EPC- Weld County- Reciprocating Compressor Stations
ZAP was contracted to provide turnkey engineering, design, and construction for a greenfield project which consisted of two separate 48 MMSCFD compressor stations. Each compressor station consisted of four natural gas engine driven reciprocating compressors, inlet liquids handling, TEG dehydration, condensate storage, and all utilities.
ZAP provided engineering, procurement of the balance of plant items, construction, and construction management (EPC). All disciplines, including process, mechanical, electrical, civil/structural, instrumentation & controls, were involved in the engineering of the compressor stations. ZAP completed the detailed engineering on Bernhardt Compressor Station and was able to use a majority of the same detailed engineering on the Libsack Compressor Station. Onsite duties performed by the ZAP field team included:
- Construction Management: onsite coordination with multiple contractors
- Procurement Management: receiving, handling, and managing materials onsite.
- Quality Program: weld and material maps to accompany detailed hydrotest packets, Quality Control/Safety programs for all disciplines onsite, and document controls.
- Schedule and Cost Controls
- Weekly Executive Report: photo documentation, safety issues, work accomplished, upcoming work, material and equipment deliveries, cost tracking, and a milestone schedule.
A majority of the equipment for the compressor stations was specified by another engineering firm and purchased prior to ZAP’s involvement in the project. ZAP employees rose to the occasion and were able to make the required modifications to compressor station design and equipment.
The compressor stations were constructed in parallel with a two month offset to meet client needs. ZAP was able to accommodate the client’s request to move both project schedules by a number of months. Both compressor stations were completed on schedule and on budget. As a result of ZAP’s emphasis on safety, the compressor station projects were executed with 370,500+ man hours without any safety incidents.
Compressor Stations Description:
- 48 MMSCFD (at each compressor station facility)
- 4 – 1650hp Natural Gas Engine-Driven Reciprocating Compressors
- Inlet Slug Handling
- TEG Dehydration
- Condensate Storage