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Carbon Dioxide
Projects Representative Carbon Dioxide Projects Other representative clients: Amerada Hess Corporation, American Quasar Petroleum Company, Amoco Oil Company, Chevron USA, Inc., Exxon Company USA, Gulf Pipeline Company, Llano, Inc. and Societe Entrepose S.A. DETAILS OF CARBON DIOXIDE PROJECTS
(CANYON REEF CARRIERS, INC.) Project Location - West Texas Summary Project Description - This project consisted of an upgrade of the original CRC carbon dioxide pipeline which was installed in 1971. The original system included a 2000 HP Midway Compressor Station consisting of a single unit and a 4500 HP Injection Compressor Station consisting of two units at SACROC. At each station 4,000,000 Btu/Hr heaters were required to heat the CO2 to make it compressible. The upgrade abandons the two compressor stations, including the heaters, and replaces them with centrifugal pumps and also includes five new meter stations and SCADA facilities that provides remote control of four mainline valves in addition to controlling the pump stations. Babcock Eagleton conducted a complete hydraulic analysis for the existing pipeline based on various winter and summer operating scenarios. The results of the analysis determined a range of suction and discharge pressures for the pumps. Babcock Eagleton then prepared detailed specifications for skid mounted pump/motors and variable frequency drives, acquired and analyzed bids (paying special attention to dry gas seals for the pumps), selected vendors, and issued purchase orders. Babcock Eagleton then prepared all drawings required for installation of the facilities, and prepared all construction specifications, construction contracts, and commissioning of the SCADA facilities. PETRO SOURCE CARBON COMPANY Project Location - Texas Summary Project Description - This project consisted of approximately 82 miles of 10-inch carbon dioxide transmission pipeline which transports sour carbon dioxide from four (4) existing compressor stations to a new 1,000 horsepower electric motor-driven pump station and custody transfer meter for pumping and metering carbon dioxide into the existing SACROC Carbon Dioxide Pipeline System. Babcock Eagleton performed this project on a lump sum turnkey basis. Services included pipeline route reconnaissance and route determination, supervision of rights-of-way acquisition, supervision of route survey, flow studies and calculations to determine pipeline size and pump requirements, obtain all necessary permits, preparation of all material and equipment specifications for line pipe, valves, fittings, flanges, pump, motor, variable frequency drive, and SCADA system, perform all detailed engineering design and drafting for the pig launchers and receivers, mainline valve assemblies, side valve assemblies, compressor station tie-in assemblies, and pump stations, construction and as-built surveying, and construction management for the project. All material required for this project was purchased by Babcock Eagleton. PENNZOIL PRODUCING COMPANY CARBON DIOXIDE SYSTEM PROJECT Project Location - Near Jackson, Mississippi Summary Project Description - This project consisted of a carbon dioxide processing facility, pipeline, and distribution system. The carbon dioxide processing facility includes all necessary piping, equipment, and controls for treating 20 MMSCFD of water saturated carbon dioxide containing as much as 1,500 ppm hydrogen sulfide. The carbon dioxide is produced with a flowing wellhead pressure of approximately 3,700 psig and a temperature of 160ºF. The process piping upstream of the primary pressure control valve has a design pressure of 4,000 psig. The process piping and equipment downstream of the control valve is designed for a 3,000 psig working pressure. Due to the extremely corrosive nature of water in the presence of carbon dioxide, all pressure-containing components upstream of the dehydration system are low carbon stainless steel. Dehydration of the carbon dioxide is accomplished with a solid desiccant at a pressure and temperature of approximately 2,730 psig and 100ºF to 120ºF, respectively. Dehydration of carbon dioxide at pressures above 1,400 psig had never before been successfully accomplished. The dehydration process for this project was pioneered and developed by Babcock Eagleton and was modeled and tested in a laboratory prior to an order being placed for the equipment. The dry pipeline-quality carbon dioxide is metered and injected into the pipeline at 2,700 psig. The pipeline system consisted of 40 miles of 8-5/8 inch, a 1.3 mile long high pressure flow line, and a distribution piping system totaling approximately 10 miles for delivering carbon dioxide to twenty-three injection wells. Babcock Eagleton performed all detailed engineering design, prepared construction drawings, prepared material and construction specifications, procured all materials and equipment, and provided construction management and inspection for this project. Babcock Eagleton operated the system under contract to Pennzoil from 1981 until 1993. UNION OIL COMPANY OF CALIFORNIA CARBON DIOXIDE PROJECT Project Location - Dollarhide Field, Andrews County, Texas Summary Project Description - This project includes all in-field facilities for the Unocal Dollarhide (Devonian) CO2 Project. The facilities include approximately 19 miles of CO2 distribution piping to 75 CO2 injection wells; flow lines from 68 new producing wells; new production manifolds, test manifolds, production separators and test separators at seven batteries/sub-batteries; new tankage and vapor recovery systems at two main batteries; approximately 6 miles of new gas gathering pipelines; approximately 12 miles of new water injection distribution piping; a hydrocarbon recovery plant; approximately 5,000 horsepower recycle compression and dehydration; new electrical substation and electrical distribution facilities; and new cathodic protection systems. Babcock Eagleton's Services - Initially Babcock Eagleton performed a series of studies and prepared cost estimates for the facilities. The studies included investigation of the corrosivity of produced fluids and gases, economic evaluation of hydrocarbon recovery and CO2 separation processes, evaluation of electric vs. gas-driven and slow vs. high-speed compressors, preparation of a plan for installing recycle compression, economic evaluation of electric utility vs. unit-owned substation, and investigation of the utilization of existing equipment for hydrocarbon recovery, recycle compression and dehydration. After completion of the studies, Babcock Eagleton provided detailed design, material procurement, project management, construction management, construction inspection, and start-up assistance for all facilities. BIG THREE INDUSTRIES, INC. CARBON DIOXIDE PIPELINE PROJECT Project Location - West Texas, Eastern New Mexico Summary Project Description - This project consisted of approximately 130 miles of 12, 10, and 8-inch pipeline which delivers CO2 for tertiary oil recovery to various Permian Basin oil fields. The system originates near Denver City, Texas and terminates in Pecos County, Texas. The system includes pigging facilities, mainline valves, measurement facilities and flow control stations. Babcock Eagleton's scope of work for the project includes: preliminary product cost estimates, pipeline route reconnaissance and route determination; supervision of route surveying; preparation of right-of-way acquisition procedures and all necessary forms utilized in right-of-way acquisition including property plats; detailed engineering design and preparation of all construction drawings for the pipeline and related appurtenances including mainline valves, pigging facilities, measurement and flow control stations; preparation of material specifications and bills of material; preparation of construction contracts; construction management and inspection; and commissioning and start-up assistance.
TRANSPETCO CARBON DIOXIDE PROJECT Project Location - Borger, Texas Summary Project Description - This project included four 2,000-HP electric motor driven reciprocating compressors and TEG dehydration of the discharge stream. The carbon dioxide was obtained from an ammonia plant at near atmospheric pressure and compressed to approximately 1,400 psig, then transported via pipeline to three oil fields for injection. In order to boost the pressure from suction conditions to the required discharge pressure, five stages of compression were necessary. Because of varying suction conditions, the compressor units were equipped with pneumatically operated suction valve unloaders and fixed-volume clearance pocket valves. The microprocessor-based control systems specified for the compressor units provided for monitoring, automatic valve sequencing, purging, and loading of each compressor. Three separate unloading sequences were used with 13 different unloader and pocket valve configurations in each sequence. A compressor station control system maintained a set suction pressure by starting/stopping compressor units, and by varying the loading of each compressor. Station discharge pressure was maintained at or below a set discharge pressure override valve. The station control system also adjusted the level to which each compressor is loaded in order to optimize operating efficiency. Compression and dehydration equipment were also provided at two of the oil fields to recompress the produced CO2 and gas. Babcock Eagleton performed the detailed engineering, prepared construction drawings, property plats, arranged for surveying the pipeline route, obtained pipeline right-of-way, procured materials and equipment, and provided inspection and construction management for this project. Babcock Eagleton designed a 1,000-HP field compressor station for one oil field and a 600-HP field compressor station for the second oil field. At both locations, dehydration was performed by glycol dehydration units at an interstage pressure of 550 psig. Babcock Eagleton also assisted in the design of the carbon dioxide distribution, control, and measurement systems in the Transpetco oil fields.
BRAVO CARBON DIOXIDE PIPELINE Project Location - West Texas, Eastern New Mexico Summary Project Description - This project consisted of approximately 210 miles of 20-inch high-pressure pipeline which transports carbon dioxide from the Bravo Dome formation in Northeast New Mexico to the Permian Basin oil fields in West Texas for the purpose of tertiary recovery of oil. Babcock Eagleton's scope of work for the project included: pipeline route reconnaissance and route determination; supervision of land ownership searches; supervision of route surveying; preparation of right-of-way acquisition procedures and all necessary forms utilized in right-of-way acquisition including property plats; detailed engineering design and preparation of all construction drawings for the pipeline and related appurtenances including mainline valves, pigging facilities, a 1,600-HP booster station and measurement and flow control stations; preparation of material specifications and bills of material; preparation of studies and cost estimates as required to determine pipeline sizes and construction budgets; and preparation of studies to determine the type of communication system best suited for the project. Babcock Eagleton planned and supervised a laboratory test program utilizing the services of a major pump manufacturer to determine whether carbon dioxide could be pumped with pipeline pumps as opposed to being compressed for the purpose of boosting pipeline pressures. A test loop was designed and carbon dioxide ranging from 100 mol percent purity to mixtures containing up to 20 mol percent noncondensible gas components were tested. Tests were conducted at pressures and temperatures above and below critical. CORNELL OIL COMPANY CARBON DIOXIDE PROJECT Project Location - Cornell Unit, Wasson Field, Yoakum County, Texas Summary Project Description - The project consisted of the installation of approximately 13 miles each of water and carbon dioxide distribution piping serving 36 injection wells. Associated with the water injection system was the removal of two existing water injection pumps, the installation of a new 1,000-HP centrifugal injection pump, and fifty-six prefabricated measurement and control skids. For this project, Babcock Eagleton's services included flow studies and project cost estimates, detailed engineering design, material procurement, and construction management. EXXON COMPANY, U.S.A. MEANS UNIT CARBON DIOXIDE SYSTEM Project Location - Seminole, Texas Summary Project Description - This project consisted of a CO2 distribution system for the Means oil field. The project obtained carbon dioxide from the Sheep Mountain pipeline for injection into 167 wells. Babcock Eagleton performed a review of a design for the CO2 distribution system including a check of the proposed pipe sizes; review of materials for the system components with regard to suitability for CO2 service; recommendations for locations of instruments and relief valves; recommendations for location of pipeline anchor points; and recommendations for monitoring and control system for injection wells. AMOCO PRODUCTION COMPANY BRAVO DOME CO2 GATHERING SYSTEM Project Location - Bravo Dome, New Mexico Summary Project Description - Perform a study for Amoco Production Company concerning design of their CO2 gathering system in the Bravo Dome unit. Babcock Eagleton's services included the calculation of pressure drops in each segment of the gathering system, calculation of fluid velocities throughout the system, conceptual design of wellhead measurements, identification of terrain-induced trouble spots, conceptual design and location of water removal equipment, and identification of points in the gathering system where corrosion could be a problem because of condensation of water or fluid impingement. LLANO, INC. CARBON DIOXIDE PIPELINE Project Location - Eastern New Mexico Summary Project Description - This project consisted of approximately 33 miles of 12-inch carbon dioxide transmission pipeline which transports carbon dioxide from the Shell Cortez Carbon Dioxide Pipeline to the Phillips East Vacuum Unit near Buckeye, New Mexico. Babcock Eagleton performed all calculations and flow studies necessary to determine the pipeline size with consideration given to the addition of future booster pumps. Babcock Eagleton prepared all material specifications for line pipe, valves, fittings, and flanges and performed all detailed engineering design and drafting for the pig launchers and receivers, mainline valve assemblies, side valve assemblies, and interconnecting piping at each end of the pipeline including the measurement facilities and related controls at the pipeline terminus. Babcock Eagleton prepared a comprehensive study on variable speed drives for electric motor driven pumps and assisted Llano, Inc. during construction and start-up of the pipeline and related appurtenances. USSR CARBON DIOXIDE PIPELINE Project Location - Abdurakhmanovo, U.S.S.R. Summary Project Description - Working with Entrepose of France, Babcock Eagleton assisted in the preparation of a detailed technical proposal for the engineering, design, procurement, and advisory construction services for a 190-mile liquid carbon dioxide pipeline from Togliatti to Abdurakhmanovo in the U.S.S.R., including one 1,500-HP electric motor driven pipeline booster pump station and seven electric motor driven injection pump stations for the purpose of injecting carbon dioxide into oil reservoirs for enhancing oil recovery. Babcock Eagleton's scope of work for this technical proposal included: all detailed engineering required to prepare material and equipment specifications; all flow calculations necessary to size the main pipelines and the branch lines to the injection stations; hydraulic calculations to determine necessary pump performance and to ascertain pumping arrangements in each pump and booster station design of pigging facilities, mainline valves, manifolds, metering facilities and other pipeline related appurtenances; design of instrumentation and control systems in the pump stations, and design of high voltage switch gear and motor control centers for the pump stations. AMERADA HESS CORPORATION BRAVO DOME TO ARCO JUNCTION CO2 PIPELINE Project Location - Eastern New Mexico Summary Project Description - The project consisted of a study to determine the flow capacities of 12, 14, 16, 18, and 20-inch carbon dioxide pipelines at various inlet and outlet conditions. The proposed CO2 transmission pipeline traversed 16.5 miles. Babcock Eagleton prepared the preliminary and alternate route selections, budgetary cost estimates were made for all five pipeline sizes. In addition, flow capacities were calculated for all five sizes with flow reversed from the Arco Junction to the Bravo Dome Station. Following this study, Babcock Eagleton prepared detailed drawings and material specifications for the pig traps and interconnecting piping at each end and for a complete monitoring system for the pipeline. Babcock Eagleton also assisted Amerada Hess in evaluating the metering systems at the inlet and outlet of the pipeline and with preparation of commissioning and operating procedures for the entire system.
Project Location - Beulah, North Dakota Summary Project Description - The project consisted of an investigation and evaluation to determine the feasibility and economics of transporting carbon dioxide via a proposed pipeline from the Great Plains Coal Gasification Facility to delivery points within the Williston Basin of North Dakota. Babcock Eagleton's Services - The end result of this study was a cost analysis encompassing all estimated costs for the proposed project in terms of yearly unit costs per thousand cubic feet of carbon dioxide delivered based on various operating conditions and throughputs, a specified rate of return over the project life, and two different methods of economic analysis. The study included preliminary and alternate route selections based on an on-site reconnaissance; investigation of major water crossings; determination of compressor requirements at the supply point; statement of design conditions; hydraulic analysis for all cases studied; consideration of governmental regulations, permitting requirements, and environmental considerations; preparation of maps of the proposed pipeline route(s) and plots of elevation profiles; and preparation of the hydraulic profiles for the various combinations of throughputs and maximum operating pressures. AMERADA HESS CORPORATION WEST BRAVO DOME CO2 COMPRESSOR STATION Project Location - Eastern New Mexico Summary Project Description - The project consisted of a preliminary design for a grass roots electric motor driven compressor station for compressing and dehydrating water saturated CO2 for pipeline service. Babcock Eagleton prepared a preliminary design and cost estimate for a compressor station to be located in Harding County, New Mexico which is intended to receive water saturated CO2 from low pressure wells in the West Bravo Dome field, clean, compress, cool, dehydrate, and deliver the CO2 into a pipeline for transportation to a CO2 transmission pipeline. The study included process flow diagrams, piping and instrument diagrams, major equipment specification sheets, electrical one-line diagrams, station plot plan, major equipment list, station control and communication systems schematic, and overall project cost estimate (-5% to +20% accuracy). AMERADA HESS CARBON DIOXIDE PIPELINE PROJECT Project Location - Seminole, Texas Summary Project Description - This project consisted of a 12.75 inch pipeline and associated processing equipment including a slug catcher, filter separator, compressor, liquid filters and liquid coalescers to handle a process stream containing gas, hydrocarbon liquids, CO2 and H2S. The system was designed to handle a future flowrate of 60 MMSCFD with a plant inlet pressure of 400 psig at which time the CO2 content will approach 90%. During the first year or two after the system was installed, flows were less than 10 MMSCFD, and contained less than 50% CO2 and entered the plant at low pressure. During this interim period, a compressor was installed to boost the incoming pressure up to the 400 psig required by the plant processing system. A slug catcher and filter separator were provided to remove the entrained hydrocarbon liquids from the gas stream. Before entering the process plant, the liquids are sent through a filter and coalescer in order to remove any entrained solids or water in the liquid stream. Babcock Eagleton performed all detailed engineering design, prepared construction drawings, prepared material and construction specifications, requisitioned all materials and provided construction inspection for this project. TRANSPETCO BRAVO DOME TO POSTLE FIELD CO2 PIPELINE Project Location - Eastern New Mexico, Texas Panhandle, Oklahoma Panhandle Summary Project Description - This project consisted of approximately 120 miles of 12-inch carbon dioxide transmission pipeline which transports carbon dioxide from Amoco Production Company's Bravo Dome Compressor Station to the Mobil Exploration and Producing U.S. Postle Field Unit near Guymon, Oklahoma. Babcock Eagleton performed all calculations and flow studies necessary to determine the pipeline size with consideration given to the addition of future booster pumps. Babcock Eagleton prepared all material specifications for line pipe, valves, fittings, and flanges and performed all detailed engineering design and drafting for the pig launchers and receivers, mainline valve assemblies, future booster pump station valving, measurement facilities and related controls at each end of the pipeline. Babcock Eagleton designed a satellite based SCADA system for remote control and monitoring of the pipeline. Babcock Eagleton performed all route surveying, obtained all necessary permits and acquired the rights-of-way. All material required for this project was purchased by Babcock Eagleton. This pipeline system was designed and installed by Babcock Eagleton on a lump sum, turnkey basis. SHELL CORTEZ PUMP STATION PROJECT Project Location - Cortez, Colorado and Tatum, New Mexico Summary Project Description - This project consisted of adding pump stations at Cortez and Tatum to the existing Cortez pipeline system. The Cortez pump station consisted of the installation of one 3000 HP pump with provisions for a future 4000 HP pump. The facilities at Cortez included VFDs for control of the pump and a building to house the pumps and switchgear. The Tatum pump station consisted of the installation of a 500 HP booster pump station at the takeoff to one of the customers. Babcock Eagleton performed all calculations and flow studies necessary to determine the pump station design and piping configuration with consideration given to the addition of future booster pumps. Babcock Eagleton prepared all material specifications for line pipe, valves, fittings, flanges and the pump building and performed all detailed engineering design and drafting for the pump stations.
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