Keyera – Simonette Condensate Processing & Expansion

Gas Liquids Engineering Ltd. (GLE) provided Energy Engineering Services, procurement and construction management (EPCM) at the brownfield site, a 150 MMSCF/d inlet and sweetening equipment, 10,000 bbl/d sour condensate stabilizer and ancillary items at an existing facility near Valleyview, Alberta. Design features of the installation:

  • 10′ x 60′ condensate feed drum
  • 10,000 bbl/d sour condensate stabilizer package:
    • Provided capability with loading rack full length Stabilizer column (42” diameter x 60’)
    • 2 x 50% reboilers
    • Feed/bottoms exchanger
    • Feed preheat exchanger
    • 2 x 50% overheads compressors (125 hp each)
    • Condensate product cooler
  • New 12,000 bbl tank farm
  • VRU compressor (75 hp, 2 stage rotary vane)
  • 32 MMBtu/hr heat medium system c/w 2 x 100% pumps (100 hp each)
  • Low pressure flare stack and FKOD/drain vessel
  • Inlet condensate filtration
  • Fuel gas letdown package c/w heat exchanger and separator
  • Amine package modifications to increase circulation rate (1500 L/min @ 50wt%)
  • Pump skid:
    • 2 x 100% condensate sales pumps (75 hp each)
    • 2 x 100% condensate recycle pumps (60 hp each)
    • Condensate transfer pump (5 hp)
    • 2 x 100% LP to HP plant condensate feed pumps (50 hp each)
  • New MCC (20’ x 70’)

GLE Engineered Image Map

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1

New LP Flare & Flare Knock Out Drum

  • 36” x 8’ S/S, internally coated and heated FKOD w/ transfer pump
  • 8” x 40’ stack with 3” removable tip

2

New Pump Skid

  • 2 x 75hp Sales Condensate Pumps,
  • 2 x 60hp, 33 stage Recycle Pumps
  • Overhead crane

3

New Hot Oil Heater

  • 32 MMBtuh
  • 2 x 100 hp pumps

4

New Stabilizer Motor Control Centre

  • 20’ x 70’ skidded building
  • Extra space for future refrigeration plant

5

New Inlet Pipe Rack

  • Stick built, two tiered 200m piperack with 3 elevation step changes
  • Carries utilities and process pipe for new and future inlets and stations inlet heating, separation and filtering

6

New Wapiti Inlet Separator & Coalescer

  • 10’ x 48’ S/S, 1,200 psig MAWP two phase separator
  • 30” x 11’ s/s ANSI 600, porous media filter

7

New Condensate Feed Drum

  • 10’ x 60’ S/S, 3,447 kPag MAWP
  • 3 Phase, sour

8

New Amine Contactor

  • 6 ½’ x 60 s/s ANSI 600, 20 tray contactor

9

New Condensate Exchanger + Recycle Pump Skid

  • Process gas pressure letdown preheater
  • 16” x 20’ OAL
  • 8 MMBTuH Duty
  • 2 x 30 HP multistage centrifugal pumps

10

New Tank Farm

  • 3 – 3,000 BBL Sales Condensate Tanks
  • 2,000 BBL Slop Condensate Tank
  • 1,000 BBL Sour Water Tank
  • All tanks c/w heated enclosure

11

New Sour Vapour Recovery Unit

  • 75hp, 2 Stage, sour rotary vane compressor

12

New Product Cooler

  • Horizontal aerial cooler w/ 4.3 MMBtuH duty

13

New Overheads Compressors

  • 2 x 125 HP single stage, sour Ariel reciprocating c/w 2 piece long distance pieces.
  • Overhead crane

14

New Stabilizer Reboiler Skid

  • 2 x 50% reboilers. 5 MMBtuH each. 22”/38” x 38’ OAL
  • Feed/Bottoms exchanger. 6.4 MMBTuH. 20” x 20’ OAL
  • Hot Oil feed heater. 9.2 MMBTuH. 22” x 12’ OAL

15

New Wapiti Gas/Gas Exchanger

  • 30” x 19’ F/S, 4.6 MMbtu/hr BHU exchangers
  • Symmetric piping for even flow

16

New Wapiti Line Heaters & New Inlet Area

  • Two 4.5 MMbtu/hr, sour ANSI 900 gas fired line heaters
  • Rack steel and piping to deliver utilities and carry heated gas into the plant

17

New Condensate Stabilizer Tower

  • 10,000 BPD design flowrate
  • 42” x 60’ S/S
  • 1,379 kPag MAWP

18

New Cabin Gas/Gas Exchanger

  • 30” x 19’ F/S, 4.6 MMbtu/hr BHU exchangers
  • Symmetric piping for even flow

19

Relocate Cabin Inlet Separator

20

New Wapiti Motor Control Centre Building

21

New HP/LP Heat Exchanger

  • Process gas pressure letdown preheater
  • 14” x 162” OAL
  • 2 MMBTuH Duty

22

New Heat Medium Glycol Pump Skid

  • 2 x 100 HP centrifugal pumps
  • Skidded package c/w building

23

New LPG Bullet Run-off Pond