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LNG plant detail design

Regional LNG Plant Detail Design

The project is a Regional LNG plant detail design with a planned production rate of 20,000 GPD, and is intended to be the first of a series of installations.  Project value is about $40 million.

Sacré-Davey Engineering acted as owner’s engineer for detail design of regional Liquefied Natural Gas (LNG) plant as well as designing all Balance-of-Plant and interconnecting systems.  The plant is made up of three major procurement packages from three different vendors.   In addition to reviewing vendor designs and coordinating process conditions, SDE was responsible for civil design and plant layout, foundations for most of the equipment, piping and electrical interconnections, procurement support, and supervisory controls.  SDE also prepared permit submissions for the BC Oil and Gas Commission (BCOGC) and an AACE Class III cost estimate for the overall project.

Regional LNG Plant Detail Design

LNG plant detail design

The project is a Regional LNG plant detail design with a planned production rate of 20,000 GPD, and is intended to be the first of a series of installations.  Project value is about $40 million.

Sacré-Davey Engineering acted as owner’s engineer for detail design of regional Liquefied Natural Gas (LNG) plant as well as designing all Balance-of-Plant and interconnecting systems.  The plant is made up of three major procurement packages from three different vendors.   In addition to reviewing vendor designs and coordinating process conditions, SDE was responsible for civil design and plant layout, foundations for most of the equipment, piping and electrical interconnections, procurement support, and supervisory controls.  SDE also prepared permit submissions for the BC Oil and Gas Commission (BCOGC) and an AACE Class III cost estimate for the overall project.

LNG plant commissioning

LNG Plant Commissioning

LNG plant commissioning at the Yukon Energy Whitehorse Generating Station for peak power loads and generation backup. The project consists of an LNG unloading, storage, and vaporization facility, two new GE natural gas-fired engine modules with a total capacity of 8.8 MW, electrical substation upgrades, and network and other auxiliary systems.

Sacré-Davey Engineering acted as Commissioning Manager for Yukon Energy to oversee the overall commissioning effort.  SDE scheduled final construction and commissioning work, coordinated the commissioning work of contractors and major equipment suppliers, approved commissioning test plans and acceptance criteria, conducted inspections of vendor-supplied equipment, kept track of construction and commissioning deficiencies, and coordinated and monitored corrective actions.  SDE also compiled records of all testing for delivery to Yukon Energy and prepared commissioning submissions for regulatory agencies.  Commissioning of the majority of subsystems was completed to schedule, and there  was no time lost due to injuries.

LNG Plant Commissioning

LNG plant commissioning

LNG plant commissioning at the Yukon Energy Whitehorse Generating Station for peak power loads and generation backup. The project consists of an LNG unloading, storage, and vaporization facility, two new GE natural gas-fired engine modules with a total capacity of 8.8 MW, electrical substation upgrades, and network and other auxiliary systems.

Sacré-Davey Engineering acted as Commissioning Manager for Yukon Energy to oversee the overall commissioning effort.  SDE scheduled final construction and commissioning work, coordinated the commissioning work of contractors and major equipment suppliers, approved commissioning test plans and acceptance criteria, conducted inspections of vendor-supplied equipment, kept track of construction and commissioning deficiencies, and coordinated and monitored corrective actions.  SDE also compiled records of all testing for delivery to Yukon Energy and prepared commissioning submissions for regulatory agencies.  Commissioning of the majority of subsystems was completed to schedule, and there  was no time lost due to injuries.

plant wide energy audit

Plant Wide Energy Audit of a Pulp Mill

In the plant wide energy audit of a pulp mill, Sacré-Davey performed a full review of site electrical usage and equipment energy performance, as well as a concept-level assessment of potential energy-efficiency projects. Our Clean Tech team reviewed historical consumption, motor lists, DCS operation data and equipment performance. Our team then identified energy conservation measures, including various compressed air system improvements, installation of automatic on/off controls, and wood plant replacement, representing an annual savings of over $800,000.

 

Plant Wide Energy Audit of a Pulp Mill

plant wide energy audit

In the plant wide energy audit of a pulp mill, Sacré-Davey performed a full review of site electrical usage and equipment energy performance, as well as a concept-level assessment of potential energy-efficiency projects. Our Clean Tech team reviewed historical consumption, motor lists, DCS operation data and equipment performance. Our team then identified energy conservation measures, including various compressed air system improvements, installation of automatic on/off controls, and wood plant replacement, representing an annual savings of over $800,000.

 

natural gas audit

Pulp Mill Lime Kiln Natural Gas Audit

Sacré-Davey performed the natural gas audit in the 350 tonne/day lime kiln under FortisBC’s Powersense Program.  SDE reviewed best operating practices and worked with specialty suppliers to identify over 150,000 GJ/yr of potential energy savings.

SDE reviewed recent natural gas usage, operational data, drawings, and maintenance records, as well as conducting a site visit and interviewing operating and maintenance staff.  SDE identified several potential energy conservation measures and estimated cost and energy savings for each.  This included contacting vendors and researching similar projects which had been carried out in other pulp mills.  SDE reviewed the results with our client and prepared a summary report.

SDE identified nine potential energy-savings projects with a total savings of 260,000 GJ/yr, worth over $2.5 million per year to our client.

Pulp Mill Lime Kiln Natural Gas Audit

natural gas audit

Sacré-Davey performed the natural gas audit in the 350 tonne/day lime kiln under FortisBC’s Powersense Program.  SDE reviewed best operating practices and worked with specialty suppliers to identify over 150,000 GJ/yr of potential energy savings.

SDE reviewed recent natural gas usage, operational data, drawings, and maintenance records, as well as conducting a site visit and interviewing operating and maintenance staff.  SDE identified several potential energy conservation measures and estimated cost and energy savings for each.  This included contacting vendors and researching similar projects which had been carried out in other pulp mills.  SDE reviewed the results with our client and prepared a summary report.

SDE identified nine potential energy-savings projects with a total savings of 260,000 GJ/yr, worth over $2.5 million per year to our client.

plant wide audit

Gas Extraction Plant Wide Audit

Under the gas extraction plant wide audit, SDE  reviewed site electrical usage and equipment energy performance and delivered a concept level assessment of potential energy efficiency projects.

SDE reviewed historical consumption, motor lists, DCS operation data and equipment performance. SDE completed a site visit to review existing equipment and discuss potential projects with operations, maintenance, and engineering staff. SDE identified the following energy conservation measures.

Energy Conservation Measure Annual Savings
Cold Box Cleaning $235,000
Upgrade to Dry Gas Seals $250,000
Automated Control of ACHEs $35,000
Regen. Compressor Control $21,000
Reflux Pumps Control $18,000

Gas Extraction Plant Wide Audit

plant wide audit

Under the gas extraction plant wide audit, SDE  reviewed site electrical usage and equipment energy performance and delivered a concept level assessment of potential energy efficiency projects.

SDE reviewed historical consumption, motor lists, DCS operation data and equipment performance. SDE completed a site visit to review existing equipment and discuss potential projects with operations, maintenance, and engineering staff. SDE identified the following energy conservation measures.

Energy Conservation Measure Annual Savings
Cold Box Cleaning $235,000
Upgrade to Dry Gas Seals $250,000
Automated Control of ACHEs $35,000
Regen. Compressor Control $21,000
Reflux Pumps Control $18,000
energy efficiency feasibility study

Natural Gas Compressor Energy Efficiency Feasibility Study

This Energy Efficiency Feasibility Study provided various options to maximize the energy efficiency of the new equipment as AltaGas planned to replace an existing 800 HP natural gas compressor at their younger plant.

SDE reviewed the duty cycle and the specifications for the new compressor to estimate the baseline energy use. SDE developed several design options to reduce energy use and performed a feasibility level assessment of each of the options shown in the table below.  The study was 100% funded by BC Hydro PowerSmart, and AltaGas received an implementation incentive for their chosen option.

Energy Conservation Measure Annual Savings
Install a VFD and resize the compressor cylinders (smaller) $73,000
Install a VFD resize the compressor cylinders (smaller) and install a pre-cooler $87,000
Install inlet valve control on two cylinders and VFD on aftercooler fan $40,000
Install inlet valve control on two cylinders and resize the compressor cylinders (smaller) $66,000

Natural Gas Compressor Energy Efficiency Feasibility Study

energy efficiency feasibility study

This Energy Efficiency Feasibility Study provided various options to maximize the energy efficiency of the new equipment as AltaGas planned to replace an existing 800 HP natural gas compressor at their younger plant.

SDE reviewed the duty cycle and the specifications for the new compressor to estimate the baseline energy use. SDE developed several design options to reduce energy use and performed a feasibility level assessment of each of the options shown in the table below.  The study was 100% funded by BC Hydro PowerSmart, and AltaGas received an implementation incentive for their chosen option.

Energy Conservation Measure Annual Savings
Install a VFD and resize the compressor cylinders (smaller) $73,000
Install a VFD resize the compressor cylinders (smaller) and install a pre-cooler $87,000
Install inlet valve control on two cylinders and VFD on aftercooler fan $40,000
Install inlet valve control on two cylinders and resize the compressor cylinders (smaller) $66,000

Energy Management Information Systems Study

Client: Potash Corp.

Under the SaskPower Industrial Energy Optimization Program, SDE performed Energy Management Information Systems (EMIS) studies for corporate and individual site levels. SDE visited the sites and interviewed the stakeholders to determine their needs and define appropriate EMIS. We then evaluated existing data collection, analysis, and reporting systems to identify gaps and estimated EMIS costs and potential energy savings and outlined a program to implement the proposed system.

Energy Management Information Systems Study

Client: Potash Corp.

Under the SaskPower Industrial Energy Optimization Program, SDE performed Energy Management Information Systems (EMIS) studies for corporate and individual site levels. SDE visited the sites and interviewed the stakeholders to determine their needs and define appropriate EMIS. We then evaluated existing data collection, analysis, and reporting systems to identify gaps and estimated EMIS costs and potential energy savings and outlined a program to implement the proposed system.

Electric Arc Furnace Upgrade Feasibility Study

A review of the existing electric arc furnace plus a concept level assessment of potential energy efficiency projects for a manufacturer of wear parts for the mining and construction industries.

SDE reviewed the existing technology, electrical performance and operation of the electric arc furnace. SDE reviewed modern technologies, issued RFPs for various upgrades and estimated project costs. SDE identified two energy conservation measures. The client chose to implement the option below.

Energy Conservation Measure Annual Savings
Replace the electrode regulation system with improved technology $18,000
Install an intelligent control system $60,000

Electric Arc Furnace Upgrade Feasibility Study

A review of the existing electric arc furnace plus a concept level assessment of potential energy efficiency projects for a manufacturer of wear parts for the mining and construction industries.

SDE reviewed the existing technology, electrical performance and operation of the electric arc furnace. SDE reviewed modern technologies, issued RFPs for various upgrades and estimated project costs. SDE identified two energy conservation measures. The client chose to implement the option below.

Energy Conservation Measure Annual Savings
Replace the electrode regulation system with improved technology $18,000
Install an intelligent control system $60,000

New Plant Design Energy Efficiency Review

A review of the design of a planned canola oil shipping terminal for potential energy savings. This study focused on the canola oil rail car unloading and marine loading systems.

SDE reviewed the preliminary design plans of the canola oil pipeline and pump system. This new plant design review provided additional engineering to assess the lifecycle costs associated with pipe diameter, type and size of pumps, and flow control equipment and was 100% funded by BC Hydro PowerSmart. SDE identified several power-saving options; the client’s chosen option was estimated to save $57,000 in electric costs per year. The client qualified for an implementation incentive of $270,000 and decided to implement the project.

New Plant Design Energy Efficiency Review

A review of the design of a planned canola oil shipping terminal for potential energy savings. This study focused on the canola oil rail car unloading and marine loading systems.

SDE reviewed the preliminary design plans of the canola oil pipeline and pump system. This new plant design review provided additional engineering to assess the lifecycle costs associated with pipe diameter, type and size of pumps, and flow control equipment and was 100% funded by BC Hydro PowerSmart. SDE identified several power-saving options; the client’s chosen option was estimated to save $57,000 in electric costs per year. The client qualified for an implementation incentive of $270,000 and decided to implement the project.

Refrigeration System Energy Efficiency Feasibility Study

A commercial bakery planned to replace the refrigeration system which provides cooling of dough during mixing.  The bakery retained SDE to evaluate the three options quoted by the vendor and determine the potential energy savings for each.

SDE verified the refrigeration heat loads, daily and seasonal duty cycles, and equipment sizing requirements.  SDE evaluated the expected energy use of the baseline system (replace in kind) and of the three alternatives and determined energy savings and expected payback for each alternative.  SDE also presented several additional design and operational suggestions for additional energy savings.

Estimated energy savings: $70,000 to $100,000 per year

Refrigeration System Energy Efficiency Feasibility Study

A commercial bakery planned to replace the refrigeration system which provides cooling of dough during mixing.  The bakery retained SDE to evaluate the three options quoted by the vendor and determine the potential energy savings for each.

SDE verified the refrigeration heat loads, daily and seasonal duty cycles, and equipment sizing requirements.  SDE evaluated the expected energy use of the baseline system (replace in kind) and of the three alternatives and determined energy savings and expected payback for each alternative.  SDE also presented several additional design and operational suggestions for additional energy savings.

Estimated energy savings: $70,000 to $100,000 per year

Waste Water Treatment

Sacré-Davey designed, integrated and delivered this 16,000 GPD waste water treatment plant for treatment and removal of heavy metals in solution.

Specific to this project was the removal and destruction of hexavalent chrome, a known cancer causing agent. Project exceeded treatment expectations.

Waste Water Treatment

Sacré-Davey designed, integrated and delivered this 16,000 GPD waste water treatment plant for treatment and removal of heavy metals in solution.

Specific to this project was the removal and destruction of hexavalent chrome, a known cancer causing agent. Project exceeded treatment expectations.

PCB Treatment

Sacré-Davey worked with Sonic Environmental to scale up their PCB destruction process.  Sonic’s novel process recovered PCB’s from contaminated soil using mining technologies.  Sacré-Davey floated contaminates from the soil into a liquor, allowing clean soil to be returned.  The subsequent PCB-containing liquor was destroyed using Sonic’s proprietary Sono Process. Sacré-Davey provided all engineering, project management, and start-up services.

PCB Treatment

Sacré-Davey worked with Sonic Environmental to scale up their PCB destruction process.  Sonic’s novel process recovered PCB’s from contaminated soil using mining technologies.  Sacré-Davey floated contaminates from the soil into a liquor, allowing clean soil to be returned.  The subsequent PCB-containing liquor was destroyed using Sonic’s proprietary Sono Process. Sacré-Davey provided all engineering, project management, and start-up services.

LNG Cold Box

Sacré-Davey provided the engineering check, including sealing of all drawings, for a replacement LNG Cold Box designed and fabricated by Chart Energy & Chemicals. The engineering check included structural (including seismic), mechanical, pipe stressing, and electrical and instrumentation. Sacré-Davey also engineered the modifications of the existing cold box foundation to suit the new cold box, and provided field review services on behalf of Chart Energy & Chemicals.

LNG Cold Box

Sacré-Davey provided the engineering check, including sealing of all drawings, for a replacement LNG Cold Box designed and fabricated by Chart Energy & Chemicals. The engineering check included structural (including seismic), mechanical, pipe stressing, and electrical and instrumentation. Sacré-Davey also engineered the modifications of the existing cold box foundation to suit the new cold box, and provided field review services on behalf of Chart Energy & Chemicals.

Sugar to Glycol Pilot Plant Design

Sacré-Davey provided design and drafting services for this pilot plant project led by our partner, S2G BioChem. Our team worked with S2G to provide foundation and spill containment design, process mechanical engineering support, HAZOP review services, and chiller and hot oil utility specifications.

Sugar to Glycol Pilot Plant Design

Sacré-Davey provided design and drafting services for this pilot plant project led by our partner, S2G BioChem. Our team worked with S2G to provide foundation and spill containment design, process mechanical engineering support, HAZOP review services, and chiller and hot oil utility specifications.

Wind Turbine-Hydrogen Energy System Feasibility Study

Sacré-Davey was contracted to undertake a study regarding the installation of wind turbines at a remote shipping port to power the industrial operation and buildings.Our team produced an energy model to determine the energy balance, production rates and Hydrogen storage on the basis of wind and grid demand data from site on 10-minute intervals. An economic model was produced to estimate the CAPEX and OPEX of the energy system. This study concluded the system can be made to produce power in the Northern climate to offset up to 70% of the electricity produced by diesel generators.

Wind Turbine-Hydrogen Energy System Feasibility Study

Sacré-Davey was contracted to undertake a study regarding the installation of wind turbines at a remote shipping port to power the industrial operation and buildings.Our team produced an energy model to determine the energy balance, production rates and Hydrogen storage on the basis of wind and grid demand data from site on 10-minute intervals. An economic model was produced to estimate the CAPEX and OPEX of the energy system. This study concluded the system can be made to produce power in the Northern climate to offset up to 70% of the electricity produced by diesel generators.

Gas Pipeline Compressor Station

Sacré-Davey performed a new plant design study on a new 460-km natural gas pipeline and compressor station. Our team reviewed the specifications for the planned pipeline and Phase 1 and 2 compressor station, including the natural gas compressors, cooling system, and auxiliary systems.  The study identified opportunities for the client to reduce fuel costs, including pipeline efficiency improvements, waste heat recovery co-generation, and compressor VFD modifications, representing annual savings of more than $7 million.

Gas Pipeline Compressor Station

Sacré-Davey performed a new plant design study on a new 460-km natural gas pipeline and compressor station. Our team reviewed the specifications for the planned pipeline and Phase 1 and 2 compressor station, including the natural gas compressors, cooling system, and auxiliary systems.  The study identified opportunities for the client to reduce fuel costs, including pipeline efficiency improvements, waste heat recovery co-generation, and compressor VFD modifications, representing annual savings of more than $7 million.

Hydrogen Recovery and Utilization System

Sacré-Davey Engineering performed a definition-level study of a $20,000,000 integrated waste hydrogen gas collection, purification, compression, storage, and distribution facility. Flow up to 5,500,000 scfd of hydrogen needed to be collected from two separate sources, dehydrated, and scrubbed of contaminants, using Sacré-Davey’s proprietary ScrubTechTM technology and ultimately purified using Pressure Swing Adsorption Technology. Purified gas was compressed to 5000 psig using a combination of reciprocating and diaphragm compressors and stored in carbon fiber-reinforced aluminum storage tanks.

Hydrogen Recovery and Utilization System

Sacré-Davey Engineering performed a definition-level study of a $20,000,000 integrated waste hydrogen gas collection, purification, compression, storage, and distribution facility. Flow up to 5,500,000 scfd of hydrogen needed to be collected from two separate sources, dehydrated, and scrubbed of contaminants, using Sacré-Davey’s proprietary ScrubTechTM technology and ultimately purified using Pressure Swing Adsorption Technology. Purified gas was compressed to 5000 psig using a combination of reciprocating and diaphragm compressors and stored in carbon fiber-reinforced aluminum storage tanks.

Mobile Hydrogen Refueller

Sacré-Davey Innovations successfully delivered a mobile hydrogen fuelling station to Air Liquide Canada. The station stores over 100 kg of gaseous hydrogen at 450 bar (6500 psig) and is capable of filling vehicles to 350 bar (5000 psig) pressure. The station also features on board gas boosters that allow boosting of pressure from tube trailers and the station’s buffers.

Mobile Hydrogen Refueller

Sacré-Davey Innovations successfully delivered a mobile hydrogen fuelling station to Air Liquide Canada. The station stores over 100 kg of gaseous hydrogen at 450 bar (6500 psig) and is capable of filling vehicles to 350 bar (5000 psig) pressure. The station also features on board gas boosters that allow boosting of pressure from tube trailers and the station’s buffers.

Whistler Liquid Hydrogen Station

Sacré-Davey Engineering performed mechanical, electrical, and structural design, as well as codes and standards support, for a liquid hydrogen fuelling station located in Whistler, BC.  The station dispenses hydrogen to a fleet of 20 transit buses, and has been in operation since 2009.

Whistler Liquid Hydrogen Station

Sacré-Davey Engineering performed mechanical, electrical, and structural design, as well as codes and standards support, for a liquid hydrogen fuelling station located in Whistler, BC.  The station dispenses hydrogen to a fleet of 20 transit buses, and has been in operation since 2009.

Copper mine audit

Copper Mine Plant-Wide Audit

For this audit, Sacré-Davey reviewed historical consumption, metered power reports, DCS operation data and equipment performance. Sacré-Davey also completed a site visit to review existing equipment and discuss potential projects with operations, maintenance, and engineering staff.  Our team identified energy conservation measures including improved ball mill loading, re-routing of seepage water discharge, and re-rating aeration blowers, representing potential annual savings of over $500,000.

Copper Mine Plant-Wide Audit

Copper mine audit

For this audit, Sacré-Davey reviewed historical consumption, metered power reports, DCS operation data and equipment performance. Sacré-Davey also completed a site visit to review existing equipment and discuss potential projects with operations, maintenance, and engineering staff.  Our team identified energy conservation measures including improved ball mill loading, re-routing of seepage water discharge, and re-rating aeration blowers, representing potential annual savings of over $500,000.