We have over 30 years experience in Industrial and Chemical Installations, covering a broad range of projects

Our experience in chemical plants covers all phases, from bid phase through to final delivery, with projects ranging from small stand-alone plants to mega projects with costs exceeding US$10 billion. 

Modularization has become necessary to reduce schedule and costs, Moving manhours off-site to fabrication yards also helps improve safety. Modularization includes Pipe Racks, Process Modules and Packaged Substations/Instrument Buildings.

We have experience in various process plants including:
  • Ethylene Plants
  • LNG Plants
  • LNG Pipelines and Pumping Stations
  • Refineries

Below, we have highlighted some of our interesting projects, and added a short description of our engagement.

Ethane Cracker and Derivatives Plant
Lake Charles, Louisiana USA [Sasol]

Project Description

At the heart of the project, is a 1.5 million tons per annum (1.5mtpa) ethane cracking plant. Part of the output is sent to the polyethylene plant (LDPE and LLDPE) and also other derivative plants.

The project is fed by by a 230kV loop tie to a GIS switchyard. Two 230kV/69kV transformers feed into a 69kV GIS line up, that distribute power to 7 primary substations. 69kV/13kV transformers and switchgear provide utilization power to the plant, via the 22 packaged substations.

In addition to a steam turbine, there are 8 diesel generators for standby power.

Bid development

Working for the equipment supplier (Siemens) as the Bid Manager, the initial bid included the supply of 230kV/69kV Gas Insulated Switchgear, 13.8KV, 4.14kV and 480V switchgear, packaged into buildings, and transformers. It included the Ethane and Derivatives Plant, as well as the future (but not installed) Gas to Liquid (GTL) plant.

The bid process involved:
  • Accurate take-offs of all equipment and sourcing capacity from various factories
  • Testing plans and testing of equipment prior to delivery to fabrication yard
  • Sourcing and pricing of fabrication yards for building of substations and integrating and testing prior to delivery
  • Shipping strategy and sourcing of shipping companies and costs
  • Estimation of site scope and manhour cost estimates for inspections and precommissioning.

Mechanical Completions and Commissioning

Working for the Joint Venture EPCM (Fluor/Technip) as Electrical Commissioning Manager, the scope of work comprised:
  • Develop Mechanical Completions Plans and Checklists
  • Coordinate inspections and mechanical completions
  • Manage initial testing methods and techniques
  • Manage specialty vendor works and time management
  • Perform energizations of equipment
  • Coordinate energizations of:
    • Plant lighting systems
    • Plant heat trace systems
    • Motor bump and controls, manual and instrumented
substation_commissioning_schedule.pdf
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Companero - Simpatico Pipelines, Fractionation and Liquefaction
​West Texas USA [Permico Midstream Partners]

Project Description

The project would bring Y-Grade feedstock 870 km from West Texas to a fractionation plant through a 500mm pipeline. The Companero pipeline would include 5 pumping / pigging stations.

A typical fraction plant (Amine Regen, Molecular Sieve, De-ethanizer, De-propanizer, and De-butanizer) would provide purity products. HP Compression of Propane, i-Butane and n-Butane would be sent to sphere storage.

The Simpatico pipeline would carry HP purity products 600km through a 400mm pipeline to the East Texas Gas Hub. Two pumping/pigging stations are included.

A liquefaction plant (gas chillers and refrigerant compressors) would provide liquefied product to LP storage tanks.

​A LPG loading wharf with 2 sets of 5 loading arms are available for purity offloading to LNG carriers for international export.

Integration Project Coordinator

By all means, this was a complex project that required coordination of many EPCs. A Work Breakdown Structure is developed to coordinate the supply of equipment and services across the various project phases.

As the principle Integrated Project Manger, activities included:
  • Coordination of performance and work scopes across all EPCs, specifically definition of interfaces
  • Development if Integrated Test Plan and interfacing of EPCs Test Plans
  • Collaboration with customer to develop performance criteria, operational profiles, operability and associated project risk identification and mitigation
  • Development of normalized inspection and test plans across the complete project
  • Development of commissioning plans in collaboration with EPC's
  • Integration manhour cost estimations

Commissioning Management

Following on from Integration Project Coordinator, the client requested our service as Electrical, Instrumentation and Controls Commissioning Management. This scope of work comprise the following key activities:
  • Review of Inspection Check Lists
  • Development of Commissioning and Start Up Plans and Test Records
  • Systemization of systems and subsystems
  • Assembly of commissioning teams according to the WBS
  • Execution of commissioning activities
  • Compilation of Inspection and Test Dossiers.
  • Management of final sign off (Transfer of Custody and Control)

Lake Charles LNG
​Louisiana USA [Shell/Energy Transfer]

Project Description

​The project, originally a 50-50 venture with U.S. midstream company Energy Transfer, envisaged converting an existing import and regasification facility in Lake Charles into a multi-train, 16.45 million tonnes per year (mtpa) facility.
​Lake Charles LNG Home Page

Electrical Systems Specialist
69kV Modularization Study

As part of the conversion process, a study was performed on the proposed 69kV Gas Insulated Switchgear building, with the key objectives:
  • Simplify the current design, that would allow easy shipping and installation
  • Design the system that could be easily tested at the factory, and easily erected at site without loss of test integrity.

A solution was developed that met the above objectives, plus, the solution:
  • Could be developed into a global design solution for all large scale electrical installations
  • Added a level of flexibility to add/reduce feeder capacity with minimal effort.

Read more about the solution: INNOVATION

On-Module Electrical Distribution Study

For large scale projects, with large electrical load requirements, it is common to design the power supply network, such that all switchgear is located at grade. The modularization of process modules does not typically include any electrical switchgear buildings located on the module. (Diagram CASE 3)

The decoupling of the electrical power supply between substation and motor proximity has a number of disadvantages:
  • advantage of reduced labour costs and efficiencies at the module yard are not harnessed
  • motor testing at site can only be started when substations are operational and cabling between substation and module motors are complete.
  • motor testing late start can increase project risk.

As a follow up to the modularization solution developed for High Voltage, two further solutions are developed for Medium Voltage and Low Voltage.

Using the Low Voltage Solution (Diagram CASE 1A), mitigated the disadvantages stated above. Similarly, the solution added to following advantages over the traditional approach:
  • Could be developed into a global design solution for all large scale electrical installations
  • Added a level of flexibility to add/reduce feeder capacity with minimal effort.

Read more about the solution: INNOVATION
​A study released by API and conducted by researchers at ICF examines the environmental benefits of U.S. natural gas use in China, Germany, and India, finding that using U.S. liquefied natural gas (LNG) rather than coal for electricity generation produces on average 50.5 percent fewer greenhouse gas (GHG) emissions in all base case scenarios studied.