The stillage from the stills is separated in new screeners and the thick stillage is pumped a considerable distance across a road and railroad track to an Anerobic Digestion facility, designed by others. After processing, the C&I team piped the RNG back to the distillery and blended it with an existing natural gas feed to power the new modular boilers. The team has navigated the challenges of working with multiple vendors, permitting entities, and engineering firms to coordinate the design and installation of this project.

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To accurately model the process changes, our team created a benchmark simulation of the entire Urea Unit. Creating a Hysys model was a challenge and had to be rigorously tested. Due to the unique chemistry of the process, the urea and ammonium carbamate components had to be created and regressed binary interaction parameters for multicomponent mixtures had to be developed. Our model was validated against a test run, providing confidence in the simulation of future operation. The process team used creativity to address the need for supplemental compressed CO₂ gas feed by using liquid CO₂ to support the overall capacity increase.

The existing unit was congested, requiring finesse in siting equipment and routing piping. This is where our expertise in retrofit design combined with the 3D modeling tool and laser scan set us up for a successful project. We were able to involve stakeholders in a constructability review early in the design process to locate several new pieces of equipment in an existing structure.

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Due to geographical constraints, the project combined three substations into one. This resulted in multiple cutovers spread over 5 years to match turnaround outages. To make space for the new substation, several storage areas had to be relocated. After installation, the project finished $3MM under budget with minimal RFIs from construction.

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The project will design and commission equipment which allows for continuous, closed loop treatment of ASO within the HF Alky unit.  As a cost savings, existing equipment will be repurposed where safety or integrity is not compromised. Drawing upon our experience from other refineries, our process team scaled the technology to match refinery flow rates based on comparison of ASO to Caustic ratios from other existing units. Our support on this project extended beyond creating a cost estimate, we also attended our client’s presentation to management. We not only care about project design, but the entire project process and are here to help our clients in any way we can!

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The team was challenged to integrate new gear into the already congested operating unit. Our open communication and interactive project management style allowed us to involve maintenance, operations, and construction to balance project objectives and meet stakeholder needs.

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The criticality of this electrical gear required extensive planning to ensure the deenergizing and energizing did not result in any loss in production or safety incidents. Our team designed the equipment layout and purchased a new building to house the gear. We coordinated construction, operations, and maintenance to develop a staging plan for demolition and install.

Scope to accomplish this included larger capacity transformers, 13.8kV arc resistant switchgear with additional feeder capacity, new current limiting reactors and interconnecting cable bus. 

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A key component of this project was repurposing dated, idled equipment, requiring C&I involvement in fit-for-service evaluations. As part of this effort, we modified the charge heater to change the burners and add a burner management system that wasn’t there before. This required installation of a SIS infrastructure, which was used to support temperature monitoring on reactor and burner management system.

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There were three streams that the system could not recover, therefore C&I identified a method for recycling them back to the plant. By recycling these streams, we were able to save $3MM in total installed costs. We were one of the first to install this new compressor and worked directly with the vendor (SIHI) to ensure smooth engineering and install and to provide a reliable system for emissions reduction.

The site selected for the compressor required significant prep work, including filling in a pond and reworking drainage to other sewer systems. Our team routed over a mile of large bore piping, including a new pipe bridge, to tie the systems together.

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To support the new electrical gear, a Power Distribution Center (PDC) was installed to house the 13.8kV and 4.16kv gear.  The existing brick substation was substantially modified internally to house the new 2.4kV and 480V gears.  In order to make this happen, the gear in the existing substation was removed and new gear was installed and tested on-site during a tight shutdown window, putting it on the critical path of the turnaround. Since there were other major upgrades occurring in the unit at the same time, C&I took the lead on a weekly coordination meeting with another engineering firm.

In addition to improved reliability, personnel safety was enhanced by providing arc resistant switchgear in a new PDC and electronic relay protective systems, providing high speed detection and clearing of electrical faults on the 13.8kV lines, transformers and switchgear buses at all voltage levels.  For added redundancy, the pump loads were redistributed so that A/B paired pump loads are split to separate switchracks fed from separate sides of the 480V MTM switchgear.  Three (3) new switchracks and a MTM configured MCC was included for the pump load redistribution and future 480V load expansion.  The 480V feeds to the switchracks were placed in a new cable tray system extending from the existing substation. 

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