Gas Processing Facilities

Gas Processing Facilities – Domestic
PROJECT: Septimus Sour Gas Plant Phase 1 – 20 MMSCFD, & Expansion to 40 MMSCFD
COMPANY: Crew Energy Inc.
LOCATION: Fort St. John, BC
Acero was responsible for the engineering, procurement and construction management of a 20 MMSCFD sour gas inlet refrigeration and LPG extraction plant, and expansion to handle 40 MMSCFD.  Scope of work included up front scoping support, including assessment of best location for plant placement, FEED and detailed design. Detailed deliverables included (but was not limited to) costing and controls, planning (scheduling), 3D model and associated outputs, E&I drawings, and I&C control schematics.costing and controls, planning (scheduling), logistics.

PROJECT:  Gas Plant Debottleneck and Expansion FEED and Detailed Engineering
COMPANY: Painted Pony Energy Ltd.
LOCATION: Fort St. John, BC
Acero’s scope of work included compressor installation to expand compression from 28 MMSCFD to 40 MMSCFD, flare system upgrade without taking the existing system offline, power generation expansion, coalescing filter installation, fuel gas measurement system, and regulatory support.

PROJECT: B-24-H Sour Gas Plant Debottleneck and Expansion FEED and Detailed Engineering
COMPANY: Confidential Client
LOCATION: Fort St. John, BC
Acero’s scope of work was to add an additional 40 MMSCFD train in parallel with an existing 20 MMSCFD raw gas facility.  Facility improvements included slug catcher, relocation and use of an available separator as FKOD for acid gas going to incinerator, evaluation and upgrade of gas power/ generator units to accommodate winter consumption (mainly heat tracing); associated instrumentation and control upgrades and accommodations.

PROJECT: Progress Venturi VRU
COMPANY: Confidential Client
LOCATION: Pouce, AB
Acero was responsible for the engineering, design, procurement and schedule of flare and VRU system revamp. Acero had already completed a capacity study to help plan for potential upgrades including the evaluation of all primary process equipment. Engineering assessments were completed for an estimate of fuel gas consumption, instrument air consumption, flare gas usage and as well, some blockage issues (resulting in thief hatch releases at the tank farm). Purge gas and venturi system designs were merged to minimize wasted gas (by conserving during tank out-breathing) and resolve thief hatch issues by providing positive gas during in-breathing.

PROJECT: McMahon Gas Plant Amine Still Replacement
COMPANY: Confidential Client
LOCATION: NE BC
Acero’s scope of work included the FEED, detailed engineering, and procurement for the replacement of an Amine Still (column #3) with an in-kind replacement, but constructed of 316 L stainless steel materials, at the McMahon Gas Plant.

Gas Processing Facilities – International
PROJECT: Badila Gas Injection
COMPANY: PCM, a Glencore Company
LOCATION: Chad, Africa
Acero was responsible for the detailed engineering and design, project controls, and technical support for all procurement activities for a gas injection facility capable of injecting 12 MMSCFD of gas at 1,500 psig.

PROJECT: Kurdamir Block Development
COMPANY: Confidential Client
LOCATION: Kurdistan, Iraq
Acero was responsible for a conceptual study for the development of the Kurdamir Block (Greenfield) in Kurdistan, Iraq. Scope of work included the conceptual study for 50,000 BOPD CPF and 300 MMSCFD gas plant c/w sulphur recovery, project scheduling and TIC estimate.

PROJECT: Amguri Interim Condensate Recovery
COMPANY: Canoro Resources Ltd.
LOCATION: Assam, India
Acero was responsible for the detailed engineering and design, procurement and logistics, and construction management of a brownfield, 20 MMSCFD gas inlet / 1,500 bpd condensate recovery project in remote, northeast India. With the reservoir in  “retrograde condensation” (ie. liquids being permanently lost in the reservoir due to depressurisation causing an in-situ gas to liquid phase change), the project was fast-tracked and interim condensate removal was installed.

Compressor Stations

PROJECT: Wilrich 16-27 Compressor Station Expansion FEED and Detailed Engineering
COMPANY: Confidential Client
LOCATION: Central AB
Acero was responsible for expanding the Wilrich compressor station with a historic throughput of 22 MMSCFD of raw gas and condensate.  The expansion was with a 48 MMSCFD train, parallel to the existing 22 MMSCFD facility; resulting in a total plant throughput capacity of 70 MMSCFD.  Other facility upgrades included 3 phase inlet separators, dehydrator, new MCC building, upgrade of existing incinerator burner, one new high pressure flare stack, one new flare knockout drum were also incorporated.

PROJECT: Daiber Compressor Station
COMPANY: Painted Pony Energy Inc.
LOCATION: Fort St. John, BC
Acero’s scope of work included the engineering, design and regulatory support of a new compressor/dehydration facility designed for 50 MMSCFD of high pressure production and 25 MMSCFD of lower pressure compression.  Water storage, power generation and sales gas metering was also required.

PROJECT: Gas Plant Debottleneck and Expansion
COMPANY: Painted Pony Energy Inc.
LOCATION:  Fort St. John, BC
Acero was responsible for the FEED, detailed engineering and regulatory support of a compression expansion from 28 MMSCFD to 40 MMSCFD.  Other facility upgrades included flare system upgrade, power generation including generator installation, and fuel gas measurement.

PROJECT: Pine Creek Compressor Station FEED
COMPANY: Confidential Client
LOCATION: Edson, AB
Acero’s scope of work included the engineering, procurement, and construction support of a green-field compressor station designed for 10 MMSCFD throughput of sour gas.

PROJECT: Pine Creek Compressor Station FEED
COMPANY: Confidential Client
LOCATION: Edson, AB
Acero was responsible for the engineering, design and procurement of a compressor station in order to process the production of new sour wells. Plant capacity designed to handle 20-25 MMSCFD of gas with a maximum liquid yield of 100 bbl/MMSCF.

Pump Stations

Pump Stations – Domestic
PROJECT: Booster Pump Installation
COMPANY: Pengrowth Energy Corp.
LOCATION: Judy Creek, AB
Acero was responsible for the detailed engineering and design, procurement of main equipment and construction support of a pump station in central Alberta.  The project featured two 750 HP pumps and housings to provide water injection capacity of 16,000 m³/d at 14,900 kPag.

PROJECT: Asset Circuitization Support
COMPANY: Confidential Client
LOCATION: Various
Acero’s scope of work was to inspect 70 sites (including several pump stations) and identify the circuitization loops and asset verification to assure integrity and safety.  Each site examined required tailoring of the inspection scrutiny based on operating conditions.

Pump Stations – International
PROJECT: Crude Oil Topping Unit
COMPANY: Griffiths, a Glencore Company
LOCATION: Chad, Africa
Acero was responsible for the conceptual study to evaluate the feasibility of installing crude oil topping at the initial pumping station of a 16” 520 km pipeline. Pipeline hydraulic simulations were also provided to analyze options for pump and heating stations, variations in MAOP, production capacities, pipeline sizes, based on crude oil assay and temperature.

Water Injection Facilities

Water Injection – Domestic
PROJECT: Water Injection Facility & Pipeline
COMPANY: Pengrowth Energy Corp.
LOCATION: Judy Creek, AB
Acero was responsible for the detailed engineering, design, procurement, regulatory support and construction management of a water injection facility and pipeline in Judy Creek, Alberta.  The project featured the installation of two salt water injection pipelines, facility piping, including pipeline tie-ins (as well as design considerations for future tie-ins), horizontal filter selection, pump design, line pipe design and selection.

PROJECT: Water Disposal Facility
COMPANY: Confidential Client
LOCATION: Peace River, AB
Acero was responsible for the detailed engineering, design, procurement and construction management of the expansion of an existing oil battery to incorporate water handling and disposal capability at the site.  The project featured new (fiberspar) pipelines to gather water from other batteries, and to deliver produced water to nearby disposal wells.  Facility work included the design and installation of three 2000 bbl water tanks, and various water transfer/skim oil/disposal pumps.

PROJECT: Parkland Water Injection
COMPANY: Confidential Client
LOCATION: Fort St. John, BC
Acero was responsible for the detailed design and procurement for a water disposal facility at the Parkland Gas Plant, capable of handling 300 m³/d, with the ability to expand to 600 m³/d in the future.  A new injection pump skid, condensate tank and pipeline will be installed as part of the project.

Water Injection – International
PROJECT: Acordionero Water Injection Facility
COMPANY: Gran Tierra Energy Inc.
LOCATION: San Martin, Colombia
Acero was responsible for providing a conceptual design for the expansion of the Acordionero central processing facility (CPF) to include produced water treatment and injection equipment. The new water handling facility was designed for a throughput capacity of 39,000 BWPD complete with necessary high pressure pipeline to inject through six (6) nearby injection wells each with two zones.

PROJECT: Badila CPF Water Injection Project
COMPANY: PCM, a Glencore Company
LOCATION: Chad, Africa
Acero was responsible for Pre-FEED and FEED  for a water treatment and injection facility over two phases (35,000 BWPD & 65,000 BWPD) by installing CPI, skimming tanks, booster pumps, filters and high pressure injection facility complete with a high pressure water injection network.  Scope of work also included an 8 MW gas to power generation facility, required to service the facilities increased power demand.

CLICK HERE TO DOWNLOAD our Water Handling Highlights Brochure

Oil Storage Facilities

Oil Storage Facilities – Domestic
PROJECT: Tank Replacements
COMPANY: Pengrowth Energy Corp.
LOCATION: Judy Creek, AB
Project featured the replacement of an existing 10,000 BBL shipping tank with 3,000 BBL tank, replacement of 3,000 BBL water tank with 2,000 BBL tank, on-site jack-n-roll relocation and refurbishment of 10,000 BBL produced water storage tank (including foundation design and roof replacement), and construction planning and schedule control.

PROJECT: Carson Creek Tank Installations
COMPANY: Pengrowth Energy Corp.
LOCATION: Carson Creek, AB
Project featured the detailed tank and foundation design and process review, procurement support of a 15,000 bbl produced water storage tank, and 10” flare installation to accommodate increased volume from tank.

Oil Storage Facilities – International
PROJECT: Acordionero Crude Oil Export P/L and Blending Terminal
COMPANY: Gran Teirra Energy Inc.
LOCATION: San Martin, Colombia
Acero was responsible for assessing two options to export crude oil from Acordionero Central Processing Facility (CPF).  Option one included a blending terminal near the CPF with a short pipeline to handle 15,000 bpd of crude oil.  The second option was to construct a new pipline 11km from the CPF to a new truck out facility. 

Pipeline Projects

Pipeline Projects – Domestic
PROJECT: Pipeline Project
COMPANY: Polar Star Oil and Gas Inc.
LOCATION: Laprise Creek, BC
Acero’s scope of work included the engineering and design, procurement, and regulatory support for a 10”, 12 km main trunk line with 4” parallel common ditch fuel gas pipeline, as part of a new gathering system.  Crossing considerations included 7 open-cut road allowances, 18 stream crossings (3 of which were bored), and 4 archaeological no-work zones, which were bored.

PROJECT: Gas Pipeline Replacements
COMPANY: Pengrowth Energy Corp.
LOCATION: Swan Hills, AB
Acero’s scope of work included the detailed design and procurement of multiple 4” to 12” LP & HP gas pipeline replacements (externally coated steel as well as free standing liner composite pipelines).  Projects featured a new pipeline separator (96” OD x 20’ S/S), surface piping, instrumentation and controls, pig launching and receiving facilities, major road and water crossings.

PROJECT: Pipeline Network Modeling
COMPANY: Pengrowth Energy Corp.
LOCATION: Irricana, AB
Project featured a Pipe-Flo model for the existing wells and pipelines in the Irricana area to evaluate the existing network, simulate options for the re-routing of production, and to bring low producing shut-in wells back online. Network contained 20 wells, 42 pipeline segments, and 1 booster compressor.

Pipeline Projects – International
PROJECT: Doseo Pipeline project FEED
COMPANY: Confidential Client
LOCATION: Chad, Africa
Scope of work consisted of cost estimating to support alternative configurations and options, development of temperature gradient monitoring, feasibility assessment of on-shore barge equipment, and development of estimating TIC template.

CLICK HERE TO DOWNLOAD our Pipeline Highlights Brochure

Pipeline Integrity Support

Pipeline Integrity Support Projects – International

PROJECT: Pipeline Integrity – Repairs, Sectional Replacements, and Rerouting
COMPANY: Confidential Client
LOCATION: Various

• Scope of work included the engineering and assessment of several temporary & permanent sleeve repairs between 8” – 22” designed to fit directly on pipe or with an elevated collar (dependent on severity of wrinkle).  Typical deliverables have included, repair drawings, Finite Element Analysis, fatigue analysis, and final report.
• Acero provided several design packages for partial pipeline replacements including rail, road and water body crossings.  Typical scope has included stress analysis, pipeline & riser details, bend specification & schedule and alignment sheets.

Power Generation

Power Generation – Domestic
PROJECT: Power Generation
COMPANY: Confidential Client
LOCATION: Central AB
Acero provided full engineering services for the scoping, design, procurement and installation of (currently) 16 MW of power (at five locations) so as to significantly reduce reliance on utility power costs while at the same time, taking advantage of available (cheap) fuel gas.

PROJECT: Power Generation
COMPANY: Confidential Client
LOCATION: Swan Hills, AB
Acero was responsible for evaluating two power generation scenarios for power generation with the option to sell excess power to the grid in the future.  Scope of work included feasibility and design, regulatory support, and construction and commissioning support.

Power Generation – International
PROJECT: Mangara Power Generation and Generation to Well Site FEED
COMPANY: PCM, a Glencore Company
LOCATION: Chad, Africa
Acero was responsible for completing a FEED study for the power generation (6 MW), sub-station and transmission line requirements to supply power to a minimum of 20 well sites with provision to expand to 50 well sites.  Scope of work included a technology optimization study, technical safety review and bid evaluations and recommendations.

PROJECT: Acordionero Power Generation and Distribution Pre-FEED
COMPANY: Gran Tierra Energy Inc.
LOCATION: San Martin, Colombia
Acero was responsible for a pre-FEED study to build a 15 MW central power generating facility located at the Acordionero CPF. The intent of the generation facility was to supply power to the CPF, water injection facility, truck loading and six (6) well pads via a transmission network. 

Specifications

PROJECT: Specification Development for E&P Facilities & Pipelines
COMPANY: Various
Acero has developed & implemented in-house mechanical specifications for Domestic and International energy companies.
A sample of some of the specifications that Acero has written include:

EQUIPMENT SPECIFICATIONS
• API 610 centrifugal pumps
• ASME B73.1 general sour horizontal centrifugal pumps
• Positive displacement/reciprocating pumps
• Direct and indirect fired heaters
• Heat medium package
• Pressure vessels and heat exchangers
• Above ground knock out drums

EI&C RELATED SPECIFICATIONS
• Emergency shutdown valves
• Instrumentation for skid-packaged equipment
• Design specifications: process design of flare and blowdown systems, pressure control and OPP guidelines, isolation standard

FACILITY PIPING SPECIFICATIONS
• Piping tables for B31.3, CSA B149.1, CSA Z662
• Services: sweet, sour, cryogenic, corrosive, fuel gas distribution system, liquid sulphur, utility, heating fluids, lubricants/hydraulic fluids
• Materials: carbon steel, stainless steel
• Manual valves
• Stainless steel tubing

OTHER SPECIFICATIONS AND STANDARDS
• Pressure welding (piping & equipment)
• Pig closure replacement procedure
• Bolting, gaskets and torquing
• Induction bends from steel pipe

International Project Highlights

International Project Highlights
Acero has successfully completed over 50 conceptual, Pre-FEED, FEED, Detailed Engineering and Construction Support Projects in Iraq, Egypt, Chad, Sudan, India, Russia and South America. Our extensive experience with full scopes of project work, from concept through detailed engineering and construction management, allows Acero to examine the feasibility of various options and work with our clients to select a ‘best path forward’ for development.

International Project Highlights Brochure CLICK HERE TO DOWNLOAD

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