Seamless Service for Successful Station Upgrade

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Project

Manor Gate Station Upgrade

Location

Maryland

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Background

Baltimore Gas & Electric (BGE), the company that operates the entire Baltimore area gas distribution system and serves more than 650,000 customers, contracted EN Engineering to upgrade their existing Manor Gate legacy station. This station takes the transmission gas from TransCanada at 720 PSIG and lowers the pressure to 269 PSIG to feed BGE’s Beaver Dam and Notch Clift transmission lines.

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Challenges

The original BGE drawing showed 16” steel, but the pipe was 24”, so the spherical tee that was ordered for 16” did not work. A custom-made tee was ordered, which resulted in a 14-week delay. In addition, commissioning was delayed due to the frigid ambient temperature and weather forecast.

Solutions

The Manor Gate Station upgrade project included two meter runs, four regulator runs, a separator/filter, heater, odorization, controls, and fire suppression, in addition to considerable construction of buildings and concrete to house this equipment. EN Engineering took the design work from conception through completion and also provided the environmental and construction materials testing, resulting in time and cost efficiencies. The team developed accurate and detailed as-built drawings, which required minimal field changes. The construction management team was on site and eliminated time lapses for design questions during construction. Throughout the project, they focused on jobsite safety, contractor oversight, adherence to BGE standards, and cathodic protection. In addition, they interfaced with the compliance team, Certified Weld Inspector, and NACE coating inspection. Weekly meetings with the client’s senior management team assured the project was on track, and the EN Engineering team’s expertise was welcome and respected.

“EN Engineering took the design work from conception through final design and also provided the environmental and construction materials testing, resulting in time and cost efficiencies.”

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Commissioning Completed On Time Despite Construction Delays

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Project

Commissioning Completed On Time
Despite Construction Delays

Location

Midwestern U.S.

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Background

The client, a multinational energy transportation company focusing on transportation, distribution and generation of energy in North America, required commissioning services and automation for a greenfield 36-inch pipeline.

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Challenges

Commissioning of a large pipeline requires the coordination of all parties involved with design, construction, management, vendors, and operations, and lack of communication can impact the schedule and cost. In addition, with simultaneous construction and commissioning activities happening across multiple facilities, logistics were also a challenge. Finally, construction ran behind schedule at many of the facilities, but the client needed to keep their in-service date due to contractual obligations.

Solutions

Automation services were provided for three compressor stations, and commissioning services were provided for three compressor stations, six meter stations, and 17 remote-controlled main line block valves. EN Engineering wrote the software for the PLCs and the HMIs for the compressor stations, and also coordinated with vendors, operations, construction, construction management, and project management to schedule resources for the commissioning efforts. On-site coordinators and technicians verified operation of all control devices and proper calibration including transmitters, pressure regulation devices, protective systems, valves, and the control system.

To help facilitate communication between all parties, the commissioning project manager hosted a weekly project-wide call with almost 100 invitees. In addition, to manage the simultaneous construction and commissioning activities across multiple facilities, EN Engineering allocated two commissioning leads, one for the compressor stations and one for the remaining facilities, as well as five commissioning coordinators, one per compressor station and two who split responsibilities on the meter and regulation stations and main line valves. This organizational structure allowed for operations and construction to have points of contact at each facility while still allowing efficient communication for global issues.

To help the client meet their in-service date and contractual obligations, the EN Engineering team mitigated the impact of the construction delays by working closely with the contractor to prioritize work and commission in parallel with construction activities. The EN Engineering team facilitated the hand off between construction and operations to bring the pipeline and facilities into service on time, and the client expressed great appreciation for the team’s capabilities.

“EN Engineering facilitated the hand off between construction and operations to bring the pipeline and facilities into service on time.”

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Engine Retrofit Reduces Compressor Station Emissions

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Project

Engine Emissions Optimization Retrofit

Location

Central Pennsylvania

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Background

The client, one of the country’s leading energy providers, called on EN Engineering to provide engineering design services to support the installation of an engine emissions optimization retrofit with the goal of reducing emissions at their compressor station.

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Challenges

Congested below-grade piping was located via a subsurface survey of the area identified for installation of major equipment, and due to existing site layout constraints, the equipment could not be installed in any other area. In addition, because of weather issues, the team was unable to access detailed soil analyses and encountered shallow rock. Finally, due to incomplete historical records, the team was unable to access a full register of existing system air demands.

Solutions

EN Engineering provided engineering design services to support the installation of an engine emissions optimization retrofit for one Cooper-Bessemer GMVA-8 recip and all ancillary equipment. In order to support this installation, various auxiliary systems underwent upgrades, including the fuel gas and compressed air systems, and a new auxiliary water cooling system was installed. The project required design of various foundations and replacement of an existing motor control center in addition to the fuel gas, water, and air system upgrades.

Because the team could not access detailed soil analyses, the foundation designs required revisions. The team reviewed past projects and used engineering judgment to devise foundation designs that were conservative yet not over engineered.

In addition, an existing air system analysis was completed based on limited information and input from station personnel because the team could not access a full register of existing air system demands. Using past projects and engineering judgement, the team revised the existing system analysis until it matched the existing operating conditions described by station personnel. This analysis was used as an accurate baseline for additions due to the requirement for completion of a full air system sizing evaluation.

The team compared existing drawings to subsurface investigation results obtained via ground penetrating radar to determine the locations and services of the buried lines, then worked with the client to identify which below grade lines could be relocated or retired, adjusting the equipment locations within the constraints to avoid those below grade lines that could not be disturbed. Despite these challenges, the installation was completed successfully and compressor station emissions were reduced.

“The project required design of various foundations and replacement of an existing motor control center.”

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CRM SCADA Updated to Unified, Modern Architecture

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Project

CRM SCADA Upgrade
Location

United States

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Background

A leader in the gathering, transportation, processing, and storage of natural gas was operating a number of gas compression pipelines using a mixture of legacy Human Machine Interface (HMI) implementations that were not unified. They approached EN Engineering seeking a solution that would encompass conversion of HMI assets across their facilities to a common platform that would leverage centralized code management and template-driven design to comply with federal mandates in 49CFR192 for Control Room Management.

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Challenges

With more than 100 stations geographically distributed from Texas to Maine, the size and scope of the completed system presented implementation challenges.

Solutions

EN Engineering created processes and tools to facilitate consistent and accurate HMI conversions to a common, modern architecture. Using these processes and tools, EN Engineering worked directly with the client to complete the conversion of more than 100 stations into a single, centrally managed HMI infrastructure. The customized tools assisted in the batch conversion process, enabling accurate progress reporting and programmatic conversion where applicable. Project-specific automated reports were generated and reviewed by the project team weekly.

An unprecedented HMI architecture, implemented under Wonderware System Platform, was created to leverage template- driven design and reduce the amount of site-specific duplication. Computer Workstation Configuration was also script-driven, reducing the possibility of human error and increasing consistency in the finished systems. Communications between all system computers were optimized through customized code to support the large deployment under Wonderware System Platform. Managing the completion of the individual station HMI conversions was facilitated using Kanban methodology and daily stand-up meetings amongst the project team to ensure smooth execution and address execution blocks early and effectively.

“EN Engineering created processes to facilitate accurate HMI conversions to a modern architecture, and converted more than 100 stations into a single, centrally-managed HMI infrastructure.”

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Compressor Station Control Panels Designed, Programmed, and Commissioned with Limited Timeline

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Project

Gibson Compressor Station

Location

Pennsylvania

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Background

The client, a large energy company with assets across the United States, tasked EN Engineering with designing and fabricating their Gibson Compressor station control panels, programming the station’s logic controllers and operator interface, and assisting with the installation and commissioning at the facility. The Gibson Compressor station was designed and constructed in 2013-2014 and is part of a gathering system in Eastern Pennsylvania that conditions and compresses natural gas from local wellheads so it can be delivered to interstate pipelines.

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Challenges

With a limited timeline to complete the design, EN Engineering had to diligently maintain a demanding project schedule to ensure timely project delivery.

Solutions

The EN Engineering team completed a detailed design package for the station control panels, procured all equipment for the control panels, and oversaw the panel fabrication process. In addition, EN Engineering completed the programming for the two programmable logic controllers responsible for maintaining the safe operation of the station and programmed the operator interface system to allow the station operator to monitor and control the facility from the control room. The team also provided on-site commissioning support to verify the functionality of all station instrumentation and control systems and assisted with the startup of the station and compressor units.

“With a limited timeline to complete the design, EN Engineering had to diligently maintain a demanding project schedule to ensure timely project delivery.”

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Compressor Station Expansion

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Project

Compressor Station Expansion 

Location

Central Ohio

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Background

EN Engineering was contracted to engineer, design, draft, procure, and create the necessary documents to install two new solar turbine compressor sets (one Solar Centaur compressor unit and one Solar Taurus compressor unit) in an existing compressor building. In 2007 the client had designed the compressor building to hold a Mars 100 unit, while allowing room for an additional Mars 100 unit.

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Challenges

Because the team was working within the confines of an existing building, the project design was extremely challenging and involved skilled space utilization. Each turbine plus intake system, exhaust system, lube oil cooling system, discharge gas cooler, and inlet filter separator had to be shoehorned into a small space. In addition, the team had to tie the piping into seven different unique services at the station.

Solutions

During the feasibility study, the team recommended adding two smaller turbines instead of another Solar Mars gas turbine to gain the additional horsepower that was needed. A 3D model allowed the client to visualize the concept, convincing them to follow the team’s recommendation—which included installing a full basement in the building. In addition, the team presented recommendations to tie the piping into the existing fuel and starting gas systems, instrument air system, HVAC system, and gas piping and header, as well as plans to connect all compressors, compressor cooling systems, emergency shutdown valves, electrical design and support, controls and instrumentation. The existing auxiliary equipment and electrical interconnections were checked to determine if any modifications were needed. The new units were designed for fully automatic operation in both local and remote control modes and are capable of unattended operation via a PLC-based control system.

EN Engineering also assisted with procurement by preparing specifications, RFQs, and purchase requisitions. The EN Engineering team’s creative design solution was instrumental in the success of the project, and the work was completed under budget.

The challenging project design involved skilled utilization of existing space and was completed under budget.

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Meter and Regulator Station Upgrades

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Project

Meter and Regulator Station Upgrades

Location

New York

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Background

The client, a large pipeline company, requested the help of EN Engineering to expand the capacity and system flexibility of their existing meter and regulating (M&R) station to approximately 1,200 MMSCFD. This was accomplished by installing two additional 16-inch ultrasonic meter runs, two full capacity filter separators, a water bath heater, two sets of dual flow and pressure control valve runs, along with the associated valves and liquid storage tank.

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Challenges

The challenging design involved adding a third M&R substation to the already space-constrained station footprint while providing maximum system flexibility for both measurement and flow control between the three substations.

Solutions

EN Engineering engineered, designed, drafted, procured and created the necessary documents to help our client increase the overall station capacity to approximately 1,200 MMSCFD thru a series of station upgrades, including the installation of new meter and regulating equipment. The new facilities were designed to have a stand-alone capacity of 900 MMSCFD. The new design consisted of two, 16-inch ultrasonic meter runs; two filter separators; an indirect fired water bath heater; flow and pressure control valves; and all associated EFM and system safety equipment. This new M&R station was designed to operate independently or in tandem with the existing two substations to provide increased system flexibility and reliability. The facility upgrades included replacing three existing turbine meter runs with new AGA-compliant ultrasonic measurement equipment, additional overpressure protection devices, and modifications to the existing RTU building to accommodate the new equipment. A station cross-tie with over pressure protection was also included to allow for an alternate feed of filtered gas to the existing measurement equipment.

The EN Engineering team worked closely with the client to develop the necessary drawings and supporting documents to meet FERC, federal, state, and local requirements. The team developed and maintained a detailed project plan to ensure everyone was working towards the same project milestones, including the FERC submittal, permit requirements, and design installation. Complete bills of material and purchasing requisitions were prepared for both long- and short-term material. EN Engineering assisted the client with the associated procurement activities by preparing Request for Quotations (RFQ), segregated by category, to allow the client to submit requests for quotation in an orderly format.

EN Engineering engineered, designed, drafted, procured and created the necessary documents to help our client increase the overall station capacity.

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Pipeline Terminal Expansion

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Project

Expand an existing system to increase capacity and meet new demand requirements

 

Location

Texas

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Background

EN Engineering provided the initial FEED study for a major crude oil pipeline client, followed by the detailed engineering design and construction support for the extension of a 350-mile pipeline system that included modifications and expansion of existing terminals, pump stations and meter stations, and the addition of grassroots terminals and pump stations.

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Challenges

The expansion project required both upgrading older, existing infrastructure and grassroots facilities to meet the new flow rate and design conditions. All of the work had to be completed without impacting current operations, while moving substantially higher volumes through an existing pipeline system under the limitations of the operating pressures.

Solutions

The project included engineering design, construction support, and procurement for the following facilities:

  • Grassroots terminal including one 150 kbl and one 250 kbl tank, six truck unloading ACT units and manifold system, and interconnection to an existing origin pump station and electrical controls.
  • Expansion of existing terminal with a new grassroots mainline pump station with two 5,500 hp VFD pumping units, DRA skid, surge protection, six truck unloading ACT units, one 150 kbl storage tank, 700 hp vertical can booster pump, custody transfer metering, new substation, and new electrical and control building.
  • Terminal expansion with new grassroots pump station with two 5,000 hp VFD pumping units, DRA skid, surge protection, new connection to central manifold connecting to the existing 16 tanks, 700 hp vertical can booster pump, repair of tank lines, custody transfer metering, new substation, and new power and control building.
  • Replacement of one mainline pump station with two 4,000 hp VFD pumping units associated piping, surge protection and facilities, DRA skid, electrical control building, and new substation.
  • Hydraulic modeling for the design modification of existing facilities and required grassroot facilities with the utilization of DRA to optimize the number of new pump stations.
  • Surge analysis to determine protection requirements for the pipeline, terminals and meter stations for the new flow conditions, and design of the new safety devices to protect the pipeline assets. The protection devices included relief valves in terminals, piping to operational tankage, and addition of relief valves and surge tanks at the meter stations.

The challenging expansion project, completed on time, increased capacity and met new demand requirements.

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Compliance Review for Pipeline Transmission

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Project

Compliance Review for Pipeline Transmission

 

Location

Multiple Locations

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Background

Pipeline transportation is one of the safest methods of delivering natural gas and hazardous liquids. Ensuring pipelines are operated and maintained in compliance with federal, state, and local regulations is critical to ensure the safety of pipeline operations and the surrounding public. EN Engineering provides comprehensive compliance review services to ensure conformance with applicable regulations including 49 CFR Parts 192 and 195.

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Challenges

Following a restructuring of their infrastructure and integrity management responsibilities, a pipeline operator was struggling to confirm critical pipeline records, including integrity assessments. The records were not organized, nor were they available to all pipeline integrity stakeholders. Our client wished to establish traceable, verifiable, and complete records containing reliable information and to confirm the maximum operating pressure (MOP) for each pipeline. In addition, the client requested an Information Analysis to evaluate the integrity of each pipeline segment in compliance with 49 CFR 195.

Solutions

EN Engineering was retained to support the improvement of the client’s pipeline integrity management and confirm pipeline features with traceable, verifiable, and complete (TVC) records. This included creating a guidance document defining key components and assumptions, developing guidance to track pipeline characteristics, pressure test data, operating pressure, document quality, pipeline repair sleeves, casings and other related features; performing line “builds” to capture fittings and other important pipeline characteristic changes; conducting thorough quality control and quality assurance checks; validating the MOP based on verifiable information; identifying features requiring additional investigation to confirm properties and characteristics; updating the company database with TVC data; and performing an Information Analysis about the integrity of the entire pipeline and the consequences of a failure to determine if any changes to future integrity assessment plans may be needed.

EN Engineering successfully completed the project, providing the client updated TVC data in their database with linked pipeline records, as well as a detailed process for establishing records supporting MOP. In addition, the team confirmed MOP for each pipeline segment and completed an information analysis of each pipeline segment.

The team enhanced the pipeline integrity management system and confirmed pipeline features with traceable, verifiable, and complete (TVC) records.

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