Oil & Gas: Processing Facilites
Maverick Engineering, Inc. has developed numerous scopes of work to support maintenance, optimization and expansion of turnarounds at gas plants including turbo expander, J-T, lean oil, refrigeration, dehydration and sweetening processes. Typical responsibilities included opportunity definition, scope definition, cost and schedule estimates, funding packages, project management, procurement and construction management.
Below listed is a sampling of projects:
TREATMENT OPTIONS PLANNING (Cherry Canyon)
Project Manager for 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. The client successfully renegotiated the third party contract.
PROCESS OPTIMIZATION (Portilla)
Project Manager to evaluate the recovery efficiency of 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 modeled using Chemshare and economic analysis completed. The facilities were optimized and operated unmanned.
TREATMENT OPTIONS DEVELOPMENT (Washburn)
Project Manager to conduct 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 (Laredo)
Project Manager for 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.
PROCESS TROUBLESHOOTING AND OPTIMIZATION (Taft)
Project Manager to troubleshoot liquid problems and process upsets at this plant. The system was modeled and various levels of processing options evaluated.
COMPRESSION STATION (Two South Texas stations)
Project Manager for planning through commissioning for two compression stations in South Texas. One station included separation, 3960 HP compression, air and fuel systems, and storage. The other station included separation, storage, 8400 HP compression and several miles of 16” & 12” pipeline.
PROCESS HAZARD ANALYSIS (Madisonville)
Led Process Hazard Analysis for this 18 MMscfd PSM facility. The facility was composed of inlet separation, 300 GPM amine treating, dehydration, compression, nitrogen rejection, acid gas injection, flare system and utilities.
PROCESS HAZARD ANALYSIS (Chatom)
Led PSM audit for this 40 MMSCFD sour gas plant and conducted PHA analysis, using HAZOP method. The scope involved updates of relevant documentation, including plot plans, PFD’s, P&ID, etc.
PLANT AND FIELD OPTIMIZATION (North Word)
Project Manager for 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 PLANT DEVELOPMENT (Schindler)
Project Engineer from concept through commissioning for a 80 GPM Amine facility, 4” pipeline, dehydration unit, storage, fuel system, and vent system. This PSM project included HAZOP.
AMINE PLANTS UPGRADES (South Texas)
Provided Basic Engineering and Detailed Engineering to upgrade and / or 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 (Equitorial Guinea)
Provided FEL 1 and 2 to evaluate 100 MMSCFD condensate liquid extraction plant. Capex and opex estimates were prepared to evaluate viabililty of increasing yield for this gas condensate early production facility.
FIELD OPTIMIZATION (Houston)
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.
- storage.
GRASS ROOTS PLANT DEVELOPMENT (Petru)
Project Manager for new gas processing facilities to allow production of shut-in gas due to excessive dewpoint spec’s.
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 (Piceance)
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 (La Gloria)
Project Manager for various upgrades to 35,000 HP compression equipment in this plant. Upgrades were implemented to improve reliability, reduce operating cost and improve fuel economy.
COMPRESSION FACILITY UPGRADES (Monte Christo)
Performed FEL 1 Conceptual engineering through commissioning to upgrade a 3200 HP compressor station. This included separation, air and fuel system, and blow case system.
PLANT CAPACITY EXPANSION (Destino)
Project Manager to design, procure, construct and commission 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.