Project Synopsis
Perform an analysis of the CDU equipment, prepare a plan to return it to operation, and to oversee the execution of upgrades from a process engineering perspective, in support of starting up a mothballed condensate splitter facility for an investment hedge fund client.
Project Summary
The client, a major US hedge fund, had purchased a bankrupt Condensate Splitter facility with a Crude Distillation Unit (CDU) in the US Gulf Coast area. The CDU was non-operational and had never operated properly due to errors in the original design. Process Engineering Associates, LLC (PROCESS) was contracted to execute an analysis of the CDU equipment, prepare a plan to return it to operation, and to oversee the execution of upgrades from a process engineering perspective. PROCESS served in an advisory role to other firms throughout the entire project including startup.
More specifically, PROCESS performed the following:
- Collected on-site data
- Simulated the CDU
- Analyzed site conditions and equipment including crude tower and internals, pump arounds, heat exchangers, and pumping systems; unit hydraulics; and overall heat integration.
- Identified and recommended improvements and equipment upgrades
- Prepared process design packages and other process engineering services to support the upgrades including development of the following:
o Heat and Material Balances and PFDs
o Red-lined P&IDs showing process changes
o New Static Equipment List
o New Rotating Equipment List
o New Critical Instrument List
o Equipment Specification Sheets
o Vendor Bid Package preparation support
o Managed all PSM functions of the project
o Manage PSM programs post-startup
o Prepared new draft standard operating procedures (SOPs)
o Prepared unit operating documentation
o Conducted Alarm Rationalization Reviews.
- Prepared work packages for EPC companies to execute modifications
- Provided “Process Engineering Project Management Consulting” (PEPMC) services to serve as an advisor (Owner’s Engineer) to other disciplines throughout the project execution
- Provided process engineering oversight for commissioning and startup activities.
Once implemented, the revamped CDU started up successfully and is currently valued at ten times (10x) the original value of the client’s purchase price.
With the technical execution and guidance of PROCESS, the facility has gone from a bankrupt site to one of the premier commodity producers in the region and it is the first operating asset for a the hedge fund client.
Industry Type
- Petroleum Refining
Utilized Skills
- Process evaluation and design
- Process simulation
- Owner’s Process Engineer role
- SOP preparation
- Process safety support
- Commissioning & startup support.