Natu tural ral Ga Gas Pro rocessi cessing ng Qualifications and Experience 2010
This document is confidential propr ietary information and disclosure of any information cont ained herein herein to any third party or use of such information ot her than to evaluate evaluate this document is stric tly prohibited.
MA G://20100517NGQual
Aker Sol ut io ns Amer ic as In c.
This document is confidential propr ietary information and disclosure of any information cont ained herein herein to any third party or use of such information ot her than to evaluate evaluate this document is stric tly prohibited.
MA G://20100517NGQual
Aker Sol ut io ns Amer ic as In c.
Table Table of Contents Cont ents
Section 1 – Summary of Qualifications Section 2 – Gas Processing Capabilities Section 3 – Gas Processing Technology Section 4 – Project Experience & Selected Profiles
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Secti Section on 1 Summary Summary of o f Qualifi Qualifications cations Aker Solutions has specialized in projects for the natural gas industry for over 40 years. We have substantial expertise in all areas of gas production and processing including the following: Inlet Gas Separation
Slug Catchers
Filters
Filter Separators
Ac id Gas Rem ov al
Benfield
Amines (MEA, DEA, MDEA)
Selexol
Sulfinol
Ryan Holmes
Mol Sieve
Membranes
Sulfur Recovery
Claus Plants
Super Claus Plants
SCOT Tail-Gas Units
Strefford
LO-CAT
Dehydration
Glycol
Drizo
Molecular Sieve
NGL/LPG NGL/LPG Extracti Extracti on and Treating
Refrigerated Lean Oil Plants
Cryogenic (turbo-expander)
Caustic Scrubbing
Merox
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Section 1 Summary of Qualifications (cont.) NGL Fractionation
Ethane Production
Ethane/Propane Production
Propane/Propylene Splitters
Iso/normal Butane Splitters
Isobutane Production (Engelhard and UOP)
Deisopentanizer
LNG
Import Terminals
Export Terminals
Liquefaction
Nitrogen Rejection and Cold Box Design Compression
Reciprocating Machines
Centrifugal Machines
Screw Type Machines
Gas Plant Simul ation Softw are Used by Aker Solut ions Software
Use
HYSIM/HYSIS
Entire gas plant simulation
Pro II (Simulation Sciences)
Fractionation, expander plants, and dehydration
SPED (Bryan Research)
Sulfur plant simulation
T-Sweet (Bryan Research)
Amine plant simulation
AMSIM (DB Robinson)
Amine plant simulation
Sulfur Recovery (Amoco)
Design claus sulfur plant according to the Amoco technology
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Section 2 Gas Processin g Capabili ties Ak er Sol ut io ns has sp eci ali zed in pr oj ect s fo r th e natu ral gas in du st ry fo r ov er 40 year s. Ak er Sol ut io ns ’ exp eri ence in gas pr oc ess in g wo rk un der tak en du ri ng rec ent year s involves the whole range of engineering and management skills from conceptual design through to start-up and operation. Study work and FEED package preparation is of ten part of a large project wh ere Aker Solutions has gone on t o do EPC scope or cont inued as the client’s project manager. Gas Processing Plants The gas treatment plant consists of several components that are typical of most plants. The design of these units is studied in some depth to create a flowsheet of the overall plant that meets the economic and technical optimization criteria imposed. Slugcatchers Slugcatchers from small single vessels to large multi-finger units have been designed and built by Aker Solutions. The recent Conoco Syria unit was a multi-finger unit with a capacity of over 400 m3. The Conoco Theddlethorpe units were 800 & 1300 m3 (5,000 and 8,000 bbls) finger units, and the British Gas North Morecambe project has a large single vessel. The S. Pars design is for 4800 m3 (30,000 bbls) and the Taweelah gas plant slugcatcher is 10,000 m3 (60,000 bbls). Our past experience with various types and sizes of slugcatchers provides the depth of knowledge Aker Solutions has in the design and construction of this equipment. Gas and Liquid Separation Gas and liquid separation using horizontal and vertical separators, with or without internals, are common components designed by Aker Solutions. For separators with proprietary designs of coalescing vanes or packs, specific equipment providers contribute to the design. Aker Solutions has developed certain proprietary technology in designing compact separators. Ac id Gas Rem ov al The range of processes offered includes physical and chemical solvents. Aker Solutions has designed straightforward MEA and DEA units and under license proprietary units such as Benfield, MDEA, Sulfinol, Selexol, Ucargol and other activated MDEA depending on bulk removal or partial removal. Molecular sieves and membrane systems for special removal services have also been addressed. The Petronas project included an in-depth assessment of all the available processes followed by the evaluation of the selected process. (Refer to recent Acid Gas Removal projects at the end of this section.)
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Section 2 Gas Processing Capabili ties (cont .) Gas Compression Gas compressors with electric motor and gas turbines drivers like the RR RB211, GE Frame machines and LM2500’s is a common part of the evaluation of the processing plant. The evaluation of compression alternatives often includes the determination of onshore and offshore options in conjunction with the pipeline options. This aspect was considered recently on the Theddlethorpe, South Pars and Taweelah projects. Dehydration and Hydrate Suppression The choice between dehydration using glycol, methanol, or molecular sieves is usually decided by the downstream processing requirements. Molecular sieves are normally utilized in cryogenic NGL/LPG Extraction plants where water concentration must be reduced to ppm levels. Aker Solutions can provide a wealth of experience in the selection of proper hydrate inhibition methods. NGL/LPG Extraction Aker Solutions has substantial experience in all areas of gas processing operations including NGL/LPG Extraction from natural gas streams. Aker Solutions’ experience in NGL/LPG Extraction processes from natural gas streams includes refrigerated lean oil absorption plants, high pressure straight refrigeration units using external refrigeration, cryogenic J.T. expansion plants and cryogenic expander plants. Aker Solutions has developed different cryogenic processes for extraction of NGL/LPG from natural gas including very high ethane and propane plus recovery utilizing turboexpanders. NGL Fractionation Aker Solutions has substantial experience in fractionation system design for separating ethane, propane, butanes and pentane plus products. The NGL fractionation systems designed by Aker Solutions are optimized for energy efficiency and capacity utilization. Our design experience includes new fractionation systems ranging from 20,000 barrels per day to over 100,000 barrels per day of inlet throughput. Aker Solutions has also worked on many capacity increases of the existing fractionation systems. Substantial increases in throughput have been achieved from upgrades of existing fractionations for Enron and TransCanada. Our experience includes butane splitters with heat cycle for energy optimization. We have also designed the Aker Solutions has achieved as butamer units for converting n-butane to iso-butane and much as 50% increase in the existing fractionation systems by integrating the butamer unit with the main fractionators carefully analyzing the existing units to achieve the overall fractionation system efficiency. In and making necessary modifications order to meet the final product specifications, product which saved substantial capital cost treating is required. Aker Solutions has experience with for the upgrade. the removal of impurities like CO2, moisture, H2S, COS and mercaptans from the various products to meet the required specifications. These methods include caustic, non-regenerables, and scavenger processes, as well as regenerable processes like molesieve for final product treating.
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Section 2 Gas Processing Capabili ties (cont .) LNG Aker Solutions’ LNG experience has evolved from an impressive background in overall gas processing. Aker Solutions has specialized in projects for the natural gas industry for over 40 years. Our experience in gas processing work undertaken during recent years involves the whole range of engineering and management skills from conceptual design through to start-up and operation. Study work and FEED package preparation is often part of a large project where Solutions has gone on to do EPC scope or continued as the client’s project manager. Our experience includes import/export terminals and liquefaction facilities. We design all LNG facilities per NFPA 59A and all worldwide industry-accepted standards. Sour Service Equipment and Materials Aker Solutions always considers materials selection for equipment and pipe to NACE requirements for sour service. For this type of study our specialists group can offer the necessary expertise to meet the requirements of the project. Sulfur Recovery Sulfur recovery in sour gas processing plants often requires the assessment of Claus type units and tail gas clean up. This has become more important now that there are tougher controls on flaring. Aker Solutions’ recent experience in sulfur recovery units (SRU) and tail gas treating units includes small units like 60 tons per day SRU units for Shell Offshore in Alabama with SCOT tail gas treating units. On the large scale units Aker Solutions is involved in design and construction of three (3) trains of 400 tons per day each SRU units with a single RESULT tail gas treating unit for SINCOR in Venezuela. Aker Solutions’ experience also includes the various enhancements of SRU including Superclause units. Additional tail gas treating experience not only includes the H2O based processes like SCOT and RESULT units, but also includes SO2 based and other processes like liquid redox. Utilities and Offsites Utilities such as vent and flare facilities, steam, hot oil, fuel etc. have a significant contribution to the economics of a process and local conditions are always different with each plant. Offsite facilities such as tankage and run down lines require process definition. Aker Solutions is well positioned to provide needed assistance to our clients in helping with the utilities, infrastructure and logistics.
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Ak er Sol ut io ns has del ivered substantial cost savings to our clients by offering dedicated teams to focus on delivering utilities and off-site project scopes to support larger capital programs.
Section 2 Gas Processing Capabili ties (cont .) Deep Ethane Recovery Aker Solutions has developed different cryogenic processes for the extraction of ethane from natural gas including very high ethane and propane plus recovery utilizing turboexpanders. Aker Solutions has considerable experience in dealing with the design of the high ethane and propane plus recovery process utilizing new as well as existing gas plants. The technical and economic considerations for the process facilities to be incorporated into the existing gas plant are different from those relating to new installations. Aker Solutions has field-proven design for high ethane and propane plus recovery processes. These processes can have many variations depending on the ethane plus content of the gas and the inlet conditions. The general outline of most of Aker Solutions-developed processes for high ethane and propane plus recovery using turboexpanders is provided in the following text. The basic process involves the dehydration of the inlet high pressure gas using fixed bed molecular sieves to remove the water to less than 1 ppmv. The bone-dry gas is processed in brazed aluminum heat exchangers to cool the high pressure inlet gas with the low pressure methane-rich residue gas. Normally a complex heat exchanger train is used to conserve the cold refrigeration from the process to minimize the external refrigeration. This involves prefractionation steps in the demethanizer column to recover the coolant from the cold NGL liquids. The high pressure cold inlet gas is separated from the condensed liquids and is expanded using the turboexpander. The expander not only helps provide the cold refrigeration in the process to condense the ethane and heavier NGL liquids, but also recovers the useful work to compress the low pressure gas to minimize the compression horsepower. The cold fluids from the expander discharge and the high pressure separator liquids are fed to the demethanizer to remove the methane and lighter components from the ethane and/or propane and heavier NGL liquids. Aker Solutions’ high ethane recovery processes utilize an internal or external reflux system to provide the cold lean reflux for the demethanizer. These processes provide high ethane recovery, higher energy efficiency and lower capital cost s. Normally the demethanizer has a side reboiler and bottom reboiler integrated in the inlet gas heat exchanger train to recover the refrigeration and also reduce the external heating requirements. The low to medium pressure methane-rich cold residue gas is heat exchanged with the high pressure inlet gas as described above to recover the refrigeration. This residue gas is usually recompressed with the turboexpander-driven compressor. The residue gas is finally compressed to a pipeline pressure using additional compressors. In addition, the front-end facility may include H2S/CO2 removal and mercury removal depending on the level of these components present in the inlet gas and the recovery level for the ethane. Aker Solutions designed the high ethane recovery process using the turboexpander for Petronas in Malaysia, Enron in the U.S, and Santos Ltd. in South Australia. The processes for these locations have been proven in the field as designed.
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Section 2 Gas Processing Capabili ties (cont .) The high ethane recovery processes designed by Aker Solutions are one of the best in the industry. They are well proven processes. Our thermodynamic and physical property data in processes for light hydrocarbons are mature and proven over the last 15 years. It is important to recognize the thermodynamic behavior at high pressure and low cryogenic temperatures for the high ethane recovery processes. The coldest temperatures in the process vary from -140oF to -160oF. At these cold temperatures it is also important to understand the CO2 freezing characteristics. The feed gas pressure and composition also play a predominant role in the process design. Apart from feed gas compositions and conditions, the amount of impurities, the product specifications and the recovery level play an important role in the process selection. Our experience in the NGL and LPG extraction plants, especially in the high ethane or propane recovery processes from the natural gas using the turboexpander, is built around the ability to meet the challenges of the industry.
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Section 3 Gas Processing Technology The following text is a summary of Aker Solutions’ resources and capabilities in gas processing technology. Some of the proprietary and open-art technologies in gas processing that we have been involved in are described below. Additionally, Aker Solutions has excellent NGL/LPG fractionation expertise. Aker Solutions has also executed various projects in past utilizing third party proprietary process technology such as Ortloff in the NGL and LPG liquid extraction area. One of the recent projects completed for PETRONAS and PTT joint venture in Thailand where Aker Solutions engineered and managed construction utilized Ortloff OHR licensed process. Proprietary and Open Art Technologies The following description provides Aker Solutions’ experience in the gas processing, especially cryogenic liquids recovery (ethane and/or propane recovery) technologies: High Pressure Absorber This design, developed by Aker Solutions, was utilized for the Statoil Kollsnes gas processing plant expansion. It is a cryogenic expander plant for NGL/LPG extraction. The process is energy efficient and allows utilization of a single train approach for inlet capacities over 1.4 BSCFD. The process can tolerate higher CO2 in the inlet gas feed as well as much lower overall compression power compared to many other technologies at present. The design configuration allows a larger capacity train while keeping the process energy efficient. Aker Solutions designed the plant, taking the availability and constructability of larger equipment into consideration. The selection of materials of construction for large vessels and columns was developed consistent with large vessels and columns constructability at higher design pressure and cryogenic temperatures. The plant also utilized large compressors for high pressure gas compression using variable speed electric motor drivers. Methane Recycle This design was used in the PETRONAS Gas SDN BHD project. The process design for two trains, 700 MMSCFD each, was developed by Aker Solutions engineers to achieve very high ethane recovery combined with high demethanizer pressure to achieve significant tolerance to CO2 in the plant feed. The process design for this facility also included the flexibility to run in an ethane rejection mode with very high propane recovery, as well as minimum liquids recovery for dewpoint control only. Cold Separator Split Similar to Ortloff’s GSP design, this process was developed by Aker Solutions (previously John Brown) in the early 1980’s and successfully installed in Santos Ltd’s Moomba Gas Plant in South Australia. This plant processed 900 MMSCFD of rich, high CO2 gas with an ethane recovery in excess of 80%.
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Section 3 Gas Processing Technology (cont.) GSP This design has been used in a number of Aker Solutions projects. In Enron’s Eunice Gas Processing plant, it served to improve ethane recovery, while in the Teesside Plant in the U.K. it was used for high propane recovery. This design has in the past been protected by a number of patents; however, most of these have expired. Pre-rectifier This is an expander process design for high propane recovery in which recoverable hydrocarbons are absorbed from the expanded feed gas using light hydrocarbons as absorption medium. Among others, Aker Solutions used this design in the ethane rejection mode of the PETRONAS Gas SDN BHD project listed above. Refrigeration Under certain circumstances, especially on upstream projects, Propane Refrigeration may be the most economical process. Aker Solutions has successfully executed many of these projects including the Shell Yellowhammer Plant. The revamp of TransCanada’s Eunice Gas Plant included debottlenecking of a 250 MMSCFD cryogenic liquids recovery plant that utilizes ethane refrigeration to generate demethanizer reflux. Aker Solutions has a long successful history of gas plant design and has built gas plants using a wide variety of liquid recovery processes. In addition to those listed above, these include Double-Expander, LSP, and Packed HP Separator. Most of these processes are no longer considered competitive or are applicable only in very specific circumstances. Aker Solutions also has extensive experience with Lean Oil Absorption plants. While in most new gas processing plants cryogenic designs have replaced lean oil absorption, in special circumstances absorption is still viable, and Aker Solutions has recently designed lean oil absorption plants. Furthermore, Aker Solutions has been involved in debottlenecking and the expansion of existing lean oil plants, some of which were originally built by Dresser Engineering, which became part of John Brown, a predecessor of today’s Aker Solutions. Grass roots Lean Oil Absorption Plant designs include:
Lean Oil Absorption facility for Nasr Petroleum Company, Suez, Egypt (1997-1999) . This
project is a vapor recovery unit in a hydrocracking complex. It recovers 85% of mixed LPGs from the hydrocracking unit’s off-gas. Lean Oil Absorption facility for Statoil in a confidential location in the FSU. Aker Solutions performed conceptual and basic design as well as a TIC estimate. Capacity was 400 MMSCFD, with propane recovery of 70%. Refrigerated Lean Oil Absorption facility (Khuff Gas Development Project, Abu Dhabi, UAE) for Abu Dhabi National Oil Company (ADNOC). Plant capacity is 540 MMSCFD. Butane recovery was 85%-95%, with a maximum propane content of 35%. Condensate vapor pressure was 8 psi maximum.
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Section 3 Gas Processing Technology (cont.) Debottlenecking and Front-End Projects include:
Refrigerated Lean Oil Absorption Facility (Eunice Gas Plant, Louisiana) for TransCanada. Capacity of the lean oil plant was approximately 400 MMSCFD. Aker Solutions’ scope included debottlenecking for additional throughput as well as optimization. The plant recovered 35%-40% of feed ethane and 90% propane. Refrigerated Lean Oil Plant (Henry Gas Plant, Louisiana) for Texaco. This plant was originally built by Dresser Engineering. Aker Solutions performed process design work for Texaco including simulation of the lean oil plant. The plant has a capacity of 1,000 MMSCFD in two trains. It recovers 40% ethane and 93% propane. Refrigerated Lean Oil Absorption Plant (Gregory Plant, Texas) for Enron. Aker Solutions developed the simulation model for this facility for troubleshooting and optimization. The plant recovered 85% propane with mild refrigeration (20°F).
Nitrogen Rejection Technology Aker Solutions also had one patented cryogenic Nitrogen Rejection Technology; however, the patent will soon expire and there is no plan to renew or resubmit at this time. Aker Solutions personnel have executed some projects in this area using other proprietary and open art technologies. Molecular Sieves Aker Solutions designed numerous plants using molecular sieve in gas and liquids service. Plant capacities up to 1,500 MMSCFD were included. Our experience includes high and low pressure regeneration as well as with and without mercury removal. We are experienced in the design of molecular sieve units with 3A and 4A mole sieve for gas dehydration. We have design experience with specialized operations for reduction in COS formation. Some of our past design experience includes special design considerations during regeneration of molecular sieve beds in which small amount of sulfur and oxygen is present in the inlet feed gas. TEG Aker Solutions has carried out many designs involving TEG as a drying medium. Some projects included using stripping gas or proprietary process enhancements such as Cold Finger, which was used in BP’s Cupiagua project/Columbia and Amoco’s Bairoil CO2 Cycling plant. The Drizo process was considered for the design of the Enron Teeside facility and ARCO’s China offshore project. Ethylene Glycol Injection Aker Solutions has used this simple design to achieve dewpoint suppression in less demanding services. This method was used for ethane drying for the PETRONAS Gas SDN BHD project.
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Section 3 Gas Processing Technology (cont.) Methanol Injection This method of hydrate control has been used in several subsea pipeline projects. Aker Solutions’ design included methanol recovery, reconcentration, storage, and export to the offshore injection location. Projects include the 290 MMSCFD Caister/Murdoch onshore facility and the 210 MMSCFD Pickerill Gas Terminal (Conoco, U.K.). The following are mercury removal technologies with which Aker Solutions has experience. Mercury removal has been part of most of the cryogenic gas processing plant projects. Mercur y Removal As part of feed pretreatment, it is necessary to remove mercury if present in the feed gas to avoid corrosion with brazed aluminum heat exchangers. Aker Solutions has designed many mercury removal systems (MRS) since 1990. Our experience with MRS includes the following:
Sulfur impregnated activated carbon adsorbents Metal sulfide systems Metal sulfide/oxide systems
Most of our systems for MRS from natural gas are based on sulfur impregnated activated carbon absorbents. The liquid systems MRS are based on metal sulfide on alumina or carbon substrate or metal oxide/sulfide based systems. We evaluated gas and liquid phase regenerable molesieve (zeolite) systems for MRS, but in most cases these systems were not installed. Experience Using Licensed Technologies Aker Solutions’ experience with gas processing technologies is described in the previous section. To our knowledge the methane recycle process is not proprietary. GSP, LSP, and DoubleExpander designs were patented by Ortloff Engineers, Ltd.; however, these patents have expired. It is possible that certain configurations of the pre-rectifier process may be covered by patents in some countries. The Lean Oil Absorption Processes are not proprietary. “Cold Finger” Technology is licensed by Gas Conditioners International Co. Drizo is licensed by OPC Drizo Inc. We utilized these technologies on BP’s Cupiagua and Enron’s Teesside projects, respectively.
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Section 4 Project Experience Sectio n 4.1
Worldw ide Project Loc ations
Sectio n 4.2
Onshore Oil & Gas Scope & Project Type Table
Section 4.3
LPG/NGL/LNG Project Experience
Section 4.4
Acid Gas Removal, Sulfur Recovery, and Tail Gas Treating Units
Sectio n 4.5
Compresso rs/Turbines and Compresso r Station Experience
Sectio n 4.6
Select Coal Degasific ation Projects
Sectio n 4.7
Project Profiles
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Section 4 Project Experience (cont.) Secti on 4.1 Worldw ide Project Locatio ns
Saudi Arabia Saudi Aramco - Hawtah Field Develop - S. Area Plant Upgrade
Norway Norsk Hydro - Ormen Lange Statoil - Kollsnes
Kazakhstan OCL - 2 P/L ORYX - FEED
China Phillips - 24-1 - Xijiang Amoco - Liuhua ARCO - Yacheng
Italy RasGas - Adriatic LNG Syria Conoco Al Furat - 8 projects North America Sempra Energy – LNG Distrigas – LNG Shell – Yellowhammer Enron – 63 projects TransCanada Pecten (Shell) PEMEX Amoco – 2 projects Anardako – 2 projects Marathon Koch Northwest Pipeline BP Alaska GTL U.S. Dept of Energy Internorth Oxy – San Miguez PSI – 2 projects Reynolds – Mustang Island Santa Fe – High Islands Sonat – Mustang Islands Texas Eastman – High Islands Transco – High Islands Union Oil Zachry – Quarters
Venezuela Pequiven SINCOR
India Enron - LNG ONGC - 23 projects
Colombia BP Colombia - Cuisiana - Cupiagua - Covenas
Ecuador Techint/Garon Conoco
Chile Methanex - 2 projects Sipetrol
Sakhalin Island Exxon Sakhalin I - Chayvo - OPF - Transportation
Thailand PTT-Petronas
Dubai Dubai Petroleum - 3 projects
Malaysia Af ri ca Petronas Mobil Nigeria - 2 projects - EDOP - UBIT QIT I&II Chevron Angola - Sanha - Malongo - Block 14 Chevron Af ri ca (co nt’ d) - EGP3 Ranger Oil Elf - Ivory Coast - platform - IME-Edikan Benin - Odudu - Saga - topsides NNPC - Kerr McGee - deepwater - Pipeline Texaco Angola - Depots - LNG Study Sasol - Pipeline - Pipeline - Offsites Study
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Indonesia P.T. Trans-Pacific Gulf Oil Mobil - BD Field
Section 4 Project Experience (cont.) Secti on 4.2 Onshore Oil & Gas Scope & Project Type Table
U.S. and Europe Onshore Oil & Gas Projects Aker So lu ti on s’ Ac ti viti es Contract Scope Plant
Project
Client
Plant
Location
n s o i e s c g i s v n e i r r g d n g e l p n o n S i i i s m d u s i t t n i t i n o a B g n n i o v n o o / n e e t r i C k i / L r r m m c e s s U / g s e s s n e o e e e u p i r r e g u n s e i i e i n a u t p g a W s S m l i t l c c i e i n l m r g a o n t e m p o i o v o o t n r i i r u t i E M P C S C P P U P S C
GULF LNG
LNG REGASIFICATION AND RECEIVING TERMINAL
PASCAGOULA, MS, USA
BP
CATS TERMINAL EMM FEDERAL CONTRACT
UK
CONFIDENTIAL
UNDERGROUND STORAGE
THE NETHERLANDS
SEMPRA LNG
LNG REGASIFICATION AND RECEIVING TERMINAL
HACKBERRY, LA, USA
BP
EMM WYTCH FARM PROJECT
UK
NIGERIA LNG
GAS TRANSMISSION SYSTEM 2/4 SLUG CATCHER
NIGERIA
NORSK HYDRO
ORMEN LANGE GAS PROCESSING PLANT
AUKRA, NORWAY
2008
2007
COLUMBIA NATL. ACID GAS REMOVAL RESOURCES
WEST VIRGINIA, USA
STATOIL/ GASSCO
KOLLSNES GAS PLANT EXPANSION
WEST COAST NORWAY
HHI/ONGC
MUT PIPELINE PROJECT
WEST COAST INDIA
PTT–PETRONAS
SONGKHLA GAS SEPARATION PLANT
SONGKHLA, THAILAND
STATOIL
VESTPROCESS MONGSTAD EXPANSION PROJECT
NORWAY
BHGL/ONGC
3 PIPELINE PROJECT
WEST COAST INDIA
ENRON
DABHOL LNG TERMINAL
INDIA
CAIRN ENERGY INDIA LTD
ONSHORE GAS FACILITY
INDIA
2006
2006 2005
2005
2004
2004
2007
2008
2007
2011
2008
15
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n o i t e l p m o C
2002 2001
Section 4 Project Experience (cont.) Secti on 4.2 Onshore Oil & Gas Scope & Project Type Table
U.S. and Europe Onshore Oil & Gas Projects Ak er So lu ti on s A ct iv it ies Contract Scope Plant
Project
Client
Plant
Location
n s o i e s c g i s v n e i r r g d n g e l p n o n S i i i s m d u s i t t n i t i n o a B g n n i o v n o o / n e e t r i C k i / L r r m m c e s s U / g s e s s n e o e e e u p i r r e g u n s e i i e i n a u t p g a W s S m l i t l c c i e i n l m r g a o n t e m p o i o v o o t n r i i r u t i E M P C S C P P U P S C
ARAMCO
SOUTHERN AREA PLANTS UPGRADE
SAUDI ARABIA
BP
D250 GAS-TO-LIQUIDS
ALASKA
CONOCO
INTEGRATED DEZ GAS PROJECT
SYRIA
DISTRIGAS
LNG REVAPORIZATION MASSACHUSETTS, USA
SINCOR
SULFUR COMPLEX
CHEVRON
MALONGO TERMINAL GAS PLANT
ANGOLA
CHEVRON
SANHA CONDENSATE RECOVERY
ANGOLA
ADCO
OILFIELD FACILITIES
ADNOC
KHUFF – ONSHORE/ OFFSHORE GAS FAC.
CONOCO
THEDDLETHORPE SITE THEDDLETHORPE, ALLIANCE SUPPORT UK
ESSO
NATUNA ONSHORE/ OFFSHORE
JOSE, VENEZUELA
2000
2000
INDONESIA
INTERCONNECTOR GAS TERMINAL
BACTON AND ZEEBRUGGE
PETRONAS
NATURAL GAS PROCESSING PLANT
MALAYSIA
SANTOS LTD.
BALLERA GAS CENTRE SW QUEENSLAND AUSTRALIA
TRANSCANADA
NGL PLANT
LOUISIANA, USA
BP AMOCO
DF OFFGAS PROJECT WASTE GAS TIMT
HULL, UK
PEDEC
ONSHORE/OFFSHORE FACILITIES
IRAN
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2001
BU HASA, ABU DHABI ABU DHABI
n o i t e l p m o C
2001
2001
2001
2001
1998
1998 1998
1998
1998 1998
1998 1998
1997
Section 4 Project Experience (cont.) Secti on 4.2 Onshore Oil & Gas Scope & Project Type Table
U.S. and Europe Onshor e Oil & Gas Projects Aker So lu ti on s Act iv it ies Contract Scope Plant
Project
Client
Plant
Location
n s o i e s c g i s v n e i r r g d n g e l p n o n S i i i s m d u s i t t n i t i n o a B g n n i o v n o o / n e e t r i C k i / L r r m m c e s s U / g s e s s n e o e e e u p i r r e g u n s e i i e i n a u t p g a W s S m l i t l c c i e i n l m r g a o n t e m p o i o v o o t n r i i r u t i E M P C S C P P U P S C
BP AMOCO GAS
OPRN & MAINT SUPPORT OF GAS TERMINAL
TEESIDE, UK
BP COLOMBIA
CUPIAGUA FIELD
COLOMBIA
CONOCO
CSM FACILITIES UPGRADE
THEDDLETHORPE, UK
ARAMCO
CENTRAL ARABIA DEV. HAWTAH FIELD, PROGRAM SAUDI ARABIA
TRANSCANADA
NGL PLANT
LOUISIANA, USA
BP
GAS TERMINAL DEWPOINT CONTROL
DIMLINGTON, UK
CONOCO
PICKERILL COMPRESSION
THEDDLETHORPE, UK
ENRON
LPG PLANT
TEXAS, USA
THAPPLINE
MULTI-PRODUCTS PIPELINE
THAILAND
1996
BP KINNEIL
OIL & GAS PROCESSING
UK
AL FURAT
OMAR OIL RECOVERY FACILITIES
SYRIA
CONOCO
CAISTER MURDOCH GAS TERMINAL
THEDDLETHORPE, UK
TRANSCANADA
LPG PLANT
LOUISIANA, USA
BP
MILLER GAS RECEPTION
PETERHEAD, UK
CONOCO
PICKERILL GAS TERMINAL
THEDDLETHORPE, UK
SAGASCO
BEHARRA SPRINGS GAS PLANT
WESTERN AUSTRALIA
CQNG
DENISON TROUGH GAS QUEENSLAND, PROJECT AUSTRALIA
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1996
1996
1995 1995
1994
1994 1993
1994 1994
n o i t e l p m o C
1993
1993
1993
1992
1992 1992
1991
Section 4 Project Experience (cont.) Secti on 4.2 Onshore Oil & Gas Scope & Project Type Table
U.S. and Europe Onshor e Oil & Gas Projects Aker So lu ti on s Act iv it ies Contract Scope Plant
Project
Client
Plant
Location
HUMBER-HERTS, UK
n s o i e s c g i s v n e i r r g d n g e l p n o n S i i i s m d u s i t t n i t i n o a B g n n i o v n o o / n e e t r i C k i / L r r m m c e s s U / g s e s s n e o e e e u p i r r e g u n s e i i e i n a u t p g a W s S m l i t l c c i e i n l m r g a o n t e m p o i o v o o t n r i i r u t i E M P C S C P P U P S C
PETROFINA
REFINED PROD PIPELINE
SHELL
YELLOWHAMMER GAS ALABAMA, USA PLANT
TEXACO
LPG PLANT
AL FURAT
OMAR N / SHAHEL GAS SYRIA GATHERING
OSOCO
SHUKEIR GAMMA GOSP EGYPT
TEXACO
NGL PLANT
OKLAHOMA, USA
STEG
GAS TREATMENT/ COMPRESSION PLANT
EL BORMA, TUNISIA
CONOCO
VIKING GAS TERMINAL THEDDLETHORPE, UK
YPF
GAS TREATMENT PLANT
LATA OIL FIELD, ARGENTINA
PETROLAND
GAS TREATMENT
HARLINGTON, NETHERLANDS
SHELL
GAS TERMINAL EXPANSION
ST. FERGUS, UK
S.C.O.P.
OIL EXPORT PIPELINE SYSTEM
IRAQ
BRITISH GAS
GAS TERMINAL
MORECAMBE BAY, UK
BRITISH GAS
GAS TERMINAL
MORECAMBE BAY, UK
SANTOS LTD.
COOPER BASIN LIQUIDS PROJECT
MOOMBA, SOUTH AUSTRALIA
SHELL
GAS TERMINAL
MOSSMORRAN, UK
BP
KINNEIL GAS TREATING GRANGEMOUTH, UK PLANT
OKLAHOMA, USA
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1991 1991
1991
1990
1990
1990
1989
1988 1988
1985
1984
n o i t e l p m o C
1987 1986
1984 1984
1984 1983
Section 4 Project Experience (cont.) Secti on 4.2 Onshore Oil & Gas Scope & Project Type Table
U.S. and Europe Onshor e Oil & Gas Projects Aker So lu ti on s Act iv it ies Contract Scope Plant
Project
n s o i e s c g i s v n e i r r g d n g e l p n o n S i i i s m d u s i t t n i t i n o a B g n n i o v n o o / n e e t r i C k i / L r r m m c e s s U / g s e s s n e o e e e u p i r r e g u n s e i i e i n a u t p g a W s S m l i t l c c i e i n l m r g a o n t e m p o i o v o o t n r i i r u t i E M P C S C P P U P S C
Client
Plant
Location
BRITISH GAS
COMPRESSION STATION
AYLESBURY, UK
BP
GAS TERMINAL PROCESS UNITS
SULLOM VOE, UK
CHEVRON
OIL REFINERY EXPANSION
PERTH AMBOY, NJ USA
CITIES SERVICES NGL FRACTIONATION EXXON
MONT BELVIEU, TX USA
OFFGAS COMPRESSION
BATON ROUGE, LA USA
SONATRACH
GAS, LPG & COND PIPELINES
ALRAR/ARZEW, ALGERIA
TECHMASHIMPORT
ETHYLENE PIPELINES (2)
USSR
MOBIL
GAS & NGL PLANTS
ST. FERGUS/ NIGG BAY UK
EXXON
DEBUTANIZER
BATON ROUGE, LA USA
BASRAH PETROLEUM
OIL EXPORT EXPANSION
RUMAILA, IRAQ
ESSO
C4 STORAGE
FAWLEY, UK
SONATRACH
COMPRESSION STATIONS (2)
SKIKDA, ALGERIA
BP
DALMENY OIL TERMINAL
FIRTH OF FORTH, UK
BRITISH GAS
COMPRESSION STATION
CAMBRIDGE, UK
SONATRACH
LPG TREATING PLANT
ARZEW, ALGERIA
MICHIGAN GAS
UNDERGROUND GAS STORAGE
MICHIGAN USA
HONOR RANCHO, CALIF., USA
SOUTHERN UNDERGROUND GAS CALIFORNIA GAS STORAGE
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1982
1982
1981
1980
1980
1982
1983
n o i t e l p m o C
1979
1978
1977 1977
1976
1975
1975 1973
Section 4 Project Experience (cont.) Sectio n 4.3 LPG/NGL/LNG Proj ect Experi ence The following list includes LPG/NGL/LNG projects:
Ak er So lut io ns’ L NG/LPG/NGL Pro ject s Client
Location
Capacity MM SCFD
Description
Scop e
TIC $MM
Product
Year Comp.
Gulf LNG
Pascagoula, MS USA
LNG Receiving & Regasification Terminal
1,500
Permitting, FEED, EPC
Conf
LNG
2011
Ingleside Energy Center LLC
Ingleside, Texas USA
LNG Receiving & Regasification
1,000
Pre-FEED, EPC (On Hold)
665
LNG/LPG /NGL
2011
Sempra Energy
Cameron, Louisiana, USA
LNG Regasification and Receiving Terminal
1,500
EPC
700
LNG
2008
ExxonMobil/QP
Offshore Italy
GBS LNG Regasification Facility
750
FEED/EPC M
900
LNG
2007
Norsk Hydro
Aukra, Norway
Ormen Lange Onshore Gas Processing Plant
2,400
FEED/EPC MA
2,000
NGL/LPG
2007
Columbia Natl. Resources
West Virginia, USA
Acid Gas Removal Unit
1,500GPM
EPCM
Conf
Acid Gas Removal
2006
Statoil/GASSCO
West Coast Norway Kollsnes Gas Plant Expansion
1,400
E
---
LPG
2006
ChevronTexaco
Gulf of Mexico & Offshore Baja, California
2000/750
FEED
1,000
LNG
2006
Port Pelican & Baja GBS LNG Facilities
Linde AG (Statoil) Melkøya, Norway
Snohvit LNG Plant
540
EPCS
100
LNG
2005
PTT-PETRONAS Thailand Gas
Gas Separation Plant
425
PMC/FEED
250
LPG
2005
Freeport McMoRan
Gulf of Mexico
LNG Regasification Facility/Energy Hub
PreFEED/C E/ Permit Support
Conf
LNG/LPG /NGL
2004
ExxonMobil
Gulf of Mexico
GBS LNG Import Terminal
1,250
S/CE
Conf
LNG
2003
Shell
Offshore Northeast USA
GBS LNG Regasification Facility
1,000
S/CE
Conf
LNG
2003
Enron*
India
Dabhol LNG Receiving Terminal
---
EC
250
LNG
2002
Aramco Services Co.
Saudi Arabia
Southern Area Gas Plants Upgrade
800
FEED
128
NGL
2001
CMS
Equatorial Guinea
LNG Liquifaction Production Facility
4MM TPA
S/CE
NA
LNG/LPG
2001
Conoco Syria
Deir Ez Zor, Syria
Integrated DEZ Gas Project
500
FEED/EPC
180
LPG
2001
Distrigas
Everett, Massachusetts, USA
LNG Revaporization Expansion
600
FEED/EP
125
LNG
2001
Dynegy
Hackberry, Louisiana, USA
LNG Import Terminal
750
S/CE
NA
LNG
2001
Texaco/Sonangol Angola
Onshore Liquefaction Facilities (PRICO Technology)
800
Pre-FEED
Conf
LNG/LPG
2001
Chevron Overseas Petroleum
Sanha Secondary Recovery Condensate/ Development Project
600
FEED/E
1,500
LPG
2000
Offshore Angola, West Africa
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Section 4 Project Experience (cont.) Sectio n 4.3 LPG/NGL/LNG Proj ect Experi ence Ak er So lut io ns’ L NG/LPG/NGL Pro ject s Client
Location
Capacity MM SCFD
Description
Shell
Kollsnes, Norway
Gas Processing & Commissioning Plant
Gazprom/Yamal
Russia
LNG Export Terminal
Scop e
1300
TransCanada Gas Geismar, Louisiana, Riverside Fractionation Plant Processing USA Debottlenecking (Enron)
TIC $MM
Product
Year Comp.
FEED/EPC
512
NGL/LPG
1996
S
NA
LNG
1995
28,000 BPD
FEED/E/SU
4
NGL
1995
60
FEED/EC/S U
NA
NGL
1994
.5
NGL
1993
Enron
Agua Dulce, Texas, Magnolia City Gas Plant USA Expansion
TransCanada
Cameron, Louisiana, USA
Sabine Pass Gas Plant
200
FEED/ECM/ SU
Enron
Argentina
EASA Gas Processing Facility
750
FEED
NA
NGL
1992
Enron
Teesside, UK
Teesside Gas Processing Plant
600
FEED
40
LPG
1991
Shell Offshore, Inc.
Mobile Bay, Alabama, USA
Yellowhammer Gas Plant
200
PM/EPCM
70
NGL
1991
Texaco
Erath, Louisiana, USA
Henry Gas Plant
1,000
SIM/E
NA
NGL
1991
British Gas
Tunisia
Miskar Gas Plant
250
S/CE
350
**CGP NRU
1990
Texaco
USA
Maysville NGL Plant
---
EPC
NA
NGL
1990
YPF
Argentina
Gas Treatment Plants 1 & 2
---
E
NA
NGL
1990
*
SCOPE
The Houston office provided engineering support to our UK office
E
=
Engineering
SU
=
Start-up
P
=
Procurement
PM
=
Project Management
C
=
Construction
SIM
=
Simulation
NRU – Nitrogen Rejection Unit NGL – Natural Gas Liquid
PMC
=
Program Management Contractor
S
=
Study
LPG – Liquified Petroleum Gas
CM
=
Construction Management
CE
=
Cost Estimate
LNG – Liquified Natural Gas
CMA
=
Construction Management Assistance
NA
=
Not Available
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** CGP – Cryogenic Gas Plant
Section 4 Project Experience (cont.) Sectio n 4.4 Acid Gas Removal, Sulfur Recovery, and Tail Gas Treating Units Aker Solutions’ experience in acid gas removal, CO2 and H2S handling, transportation and safety systems design is an accumulation of many years of experience in conceptual process development, front end engineering design and development of facilities which includes PreFEED and FEED studies, detailed engineering, construction of the facilities including modularization concepts where economically attractive in this specific area. Aker Solutions’ experience, as indicated in the following table, includes acid gas removal from the facilities design in natural gas production (both offshore and onshore). Our experience also includes the gas clean-up from refineries and synthesis gas production in which similar facilities are required. The experience in this area includes a wide range of applications in which the inlet gas contains over 65% CO2 with small amounts of H2S to less than 1% or less CO2 with higher amounts of H2S. As you will note from the experience table, the application in acid gas removal systems involve different types of solvent systems that includes primary, secondary and tertiary amine systems, formulated amines for bulk CO2 or selective H2S removal and physical solvents involving selexol, methanol, etc. In addition, we have also been involved in bulk CO2 removal using membranes, cryogenic processes and a few H2S scavenger and fixed-bed processes such as molecular sieve. The examples are noted in the table as an indication of our involvement in this specific area over the last 30 years. In many of these applications, the starting point has been in the front end conceptual process development in which the process selection and optimization has been the key part of our experience internally as well as working with appropriate vendors of formulated solvents and membrane (where applicable) in achieving the desired outcome for the process selection. The acid gas removal or clean-up applications in natural gas treatment has mainly involved the following purposes or objectives:
Removal of CO2 and H2S to meet natural gas pipeline specifications Removal of CO2 and H2S to meet cryogenic gas plant for natural gas liquids (NGL) extraction as well as process constrains to avoid CO2 freeze-up. Removal of CO2 to a low ppm levels to meet liquefied natural gas (LNG) plant process constraints, again for the CO2 freeze-up concern. Removal of CO2 and H2S from ethane product to meet petrochemical feed stock specification requirements where catalyst poisoning has been a concern Removal of CO2 to a very low ppm levels depending on the specification for downstream chemical production such as Ammonia synthesis.
Again, the following table reflects our broad-based experience and know-how which helps us optimize the new as well as existing plant applications in which the upgrades are necessary for increased throughput volumes or changes in the inlet gas conditions.
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Section 4 Project Experience (cont.) Secti on 4.4 Acid Gas Removal, Sulfur Recovery, and Tail Gas Treating Units Ak er So lutions’ Acid Gas Removal, Sul fur Recovery and Tail Gas Treating Experience Year
Solvent Type
Client/Project
Ak er Soluti ons’ Scope
2009
ExxonMobil – Natuna Gas Field Development, Offshore, Indonesia. Inlet gas volume 2400 MMSCFD, 65% CO 2 and 0.5% H2S, multiple trains
Cryogenic Process
2009
Baard Energy, CO 2 compression and injection for EOR application
N/A
2009
Bharat Oman Refinery (BORL) Project, Madhya Pradesh, India 2 x 90 MTPD Sulfur Recovery Units (SRU) (1 x 330 TPH Amine Regeneration Unit (ARU)
Selexol
2008
Statoil Claus Unit for Sulfur Recovery for SMIL Project, Mongstad, Norway
AMDEA
2008
Max Petroleum, Astrakhanskiya Field, Kazakhstan. Initial gas production 150 MMSCFD, later year 600 MMSCFD with 20% H2S and 10% CO 2 in the sour gas. High reinjection pressure
Activated MDEA based solvent comparison
2008
SES/Consol Northern Appalachia Fuel Project, Benwood, West Virginia. Synthesis gas containing 25% CO2 and 1.3% H 2S, Acid Gas removal (2000 gpm circulation), sulfur plant – approx. 150 TPD, single train with tail gas treatment unit
Selexol
2007
Chennai Petroleum Corp. Ltd., Chennai, India. 2 trains (45.5 & 35 TP) sour water stripper units (SWS)
2007
American Lignite Energy (ALE) CTL Project, North Dakota. Synthesis gas containing 32% CO2 and 0.3% H2S. Acid gas removal (11000 gpm solvent circulation) and sulfur plant (3X50%) trains with single train tail gas treating unit. Sulfur production approx. 200 TPD
Rectisol (Methanol)
Feasibility, Pre-FEED design and cost estimate support
2007
Faustina Hydrogen Products, Louisiana. Synthesis gas containing 40% CO2 and 1.4% H 2S. Acid gas removal (5500 gpm solvent circulation) and third party sulfur plant (2 X 220 LTPD) with a single tail gas treating unit
Selexol
FEED design, cost estimate support
2006
Indorama Ammonia Plant – Damietta, Egypt. Feed gas containing 17% CO2 and no H2S.
GAS/SPEC CS-Plus
Plant relocation, engineering and CM
2006
Columbia Natural Resources, West Virginia, Acid gas removal from High (25%) CO 2 field. 1500 gpm circulation, revamp of existing unit
Selexol
N/A
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Technology comparison, front end process development, layout, cost estimate Technology comparison, cost estimate, life cycle cost analysis EP
Basic Engineering & EPC Feasibility and conceptual study, cost estimate
Feasibility study
FEED
Conceptual, detailed engineering, procurement assistance, construction management
Section 4 Project Experience (cont.) Secti on 4.4 Acid Gas Removal, Sulfur Recovery, and Tail Gas Treating Units Ak er So lutions’ Acid Gas Removal, Sul fur Recovery and Tail Gas Treating Experience Year
Solvent Type
Client/Project
Ak er Soluti ons’ Scope
2006
Siirtec Nigi/Sulphur Recovery Unit at MOL Oil and Gas Plc., Hungary. 90 tons/day unit
MDEA
2006
Duke Energy Gas Transmission, Canada, Kwoen Acid Gas Plant, acid gas plant expansion
Morphysorb
2005
QNI Syngas, Queensland, Australia. Synthesis gas containing 15% CO2 and no H2S
Benfield
Existing plant revamp – process and equipment re-rated with new process conditions
2002
Westcoast Energy Inc., Canada, Kwoen Gas Plant, Sour gas processing facility designed to remove 28MMSCFD of acid gas from a stream of 300MMSCFD
Selexol
Design, procurement, fabrication and field construction
2002
Chennai Petroleum Corporation Ltd., India, Sulphur Recovery Unit
MDEA
Detailed engineering and procurement assistance
2001
SINCOR Sulfur Complex, Venezuela, refinery gas treating, two identical trains. Solvent circulation rate: 2200 gpm each (DEA). Also one train of 1850 gpm (MDEA) for tail gas clean-up. Three trains of 400 tons/day each Claus sulfur plant.
DEA/MDEA
Detailed engineering, procurement and construction
2000
Westcoast Gas Services, Inc., Jedney II Gas Processing Plant, 78MMSCFD Gas Sweetening (800 USGPM amine)
Ucarsol LE-703
Design, procurement, fabrication, field construction
2000
Elf Exploration and production,Lacq Field, Southern Cryogenic and Technology comparison, front France, Inlet volume 3.5 MM Sm 3/day, 22% H2S, Membrane end engineering study, cost 11.5% CO2, field redevelopment Process estimate
2000
BP Refining, Australia, revamp of Sulfur Recovery and Amine Unit to increase capacity of unit from 25t/d to 35 t/d and improve efficiency of unit
MDEA
Front end engineering, process design and program management
1999
Kochi Refineries Ltd., Sulphur Recovery Unit at Kochi, India. 2 trains of 72 tons/day units
MDEA
Detailed engineering and procurement assistance
1999
BP/BOP Pox unit, Australia, Syngas Treating for CO2 Removal, Solvent circulation rate: 280 gpm
BASF Activated MDEA
1997
TransCanada (formerly Enron) Eunice Plant, Louisiana, ethane product treating for high CO 2 and traces of H2S removal. Solvent circulation rate: 250 gpm
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Ucarsol
Detailed engineering and procurement assistance Engineering design, procurement assistance and construction support
Basic engineering package, detailed engineering, construction management Basic, detailed engineering, procurement, CM support, plant operator’s training, start-up support
Section 4 Project Experience (cont.) Secti on 4.4 Acid Gas Removal, Sulfur Recovery, and Tail Gas Treating Units Ak er So lutions’ Acid Gas Removal, Sul fur Recovery and Tail Gas Treating Experience Solvent Type
Year
Client/Project
1996
Texas Eastman, Texas, treating of 15 MMSCFD of syngas for CO2. Solvent circulation rate: 500 gpm
1995
TransCanada (formerly Enron) Riverside Plant, Louisiana, ethane product treating for high CO 2 removal with traces of H 2S removal. Revamp of existing 250 gpm amine treating unit (conversion from MEA to Ucarsol) and installation of new 125 gpm Ucarsol unit
1994
Petronas Gas Bhd., Malaysia. Natural gas treating containing high CO2 and traces of H 2S removal. Solvent circulation rate: 19,000 gpm
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MEA Ucarsol
BASF Activated MDEA
Ak er Soluti ons’ Scope Basic, detailed engineering, start-up support Conceptual, basic and detailed engineering, procurement, startup assistance
Conceptual studies, process optimization cost estimate, technical support for detailed engineering and start-up
Section 4 Project Experience (cont.) Section 4.5 Compressor s/Turbines and Compr essor Station Experience Aker Solutions has engineered many compressor systems for services including hydrocarbons involving natural gas, process and synthesis gas as well as various refrigerant and air compressors, ranging in size from under 100 hp to over 65,000 hp. These installations involved reciprocating, centrifugal, hyper, screw and liquid ring compressors with various types of drivers, including gas fired turbines, gas and diesel engines, electric motors and steam turbines. Our experience in design of reciprocating compressors includes units with up to five stages as well as centrifugal units with multiple process stages. The following table provides details of our compressor and driver design and installations. A majority of our compressor station experience comes from onshore and offshore oil & gas installations. Our compressor station experience includes natural gas compression at various locations in the oil & gas production, gathering, processing and pipeline transportation process. Aker Solutions’ recent experience includes the design of six (6) compressor stations for Conoco Dez Gas in Syria. The design involved multiple compressor stations located in the field at the gas gathering stations. The compressor stations were designed and placed at appropriate locations. The gas is separated from the inlet condensate, compressed to a pipeline pressure using multistage, positive displacement reciprocating compressors. The condensate separated at low and medium pressure levels is pumped to pipeline pressure. The condensate, in most cases, was combined with high pressure gas for transportation to a central gas processing plant using a multi-phase pipeline. The condensed water is separated in the three phase separators at various stages and the pressure level was combined and then pumped for re-injection. The compressor stations were designed with maximum modularization using skid mounted separation and pumping equipment, packaged reciprocating compressors with drivers, coolers and other associated equipment. A separate system was designed to provide fuel gas treatment. A majority of the interconnecting piping was prefabricated for easy installation in the field. All of the compressor stations were self-contained with required utilities and other facilities such as air, pig launchers/receivers and metering, as well as compressor auxiliaries such as lube oil. Aker Solutions also designed pipeline compressor stations for the pipeline gas transportation of the Conoco Dez Gas Syria project. Here the dry lean gas from the central gas processing facility was compressed for pipeline transportation to the sales gas pipeline as well as excess gas for reinjection. The pipeline compressors in this case were centrifugal compressors with turbine drivers. Multiple compressors were required to provide the overall compression duty. The export gas pipeline compressor stations were part of the central gas processing facility. In addition to the above project, Aker Solutions’ experience also includes the design of compressor stations for the Norsk Hydro Orman Lange project in Norway. This facility, as part of the large onshore gas processing complex, utilized large compressors for transportation of the dry gas export pipeline from northwest of the Norwegian continental shelf to the UK, a 1200 km 42” long pipeline.
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Section 4 Project Experience (cont.) Section 4.5 Compressor s/Turbines and Compr essor Station Experience The compressors were driven by one of the largest electrical motor drivers with 40 MW motors each. Aker Solutions has faced many similar challenges in the past in designing the compressor stations where the pipeline pressure has ranged from 600# ANSI systems to 1500# ANSI systems. Aker Solutions has also designed various compression systems to 6600 psig discharge pressure level where the gas is re-injected. In addition, Aker Solutions experience also includes pipeline booster stations where the compressor stations are designed to provide a pressure boost with low compression ratio at high pipeline pressure located along the export gas pipeline. Most of these compressor stations involved centrifugal compressors with turbine or electric motor drivers to provide pressure boost in the export gas pipeline. Our experience includes both offshore and onshore pipeline boosting stations. Most of these stations are highly automated and self- supported with all of the utilities and required compressor and turbine auxiliaries with the system design for high reliability. A recent example is the Exxon Mobile Sable project in Canada where the large Dresser Rand compressor with RB211turbine driver was utilized. In many of the compressor stations, especially in the gas gathering and wellhead level field locations, modularization is a key design consideration. In summary, Aker Solutions’ experience includes engineering, procurement and installation of many different types of compressor systems including various types of compressor stations for natural gas processing. Again, the following list provides examples of our compressors and drivers design, as well as our experience in the design of compressor stations.
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Section 4 Project Experience (cont.) Section 4.5 Compressor s/Turbines and Compr essor Station Experience
Gas Compressio n Projects Client
Plant Loc ation
Completion
Services Performed
Gulf LNG Energy
Pascagoula, Mississippi
In Progress
EPC service for liquefied natural gas (LNG) receiving terminal including two LNG storage tanks and a regasification facility consists of three 1,400 hp IHI boil off gas compressors. Also includes one 2,000 hp Ariel pipeline compressor, and two 200 hp Atlas Copco vapor return blowers.
Exxon Mobil
Offshore, Porto Viro, Italy
In Progress
EPC service for offshore concrete liquefied natural gas terminal and regasification facility consists of two trains of 750 hp Dresser-Rand cryogenic boil off gas compressors.
Sempra LNG
Cameron, Louisiana
2009
EPC services for liquefied natural gas receipt terminal and associated facilities consists of three 600 hp Burckhardt cryogenic boil off gas compressors, one 1,200 hp Ariel pipeline compressor and two 200 hp Atlas Copco vapor return blowers.
Exxon Mobil
Sable Island, Canada
2004
Design for Gas Compression Platform Topsides consists of one 35,000 hp, 6 stage centrifugal, Dresser-Rand export gas pipeline compressor, driven by a Rolls Royce RB-211 turbine driver.
Chevron Overseas Petroleum Company
Offshore Block 0, Angola, West Africa Sanha Project
2004
Detailed engineering services for offshore oil and gas production with LPG extraction plant consists of four 30,000 plus hp each Dresser Rand reinjection compressors driven by RB-211 turbine drivers and compressing the gas to 6,600 psig pressure. Also includes two trains of 16,000 hp Dresser Rand separation compressors driven by solar Titan turbines compressing associated gas. The makeup gas compressors consists of three solar turbines (2 Mars and 1 Taurus) ranging in hp from 6,000 to 13,000 hp. The platform also includes smaller stabilizer overhead compressors.
Pemex Exploration & Production
Offshore Mexico, Canteral Field
2003
Detailed engineering for offshore production and compression platform consists of vapor recovery and six 12,000 hp Nuovo Pignone booster compressors with turbine drivers, compressing the gas to pipeline pressure for delivery to onshore.
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Section 4 Project Experience (cont.) Section 4.5 Compressor s/Turbines and Compr essor Station Experience
Gas Compressio n Projects Client
Plant Location
Completion
Services Performed
Conoco Syria Dez Gas Ltd.
Syria
2001
EPC services for infield gas gathering with compressor stations and an onshore gas processing facility. Detailed engineering and construction for total of six multi-stage centrifugal compressors with Nuovo Pignone PGP10B gas turbine drivers site rated at 11,000 hp each for residue and gas reinjection services. The maximum discharge pressure for gas reinjection is 5,000 psig. Also includes seven reciprocating single and multi-stage Aeriel compressors, sizes ranging from 250 hp to 4,100 hp electric motor driven with some variable frequency motors for natural gas services including gas gathering and pipeline. The facility also includes three multi-stage centrifugal propane compressors, 2,000 hp each for refrigeration service.
Chevron Overseas Petroleum Company
Offshore Angola Block 14, West Africa
2000
Engineering for offshore production facility includes gas compression studies and selection of gas compressors for produced and associated gas for reinjection and gas lift. The selection includes solar Mars turbine-driven multi-stage centrifugal compressors with discharge.
Chevron Overseas Petroleum Company
Onshore Angola – Malongo Terminal, West Africa
2000
Engineering for onshore low pressure gas gathering and compression for LPG recovery and gas conditioning plant. Three solar Saturn turbines with centrifugal compressors for multi-stage high MW natural gas.
Chevron Overseas Petroleum Company
Offshore Angola Block 0 – Sanha, West Africa
2000
FEED engineering for offshore gas gathering including one 16,000 hp and four 34,000 hp gas turbine-driven centrifugal compressors for gas compression to 6,600 psig.
Methanex Corporation, Chile
Punta Arenas, Chile
1999
EPC for multi-stage, centrifugal barrel type Dresser Rand syngas compressor, 41,700 hp, Mitsubishi multistage multi-valve passout/condensing steam turbine driver.
TransCanada Gas Processing
Eunice, Louisiana
1998
EPC plant revamp including installation of 1,000 hp engine-driven reciprocating compressor. Also modernized the overall control system for the multiple (5) solar compressors and turbines.
BP Exploration & Production
Cupiagua, Columbia
1997
EPC for crude oil gathering and gas reinjection facility including two GE Frame 5, 28,000 hp gas turbinedriven Nuovo Pignone centrifugal compressors for reinjection to 6,600 psig.
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Section 4 Project Experience (cont.) Section 4.5 Compressor s/Turbines and Compr essor Station Experience
Gas Compressio n Projects Client
Plant Location
Completion
Services Performed
Methanex Corporation, Chile
Punta Arenas, Chile
1996
EPC for multi-stage, centrifugal barrel type Dresser Rand syngas compressor, 41,700 hp, Mitsubishi multistage multi-valve passout/ condensing steam turbine driver.
BP Exploration & Production
Cupiagua, Columbia
1996
EPC for crude oil gathering and gas reinjection facility including one GE Frame 6, 32,000 hp gas turbinedriven Nuovo Pignone centrifugal compressor for reinjection to 6,600 psig.
Mobil
Nigeria
1996
EP services for offshore gas compression platform including GE 25,000 hp gas turbine driven centrifugal compressor for reinjection to 3,000 psig.
Sterling Chemicals
Texas City, Texas
1996
EPC for replacement of an existing Dresser-Rand multi-stage compressor, 16,300 hp and upgrade of the multi-stage backpressure steam turbine.
Amoco Chemical Texas City, Texas
1995
One 3-stage, centrifugal compressor, one 3-stage Demag HVK-10 centrifugal compressor in tandem with one Demag VK-50 4-stage centrifugal compressor. Both compressors driven by an existing 15,000 hp synchronous motor.
Miles (Bayer)
Baytown, Texas
1995
Two Demag VK80-Z, 2-stage, centrifugal integrally geared compressors with 7,500 hp each synchronous motor driver.
TransCanada Gas Processing
Riverside, Louisiana
1995
Plant revamp including two 800 hp and one 1,000 hp engine-driven reciprocating compressor
Coastal Chemicals
Cheyenne, Wyoming
1993
EPC for one Delaval multi-stage, barrel type compressor with 4,500 hp induction motor driver and speed increasing gearbox.
ARCO Oil & Gas Company
Wilburton, Oklahoma
1992
Definition and detailed engineering of four 1,000 hp Ariel JGK compressors.
ARCO Oil & Gas Company
Denver City, Texas
1992
Engineering services for two 4,000 hp I-R electric drive compressors.
El Paso Natural Gas Company
Arizona, New Mexico and Colorado
1992
Lump sum turnkey construction to add solar Centaur turbines and other modifications at four existing compressor stations.
Texaco E&P Inc.
Andrews County, Texas
1992
EP services for one 3,000 hp Cooper Pennsylvania process and one 1,500 hp Cooper Superior reciprocating compressor.
Trident NGL, Inc.
Canton, Texas
1992
Detailed design, engineering and construction management for 3,110 hp reciprocating 2-stage gas pipeline compressors.
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Section 4 Project Experience (cont.) Section 4.5 Compressor s/Turbines and Compr essor Station Experience
Gas Compressio n Projects Client
Plant Location
Completion
Services Performed
Trident NGL, Inc.
Myrtle Springs, Texas
1992
Engineering services for two 1,440 hp CooperBessemer GMVC-8C reciprocating compressors.
Northwest Pipeline Company
Utah, New Mexico, Washington
1991
Process engineering, detailed engineering and procurement to add solar Centaur turbines at five compressor stations.
Amoco Production Company
Durango, Colorado
1990
Engineering and construction of 205 MMSCFD natural gas processing plant. Includes five 5,000 hp motor driven field compressors and two 5,000 hp motor driven residue boosters.
El Paso Natural Gas
Durango, Colorado
1990
Engineering and construction of a natural gas parallel residue compression station. Includes one 5,000 hp motor driven residue compressor.
Shell Offshore
Mobile, Alabama
1990
Process design, detailed engineering, procurement and construction of a 200 million SCFD natural gas plant to process raw and sour gas from offshore wells for pipeline distribution.
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Section 4 Project Experience (cont.) Section 4.6 Select Coal Degasifi cation Projects
El Paso Natural Gas Company Florida River Coal Degasification Project Florida River, Color ado Scope of work:..........................EPC Contract value: .........................USD 10 million General description:
This facility was part of the coal degasification (coal bed methane production) project involving 220 MMSCFD peak capacity compression facilities where the low pressure gas was boosted in pressure to deliver the gas to the pipeline. The facility includes total installed compression of 15,000 HP and other miscellaneous small water treatment. Amoc o Pro du ct io n Co mp any San Juan Basin Coal Degasification Project San Juan, Color ado Scope of work:..........................EPC Contract value: .........................USD 63 million General description:
The overall scope of work includes the following:
Coal degasification facility gathering system The processing facility with peak capacity – 220 MMSCFD DEA gas treating unit for CO2 separation TEG dehydration Field gas compression from low pressure to pipeline delivery pressure with total installed compression of 20,000 HP Water treating and other miscellaneous facilities
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es Conoco Syria Dez Gas Ltd. Integrated Dez Gas Project Deir Ez Zor, Syria Description:
This 450 MM SCFD grass roots facility included gas gathering, pipelines, compression, gas processing, offices and living quarters. Specific details of this scope include:
Scope of Work:
Inlet gas compression and cooling Gas gathering pipeline system Gas compressor stations (6) Inlet condensate separation and transportation to pipeline Dry gas chilling, condensate separation Fractionation of mixed LPG product Propane, butane and C5+ condensate Butane storage Export pipeline (± 250 KM of 18” .375 wt) Truck loading facility Lean residue gas recompression for gas reinjection High and low pressure flare systems Hot oil, cooling water and other utility system Low level propane refrigeration system requiring propane compression from near atmospheric pressure
Engineering, procurement, construction, and precommissioning.
Duration: Engineering Start: Finish: Construction Start: Construction Completion:
Bid, Concept Development & FEED (Technip): 9 months February 1999 January 2001 April 1999 September 2001
Manhours:
Approximately 400,000 engineering/design manhours Mumbai: 250,000 manhours detailed design Houston: 80,000 manhours including coordination & support Syria: 55,000 manhours buildings, pipeline systems
TIC:
$430 million TIC. Aker Solutions’ portion was U.S. $180 million. Safety: Total construction manhours exceeded 4 million. Project achieved over 3 million manhours without LTI.
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es Norsk Hydro Ormen Lange Onshore Gas Processin g Plant Aukra, Nort hwest Coast of Norway Description:
The Ormen Lange Gas Field is located 120 kilometres northwest of Kristiansund. It is being developed with subsea production facilities in 800-1100 metres water depth hooked up to the onshore sales gas processing and export plant at Aukra. The Ormen Lange development also involves the most extensive gas export pipeline system form the Norwegian continental shelve to the UK, a 1200 km long 42” pipeline. The installation also includes cavern storage for condensate and export by tanker.
Technical Data: Gas export capacity: 70 M Sm3/d Possibility for future upgrade to 80 M Sm3/d without major shutdown Condensate storage: 150,000 m3 Scope of Work:
Performance of FEED, detailed engineering and follow-up engineering, procurement, and construction management assistance for the gas plant. Main interface contractor for overall system responsible for the total Ormen Lange project including subsea facilities, community power from national grid, and transport to consumers in the UK and Europe.
Project Value:
Contract value of onshore gas processing plant is NOK 950 million. Total TIC of project is NOK 66 billion. TIC of onshore facilities is NOK 16 billion.
Award:
March 2003
Production Start: October 2007 Status:
Operational
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es Saudi Aramco Southern A rea Gas Plants Description:
The Maintain Gas Compression Capacity Project provided for the installation of Compression Train B at Abqaiq Plant 499. The primary purpose of this project was to provide a reliable, efficient and safe gas compression system at the Abqaiq Plants, which have sufficient capacity to process the low pressure gases in a manner that complies with current environmental regulations. This project also allowed the retirement of old inefficient fired steam boilers and provided for efficient generation of high pressure steam with the installation of heat recovery steam generations (HRSGs), as well as diversification of the flare system to reduce the risk of business interruption through the strategic location of existing flare equipment and correction of deficiencies in the standby flare. This project also allowed for the retirement of Plant 332, which was approximately 35 years old. Machine units in this plant were no longer being manufactured and the equipment became unreliable with low efficiency. The Abqaiq Plants had eight gas compression trains to compress gasses that have been removed in the spheroids and stabilization process at the Abqaiq Plants and in Intermediate Pressure (IP) and Low Pressure (LP) traps at Abqaiq GOSPs 5 and 6. The compressed gas and the NGL liquids recovered in the compression process are shipped to downstream facilities for treating and sales product separation. Under a previously completed project, a new compression train with a design capacity of 100 MMSCFD and NGL stripper facilities were installed in Plant 499 Train A commissioned in 1999. This compression train allows Abqaiq Plants to process offgas from Shaybah crude stabilization and to retire the old NGL Plant 337 commissioned in 1965. This facility consists of a gas compression train having two compression stages that are operated in tandem and driven by a common CGT driver. The new NGL stripper installed with Train A has spare capacity to handle future expansion in Plant 499 that will be installed under this project (Plant 499 Train B).
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es The boilers at the Abqaiq Plants were also aging, and some existing boilers were in need of major repairs. The Master Plan for Abqaiq Plants is the recommendation that heat recovery projects be implemented to reduce the need for replacing these boilers. Heat recovery projects include the installation of heat recovery steam generators, which will use the waste heat from the exhaust of the combustion gas turbine drivers to provide additional highpressure steam. Heat recovery steam generation units were also installed on the existing Train A as well as the proposed Train B being installed under this project. Additionally, a second plant flare system, sized for a capacity of 700MM SCPD was designed for the project. Support facilities required for the Compression Train B included a new electrical substation as well as a team building and operator shelter. Numerous engineering studies were conducted in conjunction with the preliminary design effort. They included electrical studies for load flow, short circuit and motor starting analysis and protective device coordination, operability and maintainability studies for the combustion gas turbine and flare installations, constructability studies for all facilities, a team building risk assessment and a motor control center load list, an environmental assessment of the Train B facilities as well as the new flare system, and a preliminary process hazards analysis of both facilities. Duration:
Conceptual work was awarded in July 2000 under a reimbursable General Services Agreement with Aramco Services Company. Conceptual engineering for the gas compression train and flare system was completed March 2001. The LSTK project detail design, procurement and construction was awarded to others in July 2001 with completion expected in 2003.
Scope of Work:
Conceptual design, optimization studies, preliminary engineering, and detailed FEED package of the total project and detail design of the 69kV substation. Conceptual work consisted of generating the following deliverables:
Generate Definitive Scope of Work and EPC Schedules Generate Project Proposal Books Perform the ER Estimate for the Total Installed Costs of the Project Generate the LSTK Contract Bid Packages
HO Manhours:
37,000 manhours
Project Value:
TIC: $128 million
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es PETRONAS Gas Sdn. Bhd. Gas Processing Plants 5 & 6 Terengganu, Peninsu lar Malaysia Description:
Cryogenic expander plant & NGL fractionation. 1,000 MMSCFD net sales gas, approximately 1400 MMSCFD inlet gas. The grass roots facility includes two cryogenic expander units. Each unit has a capacity of 700 MMSCFD. The plant extracts over 90% ethane and over 99% of propane and heavier components from the inlet gas using Aker Solutions’ developed high ethane recovery process. In addition to the cryogenic expander plant, the design also includes the following:
Acid Gas (CO2) removal using BASF activated MDEA process Mercury removal from the inlet gas stream Molecular sieve dehydration NGL treating Inlet condensate stabilization Two NGL fractionation trains, 100,000 BPD capacity each Ethane, propane, butanes and gasoline separation Refrigerated and pressurized storage for different products Environmental and utilities design
Scope of Work:
Program Management Consultant (PMC) scope including design basis development, conceptual design, basic engineering package, EPC bid evaluation support, detail engineering supervision at contractor’s office on behalf of client and technical support during construction and commissioning.
Manhours:
100,000 engineering/design manhours
Value:
Estimated installed cost of the project is U.S. $800 million. Aker Solutions’ services value at $8 million.
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es Shell Offshore Inc. Yellowhammer Gas Plant Mobile, Alabama Description:
Refrigerated NGL recovery plant, sour gas treating and sulfur plant with capacity of 200 MMSCFD. This 200 MMSCFD facility consisted of sour gas treating unit to remove H2S using sulfinol solvent, Claus sulfur recovery unit and a SCOT tail gas unit. The facility also included a refrigerated NGL recovery unit and an NGL treating unit to produce approximately 2500 BPD of NGL, produced water stripping, gas turbine electric cogeneration unit, waste heat boilers, product storage and truck loading facilities.
Scope of Work:
Project management, detailed engineering, procurement and construction management.
Manhours:
220,000 manhours
Value:
Estimated installed cost for the project was U.S. $70 million.
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es TransCanada Gas Processing Inc. Eunice Gas Processing Plant Expansion Eunice, Louisiana Description:
Lean oil and two cryogenic expander plants with NGL fractionation facility. Plant capacity of 1050 MMSCFD. The existing plant expansion included basic engineering of the existing refrigerated lean oil extraction plant, two cryogenic expander plants, one of which was designed for 95% ethane recovery from the inlet gas and NGL fractionation facility. The process study also included the UCARSOL treating unit evaluation for CO2 removal from the ethane product, existing equipment evaluations, additional equipment requirements to meet future change in feed stock with increased throughput of 100 MMSCFD, new two phase pipeline hydraulics and cost estimate for additional equipment to eliminate the plant bottlenecks. Gas plant revamp detailed engineering for the work included:
Fractionation column revamp for capacity increase Refrigeration system (propane) expansion Steam system revamp Cooling tower addition Amine Unit addition Propane treater addition Various vessels, exchangers and pumps addition for capacity expansion Plant flare and thermal oxidizer debottleneck Complete modernization of the plant and advanced control implementation
Scope of Work:
Design basis development, basic engineering, detailed engineering, procurement and start-up support.
Manhours:
125,000 engineering/design manhours
Value:
Estimated installed cost of the project was U.S. $40 million. Aker Solutions’ services value U.S. $8 million.
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Eunice Gas Plant with High Pressure 39 Demethanizer
Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es TransCanada Gas Processing Inc. Riverside Fractionation Plant Debottlenecking Geismar, Louisiana Description:
NGL fractionation facility with plant capacity of 28,000 BPD demethanized liquid. The scope of work included the debottlenecking of the existing fractionation facility which included the deethanizer, depropanizer, debutanizer, and iso-normal butane splitter columns. The plant throughput was increased from approximately 15,000 BPD of lower ethane containing feed to 28,000 BPD of higher ethane and much higher CO2 containing demethanized liquids. Aker Solutions also provided the advanced control configuration and optimization for four distillation columns which reduced the energy consumption (Btu/gallon) of the fractionation facility by 20%. Debottlenecking of the facility also included revamping the existing amine treating (UCARSOL) unit and addition of new parallel unit to remove the CO2 from ethane product.
Scope of Work:
Design basis development, basic engineering package, detailed engineering and plant start-up support.
Manhours:
12,000 engineering/design manhours
Value:
Estimated installed cost of the project was U.S. $4 million
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Section 4 Project Experience (cont.) Secti on 4.7 Project Profil es TransCanada Gas Processing Inc. Sabine Pass Gas Plant Cameron, Louisiana Description:
Cryogenic expander plant with plant capacity of 200 MMSCFD. The scope of work included the debottlenecking of the existing cryogenic expander plant for CO2 freeze-up problems in the demethanizer due to the increased CO2 in the inlet feed. Aker Solutions developed the process to achieve the solution to the problem for this existing plant without the addition of an amine unit to remove the CO2 from the inlet gas. The solution was achieved by addition of minimum equipment, piping and instrumentation within the cryogenic plant and saved substantial capital cost compared to the solutions under consideration.
Scope of Work:
Design basis development, basic engineering package, detailed engineering, construction management and plant start-up support
Manhours:
3,000 manhours
Value:
Estimated cost U.S. $0.5 million.
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