Modular Oil & Gas Equipment Onshore & Offshore

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1 Modular Oil & Gas Equipment Onshore & Offshore

2 Separators & Desalters AI Energy Solutions onshore and offshore oil process solutions offer innovative technologies packaged with global project management and execution expertise. 3 Phase Separator Package Individual treating units to fully integrated process trains Mechanical and electrostatic coalescing internals Single-stage and multi-stage desalting systems End to end and double ended designs Both onshore and offshore designs Global project management and execution expertise 2/3 PHASE SEPARATOR AI Energy Solutions can provide twophase (gas/liquid) or three-phase (gas/oil/water) separators depending on the client s particular needs. Generally separator sizing is based on gas quality performance, neither addressing oil nor water quality. FREE WATER KNOCKOUTS (FWKO S) AI Energy Solutions FWKO designs are based on empirical data developed over 50 years of practical experience. AI Energy Solutions provides two-phase (oil/water) and three-phase (oil/gas/ water) FWKO designs. The primary focus of a FWKO is to remove free water from the production inlet stream. DESALTER The presence of salt in the crude oil poses a risk to downstream oil processes. High salt content causes increased corrosion, increased fouling of equipment, and will hinder certain chemical & physical reactions. AI Energy Solutions can provider 1st stage to 3rd stage desalters to suit the clients requirements. 2

3 Crude Oil & Condensate Treating & Stabilization With the high value of hydrocarbon liquids makes it essential that you install reliable, high-performing systems for treating the liquids, maximizing recovery, and transporting and storing them safely. Stabilizer Systems Condensate Stabilizer tower Stainless steel packing Inlet heat exchanger Shell and tube Outlet gas ambient heat exchanger Indirect heater with expansion tank Vertical three-phase separator Vertical blowcase Pneumatic instrumentation High/low shutdown valve Heavy-duty oilfield skid with lifting lugs STABILIZERS Stabilizer plants are used to reduce the volatility of stored crude oil and condensate. These novel process units also maximize recovery of hydrocarbon liquids that might otherwise be lost to the natural gas stream. AI Energy Solutions designs are field-proven to be reliable and easy to operate, ensuring maximum liquid recovery. C5 RECOVERY PLANTS AI Energy Solutions C5 recovery plants are optional extensions of the AIES stabilizer plant, and often provide increased recovery of natural gas liquids. 3

4 Gas Dewpointing Natural gas contains a wide range of hydrocarbon compounds, some of which can condense and form liquids that can cause problems with pipelines and downstream equipment. Refrigerating the gas lowers the hydrocarbon dewpoint, thereby condensing and removing these hydrocarbon liquids. JT VALVE JT plants use the Joule-Thompson effect to cool natural gas by expanding it across a pressure-reducing valve. The expanded gas cools rapidly, causing gas liquids to condense for separation in a gravity separator. HOW IT WORKS Joule Thompson Modular Package JT valve with pressure pilot controller NGL/gas exchanger ASME code gas/gas exchanger ASME code -20 F cold separator Temperature controller Instrument gas/air manifold Thermal relief valves CFD Sight glass assembly Methanol pump and delivery system Cold thermal insulation Hot gas bypass system for startup Heavy-duty steel skid with lifting lugs High-pressure gas enters through the gas/gas exchanger and chiller for precooling. Methanol is injected to help prevent formation of hydrates, and the raw natural gas passes through a JT valve. The resulting Joule-Thomson effect causes a pressure drop that expands the gas and significantly reduces temperature. The cooled gas is routed to the cold separator, which removes condensed NGL. Outlet gas from the cold separator is routed through the gas/gas exchanger for0 inlet cooling. The NGL from the cold separator is routed through the inlet NGL/gas exchanger and then to a pressurized NGL storage tank. 4

5 Gas Sweetening Produced natural gas often contains too much carbon dioxide (CO2) and hydrogen sulfide (H2S) gasses to allow safe production and sale. AI Energy Solutions offer advanced amine and scavenger plants to remove CO2 and H2S from natural gas production at the wellhead. AMINE PLANTS SCAVENGER PLANTS AI Energy Solutions Amine System removes contaminants such as carbon dioxide and hydrogen sulfide from natural gas streams in order to meet pipeline or pretreatment specifications. With expertise in engineering state-ofthe-art plant designs and bringing them online quickly. So you can see production profits faster. AI Energy Solution scavenger plants are also modular and self-contained, and are used to remove up to 2,000 ppm of H2S from natural gas using chemical scavengers. The scavenger plant maximizes the efficient use of the chemical, and the resulting spent chemical is safe for disposal with produced water. Inlet Gas System Inlet Gas Coalescer Amine Contactor Treated Gas Scrubber Regeneration System Regeneration Module Flash Tank Module Hot Oil Module Amine Reboiler Amine Cooler Amine Still Reflux Condenser Amine Still Hot Oil Heater Amine Plant Structured Packing 5

6 Gas Dehydration Natural gas contains water vapor that cannot be removed with separators or filters. This water vapor can condense and turn to liquid water, which can corrode or block downstream pipelines and equipment. HOW IT WORKS Wet gas enters the bottom of the absorber tower. As the gas rises through the tower s packing or bubble cap trays, water is absorbed by descending lean glycol (water removed through regeneration process),. Drier gas exits the top of the tower and passes through the glycol/gas heat exchanger to the gas outlet. The rich glycol collects in the hat tray at the bottom of the tower and flows to the power side of the glycol pump. From the pump, the rich glycol flows through a reflux coil, heat exchanger and flash gas separator, which divides gas and entrained hydrocarbons from the glycol. The gas then flows to the fuel gas scrubber and the lean glycol flows through a filter into the reboiler. The hot, reconcentrated glycol flows from the reboiler to the sparger box to remove additional water vapor. The lean glycol flows to the storage compartment and then to the heat exchanger for cooling. The cooled, lean glycol then flows through a glycol sock filter before passing to the glycol pump. Lean glycol and gas from the absorber together power the glycol pump, which pumps the glycol through a glycol/gas heat exchanger to minimize glycol loss and then to the absorber tower to continue the dehydration process cycle. TEG Dehydration Package GLYCOL REGENERATORS Glycol regenerators: Regenerators are used to reconcentrate or regenerate TEG by heating and driving off absorbed water so that the TEG can be reused for natural gas dehydration. AI Energy Solutions offers standard designs with heat rates ranging from 125,000 btu/ hr. ABSORBERS AI Energy Solutions offers a wide range of absorbers (contactors) that are used to contact natural gas with TEG to remove water vapor from the gas. Packed Absobers Trayed Absorbers 6

7 Natural Gas Liquids The various hydrocarbons in the NGL stream have different boiling points; the fractionation process separates and captures each hydrocarbon by boiling them off in stages, from lightest to heaviest. Demethanizer/Expander Valve Module Mol Sieve Dehydration/ Regeneration Module Regeneration Gas Heater Module Turbo Expander/Compressor Module Power Distribution Center (PDC) NGL Plant Modular Package 3d OPTIONALS Auxiliary refrigeration system (closed-loop propane) Product treating Inlet treating Inlet/residue gas meters Fuel gas meter Fuel gas skid Mercury removal bed Condensate stabilizer Fractionation Horizontal and vertical product pipeline pumps specific to product analysis Inlet and residue compression Interconnect piping Pipe rack modules Gas flare system Modular Power Distribution Center 7 (PDC)