Suncor PIT

Suncor - Steepbank Expansion Project ($950 million)

A  PIT Team of 15 engineers and designers were mobilized to the new Extraction Plant once field construction was substantially complete.  The Team was responsible for:

• Management and liquidation of remaining engineering deficiencies
• Support to the Commissioning and Operations Groups
• Troubleshooting during start-up
• Fast Track re-design as required to meet Production targets

In the 10 months of operation the PIT team was responsible for closing approximately 700 deficiency items through investigation, design changes and new construction package implementation.

Suncor HT Booster

Suncor - Hydrotransport Booster Project ($15 million)

During the commissioning of the new Plant 300 Extraction Plant a production restriction was identified.  Process evaluation of the Hydro transport System uncovered a solution utilizing available Client equipment that would eliminate the production shortfall.  Rally was responsible for Project Engineering, Front End Design and AFE development, and detail process design.

The project included installation of two 3500hp VFD driven slurry pumps capable of 5,000 ton/hour capacity, 13.8kV transformer yard, electrical distribution and DCS control.

Suncor Fiber Optic

Suncor - Fiber Optic Upgrade ($5million)

Fiber Optic system upgrades to improve overall system reliability.  Scope included detailed evaluation and SIL analysis of the existing system and development of a recommended path forward to meet Suncor standards for system reliability.  All work was completed in a operating facility without facility outage or interruption.  Rally was responsible for Front End Design, AFE development, Multi-discipline Engineering, Procurement, and Construction support. 

Suncor HT Flush

Suncor - Hydrotransport Flush System ($5 million)

During the commissioning of the new Plant 300 Extraction Plant an opportunity to reduce Seperator Cell downtime was identified.  Process evaluation of the Hydrotransport System uncovered a practical solution that could be implemented without significant outage of the facility.  The resulting installation has eliminated the production loss.  Design and installation of new hydrotransport flush system included installation of a 24” heavy wall header system and 24” pipeline as well as hydraulic automation of new 24” DBB valves and integration into the existing Fieldbus / DeltaV control system. Rally was responsible for Front End Design, AFE development, Multi-discipline Engineering, Procurement, and Construction support.  

CCRL HDS

CCRL Refinery - HDS Distillate Product Cooler ($400k Engineering)

A new HDS Distillate Product Cooler was required on top of an existing pipe rack structure in Section IV Crude/Vacuum Unit in the Regina Saskatchewan Facility.  Rally Performed detailed design for the following items:

Structural

Validation of the Crude/Vacuum Unit pipe rack structure to ensure that it can adequately support the new cooler.

A walkway from Crude/Vacuum Unit aerial coolers across to the HDS Unit aerial coolers. This walkway was designed for placement on top of the bridge that links the pipe rack structure between the operating units.

Mechanical/Piping

New Cooler was equipped with 2 fans/bay and 25hp motors (2 bays total).

6” HDS distillate supply line to the cooler

6” Distillate discharge line from the cooler

4” Distillate slop line from the cooler

4” Flow control station for the new distillate cooler

2” Steam and condensate piping to the new unit heaters located inside the cooler housing

Electrical

Power & Instrument Cables

MCC modifications for VFD installation

Instrumentation

Redundant Temp control

Flow control with interlock on Distillate Stripper Level

Pearl Lake Barge

Imperial Oil - Kearl Lake Oil Sands - Reclaim Water Barge ($1.3M Engineering)

This EPC project consisted of 3-1250hp vertical turbine, 4160volts, pumps enclosed on a barge (i.e. floating pumphouse) with a 42”diameter pipeline to shore. Work included all process, mechanical, electrical, structural, instrumentation and marine engineering required to design and construct the barge system including architectural aspects of the building.  Allswater Engineering was responsible for the marine engineering including stability of the overall system, the walkway/gangway and in-water pipe supports. An import aspect of this design was adequate strength of the hulls to withstand all anticipated loading conditions and intact stability operation.

Rally managed the Engineering team, taking all necessary actions for proper completion of the work, in accordance with accepted standards and practices used in the oil sands and the marine industries.

Rally Engineering was responsible for detailed design including all necessary engineering drawings, specify auxiliary equipment and materials requirements, and procedures required for fabrication, assembly, and installation and commissioning of the Barge system.

Rally conducted the required engineering analysis to convert the owner's requirements into a final design by executing the following:

• Perform all required design calculations
• Prepare layout and detailed drawings
• Detailed design of HVAC Systems
• Develop material take-offs
• Prepare material and equipment requisitions
• Prepare electrical equipment and load list (power requirement)
• Provide quality assurance and quality control for engineering documentation
• Assist in installation procedure and standards
• Assist in final testing and commissioning

Suncor PSI

Suncor Extraction PSI/PSM

Rally has been involved in the Suncor PSM program since 2009.   Rally has provided PSI walkdown services and Pre-PHA development of PTP packages for the Following Plants:

Plant 85

Ore Preparation Unit capable of 12,000t/hr capacity which has been in operation since 1997.  Rally was responsible for development and Suncor acceptance of a full PTP package including development from scratch of many PTP deliverables.   

Plant 86

Primary Separation Facility capable of 12,000t/hr capacity which has been in operation since 1997.  Rally was responsible for development and Suncor acceptance of a full PTP package including development from scratch of many PTP deliverables.   

Rally continues its ongoing partnership with Suncor PSM in 2011 with the as-built and PTP package development for Plant 82 and Primary Extraction complex utility systems.