ASME

INTRODUCTION

Gasco Combustion, Process and Thermal Engineering

Gasco Pty Ltd has established a reputation

as Australias leading combustion and
process engineering company.
Gasco was formed in 1991 and is an
independent, 100 per cent Australian owned
company. Its board and management are
acknowledged for their experience and
expertise in the industry.
Gasco, with its highly skilled, multicultural staff
and its modern office and manufacturing
facility is able to offer a comprehensive range
of equipment and services including design,
engineering, project management, fabrication,
installation, commissioning and service.
The equipment and complete systems provided
by Gasco include water bath heaters, thermal
oxidizers, fired heaters, thermal oil heaters,
flares, heat recovery systems, HRSG boilers,
burner management systems and gas
conditioning including: metering skids, pressure
control skids and filter coalescers.

Gasco has supplied

Fired Heaters to
Pakistan, Turkmenistan
and UAE, Smelter
Burners to China and
India, Crude Oil & Gas
Heaters to Russia,
Thermal Oxidizers to
Pakistan, Hot Oil
Heaters to Indonesia,
South Africa, Tanzania,
Malaysia and the
Philippines, Convective
Condensate Heaters to
Thailand, Flares to Vietnam, Gas Skids to
Bahrain, Burner Management System to UAE
and Fuel Gas Skid package to Oman.
Gasco holds ASME U, U2 and S stamps
for the design and manufacture of Pressure
Vessels and power to Power Boilers and an
ASME R stamp to repair Pressure Vessels and
Boilers to NBIC Codes..
Gasco has been presented with Industry
Achievement Awards from ICN and Innovation
Australia and Directors Award from Santos for
EHS performance. Gasco was also featured in
Business Review Australia and Resource in
Focus magazines in 2013.
Quality Assurance and Health & Safety are key
aspects to all our projects. Gasco is certified by
DNV to the requirements of ISO 9001:2008.

Gasco has a wide range of clients across various

industries including oil and gas both onshore
and offshore power generation, environmental,
mining, mineral, chemical processing, refining
and petrochemical, food, automotive, waste
water treatment and biogas.

Gasco clients include Shell, Petronas, Exxon

Mobil, BP, Chevron, Conoco Phillips, Toyota,
Boeing, Total, Dolphin Energy, Jemena, AGL
Energy Australia, Origin Energy, APA Group,
Orica, BHP Billiton, Bechtel, KBR, Worley
Parsons, Clough, Uhde Shedden, Technip,
Santos, Wood Group PSN, Oil Search, Power &
Water, Pertamina, Foster Wheeler, Zadco and
many others.

(Left to right): Ed Strauks Engineering Director,

John Peruzzo Director/Chairman,
Nicholas Grzegorczyn Managing Director/CEO,
Ian Matthews Sales & Marketing Director,
Alan Hovorka Engineering Director.

THERMAL OXIDIZERS
Thermal Oxidizers are a class of pollution control
devices that use the combustion process to destroy
HCs, volatile organic compounds (VOC) and
Hydrogen Sulphide, hence they are sometimes
called afterburners, fume incinerators or tail gas
incinerators.

Gasco Thermal Oxidizers include:

Straight Thermal Oxidizers with or without heat
recovery
Recuperative
Catalytic
Regenerative (RTO)
Gasco Thermal Oxidizers can handle a wide range
of process parameters including variable waste flow
rates, calorific values, temperature and oxygen
content.
Features of our Thermal Oxidizers are their robust
performance, ability to operate at high thermal
efficiency and achieve >99.99 per cent destruction
efficiency.
Gasco Thermal Oxidizers scope may include turnkey
projects, designed to comply with our clients
specifications and environmental authority
regulations.
We have supplied Thermal Oxidizers to the oil and
gas, chemical, automotive, medical, food, minerals
and metals industries.
Heat from the exhaust of a Thermal Oxidizer can be
recovered in a Waste Heat Recovery Unit, energy
can be utilized in the form of heat transfer fluids
oil, water, air and to raise steam.
A Gasco RTO can provide average thermal efficiency
of up to 95+% and use about 20 times less fuel
than a TO with no heat recovery. In some
applications the VOC present in the waste gas
stream may enable the Gasco RTO to operate
without any supplementary fuel gas (except at start
up). Destruction efficiency of up to 99.5+% is
achievable.

Top: RTO for Woodside Pluto LNG, Acid Gas project

loaded on ship at BAE Systems Melbourne, Australia.
Centre: Recuperative Thermal Oxidizer for Conoco
Phillips Darwin LNG plant.
Bottom: Bottom: Thermal Oxidizer and Hot Oil Heat
Recovery OMV/Clough Sawan, Pakistan.
3

F I R E D H E AT E R S
Gasco supplies Fired Heaters to API 560 and
ISO 13705 and proprietory Gasco forced draft
convective designs.

A typical API 560 Fired Heater would consist of a:

Radiant Section
Convective Section
Stack
Burners
Fuel Skid
Control System

Gasco being both a combustion and heat transfer

company is uniquely placed to achieve the best
possible outcomes with respect to high thermal
efficiencies, low emission, reliable operation and
state-of-the-art Burner Management Systems (BMS)
to NFPA, IEC and other codes.
Gasco can supply cylindrical or box cabin type direct
fired heaters, equipped with low NOx natural draft
or forced draft burners.
To increase efficiency, preheating of combustion air
can be achieved by adding a variety of air preheater
exchangers.
With the demand for ever increasing safety and
reliability levels Gasco can design and supply BMS to
IEC 61508 Programmable Electronic Safety Systems.
We can also provide a basic hard wired system up
to SIL 3.
Gasco convective heaters rely on forced convection
heating only, are compact and can achieve thermal
efficiency of 90 per cent using convective heat
transfer.
Fired Heater Upgrades for Existing units.
Gasco has upgraded old existing heaters to improve
efficiency, safety and emissions using the latest PLC
based BMS and NOx reduction technology.

Top: Forced Convection Regeneration

Gas Heater, APA Group.
Centre: Origin Energys Bassgas 43MW Fired Heater
project, South Gippsland, Victoria, Australia.
Bottom: Fired Heaters Turkmenistan gas plant
18.8MW each.
4

WAT E R B AT H H E AT E R S
Water Bath Heaters are Indirect Fired Type
usually designed to API 12K, these devices are
traditionally used to heat natural gas and oil.

Water Bath Heaters can also be used for heating:

High pressure gas

Crude Oil
Vaporizing and superheating LPG & LNG
Regeneration Gas Heating
Heat Transfer Fluids
Heat sensitive gas and fluids
Molten Salt Heaters
Direct Fired Reboilers
Amine Reboilers
TEG Reboilers

The main application for Indirect Fired Water Bath

Heaters is to heat high pressure gas prior to
pressure reduction, this prevents hydrate formation
that can occur because of the temperature drop
due to the Joule Thomson effect. The natural gas
can also be post heated to suit the operation of gas
turbines.
A typical water bath heater consists of an insulated
shell, removable process coil, removable fire tube,
stack burner, gas train and control system.
Gasco options include:

Natural Draft Burners

Forced Draft Burners
Pneumatic Gas Control
Electric (Electronic) Control
Remote Monitoring

Gasco can also supply complete gas conditioning

skids consisting of Water Bath Heater, Pressure
Reduction, Filter Coalescer and Metering.

Top: 3,500KW Crude Oil Heating Sakhalin,

Russian Federation Exxon.
Centre: 6,300KW Gas Turbine Water Bath Heater,
NSW Australia Jemena.
Bottom: Todd Energy API 12K Well Head Heater,
New Zealand Todd Energy.
5

FLARES
Gasco together with our technology partner has
supplied flares to the oil and gas, flares for
petrochemicals, flares for terminals, flares for
landfill and flares for sewage (biogas) industries.

Flares type
Utility (Pipe) flares
Steam Assist flares
Air Assist flares
Gas Assist flares
High Pressure Staged
flares
Enclosed Ground flares
Pit/Ground flares
Flame support
structures
Self Supporting
Guyed
Derrick
Purge seals
Dynamic
Molecular
Non Pulsating Liquid
Vessel
Ancillaries
Knock Out Drums
Staging control
Control systems:
hazardous and
non hazardous
area rated
Snuffing
Remote Flame
Radiation Shields
Seal Drums
Flame and Detonation
Arrestors
Platforms
Consulting
Radiation shields for
offshore

Applications
Gas treatment plants
Gas well testing
LNG plants
Oil refining
Landfill gas (LFG)
Sewage lagoons
Digestor gas
Coal seam methane
(CSM)
Coal mine drainage
Metal smelting
Biofuels
Codes
To Australian and
Regional codes and
standards
Type B Systems
Monitoring
Thermocouple
Remote IR
Installations
Commissioning
Gasco own crew
Supervision of third
parties
Commissioning is
routine
Service
By Gasco TypeB
technicians
24 hour on call service
Engineering support

Top: Flare, Mole Seal, Dual Ignition Electronic & Flame Front
Generator. Coal Seam Methane, Santos.
Centre: Five Coal Seam Methane Enclosed Flares, Anglo Coal.
Bottom: Self supporting Flare for Nickel Smelter, BHP Billiton.
6

H O T O I L H E AT E R S
Gasco supplies a range of Hot Oil Heaters:
100KW to 15,000KW gas fired, 25KW to
1,500KW electric.

The gas fired heaters consist of two concentric helical

coils which has the advantage of:

Compactness
High Efficiency
Low Thermal Mass
Low weight (ideal for offshore applications)

The dual helical coil design allows maximized heat

transfer, minimises thermal stresses and prevents
overheating. The coil design has the advantage that
ensures high fluid velocities, low film temperatures and
no accumulation of gases.
The burner can be selected to suit the application, type
of fuel gas, oil, heavy oil, timber and turndown. The
flame shape is carefully matched to the coil
configuration. Typical efficiency with air preheating can
range up to 90+ per cent depending on thermal fluid
outlet temperature, fuel, and atmospheric conditions.
Each heater has a pre wired control panel that ensures
safe and efficient operation of the heater.
As well as supplying heaters, we can provide skid
mounted units that incorporate primary and secondary
pumps, expansion tanks, stack and drain/fill tanks.
There are a myriad of applications that are suitable for
hot oil heating.

Gas Plant Regeneration

Tank Heating Bitumen, Wax, Emulsions
Reactor Heating Chemical Industry, BioTech
Platen Presses Timber Industry, Moulding
Hollow Flight Screws Mineral Processing
Pipe Tracing Heavy Fuel Oil, Bitumen, Wax
Ovens Printing, Automotive
Extruders Plastic
Fryers Food
Calendar Rolls Plastic, Film
Autoclaves Aerospace, Rubber, Brick
Dryers Timber, Food
Kilns Timber

Gasco can supply a stand-alone heater or a total

engineered package to suit any or all of the above
applications. Turnkey bitumen heating is a speciality.
Top: 2,500KW Thermal Oil Heater & Pump Skid Santos
Gas Plant, Victoria, Australia.
Centre: 11,000KW Hot Oil Heater for Chevron offshore
platform, South East Asia.
Bottom: Hot Oil Heater Package, New Zealand.
7

GAS CONDITIONING AND CONTROL SKIDS

Gasco designs, fabricates, commissions and
services an extensive range of Process
Skids for Gas Conditioning and Oil
Treatment including:

Emergency Shut Down Systems

Filter Coalescers
Custody Transfer Metering with Analysers
Hot Water Heater/HX gas heating
Water Bath Heaters API 12K
Pressure Reduction Stations
Black Start Heaters (Electric/steam/hot water)
Waste heat recovery for gas heating
Total gas conditioning systems for Power
Stations a speciality

Gasco designs and builds skid mounted equipment to meet

client, Australian and International Standards including:
AS1210 AS4140, ASME B31.3, API 12K, etc.
Gasco utilizes 3-D CAD systems to model layouts and
enhance layout detail design. Equipment and piping are
sized utilizing in-house computer programming and well
known proprietary software. Piping and flange loads are
computer calculated.
Instrumentation and controls are normally part of scope and
skids are prewired and functionally factory acceptance tested
(FAT) before leaving our workshop.
Multiple skids may be trial interconnected and tested before
disassembly for transport. Additional features may include
hot or cold insulation and heat tracing.

Gasco has supplied gas conditioning systems for GE, Rolls

Royce, Pratt & Whitney and Siemens gas turbines.

Top: Origin Energy Pressure Reduction Skid

Mortlake Power Station, Victoria.
Middle: Pressure reduction and associated skids for
Gas Fired Power Station in Northern Territory.
Bottom: Filter Coalescer, Mortlake Power Station
8

WA S T E H E AT R E C O V E RY
Waste Heat Recovery systems reduce energy
costs, provide carbon credits for emission
trading systems and help the environment
by reducing emissions.

Gasco provides a comprehensive range of Waste Heat

Recovery systems for the following:

Gas Turbines Thermal Oil, Hot Water, Glycol

Gas and Diesel Engines
Thermal Oxidizers Thermal Oil, Glycol
Air Preheat / Recuperators
Furnaces
Heat Recovery Steam Generators (HRSGs)

For gas turbine heat recovery systems Gasco offers a

complete turnkey plant comprising:

Inlet duct
Divertor valve
Divertor stack
Supplementary burner and controls
Waste Heat Recovery Unit
Exhaust Stack

Gasco can provide for either individual pieces of equipment

or supply a complete turnkey operating system for either a
new application or modifying an existing plant.
Our range of services includes:

Survey / Analysis of existing systems

Engineering
Hardware
Hot Oil, Hot Water or Steam distribution systems
Erection
Commissioning
Turnkey Solution
Heat Recovery Steam Generators HRSGs

Gasco is a licensee of ERK, Berlin, Germany for their world

famous Corner Tube Heat Recovery and Steam Generators
and Boilers.
To date over 6,000 ERK boilers, HRSGs and high
temperature recuperators have been supplied world wide.

Top: Waste Heat Recovery Energy, Australia.

Centre: BHP Macedon. 3x3MW WHRU on Solar Turbines.
Bottom: HRSG for Australian food company.
9

G R I M W O O D E L E C T R I C H E AT I N G S Y S T E M S
Gascos Grimwood Heating Range now provides
complete electric heating systems to complement its
range of combustion products. Circulation Heaters
and Tank Heaters are available to heat virtually any
gas or liquid.

Element Bundle and

pressure Vessel.

Gasco can supply nonhazardous or IECEx certified

flameproof heaters suitable
for hazardous areas.
Features include:
Custom designs to
specified process
conditions.
System includes Element
Bundle, Pressure Vessel and
Control Panel.
Small footprint, low
maintenance, low
operating costs, accurate
control.

Typical applications:
J-T Effect Compensation
Heaters
Fuel Gas Heaters
Thermal Oil Heraters
Winter Diesel freeze
protection
Industrial Processing Tanks
Water Heaters
Steam Superheaters
Re-Boilers and Vapourizers
Process Fluid
Corrosive Materials

BURNERS AND COMBUSTION

Gasco prides itself as a combustion company

on its ability to creatively solve your
combustion problems.

Gasco can supply a solution to your combustion

requirements. We design and manufacture specialized
burners and systems such as 40GJ /h smelter start-up burners.
We also incorporate other leading proprietary brands of
burners in combustion packages to provide our clients with
the most cost effective solution. Specifically, we can offer:
Low NOx
Recirculated
Combustion Gas
Burner System.

10

Combustion System
Design
Burners
Gas Trains
Skid Mounting
Burner Management
Systems (BMS)

Instrumentation and
Control Systems
Hardwired, PLC, PES to
IEC 61508
Safety PLC with SIL
analysis
Scada Systems

DESIGN
FA B R I C AT I O N
SERVICE

1.
2.
3.
4.

3D in house design.
Purpose built facilty, Melbourne, Australia.
24-hour service.
Industry and Santos Directors awards.

11

G A S C O P R O D U C T S B Y I N D U S T RY

AUTOMOTIVE Paint and Curing

Lines, Spray Booths, Ovens, Core
Drying, Air Houses, Heat Recovery,
Washing Systems, Thermal Oxidisers,
RTOs.

OIL, GAS Fired Heaters, Thermal

Oxidisers, RTOs, Flares, Waste Heat
Recovery.

BIOFUELS Flares & RTOs for ethanol

and biodeisel.

PETROCHEMICAL Hot Oil Heaters,

Filter Coalescers, Acid Gas/Tail Gas
Incineration, Water Bath Heaters,
Crude Oil Preheaters, Condensate
Heaters, Pressure Reduction Skids,
Heater Treaters, Radiation Shields,
Metering Skids.

CHEMICAL Combustion Systems, Air

Heaters, Heat Exchangers, Thermal
Oxidation, Heat Recovery, Hot Oil
Systems, Resin Kettles, RTOs.

PHARMACEUTICAL Air Heaters,

Driers, Thermal Oxidisers, Flares,
Heating and Combustion, Hot Oil
Systems, RTOs.

ENVIRONMENTAL Afterburners,
Incinerators, Thermal Oxidisers,
Flares, Scrubbers, Landfill Gas Flares,
Odour Incineration, Biogas Flares and
Burners, Heat Recovery, Soil
Remediation Systems, Liquids
Incineration.

PIPELINE & TERMINAL City Gate

Heaters, Gas Conditioning, Water
Bath Heaters, Pressure Control Skids,
Filter/Coalescers, Metering Skids,
Flares, Custody Transfer.

FIRE TRAINING AND RESEARCH

Thermal Oxidisers for Compartment
Fire Behaviour Training & Research
Centres.
FOOD Air heaters, Ovens, Burners
and Combustion Systems, Thermal
Oxidisers, Hot Oil Systems, Heat
Exchangers, RTOs.
GENERAL INDUSTRIAL Driers,
Ovens, Kilns, Furnaces, Hot Oil
Systems, Heaters, Thermal Oxidisers,
RTOs.

Represented by:

MINERALS & METALS Air Heaters,

Driers, Kilns, Hot Oil Systems, Heaters
for Launders, Ladles, Burners and
Combustion Systems, Start Up
Burners, Flares & Thermal Oxidisers,
RTOs.

Head office: Gasco Pty Ltd

POWER GENERATION Gas

Conditioning Skids, Turbine Exhaust
WHRU, Water Bath Heaters, Let
Down and Filter/Coalescer Skids,
Custody Transfer Metering, Heat
Recovery Steam Generators (HRSGs).
STEEL Heaters and Driers for Ladles,
Tundish, Launders, Vessels, Start Up
Burners, Combustion and Control
Systems, Thermal Oxidisers,
Refurbishment of Furnace
Combustion Systems.

ABN: 55 869 575 588 ACN: 051 824 741

170 Colchester Road, Bayswater

Victoria 3153 Australia
Ph: +61 3 9237 7111
Fax: +61 3 9237 7171
24hr Service +61 3 9237 7177
Email: [email protected]
Internet: www.gasco.net.au
Sydney: Unit 15, 11 Brookhollow Ave, Baulkham Hills NSW 2153 Ph: +61 2 9634 4412. Brisbane: 65-69 Manilla St, East Brisbane QLD 4169 Ph: 0429 100 430
12

cumquat design www.cumquatdesign.com.au Feb 2014

ALUMINIUM Custom designed

heaters or dryers for the following:
ladles, crucibles, siphon tubes,
cathode collector bars, aluminium
scrap, moulds, launders, anode stubs,
anode blocks. Tar waste melt out and
collection. Tar Hot Oil Heaters, Air
Heaters, Thermal Oxidisers, Gas
Conditioning Skids, Carbon Bake
Furnace Conversions.