Gas Conditioning and Processing
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Did you know that modern gas plants now restore TEG dehydration performance by removing fouling and repairing purifier filters to stabilize dew point control, can lose more than 350,000 liters of glycol per year if flash tanks and circulation rates are poorly designed, and increasingly adopt compact floating LNG facilities that integrate pre‑treatment, NGL recovery, and liquefaction on a single offshore hull to monetize remote gas?
Course Overview
The Gas Conditioning and Processing course by Rcademy is designed to equip process engineers, operators, production operations engineers, field supervisors, facility engineers, design engineers, project managers, maintenance and reliability engineers, plant supervisors, operations managers, technical specialists, and HSE professionals with comprehensive understanding of gas field production facilities, gas conditioning and processing technology, and equipment used in separation and gas treating systems. Participants gain expert knowledge of gas dehydration operations using absorption, adsorption, refrigeration and low-temperature separation techniques, gas sweetening technologies for acid gas removal, NGL recovery systems, fractionation units, phase behavior analysis, and thermodynamic properties critical to gas processing design.
Without specialized gas conditioning and processing training, professionals may struggle to design TEG dehydration systems, troubleshoot glycol losses and regeneration issues, configure amine treating for H2S/CO2 removal, optimize NGL recovery using turbo-expander systems, analyze vapor-liquid equilibrium for separation processes, or implement systematic debottlenecking strategies, limiting their ability to support efficient gas plant operations and meet pipeline specifications. This comprehensive course provides a structured path to mastery across natural gas processing fundamentals, thermodynamics and phase behavior, gas-liquid separation systems, dehydration technologies, gas sweetening and acid gas removal, mercury removal, hydrate prevention, NGL recovery and fractionation, compression systems, process control, and practical troubleshooting methodologies, preparing attendees to lead gas processing optimization and reliability initiatives.
Why Select This Training Course?
The Gas Conditioning and Processing course covers introduction to natural gas processing, thermodynamics and phase behavior, gas-liquid separation systems, gas dehydration using absorption processes (TEG, DEG, MEG), gas dehydration using adsorption and alternative methods, gas sweetening and acid gas removal (amine treating, Claus process), mercury removal, hydrate prevention and management, natural gas liquids (NGL) recovery, fractionation and product separation, compression systems, heat transfer and refrigeration, process control and instrumentation, fluid flow and pumping systems, gas measurement and quality analysis, plant operations and safety, troubleshooting and optimization, emerging technologies (FLNG, CCS, hydrogen production), and practical exercises with real-world case studies. Participants learn to design TEG dehydration unit components (contactor, regenerator, flash tank, filters, coolers), configure amine sweetening systems with proper circulation and regeneration, size separators with appropriate retention time and droplet settling, perform hydrate formation prediction and prevention, optimize NGL recovery using refrigeration and turbo-expander systems, troubleshoot fractionation column issues, and apply systematic performance optimization methodologies.
Real-world cases show how Saudi Aramco’s investigation of erratic sour-gas dew point performance at Khurais Central Processing Facility revealed activated-carbon and black-powder deposits in TEG distributor channels and damaged purifier filters, with corrective actions including cleaning internals, repairing filters, and restoring operating conditions returning the plant to design-basis performance with stable gas moisture dew point.
Studies also show that Shell’s Utorogu gas plant in Nigeria experienced glycol losses of 356,605 liters per year due to excess glycol circulation, absence of flash tank separator, use of gas-driven pumps, and over-circulation of stripping gas, with recommended solutions including flash tank separator installation, glycol and stripping gas circulation optimization, and improved pump selection.
Take charge of your gas processing expertise. Enroll now in the Rcademy Gas Conditioning and Processing course to master the design and troubleshooting skills that drive reliable plant operations.
Who Should Attend?
The Gas Conditioning and Processing course by Rcademy is ideal for:
- Process engineers and operators in natural gas production
- Production operations engineers and field supervisors
- Facility engineers and design engineers
- Project managers overseeing gas processing projects
- Maintenance and reliability engineers
- Plant supervisors and operations managers
- Technical specialists in gas treatment facilities
- HSE professionals in gas processing
- Dehydration unit operators
- Gas sweetening specialists
- NGL recovery engineers
- Fractionation plant engineers
- Compression system engineers
- Process optimization specialists
- Anyone seeking comprehensive gas processing certification
What are the Training Goals?
The main objectives of the Gas Conditioning and Processing course are to enable professionals to:
- Master fundamental concepts and techniques for designing, specifying, and managing gas field production facilities and processing plants.
- Understand comprehensive gas conditioning and processing technology including equipment and processes used in separation and gas treating systems.
- Execute gas dehydration operations using absorption, adsorption, refrigeration, and low-temperature separation techniques.
- Implement gas sweetening technologies for acid gas removal (H2S, CO2) to meet pipeline and sales specifications.
- Design and operate natural gas liquid (NGL) recovery systems, fractionation units, and hydrocarbon processing facilities.
- Analyze phase behavior, vapor-liquid equilibrium, and thermodynamic properties critical to gas processing design.
- Troubleshoot equipment and systems used in gas conditioning including separators, compressors, TEG units, and amine systems.
- Apply risk management, safety protocols, and environmental compliance standards in gas processing operations.
How Will This Training Course Be Presented?
At Rcademy, the extensive focus is laid on the relevance of the training content to the audience. Thus, content is reviewed and customised as per the professional backgrounds of the audience.
The training framework includes:
- Expert-led lectures by senior gas processing professionals using audio-visual sessions
- Hands-on exercises with separator sizing calculations and TEG unit mass balance
- Interactive workshops for amine sweetening system design and troubleshooting scenarios
- Case studies covering Saudi Aramco Khurais TEG dehydration troubleshooting, Shell Utorogu glycol loss analysis, and Petronas FLNG Satu compact gas conditioning
- Practical labs for NGL recovery optimization and fractionation column troubleshooting
The theoretical part of training is delivered by an experienced professional from the relevant domain, using audio-visual presentations. This gas processing-focused approach ensures professionals translate theory into practical workflows through TEG unit design, amine system configuration, separator optimization, and systematic troubleshooting methodologies.
This comprehensive certification model ensures participants gain both gas processing fundamentals and hands-on proficiency to immediately apply design and optimization expertise in dehydration, sweetening, NGL recovery, and plant troubleshooting roles.
Register now to experience a rigorous, hands-on learning journey designed to equip you for leading gas processing design, optimization, and troubleshooting projects.
Course Syllabus
Module 1: Introduction to Natural Gas Processing
- Fundamentals of natural gas engineering and production systems.
- Physical and chemical properties of natural gas: composition, density, heating value, viscosity.
- Overview of natural gas production: associated and non-associated gas, impurities, and contaminants.
- Natural gas specifications: pipeline quality, export specifications, and contract requirements.
- Introduction to NGL (Natural Gas Liquids), GTL (Gas-to-Liquids), and LPG (Liquefied Petroleum Gas).
- Contract terms, heating value (BTU/calorific value), and Wobbe Index significance.
Module 2: Thermodynamics and Phase Behavior
- Basic thermodynamic concepts for gas processing: pressure, temperature, enthalpy, entropy.
- Physical properties of hydrocarbons and hydrocarbon mixtures.
- Qualitative phase behavior: single component and multicomponent systems.
- Vapor-liquid equilibrium (VLE) and phase diagrams for natural gas systems.
- Water-hydrocarbon phase behavior: hydrate formation, water content, dew point.
- Equations of state: ideal gas law, real gas behavior, and compressibility factor.
Module 3: Gas-Liquid Separation Systems
- Principles of gas-liquid separation and two-phase flow.
- Separator types: vertical, horizontal, and spherical separators.
- Separator design considerations: sizing, internals, retention time, droplet settling.
- Three-phase separators for oil, gas, and water separation.
- Slug catchers and scrubbers for liquid knockout.
- Separator performance optimization and troubleshooting.
Module 4: Gas Dehydration – Absorption Processes
- Purpose of gas dehydration: hydrate prevention, pipeline corrosion, meeting specifications.
- Absorption dehydration using glycols: TEG (Triethylene Glycol), DEG, MEG.
- TEG dehydration system components: contactor, regenerator, flash tank, filters, coolers.
- TEG unit operation: gas-glycol contact, rich glycol circulation, regeneration process.
- Glycol regeneration: stripping gas, DRIZO process, and Coldfinger technology.
- Dew point control and depression requirements.
- Alternative operating conditions and optimization of TEG systems.
Module 5: Gas Dehydration – Adsorption and Alternative Methods
- Adsorption dehydration using solid desiccants: molecular sieves, silica gel, alumina.
- Adsorption tower design, sizing, and cycle operations.
- Regeneration of solid desiccants: thermal swing and pressure swing adsorption.
- Refrigeration and low-temperature separation (Joule-Thomson effect).
- Comparison of dehydration methods: absorption vs. adsorption vs. refrigeration.
- Selection criteria based on feed gas conditions and product specifications.
Module 6: Gas Sweetening and Acid Gas Removal
- Purpose of gas sweetening: H2S and CO2 removal for safety and corrosion control.
- Amine treating systems: MEA, DEA, MDEA, and specialty amines.
- Amine sweetening process: absorption, rich/lean amine circulation, regeneration.
- Amine contactor and regenerator design and operation.
- Alternative sweetening technologies: solid bed scavengers, membranes, physical solvents (Selexol, Rectisol).
- Sulfur recovery: Claus process and tail gas treatment.
- Acid gas injection and disposal considerations.
Module 7: Mercury Removal
- Mercury in natural gas: sources, forms, and impact on equipment and operations.
- Mercury removal technologies: fixed bed adsorption, activated carbon, metal sulfides.
- Mercury removal unit design and operation.
- Monitoring and measurement of mercury concentrations.
- Disposal and regeneration of mercury-laden adsorbents.
Module 8: Hydrate Prevention and Management
- Hydrate formation conditions and thermodynamic prediction.
- Hydrate problems: plugging, flow restriction, equipment damage.
- Hydrate prevention methods: dehydration, insulation, heating, chemical inhibition.
- Thermodynamic inhibitors: methanol, ethylene glycol (MEG).
- Low-dosage hydrate inhibitors (LDHI): kinetic and anti-agglomerant inhibitors.
- Hydrate remediation techniques for existing blockages.
Module 9: Natural Gas Liquids (NGL) Recovery
- NGL composition: ethane, propane, butanes, pentanes, and heavier hydrocarbons.
- NGL recovery principles and economic drivers.
- Refrigeration processes for NGL extraction.
- Turbo-expander systems for deep ethane and NGL recovery.
- Cryogenic processing and low-temperature separation.
- NGL recovery optimization and troubleshooting.
Module 10: Fractionation and Product Separation
- Fractionation principles: distillation, vapor-liquid equilibrium, relative volatility.
- Demethanizer, deethanizer, depropanizer, and debutanizer columns.
- Fractionation column design: trays, packing, reflux ratio, feed location.
- Product specifications: commercial propane, commercial butane, natural gasoline.
- Fractionation column operation and control.
- Troubleshooting fractionation issues: flooding, weeping, poor separation.
Module 11: Compression Systems
- Purpose of compression in gas processing: pressure boosting, gas lift, reinjection.
- Reciprocating compressors: types, operation, and maintenance.
- Centrifugal compressors: principles, performance curves, surge control.
- Compressor selection criteria based on flow, pressure ratio, and gas composition.
- Compressor station design and auxiliaries: coolers, separators, anti-surge systems.
- Compressor troubleshooting and performance optimization.
Module 12: Heat Transfer and Refrigeration
- Heat transfer fundamentals: conduction, convection, radiation.
- Heat exchangers: shell-and-tube, plate-frame, air-cooled exchangers.
- Refrigeration cycles: vapor compression, cascade refrigeration.
- Refrigerants: selection, properties, and environmental considerations.
- Refrigeration system components: compressors, condensers, evaporators, expansion valves.
- Refrigeration troubleshooting and efficiency optimization.
Module 13: Process Control and Instrumentation
- Process control fundamentals: feedback, feedforward, cascade control.
- Control loops for gas processing: level, pressure, temperature, flow control.
- Instrumentation: transmitters, control valves, analyzers, safety systems.
- Distributed Control Systems (DCS) and SCADA for gas processing plants.
- Alarm management and safety instrumented systems (SIS).
Module 14: Fluid Flow and Pumping Systems
- Fluid flow principles: laminar vs. turbulent flow, pressure drop, friction losses.
- Pipeline design and sizing for gas and liquid systems.
- Pump types: centrifugal, positive displacement, diaphragm pumps.
- Pump selection, sizing, and performance curves.
- Cavitation, NPSH (Net Positive Suction Head), and pump troubleshooting.
Module 15: Gas Measurement and Quality Analysis
- Fluid measurement techniques: orifice meters, turbine meters, ultrasonic meters, Coriolis meters.
- Gas sampling and laboratory analysis procedures.
- Gas chromatography for composition analysis.
- Heating value, specific gravity, and Wobbe Index determination.
- Field vs. fiscal measurement: accuracy, uncertainty, and error analysis.
Module 16: Plant Operations and Safety
- Normal operating conditions and process monitoring.
- Abnormal conditions: upset scenarios, emergency shutdown procedures.
- Start-up and shutdown procedures for gas processing units.
- Hazard identification: HAZOP, risk assessment, and mitigation strategies.
- Process safety management and emergency response planning.
- Environmental compliance: emissions monitoring, flaring, venting regulations.
Module 17: Troubleshooting and Optimization
- Systematic troubleshooting methodology for gas conditioning systems.
- Common operational problems: foaming, corrosion, fouling, capacity limitations.
- Performance optimization: energy efficiency, product recovery, debottlenecking.
- Monitoring and metrics: KPIs for gas processing plants.
- Predictive maintenance and reliability engineering.
Module 18: Emerging Technologies and Future Trends
- Floating LNG (FLNG) and offshore gas processing.
- Modular and small-scale gas processing units.
- Carbon capture and storage (CCS) integration with gas processing.
- Digitalization: advanced process control, AI/ML for optimization.
- Hydrogen production from natural gas: steam methane reforming, blue hydrogen.
Module 19: Practical Exercises and Case Studies
- Hands-on: separator sizing calculations and design exercises.
- Hands-on: TEG dehydration unit mass balance and performance calculations.
- Hands-on: amine sweetening system design and troubleshooting scenarios.
- Case studies: real-world gas processing plant challenges and solutions.
- Field application analysis and optimization opportunities.
Training Impact
The impact of Gas Conditioning and Processing training is visible in how operators improve TEG dehydration performance through systematic troubleshooting, reduce chemical losses and operating costs through better system design, and monetize remote gas reserves via FLNG technology.
Saudi Aramco – Improving TEG Dehydration Performance at Khurais Central Processing Facility
Implementation: At Saudi Aramco’s 1.2-million b/d Khurais Central Processing Facility (KhCPF), a 2017 study investigated erratic sour-gas dew point performance in TEG dehydration units where spikes in TEG reboiler temperature caused lean TEG purity to drop below the 98 wt% target and sour-gas dew point to approach the maximum allowable specification. The facility processes gas from multiple producing wellheads, with dehydration systems critical for meeting pipeline specifications and preventing downstream corrosion and hydrate formation. Internal inspection revealed activated-carbon and black-powder deposits accumulating in the TEG distributor channel and physical damage to TEG purifier filters, with downstream spools and lines heavily clogged by sludge issues traced to inadequate monitoring of filter performance. The investigation employed detailed process analysis, equipment inspection during turnaround, and systematic review of operating parameters including TEG quality, filter pressure drop, and reboiler temperature.
Results: After turnaround and inspection, including cleaning internals, repairing filters, and restoring correct operating conditions, the plant returned to design-basis performance with stable gas moisture dew point. Lean TEG purity was stabilized above 98 wt%, and sour-gas dew points were brought back within sales gas limits, reducing off-spec gas risk and minimizing unplanned downtime. This kind of systematic optimization protected revenues tied to strict pipeline and export specifications, demonstrating the importance of continuous monitoring of TEG quality, filter pressure drop, and reboiler temperature exactly the type of troubleshooting and optimization skills covered in advanced TEG modules. The case illustrates how professionals trained on root cause analysis can move from symptoms (dew-point instability, high water content) to corrective actions and optimized operating windows, directly supporting senior process, operations, and troubleshooting roles in gas plants.
Shell – TEG Dehydration Losses and Remediation at Utorogu Gas Plant (Nigeria)
Implementation: A case study of Shell’s Utorogu gas plant in Nigeria examined TEG-based gas dehydration and identified key problems including insufficient dehydration in the absorber, foaming, hydrocarbon solubility in TEG, vaporization loss, salt contamination, glycol degradation, corrosion from acid gases, and over-circulation of stripping gas. The Utorogu facility is a major gas compression and dehydration plant operated by Shell Petroleum Development Company (SPDC) in Ughelli, processing associated gas from oil production fields. Analysis showed that emissions and glycol losses from the dehydration unit were primarily due to excess glycol circulation, absence of a flash tank separator, use of gas-driven pumps, and over-circulation of stripping gas, leading to excess glycol loss estimated at 356,605 liters per year evidence of inefficient operation and poor cost control. The study performed sensitivity analysis of process parameters such as inlet gas temperature, lean TEG temperature, reboiler temperature, stripping gas flowrate, and lean glycol circulation rate to identify optimization opportunities.
Results: The study recommended installing a flash tank separator, optimizing glycol and stripping gas circulation rates, improving pump selection by replacing gas-driven pumps with electric pumps, and enhancing corrosion and contamination control practical, calculation-driven decisions that mirror course exercises on TEG unit design, mass balance, and performance optimization. By redesigning the dehydration system with these modifications, operators could sharply cut chemical consumption estimated at over 350,000 liters per year, reduce emissions of volatile organic compounds (BTEX), and improve overall plant economics. Additional recommendations included turn-around maintenance of the entire glycol plant system, frequent draining and reclaiming of glycol to prevent dissolved salt from exceeding maximum allowable concentration, adding amine solution to provide corrosion protection from acid gases, keeping reboiler temperature below 402°F to prevent thermal degradation, and adequate separation of liquid hydrocarbons, salts, and solids to avoid foaming. This case demonstrates how professionals who can build data-driven business cases for debottlenecking, energy reduction, or chemical savings become key contributors to investment decisions and continuous improvement programs.
Petronas – FLNG Satu Offshore Malaysia and Compact Gas Conditioning/Liquefaction
Implementation: Floating LNG technology has been demonstrated by Petronas FLNG Satu, the world’s first operational floating LNG facility, which processes gas from the Kanowit field offshore Sarawak, Malaysia and integrates gas separation, dehydration, sweetening, NGL removal, and liquefaction on a single floating platform. PFLNG Satu is 365 metres long with a dry weight of 132,000 tonnes and was constructed at Daewoo Shipbuilding & Marine Engineering Co. Ltd (DSME) shipyard in South Korea before being towed 2,120 nautical miles to its location 180 kilometres offshore Sarawak in May 2016. The facility achieved first gas on 14 November 2016 with a production capacity of 1.2 million tonnes per annum (mtpa), becoming operational in 2017. Reviews of FLNG developments highlight how Petronas FLNG Satu uses modular, compact process schemes and mixed-refrigerant liquefaction cycles to reduce equipment count and footprint while maintaining energy-efficient LNG production, thereby enabling commercialization of remote offshore gas fields that would be uneconomic with long export pipelines and onshore plants.
Results: This FLNG approach lets operators monetize remote or marginal gas reserves that would otherwise remain stranded, while compact, energy-efficient liquefaction schemes reduce CAPEX and OPEX per unit of LNG produced. The facility eliminated the need for long export pipelines and large onshore plants, validating FLNG technology’s versatility in navigating complex offshore conditions and solidifying its position as a reliable solution for harnessing gas resources in challenging marine environments. These projects rely on robust upstream gas treatment including acid gas removal, mercury removal, and dehydration, advanced process control, and rigorous safety and environmental management capabilities that are central to modern gas conditioning and processing curricula. Understanding how Petronas FLNG Satu combines dehydration, sweetening, NGL removal, and liquefaction on a constrained floating footprint prepares engineers for offshore roles where weight, space, and maintainability are critical design drivers, with skills in compact process configuration, modular design, and safety/environmental management in FLNG contexts increasingly valued as more operators pursue floating gas processing solutions.
Be inspired by how global operators stabilized gas quality, cut glycol losses, and delivered first of its kind LNG operations. Join the Rcademy Gas Conditioning and Processing course to gain the design and troubleshooting skills that keep gas plants running reliably.
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Our course consultants on most subjects can cover about 3 to maximum 4 modules in a classroom training format. In a live online training format, we can only cover 2 to maximum 3 modules in a day.
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