Page 62 - Industrial Plants

stream from the pig trap unit and deliver it to separation power to selected critical users in case of a major
unit. malfunction of the main power generators or ESD
(emergency shutdown). It also provides power to
The separation unit consists of one separator/slug selected users on initial start up (black start), when fuel
catcher, rating 600lbs, designed to operate 1x100% gas and other ancillary systems are not yet in operation.
during phase 1 and phase 2 and two separators, rating The instrument and utility air is provided by unit
150 lbs, designed to operate only during phase 1, “compressor air”, by means of three 50% air
when the operating pressure is set at 6 bara. compressors. The compressors are controlled by an
During Phase 1, the process separators and the on-skid PLC based control system. Limited unit alarms
separator/slug catcher receive the multiphase fluid in and status inputs interface via hardwired connections
order to separate gas, oil and water streams, measure to the PCS (process control system) for display on the
them, commingle oil & water in one stream and deliver HMI (human machine interface).
separately gas and liquid phase to the Pemex plant Project strategy aimed to optimize as much as possible
named Bateria San Ramon. the schedule, maximizing parallel execution of design,
procurement and prefabrication, in Italy and Mexico,
Then, in Phase 2, the process separators / slug taking advantage of the support of the local content,
catcher receives the raw gas in order to separate gas for a time frame of 12 months from KOM (May 2018)
and condensates, measure them and deliver both to plant handover (May 2019).
commingled to the Pemex plant named ECO San All project execution phases have been carefully
Ramon. planned to minimize the risks. In particular, the logistic
The flare, vent and blowdown system ensure the safe strategy has been set out through site surveys and
and reliable collection and disposal of the fluids relieved feasibility studies to find the most suitable mean of
from the plant during upset scenarios, start up, transportation for each item, from ground to air freight,
maintenance and depressurization operations. The including the rental of a dedicated air charter (Antonov)
Unit is composed by: for the shipment of the critical items.
• One sonic flare, designed to ensure smokeless
flame under the most severe scenario (hot blow “The project strategy optimized the
down of unit 200); schedule by maximizing parallel
• One flare KO drum, designed to separate the execution of design, procurement and
liquid droplets above 600 microns from the gas, prefabrication, in Italy and Mexico,
before it is relieved to the flare, with the capacity taking advantage of the support of
to hold the maximum amount of liquid, which can the local content, for a time frame of
be relieved during an emergency; 12 months from KOM (May 2018) to
• 2x100% flare KO drum pumps, designed to plant handover (May 2019)
empty the drum in approximately two hours
during phase 1. The construction involved 270,000 man-hours in four
months – from January 2019 to May 2019, date of
The flare network system is designed with an plant handover to client- for the installation of 137 tons
unpocketed , sloped header draining to the KO drum. of steel structures, 3720 dia inch of piping , 30,000 m
The fuel gas is used to purge the main header, vent and of electrical and instrumentation cables, 1170 manual
blowdown system and to feed the flare pilot. The fuel and automated valves, reaching the successful goal of
gas is supplied by unit fuel gas: the main source of fuel zero LTI ( Lost Time Injury).
gas comes from downstream of separation and Notwithstanding the difficulties of a harsh environment
upstream of measurement system. The fuel gas skid and the frequent hinders of the local communities, this
allows to reduce gas pressure, to remove any possible performance was made possible by the flexible
condensate from the fuel gas, to heat and condition organization of DG IMPIANTI, which allowed the
the gas to reach the required values and to distribute maximum integration with the stakeholders ( client,
the fuel gas liquid-free mixture to the various users at local suppliers and subcontractors, communities) and
constant pressure (3 barg). the fast decision making process which enabled to
carry out timely the most suitable solution.
Another use of the fuel gas is to feed the main power
generation unit, composed by two generators,
designed for stand alone mode operation, with gas Phase 2 Project Detail

internal combustion engine. The main objective (just concluded in March 2022) of
Besides main power generation unit, the plant foresees the ORF transition from Phase 1 to Phase 2 is to
an emergency generation unit, designed to provide convert the ORF plant as follows:

IndustrIal Plants - May 2022
60