Cryogenic processing complex in Watford City, North Dakota

Project Summary

One of North America’s largest midstream companies hired Saulsbury to complete the civil and mechanical construction, as well as instrumentation and electrical for a 60-MMSCFD cryogenic plant.

The company later awarded Saulsbury an EPC contract for the installation of a 150-MMSCFD cryogenic plant as the second train to this facility. In addition to the engineering and construction of the facility, this full turnkey project included procurement of all packaged equipment, site work, building erection, and startup and commissioning scope. The plant was fully operational ahead of schedule.

Due to the remote job location and desire to minimize field construction during the winter months, the project team executed the design and fabrication oversight of modular pipe racks. These pipe rack modules were engineered in-house at our Odessa and Abilene engineering offices and were pre-loaded with piping and cable tray to minimize field installation manhours.

Scope of the Project

The second phase of the project included:

  • One — 200-MMSCFD UOP Russell GSP cryo plant (derated to 150 MMSCFD)
  • One — 5,000-BBL slug catcher (harp style)
  • Two — 6,000-HP residue compressors
  • Two — 600-HP NGL pipeline pumps
  • One — 10,000-bbl/day condensate stabilizer
  • Two — 1,550-HP stabilizer overhead compressors
  • One medium-voltage PDC building
  • One low-voltage PDC building
  • Emerson DeltaV DCS and SIS primary and safety plant controls hardware integrated into the existing plant control system
  • One residue/overhead compressor building
  • Balance of plant equipment, utilities, and electrical systems

Goals and Achievements

The first phase of this project represents Saulsbury’s 54th cryogenic construction project.

In August 2019, the second phase of the project celebrated 150,000 safe working hours with an employee luncheon. Overall, the second phase of the project was completed on budget, ahead of schedule, and without a recordable injury or incident.

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