FEED Verification for a 5 Billion Cubic Meters per Year Gas Processing Plant: Ensuring Design Excellence and Project Readiness

In a recent project, the PMech team was engaged verify the Front-End Engineering Design (FEED) and Safety studies for a Gas Processing facility with a staggering capacity of 5.0 Billion standard cubic meters per year. To put that in perspective — it’s enough to power over 20 million households annually. This facility isn’t just large on paper — it plays a real, strategic role in supporting industrial demand and contributing to the global energy transition.

Projects of this scale demand more than drawings and datasheets. They require thoughtful engineering, technical depth, and a relentless focus on safety and quality. At PMech, that’s exactly what we bring to the table.

Scope & Complexity :

The scope was substantial: with 400 P&IDs (240 for core process units and 160 for utilities). Handling this quantum is no small task – modern gas plants often involve hundreds of pieces of equipment.

At its core, the facilities are built around a series of highly integrated process units – each demanding deep domain expertise and a disciplined review approach. The different units were:

• Inlet Gas Separation Unit :
Validating feed composition data, separator sizing, and slug handling capacity to ensure stable operation under all loads.
• Acid Gas Removal Unit (AGRU) :
Sulfinol system, reviewed for solvent circulation rates, and H2S/CO2 removal efficiency.
• Gas Dehydration Unit :
Assessment of glycol circulation loops, reboiler sizing and dehydration efficiency for pipeline quality gas.
• Sulphur Recovery Unit (SRU) :
A two stage Claus process verified for air fuel ratio balance, catalyst performance, and overall sulfur recover efficiency.
• Sour Water Treatment (Chemical Oxidation) Unit :
Designed to treat sour water containing H2S & NH3.

Each of these process units forms the operational backbone of the gas processing plant, and every process unit was meticulously verified to ensure and check design compliance.

Supporting this critical process system are several equally important Utility systems which included the full range of gas plant utilities like:

  • Formation Water Treatment
  • Sulfur Solidification
  • Acid Gas Flare System
  • Steam and Boiler Feedwater System
  • Demineralized Water System
  • Wastewater Treatment System
  • Firewater System
  • Nitrogen System (instrument air/N₂ generation)
  • Hot Water System (plant heating medium)

Project Outcome :

  • Early identification of design gaps during FEED reduced project risks, prevented costly rework, and ensured smoother downstream execution.
  • Embedding hazard mitigation and safety controls in the FEED design.
  • Early identification of overdesigns and unnecessary redundancies led to better material and equipment sizing — translating into CAPEX savings.
  • The design reached a higher maturity level before EPC kickoff, minimizing ambiguity and boosting readiness for procurement and construction phases.

Next Steps :

PMech’s success on this gas-processing FEED verification highlights the value a rigorous design review brings to large-scale projects. When you’re embarking on any facility FEED, we can provide the same depth of support—closing design gaps, validating critical engineering assumptions, and helping you lock down a safe, executable design.

We can step in as your third-party reviewer, Owner’s Engineer, Project Management Consultant, or simply your engineering and design partner for the complete scope—ensuring technical clarity and project readiness at every stage.

Contact PMech today or write to info@pmecheng.com to learn how our FEED and FEED verification services can help your project start right.