Horizon Primary Separation Cells
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Project Timeline
Start Date: 2011
Completion Date: 2015
Horizon Primary Separation Vessels
Phase 3 Horizon Project
Canadian Natural Resources Limited (CNRL)
ThyssenKrupp Canada
Structural design, piping stress analysis and design
Mining, Oil & Gas
Fort McMurray, Alberta, Canada
The CNRL primary separation vessels (PSV) are conical in shape, with a diameter of 26 meters and a capacity of 5400 cubic meters. The tank roof elevation is 27.8 meters and bottom-of-tank elevation is 7.8 meters above grade, respectively. MGA's work covered all aspects of the project, including structural design, piping stress design and analysis, fabrication and erection technical supervision. Issues of corrosion and welding of thick plates posed a challenge in the design. Vibration studies, including accounting for all static and dynamic loads imposed on the new facilities by surrounding and connecting facilities, posed another challenge.
Primary Separation Vessels Data:
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Process Data: Oil Sand Slurry, Bitumen Froth/Sand, Slurry Tailings
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Feed Rate (not including air): 10,000 – 12,000 tph
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Standards: API 650, API 620, ASME B31.11 and ASME B31.1
MGA mandates in this project included design, as well as the fabrication and construction.
Design:
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Support structure including support ring, columns, bracing and base plates
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Froth collection launder including outer peripheral launder, stiffeners, drain, overflow, and overflow downspout pipe
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PSC feed system including feed pipe from tie-in point feed-well, feed-well vent and feed-well lining
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Under-wash piping distribution system, from the tie-in point, complete with drop pipes, supports and hangers
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Middling piping collection system including internal middling withdrawal headers, valves and middling collection headers to tie-in points
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Roof and roof structure with supports for feed pipe, feed well and under-wash
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All connections including nozzles, vents, manways, openings, sight glass (with flushing piping), gaskets and bolts
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All appurtenances including nameplate, lifting/rigging lugs, cable tray supports, lighting supports, support for Canadian Natural pipe, insulation supports, lightening rod and grounding lugs
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External protective coatings including galvanized roof vapor space and painting
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Erosion/corrosion protection for wetted surfaces including chromium carbide overlaid plate wear lining, galvanized steel and internal coatings as specified per data sheets
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Insulation, including girt system and clips, on external surfaces of the outer peripheral launder for heat conservation
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Insulation system on support structure, if required for thermal transients during plant start-up/shutdown
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Sight glass, suitable for service as shown on reference drawings
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Access ladders, walkways, stairs, platforms, kicker plates and handrails, etc.
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Sight glass flush piping system, supports and valves
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Middling flush piping system, supports and valves
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Installation of crane pads
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PSC overflow line
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Manual valves and blinds
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Trial assemblies
Fabrication/Construction Support:
Provide fabricator with detailed shop drawings, plate profiling files, weld map requirements, connection details, bill of materials and other as needed to properly fabricate the work.