Services: Petroleum Refining
Petroleum Refining Services
Representative Project Experience
Wink specializes in Refinery Engineering. While maintaining a diverse market — including oil and gas exploration and production; chemicals and petrochemicals manufacturing; electric utilities; and commercial / institutional clients — the majority of our current and historical workload has been in refinery revamps and upgrades; grass roots projects; utilities and infrastructure.
We have experience in virtually all refinery processes, as illustrated in the selected project listing below.
Staff Experience: Refinery Engineering
Our professional technical staff — engineers, project managers, designers, estimators and schedulers — includes experience and expertise in virtually every refinery process. Staff experience ranges from senior process and project engineers with 25+ years of practice to a younger generation of talent with 3 to 10 years experience gained in the refinery environment and under the tutelage of Wink's refinery experts.
Engineering Alliances / MSA Services
We provide ongoing engineering services to a number of refinery clients through Master Services Agreements in which the Wink team serves as an extension of the plant's engineering department, taking total ownership of each project. A dedicated Wink project team provides services which may include:
- FEL (project development to AFE, including scope refinement, concept approval, process design, economic evaluation, environmental impact documentation, HAZOP analysis)
- AFE submittal (definitive scope, budget quality estimate, schedule)
- Definitive design, in all engineering disciplines
- Project management, estimating, scheduling, project controls
- Procurement
- Construction support of onsite construction contractors
- Startup and commissioning
- Project closeout, including all required MOC documentation
- Mechanical Integrity / Equipment Condition Monitoring
- Surveying
Plant Utilities and Infrastructure
Wink has significant experience in engineering studies, alternatives analysis and front-end engineering, and detailed design engineering for industrial plant utility and infrastructure projects. Sample projects include cooling water, steam, air, boiler feed water, plant fuel gas, natural gas, nitrogen, and oxygen systems.
Additional Capabilities and Experience
- PSV and Relief Systems – We have performed system-wide studies; adequacy review and assessment; and detailed design services for flare and pressure relief systems.
- System Hydraulic Modeling – Wink's process engineers perform hydraulic modeling of plant systems using PipePhase, KY Pipe, DynSim, Pipeflo, Sinet XLT, Inplant, Visual Flow, and internally developed software.
- Process Safety Management – Comprehensive services related to the implementation of OSHA 1910.119.
- Safety Instrumented Systems – Including LOPA and SIL studies.
- Process Hazard Analysis – Wink has provided Process Hazard Analysis services for projects, initial unit studies and for unit revalidations. We have trained PHA facilitators and scribes who have performed the full range of PHA services.
Representative Project Experience
"Grass Roots" Propane Deasphalting (PDA / ROSE) Unit
Multi-discipline engineering design and project management for a new, "grass-roots" 8,000BPD PDA unit to separate asphaltene components from higher value oils. Wink services included development of a full Schedule "A" front-end engineering package from Process Design Package provided by KBR, with purchase-quality specification on long-lead equipment items; detailed design in all disciplines and development of construction packages; and on-site field construction support.
Propane Storage Facility
Multi-discipline engineering design for a propane storage facility to support the new PDA Unit. The storage facility includes new propane storage bullets. Wink provided detailed design including mechanical / piping, electrical, instrumentation, and civil / structural for the storage bullets; pumps and piping; and a truck unloading system.
Cat Feed Hydrotreater Revamp
- Expanded unit capacity from 46,000 BPD to 58,000 BPD
- Renovated and repacked main fractionator
- Designed and installed new reactor; modified reactor charge heater
- Designed and installed fin fan exchangers, process pumps, heat exchangers, vessels, feed filtration, E&I infrastructure
FCC Recovery Modifications and Upgrade
Design of modifications to the main fractionator and gas plant to accommodate increased unit throughput. Services included process simulation, work scope development, total installed cost estimate, and front end engineering; laser scanning for development of design model; and definitive engineering design in all disciplines.
Crude Unit Modifications and Debottleneck
FEL followed by detailed design (process, mechanical, civil, structural, electrical, instrumentation) for a project which increased crude unit production from 80,000 BPD to 92,000 BPD. Some of the modifications included:
- Modify internals of (6) major vessels including atmospheric and gas oil towers
- Addition / modifications of (18) heat exchangers
- Modifications to (2) unit process heaters
- Replace or modify (12) process pumps
Diesel Hydrotreater Unit Revamp
- Fast track project to increase capacity of Diesel Hydrotreater from 27,700 BPD to 35,000 BPD (increase revenues enough to recover investment in 5 months)
- Performed process analysis, heat and material balances (conceptual engineering)
- Front End Engineering, including Project Cost Estimating and Scheduling
- Definitive Design and Construction Documents, Construction Supervision
Hydrotreating Unit Expansion
Front-end engineering, followed by detailed engineering design in all disciplines to increase the processing capacity of the diesel hydrotreater. Project included new exchangers designed to maximize the heat integration between the feed and product streams, new Unit Feed Pumps, and Fractionator Bottoms Pumps.
Sulfur Recovery Unit Revamp
Wink developed FEE packages on two SRU Revamp options, then provided process engineering, definitive design in all disciplines, project management and construction liaison services for a 100% oxygen enrichment system which doubled unit capacity to 426 LTPD. Technology and Gate 2 process design was provided by Parsons / BOC cases.
Debottleneck of Coker and Crude Unit
Front-end engineering and detailed design services for project to increase throughput on Refinery Crude Unit from 96.5 to 100 KBD and throughput on Coker from 25 to 30 KBD.
OSBL Facilities for Major Refinery Expansion
Wink provided front-end engineering and cost estimating, followed by detailed design in all disciplines, procurement, project management and project engineering for offsite facilities valued at $400 Million, for a $3.2 Billion refinery expansion. Offsite facilities designed and engineered by Wink included:
- Major East-West Piperack
- Truck Loading Facilities – Sulfur and LPG
- Potable Water System
- Tank Farm Expansion
- Wastewater Treatment Plant (FEED only)
- New Sulfur Tank
- New Stormwater Tank (FEED only)
- Interconnecting Piping
Flare Gas Management
Front end engineering, definitive engineering and construction management for a $40 MM project to bring a refinery's two flares into compliance with NSPS, Subpart J. This consisted of segregating and capturing the refinery sour streams after they discharge into the flare header, but prior to burning in the flare. Liquid ring compressors take suction off the flare header, compress and direct the recovered gases to a new amine treating unit for sweetening prior to introduction into the refinery fuel gas system.
HF Alky Water Mitigation System
Wink provided multi-discipline engineering services including Schedule "A" / FEL services and detailed design, for installation of a water mitigation system in the HF Alkylation unit, including development of a long-term solution for containment, treatment, and disposal of the mitigation water. Equipment included pumps, tanks, firewater monitors, detectors, remote controlled cameras, MCCs and transformers, safety showers.
Refinery Electrical Systems
System Analyses for Refineries include mapping, preparation of computer models, load flow / voltage drop studies, fault current studies, and system coordination analysis. We provide engineering design, construction documents, and construction management for electrical system additions and improvements. We perform electrical power and control systems design in support of capital projects throughout the refinery.
Hot Well Gas Project
Wink provided FEL and detailed design services to capture, compress and treat three (3) low pressure process gas streams. A HiJet eductor system was utilized to compress the gas and amine treating was the selected method for H2S removal. The treated stream was routed to the refinery fuel gas distribution system. The streams treated were: ROSE Unit Hot Solvent Vent Gas, Hot Well Gas from the Crude Unit Vacuum Tower, Vent Gas from the MDH Fractionator.
Alky Vent Gas Scrubber
Replace existing vent gas scrubber on the HF Alky Unit with new, larger system to increase overall capacity to neutralize flare relief system upstream of refinery flare system. Project included new caustic scrubber system, pumps, and flare header flow monitoring instrumentation.
Wastewater Treatment Plant Expansion
Provided engineering services in support of an EPC (Engineering / Procurement / Construction) project to modify existing Wastewater Treating Facility by adding a fourth train to the existing wastewater treatment facility. The addition increased the wastewater treatment capacity of the plant by 900 gpm by addition of a new 1,500,000 million gallon treatment reactor, pre-treatment skid unit, cooling tower, substation, piping and instrumentation. Our team procured all equipment, instrumentation and bulk materials in addition to the engineering and construction activities. This was a fast track project completed in 15 months, on time and within budget, with no safety recordables.