process group

I 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
DESI GN FABRI CATI ON I NSTALLATI ON COMMI SSI ONI NG
PROCESS GROUP INTERNATIONAL
COMPANY PRODUCT PROFILE
PROCESS GROUP: Abu Dhabi
P.O. Box 46153
Abu Dhabi
United Arab Emirates
Phone:
Fax:
E-Mail:
Website:
+971 2 5500898
+971 2 5500899
sales@processgroupintl.com
www.processgroupintl.com

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 Graham
Managing Director
process group
I N T E R N A T I O N A L
DESIGN FABRICATION INSTALLATION COMMISIONING
Capability & Resources
Z.01
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 Rening & Petrochemical,
Power Generation,
Coal Seam Methane Production,
Industrial Gas Processing,
Greenhouse Gas Abatement / Carbon Capture,
Etc.
Founded in 1978, Process Groups 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 Groups technical staff posses a wide range of
specialist disciplines with a long history in their respective
elds, which provides signicant depth to the organisations
skills and capabilities.
Resources
Process Design
Process 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 Design
Designing complex plant is an extremely difcult task when
combining the many requirements of plant design, operability
and safety, while still ensuring perfect integration with surround-
ing equipment.
Process Groups engineers have years of experience in the de-
sign and construction of complex plant, which ensures optimal
plant design and performance.
Project Management
Process Groups project team uses a hands-on approach to
ensure that projects are closely monitored through every phase.
Procurement, 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 & Resources
Z.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 Purication,
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 specic project requirements.
Contact Process Group if you have any
special requirements.
Process Group Pty Ltd, 2008 2010.
Fabrication

Process Group operates a fabrication facility at its Aus-
tralian Head-ofce. 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
Process Groups staff and Directors are committed to pro-
viding quality plant and equipment that is designed and
constructed in accordance with project specications,
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
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 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
Introduction
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 specic 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
The design of TEG and MEG Dehydration Systems is unique for
every requirement and the overall package design will vary to meet
the specied 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 efciency & design integrity
Compliance with HSE requirements
Environmentally conscientious design
Process Description
In a typical TEG package, water saturated gas enters near the
bottom of the Contactor Tower and 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-owing gas stream. The counter-
current 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 ows out of the top of the Contactor, while
the Rich Glycol 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 / modied / removed to suit the requirements of each individual application
Process Group Pty Ltd, 2008 2010.
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 Control
A.03
Introduction
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 specic 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 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.
Each system is typically designed and built as a complete turn-
key package with particular emphasis given to the following
issues:
Discharge gas hydrocarbon dew point,
Discharge gas water dew point,
Minimum inhibitor losses,
Minimum power consumption,
Optimum plant efciency & design integrity,
Compliance with HSE requirements,
Environmentally conscientious design.
The resulting design will be inuenced by all of these factors,
and the emphasis & importance given to each particular issue.
Rev 07/2010
Hydrocarbon
Dew Point
Control
A.03
Process Description
In a typical MEG Injection Dew Point Control Unit
(DPCU), the gas is 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/
Orice) 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.
Process Group Pty Ltd, 2008 2010.
(OPTIONAL)
CONDENSATE
STABILISATION
UNIT
Hydrocarbon Dew
Point Control Unit
OUTLET GAS
INLET GAS
1
MEG
REGENERATION
PACKAGE
EXPANSION
2
6
REFRIGERATION
3
5
4
Carbon Capture
C.02
Introduction
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 retrotted to virtually any exhaust gas
system, including coal or gas-red boilers, gas turbines, blast
furnaces, and cement kiln off-gas.
The process enables carbon dioxide to be selectively absorbed
from 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 Basis
The design of Carbon Capture Systems is unique to each situ-
ation with the overall package design varying to meet each
clients specied process conditions.
Each system is typically designed and built as a complete turn-
key package with particular emphasis given to the following
issues:
CO2 product purity
Minimum solvent losses
Minimum utilities consumption
Optimum plant efciency & design integrity
Compliance with HSE requirements
Environmentally conscientious design
Process Description
In a typical CO2 Capture package, hot 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 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 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 Capture
C.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 reux accumulator to re-
move excess water (9). The pure carbon dioxide product
gas is then ready for direct use or further processing.
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
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.
Process Group Pty Ltd, 2008 2010.
A typical Amine CO2 Capture Package:
A number of process components are added /
modied / removed to suit the requirements of
each individual application.
Hydrocyclones
Deoiling D.01
Introduction
Deoiler Hydrocyclones were developed for the offshore oil industry
in the 1980s and are established as the primary equipment used
for recovery of oil from Produced Water streams.
Deoiler Hydrocyclones exhibit the following benets:
Compact design,
Cost effective with low OPEX costs,
No moving parts with little maintenance required,
Highly consistent performance,
Proven technology,
Suitable for use on FPSOs, etc,
Range of material selections.
Description
Process Groups 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 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 ow rates to be handled.
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
Hydrocyclones
Deoiling D.01
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 prole,
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 orice as the Oil
Reject Outlet. The Oil Reject stream ow is largely controlled
by this orice size, but can also be regulated by an outlet
control valve, and is typically set to allow a ow at 2-4% of
the inlet 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: FPSOs).
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 Systems
If 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 benet of pump-fed systems is that very high turn-down
rates are achievable, as water is recycled to maintain pump
owrates. This ensures that high oil-removal is maintained
regardless of the water throughput.
Oil Droplet Size /Distribution
The Oil droplet size range has a major impact on the Deoiler
Cyclones performance, and it is important to maintain as little
shearing of oil droplets as possible prior to the Cyclone.
Deoiler Unit Sizing
Process 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.
Process Group Pty Ltd, 2008 2010.
Hydrocyclones
Desander D.02
Introduction
Desander Hydrocyclones are used to provide efcient 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 Efciency Solids Removal,
Compact, small footprint,
Cost effective protection against erosion damage,
No moving parts and minimal maintenance,
Highly consistent performance.
Description
Process Groups 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 congu-
rations inside vessels.
The Cyclone Liner size and type selected is dependent on the
process 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 Efciency 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
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 cyclones internal prole. 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 Underow, where
they exit. It is typical to collect the solids in a closed underow
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 Overow.
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 Flowrate
Capacity based on ~100 psi (~7 Barg) Inlet Pressure
Hydrocyclones
Desander D.02
Schematic of Desander Vessel
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 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 efciency (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.
Process Group Pty Ltd, 2008 2010.
Induced Gas Flotation
D.04
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,
reneries, ballast treatment facilities, etc.
IGF is primarily used for the removal of oil and ne solids from oily
water streams, and to deliver the following outcomes:
High efciency oil removal,
Low outlet oil levels,
Simple, efcient operation and maintenance,
Low or nil chemical consumption,
No fugitive gas emissions,
Minimal environmental impact.
Description
Process Groups IGF units are hydraulically-operated Induced Gas
Flotation Units that provide efcient oil recovery from water streams
with complete process containment. Oil recovery is achieved
efciently and economically, with operator and environmental safety
ensured by the fully enclosed otation process.
IGF Units separate and recover oil and ne solid particles from
water through the creation of ne gas bubbles (typically < 50
microns in diameter), that are dispersed through the incoming water
stream. Oil and ne solid particles that are present in the water
stream adhere to these gas bubbles and 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 otation
of oil and ne solids from the oily water stream.
Rev 07/2010
Induced Gas Flotation
D.04
Operating Principles
The creation of small gas bubbles (typically < 50 micron)
results in efcient 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 uid stream of small bubbles
that is fed back into the IGF unit and dispersed through the
water.
Flocculant or otation chemicals can assist in oil and or
solids removal by Induced Gas Flotation.

Technical
Induced Gas Flotation Units are available for ow rates,
typically from 800 - 24,000 m3/day (5,000 150,000
BPD), although any specic size can be catered for.
Each IGF system consists of:
A cylindrical vessel partitioned into 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 efcient
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 specic applications require
design performance verication.
Benets & Features
Benets associated with properly designed and implemented
IGF systems include:
Low or nil chemical consumption,
Low operation and maintenance manpower,
Retro-t option for existing skim tanks or vessels,
Can be vertical or horizontal,
Removal of oil down to <20 ppm,
Removal of ne solids (<10 micron),
No internal moving parts.
The IGF system has no internal moving parts, which
signicantly 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 signicant motion occurs.
In these and other specic applications, CFD analysis
can be used to provide optimum internal bafe 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 oated
layer is skimmed off the surface into collection troughs.
The otation cells are designed to provide >90% oil removal
and >80% removal of ne (<10 micron) solid particles at full
design capacity.
Process Group Pty Ltd, 2008 2010.
Fuel Gas Systems
E.01
Rev 07/2010
Introduction
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
Gas Turbine Power Plants
Offshore Power Generation
Cement Plants
Utility Fuel/ Instrument Gas Systems
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

System Design & Integration
Construction Supervision and Commissioning
Plant Operation and Operator Training
Plant Maintenance & Spare Parts
Fuel Gas Systems
E.01
Knock Out Drums
Using a range of Technologies:
Mesh Type Demisters
Hook Vane Demisters
Axial Flow Cyclone Demisters
Process Group Pty Ltd, 2008 2010.
Fiscal Metering Systems
Integrated Systems:
Orice Metering ISA5167/AGA 3
Ultrasonic Metering AGA 9
Turbine Metering
Flow Computers
Gas Chromatographs
Supervisory Systems
Filters & Filter Coalescers
Horizontal (High Capacity)
Vertical (Compact Layout)
Efciency:
Standard: High Efciency
Liquids: 99.8% @ 1um Liquids: 99.8% @ 0.3um
Solids: 99.8% @ 1um Solids: 99.8% @ 0.3um
Pressure 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 Management
F.01
Introduction
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 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 specic
intervals to avoid some or all of the problems listed above.
In some cases, ne solids are 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).
Description
A typical Sand Management System will include a number of
items of equipment and techniques to 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 satised and catered for in order to provide a
suitable outcome.
Rev 07/2010
Solids Management
F.01
Stage 3: Solids Disposal.
The 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 landll (hazardous/non-hazardous),
Discharged to sea, etc.
Technical
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 difcult to handle and are more difcult 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 ushing from Separators and Solids
Washing will be site-specic.
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 specic
requirement, although a number of key elements tend to be
common to most designs.
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 Group Pty Ltd, 2008 2010.
Process Scheme
Before designing a Sand Management Scheme, a few
important issues need to be identied, 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 & Removal
In many applications, the main Separator vessel will be
horizontal and may have little or no ushing nozzles or sand
removal capability. For any Sand Management scheme,
a means of ushing/removing solids from the Separator is
essential, and if none is present a solids uidising and removal
system must be installed.
This can take either of 2 main forms:
Traditional jetting manifolds with ushing water,
Specialised uidising & Eductor devices.
For either option, an external water source is required
to provide the motive force to uidise and transport the
accumulated solids out through dedicated discharge lines, and
into a collection vessel.
Stage 2: Solids Handling & Cleaning.
Solids are 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 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
I N T E R N A T I O N A L
Process Group International is a global engineering company specialising in the design and
supply 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 packages
and to provide continuing sales, commissioning and aftermarket services through the product
lifetime.
FIELD SUPPORT SERVICES
Process Group International will be there for you. We maintain a well stocked spare parts service so that
you can get the items you need to get your equipment back on-line quickly. Many parts can be
shipped the same day, including vessel gaskets/parts, bearings, shaft assemblies, and associated
components 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 related
departments. 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 and
preventive maintenance schedules we can provide your Process Group International installations with
the best possible care.
Insurance spares
Commissioning / start up
Recommended parts for operation & use
reduce non-scheduled downtime
improve efficiency
enhance performance
increase the life time of your plant
Our services include the supply of recommended parts for:
ENGINEERED REPLACEMENT PARTS
Heat exchangers
Air coolers, pumps and controls
Tube bundles, ire tubes
Pipe and fittings
Valves
f
Site erection services
Pre-commissioning
Commissioning
Training
SITE SUPPORT
Plant inspection
Regular service plant maintenance
Optimisation of spares and inventories
MAINTENANCE CONTRACTS
WARRANTY MANAGEMENT
Process Group International is highly experienced in high quality, rapidly executed, manufacturing of engineered
equipment against to client designs. Our scope of supply includes such items as:
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