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900 TPH Specialty Grain Shiploading System

Sacré-Davey’s client requested a new 900 TPH portable shiploader capable of loading numerous ships including a Gearbulk Generation 5 Ship. The shiploader embodied 3 separate conveying systems, including the tail conveyor, main boom conveyor, 28′ telescoping stinger and soft spout.

Sacré-Davey provided complete civil, structural, mechanical, and electrical design services for the concept, detailed design, and construction of the shiploader, shuttle and tie-in systems.

900 TPH Specialty Grain Shiploading System

Sacré-Davey’s client requested a new 900 TPH portable shiploader capable of loading numerous ships including a Gearbulk Generation 5 Ship. The shiploader embodied 3 separate conveying systems, including the tail conveyor, main boom conveyor, 28′ telescoping stinger and soft spout.

Sacré-Davey provided complete civil, structural, mechanical, and electrical design services for the concept, detailed design, and construction of the shiploader, shuttle and tie-in systems.

automated conveyor sampler

Automated Conveyor Sampler Design and Installation

The installation of an automated conveyor sampler for a 3000 tph material stream. SDE provided complete design and project management services for the installation of the sample taker, stream splitter, bagger and return conveyor. The scope included civil, structural, mechanical (materials handling), electrical and controls engineering.

Automated Conveyor Sampler Design and Installation

automated conveyor sampler

The installation of an automated conveyor sampler for a 3000 tph material stream. SDE provided complete design and project management services for the installation of the sample taker, stream splitter, bagger and return conveyor. The scope included civil, structural, mechanical (materials handling), electrical and controls engineering.

bakery decommissioning

Bakery Decommissioning: Engineering & Project Management

Bakery decommissioning: manufacturing plant and distribution center, and building repairs and modifications.

SDE provided Engineering expertise and managed the project from concept to completion. Project scope included:

  • Scope definition and cost estimating, through discussions with client and negotiations with the landlord.
  • Removal of the equipment for use in other facilities, for sale or for scrap.
  • Building repairs and modifications as per agreed upon scope with client and landlord.
  • Final reviews and approvals with client, landlord and authorities.

Project achieved all defined objectives, completed on time and under budget.

Bakery Decommissioning: Engineering & Project Management

bakery decommissioning

Bakery decommissioning: manufacturing plant and distribution center, and building repairs and modifications.

SDE provided Engineering expertise and managed the project from concept to completion. Project scope included:

  • Scope definition and cost estimating, through discussions with client and negotiations with the landlord.
  • Removal of the equipment for use in other facilities, for sale or for scrap.
  • Building repairs and modifications as per agreed upon scope with client and landlord.
  • Final reviews and approvals with client, landlord and authorities.

Project achieved all defined objectives, completed on time and under budget.

Building Expansion and Installation of a Tortilla Line

Sacré-Davey Engineering provided complete project management services and detailed engineering for a 10,000 sq. ft. expansion which involved the installation of a new tortilla manufacturing and packing line, ingredient storage, and silo enclosure. This project included important site works such as interior painting of the existing bakery, expansion of the parking area, repairs to the roofing and driveway, and yard improvements to resolve seasonal swamping.

Building Expansion and Installation of a Tortilla Line

Sacré-Davey Engineering provided complete project management services and detailed engineering for a 10,000 sq. ft. expansion which involved the installation of a new tortilla manufacturing and packing line, ingredient storage, and silo enclosure. This project included important site works such as interior painting of the existing bakery, expansion of the parking area, repairs to the roofing and driveway, and yard improvements to resolve seasonal swamping.

Canola Oil Transfer and Storage

Sacré-Davey was contracted to prepare an engineer’s study and AACE class 2 capital cost estimate for a canola oil transfer and storage system. The study included process equipment, tanks and piping specification, selection and budgeting. Modification to the railcar unloading and marine loading area was required to accommodate the transfer of the canola oil. Pumps and process piping were optimized in conjunction with a BC Hydro Power Smart study.

Canola Oil Transfer and Storage

Sacré-Davey was contracted to prepare an engineer’s study and AACE class 2 capital cost estimate for a canola oil transfer and storage system. The study included process equipment, tanks and piping specification, selection and budgeting. Modification to the railcar unloading and marine loading area was required to accommodate the transfer of the canola oil. Pumps and process piping were optimized in conjunction with a BC Hydro Power Smart study.

Machine that stores carbon dioxide

Carbon Dioxide Storage & Injection System

Sacré-Davey was contracted by Air Liquide Canada to perform the process, structural, civil, mechanical, and electrical engineering services for a CO2 storage and injection facility. Sacré-Davey performed a computer simulation of the process with VMGSim™ to check the heat and material balance, and provided equipment specifications and detailed design of four equipment skids including a refrigeration system and all field piping. Sacré-Davey designed the power distribution and instrumentation systems, the storage vessel foundations, and site road access.

Carbon Dioxide Storage & Injection System

Machine that stores carbon dioxide

Sacré-Davey was contracted by Air Liquide Canada to perform the process, structural, civil, mechanical, and electrical engineering services for a CO2 storage and injection facility. Sacré-Davey performed a computer simulation of the process with VMGSim™ to check the heat and material balance, and provided equipment specifications and detailed design of four equipment skids including a refrigeration system and all field piping. Sacré-Davey designed the power distribution and instrumentation systems, the storage vessel foundations, and site road access.

Compression station unit

Compressor Station Unit

Sacré-Davey has been contracted to switch a Taylor Compressor Station 1 (CS-1) Unit 15 from sweet residue gas service to sour service, replacing the existing 50 years old reciprocating compressors. Project objectives include reducing CS-1 operating costs by replacing the current compressors with the more efficient, reliable and cost-effective turbine compressor Unit 15. With this project, Sacré-Davey will improve the reliability and efficiency of the compressor station while avoiding the high capital and installation costs of a new compressor.

Compressor Station Unit

Compression station unit

Sacré-Davey has been contracted to switch a Taylor Compressor Station 1 (CS-1) Unit 15 from sweet residue gas service to sour service, replacing the existing 50 years old reciprocating compressors. Project objectives include reducing CS-1 operating costs by replacing the current compressors with the more efficient, reliable and cost-effective turbine compressor Unit 15. With this project, Sacré-Davey will improve the reliability and efficiency of the compressor station while avoiding the high capital and installation costs of a new compressor.

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.

Facility of depropanizer tower

Depropanizer Tower Replacement

Sacré-Davey provided full-scope engineering services and project management for the preparation of drawings, bid package for purchase, as well as all necessary purchasing and construction documents for an existing depropanizer tower which had reached the end of its service life. Our client wanted to replace the existing tower and meet new capacity and feed conditions. Sacré-Davey simulated the tower with the new feed composition and increased rate.  The simulation showed that the existing tower diameter was adequate but high-capacity trays were required to match the new feed composition and rate.

Depropanizer Tower Replacement

Facility of depropanizer tower

Sacré-Davey provided full-scope engineering services and project management for the preparation of drawings, bid package for purchase, as well as all necessary purchasing and construction documents for an existing depropanizer tower which had reached the end of its service life. Our client wanted to replace the existing tower and meet new capacity and feed conditions. Sacré-Davey simulated the tower with the new feed composition and increased rate.  The simulation showed that the existing tower diameter was adequate but high-capacity trays were required to match the new feed composition and rate.

dough mixers refrigeration system

Dough Mixers Refrigeration System Glycol Conversion

Conversion of the existing dough mixers refrigeration system from a “Direct expansion” system to “Glycol” system and complete overhaul of the 2500 lb. bread dough mixers.

SDE provided Engineering expertise and managed the project from concept to completion. Project scope included:

  • Design and construction of an addition to the existing building to accommodate the new Glycol system.
  • Installation of the new Glycol system, including Glycol tank, pumps, control panel, pipes, valves and tie in to the existing Mixers and compressors.
  • Complete overhaul of the Bread mixers and replacement of the dough bowls and refrigeration jackets.
  • Design and installation of the temporary reinforcements and shoring of the existing elevated concrete floor slab during installation.

Project achieved all defined objectives and resolved the environmental issues associated with the old system.

Dough Mixers Refrigeration System Glycol Conversion

dough mixers refrigeration system

Conversion of the existing dough mixers refrigeration system from a “Direct expansion” system to “Glycol” system and complete overhaul of the 2500 lb. bread dough mixers.

SDE provided Engineering expertise and managed the project from concept to completion. Project scope included:

  • Design and construction of an addition to the existing building to accommodate the new Glycol system.
  • Installation of the new Glycol system, including Glycol tank, pumps, control panel, pipes, valves and tie in to the existing Mixers and compressors.
  • Complete overhaul of the Bread mixers and replacement of the dough bowls and refrigeration jackets.
  • Design and installation of the temporary reinforcements and shoring of the existing elevated concrete floor slab during installation.

Project achieved all defined objectives and resolved the environmental issues associated with the old 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

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.

Filtrate Pump System Study

The client was experiencing cavitation and weld failures on the downstream side of the Pulp and Paper Dilution tank level control valves. SDE was contracted to study the system and identify the cause of the cavitation and make recommendations for remedy. Sacre-Davey Engineering conducted field measurements, pump system analysis, and hydraulic analysis. The recommendations included removing high pressure drop devices, changing the control system from a control valve to a variable frequency drive motor, and matching the pump speed to the system requirements. The energy reduction from 200 HP to 75 HP pump motors and control system changes projected a savings of 1,670 MWh/yr, substantial enough for significant BC Hydro PowerSmart funding.

Filtrate Pump System Study

The client was experiencing cavitation and weld failures on the downstream side of the Pulp and Paper Dilution tank level control valves. SDE was contracted to study the system and identify the cause of the cavitation and make recommendations for remedy. Sacre-Davey Engineering conducted field measurements, pump system analysis, and hydraulic analysis. The recommendations included removing high pressure drop devices, changing the control system from a control valve to a variable frequency drive motor, and matching the pump speed to the system requirements. The energy reduction from 200 HP to 75 HP pump motors and control system changes projected a savings of 1,670 MWh/yr, substantial enough for significant BC Hydro PowerSmart funding.

Fish Oil Omega 3 Concentration

SDE3 was retained to develop a novel, ship-mounted process for concentrating high value omega-3 and omega-6 fatty acids from fish oil. SDE3 developed an interesterification technology that would concentrate higher molecular weight unsaturated fatty acids, without losing the natural triglyceride structure.

SDE3 set up and conducted laboratory trials to validate the process and determine operating parameters for a commercial scale operation. Following laboratory trials, a capital estimate was developed for installing the process on board a factory trawler that had been previously removed from service.

The mobile oil processing factory would be located close to the Bering Sea fishing grounds to allow immediate processing into value-added products.

Fish Oil Omega 3 Concentration

SDE3 was retained to develop a novel, ship-mounted process for concentrating high value omega-3 and omega-6 fatty acids from fish oil. SDE3 developed an interesterification technology that would concentrate higher molecular weight unsaturated fatty acids, without losing the natural triglyceride structure.

SDE3 set up and conducted laboratory trials to validate the process and determine operating parameters for a commercial scale operation. Following laboratory trials, a capital estimate was developed for installing the process on board a factory trawler that had been previously removed from service.

The mobile oil processing factory would be located close to the Bering Sea fishing grounds to allow immediate processing into value-added products.

fondant icing production line

Fondant Icing Production Line Upgrade

Sacré-Davey provided complete engineering, project management, and procurement services for a Fondant Icing production line expansion.

The final design included strategic replacement of aging equipment combined with new equipment to allow for continuous production and pack-out with a 250% increase in throughput.  Plant infrastructure improvements include two new 10,000 gallon bulk ingredient storage tanks and automated ingredient delivery systems.

 

Fondant Icing Production Line Upgrade

fondant icing production line

Sacré-Davey provided complete engineering, project management, and procurement services for a Fondant Icing production line expansion.

The final design included strategic replacement of aging equipment combined with new equipment to allow for continuous production and pack-out with a 250% increase in throughput.  Plant infrastructure improvements include two new 10,000 gallon bulk ingredient storage tanks and automated ingredient delivery systems.

 

Food Processing Line & Building Expansion

Sacré-Davey provided complete project management services for a 7,100 square foot expansion which involved the relocation of two existing pasta lines and the installation of a new pasta line within the existing building.  This expansion also included the new packaging facility for the pasta lines, a new truck loading bay, and an office complex.

Food Processing Line & Building Expansion

Sacré-Davey provided complete project management services for a 7,100 square foot expansion which involved the relocation of two existing pasta lines and the installation of a new pasta line within the existing building.  This expansion also included the new packaging facility for the pasta lines, a new truck loading bay, and an office complex.

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

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.

Upgraded ratio for operating mines

High Upgrade Ratio for Operating Mine

This confidential active silver mine was able to reject 80-90% of current ore while maintaining 94-96% recovery. Ore sorting had a large impact on project economics by increasing mine tonnage, sorting old waste piles and increasing silver production while lowering milling costs.

High Upgrade Ratio for Operating Mine

Upgraded ratio for operating mines

This confidential active silver mine was able to reject 80-90% of current ore while maintaining 94-96% recovery. Ore sorting had a large impact on project economics by increasing mine tonnage, sorting old waste piles and increasing silver production while lowering milling costs.

Hog Fuel Handling

Sacré-Davey provided complete civil, structural, and mechanical design services for the detail design and concept review of the materials handling system. The new hog fuel handling system receives, processes, stacks, and reclaims hog fuel at a rate of 150 metric tonnes per hour to the newly converted boiler at Crestbrook’s Skookumchuck Mill.  The project encompassed a new truck dumper, screening system, hog hammermill/conditioning system, stacker/reclaimer, boiler delivery, and return conveyors.

Hog Fuel Handling

Sacré-Davey provided complete civil, structural, and mechanical design services for the detail design and concept review of the materials handling system. The new hog fuel handling system receives, processes, stacks, and reclaims hog fuel at a rate of 150 metric tonnes per hour to the newly converted boiler at Crestbrook’s Skookumchuck Mill.  The project encompassed a new truck dumper, screening system, hog hammermill/conditioning system, stacker/reclaimer, boiler delivery, and return conveyors.

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.

hydrogen storage

Hydrogen Storage & Transport System

SDE3 was retained to provide design and scale-up of a process for safe hydrogen storage and retrieval hydrogen via manipulation of a proprietary liquid media based on nano-tech, self-assembling molecules. Applications for the technology included automotive fuel, off-peak electrical energy storage, and bulk storage of hydrogen. SDE3 investigated the feasibility and economics of the process scale-up. SDE3 developed a detailed fluidized bed reactor simulation and preliminary design of hydrogenation and dehydrogenation commercial-scale systems. SDE3 also developed a commercial synthetic procedure to produce the self-assembling molecule in bulk quantity.

Hydrogen Storage & Transport System

hydrogen storage

SDE3 was retained to provide design and scale-up of a process for safe hydrogen storage and retrieval hydrogen via manipulation of a proprietary liquid media based on nano-tech, self-assembling molecules. Applications for the technology included automotive fuel, off-peak electrical energy storage, and bulk storage of hydrogen. SDE3 investigated the feasibility and economics of the process scale-up. SDE3 developed a detailed fluidized bed reactor simulation and preliminary design of hydrogenation and dehydrogenation commercial-scale systems. SDE3 also developed a commercial synthetic procedure to produce the self-assembling molecule in bulk quantity.

port facility

Kinder Morgan Port Facility

Sacré-Davey Engineering provided services for Kinder Morgan Port Facility project that consisted of two phases.

Phase 1 – Feasibility study for the installation of a network of conveyors and transfer chutes to transport copper concentrate from their existing rail car unloading system to a storage shed.

  • In Phase 1, SDE produced a number of concept designs. Option evaluation and value engineering as preformed between the SDE engineering team and the SDE estimating group to provide the client with the appropriate information to select a concept and budget on which to proceed.

Phase 2- Comprehensive detailed design construction package for the concept produced in Phase 1.

  • In Phase 2, SDE completed the design of the conveyors, transfer chutes and transfer towers. In addition, SDE developed the purchasing specifications where applicable performance specifications for the equipment purchased by Kinder Morgan.

SDE also designed the modifications to existing structures and foundations as well as the new transfer towers supporting the conveyors.

Kinder Morgan Port Facility

port facility

Sacré-Davey Engineering provided services for Kinder Morgan Port Facility project that consisted of two phases.

Phase 1 – Feasibility study for the installation of a network of conveyors and transfer chutes to transport copper concentrate from their existing rail car unloading system to a storage shed.

  • In Phase 1, SDE produced a number of concept designs. Option evaluation and value engineering as preformed between the SDE engineering team and the SDE estimating group to provide the client with the appropriate information to select a concept and budget on which to proceed.

Phase 2- Comprehensive detailed design construction package for the concept produced in Phase 1.

  • In Phase 2, SDE completed the design of the conveyors, transfer chutes and transfer towers. In addition, SDE developed the purchasing specifications where applicable performance specifications for the equipment purchased by Kinder Morgan.

SDE also designed the modifications to existing structures and foundations as well as the new transfer towers supporting the conveyors.

Man looking at molybdenum rocks

Large Copper Molybdenum Greenfield Project

For the American CuMo Mining Corporation, Sacré-Davey performed a scoping study to investigate the technical and economic impact of ore sorting. X-ray based sorting was able to discard 50-75% of coarse material as waste.

Large Copper Molybdenum Greenfield Project

Man looking at molybdenum rocks

For the American CuMo Mining Corporation, Sacré-Davey performed a scoping study to investigate the technical and economic impact of ore sorting. X-ray based sorting was able to discard 50-75% of coarse material as waste.

Liquid natural gas production

Liquid Natural Gas Production/Dispensing Facilitiy

Sacré-Davey Engineering and Berg Chilling Systems Inc. (Berg) investigated the feasibility and costs of building and operating a small scale liquefied natural gas (LNG) plant to produce, store, and dispense LNG to a fleet of 50 trucks employing Westport High Pressure Direct Injection (HPDI) natural gas engines. Sacré-Davey prepared process flow diagrams and equipment layout and preliminary site plans. Sacré-Davey also prepared a Class III cost estimate to compare the cost for the purchase and installation of the packaged facility versus the cost for a facility consisting of individual integrated equipment.

Liquid Natural Gas Production/Dispensing Facilitiy

Liquid natural gas production

Sacré-Davey Engineering and Berg Chilling Systems Inc. (Berg) investigated the feasibility and costs of building and operating a small scale liquefied natural gas (LNG) plant to produce, store, and dispense LNG to a fleet of 50 trucks employing Westport High Pressure Direct Injection (HPDI) natural gas engines. Sacré-Davey prepared process flow diagrams and equipment layout and preliminary site plans. Sacré-Davey also prepared a Class III cost estimate to compare the cost for the purchase and installation of the packaged facility versus the cost for a facility consisting of individual integrated equipment.

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.

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.

A molybdenum mine

Max Molybdenum Mine

For this two-phase project, Sacré-Davey first performed structural checks and designed updates and structural modifications in order to meet code and snow loads at the MAX site. In the second phase, Sacré-Davey provided plant layout and structural engineering services, including a building refit, building and equipment foundations, platforms, and complete mill structures for the 1000 TPD mine.

 

Max Molybdenum Mine

A molybdenum mine

For this two-phase project, Sacré-Davey first performed structural checks and designed updates and structural modifications in order to meet code and snow loads at the MAX site. In the second phase, Sacré-Davey provided plant layout and structural engineering services, including a building refit, building and equipment foundations, platforms, and complete mill structures for the 1000 TPD mine.

 

mineral nano-fiber

Mineral Nano-Fiber Plant

SDE3 was retained by GR International to develop a scale-up of their mineral nano-fiber production process from pilot to commercial scale. The process involves the production of two different families of nano-fiber products, with each product requiring precise control of temperature, pressure and ingredients in a batch reactor.

With this project, SDE3 developed a detailed mass and energy simulation of the process to produce each nano-fiber product. The simulation was used to test various production processes and post-treatment methods for each product. Extensive laboratory and pilot plant testing was conducted to determine scalability of the process, and to provide data to calibrate the simulation. Simulation modeling was conducted to determine profile, mixing, and heat transfer characteristics for the full-size reactor. Design of the full-scale plant was conducted using 3D CAD process modeling software.

Mineral Nano-Fiber Plant

mineral nano-fiber

SDE3 was retained by GR International to develop a scale-up of their mineral nano-fiber production process from pilot to commercial scale. The process involves the production of two different families of nano-fiber products, with each product requiring precise control of temperature, pressure and ingredients in a batch reactor.

With this project, SDE3 developed a detailed mass and energy simulation of the process to produce each nano-fiber product. The simulation was used to test various production processes and post-treatment methods for each product. Extensive laboratory and pilot plant testing was conducted to determine scalability of the process, and to provide data to calibrate the simulation. Simulation modeling was conducted to determine profile, mixing, and heat transfer characteristics for the full-size reactor. Design of the full-scale plant was conducted using 3D CAD process modeling software.

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.

Molybdenum Floatation Cell Replacement

Sacré-Davey was contracted to provide services for two existing banks of Denver flotation #100 (eight cells each) which had reached the end of their useful life and required replacement. Our design approach was to make the changeover with minimal disruption to production. The existing structural support steel was used and reinforced. The tank cells were covered with lids to contain the H2S gas, and a manifold connected with duct work to a new scrubber. The two conditioning tanks were raised and pump boxes and pumps were added to the floor level below the cells to pump concentrates to the thickeners.

Molybdenum Floatation Cell Replacement

Sacré-Davey was contracted to provide services for two existing banks of Denver flotation #100 (eight cells each) which had reached the end of their useful life and required replacement. Our design approach was to make the changeover with minimal disruption to production. The existing structural support steel was used and reinforced. The tank cells were covered with lids to contain the H2S gas, and a manifold connected with duct work to a new scrubber. The two conditioning tanks were raised and pump boxes and pumps were added to the floor level below the cells to pump concentrates to the thickeners.

Mono-ethylene Glycol (MEG) Handling

The client wished to re-purpose a storage tank from ethanol service to mono-ethylene glycol (MEG) service. The project required relocating the tank and installing new railcar unloading and ship loading systems and associated fall protection systems.

SDE provided detail design for the tank relocation including foundation design, new piping and piping supports in the containment area, electrical and controls, and fire protection.   Scope for detail design of the railcar unloading system included modification of the platform to facilitate the new unloading arms, new piping and supports, new gangways and associated fall protection.  For the ship loading system, SDE provided detail design for new pump and piping, pipe support modifications, extension of the valve and filter access platform together with all electrical and controls. SDE also provided demolition packages for removal of old piping and supports in all areas.

Mono-ethylene Glycol (MEG) Handling

The client wished to re-purpose a storage tank from ethanol service to mono-ethylene glycol (MEG) service. The project required relocating the tank and installing new railcar unloading and ship loading systems and associated fall protection systems.

SDE provided detail design for the tank relocation including foundation design, new piping and piping supports in the containment area, electrical and controls, and fire protection.   Scope for detail design of the railcar unloading system included modification of the platform to facilitate the new unloading arms, new piping and supports, new gangways and associated fall protection.  For the ship loading system, SDE provided detail design for new pump and piping, pipe support modifications, extension of the valve and filter access platform together with all electrical and controls. SDE also provided demolition packages for removal of old piping and supports in all areas.

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

New 50% Hydrogen Peroxide Receiving And Distribution System

Norske Canada required a new peroxide unloading, makedown and distribution facility to enable them to receive railcars in lieu of tanker trucks. The project included new foundations, tank design, spill containment, as well as pumping and piping systems. Previously estimated by others at $1.2M for the new plant, SDE/SN worked with facility owners to complete the project for under $700K.

SDE provided project estimating, conceptual and detailed design, and some procurement. Our associate, Solutions Now (SN) provided project management services.

New 50% Hydrogen Peroxide Receiving And Distribution System

Norske Canada required a new peroxide unloading, makedown and distribution facility to enable them to receive railcars in lieu of tanker trucks. The project included new foundations, tank design, spill containment, as well as pumping and piping systems. Previously estimated by others at $1.2M for the new plant, SDE/SN worked with facility owners to complete the project for under $700K.

SDE provided project estimating, conceptual and detailed design, and some procurement. Our associate, Solutions Now (SN) provided project management services.

new brewery conveyor line

New Brewery Conveyor Line

Addition of new conveyor line in Okanagan Spring Brewery in Vernon BC.

This project involved integrating new feed conveyors and a new palletizer into an existing bottling line. This project involved design of new motor control panels, PLC IO panels, PLC IO panels, generation of electrical layouts, cable tray and grounding plans, cable lists and a bill of materials for installation. Construction Management and Commissioning service were also provided by SDE.

New Brewery Conveyor Line

new brewery conveyor line

Addition of new conveyor line in Okanagan Spring Brewery in Vernon BC.

This project involved integrating new feed conveyors and a new palletizer into an existing bottling line. This project involved design of new motor control panels, PLC IO panels, PLC IO panels, generation of electrical layouts, cable tray and grounding plans, cable lists and a bill of materials for installation. Construction Management and Commissioning service were also provided by SDE.

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.

Ongoing projects: Plant, pipeline and compression

Ongoing Projects: Plants, Pipelines, and Compression

Sacré-Davey is one of Spectra’s preferred engineering service providers for critical ongoing capital support.  Sacré-Davey provides around $2 million engineering services per year and has completed approximately 850 projects of varying sizes over the past 4 years.

Ongoing Projects: Plants, Pipelines, and Compression

Ongoing projects: Plant, pipeline and compression

Sacré-Davey is one of Spectra’s preferred engineering service providers for critical ongoing capital support.  Sacré-Davey provides around $2 million engineering services per year and has completed approximately 850 projects of varying sizes over the past 4 years.

Forceps holding a piece of gold

Ore Sorting For Gold Mine

Sacré-Davey performed a scoping study for Barkerville Gold Mines to investigate the technical and economic impact of ore sorting.

Ore Sorting For Gold Mine

Forceps holding a piece of gold

Sacré-Davey performed a scoping study for Barkerville Gold Mines to investigate the technical and economic impact of ore sorting.

manufacturing facility relocation

Overlay Manufacturing Facility Relocation

For DYNO Overlays manufacturing facility relocation SDE3 provided complete project services, including conceptual design, detailed engineering of the structural, mechanical, electrical and instrumentation systems. This project included the construction of a new manufacturing facility in an existing warehouse. Included in this facility was a tank farm, two class I, Div 2 mix rooms, a non-hazardous mix room, boiler room, storage mezzanine, installation of two MF/UF resin impregnation lines, two VOC thermal oxidizers, HVAC for the entire manufacturing plant, all pumps, piping and electrical systems.

Scope of Work:

  • As-Built of the existing plant
  • Process Plant layout and design
  • Structural for Tank Farm, Mix rooms and utility supports
  • All Tank specification, mechanical and piping design
  • New P&IDs and process development
  • New Service Entrance and Power Distribution
  • PLC configuration
  • Loop, Logic and Interface wiring
  • PLC interface

Overlay Manufacturing Facility Relocation

manufacturing facility relocation

For DYNO Overlays manufacturing facility relocation SDE3 provided complete project services, including conceptual design, detailed engineering of the structural, mechanical, electrical and instrumentation systems. This project included the construction of a new manufacturing facility in an existing warehouse. Included in this facility was a tank farm, two class I, Div 2 mix rooms, a non-hazardous mix room, boiler room, storage mezzanine, installation of two MF/UF resin impregnation lines, two VOC thermal oxidizers, HVAC for the entire manufacturing plant, all pumps, piping and electrical systems.

Scope of Work:

  • As-Built of the existing plant
  • Process Plant layout and design
  • Structural for Tank Farm, Mix rooms and utility supports
  • All Tank specification, mechanical and piping design
  • New P&IDs and process development
  • New Service Entrance and Power Distribution
  • PLC configuration
  • Loop, Logic and Interface wiring
  • PLC interface

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.

Machine sorting pebbles

Pebble Crusher Area Improvement

Sacré-Davey performed a study to remove the existing 350 HP pebble crushing units and replace them with larger 900 HP units, as well as examining the proposed installation of a dust collection system. A new maintenance building was proposed which will be attached to the existing pebble crusher building and will be designed to allow the existing overhead crane to roll through. A new lube area for the new crusher lube units as well as lube storage was proposed. A new MCC building was also proposed which will be located over the new lube area.

Pebble Crusher Area Improvement

Machine sorting pebbles

Sacré-Davey performed a study to remove the existing 350 HP pebble crushing units and replace them with larger 900 HP units, as well as examining the proposed installation of a dust collection system. A new maintenance building was proposed which will be attached to the existing pebble crusher building and will be designed to allow the existing overhead crane to roll through. A new lube area for the new crusher lube units as well as lube storage was proposed. A new MCC building was also proposed which will be located over the new lube area.

LNG station

Permanent LNG Station

Sacré-Davey acted as the owner’s engineer for the project from its inception, and performed the preliminary feasibility study, preparation of vendor bid packages for major equipment, overall site layout and design, preparation and submission of safety documentation to local authorities, and mechanical, structural, and electrical integration engineering for all site equipment.

Permanent LNG Station

LNG station

Sacré-Davey acted as the owner’s engineer for the project from its inception, and performed the preliminary feasibility study, preparation of vendor bid packages for major equipment, overall site layout and design, preparation and submission of safety documentation to local authorities, and mechanical, structural, and electrical integration engineering for all site equipment.

phosrock unloading

Phosrock Unloading, Loading & Storage

This Neptune Bulk Terminals facility improvement project for phosrock unloading, loading and storage required the installation of dry bulk ship unloading machinery, network of inbound conveyors, a storage shed, a network of outbound conveyors including a surge bin and a rail car load out system. Due to environmental concerns, a number of large dust collectors were required to ensure that fugitive dust was captured.

As part of the engineering, procurement and construction team, SDE assisted in this design build contract in taking a conceptual design through to final installation. SDE’s scope included the detailed design of structures and select elements of the mechanical system such as the dust collector.

Phosrock Unloading, Loading & Storage

phosrock unloading

This Neptune Bulk Terminals facility improvement project for phosrock unloading, loading and storage required the installation of dry bulk ship unloading machinery, network of inbound conveyors, a storage shed, a network of outbound conveyors including a surge bin and a rail car load out system. Due to environmental concerns, a number of large dust collectors were required to ensure that fugitive dust was captured.

As part of the engineering, procurement and construction team, SDE assisted in this design build contract in taking a conceptual design through to final installation. SDE’s scope included the detailed design of structures and select elements of the mechanical system such as the dust collector.

Ore sorting maching

Pilot Plant Design

At Teck’s Red Dog zinc, lead and silver mine, Sacré-Davey developed a detailed design for an ore sorting pilot plant. Engineering and economic studies of full scale ore sorting were also performed.

Pilot Plant Design

Ore sorting maching

At Teck’s Red Dog zinc, lead and silver mine, Sacré-Davey developed a detailed design for an ore sorting pilot plant. Engineering and economic studies of full scale ore sorting were also performed.

A series of pipeline

Pipeline Design Input & Stress Analysis

Sacré-Davey provided design and optimization input and stress analysis services for seven compressor stations along the west coast’s mainline. The work involved installation of an additional turbine compressor, aftercooler and scrubber system at both Westcoast’s CS7 and CS6 compressor stations.

Pipeline Design Input & Stress Analysis

A series of pipeline

Sacré-Davey provided design and optimization input and stress analysis services for seven compressor stations along the west coast’s mainline. The work involved installation of an additional turbine compressor, aftercooler and scrubber system at both Westcoast’s CS7 and CS6 compressor stations.

Piping Integrity Assessment

SDE completed an integrity assessment on steam, condensate, chloride, brine, and slurry piping systems within the process plant.

Sacré-Davey Engineering reviewed the piping systems to identify leaks, wall thinning, vibrations, misalignment, missing supports and poor practices. A comprehensive list of recommended repairs and replacements was provided.

Piping Integrity Assessment

SDE completed an integrity assessment on steam, condensate, chloride, brine, and slurry piping systems within the process plant.

Sacré-Davey Engineering reviewed the piping systems to identify leaks, wall thinning, vibrations, misalignment, missing supports and poor practices. A comprehensive list of recommended repairs and replacements was provided.

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.

Reclaim Barge Conditional Assessment

The client had concerns of two reclaim barges at their tailings pond site for both short and long term viability. Sacre-Davey Engineering conducted NDT, visual inspections, a pump performance assessment and an investigation of the equipment historical and operational information. The report allowed the client to make decisions with respect to Capex planning.

Reclaim Barge Conditional Assessment

The client had concerns of two reclaim barges at their tailings pond site for both short and long term viability. Sacre-Davey Engineering conducted NDT, visual inspections, a pump performance assessment and an investigation of the equipment historical and operational information. The report allowed the client to make decisions with respect to Capex planning.

Recovery Boiler Improvements

SDE provided Mechanical and Structural engineering and design services during the design and construction phases.

Recovery Boiler Improvements

SDE provided Mechanical and Structural engineering and design services during the design and construction phases.

A refinery

Refinery Modifications

Sacré-Davey was requested to provide ongoing evaluation and design for follow up to specific HAZOP items provided by the refinery. These items included evaluation of the risks, definition of mitigation requirements, and preliminary and detailed engineering. Sacre-Davey also provided consulting services regarding the replacement of miscellaneous equipment and piping modifications to support equipment changes.

Refinery Modifications

A refinery

Sacré-Davey was requested to provide ongoing evaluation and design for follow up to specific HAZOP items provided by the refinery. These items included evaluation of the risks, definition of mitigation requirements, and preliminary and detailed engineering. Sacre-Davey also provided consulting services regarding the replacement of miscellaneous equipment and piping modifications to support equipment changes.

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

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.

remote project image

Remote Location Emergency Power and Fuel Supply

Sacré-Davey was contracted to provide mechanical, civil, and electrical design services, as well as construction management services, to several remote British Columbia locations. The work involved the conversion of diesel-fuelled emergency generators to propane and natural gas systems.  Strict new federal codes and standards on the design of liquid petroleum facilities made these propane and natural gas systems a clean and reliable alternative. Maintenance guides and overall project reports were provided to the client to facilitate the year-to-year maintenance of the facility.

Remote Location Emergency Power and Fuel Supply

remote project image

Sacré-Davey was contracted to provide mechanical, civil, and electrical design services, as well as construction management services, to several remote British Columbia locations. The work involved the conversion of diesel-fuelled emergency generators to propane and natural gas systems.  Strict new federal codes and standards on the design of liquid petroleum facilities made these propane and natural gas systems a clean and reliable alternative. Maintenance guides and overall project reports were provided to the client to facilitate the year-to-year maintenance of the facility.

Review of Natural Gas Pipeline

SDE provided design review, stress analysis and design input for a 1000 PSIG, 20” diameter pipeline servicing the new gas plant in Northern BC. SDE’s input saved considerable cost and effort during the design phase by developing a file transfer protocol for importing client’s 3-D pipe model directly into Caesar for analysis. The timely analysis of different variation of the proposed pipe routing also saved considerable costs at road crossings and equipment tie-in locations.

Review of Natural Gas Pipeline

SDE provided design review, stress analysis and design input for a 1000 PSIG, 20” diameter pipeline servicing the new gas plant in Northern BC. SDE’s input saved considerable cost and effort during the design phase by developing a file transfer protocol for importing client’s 3-D pipe model directly into Caesar for analysis. The timely analysis of different variation of the proposed pipe routing also saved considerable costs at road crossings and equipment tie-in locations.

Machine scoping in the wild

Scoping Study

Sacré-Davey worked with Sherwood Copper and the rest of the Kutcho team to produce a comprehensive scoping study for the optimization and development of the new Kutcho Creek Mine. Sacré-Davey’s responsibilities included all onsite facilities, including the mill building (from the crusher to the concentrate load-out), offices, maintenance shops, stores, camp, water & waste water treatment, and transportation of tailings. Sacré-Davey prepared flowsheets, mass balances and equipment layouts for the mill, together with sizing of key process equipment, including flotation cells, cyclones, pumps and filter process.

Scoping Study

Machine scoping in the wild

Sacré-Davey worked with Sherwood Copper and the rest of the Kutcho team to produce a comprehensive scoping study for the optimization and development of the new Kutcho Creek Mine. Sacré-Davey’s responsibilities included all onsite facilities, including the mill building (from the crusher to the concentrate load-out), offices, maintenance shops, stores, camp, water & waste water treatment, and transportation of tailings. Sacré-Davey prepared flowsheets, mass balances and equipment layouts for the mill, together with sizing of key process equipment, including flotation cells, cyclones, pumps and filter process.

Steam Supply Upgrade

Okanagan Spring Brewery undertook replacement of older fire tubed boilers with state of the art steam generators. The new system allowed for increased steam capacity and efficiencies whilst maintaining boiler branch staffing requirements. Sacré-Davey Engineering was retained for providing vendor and general contractor Request for Proposal documents, assessment of bids, and Construction Management.

Steam Supply Upgrade

Okanagan Spring Brewery undertook replacement of older fire tubed boilers with state of the art steam generators. The new system allowed for increased steam capacity and efficiencies whilst maintaining boiler branch staffing requirements. Sacré-Davey Engineering was retained for providing vendor and general contractor Request for Proposal documents, assessment of bids, and Construction Management.

piping restraint

Stock Pump Piping Restraint

In a previous study for Canfor Prince George Ltd, Sacré-Davey Engineering identified high pipe stresses and inadequate restraint to be one of the causes of piping and stock pump failures.

SDE completed stress analysis calculations and determined additional fixed restraints and locations to reduce the pipe stresses. In addition, spring hanger sizes where identified for the piping above the stock pumps. A General Arrangement drawing was provided to Canfor with the required details.

Stock Pump Piping Restraint

piping restraint

In a previous study for Canfor Prince George Ltd, Sacré-Davey Engineering identified high pipe stresses and inadequate restraint to be one of the causes of piping and stock pump failures.

SDE completed stress analysis calculations and determined additional fixed restraints and locations to reduce the pipe stresses. In addition, spring hanger sizes where identified for the piping above the stock pumps. A General Arrangement drawing was provided to Canfor with the required details.

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.

featured project image for terminal expansion feasibility study

Terminal Expansion Feasibility Study

Sacré-Davey conducted a multi-discipline feasibility study on the expansion of the client’s terminal, for the purpose of modifying existing systems to both load and unload new products. Product is received by rail and loaded onto ocean-going bulk liquid vessels. One of the challenges with this particular project is the limited space available for additional storage capacity, resulting in innovative design using a combination of existing and new storage tanks. As part of the study, Sacré-Davey is providing an AACE Class III Capital Cost Estimate and construction plan to minimize the amount of shutdown time required while modifying the client’s facilities.

Terminal Expansion Feasibility Study

featured project image for terminal expansion feasibility study

Sacré-Davey conducted a multi-discipline feasibility study on the expansion of the client’s terminal, for the purpose of modifying existing systems to both load and unload new products. Product is received by rail and loaded onto ocean-going bulk liquid vessels. One of the challenges with this particular project is the limited space available for additional storage capacity, resulting in innovative design using a combination of existing and new storage tanks. As part of the study, Sacré-Davey is providing an AACE Class III Capital Cost Estimate and construction plan to minimize the amount of shutdown time required while modifying the client’s facilities.

Man drilling for silver underground project image

Underground Silver Project

Sacré-Davey performed a scoping study to investigate the technical and economic impact of ore sorting at Bayhorse Silver Mine. X-ray sorting was able to discard 75% of coarse material as waste and remaining fines material could be pre-sorted by HMS.

Underground Silver Project

Man drilling for silver underground project image

Sacré-Davey performed a scoping study to investigate the technical and economic impact of ore sorting at Bayhorse Silver Mine. X-ray sorting was able to discard 75% of coarse material as waste and remaining fines material could be pre-sorted by HMS.

underground project image

Underground Storage Solvent Tank

Sacré-Davey was asked to verify the design of a tank truck unloading facility with an underground pentane storage tank and confirm that it would meet all applicable fire and safety codes. Sacré-Davey based its evaluation on a summary of the BC Fire Code, provided P&ID’s, datasheets and production information, vendor communication, and specifications as well as general knowledge of similar installations for fuelling applications. Sacré-Davey developed a modified design concept and then completed detailed design, equipment specification, permitting, and purchasing as well as construction and commissioning assistance.

Underground Storage Solvent Tank

underground project image

Sacré-Davey was asked to verify the design of a tank truck unloading facility with an underground pentane storage tank and confirm that it would meet all applicable fire and safety codes. Sacré-Davey based its evaluation on a summary of the BC Fire Code, provided P&ID’s, datasheets and production information, vendor communication, and specifications as well as general knowledge of similar installations for fuelling applications. Sacré-Davey developed a modified design concept and then completed detailed design, equipment specification, permitting, and purchasing as well as construction and commissioning assistance.

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.

water intake system

Water Intake System on the Kitimat River

Alcan Smelters & Chemicals’ requirements for year-round uninterrupted production water called for the construction of a new 16,000 USGPM fresh water intake system at its pumping station on the Kitimat River. The project entailed the underwater installation of two new screened intakes, a protective grille, conductor pipes and a new compressor building attached to the pumping station.

SDE provided complete project definition, project management, multi-disciplinary detailed design services, cost estimating, procurement, permitting and construction management supervision. The project took 2 years and 1 in-stream construction window to complete. The avoided cost to the client associated with the keeping water flowing to the plant was in the range of $100,000,000 (their estimate).

Water Intake System on the Kitimat River

water intake system

Alcan Smelters & Chemicals’ requirements for year-round uninterrupted production water called for the construction of a new 16,000 USGPM fresh water intake system at its pumping station on the Kitimat River. The project entailed the underwater installation of two new screened intakes, a protective grille, conductor pipes and a new compressor building attached to the pumping station.

SDE provided complete project definition, project management, multi-disciplinary detailed design services, cost estimating, procurement, permitting and construction management supervision. The project took 2 years and 1 in-stream construction window to complete. The avoided cost to the client associated with the keeping water flowing to the plant was in the range of $100,000,000 (their estimate).

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.

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.

Facility that collects dust

Wood Dust Collection System

Upgrade of combustible dust collection system for the chip unloading, transfer stations, and chip screening areas in a pulp mill.

SDE performed preliminary design of the upgraded dust collection system, prepared the specification, and performed the bid comparison. SDE also designed the building structural modifications to support the dust collection piping and roofmounted baghouse. SDE was acting as the owner’s representative for system construction.

SDE determined the system requirements: duty cycle and loads as well as applicable codes and standards. The preliminary design included identifying collection points and required air flows and the collection system layout, in addition to the preliminary design of the collection hoods, sizing of the fan, screw conveyor, and airlock system, identifying required instrumentation.

Wood Dust Collection System

Facility that collects dust

Upgrade of combustible dust collection system for the chip unloading, transfer stations, and chip screening areas in a pulp mill.

SDE performed preliminary design of the upgraded dust collection system, prepared the specification, and performed the bid comparison. SDE also designed the building structural modifications to support the dust collection piping and roofmounted baghouse. SDE was acting as the owner’s representative for system construction.

SDE determined the system requirements: duty cycle and loads as well as applicable codes and standards. The preliminary design included identifying collection points and required air flows and the collection system layout, in addition to the preliminary design of the collection hoods, sizing of the fan, screw conveyor, and airlock system, identifying required instrumentation.

Zero Liquid Discharge

System to capture and recover boiler water treatment system and blow down waste as boiler feed water to eliminate liquid discharge.

SDE was contracted to prepare a study and capital cost estimate for a water treatment system. The study and engineering included a water balance for the entire facility, process and equipment selection, specification and budgetary equipment pricing for multiple equipment skids including a new building, interconnecting piping, foundations and road access.

Zero Liquid Discharge

System to capture and recover boiler water treatment system and blow down waste as boiler feed water to eliminate liquid discharge.

SDE was contracted to prepare a study and capital cost estimate for a water treatment system. The study and engineering included a water balance for the entire facility, process and equipment selection, specification and budgetary equipment pricing for multiple equipment skids including a new building, interconnecting piping, foundations and road access.