List of equipment in a Gas Plant

The equipment in a gas plant can vary depending on the specific processes and operations carried
out in the plant. However, here is a general list of equipment commonly found in gas processing
plants:

1. Inlet Separator: Removes liquid droplets and solids from the incoming gas stream.
2. Gas Compressor: Increases the pressure of the gas for transportation or further processing.
3. Dehydration Unit: Removes water vapor from the gas stream to prevent corrosion and hydrate
formation.
4. Gas Sweetening Unit: Removes sulfur compounds (such as hydrogen sulfide) from the gas to meet
pipeline specifications.
5. Fractionation Tower: Separates the gas into different components based on their boiling points
(e.g., methane, ethane, propane).
6. Heat Exchangers: Transfer heat between different streams to optimize energy efficiency.
7. Condensate Stabilizer: Separates hydrocarbon liquids from the gas stream and stabilizes them for
storage or transport.
8. Flare System: Safely burns off excess gases during emergency or maintenance situations.
9. Storage Tanks: Store liquids such as condensate or natural gas liquids (NGLs) before further
processing or transportation.
10. Instrumentation and Control Systems: Monitor and control various processes within the plant for
safe and efficient operation.
11. Utilities: Include equipment such as boilers, cooling towers, and power generators to support
plant operations.
12. Safety Systems: Include fire detection and suppression systems, emergency shutdown systems,
and safety valves to ensure plant safety.

This list provides a basic overview, and the actual equipment in a gas plant can be more extensive
and specialized based on the plant's design and operational requirements.

What are the Corrosion issues in Gas Plant equipment?

Corrosion is a significant concern in gas plant equipment due to the corrosive nature of some
components in the gas stream, such as hydrogen sulfide (H2S) and carbon dioxide (CO2). Some
common corrosion issues in gas plant equipment include:

1. Sulfide Stress Cracking (SSC): Hydrogen sulfide (H2S) in the gas stream can lead to SSC, especially
in carbon steel equipment. This type of corrosion can cause sudden failure under tensile stress,
leading to equipment ruptures.

2. Carbon Dioxide Corrosion (CO2 Corrosion): Carbon dioxide (CO2) can lead to localized corrosion,
especially in areas with stagnant or low-velocity gas flow. It can cause pitting corrosion, which can
lead to leaks and structural integrity issues.

3. General Corrosion: General corrosion can occur due to the presence of moisture, oxygen, and
corrosive contaminants in the gas stream. This type of corrosion can affect various equipment
surfaces, including pipelines, vessels, and valves.

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4. Acid Gas Corrosion: Acid gases such as hydrogen sulfide (H2S) and carbon dioxide (CO2) can form
acidic solutions in the presence of water, leading to acid gas corrosion. This type of corrosion can be
particularly damaging to carbon steel equipment.

5. Corrosion Under Insulation (CUI): Insulated equipment can be susceptible to CUI, where moisture
trapped under the insulation can lead to corrosion of the underlying metal surfaces. This can be
challenging to detect and mitigate.

6. Stress Corrosion Cracking (SCC): SCC can occur in the presence of specific environments and
stresses, such as tensile stress and corrosive gases. It can lead to cracks and failures in equipment
over time.

7. Microbiologically Influenced Corrosion (MIC): Microorganisms in the gas stream or water can
promote corrosion through microbiologically influenced corrosion mechanisms, leading to localized
damage.

To mitigate these corrosion issues, gas plants often employ various corrosion control strategies,
including material selection (using corrosion-resistant alloys), coatings and linings, corrosion
inhibitors, cathodic protection, monitoring and inspection programs, and proper maintenance and
operating procedures.

List of failure modes in main equipment in gas plant facility

In a gas plant facility, the main equipment can experience various failure modes due to factors such
as operational conditions, corrosion, mechanical stress, and environmental factors. Here is a list of
common failure modes that can affect the main equipment in a gas plant:

1. Corrosion-Related Failures:
- Sulfide Stress Cracking (SSC)
- Carbon Dioxide Corrosion (CO2 Corrosion)
- General Corrosion
- Acid Gas Corrosion
- Corrosion Under Insulation (CUI)
- Microbiologically Influenced Corrosion (MIC)

2. Mechanical Failures:
- Fatigue Failure: Repeated stress cycles leading to material fatigue and crack initiation.
- Brittle Fracture: Sudden, brittle failure of materials, often under low temperatures and high stress.
- Erosion and Abrasion: Wear and material loss due to high-velocity gas flow or abrasive particles in
the gas stream.
- Mechanical Overload: Excessive stress or pressure leading to equipment deformation or rupture.

3. Operational Failures:
- Operational Upsets: Process deviations or abnormalities leading to equipment malfunctions or
failures.
- Control System Failures: Malfunction or failure of control systems leading to unsafe operating
conditions.
- Leakage and Seal Failures: Seals, gaskets, and packing failures leading to gas leaks or loss of
containment.

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 - Valve and Actuator Failures: Malfunction or failure of valves and actuators impacting process
control and safety.

4. Environmental Failures:
- Fire and Explosion: Ignition of flammable gases or materials leading to fires or explosions.
- Environmental Hazards: Exposure to harsh environmental conditions such as extreme
temperatures, humidity, or weather events.

5. Material-Related Failures:
- Material Degradation: Degradation of materials over time due to exposure to aggressive gases,
chemicals, or operating conditions.
- Welding and Joining Failures: Weld defects, cracks, or failures in welded joints or connections.

6. Electrical and Instrumentation Failures:

- Electrical Shorts and Arcing: Electrical faults leading to short circuits, arcing, and potential fire
hazards.
- Instrumentation Malfunctions: Malfunction or failure of sensors, meters, and monitoring devices
impacting process control and safety.

Mitigating these failure modes requires a comprehensive approach that includes proper design,
material selection, maintenance programs, monitoring and inspection, training and procedures, and
risk management strategies.

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 ASSET/ ASSET/ DAMAGE
EQUIPMENT EQUIPMENT MECHANISM (MAINLY MITIGATION STRATEGY
NAME DESCRIPTION CORROSION)
Regular inspection and
Removes liquid
General Corrosion, maintenance, use of
droplets and solids
Inlet Separator Corrosion Under corrosion-resistant
from incoming gas
Insulation (CUI) materials, CUI detection
stream
and prevention techniques
Increases gas Sulfide Stress Cracking Material selection (H2S-
Gas pressure for (SSC), Carbon Dioxide resistant alloys), corrosion
Compressor transportation or Corrosion (CO2 monitoring, periodic
processing Corrosion) integrity testing
Use of corrosion inhibitors,
Removes water Acid Gas Corrosion, monitoring and
Dehydration
vapor from gas Corrosion Under controlling pH levels, CUI
Unit
stream Insulation (CUI) detection and prevention
measures
Material selection (H2S-
Removes sulfur Sulfide Stress Cracking resistant materials),
Gas Sweetening
compounds from (SSC), Acid Gas corrosion monitoring,
Unit
gas Corrosion regular maintenance and
inspection
Coating and lining of
Carbon Dioxide
Separates gas internal surfaces, periodic
Fractionation Corrosion (CO2
components based cleaning and inspection,
Tower Corrosion), General
on boiling points corrosion-resistant
Corrosion
materials
Material selection
Transfers heat (corrosion-resistant alloys),
Heat General Corrosion,
between gas regular cleaning and
Exchangers Erosion and Abrasion
streams maintenance, monitoring
erosion rates
CUI detection and
Separates General Corrosion, prevention, use of
Condensate
hydrocarbon liquids Corrosion Under corrosion-resistant
Stabilizer
from gas Insulation (CUI) materials, regular integrity
checks
Corrosion Under Protective coatings,
Safely burns off Insulation (CUI), regular inspection and
Flare System
excess gases Environmental maintenance, monitoring
Corrosion environmental conditions
Corrosion monitoring and
General Corrosion,
prevention, cathodic
Stores liquids such Microbiologically
Storage Tanks protection, regular
as condensate Influenced Corrosion
inspection and
(MIC)
maintenance

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List of equipment in a Gas Plant

1. Inlet Separator: Removes liquid droplets and solids from the incoming gas stream.
2. Gas Compressor: Increases the pressure of the gas for transportation or further processing.
3. Dehydration Unit: Removes water vapor from the gas stream to prevent corrosion and hydrate
formation.
4. Gas Sweetening Unit: Removes sulfur compounds (such as hydrogen sulfide) from the gas to meet
pipeline specifications.
5. Fractionation Tower: Separates the gas into different components based on their boiling points
(e.g., methane, ethane, propane).
6. Heat Exchangers: Transfer heat between different streams to optimize energy efficiency.
7. Condensate Stabilizer: Separates hydrocarbon liquids from the gas stream and stabilizes them for
storage or transport.
8. Flare System: Safely burns off excess gases during emergency or maintenance situations.
9. Storage Tanks: Store liquids such as condensate or natural gas liquids (NGLs) before further
processing or transportation.
11. Utilities: Include equipment such as boilers, cooling towers, and power generators to support
plant operations.
12. Safety Systems: Include fire detection and suppression systems, emergency shutdown systems,
and safety valves to ensure plant safety.

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Process (Compression Unit)

1. Well Head
2. Gas Processing Unit
3. Slag Catcher
4. Filtration System
5. Knock Out/ Scrubber
6. Compressor
7. Cooler
8. Discharge Header

Process (Compression Unit)

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