modular oil & gas equipment onshore & offshore · 3 phase separator package ai energy...
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Modular Oil & Gas Equipment
Onshore & Offshore
2
Separators & Desalters
3 Phase Separator Package
www.aienergysolutions.com
AI Energy Solutions onshore and offshore oil process solutions offer in-
novative technologies packaged with global project management and
execution expertise.
FEATURES
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 de-
signs
Global project management and
execution expertise
2/3 PHASE SEPARATOR
AI Energy Solutions can provide two-phase (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 ad-
dressing 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 re-
move free water from the production
inlet stream.
DESALTER
The presence of salt in the crude oil
poses a risk to downstream oil pro-
cesses. High salt content causes in-
creased 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.
3
Crude Oil & Condensate Treating & Stabilization
Stabilizer Systems
With the high value of hydrocarbon liquids makes it essential that you
install reliable, high-performing systems for treating the liquids, max-
imizing recovery, and transporting and storing them safely.
FEATURES
Condensate Stabilizer tower
Stainless steel packing
Inlet heat exchanger
Shell and tube
Outlet gas ambient heat exchang-
er
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 con-
densate. These novel process units also
maximize recovery of hydrocarbon
liquids that might otherwise be lost to
the natural gas stream. AI Energy Solu-
tions 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 in-
creased recovery of natural gas liq-
uids.
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4
Gas Dewpointing
Joule—Thompson
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 hydro-
carbon liquids.
JT VALVE
JT plants use the Joule-Thompson ef-
fect 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
High-pressure gas enters through the
gas/gas exchanger and chiller for pre-
cooling. 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 re-
duces 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 pres-
surized NGL storage tank.
Modular Package CFD
FEATURES
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
Sight glass assembly
Methanol pump and delivery
system
Cold thermal insulation
Hot gas bypass system for
startup
Heavy-duty steel skid with
lifting lugs
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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 re-
move CO2 and H2S from natural gas production at the wellhead.
AMINE PLANTS
AI Energy Solutions Amine System re-
moves contaminants such as carbon
dioxide and hydrogen sulfide from natu-
ral gas streams in order to meet pipe-
line or pretreatment specifications.
With expertise in engineering state-of-
the-art plant designs and bringing them
online quickly. So you can see produc-
tion profits faster.
SCAVENGER PLANTS
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.
Amine Plant
Structured Packing
FEATURES
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
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6
Gas Dehydration
TEG Dehydration Package
Natural gas contains water vapor that cannot be removed with separa-
tors 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 bub-
ble cap trays, water is absorbed by
descending lean glycol (water re-
moved through regeneration pro-
cess),. Drier gas exits the top of the
tower and passes through the gly-
col/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 sepa-
rator, which divides gas and en-
trained hydrocarbons from the gly-
col. 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 gly-col 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.
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 So-
lutions 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
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7
Natural Gas Liquids
NGL Plant
The various hydrocarbons in the NGL stream have different boiling
points; the fractionation process separates and captures each hydro-
carbon by boiling them off in stages, from lightest to heaviest.
FEATURES
Demethanizer/Expander Valve
Module
Mol Sieve Dehydration/
Regeneration Module
Regeneration Gas Heater
Module
Turbo Expander/Compressor
Module
Power Distribution Center (PDC)
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 prod-
uct analysis
Inlet and residue compression
Interconnect piping
Pipe rack modules
Gas flare system
Modular
Power Dis-
tribution Center
(PDC)
Modular Package 3d
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