Industrial & Processing Facilities sample projects

Maderra provided Engineering services for design of a 1500 sqft, 50 ft high scaffolding system (including stair tower) for the Maritime Link Project subsea cable terminations.  Scaffolding systems were Engineered for both cable termination sites – Point Aconi, Nova Scotia side and Cape Ray, Newfoundland.

Maderra provided Project Management and multi-disciplinary Engineering services covering extensive assessments and upgrades of the Bull Arm Topsides construction site infrastructure and related systems, to ready the site for the Hebron project work. Work was completed in conjunction with four partner Engineering firms, and included the following:

Site Inspections and Condition Assessments

Completed Site inspections and prepared detailed condition assessment reports covering: main pier, quay, mooring bollards, wheelguards, and fenders; Site civil works including roads, laydowns, potable water, and sewage; building infrastructure and related systems; electrical distribution systems; mechanical systems and equipment; propane tank farm; and elevators and overhead doors.

The work included: visual inspections; arc flash studies; finite element modelling; geotechnical assessments; environmental assessments and water quality monitoring; coordination of testing services, underwater dive programs, borehole and drilling programs; preparation as built drawings; and development of maintenance plans.

Site Remediation and Upgrades

Completed Engineering, design, cost estimating, Tender packages, and procurement support for the remediation and upgrades to the Site infrastructure as required to support the project fabrication and module integration works.  This included: major upgrades to the pier, quay, bollards, anchors, fenders, ladders, and wheelguards; subgrade remediation and foundations to support module movements, stools and jacking towers; replacement of a 25kV power transformer and 5kV underground radial feeders; removal of 5kV substation; relocation of a sewage pumping station; remediation and recertification of propane tanks, elevators, and overhead doors; and upgrades to buildings and building systems.

Modelling of Module Movements and Travel Paths

Completed 3-D digital terrain modelling, 3-D modelling of rock face and required rock excavation, and 3-D models depicting the Module movements and travel paths, to ensure sufficient space to move the fabricated Topsides modules around the yard.

Temporary Utilities

Completed Engineering, design, Tender packages, and procurement support for: temporary distribution systems for construction, integration, and commissioning activities, including 25kV, 5kV and small power systems and equipment; and temporary process utilities for construction and commissioning activities .

Site Support

Provided home office Engineering support, Site Engineering support, and Site coordination for all inspection, remediation, and upgrade works.

The project included the installation of a new electronic fuel metering and measurement system located at airport fueling stations in Saint John, Moncton, Sydney, Charlottetown, and Fredericton. The design included selection of new electronic metering systems, mechanical flow control valves, and the piping modifications required to accommodate these installations.

The National Research Council of Canada, Ocean Coastal and River Engineering Portfolio (NRC-OCRE), in St. John’s, NL, replaced the existing Tow Tank facility wave generation system. The Tow Tank facility is 200m long, 12m wide and 7m water depth. It previously had a hydraulic powered dual flap wave maker 12m wide by 5m deep located at one end of the tank. The existing wave maker was replaced with an electrically driven multi segmented system.

Maderra provided Structural, Architectural, Electrical, and Mechanical design services and issued a full tender package to accommodate the new Wavemaker system.

The Electrical scope included a new high voltage electrical room including a dedicated 12.5kV electrical supply to a new 800kVA transformer, four 440V Motor Control Centers containing 20 variable speed drives configured to create precise wave generation.

The Structural scope included the demolition of the existing wave maker concrete curb, design of a new concrete curb with capacity to handle the forces generated by the new Wavemaker, design of concrete pads for electrical equipment, and a block wall for the new electrical room.

The Mechanical scope included ventilation for the new electrical room and redesign of piping systems.

The Architectural scope included design of the new electrical room including design of fire rated partitions.

Engineering and design of electrical heat trace systems for the replacement of Oily Water and Hydrocarbon drain lines on the North Atlantic Refinery Jetty.  The work also included design of motor control center upgrades, motor starters, and motor controls for new pumping systems.

This work involved the design of electrical equipment for installation in hazardous areas.

Maderra Engineering was contracted by Irving Oil Limited to assess the instrumentation and associated control functions on seven surge tanks at the Irving St. John’s Marine Terminal, and provide recommendations to upgrade and automate surge tank level controls.

After completion of the engineering study, Maderra was contracted to complete the engineering design and produce tender documents for the installation of the surge tank instrument upgrades. The engineering design included conducting a HAZOP assessment, P&ID updates, producing instrument data sheets and hook-up details, preparation of a control narrative for the control system upgrades, and the design of local control panel and new control system I/O panel.

The work includes the design of pulsation dampeners on suction and discharge of the LRWT system due to premature failure of hose pumps.  The proposed solution is to improve both the suction and discharge dampening on the LRWT hose pumps – PHE-015/PHE-016.

The scope includes:  review of technical proposals received from Vendors; evaluation of the proposed options to ensure the dampeners are properly sized; consideration of flushing/cleaning requirements, material compatibility, gas pre-charging, etc; design of piping tie-ins and supports to install the selected options off both pumps.

Maderra completed Structural Engineering and Design of the following items:

• Design verification of an existing lift frame and production of a stamped engineering drawing.
• Conveyor catwalk extensions & modifications to meet Code requirements.
• Protection structure (steel frame with concrete foundations) below conveyor walkways to avoid spillage on personnel.
• Slab-on-grade, retaining walls and sump pit between weigh bridge and building.
• Design of 2 building structures:
  • Welding shop (~30ft x 80ft) consisting of slab-on-grade, structural steel framing, roof trusses and foundations.
  • Wash bay (~30ft x 80ft) consisting of slab-on-grade, structural steel framing, roof trusses, foundations, retaining walls and a drive-in sump and oil separator pit.

Great North Data engaged Maderra to provide Structural, Architectural, Mechanical, and Electrical design services for a 10MW Bitcoin Data Mining Centre for Labrador City.

The Bitcoin centre was created by renovating an old strip mall building.  The building required substantial electrical and ventilation systems to facilitate the supply and cool the massive server array power demand and waste heat. The building also required major construction to the steel structure, concrete foundation, and roof. Architecturally, the building’s interior layout was completely reconfigured to allow for a new high voltage electrical room and server rack area, and to facilitate proper cooling of the BitCoin equipment.

Adjacent to the building, a new electrical substation was designed for the installation of a refurbished 10MVA, oil filled transformer fed by overhead power lines.  Maderra worked closely with the local utility, NL Hydro and the electrical equipment supplier (MGB) to coordinate this work and for the connection of power from the utility to the Bitcoin facility. In addition, the new indoor electrical room was designed to allow for the installation of high voltage switchgear and zig-zag autotransformers to step down the voltage to the required levels of the BitCoin equipment. Maderra also completed a detailed ETAP electrical system analysis to provide Arc Flash and Coordination Studies.

The Mechanical design included cooling systems comprised of 20 fans controlled from 4 variable speed drive controllers. This system was designed to ensure adequate cooling of the BitCoin equipment in response to power consumption and ambient temperature variations throughout the year.

Structurally, the building’s concrete foundation and structural steel bracing required major modifications and repair to reinstate the building to meet current occupancy code requirements.