ALKY BUTANE DEFLUORINATION PROJECT:
The design basis for this Project is to optimize the removal of trace hydrofluoric acid from the final product butane stream for the purpose of making a finished product that meets or exceeds industry standard of < 1ppm fluorides content. MEI has been selected to perform the Process Design (Phase II), Preliminary Engineering & Design (Phase III) and Detailed Engineering & Design (Phase IV) Packages for this project. This project will install upgraded canned motor pumps, a butane treatment system, multiple heat exchangers, a new coalescer, foundations for new equipment and vessels, associated piping systems, instruments & controls and required electrical modifications.
NEW PIPELINE TIE-INS TO EXISTING REFINERY PIPING HEADER PROJECT:
Provided Detailed Engineering & Design Packages for connecting a new pipeline extension into and existing refinery supply header. The scope of this project included the installation of a 4” underground pipeline, a concrete retaining wall, new pig launchers and receivers, a new custody transfer metering skid, concrete foundations for new equipment, electrical power supply, instrument communications & controls, perimeter security fencing and an access roadway to the new secured equipment area.
SINGLE SEAL PUMPS RISK REDUCTION PROGRAM:
The objective of this program is to replace approx. 60 pairs of single seal pumps in light hydrocarbon service with seal less, canned motor / pumps. MEI is confirming the process conditions of all pumps, preparing mechanical data sheets, obtaining vendor quotes, and preparing detailed engineering and design Issue for Construction (IFC) Packages for installing these new pumps. This includes Process, Piping; Structural, Instrument & Electrical Engineering & Design.>
VESSEL OVER PRESSURE PROTECTION PROGRAM:
The client contracted a third party engineering company to study the relief and flare systems in one of their plants. The third party only noted deficiencies, but did not make recommendations to address the deficiencies. MEI performed the Process Studies to verify the findings of the other engineering company, sizing relief systems, engineering and designing new relief valves and systems, new flare headers, and performing vessel calculations to modify and / or re-rate vessels and heat exchangers. The effort addressed every unit in the refinery and has spanned a period of approx. 7 years.
PRODUCT STORAGE TANKS FIRE PROTECTION SYSTEM IMPROVEMENTS PROGRAM:
MEI performs hydraulic analysis of the fire foam piping system modifications recommended by our client’s third party Fire Protection System Specialty Company. Upon completion of this analysis, all foam piping sizes are finalized and MEI prepares the detailed Piping & Structural Design Issue for Construction (IFC) Packages that are required to implement the recommended fire foam piping system improvements to the particular product storage tanks.
OSBL PIPING FOR SRU & FUEL GAS TREATING PROJECT:
MEI is preparing the Phase IV Detailed Piping Design Issue for Construction (IFC) Packages. The scope of work includes installation of new tie-in valves and the installation of the interconnect piping from the new tie-in valves to the new piping connections located at the battery limits of the new unit. Piping systems include: 400 lb. steam, 150 lb. steam, condensate return, nitrogen, slop oil, instrument air, amine acid gas, rich amine, lean amine, plant air, storm water sewer, and tie-ins to the flare header.
TANK HEATING & PRODUCT TRANSFER SYSTEMS PROJECT:
Developed the Scope of Work, Execution plan, TIC Estimates, 3D modeling, and infrastructure upgrades to convert (4) Heavy Crude Oil Storage Tanks to No. 6 Fuel Oil Storage and installed a Tank Blending System. Included the installation of (3) 17,500 GPM, 4184 HP pumps, (2) 1750 HP pumps, (3) Pre-Engineered Metal Buildings, (2) engineered hot oil heating systems, (8) heating coils in each of the (4) storage tanks, (2) new 1000KW generators and a new Motor Control Center. Provided detailed engineering & design Issue for Construction Packages for all design disciplines.
POTABLE WATER SYSTEM UPGRADES PROJECT:
After the Texas Commission of Environmental Quality (TCEQ) determined that refineries, chemical plants, and like facilities were Public Water Distributors, Maverick worked with client on a five year program to perform hydraulic studies to determine the pressure and flow throughout two plants. Worked with client to upgrade underground water mains, metering stations, and installing booster pumps as necessary to meet distribution requirements. Worked with client to develop an aboveground pipe specification which met NSF / ANSI 61, and AWWA requirements. Audited one plant, determined areas that needed to be upgraded to meet the new specification and designed the upgrades. Engineered and designed a complete replacement of the potable water system in one plant.
INSTALLATION OF EMERGENCY BACKUP POWER PROJECT:
This project minimizes the potential of a catastrophic release of hydrofluoric acid into the atmosphere in event of a power failure by installing an emergency backup power system that will keep the Alky Release Mitigation System operational during the power failure. MEI is providing Detailed Engineering & Design Issue for Construction Packages for installing an 800KW diesel powered generator, a fuel tank to allow the generator to run for 72 hours, and a new load bank and Motor Control Center with a new building enclosure. An automatic transfer switch will also installed to allow for automated transfer from normal power to emergency generator power during a power outage event.
TERMINAL IMPROVEMENTS / ETHANOL BLENDING PROJECT:
Performed the Detailed Engineering & Design for the Instrumentation and Electrical portion of the installation of new pumps, metering stations, new tank installations, injection control skids, and new truck racks for over 8 separate ethanol upgrade projects.
Performed the Project, Mechanical, Civil / Structural, Instrument, and Electrical design on two projects for the upgrade of terminal facilities to accept, store, and dispense ethanol including MCC upgrades, new tanks, new truck racks and city permitting.
PLANT CLARIFIER PIPE REPLACEMENT PROJECT:
Performed Detailed Piping, Structural, Instrument & Electrical Engineering & Design and prepared Issue for Construction (IFC) Packages to replace the majority of all influent, effluent and pump suction and discharge piping including motorized isolation valves associated with the East & West Wastewater Clarifiers. All underground piping was relocated above ground.
FLARE GAS RECOVERY SYSTEM PROJECT:
Analyzed the existing Amine Contactor, reviewed the refineries sour water stripping capabilities, and performed hydraulic analysis on the two flare headers. Analyzed the systems based on three (3) design conditions. Worked with the client and John Zink to size and to install a Flare Gas Recovery System that included three (3) 1040 scfm 600HP liquid ring compressors, a liquid / gas separator drum, seal liquid coolers and a flare system water seal. Performed all the OSBL effort including process, power, arc flash studies, piping, civil, structural, instrument, and electrical work.
RECYCLE COMPRESSOR BUFFER / SEAL GAS SYSTEM PROJECT:
Performed Detailed Piping, Structural, Instrument & Electrical Engineering & Design for installing a third party provided Buffer Gas Contaminant Reduction Skid that reduces chlorides and particulate contamination from the hydrogen gas stream feeding the Recycle Compressor Seals. Installation of this skid is expected to triple the expected run time of the compressor.
TRUCK RACK LOADING / UNLOADING DEBOTTLENECKING PROJECT:
This project identified problems, recommended improvements and implemented the recommendations needed to improve the operating performance of the finished product terminal; increase throughput by 8,500 BPD. A summary of the improvements implemented are as follows: installed three (3) new diesel pumps; installed four (4) new gasoline pumps; increased various product transfer line sizes to the next size or greater, installed diesel and gasoline tie-in valves in all four (4) loading bays to allow for installation of new loading arms; installed a new terminal entrance and roadway with a new security building and motorized entry gates; installed new transformer and new motor control center required to provide 480V power to the new motors / pumps; installed pump instrumentation and controls; installed additional area lighting; and installed new foundations and structural supports. Provided Detailed Engineering Design Issue for construction (IFC) Packages for all disciplines: Piping, Civil / Structural, Electrical & Instrument.
INSTALLATION OF FLARE FLOW METERS & SULFUR ANALYZER PROJECT:
Prepared detailed Engineering & Design Issue for Construction Packages for installing flow meters and sulfur analyzers in 24”, 30”, 36” and 60” flare headers. This compliance driven project provided the capability to measure flare flows and total sulfur concentrations for environmental reporting and process engineering evaluation. A Gas Chromatograph was also installed for further analysis of the flare stream. Overall scope of work included the installation of analyzer buildings, access platforms & ladders, backup power generators, automatic power transfer switches and associated piping modifications and instrument / control wiring.
INSTALLATION OF COOLING TOWER PUMPS:
Prepared Detailed Engineering & Design Issue for Construction Packages for installing two (2) new 5,000 gpm vertical cooling water pumps and associated suction and discharge piping, isolation valves, pump support structure and access walkways, piping and electrical structural supports, 480V power supply to pumps and electrical grounding as required.
CRUDE PIPELINE FROM STORAGE TERMINAL TO REFINERY PROJECT:
Objective of this project was to install a new pipeline for the Crude Storage Terminal to the Refinery. The scope of work included installation of a new 1500 HP main line pump, metering skid and pig launcher at the Terminal; installation of the underground pipeline; installation of a metering skid and pig receiver on the Refinery side include tying in to the refinery pipeline; installation of required electrical power and communication / control wiring. Issue for Construction Packages were prepared and issued for all design disciplines: Piping, Structural, and Instrument & Electrical Design.
NEW HYDROGEN COMPRESSOR:
The objective of this project was to improve the overall reliability of the existing hydrogen compression system in the DOT unit by installing a new 3500hp hydrogen recycle and make-up compressor and associated equipment and piping. Maverick performed the detailed engineering and design for this new compressor project including the mechanical, civil/structural, piping, instrumentation, and electrical engineering and design.
STORM WATER IMPROVEMENTS:
Performed a drainage study, consisting of a contributing drainage area of approximately 127 acres, to identify needed drainage improvements. Improvements for this project included a concrete lined trapezoidal ditch, reinforced concrete box culvert and headwall structure, and metal beam safety guard fence. Performed the detailed engineering and design for this project including the field topographic survey; foundation, hydrological, hydraulic, and sizing calculations; and preparation of the detailed design drawings and documents including city and county permits.
MSTDP HEATER LOW NOx MODIFICATIONS
Performed the engineering and design to replace the existing burners in two heaters with “Next Generation” Ultra Low NOx burners (ULNB). The new burners decreased NOx emissions below 0.045 lbs./MM BTUs. The installation of the new burners required modifications to the air preheat ductwork, installation of parallel coalescing filters, and replacing the existing fuel gas piping and pilot gas piping. The project also added Continuous Emission Monitoring System (CEMS) in the common stack between the two heaters.