Esdiac Industries is an independent engineering contractor in chemical, petrochemical, and related industries.  Our engineering department designs,  manufactures, delivers, and maintains oil and gas processing facilities.  Our team includes: process engineers (mechanical and electrical), service professionals, automation engineers and experienced project managers.  With the joint efforts of the specialists, we strive to achieve the highest level of customer satisfaction. 

 

Our products and services are available as part of a retrofit, an upgrade or simply as a new design solution to a specific need.  We design and manufacture all types of process packages according to custom needs.

 

OUR SERVICES INCLUDE:

• Filtration - De-misters, Coalescing or Particulate all types of filter elements: sludge treatment and processing, all aspects of gas plant engineering

• Compressors Packages - CNG compressors industrial types 

• Oil Desalters - all types of electrostatic coalescers including vessels and internals

• Flare Gas Processing - H2S Removal, NGL Recovery, CO2 Recovery

• Gas Processing - separation, sweetening, dehydration 

• Designing of systems for separation, dehydration, and compressing

• Improvement/modernization of equipment (optimization engineering)

• Process Equipment Examination (elimination of faulty equipment) 

• Drafting

• Piping Design

• Design Engineering 

• Process Engineering

• FEED

• FEL

 

INSTALLATION OF INTEGRATED GAS TREATMENT

Gas Treatment Plants 

The complex gas treatment unit (GPP) is a complex of technological equipment and various auxiliary devices, which provides for the collection and appropriate processing of natural gas and condensate in accordance with the requirements of Russian industry and state standards. The raw material for GPP is natural gas from gas and gas condensate fields. Commercial products of GPP are: dry gas from gas fields and dry stripped gas from gas condensate fields (used as domestic and industrial fuel), as well as raw materials for producing liquefied natural gas (LNG) and gas condensate being raw materials for gas processing plants). For gas supplied to main gas pipelines, the main indicator of quality is the dew point (for moisture and hydrocarbons). For a cold climate zone, the dew point on moisture should not exceed -20 ° С, on hydrocarbons - not higher than -10 ° С. In addition, the OST regulates such consumer properties of gas as the heat of combustion and the permissible content of sulfur compounds. The requirements for gas going to liquefaction are even more stringent - the dew point on moisture and hydrocarbons should not exceed -70 ° C, and the content of carbon dioxide should not exceed 50 ppm. When using gas as a gas engine fuel for motor vehicles, the main indicator of quality is the calculated methane number. Gas condensate produced at GPP is divided into stable and unstable. The requirements for different types of condensate vary. In addition, the OST regulates such consumer properties of gas as the heat of combustion and the permissible content of sulfur compounds. The requirements for gas going to liquefaction are even more stringent - the dew point on moisture and hydrocarbons should not exceed -70 ° C, and the content of carbon dioxide should not exceed 50 ppm. When using gas as a gas engine fuel for motor vehicles, the main indicator of quality is the calculated methane number. Gas condensate produced at GPP is divided into stable and unstable. The requirements for different types of condensate vary. In addition, the OST regulates such consumer properties of gas as the heat of combustion and the permissible content of sulfur compounds. The requirements for gas going to liquefaction are even more stringent - the dew point on moisture and hydrocarbons should not exceed -70 ° C, and the content of carbon dioxide should not exceed 50 ppm. When using gas as a gas engine fuel for motor vehicles, the main indicator of quality is the calculated methane number. Gas condensate produced at GPP is divided into stable and unstable. The requirements for different types of condensate vary. When using gas as a gas engine fuel for motor vehicles, the main indicator of quality is the calculated methane number. Gas condensate produced at GPP is divided into stable and unstable. The requirements for different types of condensate vary. When using gas as a gas engine fuel for motor vehicles, the main indicator of quality is the calculated methane number. Gas condensate produced at GPP is divided into stable and unstable. The requirements for different types of condensate vary. 

 

Gas field processing at the GPP consists of the following steps:

• stonecrop from mechanical impurities and dropping liquid; 

• absorption or adsorption drying; 

• low-temperature separation or absorption; 

• oil absorption.

• In gas fields, gas treatment mainly consists in its drying, therefore absorption or adsorption processes are used there (the method of drying depends on the field productivity). In gas condensate fields, the drying and separation of lightly condensable hydrocarbons is carried out by low-temperature separation, low-temperature absorption or low-temperature oil absorption.

 

The composition of GPP includes:

- pre-treatment unit (separation); 
Provides separation from gas of drop moisture, liquid hydrocarbons and mechanical impurities. The unit includes equipment that provides operating parameters.

 

Gas processing technology:

• separators and filter separators; 

• technological installations for cleaning, drying, low-temperature absorption and cooling of gas; 

• booster compressor stations; 

• air coolers; 

• condensate stabilization equipment with technological heater, column and pumping equipment; 

• units for measuring condensate and gas consumption; 

• auxiliary systems for industrial purposes (operator, power, heat and water supply, electrochemical protection, communications equipment, fire extinguishing system, storage tank storage of condensate, diethylene glycol or triethylene glycol, air conditioning equipment, nitrogen station, flare system, etc.) 

 

Technical characteristics of GTU

The performance of the gas treatment facility package for gas, condensate, outlet pressure and other parameters as per the Customer’s specifications. Gazteh LLC for the GPPG is ready to provide a full range of turnkey services - design, delivery, installation (installation supervision), commissioning, training and after-sales service.

 

GAS DEHYDRATION

The dehydration of natural gas is the process of removing water found in natural gas in a vapor state. It is generally accepted that gas drying is a prerequisite for ensuring uninterrupted operation of gas pipelines. It prevents the formation of hydrates and reduces corrosion. When transporting wet gas in certain conditions, moisture can condense and accumulate in lower parts of the pipeline, resulting in reduced throughput capacity of the pipeline.

Several drying methods are used:

a) Adsorption. 
b) Absorption. 
c) Direct cooling 
d) Compression followed by cooling 
e) Chemical drying

Complete design and construction of gas drying systems for both adsorption and absorption

• Contactors

• Internal construction of absorbers

• Regular nozzles

• Liquid and gas distributors

• Heat exchangers

• Reboilers

• Glycol quality

• Filtration

• Hydraulics

• TEG Dehydration (gas)

• Pumps

 

Gas cleaning of sulfur-containing compounds

Many natural gases contain hydrogen sulfide H2S from a barely perceptible amount to 30 mol%. and more. Natural gas, intended for supply to consumers, must comply with the mandatory standards that determine the maximum H2S content in the amount of 0.23-0.88 g per 100 m3. Such stringent requirements are fully justified, since H2S is a poisonous gas, and when it is burned, CO2 or SO3 trioxide is formed. Removal of hydrogen sulphide from natural gas is accompanied by removal of carbon dioxide (if it is contained in the gas), since CO2 is similar in its acidic character to H2S. The removal of H2S and CO2 from the gas entering the pipeline significantly reduces its corrosivity, which is especially important if water condensate can form in the pipeline.
 

The gas cleaning process should provide:

a) Almost complete removal of H2S 
b) Treatment of large quantities of gas. 
c) cleaning at high pressure

There are many processes that can meet these requirements. Some of these processes have been successfully applied in the chemical and gas processing industry and have been improved recently.

Amine gas cleaning

These are the chemical solvents most commonly used to remove H2S and CO2. They are divided into primary, secondary and tertiary, depending on the hydroxyl groups of nitrogen associated with the amine. The most famous amines are: mono-ethanol-amine (MEA), di-ethanol-amine (DEA) and methyl-di-ethanol-amine (MDEA). In addition to simple aqueous solutions of amines, own formulations of amine with various additives are also widely used. Rectified solvents provide additional selectivity when removing H2S in the presence of CO2 and, in some cases, also enhancing the absorption capacity. Amine purification is a regenerative process. The absorption of acidic pollutants occurs at about ambient temperature, and the recovery of the amine occurs at the boiling point in the stripping column.
 

Scope of application

Remove acidic pollutants such as hydrogen sulfide (H2S) and carbon dioxide (CO2) from natural gas, refinery and synthesis gas gases to ensure compliance with the technical requirements of pipelines, LNG plants and petrochemical plants and / or environmental requirements Typically, the volume of residual acidic compounds is 4ppm H2S and 2% CO2 in natural gas in pipelines and 50-100ppm H2S in refinery gases used as fuel gas in process plants.

 

DIAGNOSTICS OF PIPELINES VTD 

offers services in the field of In-line Diagnostics (VTD)

Esdiac Industries  offers services in the field of In-line Diagnostics (HTD), non-destructive testing (NC) and provides an engineering solution for diagnosing problematic pipelines, as well as pipelines that are not subject to HTD using various diagnostic methods. In the diagnostic system, it offers services in the field of In-line Diagnostics (VTD). Esdiac Industries offers services in the field of In-line Diagnostics (HTD), non-destructive testing (NC) and provides an engineering solution for diagnosing problematic pipelines, as well as pipelines that are not subject to HTD using various diagnostic methods. In the system of diagnostic inspection of main pipelines, the key role is played by in-line inspection, which is the most effective and informative method of technical diagnostics. In-pipe inspection of pipelines (ITD) is a set of technological operations based on the use of “intelligent” autonomous shells-flaw detectors (inspection pistons) moving inside a controlled pipe under the pressure of the pumped product (oil, oil products, gas, etc.).

Esdiac Industries develops a sequence of in-tube projectiles permits for pipeline sections to obtain qualitative in-line inspection data on the basis of a technological operational plan, which contains the sequence and duration of each operation in the production of the whole complex of inspection work. The developed plan with specific deadlines for work is agreed with the customer, approved by both parties and is an integral part of the contract for in-line inspection of the pipeline. The sequence of in-tube shell passes through gas pipeline sections to obtain quality in-line inspection data is as follows:

 

Cleaning and calibration.

Skip the cleaning scraper and then the caliber scraper to determine the integral bore of the pipeline. The minimum flow area after the passage of the projectile is determined by the presence or absence of bending gauge plates, which is equipped with a scraper. The scraper plates are made for the deformation-free passage of the minimum allowable flow area for the used projectiles. The gauge scraper is equipped with a transmitter, so if it gets stuck you can find its location.

Profiler

skipping a projectile — a device profiler needed to obtain complete information about the internal geometry of the inspected gas pipeline section along its entire length; pipeline elements, measurements of the navigation coordinates of welded ring joints and detected defects; -pass magnetic inspection devices longitudinal (MFL) or transverse (TFI) magnetization to identify, identify and determine the size of defects of a corrosion nature, anomalous annular and longitudinal welds, crack-like defects. We carry out full control of the section of the main oil pipeline on the basis of determining the parameters of defects and features of the pipeline that go beyond the limits of acceptable values: 
- information should be obtained about the features and defects of the pipeline geometry causing a reduction in its flow area. To obtain such information, you should use a set of technical equipment in the composition of the scraper-caliber and projectile-profiler. Caliber projectiles make it possible to determine the minimum flow area of the examined pipeline section.

After successfully skipping a scraper gauge, i.e. confirmation of the required safe passage section of the pipeline for the passage of the VIP is performed by passing the profiler, defining the defects of the geometry and the particular position of the pipeline.

- detection of defects such as metal loss, which causes a reduction in the wall thickness of the pipeline, delamination, inclusions in the pipe wall using an ultrasonic flaw detector with radially installed ultrasonic sensors in the cross-section plane of the pipe.

Our company has the latest generation of inspection equipment to help you get complete technical information about the status of your pipelines.

 

 Defectosop MFL

Magnetic flaw detector (MFL) is designed for high-precision pipeline flaw detection by recording magnetic flux scattering, detecting and determining the size of metal loss defects and transverse cracks along the entire pipeline circumference. The projectile is introduced into the controlled pipeline through a special launch-acceptance chamber. After the projectile is unloaded, the information is read to an external terminal, and then it goes to the database server, is decoded, processed by the data processing program, analyzed by the operator and presented in the form of a report. An important advantage of really high resolution MFL shells is the possibility of registering deep pits (“puncture”, fistula) with a higher degree of probability, which cause leaks on pipelines and are the most frequent cause of accidents on field pipelines.

 

Tfi

High-resolution magnetic flaw detectors of the “TFI” type are used for recording and measuring transverse magnetic flux signals at locations where pipeline wall defects are located. They are designed to identify, locate and assess the size of all defects in the longitudinal orientation, including individual longitudinal structural elements of the pipeline and other defects in the longitudinal orientation pipeline. Thus, TFI technology provides detection of defects that are difficult to detect using conventional MFL axial technologies.

 

UT Ultrasonic flaw detection.

In-tube ultrasonic flaw detectors are high-resolution projectiles and are intended for in-line non-destructive testing of pipelines without removing them from service. In the flaw detector, the method of ultrasonic scanning of the material during the movement of the projectile by the flow of the medium is used. Scanning the surface of the pipe is carried out in the longitudinal and transverse directions.

 

EMAT

EMAT technology is an electromagnetic acoustic non-destructive testing method that uses a non-contact inspection device capable of generating and receiving a signal using electromagnetic mechanisms. The EMAT transducer consists of two components, one of which is a magnet, and the other is an electric coil. An electric coil is driven with an alternating current of an electrical signal at an ultrasonic frequency, usually in the range from 20 kHz to 10 MHz. An alternating current electrical coil also generates an alternating magnetic field. When the material under study is close to EMAT, ultrasonic waves are generated in it by the interaction of two magnetic fields. This technology is widely used in the field of quality control of insulation coating. Absorption of acoustic waves in different types of coatings of the pipeline occurs in different ways. For example, there is a strong attenuation of the acoustic wave in the pipeline section with a bitumen coating. When a wave passes through an uninsulated section, the attenuation will be negligible. In addition, the recorded signal varies depending on the continuity of the insulating coating, allowing you to detect local delamination of the insulation.

 

PIPELINE REPAIR
 

Offered methods and technologies for pipeline repair

1. Repair critical defects using clutches.

2. Perform fire (flammable) work on the pipeline, in which the pressure is reduced to 50 - 100 mm. waters pillar. Cutting of pipeline sections, tees, outlets, clogged sections and other works related to the need to cut the pipeline.

3. Execution of works on the replacement of worn insulation coating by three methods:

• • Replacement of the insulation coating on the existing pipeline (without pressure reduction or with minimal reduction).

  • Replacement of the insulation coating in the disconnected area (with complete pressure relief).

  • Replacement of the insulation coating on the disconnected section with preliminary replacement of defective sections of the pipeline.

  • Preliminary diagnosis of the surface of the pipeline, to identify unacceptable defects.

Our competitive advantage is the application of a unique coating that is not inferior to a three-layer factory coating (3LPE) in route conditions. 
The coating can perform its functions at pipeline operating temperatures of 100ºС.

The principle of operation of composite couplings

• Composite coupling assumes part of the load acting on the pipe wall at the location of the defect.

• The defect area is filled with a special filler (based on epoxy), which creates high compressive stresses, which guarantees the transfer of the load from the pipe to the composite coupling.

• The load distribution between the pipe wall and the composite directly depends on the stiffness or hardness of the composite: the higher the stiffness of the composite, the better the hardening of the pipe wall.

 

The following defects cannot be repaired:

• cracks; through

• defects; stress corrosion defects;

• corrugations,

• dents in combination with an additional hub.

 Before carrying out repairs, it is mandatory to inspect the local area of the defect using non-destructive testing methods to detect cracks.
 

advantages of using composite materials when repairing gas oil pipelines 

Saving of time, resources, labor costs and equipment:

• Eliminates the need to stop the pipeline.

• Restored structural integrity of the material.

• Corrosion stops.

• Prevents the development of cracks.

• Extends the life.

• No need to replace plots.

• No welding, lifting mechanisms, labor costs are minimal.

The ability to repair any sections: elbows, tees, straight sections and so on. 

 

ELECTRODEHYDRATORS

We design and construct dehydrators designed for desalting crude oil according to your requirements. Depending on the salt content at the start of production and on the specification of the oil at the outlet, desalting of crude oil can be carried out using various processes. Our capabilities range from simple dehydration to multi-stage dehydration combined with injecting dilution water to reduce the total salt concentration.

Electrostatic coalescence. 

Crude oil is extracted from the depths of the earth, where mineral oil and various undesirable impurities, such as salts and inorganic solids, are found along with oil.

Most of the passing water forms an emulsion mixed with oil, and does not naturally precipitate in storage tanks or conventional separators under its own weight. In these structures there is no force sufficient to combine small droplets of the aqueous emulsion together for rapid adhesion (coalescence) into large water droplets.

In an electrostatic separator, the emulsion is subjected to a high voltage electrostatic field, which causes polarization of water droplets, which stick together into larger droplets (see figure). The result of such an impact appears almost instantly. Because of its size, such larger droplets are quickly separated by their own weight. The minimum percentage of water at which an optimal amount of water droplets is provided is 3%. In order to achieve near-perfect coalescence, it is imperative that the proper amount of water droplets is in the electrostatic field. In our electrostatic separator, this is achieved using a special distribution system.

 

 

UTILIZATION OF GAS EMISSIONS AND NGL PROCESSING

Methods for the utilization of associated petroleum gas

1. Gas processing at gas processing plants and small-sized installations;

2. Generation of electric energy and heat for own needs of the oil field;

3. Gas injection into productive oil reservoirs;

4. Methanol production (СН3ОН-methyl alcohol) on low-tonnage plants;

5. Production of aromatic hydrocarbons (benzene, toluene, etc.);

6. Production of liquefied natural gas (LNG) in the field.

A wide fraction of light hydrocarbons (NGL)  is a product of processing of associated petroleum gas and gas condensate. It is a mixture of liquefied hydrocarbon gases and heavier hydrocarbons (C2-C6 and higher).

 

 

 Stages of processing NGL

NGL is obtained as a result of separation of associated gas at a gas processing plant. This also produces stripped gas and gasoline. Stripped gas is used to generate electricity. Gasoline for the production of motor fuel.

One of the progressive methods of obtaining NGL from oil and gas condensate is a method that includes heating the raw material in a heat exchanger and furnace, stripping to obtain a heavy fraction and a wide fraction of light hydrocarbons, cooling and condensing the latter to produce a stable condensate and non-condensed vapor phase which is withdrawn.

 

 

  Scheme of cooling NGL

The final stabilization of the finished product is achieved by pumping out light vapor by injecting and then burning them in an oven, which makes it possible to further increase the efficiency of the process, since decreases the flow of the required amount of fuel gas from outside with simultaneous achievement of the required quality of the finished product at the saturated vapor pressure.

To reduce energy and metal consumption and dimensions of the process equipment, the method is implemented in that the distillation of a wide fraction of light hydrocarbons is carried out by hydro-cycloning of the heated raw material, and removal of the non-condensed vapor phase of hydrocarbons is carried out by injecting high-pressure gas flow into the furnace for combustion. The method allows to most effectively implement the process of obtaining NGF.
 

The separation of NGL into its constituent components - individual hydrocarbons - occurs at gas fractionation units (GFC). 

The separation process is similar to the separation of associated petroleum gas. However, in this case, the separation should be more thorough. From NGL in the process of gas fractionation can be obtained various products. It could be propane
 

 

  Separation of NGL on HFC

or butane, as well as a mixture of propane-butane (SPBT, or a mixture of propane-butane technical). LPG - the most common type of liquefied gas - in this form, this product is supplied to the public, industrial enterprises and sent for export. Also, by separation of NGL, technical butane and technical propane, automobile propane (PA) or mixture of PBA (propane-butane automobile) are obtained. There are other components that produce by processing NGF. These are isobutane and isobutylene, pentane, isopentane. NGL is used as a raw material by petrochemical enterprises to obtain, first of all, the method of fractionating individual hydrocarbons (propane, butane, pentane) and a wide range of products for further processing of individual hydrocarbons: rubber, plastic, ethanol, solvents, components of high-octane gasolines. The propane-butane mixture released from the NGL can be used as a gas engine fuel, as an alternative to the usual gasoline and diesel fuel. Recently, the use of NGL as a raw material in the process of pyrolysis has acquired particular relevance. The resulting ethylene and propylene, are sent to the production of polyethylene and polypropylene (the most common in the use of polymers).