Fuel Gas Supply & Balance-of-Plant Utilities
ZAP’s scope encompassed fuel gas supply design, including pressure regulation from the facility fuel gas header, relief protection, and integration with generator package-supplied filtration and metering equipment. Instrument air, RO water treatment and distribution, evaporative cooler systems for generator air intake conditioning, and lube oil utility routing were evaluated during FEED and carried through to detailed design.
Electrical Integration & Black Start Capability
The electrical scope addressed integration of the four generator sets into the existing facility power distribution infrastructure, including two new 480V motor control centers serving generator auxiliary loads, a new generator power distribution center building, and a permanently installed diesel black start generator with automatic transfer switching and passive synchronization logic.
Integrated Control Architecture & Seamless FEED-to-EPC Delivery
The control system architecture integrates generator set controls into the existing facility distributed control system via fiber, with a standalone ESD system, fire and gas detection, and hardwired emergency shutdown throughout. By self-performing both the FEED and subsequent EPC, ZAP delivered a seamless transition from scope definition to construction, minimizing rework and maintaining continuity across all engineering disciplines through mechanical completion.
