PROJECT OVERVIEW (Deep Dive Example)
Project Scope:
Install a gas treatment and compression facility to:
• Sweeten 50 MMSCFD of sour gas (remove 2% H₂S, 4% CO₂)
• Dehydrate the gas (down to 5 lb/MMscf water content)
• Compress treated gas to 90 barg for pipeline export
1. PROJECT INITIATION & FEASIBILITY
Client Input & Feasibility Studies
• Feed gas composition is analyzed using gas chromatography.
• Simulation in HYSYS:
o Select amine process (MDEA vs DEA)
o Evaluate CO₂ slip for cost-saving
• TEG dehydration vs Molecular sieve compared:
o TEG selected due to moderate dew point spec and continuous operation
Key Output:
• Project Design Basis: Standard design doc used across disciplines.
• Risk Register: Identifies early HSE and constructability risks (e.g., sour gas handling)
2. BASIC ENGINEERING (FEED)
Process Engineering (PFDs, HMBs)
• Mass & energy balance using steady-state simulation
• Preliminary sizing of:
o Amine contactor (tray or packed? → packed selected for low-pressure drop)
o TEG reboiler duty
o Scrubbers, separators, knockout drums
• Control philosophy: Basic outline of trips, interlocks, start-up and shutdown logic
Plot Plan Development
• Consider compressor access, maintenance area, fire separation
• Flare KO drum placed downstream for emergency depressurizing
3. DETAILED ENGINEERING
Process (Advanced)
• Final P&IDs with valve numbers, tags, ESD/PSD zones
• Cause & Effect Matrix: Describes interlock logic
o Example: "High H₂S at outlet → shutdown amine feed + block gas inlet"
Mechanical
• Compressor Design:
o Vendor selection (Ariel, Dresser Rand)
o Define interstage scrubbers, pulsation bottles, suction/discharge drums
o Anti-surge system for centrifugal compressors
• Vessel Design:
o Amine Contactor: 24" ID x 60 ft H, 304L SS cladding inside
o Pressure vessel design per ASME Sec VIII Div 1
o Nozzle orientation, demister type, access manways
Electrical & Instrumentation
• DCS (DeltaV or Honeywell Experion), integration with field instruments
• Smart transmitters with HART/FOUNDATION Fieldbus
• ESD push buttons, flameproof JB layouts
• E&I cable schedules, termination drawings
Civil/Structural
• Foundation load data from vendors
• Dynamic analysis for reciprocating compressor block
• Vibration isolation pads, anchor bolt layouts
4. PROCUREMENT
Technical Evaluation
• Compressors: Motor vs Gas turbine driven
o Motor preferred for low OPEX & easy startup
• Skid Packages:
o Amine system: Tray design with rich/lean heat exchanger
o TEG system: Reboiler + flash tank + surge drum + filters
Logistics
• Freight forwarding, sea transport coordination
• Site handling plan for heavy equipment (>20 tons)
FAT Coordination
• Compressor skid: vibration test, lube oil skid check
• Control panels: PLC logic simulation
• Witnessed by QA/QC and client
5. CONSTRUCTION
Site Execution
• Early works: Surveying, fencing, civil excavation
• Erection: Equipment lifting with crane lift plans (heavy lift study for compressors)
• Piping:
o Isometric drawings
o Welding WPS, WPQ approval
o Radiography % as per piping class (e.g., 10% for Class 150, 100% for Class 600)
QA/QC Inspections
• Hydrotesting: Hold points as per ITP
• Paint DFT measurement
• Instrument loop continuity checks
HSE Focus
• H₂S area zoning, gas detectors, escape routes
• Permit to work (PTW) system enforced
6. PRE-COMMISSIONING
Activities
• Oil flushing (target NAS 6 or better)
• Air blowing with target velocity >90 m/s
• Electrical continuity and insulation resistance tests
• DCS loop checks: Simulated input → check final element response
7. COMMISSIONING
Key Steps
• Inerting with N₂ → Pressure hold → Leak check
• Fill and circulate amine → Check rich/lean loading
• Introduce sweet gas → Dehydrator drying → Pressure stabilization
• Compressor startup:
o Load sharing
o Intercooler temp checks
o Anti-surge control validation
Performance Tests
• H₂S < 4 ppm at outlet
• Water dew point < –5 °C
• Compressor discharge pressure 90 ±2 barg @ rated flow
8. HANDOVER
Final Deliverables
• Redline drawings → As-Built
• Final dossier (DCS configs, loop checks, FATs)
• O&M manuals: Startup, shutdown, maintenance
• Training sessions: On-site classroom + live demonstration
ADDITIONAL NOTES
Vendor Coordination
• Skid packages come partially assembled → tie-ins at site
• Compressor vendor provides commissioning engineer
• DCS vendor supports control loop tuning during startup
Lessons Learned (Typical)
• Early involvement of vendors reduces integration issues
• Compressor lube oil system issues delay commissioning if flushing isn’t proper
• Control loop tuning is critical for pressure stability at different loads