LOCATION: Redwater, Alberta
CLIENT: Pembina Pipeline Corporation
RELATIONSHIP: since 2001
The Redwater Fractionation complex is the largest NGL fractionation facility in Canada and includes three sites: one existing, one under construction and a third in design. With engineering responsibilities for sites two and three, Rangeland had to draw on all aspects of their service and expertise for this project.
The second facility is both integrated into the first site and uses a similar design, which required extensive consultation with plant operators. Upon completion, RFS II will produce C2, C3, C4 and C5+ spec products. The facility houses three fractionation towers—a de-ethanizer, de-propanizer and de-butanizer—with super fractionation trays and a propane refrigeration system for the de-ethanizer. As well, it includes mole sieve, Mercaptan Oxidization system design (UOP Merox), salt-cavern storage for all products, high-pressure and capacity injection pumps, custody metering, and delivery to rail, truck and pipelines.
The facility was built using a complex modular design with 20 process skids (including mechanical equipment) and 35 pipe-rack modules. Building in this way gained both efficiency and improved quality, as well as allowed the equipment to be inspected and FAT tested (functional acceptance testing) in advance of shipping to site.
In addition to the size of the project, Rangeland’s key engineering challenge was to base the new design on an existing facility (RFS I), while modernizing & improving that design.
The RFS II and RFS III facilities were both heavily modularized and constructed off-site. To execute the project, Rangeland had to meet a demanding design schedule and track deliverables, equipment and materials at all times.
The facility design includes:
- 94,000 BPD cavern injection pumps and associated cavern piping.
- 73,000 bpd fractionation system including de-ethanizer, de-propanizer, and de-butanizer towers and associated overhead condensers, reflux drums, exchangers, re-boilers and pumps.
- Propane and Butane Product Treatment including Propane COS hydrolysis, Propane and Butane mercaptan removal (Merox) system and calcium chloride dryers.
- Product storage and handling, product booster and high pressure multi-stage pumps.
- Propane refrigeration system include three 2500hp Frick screw compressors and air cooled condenser for de-ethanizer.
- 64.6 MW Heat medium heater and burner management system.
- 302560 kg/h hydrocarbon vapors handling capacity flare system.
- TEG propane dehydration system and other plant utilities including instrument air, plant air, nitrogen, fire water and treated water.
We consulted with the facility operators a lot on this project. We wanted to really know the operational challenges of the initial design so that we could deliver an improved facility.
— Russell Bandura, Rangeland Project Manager
- Pre-FEED study
- Review of five FEED compositions to ensure the facility could process the lean and rich feeds in summer and winter
- Front-end loading (FEL 3) project planning
- Detail engineering of all disciplines
- Procurement of all equipment, materials management, expediting, and logistics
- Home-office construction support
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Markets: NGL processing & transport, product storage, salt caverns, API tanks