Project Overview
A Global EPC engaged with CIU to replace an ageing trailer-mounted methanol injection package at a UK gas processing terminal. The existing equipment had reached the end of its operational life and was becoming increasingly maintenance-intensive, impacting reliability and efficiency.
The replacement package needed to minimise operator retraining, improve ergonomics and accessibility, reduce ongoing maintenance requirements and provide a fully portable solution that could be easily deployed across site. Working closely with the client, CIU reviewed the incumbent system, identified opportunities for improvement and developed a modern trailer-mounted methanol storage and injection package tailored to operational requirements.
The Benefits
At St Fergus, the CIU team replaced an ageing methanol injection package with a modern, portable solution designed around the realities of day-to-day operations - which meant less time dealing with ageing, maintenance-heavy equipment and more time keeping operations moving.
75% REDUCTION IN START-UP TIME AND DEPLOYMENT
50% REDUCTION IN EQUIPMENT DOWNTIME
100% PORTABLE PLUG-AND-PLAY DEPLOYMENT CAPABILITY
2X INJECTION PUMP REDUNDANCY THROUGH DUTY/STAND-BY CONFIGURATION
The Solution
An engineered methanol injection solution;
● 0.5m³ stainless steel methanol storage vessel
● Dual Maximator GX60 high-pressure methanol injection pumps in duty/standby configuration
● Air-operated tank filling pump
● Stainless steel skid and pipework construction for enhanced durability
● Retractable hose reels for suction, air and discharge lines
● Integrated tank level indication and pump calibration facilities
● Portable twin-axle galvanised trailer package for plug-and-play deployment
● Standard trailer specification to simplify future maintenance and spare parts availability
●Integrated safety equipment including two 9-litre freeze-protected foam fire extinguishers housed within a dedicated twin cabinet
● Full manufacture, assembly and testing to CIU quality standards prior to delivery
Results
The methanol injection package delivered significant operational improvements for the client at the SAGE Terminal, St Fergus.
By replacing ageing, maintenance-intensive equipment with a modern stainless-steel system, start-up and deployment times were reduced by approximately 75%, while downtime decreased by an estimated 50%. The fully portable plug-and-play design enhanced operational flexibility across site, and the inclusion of retractable hose reels improved ergonomics and reduced manual handling during deployment.
Additional features such as integrated tank level indication provided greater visibility of methanol consumption, helping minimise chemical waste and improve inventory management. The use of a standard trailer platform also simplified maintenance and ensured long-term spare parts availability.
Delivered on time and within budget, the new package provided a robust and cost-effective replacement for the ageing system. The solution improved reliability, reduced maintenance requirements, enhanced operator safety and delivered greater deployment flexibility across the site.