Case Studies


Case Study 1: 9 Burner API Heater

Case Study 2: NFPA 87 Solar-Powered Glycol Dehydrator

Case Study 3: Acid Gas Thermal Oxidizer Upgrade


CASE STUDY #1

9 BURNER API HEATER

Federal Services LLC was contacted by a major midstream company, requesting assistance in moving and modernizing a 43MM BTU/hr API chest heater.

Objectives:
1. Move API Heater 375 miles to new location
2. Upgrade burners to meet current area emissions standards
3. Upgrade combustion and flame safeguard controls to meet:
a. NFPA 87 Guidelines
b. API 556 Guidelines
c. EPA Air Quality Standards
d. SIL-3 Burner Controls
e. SIL-3 Fuel Safety Shut off Valves

7-1

Surplus 43MM BTU/Hr. API Heater to be moved across 2 state lines to a new location

7-2

Nine 20+ year-old high-NOX and high-CO emission end-shot burners, with outdated burner management and flame safeguard

7-3

1 of 9 new, high-efficiency low-NOX burners being prepped for installation

7-4

New burners and flame safeguard scanners installed on relocated API heater

7-5

New SIL-3 safety shutoff valves

7-6

Burner control panel with flame safeguard controls. Solar-powered SCADA system

7-7

NEMA 4X ATEX NFPA 87 stainless steel panel — with burner safety management and SIL-3 flame safeguard controls

7-8

15-inch touchscreen HMI for burner and process controls. Individual burner flame safeguard display screen

7-9

Completed and commissioned API heater: meeting all requirements, on time, and on budget


CASE STUDY # 2

NFPA 87 SOLAR-POWERED GLYCOL DEHYDRATOR

Federal Services LLC was contacted by a major midstream company to modernize 11 glycol heaters to NFPA 87 standards and operate in areas with no electrical power.

Objectives:
1. Replace Burner Ignition / Management with NFPA 87 Electronic Systems
2. Replace Burner and Flame Arrestor Damaged by Accidental BTEX Fire
3. Upgrade Combustion and Flame Safeguard Controls to meet
a. NFPA 87 Guidelines
b. EPA Air Quality Standards
c. Solar Powered

8-1 NFPA 87 Fuel Train

NFPA 87 Fuel Train
Double-block with valve proving sequencing and high/low pilot gas control

8-2 Rebuilt unit

Rebuilt unit with new new burner, flame arrestor, fuel train, and BTEX control

8-3 control panel

NFPA 87 control panel with flame safeguard, temperature controls, and 72-hour storage backup batteries

8-4 flamesafeguard control

NFPA 87 Flame safeguard control and temperature control for media, combustion, and stack limit

8-5

Control panel for solar-powered battery charging system

8-6

Completed and commissioned solar-powered NFPA burner management and flame safeguard system


CASE STUDY # 3

ACID GAS THERMAL OXIDIZER UPGRADE

Federal Services was contacted by a major midstream company that needed assistance in rebuilding an acid gas thermal oxidizer.

Objectives:
1. Increase Thru-put of thermal oxidizer
2. Replace burners with higher output and better turn-down ratios
3. Upgrade combustion controls and flame safeguard controls to meet
a. NFPA 87 Guidelines
b. API 556 Guidelines
c. Compliance with EPA Air Quality Standards

3-1

Thermal Oxidizer with end-shot atmospheric burner, incapable of meeting incineration and emissions requirements

3-2

New burners and SIL-3 fuel trains nearing completion

3-3

Combustion air fans for new burners installed

3-4

Modulating rate forced-air burners, SIL-3 fuel trains and combustion air blowers installed

3-5

Dual-burner control panel

3-6

Successful, completed project in service