BTC Expansion Project

Project Description

The BTC Expansion Project comprised modifications at PSA-2 facilities in Azerbaijan. The works included construction of concrete bases for the DRA equipment and shelter, construction of the shelter itself, hook-up of the DRA equipment and subsequent pre-commissioning and commissioning of system. The engineering disciplines involved in the project included civil, structural, piping, mechanical, electrical, instrumentation and telecommunications works. Furthermore, Encotec participated in Hand-over and Start up activities.

Project Specifics

  • The work was carried out on a live plant in normal operation mode.
  • Coordination and control of a large number of Sub-contractors and suppliers.
  • Termination of new Electrical and Mechanical systems to existing one.
  • Integration of new Instrumentation system to existing ICSS system.
  • Undertake a thorough preparatory work prior to the commencing construction activities.

Site specifics

  • Difficult soil condition.
  • Many crossings of underground utilities.
  • Specific site HSE requirements for hot work activities.
  • Small allotted territory for construction, with need to use heavy equipment including crane, excavator, piling machine, etc.

Project Goals achieved

  • Excellence in Health, Safety and Environment performance during the project execution.
  • Achieve timely completion of the project.
  • Manage and minimize social impacts and encourage social development activities.

Project Scope of Work

  • Project scope cover detail design, construction and commissioning of the following:

Civil works

  • Foundation for DRA injection skid (including piling).
  • DRA day tank foundation.
  • DRA injection platform foundation.
  • DRA shelter foundation.
  • Pipe support foundations for injection lines.
  • Re-surfacing of the existing asphalt road into concrete within the specified boundaries.

Structural works

  • DRA Shelter.
  • Steel pipe supports.
  • DRA injection platform.

Piping works

  • Preparation of all shop drawings and shop isometrics for piping.
  • Specifying field weld locations and cutting allowances for installation.
  • Removal of all existing pipe work and isolating operating service lines.
  • Pre-fabrication of pipe spools.
  • Installation of all piping items.
  • Procurement of all piping, piping fittings / components, valves, pipe supports, insulation, piping special items, coatings, etc.
  • Pre-commissioning, commissioning/ certification and handover.

Mechanical works

  • Procurement and installation and commissioning of:
  • Rotating equipment including pumps, drivers, cans and mountings, etc.
  • Fixed equipment including tanks, filters, stacks/vents, etc.
  • Skid mounted and package units.

Electrical Works

  • Removal of all redundant cables
  • Subsequent supply, installation and testing of the following equipment and materials:
  • Supports and fixings for cable ladder rack, cable trays and electrical equipment supports.
  • Electrical equipment including switchboards, motors, control panels, MCC's, lighting fixtures, floodlights, fans, switches, outlets, junction boxes and other electrical equipment associated with the Facilities.
  • Power, control and lighting cables.
  • Earthing systems, including earthing cables, bars, electrodes and connections.
  • Lightning Protection equipment and materials.
  • Cathodic protection systems applicable to all facilities and interfaces with the Pipeline System, including control panels, resistor cabinets, anodes, cables, bars and connections.
  • Trace heating tapes, and associated power and control.
  • Testing, certification, commissioning, handover and final "As Built" surveys for all equipment and cabling including points of interfaces with other facilities.

Instrumentation Works

  • Supply, installation and testing of the following equipment and materials:
  • Instrument air, hydraulic and gas lines from main header isolation valves including supports and protection.
  • Instrument mounting stands and supports.
  • Field instruments and weatherproof enclosures (including bench calibration of instrumentation), this includes all associated impulse, and pneumatic lines, complete with supports and protection.
  • Supplier’s packaged equipment instrumentation (including bench calibration of instrumentation as necessary).
  • In-line instruments (Including Items mounted on CV’s, PSV’s, MOV’s & Flow Meters etc.).
  • Instrument Junction Boxes, Local Panels, Field Switches and F&G Detectors etc. c/w stands and supports.
  • Instrument, control and inter-connecting equipment cabling, including supply and installation of all glanding, terminations and earthing to field instruments, local control panels and main equipment.
  • Cable transit c/w all necessary cable blocks, clamps and accessories.
  • Cabling as required for interfaces to ICSS.
  • Packaged equipment including receipt and re-assembly of equipment skid breakdowns, connections between skids, cabling to remote panels, connections to process equipment and utilities.
  • Field F&G devices.
  • Performed final As-built Surveys for installed equipment and cabling including interface with other facilities.

ICSS

  • Carried out installation of ICSS equipment and provided pre-commissioning and commissioning assistance of the ICSS Systems and associated control interfaces.
  • Installation of ICSS equipment included Interfacing with Company, Sub-contractors and Suppliers representatives, for the supply of the cabinet sub-floor frame supports.
  • Installation of the following equipment and materials was included within the ICSS scope:
  • Consoles and cabinets in the Control and Local Equipment Rooms
  • Control and Local Equipment Room’s under-floor cable tray network
  • ICSS system cables between cabinets and consoles
  • UPS Power Supplies cabling to consoles and cabinets
  • Utility Power cabling to consoles and cabinets
  • IS earthing cables between cabinets and to room earth bars
  • Cabinet earthing cables between cabinets and to designated earth bars
  • Networking cabling (fibreoptic or copper) from ICSS equipment to Telecoms hub or termination panels
  • VESDA tubing from cabinets to VESDA main system tubes

Telecommunication works

  • Encotec carried out relocation activities for existing CCTV cameras, underground cable ducts and draw pits.
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