hand tools.

Liner Blanks are used where water rates vary over time, and the number of Deoiler Cyclone Liners needs to be varied accordingly.

Additionally, vessels can be built with internal partitions or zones to allow a wide range of fl ow rates to be handled.

Operating Principles Operating Principles

Deoiler cyclones are driven by inlet water pressure and utilise a pressure drop across the Cyclone to provide the energy or driving force to cause oil-water separation.

Normally, system pressure is used to provide the driving pressure, but if too low (<75 psig / 5 Barg), a pump can be used to boost the feed pressure. Typically, single stage centrifugal pumps are used, where pressures are too low.

Rev 07/2010“Cyclonixx” is a registered trademark of Process Group Pty Ltd.

oil outlet

water outlet

water inlet

HydrocyclonesDeoiling D.01

View of Deoiler Hydrocyclone Vessel:View of Deoiler Hydrocyclone Vessel:

Each Cyclonixx® Deoiler Cyclone Liner includes a tangential Inlet Section where the water enters, and is forced to spin rapidly, generating high centrifugal forces. These forces, combined with the tapering shape of the internal profi le, accelerate the spinning. This effectively forces the water away from the centre axis to the outer walls, and forces the lower density oil to the central core that forms along the axis of the Deoiler Cyclone. The water spirals down the tapered section of the Cyclone and exits via the clean Water Outlet nozzle. The central oil core is forced in the reverse direction by back-pressure on the Water Outlet, and exits via a small orifi ce as the Oil Reject Outlet. The Oil Reject stream fl ow is largely controlled by this orifi ce size, but can also be regulated by an outlet control valve, and is typically set to allow a fl ow at 2-4% of the inlet fl ow.The gravitational forces generated within each Cyclonixx Deoiler Cyclone Liner are very high, and therefore these Deoiler Cyclones can be installed vertically, horizontally or on moving structures (eg: FPSO’s).

Technical Technical

There are a few important factors involved in the process design and selection of a Deoiler Cyclone Liner type, and these are:

• Available pressure/Pressure Drop,• Oil droplet size & distribution,• Liquid Viscosity/Temperature,• Cyclone diameter,• Required Oil Recovery.

System Pressure If there is adequate system pressure available (>75 psig), this is used to drive Deoiler Cyclones to maximise oil recovery and throughput. The preferred site to locate Cyclones in a process is on the water outlet line from the Separator or Water Knock-out Vessel, upstream of the Level Control Valves. This generally provides the highest Deoiler Cyclone capacity with minimal oil droplet shearing.

Pumped SystemsIf the system pressure available is too low (typically <75 psig), a pump will need to be installed to raise the inlet pressure to the Deoiler Cyclone. When a pump is installed, the pump type and size will need to be carefully selected to minimise oil droplet shear. However, Process Group has many years experience at designing pump-fed Deoiler Cyclones, and can readily provide a solution while meeting discharge targets.A benefi t of pump-fed systems is that very high turn-down rates are achievable, as water is recycled to maintain pump fl owrates. This ensures that high oil-removal is maintained regardless of the water throughput.

Oil Droplet Size /DistributionThe Oil droplet size range has a major impact on the Deoiler Cyclone’s performance, and it is important to maintain as little shearing of oil droplets as possible prior to the Cyclone.

Deoiler Unit SizingProcess Group manufactures a number of Deoiler Cyclone types as Spare Parts for most common brands of Deoiler Cyclones.

Photo of 2 skid-mounted 60,000 BWPD Deoiler Cyclone Units.


HydrocyclonesDesander D.02


Desander Hydrocyclones are used to provide effi cient and reliable separation of sand and solids from Produced Water, Condensate and/or Gas streams. They have proven to be a valuable part of many Oil and Gas production facilities, by providing:

• High Effi ciency Solids Removal,• Compact, small footprint,• Cost effective protection against erosion damage,• No moving parts and minimal maintenance,• Highly consistent performance.


Process Group’s Cyclonixx® range of Desander Cyclones are static cyclone separators commonly used for continuous sand and solids removal from Produced Water, Condensate or Gas streams. They are supplied either as single-liner units, or as multiple-liner confi gu-rations inside vessels.

The Cyclone Liner size and type selected is dependent on the process fl uid, temperature, pressure and the concentration and type of solids present in the Liquid (Water or Oil) or Gas stream.

Small Diameter (2”/50mm), High Effi ciency Cyclonixx® Desander Cyclones are typically constructed of ceramic materials to provide excellent erosion resistance, while larger units are made from spe-cialised organo-metallic compounds, to provide erosion protection.

Operating Principles Operating Principles

Desander Cyclones are pressure-driven separators that require a pressure drop across the unit to cause separation of the solids from the bulk phase (water, oil or gas, etc).

The inlet stream (containing solids) enters the cyclone through a tangential Inlet Section under pressure, where it is forced into a spiral motion by the cyclone’s internal profi le. The internal cone shape causes the spinning to accelerate, which generates high centrifugal forces, causing the denser solid particles to move to the outer wall of the Cyclone, while the Water/Oil/Gas is displaced to the central core.

Solids continue to spiral down along the outer wall of the coni-cal section inside the Cyclone to the Outlet or Underfl ow, where they exit. It is typical to collect the solids in a closed underfl ow container or vessel, and periodically dump these solids.De-sanded Water/Oil/Gas in the central core section reverses direction and is forced out through the central Vortex Finder at the top of the Cyclone as the Overfl ow.

Rev 07/2010“Cyclonixx” is a registered trademark of Process Group Pty Ltd.

Photo of 2 skid-mounted 60,000 BWPD Deoiler Cyclone Units.

Deoiler Cyclone Vessel Size on FlowrateCapacity based on ~100 psi (~7 Barg) Inlet Pressure

HydrocyclonesDesander D.02

Schematic of Desander VesselSchematic of Desander Vessel

Technical Technical

Factors involved in the selection of Desander Cyclone are:

• Desired particle size removal (in micron)• Temperature/Viscosity of the Water/Liquid,• Liquid density• Solids density• Volume to be treated,• Available pressure/pressure drop to drive cyclone

Particle Size Removal:The rule in selecting a Desander cyclone size is that smaller cyclones remove smaller particles.

Temperature/Viscosity: Temperature of the water/liquids is very important, as higher temperature reduces liquid viscosity, which improves separation by reducing the drag forces on the particles.

Liquid Density:Water Density is ~1.0, although it varies slightly according to temperature, salt concentrations, etc. Oil can vary from 0.6 - 0.99 S.G.

Solids Density: The solids density seen in production fl uids has a typi-cal density ~2.2 - 2.65 S.G. This density directly effects separation potential, with higher density solids being more easily separated. There can be a range of different types of solids with a range of densities, although there is typically one major component.

Pressure drop:Cyclones can be installed to operate at any pressure. They use pressure as the energy for separation, and the pressure drop (across the cyclone) required for solids removal is 15 – 70 psi. (1.0 – 4.8 Bar), as this range provides optimum performance, while minimising erosion and pressure loss.

Applications • Removal of abrasive solids from process piping to minimise maintenance on pumps, control valves and other process equipment.

• Sand removal from process to minimise Separator sand build-up, to improve Separator effi ciency (more residence time), and to reduce or eliminate shut-down maintenance to remove sand, etc.

• Solids removal for water reinjection to prevent formation blockage and damage to pumps,

• Removal of heavy metals from process liquids (conden-sate and/or water) to comply with environmental or sales requirements.


Induced Gas FlotationD.04

Introduction Introduction Induced Gas Flotation (IGF) is a well-proven method of oil recovery in water treatment applications. IGF Units are used extensively around the world for the recovery of oil from produced water streams in a wide range of applications at onshore and offshore production and processing facilities, refi neries, ballast treatment facilities, etc.

IGF is primarily used for the removal of oil and fi ne solids from oily water streams, and to deliver the following outcomes:

• High effi ciency oil removal,• Low outlet oil levels,• Simple, effi cient operation and maintenance,• Low or nil chemical consumption,• No fugitive gas emissions,• Minimal environmental impact.


Process Group’s IGF units are hydraulically-operated Induced Gas Flotation Units that provide effi cient oil recovery from water streams with complete process containment. Oil recovery is achieved effi ciently and economically, with operator and environmental safety ensured by the fully enclosed fl otation process.

IGF Units separate and recover oil and fi ne solid particles from water through the creation of fi ne gas bubbles (typically < 50 microns in diameter), that are dispersed through the incoming water stream. Oil and fi ne solid particles that are present in the water stream adhere to these gas bubbles and fl oat to the surface where they are skimmed off.

The gas bubbles are dispersed into the incoming water stream by recirculating a side stream of clean water from the outlet of the IGF Vessel and pumping this back through an Eductor.

The high velocity through the Eductor induces gas into the recycle water stream, where the water and gas are mixed and sheared to create a dispersion of small gas bubbles in the water.

This recycled water stream is then returned to the IGF Vessel at selected entry points, where the gas bubbles are utilised for fl otation of oil and fi ne solids from the oily water stream.

Rev 07/2010

Induced Gas FlotationD.04

Operating PrinciplesOperating Principles

The creation of small gas bubbles (typically < 50 micron) results in effi cient recovery of small oil droplets present in the water stream due to:

• High probability of bubble/oil attachment,• High bubble concentration,• Large surface area / volume ratio of bubbles,• Low bubble rise velocity/less turbulence,• Increased volume of oil and solids removed with low gas

consumption.

The IGF Recirculation system incorporates a re-circulating loop, where a side-stream of clean water is taken from the outlet of the IGF Vessel, and pumped through an Educator. The Educator creates a gas-rich fl uid stream of small bubbles that is fed back into the IGF unit and dispersed through the water.

Flocculant or fl otation chemicals can assist in oil and or solids removal by Induced Gas Flotation.

TechnicalTechnical

Induced Gas Flotation Units are available for fl ow rates, typically from 800 - 24,000 m3/day (5,000 – 150,000 BPD), although any specifi c size can be catered for.Each IGF system consists of:

• A cylindrical vessel partitioned into fl otation, degassing and optional oil collection zones,

• Recirculating pump and gas eduction piping,• Liquid level control system.

The IGF system designs include features that result in effi cient operation and maintenance:

• All equipment is mounted on a single, compact skid for rapid installation and start-up,

• Low Power demand: gas induction and mixing is achieved by a recirculation pump, (no oil skimming motor is used).

IGF Units are designed and built to the required Pressure Vessel Codes required for pressurised operation, and are fully sealed to prevent fugitive gas emissions.

Materials of construction are selected to suit the process requirements, eg: carbon steel or duplex stainless steel. CFD Analysis can be used where specifi c applications require design performance verifi cation.

Benefi ts & FeaturesBenefi ts & Features

Benefi ts associated with properly designed and implemented IGF systems include:

• Low or nil chemical consumption,• Low operation and maintenance manpower,• Retro-fi t option for existing skim tanks or vessels,• Can be vertical or horizontal,• Removal of oil down to <20 ppm, • Removal of fi ne solids (<10 micron),• No internal moving parts.

The IGF system has no internal moving parts, which signifi cantly reduces maintenance downtime. The Pump and Eductor are externally located for easy access.

IGF units can be horizontal or vertical orientation. They are used on FPSO installations, where signifi cant motion occurs. In these and other specifi c applications, CFD analysis can be used to provide optimum internal baffl e designs to mitigate the effects of motion.

Skimming of the oil and particle-laden surface layer is controlled by the liquid level inside the vessel. The fl oated layer is skimmed off the surface into collection troughs.

The fl otation cells are designed to provide >90% oil removal and >80% removal of fi ne (<10 micron) solid particles at full design capacity.


Fuel Gas SystemsE.01

Rev 07/2010

IntroductionIntroduction

The increasing focus on reducing emissions from Power Genera-tion has seen increased demand for Gas Fired Power Stations.

Process Group has a well established track record in the design and supply of these plants.

Applications Applications

• Gas Turbine Power Plants

• Offshore Power Generation

• Cement Plants

• Utility Fuel/ Instrument Gas Systems

System Components System Components

• Emergency Shutdown Systems

• Knock-Out Drums

• Filter Coalescers

• Fiscal Gas Heaters

• Fuel Compression

• Pressure Reducing Stations

• Final Filters

• Condensate Handling Systems

• Vent & Flare Stacks

• Gas Storage Systems

• Process Control Systems

Engineering Services Engineering Services

• System Design & Integration

• Construction Supervision and Commissioning

• Plant Operation and Operator Training

• Plant Maintenance & Spare Parts

Fuel Gas SystemsE.01

Knock Out DrumsKnock Out Drums

Using a range of Technologies:

• Mesh Type Demisters• Hook Vane Demisters• Axial Flow Cyclone Demisters


Fiscal Metering SystemsFiscal Metering Systems

Integrated Systems:

• Orifi ce Metering ISA5167/AGA 3• Ultrasonic Metering AGA 9• Turbine Metering• Flow Computers• Gas Chromatographs• Supervisory Systems

Filters & Filter CoalescersFilters & Filter Coalescers

Horizontal (High Capacity)Vertical (Compact Layout)

Effi ciency: Standard: High Effi ciency Liquids: 99.8% @ 1um Liquids: 99.8% @ 0.3um Solids: 99.8% @ 1um Solids: 99.8% @ 0.3um

Pressure Reducing StationsPressure Reducing Stations

• Slam Shut Valves• Active/Monitor Regulator Systems• Creep Relief Systems• Flow Balancing & Integration

Flow rates from 10kg/h to 250,000kg/h

Pressures up to 135 barg

Solids ManagementF.01


Solids can occur naturally in the production of Oil & Gas. These solids enter production facilities and can cause a range of problems, including:

• Accumulation in Separators, Vessels & Tanks,• Reduced production capability,• Reduced separation performance of equipment,• Level instrumentation failure,• Erosion and damage to pumps, valves, etc.,• Increased corrosion potential (e.g. SRB, etc.),• Lost production during clean-out of solids.

In many production facilities, no consideration was made for solids in the original design of the process equipment. Consequently, solids settle by gravity and build up in the Inlet Separators, vessels and piping.

The solids are typically formation sand and silt, but can also include precipitated solids and corrosion products. These solids can range from low concentrations (<1 ppm of gross fl uids) to far higher concentrations (e.g. >1%).

In most cases these solids settle out in the bottom of Separators & Tanks. These settled solids need to be removed at specifi c intervals to avoid some or all of the problems listed above.In some cases, fi ne solids are fl ushed through the Separator with the produced water and carry through into the Water Handling system, where they can be readily removed (refer to Brochure D.02 for information on this application).

DescriptionDescription

A typical Sand Management System will include a number of items of equipment and techniques to fl uidise, transport, clean and dispose of the solids.

For each facility, a Sand Management scheme needs to be developed to identify the requirements and options available, along with the required outcomes, before any decision can be made about the best overall system approach.

There are 3 distinct stages of Solids Management that can be summarised as follows:Stage 1: Solids collection & removal from the process,Stage 2: Solids handling & cleaning,Stage 3: Solids disposal.

Any combination of the above activities may need to be provided for in the design of a scheme. A range of issues will need to be satisfi ed and catered for in order to provide a suitable outcome.

Rev 07/2010

Solids ManagementF.01

Stage 3: Solids Disposal.The fi nal stage is disposal of the solids. In some regions the solids may also contain hazardous contaminants, which have limits imposed on discharges. These may include Mercury, Arsenic, NORM (Naturally Occurring Radioactive Material), etc.

Many of these contaminants pose health and safety issues for personnel and consideration must be given to any solid, liquid or vapour emissions that may occur from any handling.

Depending on the entrained contaminants, company policy and the prevailing regulations, the solids may be disposed of either by:

• Re-injection into disposal wells,• Sent to onshore landfi ll (hazardous/non-hazardous),• Discharged to sea, etc.

TechnicalTechnical

The design and success of a Solids Management Scheme will depend on a number of parameters:

• Solids particle size & size range: solids <20 micron are more diffi cult to handle and are more diffi cult to remove oil from,

• Availability of clean water to be used as the washing medium for the removal of oil from the solid particles.

• Solids sizes from 20 – 1000 micron, with a relative density of 1.6 – 2.65 S.G.

• Frequency of solids fl ushing from Separators and Solids Washing will be site-specifi c.

Product Range Product Range

Process Group provides a range of Sand Management Schemes to cover the range of conditions that may occur.

Most systems are custom designed to meet a specifi c requirement, although a number of key elements tend to be common to most designs.

Applications Applications

There are many varied applications for implementing a Solids Management Scheme, including the following:

• Continuous or batch removal of solids from Separators to avoid poor Separator performance,

• Allowing on-site disposal of solids,• Solids removal for water reinjection to prevent formation

blockage and damage to pumps, etc.


Process SchemeProcess Scheme

Before designing a Sand Management Scheme, a few important issues need to be identifi ed, namely:

1. Solids volumes/concentrations anticipated,2. Solids size ranges and density,3. Solids types (eg: oil, scale, mercury, corrosion products,

etc.),4. Is solids removal to be continuous or batch?5. Proposed solids disposal method and location?

In many production systems little clear information exists on solids production occurring, and estimates are often all that is available at the initial design stage. In addition, solids production changes over time and so some consideration must be given to future expectations of solids production.

Stage 1: Solids Collection & RemovalIn many applications, the main Separator vessel will be horizontal and may have little or no fl ushing nozzles or sand removal capability. For any Sand Management scheme, a means of fl ushing/removing solids from the Separator is essential, and if none is present a solids fl uidising and removal system must be installed.This can take either of 2 main forms:

• Traditional jetting manifolds with fl ushing water,• Specialised fl uidising & Eductor devices.

For either option, an external water source is required to provide the motive force to fl uidise and transport the accumulated solids out through dedicated discharge lines, and into a collection vessel.

Stage 2: Solids Handling & Cleaning.Solids are fl uidised and removed from the Separator and collected in a dedicated vessel, which is separate from the main production equipment. The solids may contain oil, corrosion product, scale, chemical residue, and other contaminants.

The primary objective is typically to remove oil from the solids to allow the solids to be discharged within environmental limits.

This is achieved by pumping a heated wash water stream into the Sand Management Package to fl uidise and wash oil from the solids. This stream passes through a Desander Cyclone to recapture the solids from the wash water, which is then processed to recover the oil washed from the solids.

After one or more times being recirculated, the majority of the oil will have been removed and the solids can be discharged.

This combination of heat and washing water is a simple and effective method of oil recovery, which avoids the use of chemicals.


Process Group International is a global engineering company specialising in the design andsupply of packaged process plant equipment for the Process Oil and Gas industry.

Our field support department is committed to deliver total support for your delivered packagesand to provide continuing sales, commissioning and aftermarket services through the productlifetime.

FIELD SUPPORT SERVICES

Process Group International will be there for you. We maintain a well stocked spare parts service so thatyou can get the items you need to get your equipment back on-line quickly. Many parts can beshipped the same day, including vessel gaskets/parts, bearings, shaft assemblies, and associatedcomponents for your installed equipment and as detailed in our package SPIR lists.

The After-Market Sales Department offers a wide range of services to process operations and relateddepartments. Our services help you to be sure that you are maintaining continuity of production,optimal operational efficiency, maximum product quality with state-of-the-art systems.

SPARE PARTS

We do more than just supply spare parts. Through key component repair, overhauls andpreventive maintenance schedules we can provide your Process Group International installations withthe best possible care.

Insurance sparesCommissioning / start upRecommended parts for operation & use

reduce non-scheduled downtimeimprove efficiencyenhance performanceincrease the life time of your plant

Our services include the supply of recommended parts for:

ENGINEERED REPLACEMENT PARTS

Heat exchangersAir coolers, pumps and controlsTube bundles, ire tubesPipe and fittingsValves

f

Site erection servicesPre-commissioningCommissioningTraining

SITE SUPPORT

Plant inspectionRegular service plant maintenanceOptimisation of spares and inventories

MAINTENANCE CONTRACTS

WARRANTY MANAGEMENT

Process Group International is highly experienced in high quality, rapidly executed, manufacturing of engineeredequipment against to client designs. Our scope of supply includes such items as:

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October 2010

PGI Product Profile Nov10

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