Inlet Handling & Cryogenic NGL Recovery
Inlet gas first enters a high-pressure slug catcher with six finger pipes holding 8,300 barrels, with liquids feeding a 60,000 barrel-per-day stabilizer system that produces a color-treated stabilized natural gas liquids product. Two electric-driven 2,000-horsepower overhead compressors recycle stabilizer vapor. Gas treatment includes an inlet scrubber, molecular sieve dehydration, and a regeneration loop, feeding a 225 MMSCFD recycle split-vapor cryogenic unit with refrigeration compression sized as two 3,000-horsepower units and a 60,000-gallon natural gas liquids surge tank.
Residue Compression & Liquids Handling
Residue compression uses six engine-driven Ariel units inside a dedicated compressor building, with provisions for a seventh unit. The plant also includes natural gas liquids pipeline pumps, stabilized liquids storage bullets and pumps, and main process flare and tank combustor systems to manage relief and emissions across the facility.
Electrical Systems & Cold-Climate Engineering
ZAP’s electrical scope was built around a 20 MVA primary transformer feeding 4.16-kilovolt medium-voltage switchgear in elevated power distribution buildings, variable frequency drives on all large motors, and 480-volt distribution, along with an Allen-Bradley ControlLogix control system, a safety-relay emergency shutdown system, and fire-and-gas detection. Engineering addressed extreme cold-climate conditions, including minus 20 degree Fahrenheit ambient temperatures, arctic compressor packaging and freeze protection, and rigorous relief and flare analysis across numerous integrated vendor packages.
