Front-End Treater & Slug Handling
The Front-End Treater handles the full inlet stream through a harp-style high-pressure slug catcher with 5,000 barrels of finger volume, dual 450 MMSCFD inlet separators, an amine treatment unit with a 2,400 gpm regeneration package, acid gas compression, triethylene glycol dehydration, and a condensate treating and acid gas stripping system producing condensate below 4 ppm hydrogen sulfide.
Balance of Plant & Cryogenic NGL Recovery
The Balance of Plant adds a second amine unit, molecular sieve dehydration, a cryogenic natural gas liquids processing unit, and residue compression. Major rotating equipment includes multiple electric-driven Ariel reciprocating compressor frames across medium-pressure, acid gas injection, refrigeration, and residue compression services, with acid gas compressed and injected via a dedicated acid gas injection system rather than a sulfur recovery unit.
Electrical Systems & Expandable Sour Gas Design
ZAP’s electrical scope included a dual-train architecture with both 4,160-volt and 24.9-kilovolt switchgear, an Allen-Bradley ControlLogix process control system, and an independent PLC-based emergency shutdown and safety control system. The facility was engineered for expandability to handle rising acid-gas content over its life, sour service requiring NACE-compliant materials and post-weld heat treatment, and large-volume slug handling.
