TRAINING GAS HANDLING & PLANT PROCESSING

OVERVIEW

Processes and operations are the scope of gas processing activities. Quite a lot of processes that take place in gas treatment plants, such as gas sweetening, dehydration, fractionation, and heat exchangers. Therefore we need good knowledge and understanding of the processes and operations that occur in gas processing. This training will provide a comprehensive explanation regarding these matters, beginning with a discussion of the nature and characteristics of hydrocarbons as the main components of gas compilers. In general, after participating in this training, participants are expected to gain knowledge and understanding of the nature and characteristics of gas hydrocarbons, and what and how the handling, conditioning and processing facilities are used in gas processing.

OUTLINE COURSE

Module 1: Process Foundations & Physical Properties Gas Characteristics

• Hydrocarbon mixtures, molecular weight, real vs. ideal gas behaviors, and equations of state.
• Phase Behavior: Vapor-Liquid Equilibrium (VLE), phase envelopes, dew points, and bubble points.
• Product Specifications: Sales gas requirements, LNG/NGL feed criteria, and impurity limits (H₂S, CO₂, H₂O, Hg).
• Plant Layout: Standard facility process flow diagrams (PFDs), piping setups, and primary unit operations.

Module 2: Inlet Reception & Liquid Separation Inlet

• Flow Management: Managing slugging, pigging receivers, and slug catcher operations.
• Separation Systems: Physics of 2-phase and 3-phase separation using vertical and horizontal vessels.
• Internal Equipment: Troubleshooting mesh pads, vane packs, multi-cyclone separators, and KO drums.
• Condensate Handling: Condensate stabilization, multi-flash distillation, and vapor recovery systems.

Module 3: Gas Sweetening (Acid Gas Removal)

• Contaminant Problems: Corrosion mechanisms, toxic hazards of H₂S, and solvent degradation.
• Amine Plant Operations: Absorption chemistry utilizing MEA, DEA, and MDEA systems.
• Equipment Mechanics: Managing contactor towers, stripping columns, and flash tanks.
• Process Variables: Mitigating amine foaming, amine loss, heat exchanger fouling, and corrosion.

Module 4: Dehydration & Hydrate Inhibition

• Water Content: Calculating water dew points and diagnosing thermodynamic risks.
• Gas Hydrates: Conditions causing hydrate formation and prevention using MeOH or MEG injection.
• Glycol (TEG) Dehydration: Absorber operations, glycol regeneration loops, and reboiler optimization.
• Solid Bed Adsorption: Dry-bed Molecular Sieve operations, sequencing, and regeneration cycles.

Module 5: NGL Recovery, Refrigeration & Fractionation

• Hydrocarbon Dew Point Control: Joule-Thomson (J-T) valve expansion and mechanical refrigeration cycles.
• Advanced Extraction: Turbo-expander plant operations for deep ethane and NGL recovery.
• Fractionation Trains: Operations of Deethanizers, Depropanizers, and Debutanizers.
• Cryogenic Storage: Cold-box operations, mixed refrigerant systems, and storage safety.

Module 6: Utility Systems, Compression & Safety

• Gas Compression: Reciprocating and centrifugal compressor configurations, surge control, and intercoolers.
• Fired Heaters & Exchangers: Shell-and-tube performance, aerial coolers, and heat recovery optimization.
• Process Controls: Emergency Shutdown Systems (ESD), pressure relief valves, and flare management.
• Abnormal Operations: Mitigating power loss, instrument air failures, and plant restarts.

RECOMMENDED AUDIENCE

• Process Engineers
• Mechanical & Piping Engineers
• Insrtumentation & Control Engineers
• Operation & Field Personnel
• Plant Operator
• Production Supervisor
• Maintenance  Technician