A partial listing of MEI Maverick Engineering’s production facility project experience is as follows:
PSVS ON PROPANE, BUTANE AND NATURAL GASOLINE
Owner’s Gulf Plains facility asked MEI Maverick Engineering to provide engineering, design and analysis to support the proper installation of three (3) PSV sets. MEI evaluated and designed the PSVs and their associated discharge piping to the flare header.
COASTAL AND INGRAM STATION COMPRESSOR COOLER PLATFORMS
MEI scope of work included engineering and design of foundation tie-ins to an existing skid, steel framing for the access platform on three compressor coolers, design to the existing building columns to support platform beams, and design of new columns to support the access platforms.
FEL-2 STUDY AND TIC ESTIMATE
Eagle Plant facility is located in South Texas. This facility was a Greenfield project designed to process 200 MMSCFD of raw gas. The plant was designed and built utilizing new equipment and standard Thomas Russell skids. The facility included amine and glycol treating, ethane rejection and recovery, condensate stabilization, propane chilling, inlet compression, and residue compression. There were multiple sub-projects that have been grouped by area.
- Amine System Modification Project
- Closed Drain Project
- Compression Project
- PSV Modification Project
- Controls Project
- Construction Projects
Owner’s engineering preliminarily reviewed each of these sub-projects and developed possible solutions. MEI reviewed those solutions and verified their feasibility. MEI provided an FEL-2 and TIC Estimate for the projects mentioned above.
SECURITY UPGRADES
MEI was asked to provide engineering support to develop a bid package for the installation of the controlled access gate. MEI sized the cable to power up the gates, identified the power sources for the contractor to validate, developed a suggested cable routing for the contractor to validate based on NEC standards. Fences were designed using client’s standards and sketches were provided for civil design.
TEXAS CITY SECURITY UPGRADES
Engineering support consisted of developing a bid package for the installation of the controlled access hardware equipment and the installation of the cameras in the locations previously identified. Connection and configuration to security network was defined by the client and will be provided to by a third party. The scope of work for the engineering work to be provided by MEI was divided into the following categories: Fencing, Access Control, & Camera Installation
DEAN PIPELINE – REDA PUMP INSTALLATION
MEI Maverick Engineering provided engineering and design support for the installation of one (1) Reda Pump including seal pot and VFD, P&ID's update, process support, foundations and piping; also, reviewed the electrical and instrumentation work performed by other contractors.
BONE SPRING CENTRAL PRODUCTION FACILITY
MEI completed the engineering of its Bone Springs Central Production Facility which accommodates production from a number of nearby wells. It is envisioned that the facility will be built upgraded in several phases in keeping with the anticipated production profile.
MEI provided all engineering, design and related project support services, including: process, mechanical, electrical and instrumentation, civil and structural engineering; piping, civil and structural, electrical and instrumentation design; procurement assistance; and development of a ± 30% Total Installed Cost estimate.
BOP ENGINEERING AND DESING FOR RESIDUAL GAS COMPRESSION PLANT
Maverick teamed with a Turbo Compressor OEM to provide engineering and design services for the balance of plant portion of the residual gas compression for an international customer. The OEM is the prime contractor and is providing the compression and turbo-machinery. The maximum capacity of each Compressor train (about 370 MMSCFD) is such that the total flow through the facility will be split equally between three (3) compressor trains, when one compressor is out of service. Maverick assisted the OEM in the proposal phase providing support for all equipment and material pricing as well as for all balance of plant engineering and design services.
INSTALLATION OF TURBO COMPRESOR PACKAGES
Maverick acted as the Engineering, Procurement and Construction Management (EPCM) contractor. This project consisted of installation of two (2) Solar Saturn turbo-compressor packages, coolers, inlet scrubber, MCC, and associated piping, all to provide residual gas compression. Maverick purchased all equipment and materials with the exception of the client provided Solar packages and managed the site construction contractors. The project was completed on an accelerated schedule.
CENTRAL PROCESSING FACILITY (CPF)
A South Texas Central Processing Facility desired to upgrade an existing area tank batteries and facilities. MEI provided engineering/design support services for process, mechanical, piping, civil/structural and I&E for both FEED and detailed engineering.
SLUG CATCHER – LARGEST IN THE WORLD
MEI participated in the largest slug catcher ever engineered and designed. MEI contributed the design of the civil and structural work as well as the piping and modelling of this system. A total of 28 finger sections (storage tubes) of 56” in diameter each with a length of over 175 meters (574 feet) were required to handle the storage of the large volume of condensate. The 28 parallel storage tubes coupled with the 175 meters length required a plot area of over 15,000 square meters (161,000+ square feet), equivalent to several soccer fields, making this slug catcher the largest single piece of equipment on the entire project.
TREATMENT OPTIONS PLANNING
Feasibility Study (FEL 1 & 2) to evaluate options to third party treating. The study included refrigeration versus cryogenic processing with capital and operating costs for new and used facilities.
PROCESS OPTIMIZATION
Project Management services for the evaluation of the recovery efficiency for an existing lean oil process, possibly replace the process with a new cryogenic process, and recommend manned versus unmanned facilities. The process and compression facilities were modelled using Chemshare and economic analysis completed. The facilities were optimized and operated unmanned.
TREATMENT OPTIONS DEVELOPMENT
Provided a feasibility study for gas treating. The study included alternative treating options, air permitting requirements; detailed capital cost estimates and projected operating costs with recommendation for the most cost effective option.
PROCESS DEVELOPMENT
Provided a feasibility study of a J-T unit. The scope included preliminary process design, detail capital costs, projected operating costs with forecasted product pricing. A base-case economics plus 10 sensitivities were developed.
EAST TEXAS GAS PLANT AMINE VENT CONTROL PROJECT
Midstream client’s East Texas Gas Plant installed a Direct Fired Thermal Oxidizer Unit fed from a new gathering header. This header was routed from five existing Amine Plants, through liquids separation equipment, to the Thermal Oxidizer. The Thermal Oxidizer was selected by the client. Maverick Engineering, Inc. (MEI)’s provided all the required design and engineering services.
PLANT AND FIELD OPTIMIZATION
Replacement of an existing out of compliance heater/ incinerator with a new heater/ incinerator. Project included plant optimization, economic analysis, capex and Opex estimating and project implementation. Led HAZOP study at this plant along with other miscellaneous projects associated with the PSM efforts, including documentation of PSV calculations, development of cause & effect diagrams and updating of plot plan and P&ID’s.
In addition, MEI was the Project Manager to debottleneck and upgrade the gathering system. Field data and well performance was gathered to construct a model (Chemshare) and validate results. Three additional compressors were installed and total field uplift increased by 30%.
AMINE PLANTS UPGRADES
Provided Basic Engineering and Detailed Engineering to upgrade and install Amine facilities for various locations in Texas. These projects included 10 GPM, 150 GPM, 200 GPM, 350 GPM, and 420 GPM amine units.
CONDENSATE LIQUID EXTRACTION PLANT
Provided FEL 1 and 2 to evaluate 100 MMSCFD condensate liquid extraction plant. Capex and Opex estimates were prepared to evaluate viability of increasing yield for this gas condensate early production facility.
FIELD OPTIMIZATION
Project Manager for field optimization project. The scope consisted of FEL planning, AFE preparation and project execution. The project included: installation of an 1800 HP compressor station, 1-mile 12” pipeline, separation, air system, fuel system, vent system and storage.
GRASS ROOTS PLANT DEVELOPMENT
Project Management services for new gas processing facilities to allow production of shut-in gas due to excessive dewpoint specs. Scope of work consisted of: conceptual engineering through commissioning for 3200 HP compression, dehydration unit, 60 MMSCFD JT unit, separation, 3000 BPD stabilization unit, 400 BBL storage.
DEVELOPMENT PLANNING
Provided FEL 1 Conceptual and FEL 2 Preliminary engineering for a 8000 HP compressor station, 170 GPM amine unit, 225 GPH Dehydration unit, refrigeration system, separation, fuel and air systems, and storage.
PROCESS PLANT UPGRADES
Project Manager for various upgrades to 35,000 HP compression equipment at a plant. Upgrades were implemented to improve reliability, reduce operating cost and improve fuel economy.
PLANT CAPACITY EXPANSION
Engineering, design, procurement, construction and commissioning of a sweet gas bypass system to handle additional volumes of gas at this plant. Our responsibilities included development of all start-up and operating procedures.