Kaybob Multi-Well Gas Battery Expansion

Project Details:

OEL completed all four phases of expansion and modification to this brownfield site, upgrading the existing Kaybob multi-well gas battery to a gas plant. This included FEED, DBM, detailed engineering & design, Procurement and Construction Management, and project commissioning.

OEL completed the coordination and regulatory work for the design of the wellsite facilities. Quality assurance on the mechanical, civil and structural and electrical and instrumentation design was completed in accordance with all applicable regulations and codes.

The process of upgrading the Kaybob site was broken down into 4 parts. Part 1 involved the battery expansion, including the installation of a 1480 HP 3 stage reciprocating sales compressor, a 36” x 30’ Dehydrator package, 8’ x 30’ 2.5mmbtu/hr treater pkg, a 220 HP VRU screw compressor, and 4 additional 750 BBL tanks. It also involved flare system upgrades to 6” LP and 10 HP dual flares with 200 BBL KO tanks, as well as site transfer pumps and heat exchangers.

Part 2 was another battery expansion, including installation of an additional 96” ID z 30’ S/S 300 ANSI inlet separator to replace the existing inlet and handle slugging volumes.

A flow split arrangement upstream of the new separator sales gas meter was also added to allow excess flow to another site. The addition of a 2,370HP, 3 stage, 4 throw reciprocating compressor downstream of the inlet separator allowed us to increase the battery’s sales gas capacity, and the existing treater was replaced with a condensate stabilizer and associated heat medium package.

The existing line heater was relocated and converted into a heat medium skid. Three (3) 2,000BBL storage tanks were also added in order to handle additional liquid capacity.

In addition to these process changes, the existing office building was relocated to free up additional rack room and to accommodate requests from operations.

Part 3 included the addition of a 1,200HP refrigeration package along with an associated 5 MMBTU/hr capable heat medium package, installation of a 623 HP recip overheads compressor, and installation of bullets and VRU upgrades for NGL storage. The existing dehydrator was decommissioned for this part.

Part 4 included the installation of a 200HP high pressure water disposal package, along with a line heater package (1.0 MMBTU/hr) and other accessories and equipment to allow sales of a NGL (C3+) product into Pembina’s planned HVP gathering/sales system.

This equipment included a 75HP NGL booster pump package. The package included a final metering and the needed sales pump along with the associated MCC.

This was shortly followed up with water treatment facility install to aid in the water disposal process.

Project Scope

  • 5,200hp gas compression
  • 96”x 30’ inlet separator & slug catcher
  • 1,200hp refrigeration package
  • 5MMbtu/hr heat medium
  • Over 8,000bbl onsite storage tanks
  • Water filtration & injection
  • 2x 60,000USgal NGL & condensate bullets with sales pumps