Client	Large Oil Sands Producer
Compressor Manufacturer	Howden WRVi series
Location	Fort McMurray, Alberta
Method	Screw Compression
Oil & Gas	Compression
Size	100-150 HP
Application	OilSands Application

High CO2 H2S & O2 Content

A large oil sands petroleum producer required a custom solution for a highly specialized production process within an oil sands refinery. The assignment involved the compression of a toxic, corrosive and potentially volatile gas mixture with high levels of CO2, H2S & O2.

The client and its engineering firm discussed this unique, technically demanding assignment with a number of industry gas compression providers. While other vendors deemed the project too complex, Startec engineers worked with the Customer's engineers to reduce the risks involved and conceived, created and delivered an effective solution.

The oil sands project demonstrates Startec's proven capabilities in:

• Tackling custom projects other gas compression companies deem too complex
• Engineering reliable compression solutions for corrosive and potentially volatile gases
• Fabricating components to achieve the highest level of corrosion resistance

Equipment

• 125 HP Howden WRVi series screw compressor
• Electric motor drive
• Custom-fabricated package comprised of carbon steel and stainless steel components. Stainless steel specified on critical components to meet corrosion control and safety objectives.

Engineering & Design Factors

• Unit designed to meet all manufacturing specifications for refinery location
• The toxic, corrosive and potentially volatile nature of the gas required highly stringent measures to protect health and safety at the facility
• Extra control systems, including triple redundancy measures, were incorporated into design to maximize safety

Material Selection

• The CO2, H2S, O2 combination required the ultimate level of corrosion resistance, so stainless steel was specified for many components
• The presence of O2 necessitated the selection and use of components suitable for O2 service

Fabrication

• Startec employed specialized fabrication techniques to guard against material corrosion, stress and cracking
• All weld joints in pressure vessel and piping components were subjected to extended periods of extreme heat to achieve NACE-specified hardness values. The heating, cooling and soaking process was tightly controlled to achieve optimum joint integrity.
• The presence of O2 required stringent cleanliness control during assembly

Testing

• Entire fabrication process constantly monitored by Startec's Quality Control program (ISO 9001:2000)
• Integrity of all pressure vessel heads and shells verified by HIC (Hydrogen Induced Cracking) testing
• All welds verified according to Startec and client testing procedures

Contact Startec

To discuss the specifications of your gas compression projects, contact a Startec Oil & Gas Customer Representative at 403.295-5855 or toll free at 1-800-555-9439