.png)
There is no doubt in my mind that Integra Engineering is the best EPCM I have dealt with. For me, at the end of the day, it comes down to one thing: trust. I know that when Integra took on a project for me it was done right. I highly recommend Integra for any project that your company may have.
– Mike Hanson, Operations Manager,
Deltastream Energy Corporation
PROJECTS
Integra Engineering Ltd is an engineering, procurement and construction management (EPCM) firm that specializes in providing comprehensive engineering solutions. We pride ourselves on our technical expertise, quality service and quick turnaround. Our in-house team of engineers and designers are passionate about finding the best solutions for our clients. Our experienced team provides a comprehensive range of services including project management, engineering design, procurement and construction supervision. We deliver projects on time and on budget, with attention to detail and a focus on safety.
Project Name: Nipisi 09-34 Heavy Oil Central Processing Facility
Location: Nipisi, Alberta
Timeline/Schedule: Project completed and operational 9 months from inception.
Description: 15,000 bpd Heavy Oil Battery for the quickly developing Clearwater reservoir in Northern Alberta. This facility consists of four truck load/offload stations, an inlet exchanger, pressure treater, twin tank settling train, shipping pumps, 1600 HP compressor, dehydrator, low/high pressure flare system, and twin 700 kW generation.
All areas of service within Integra Engineering play an essential role in the success of our projects. In particular, our mechanical engineering team worked very closely with our drafting and electrical teams for this project. 3D scan technology was used to complete some aspects of the design phase and with nearly 400 piping and structural design drawings, over 500 piping isometric drawings and over 200 electrical design drawings completed taking over 2,600+ man-hours of drafting time by our entire drafting team, this massive project hit it's target completion deadline of being operational within 9 months from inception.
Project Name: Tucker Lake Weak Acid Cation (WAC) Piping Upgrades
Location: Tucker Lake, Alberta
Timeline/Schedule: Project Completed and Operational 1 year from inception.
Description: The piping associated with the Weak Acid Cation (WAC) softening vessels at the Tucker Lake Thermal Facility needed to be replaced due to failures caused by improper rubber lined piping not fit for service and fitting/valve failure caused piping overstress due to improper installation of piping components. The project consisted of replacing the rubber lined piping and valves with Teflon lined piping and valves and completing a comprehensive stress analysis of the piping to determine required structural, anchor and guide modifications required to allow for proper movement and alignment of piping.
The piping could not be replaced without taking the WAC softening vessels out of service. Due to the vessels being critical to the operation of the facility, the piping would need to be replaced during a planned plant shutdown. All Teflon coated valves, piping and fittings were ordered through a specialty shop in Calgary, Alberta. The piping was prefabricated and coated and shipped to site to be installed during the 12-day plant shutdown in Q3 2020.
To ensure exact measurements of piping were obtained, 3D scans were completed of the piping to allow Integra to model the piping and produce piping isometrics for fabrication. The dimensioning of the prefabricated piping was critical to the success of the project due to the limited installation window during the planned plant shutdown.
The installation was completed successfully during the shutdown window.
Project Name: 15-15 Free Water Knock-Out Design and Install
Location: Marten Hills, Alberta
Timeline/Schedule: Project completed and operational 7 months from inception.
Description: To accommodate the new production of this multi-well oil battery it needed to be done in phases. This is the first phase, the installation of a new heated Free Water Knock-Out (FWKO) and pop tank.
The intent of installing the FWKO at this stage is to de-gas the pipeline inlet emulsion. Currently, the emulsion is carrying gas in solution that is breaking out along the pipeline and as it enters the production tanks. The pipelined emulsion will enter the FWKO where it will be degassed and pre-heated. The produced gas will be collected and tied into the inlet of the existing gas separator. The oil and water that are separated within the FWKO will be commingled and sent to the production tanks for treatment. The FWKO PSV will be relieved into a newly installed pop tank. The PSV has been sized such that future projects can remove the pop tank and re-direct this PSV into an HP relief header to flare.
The FWKO is an 8’x30’ vessel equipped with a 2.5 MM BTU/hr burner. The burner and vessel bottom are equipped with a de-sand system. As the battery expansion has not yet been completed – the de-sand system is currently set up to be completed manually via pressure trucks. There are provisions in place to convert the de-sand system to a fully automated system once the expansion is completed.
Prior to the installation of the free water knockout (FWKO), the emulsion was fed directly into the production tanks at a rate of 6,000 BBLs/day. Currently, there are 8,000 BBLs/day flowing through this FWKO and plans to increase production to 12,000 BBLs/day. Operations were having issues with the gas in solution, breaking out once it reached the production tanks. This was overloading the LP flare header as well as causing inefficient treatment within the initial heating tank. Since the FWKO has been installed it has been reported that those issues have been resolved and the emulsion has been able to reach 40 deg C prior to entering the initial heating tank.
Project Name: Exchanger Double Block and Bleed Isolation Valves
Location: Lloydminster, SK
Description: Exchanger 10-E-009, a Crude/Residue Shell and Tube exchanger in Lloydminster, is currently only equipped with double block and bleed isolation valves on the shell side piping. This means a full shutdown of the Plant 10 exchanger system is required to complete any maintenance on 10-E-009. The tube side inlet and outlet piping is being modified to incorporate new 10” double isolation and bleed valves so the exchanger can be cleaned and maintained while the plant is online. The tube-side bypass line is being rebuilt to optimize for new bypass flow rates. At the same time, nearby piping and exchangers are being re-rated at higher design temperatures. This includes all pipe stress analysis, pipe modifications, hydro testing, instrument replacement, and re-registration required to achieve the new desired design temperatures.
Project Name: Emulsion Tank Farm Replacement
Location: Edmonton, AB
Description: Replacement of an existing emulsion storage tank farm, which had reached the end of its serviceable life. The project included the installation of eight 159 m3 (1000 bbl) emulsion storage tanks, central piperack, catwalks, as well as upgrades to existing loading pumps and loading stations. The tank farm was replaced in multiple stages to avoid interruptions in the client’s ability to store and sell product.
Project Name: Kerosene Distillate Storage Tank Replacement
Location: Lloydminster, AB
Description: Replacement of a 3,179 m3 (20,000 bbl) API 650 light ends storage tank, complete with new concrete ringwall foundation, secondary containment cell, piping, instrumentation, controls, and electrical tie-ins. Upgrades were completed without interruption to plant operation through temporary changes to the process and controls design.
Project Name: Magnetic Drive Pumps for Single Seal Risk Mitigation
Location: Lloydminster, AB
Description: This Refinery has several high-risk fluid services utilizing pumps with only a single mechanical seal. These include hot hydrocarbons above flashpoint and autoignition temperatures, as well as high H2S hydrocarbon and water streams. The consequence of a single seal failure in these applications would result in a flammable vapour cloud, flash fire, or toxic vapour cloud release. This project required a solution that mitigates the risk of a seal leak in these services to an acceptable level. This will be accomplished by replacing the existing API 610 single seal pumps with API 685 seal-less magnetic drive pumps. The pumps to be replaced include P-503A/B Straight Run Gas Pumps, P-504 Kerosene Distillate Pump, P-505A/B Pump Around Pumps, P-506A Atmospheric Gas Oil Pump, and P-506B Kerosene Distillate/Atmospheric Gas Oil Spare Pump.
The Project will take place in two phases. Phase A has already occurred during the 2022 turnaround. During Phase A, the pump’s suction and discharge piping was replaced to incorporate double block and bleed valving. This allows for the pumps to be replaced in Phase B while the Process Unit is operational. Phase B will include the replacement of all seven pumps. Activities associated with Phase B will also include the replacement of a small portion of the suction and discharge piping, structural supports, concrete bases, installing filter skids associated with the new pumps, and the installation of new electrical switchgear. The pump replacements will be completed sequentially, one at a time, to minimize the risk of a plant upset if a pump being replaced is required for operations.
The existing concrete pump pedestals will be replaced to accommodate the dimensions of the new pumps. The existing concrete pedestal for each pump will be demolished and a new pedestal will be constructed. The existing steel piles which support the existing pump pedestals will be re-used to support the new pedestals.
All seven pumps are currently controlled by 600V, Full Voltage Non-Reversing (FVNR) combination starters. The new magnetic drive pumps will be controlled by Variable Frequency Drives (VFD’s). The new VFD’s will be powered by 600V contactors. These contactors will provide a secondary means to shut down the pumps in the event of high discharge pressure if the primary control system were to fail. This additional layer of protection was required to satisfy the requirements of the HAZOP and LOPA studies that were conducted.
Project Name: T - 46 Tank Replacement
Location: Lloydminster, AB
Description: Tank T-46, in Lloydminster, is used as a storage tank to store 200/300A Pen Asphalt. The original tank was built in 1955 and suffered a fire in the 1980’s. The last API inspection was completed in 2009 in which repair work was identified and completed in 2010. In January 2022 the roof on Tank T-46 collapsed and has been out of service since. The existing Tank T-46 has been demolished. The existing tank was supported by a concrete ringwall, which was demolished and was replaced with a new concrete ring wall foundation. The tank has been replaced in kind and has the same dimensions as the previous tank, 42’-0” (12,800mm) High x 84’-0” (25,604mm) Diameter. A new Tank Mixture TMX-4601, heat tracing, and instrumentation will be added to the new tank.