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Industrial Portfolio

Meleiha Phase II Gas Gathering & Export, MSD
Services: Providing Material Selection & Control Study
Client: PetroJet for AGIBA / ENI
2023

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PetroJet engaged Astra Petroleum to perform material selection assessment for gas gathering network from Nada-Zahra, Bostan, and Arcadia-Dorra clusters to the new Gas Treatment facility and from the facility via 150 km export pipeline. 

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The material specialist services focused on

  • Reviewing the system, chemical injection program, stream properties and contaminants

  • Assessing material selection and corrosion control recommendations

  • Delivering a comprehensive report and MSD.

Seawater Treatment & Degassing Material Selection
Services: Providing Material Selection Assessment 
Client: Petro-Techna for Aramco, KSA
2023

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Petrotechna engaged ICE-Genesis, Astra owned operation to perform material selection assessment and CP calculations for a two-stage sea water degassing vessels and gas compression system of Zulfar Water Treatment Plant upstream of well injections at Saudi Aramco facility. 

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The material specialist services focused on

  • Reviewing the system, chemical injection program, inlet properties and contaminants.

  • Assessing material selection and coating requirements for the vessels and their internals.

  • Performing CP Calculations

  • Delivering a comprehensive report and drawings markup of the recommendations.

New Condensate Distillation Unit (CDU4) and Flare (FGU2)
Services: Commissioning & Startup Support
Client: Nasr Petroleum Company, Suez, Egypt
2023

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Nasr Petroleum Company intends to startup a new Condensate Distillation Unit (CDU4) and Flare Gas Unit (FGU2).  AstraConcepts is providing commissioning & startup services. 

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AstraConcepts services focuses on

  • Advising on steady state operation adjustment to reach compliance with assigned product specifications.

  • Resolving change management issues for cases relevant to deviation from IFC drawings.

  • Assisting on troubleshooting operational startup issues.

  • Updating the operating manual, cause & effect and alarm & set point list.

Safe Integrity Operating Window
Services:  Define IOWs using Fitness for Service (FFS) Analysis
Client: HF Sinclair
2023

AstraConcepts engineering is carrying out a fitness for service analysis for one of our client boiler system vessels in order to define safe integrity operating window (IOW).  The scope of work includes 

  • Review of historical operation, inspection, material integrity data

  • Performing FEA model development and stress analysis predictions

  • Conducted FFS calculations based on API 571 – Corrosion and Materials – 2020, API 579 – Fitness for Service – 2021, NACE SP0590 – 2015 and ASME VIII-2 – 2021 codes

  • Developed Safe Integrity Operating Window (IOW)

Carbon Capture, Utilization and Storage
Services:  Project Management - Subcontract, Scoping Studies
Client: Metro Vancouver
2023

AstraConcepts is involved in the project management of CCUS study for Metro Vancouver that involves the following activities

  • Review and benchmark of GHG emission sources by industries (refining, power, cement, etc) and clusters (by geographical area) within the Metro Vancouver area.

  • Evaluation of capture technologies including amine, solvent, membrane and other proven and emerging technologies.  

  • Review of possible transportation modes such as one or a combination of trucking, pipelines and shipping.

  • Investigate at potential storage locations on-shore / offshore

  • Participate in risk assessment and combinations review workshops

  • Participate report development

  • Manage project progress, manhours and spend control. 

Crude & Vacuum Distillation
Vapor & Light Liquid Recovery
Services:  Process Engineering - Independent Contractor, Benchmark and Debottleneck Studies
Client: NWR
2023

AstraConcepts process engineering is supporting the works on Crude & Vacuum distillation and Vapor & Light liquids Recovery debottlenecking works.  Exercise Includes:

  • Review benchmark data and validate process model using PRO II

  • Evaluate the facilities based on current operation and anticipated capacity increase.

  • Evaluate impact of summer conditions on compressor, and air coolers evaluations.

  • Evaluate tower internals with focus on vapor/liquid and liquid/liquid distillation towers: Atmospheric Tower, Vacuum Tower, Naphtha Splitter, Production Fractionator, LPG Amine Treater, Sour Gas Amine Treater, Lean Oil Absorber and Deethanizer.

  • Check adequacy of multistage Compressor Systems

  • Air Coolers capacity assessment

  • Vessels sizing check and others. 

  • Pump circuits adequacy check

Dry Seal Gas Skid Upgrades
Services:  Process Engineering - Independent Contractor, Scoping Studies
Client: Cenovus
2023

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AstraConcepts process engineering is performing engineering evaluations of Dry Seal Gas skids of hydrotreater Recycle Gas Compressors.  Exercise Includes:

  • Develop Basis of Design for 13 operating and start up scenarios such as NiCool, Pre-sulphiding, unplanned shutdown, planned shutdown, startup scenarios, nitrogen purging and hydrogen purging for the dry seal gas skid of the Recycle Gas Compressor systems within two hydrotreating units. 

  • Examine instruments sizing and operating conditions utilizing recycle gas, hydrogen and nitrogen as primary and secondary seal gases.

  • Review Root Cause Analysis (RCA) reports, analysis issues and develop solutions

  • Conduct phase-envelop analysis and predict seal operating pressure and temperature for different scenarios using compressor curves at various seal gas molecular weights.

  • Communicate with client and OEM to discuss findings and evaluate solutions.

  • Carry out hydraulic calculations, pre-heater sizing, filters evaluations, precooler evaluations and other evaluations

  • Review design against latest API 692 guidelines.

  • Review set points and controllability within the seal gas skids.

Gasification Metallurgical Engineering
Services:  Process Engineering - Subcontract, DBM and Detailed Engineering
Client: NWR
2023

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AstraConcepts process engineering is supporting the works on Gasification Plant metallurgical engineering works.  Exercise Includes:

  • Model of Gasification Unit and Validation of Heat & Material Balance using HYSYS

  • Develop material selection input tables and participating in material selection assessment works

  • Review site data and assessing root causes and sources of corrosive components and conditions.

  • Developing, assessing and detailing engineering solutions to eliminate sources of corrosive components and alleviate conditions that induce excessive corrosion rates and undesired stress cracking conditions.

  • Participating in material selection - what if analysis / HAZOP sessions.

  • Performing sizing and hydraulic calculations and supporting piping and mechanical modification works 

Risk Based Inspection and OSI Program
Services:  Asset Integrity Management Services - Subcontract
Client: TUV Rheinland, SIPCHEM (KSA)
2022 - 2023

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ICE-Genesis (Canada), subsidiary of AstraConcepts, awarded the project of RBI and OSI Programs for the following Units (EA, IVC (VA), IMC (Methanol), Waha, Utilities, IAC (Acetyl) & IPC (Polymer). exercise Included:

  • Corrosion Control Documents

  • Corrosion Risk Assessment Workshops

  • Corrosion Loop Identification and Marking

  • Fully Quantitative RBI Program

  • Deadleg Program

  • Corrosion Under Insulation Program

  • Small Bore Piping Program

  • Mixing & Injection Points Management Program

  • Piping Nipples Program

Slab Caster Upgrade
Services: Multi-discipline engineering for FEL I, II and II - Subcontract
Client: STELCO
2022 - 2023

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Our client is performing a slab caster upgrade project including modifications to segments, ladle turret lift, tundish, crane and chain length extension in order to match the increase in blast furnace capacity.   AstraConcepts is providing process, mechanical, piping, I&C engineering consultancy focused on

  • FEL I/II and FEL III works

  • Developing the engineering works for utilities and tie ins

  • Interfacing with the process licensor

  • Providing 3D scan services

  • Evaluation of adequacy of water and oil grease pumps

Lithium Battery Recycle
Services: Multi-discipline engineering for FEL I, II and III
Client: CONFIDENTIAL
2022 - 2023

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Our client is installing a new lithium battery recycling unit within their industrial facility.   AstraConcepts is providing process, mechanical, piping, I&C and Telecom engineering consultancy focused on

  • FEL I, FEL II and FEL III works

  • Developing the engineering works for utilities and tie ins

  • Interfacing with the process licensor

  • Providing 3D scan services

  • Technical procurement of mechanical packages for wastewater treatment, water treatment, boiler, instrument air and dehydration packages

  • Technical procurement of Tanks and Pumps for the storage tank

  • Support the design of the storage layout for the lithium batteries and products: black mass, metals, plastics and others

New Crude Distillation Unit (CDU) and Vapor Recovery Unit (VRU)
Services: Detailed Engineering, Process and Mechanical
Client: Alexandria Petroleum Company, Alexandria, Egypt
2021-2022

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Alexandria Petroleum Company intends to install a new Crude Distillation Unit (CDU) and Vapor Recovery Unit (VRU).  AstraConcepts is providing process engineering works for detailed engineering. 

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AstraConcepts is providing process engineering consultancy focused on

  • Crude oil characterization, Basis of Design and Process Philosophies

  • Modeling the crude distillation unit and vapor recovery unit

  • Developing process deliverables such as Basis of Design, H&M Balances, Data Sheets, PFDs and P&IDs

  • Support HAZOP and SIL and closure reports

  • Operating Manual, Pre-commissioning & Commissioning Plan, Startup Procedures and System/Subsystem List.

  • Vendor Document Reviews (VDRs)

  • Resolving process issues and responding to client technical queries

  • Working with engineering disciplines for integrated multi-discipline delivery of EPC works

Steam Flooding Plant (SFP) Debottleneck and Off Plot Facility 
Services: Detailed Engineering, Multi-Discipline
Client: Madagascar Oil S.A., Antananarivo, Madagascar
2021-2022

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Madagascar Oil S.A intends to debottleneck its existing steam flooding plant (SFP) to process and produce HFO spec oil.  The project includes also the development off plot facilities to connect to new wells including new Manifolds, CVCs, Testing Packages, Roads, Piping & Pipelines and Electrical facilities.​

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The works also involved the characterization of heavy oil and the debottleneck of the plant using specialized heavy oil calculations to predict water removal, hydraulic behavior and emulsion breakdown.  The project also included the evaluation of continuous and semi-batching processes and technologies to achieve dewatering using FWKO / Treater, Settling Tanks, Centrifuge and others.

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AstraConcepts is providing multi-discipline engineering consultancy to develop the detailed engineering solutions for the above project until IFC. AstraConcepts is also providing procurement services to Madagascar Oil.

Concentrator Dust Remediation Project 
Services: Value Engineering Workshops & Report (Sub-Consultant)
Client: Rio Tinto - IOC, Labrador City, Canada
2021

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Rio Tinto is intending to install air scrubbing facilities to dedust its mining operation at Labrador City.  The project includes the design and installation of four wet scrubbers and associated pumping / piping. ​

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AstraConcepts has chaired the Value Engineering sessions focus on technology selection, process simplification and constructability.

Nipigon LNG
Services: Program Monitoring Services
Client: Infrastructure Ontario, Canada
2020-2021

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Nipigon LNG is a strategic infrastructure project in northern Ontario to lower energy costs, reduce GHG emissions, and support economic development. 

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AstraConcepts provided program management services focused on

  • Understand Infrastructure Ontario and Northeast Midstream objectives

  • Assess the engineering design and specification completeness to provide +/-15% estimate

  • Assess the project risks under four categories: Capacity Risk, Delivery Risk, Financial Risk, Operational Risk

  • Monitoring and Supervision of Contractors performing FEED and EPC works

  • Reviewing and approval of project service and control planning package

  • Ensuring contractors implement robust quality assurance program

  • Addressing and managing environmental and social matters

  • Enforcing HSE guidelines in engineering, procurement and construction

  • Providing technical, engineering and design review

  • Protecting the project financial obligation and assure quality with project monitoring

  • Ensuring that the project adheres to schedule and can be completed on time and within projects budget

  • Evaluating the engineering and technical specifications carried out by Northeast Midstream and its subcontractors in order to verify that they meet the intended objectives and identify any technical risks that may impact capacity, CAPEX and OPEX. 

  • Provided recommendations such as the identification of Canadian specifications that should be met by the project related to environmental emissions permitting, water removal permitting and soil management requirements

  • Evaluating the schedule basis and EPC sequence compared to best practices

  • Evaluating the procurement cycle and engineering schedule to identify the critical path in order to strategy project execution to minimize potential project delays

  • Providing recommendations in order to support modularization and minimize risk of delays due to extensive permitting process.

  • Assessing the overall cost estimate CAPEX developed by the engineering subcontractor for Northeast Midstream and provided recommendations regarding inclusion of appropriate material cost for extreme cold weather (Low Temperature Carbon Steel), adequate estimation of indirect field costs such as temporary facilities, mob/demob, scaffolding, etc., and identification of missing equipment/facilities. 

  • Reviewing the supply and demand for the facility products, pricing review of raw material and products in comparison with other Utility companies, OPEX, IRR and NPV.

  • Energy Management System, Asset Management System, HSE) as well operating and maintenance training requirements. 

  • Reviewing turndown capacity requirements based on customer demand during summer and winter. 

  • Reviewing and discussion of sparing philosophy for equipment, storage and electricity.

  • Providing regular, accurate project status information on engineering, material delivery, production, inspection, testing, packing and shipping, helping the client make informed decisions

  • Ensuring that the project adheres to schedule and can be completed on time and within budget

  • Capturing possible issues, risks and opportunities with regular reporting

  • Utilizing KeyGates checklist process in order to systematically review project completion at each phase of stage-gated process utilizing team review sessions with Northeast Midstream.

  • Reviewing operational issues related to management systems such as (Quality Management System,

  • Establishing Mechanical Completion checklist and rules

  • Establishing Plant Completion Certificate checklist and rules

  • Maintaining Action Plan, Risk Register and Punch list for closure of outstanding FEED and EPC items.

New Vapor Recovery Unit (VRU3)
Services: Detailed Engineering, Process (Sub-Consultant)
Client: Nasr Petroleum Company, Suez, Egypt
2020-2023

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Nasr Petroleum Company intends to install a new Vapor Recovery Unit (VRU3).  AstraConcepts is providing process engineering works for detailed engineering. 

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AstraConcepts provided process engineering consultancy focused on

  • Developing Basis of Design and Process Isolation, Shutdown, Emergency and Operating Philosophies

  • Modeling the Vapor Recovery Unit

  • Developing process deliverables such as Basis of Design, H&M Balances, Data Sheets, PFDs and P&IDs

  • Performing pump calculations, vessels & towers sizing, tower Internals sizing and selection, relief load calculation and PSVs Sizing.

  • Developing instrument data sheets, PSV data sheets, cause & effect diagrams.

  • HAZOP and SIL and closure report.

  • Developing the Operating Manual, Pre-commissioning & Commissioning Plan, Startup Procedures and System/Subsystem List.

  • Performing Vendor Document Reviews (VDRs) including tower internals and tower sizing, vessels, shell & tube heat exchangers, water coolers and pumps.

  • Supporting Mechanical evaluations using HTRI

  • Interface and review of vendor prints of packaged systems of the Stabilizer Fired Heater and the Vapors Compressor. 

  • Resolving process issues and responding to client technical queries.

  • Working with engineering disciplines for integrated multi-discipline delivery of EPC works.

New Condensate Distillation Unit (CDU4) and Flare (FGU2)
Services: Detailed Engineering, Process (Sub-Consultant)
Client: Nasr Petroleum Company, Suez, Egypt
2020-2022

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Nasr Petroleum Company intends to install a new Condensate Distillation Unit (CDU4) and Flare Gas Unit (FGU2).  AstraConcepts is providing process engineering works for detailed engineering. 

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AstraConcepts provided process engineering consultancy focused on

  • Condensate oil characterization and properties predictions / analysis

  • Developing Basis of Design and Process Isolation, Shutdown, Emergency and Operating Philosophies

  • Modeling the Condensate Distillation Unit.

  • Developing process deliverables such as Basis of Design, H&M Balances, Data Sheets, PFDs and P&IDs

  • Performing pump calculations, vessels & towers sizing, tower Internals sizing and selection, relief load calculation and PSVs Sizing.

  • Developing instrument data sheets, PSV data sheets, cause & effect diagrams.

  • HAZOP and SIL and closure report.

  • Developing the Operating Manual, Pre-commissioning & Commissioning Plan, Startup Procedures and System/Subsystem List.

  • Performing Vendor Document Reviews (VDRs) including tower internals and tower sizing, vessels, shell & tube heat exchangers, water coolers, air coolers and pumps.

  • Supporting Mechanical evaluations using HTRI

  • Interface and review of vendor prints of packaged systems of the Stabilizer Fired Heater and the Vapors Compressor. 

  • Resolving process issues and responding to client technical queries.

  • Working with engineering disciplines for integrated multi-discipline delivery of EPC works.

FCC Catalysis Spray Dryer Project
Services: FEL II, Process (Sub-Consultant)
Client: Grace, Valleyfield, Quebec, Canada
2020

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Grace intends to install a new spray dryer along with auxiliary systems, furnace and heat recovery system at their Valleyfield facilities as part of expansion activities.​

 

AstraConcepts provided process engineering consultancy focused on

  • Site Visit

  • Process Modeling

  • Process Data Sheet

  • Interaction with Licensors

  • Process Flow Diagram & H&M Balance validation

  • Process & Utility P&IDs

Liquid Flare Technology Selection Study
Services: Feasibility Study, Process (Sub-Consultant)
Client: ADNOC LNG, Abu Dhabi
2020

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ADNOC LNG intends to install a new cold and warm liquid flare system to service the LNG trains.   AstraConcepts is assisting STONE Oil & Gas in performing the technology selection study for this purpose.  ​The work involved screening for technologies, developing configurations with cost estimates, investigating and selecting site locations and developing radiation and emissions modeling maps//contours.  ​A life cycle analysis was conducted to examine OPEX, CAPEX, HSE, operability, maintainability, reliability and experience aspects.

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AstraConcepts provided engineering consultancy focused on

  • Modeling the flare system using Flaresim

  • Performing Heat Radiation and Dispersion Calculations

  • Evaluating the adequacy of cold and warm liquid flare systems

  • Evaluating various Liquid Flare technologies

  • Soliciting information and quotations from Flare vendors

  • Optimizing of flare location and pipe routing in terms of cost, constructability and adherence to process and HSE design criteria.

  • Reviewing Structure Adequacy

  • Reviewing of underground services and interference with pipe routing

  • Revamping of existing flare network

Dissolved Light-Ends Removal Project
Services: Engineering Management (Sub-Consultant)
Client: ADNOC Offshore, Abu Dhabi
2018-2020

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ADNOC Offshore intends to remove dissolved gas from its crude production streams in order to avoid build up of light hydrocarbons in the storage tanks and facilities.

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During this work, AstraConcepts provided project and engineering management for multi-discipline engineering as well as project control and monitoring, progress reporting, financial management, invoicing, technical engineering management and coordination.​

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The work involved Process modeling and engineering using HYSYS and PIPESIM converting current system to vacuum conditions using vacuum ejectors, Piping modifications using PDMS and stress analysis using Caeser, Civil & Structural modifications of several piperacks, design of new structures, Mechanical evaluation and modification of eight vessels under stringent corrosive conditions to accommodate for new vacuum conditions and nozzle stress loads.

Nigeria LNG Generation & Distribution Project
Services: Conceptual Study
Client: Maple Leaf International, Toronto
2019

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Maple Leaf International intends to build an LNG Production & Distribution Facility for the government of Nigeria to assist in enhancing the country's access to the abundant natural gas resources currently produced for export purposes. 

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AstraConcepts provided a comprehensive technical, feasibility and market study for the Project.  The LNG Production & Distribution Facilities will have the following specifications:

  • LNG Liquification & Production

  • LNG Distribution Logistics

  • LNG Consumer Degasification Facilities

  • LNG Consumer Supply Network

 

The work was conducted by evaluating the international and Nigerian LNG market trends.  The Nigerian LNG production and distribution legal and structural framework was researched and presented.  AstraConcepts reviewed the Nigerian natural gas production and pipelines landscape to identify best-fit location for the proposed facilities.  Detailed financial feasibility analysis was conducted to determine CAPEX and OPEX , which was benchmarked against international trends.

Nigeria PV Solar Project
Services: Conceptual Study
Client: Maple Leaf International, Toronto
2019

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Maple Leaf International intends to build a 50 MW-DC PV Solar Power plant for the government of Nigeria to assist in enhancing the country access to electrical power. 

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AstraConcepts provided a comprehensive technical, feasibility and market study for the Project.  The PV solar plant will have the following specifications:

  • Capacity:                                             50 MW–DC (43 MW-AC)

  • Type:                                                   Fixed or Single Tracker PV

  • CUF                                                    15.4% (South-West) to 19.7% (North-East)

  • Required Site Size                              380 acres / 1,540,000 sqmt

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The work was conducted by evaluating the international and Nigerian electrical power generation mix and trends.  The Nigerian electrical power generation and distribution legal and structural framework was researched and presented.  AstraConcepts reviewed the Nigerian solar landscape and power distribution grid and network across the country to identify best-fit location for the new PV Solar facility.  Financial feasibility analysis was conducted to determine CUF, CAPEX, OPEX and LCOE, which were benchmarked against international trends.

LNG Trains Debottleneck Project
Services: Conceptual Study (Sub-Consultant)
Client: ADNOC LNG, Abu Dhabi
2018-2019

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ADNOC LNG intends to process heavier associated gases in their offshore associated gas compression facilities (two trains) and LNG production and export facilities (two trains) producing dense phase dry gas, LNG, Propane, Butanes, Heptanes and Sulphur.  AstraConcepts performed conceptual studies to debottleneck these facilities:

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  • Booster and multi-stage compression facilities for low pressure (LP) gases

  • DEA Gas Sweetening Unit

  • Gas Dehydration Unit and Liquid Dehydration Unit using Molecular Sieve

  • Liquid Splitter Unit

  • Gas Plant Unit - Deethanizer, Depropanizer and Debutanizer Towers

  • LNG Refrigeration Unit / Box

  • Propane and Mixed Gas Refrigeration System

  • Sulphur Recovery Unit

  • Hot Oil System

  • Export Pipelines

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The work was conducted by developing benchmark, design and mitigation simulations, studying the feasibility and operability of various options and providing cost effective recommendations and plot plan modifications.  In addition, equipment sizing and hydraulic calculations of all process units were conducted.  Deliverables included comprehensive reports, process data sheets, implementation schedule and +/-30% cost estimate.

Ras Gharib Refinery Complex
Services: Bankable Feasibility Study
Client: Arteek, Cairo.
2018-2019

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The client intends to build and operate and a refinery complex including process, utilities, offsites and port utilities to process local heavy and sour opportunity crude oil and regional heavy crude oil to produce LPG, Naphtha, Kerosene, Diesel, and Fuel Oil. AstraConcepts professionals have been appointed to provide professional services to develop the feasibility and marketing study for the new refinery

  • Study local and regional oil product markets

  • Evaluate supply change and optimum crude mix for raw material

  • Determine product markets supply chain channels

  • Evaluate different refinery schemes

  • Select and design the optimum refinery scheme

  • Develop a high level cost estimate in accordance with applicable AACE cost estimation standards

  • Develop FEED and EPC implementation schedule

Power Distribution Program Management
Services: Program Management Services
Client: Toronto Hydro, Toronto.
2018-2019

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The client operates and installs multi-million dollar Electrical overhead and underground assets in the city of Toronto. AstraConcepts has been seconded to provide program management consultancy focused on

  • Managing a portfolio of multi-million dollars project

  • Liaison with design and construction

  • Monitoring progress, budget, variance and risks

  • Progress and schedule reviews

  • Developing processes, standards and procedures

  • Producing reports and developing mitigation plans

Associated Gas Plant Debottleneck
Services: Engineering Management (Sub-Consultant)
Client: ADNOC LNG, Abu Dhabi
2018

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The client operates two five-stage compressor trains, where one train is active and the second is on stand-by.  The client intends to increase low pressure associated gas processing capacity by switching the stand-by train into on-line train while increasing total capacity of the two trains by 20%.  The scope of work includes management of engineering activities and subcontractor evaluations, including the evaluation of compressors (OEM by GE), condensate stripping system, hot oil heating system, gas dehydration units and utilities where required.  

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AstraConcepts is providing engineering project management PMC consultancy focused on

  • Steady state and dynamic modeling

  • Process and Mechanical engineering design

  • Multi-discipline evaluation/input including Piping and CSA

  • Hydraulics adequacy checks from process and piping design point of view

  • Thermal Evaluation of Air Coolers

  • Compressor Dynamic and Anti-Surge Evaluation

  • Controls Evaluation and Modifications

  • Process Flow Diagrams (PFDs) and Heat & Material Balance Reports

  • Equipment Data Sheets

  • Progress and schedule reviews

Expansion and Gas Compressor Re-bundling
Services PMC (Sub-Consultant)
Client: ADNOC LNG
2017-2018

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The client operator a network of high pressure HP gas pipelines and a three trains of high pressure dry gas compressors and gas dehydration units. The client intends to increase HP gas processing capacity by 17% downstream, including the evaluation of slug catcher, gas dehydration unit (GDUs), Fuel Gas Treatment Unit (FGTU) and the revamping (re-bundling) of Dry Gas Compressors (DGC) manufactured by GE.

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AstraConcepts provided engineering project management PMC consultancy focused on

  • Modeling the sour gas pipelines and network in steady state and dynamic modes

  • Increasing capacity of Fuel Gas Treatment Unit (FGTU)

  • Evaluation of Gas Dehydration Units (GDUs)

  • Enhance Reliability and Availability of Slug Catcher Unit

  • Hydraulics adequacy checks from process and piping design point of view

  • Thermal Evaluation of Air Coolers

  • Compressor Dynamic and Anti-Surge Evaluation

  • Relief and Flares network adequacy evaluation

  • Controls Evaluation and Modifications

  • Process Flow Diagrams (PFDs) and Heat & Material Balance Reports

  • Equipment Data Sheets

  • Progress and schedule reviews

Flare GHG Emissions Reduction
Services: PMC Services (Sub-Consultant)
Client: ADNOC LNG
2017-2018

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The client operates a sour gas network and fuel gas sweetening units supplying gas (sour, sweet and semisweet) to compressor gas turbines and power generation turbines across multiple facilities.  The project aim is to reduce SO2 emissions in line with emissions targets and local environmental regulations.  An integrated sweet fuel gas distribution system is installed to integrate existing and future fuel gas users (Compressor Gas Turbines and Power Plant Gas Turbines) and fuel gas sources (Fuel Gas Sweetening Units (FGTUs) and Sour Gas suppliers).

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The initial phase of the project is to build a sweet fuel gas finger distribution system.  The scope of work also includes back-up sour fuel gas available to all users in the event of insufficient sweet gas supply.

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AstraConcepts provided engineering project management consultancy focused on

  • Modeling the fuel gas network in steady state and dynamic modes

  • Heater Optimization Studies

  • Process Flow Diagrams (PFDs), Safeguarding Diagrams (SFD), Safeguarding Narratives, Hydraulic Evaluation and Heat & Material Balance Report

  • Piping & Instrumentation Diagrams P&IDs

  • Flare Adequacy Evaluation

  • Instruments and Equipment Data Sheets

  • HAZID and HAZOP reviews

  • Layout and 3D Model Reviews

  • Progress and schedule reviews

HP Gas Expansion Study
Services: PMC Services (Sub-Consultant)
Client: ADNOC Offshore
2017

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The client operator a network of high pressure HP gas pipelines and three trains of high pressure dry gas compressors and gas dehydration units.  The client has received request to evaluate capital cost options to process additional gas from newly developed gas fields.

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The scope of services was to investigate CAPEX options for modifying existing facilities vs adding additional trains in addition to evaluating utilities adequacy to accommodate the additional capacity

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AstraConcepts provided engineering consultancy focused on

  • Modeling the gas dehydration and compressor units using HYSYS

  • Evaluating existing GDU and Compressors capacity

  • Reviewing Third Party Dynamic Model of import and export pipelines

  • Soliciting information and quotations from Compressor and GDU vendors

  • Evaluating Flare Adequacy and Upgrade Options

  • Evaluating utilities adequacy

  • Evaluating Tie-Points feasibility

  • Supporting Capital Cost Estimation 

  • Performing Layout Review using 3D Model, Piping GAs and Plot Plans

  • Working with Civil to construct new reclaimed area

  • Liaison with Operation and HSE

Flare System Relocation
Services: PMC Services (Sub-Consultant)
Contractor: Mott MacDonald, Abu Dhabi.
Client: ADNOC LNG
2017

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The client intends to build new low pressure sour gas compression facilities and requested to evaluate the relocation of two new flare systems from offshore structure to onshore.

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The scope of services is to design two flare networks including flare gathering system, flare knock out drums and flare stack and tip and locate them onshore while adhering to codes regarding heat radiation contours and gases dispersion limits.  The evaluation to include the ability to back existing LP and HP flare systems and the flexibility to maintain surrounding flares during active operations.

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AstraConcepts provided engineering consultancy focused on

  • Modeling the flare system using Flarenet

  • Performing Heat Radiation Calculations

  • Review Dispersion Calculations

  • Managing third party HSE report development and approval

  • Communicating with adjacent facilities

  • Designing and sizing of K.O. Drums, Flare Stack and Flare Tip

  • Evaluating various Flare Stack technologies

  • Soliciting information and quotations from Flare vendors

  • Optimizing of flare location and pipe routing in terms of cost, constructability and adherence to process and HSE design criteria.

  • Reviewing Structure Adequacy

  • Reviewing of underground services and interference with pipe routing

  • Revamping of existing flare network

  • Performing Constructability review and Developing Construction Plan

  • Conducting Site Visit and Data Collection

  • Markup of Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams P&IDs

  • Updating Flare Package process data sheets

  • Developing cost estimates

  • Plant Layout and 3D Model Layout Review

  • Working with Civil to construct new reclaimed area

  • Liaison with Operation and HSE

Integrated Steam Boiler System
Services: PMC Services (Sub-Consultant)
Mott MacDonald, Abu Dhabi
Client: ADNOC LNG
2017

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The client intends to build a new low pressure sour gas compression facilities and requested to evaluate the installation of a steam boiler package to be integrated with the project hot oil system feeding multiple reboilers for gas dehydration regeneration, gas sweetening regeneration and condensate stripper units.

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The scope of services was design a boiler package that supplies steam for start-up of the hot oil system, steam-out of multiple units during shutdowns and supplementing heat when waste heat recovery units are shutdown.

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AstraConcepts provided engineering consultancy focused on

  • Modeling the boiler package and hot oil system in steady state for multiple operating scenarios

  • Establishing utility water treatment requirements

  • Process design of closed circuit steam condenser, steam/hot oil heat exchanger, condensate return system, deaerator and BFW Pumps.

  • Soliciting information and quotations from boiler vendors

  • Optimization of heat oil system and boiler package configuration to maximize heating efficiency, controllability of operation and maximize steam out availability.

  • Markup of Process Flow Diagrams (PFDs) and Piping & Instrumentation Diagrams P&IDs

  • Developing the Control Philosophy

  • Layout and location HSE review in light of presence nearby high risk gas facilities and flight path.

Gas Dehydration Unit and Interconnecting Piping
Services: PMC Services (Sub-Consultant)
Client: ADNOC LNG
2017

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The Gas Development Project aim is to increase export capacity of natural gas for local use in UAE through modifications to the compression capacity and cooling system and the addition of a gas dehydration unit (GDU), export pipeline and pig launcher facility.

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AstraConcepts engineering team provided engineering project management consultancy focused on

  • Modeling gas plant, compressors and pipelines

  • Process Flow Diagrams (PFDs), Safeguarding Diagrams (SFD), Safeguarding Narratives, Hydraulic Evaluation and Heat & Material Balance Report

  • Process and Mechanical Equipment Data Sheets
  • Piping and Mechanical GAs and MRs development and reviews
  • Material Selection Diagrams
  • Liaison with GDU Licensor
  • Piping & Instrumentation Diagrams P&IDs

  • Relief Load Calculations and PSV Sizing

  • Flare and Utilities Adequacy Evaluation

  • Instruments and Equipment Data Sheets

  • Equipment List, Ties In Lists

  • HAZID and HAZOP reviews

  • PHSER Reviews

  • Layout and 3D Model Reviews

  • Progress and schedule reviews

  • Underground facilities design and review

LNG Conceptual Studies
Services: PMC Services (Sub-Consultant)
Client: ADNOC LNG
2017

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Our client operates three LNG trains processing different level of sour gas from offshore wells as well as oil production facilities.

The LNG Trains Expansion study included the evaluation of the feasibility to process additional new low pressure, high CO2 gases supplied by offshore companies.

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AstraConcepts engineering team provided consultancy focused on

  • Modeling the LNG plant using HYSYS including Gas Plant, Gas Dehydration Unit (GDU), Gas Sweetening Unit, Refrigeration Unit and N2 Rejection Unit.

  • Evaluating plant and equipment capacities including Gas Plant, Gas Sweetening Plant, Gas Dehydration Unit (GDU), N2 Rejection Plant and Refrigeration Unit

  • Reviewing Piping & Instrumentation Diagrams P&IDs

  • Identifying bottlenecks and required modifications

  • Evaluating anticipated CAPEX

NPK Liquid Fertilizer Plant
Services: Feasibility Study
Client: Sand Valley - Cairo
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Sand Valley assigned AstraConcepts to provide a conceptual design for a liquid fertilizer facility producing Speciality NPK Fertilizers.

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AstraConcepts services included:

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  • Market Research including Segmentation, Targeting and Positioning

  • Product Mix: Product, Price, Place, Promotion

  • Location Selection

  • Process Flow Diagram

  • Plot Plan

  • Equipment Sizing and Data sheets

  • Equipment List

  • Technology Selection

  • CAPEX and OPEX estimate (Class 4)

Humic Acid Plant
Services: Feasibility Study
Client: Sand Valley - Cairo

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Sand Valley assigned AstraConcepts to provide a conceptual design to produce soluble Humic acid powder utilizing advanced technology that preserves quality.

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AstraConcepts  services included:

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  • Powder generation technology review

  • Laboratory testing

  • Market Research including Segmentation, Targeting and Positioning

  • Product Mix: Product, Price, Place, Promotion

  • Location Selection

  • Process Flow Diagram

  • Plot Plan

  • Equipment Sizing and Data sheets

  • Equipment List

  • CAPEX and OPEX estimate (Class 4)

NPK Soluble Fertilizer Plant
Services: Feasibility Study
Client: Sand Valley - Cairo
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Sand Valley assigned AstraConcepts to provide a conceptual design for a soluble powder fertilizer facility producing Specialty NPK Fertilizers.

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AstraConcepts  services included:

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  • Market Research including Segmentation, Targeting and Positioning

  • Product Mix: Product, Price, Place, Promotion

  • Location Selection

  • Process Flow Diagram

  • Plot Plan

  • Equipment Sizing and Data sheets

  • Equipment List

  • Technology Selection

  • CAPEX and OPEX estimate (Class 4)

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