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S-Con Inc.: Dedicated to the Natural Gas Processing Industry

From US Business Executive:

S-Con Inc. (S-Con), based in Bryan, Texas, is a full-service engineering, procurement, fabrication and construction company. Green Smith, having spent almost 20 years prior in the industry, founded S-Con in 1990 to target the natural gas treating and processing industry.

Trey Brown, current vice president of engineering and construction at S-Con, explains the company has evolved over its history to become a one-stop solution for the natural gas industry. When initially founded, S-Con catered to refurbishing and relocating existing natural gas plants. By 2003 shop fabrication services were added to S-Con’s array of services to increase quality control and additional control over skid package fabrication and deliveries.

S-Con – with 100,000 square feet of office, shop and warehouse space, as well as a new state-of-the-art paint facility – is now able to meet many needs. These include the removal of acid gas components in an amine gas treating process or recovery of natural gas liquids (NGL) or liquefied petroleum gas (LPG) in refrigerated, JT or cryogenic gas processing plants.

“We’ve more than doubled in size over the last three years,” says Brown. “It’s been a little challenging as of late with some of the new government regulations and ongoing uncertainty, but generally S-Con has grown and become much more prominent in the industry.”

S-Con has a team of 165 employees working with a variety of customers. “Green Smith and his team built this company from the ground up,” says Brown. S-Con performs most of its work in Texas, as well as the four surrounding states of Louisiana, Arkansas, Oklahoma and New Mexico. However, jobs have been performed in several other states, as well, including Colorado, Wyoming, Montana and other states along the Gulf Coast.

The company takes pride in delivering innovative design, robust engineering, superior fabrication and quality construction. Brown also claims S-Con lives up to the motto of producing projects as ordered, on time and on budget.

Innovation and Resourcefulness

According to Brown, S-Con continues to evolve by way of adapting to the economic and regulatory climate within the country. In addition to working with a variety of customers, S-Con doesn’t stop looking for ways to provide a better service or product. “We have to adapt to the changing landscape of the industry,” says Brown.

A lot of the facilities S-Con is currently working on are much smaller due to government regulations that prohibit or limit CO2 emissions. Another innovative aspect includes the development of a new technique for liquefaction and fractionation of natural gas into Liquefied Natural Gas (LNG) and NGL products, allowing the products to be transported to market and eliminating emissions.

“It’s a brand-new technology that we have developed,” says Brown. “It allows people to be green, while also marketing a cleaner alternative fuel [LNG].”

Identifying Stability and Growth

When the economy took a downward turn in 2008, S-Con was able to maintain its staff. “S-Con management used the good times to prepare for the bad times,” says Brown. “Those were tight times, but upper management kept the company in good financial condition.”

S-Con’s ability to survive the tumultuous economy was driven by its innovation. “If you don’t adapt, then you end up going out of business,” says Brown. “We’re always looking for the next opportunity and how to best manage the company.”

Brown admits a lot of business decisions have come based on what S-Con employees have heard directly from clients. The company takes great care to sit down with each customer and have a conversation about his or her needs. Then the team takes the required steps to find a solution for the client and produce it.

Smart scheduling is also a major component to the success of S-Con. Brown explains that without proper scheduling the company can’t deliver a project on time and at the price given. “If we can maintain the schedule and the budget, we feel that we’ve done our job properly,” he says.

Brown doesn’t see the company’s growth slowing down any time soon. “If everything goes according to plan, we’ll be expanding in the next few years,” he says. “We believe the new process we created is going to open up all kinds of opportunities for us.” The company will continue to offer the services and products it has in the past, while innovative efforts will ensure S-Con Inc. thrives through the future.

New, patent-pending SUPERCOOL process

S-Con’s W.G. “Trey” Brown introduced the new patent-pending SUPERCOOL process to the Oil & Gas Industry at the annual Gas Processors Association (GPA) Convention in San Antonio, Texas. While S-Con has been discussing the SUPERCOOL technology with various Producers and Midstream companies since its beginning in June of 2012, this presentation was the first time SUPERCOOL had been presented to a mass audience. Appearing before a crowd estimated to be over 400 strong, Mr. Brown described what SUPERCOOL is and how and why it was developed. According to Mr. Brown, the amount of stranded and flared gas from the various shale-gas plays across the United States has reached astronomic levels and could very well lead to the shutdown of oil and gas production if the amount of flaring is not severely curtailed or eliminated. Mr. Brown also pointed out that the gas currently being flared could be used as an alternative fuel source, either LNG or CNG. Thus, SUPERCOOL was invented as a means to an end; to provide a cost effective alternative that will process and recover 100 percent of flare gas (in liquid form) from any given location and deliver a Y-Grade NGL product stream meeting all pipeline specifications, and a transportation grade LNG and/or pipeline quality gas stream. It was further pointed out that SUPERCOOL also acts as a Nitrogen Rejection Unit (NRU), in order to meet LNG and/or pipeline specifications.

Mr. Brown contends that, by having SUPERCOOL plants across the country, the Consumer will quickly accept and adapt to using LNG/CNG as the fuel of choice. “LNG/CNG is significantly less expensive than either gasoline or diesel and burns cleaner, thus reducing emissions into the atmosphere. If the Consumer is provided with a reliable, inexpensive alternative, they will choose that option every time; the problem has been the supply reliability as the LNG product is often transported anywhere from 250 miles to 800 miles, thus leading to uncertainty in the supply chain.” Having local production of the LNG ensures that the supply is always available and will further reduce costs by eliminating or reducing transportation costs.

Lump-Sum Turn Key Projects Offer Better Project Control

Lump Sum Turn Key (LSTK) projects allow the Client and Contractor to better coordinate efforts and control project costs. Under LSTK projects, the Client directs all questions, modifications and communications through a single Contractor entity, eliminating the need to contact numerous parties.  If there is a problem, there is only one Contractor to deal with and the ability to point fingers elsewhere is eliminated.

Additionally, LSTK contracts are based on a specified and well-defined scope of work to be provided for an agreed upon fixed sum.  This allows both the Client and the Contractor to address any proposed changes, discuss impacts to project cost and schedule and track the impacts of the changes more closely.  This is much more efficient and cost effective than what is oftentimes seen in Time and Material (T&M) contracts, where the impact due to changes are rarely monitored or tracked.

Collaboration Leads to Shorter Project Schedules

Successfully executing EPC project installations in a timely manner requires collaboration between field construction and shop fabrication. Communication and collaboration amongst all disciplines is vital for proper sequencing of work and final equipment installation.

A master schedule can assist in breaking the overall project into phased schedules and demonstrating how the work within each phase will be performed. The schedule can also assist in establishing the sequence and timing of all necessary activities for the completion of the final project. Through a teamwork approach, it is possible to shorten schedules and ensure quality from conception through fruition.

Modifications on Standard Designs Offer Efficiency

Numerous types of technologies are now available for the purposes of processing and treating natural gas. Selecting the proper technology to use for specific applications can sometimes be confusing. As new technologies continue to emerge and old technologies are applied in innovative manners, the decision making process has become even more complex. To complicate matters even further, there are now more types of gas streams requiring treatment than ever before. Regardless of which types of gas it is, one thing is certain, however. Almost all forms of gas produced today contain at least some form of contaminants that must be removed prior to being sold. This is precisely why it is crucial to properly evaluate possible gas processing company options in order to find the solution that is most cost-effective and efficient.

In many cases, this means starting with a standard design and then making modifications to meet the client’s specific requirements. Experience has proven that this typically produces a processing solution that is not only effective for the specific type of production environment involved, but also cost-effective as well

Collaboration Shortens Project Schedules

In the design of any new gas plant fabrication or facility, it is crucial to recognize the importance of the relationship between the design and the final construction. Both processes must work together and be viewed as a fully-integrated system in order to achieve a final successful outcome. In a broad sense, design involves the creation of a description of the new facility and typically incorporates the use of detailed specifications and plans. The construction planning process identifies all resources and activities that are necessary in order for the new design to become a physical reality.
In both construction and design, a number of operational tasks must be carried out with a range of precedence. When both shop fabrication and field construction work together in a harmonious relationship, it is possible to shorten project schedules and remain on budget.  This is made possible by keeping elements that are unique to the planning of constructed gas treating facilities in mind during the early stage of a project life cycle. For instance, the design as well as the construction of the facility should meet the conditions unique to the specific site. The collaboration of shop fabrication and field construction early-on and throughout a project design can produce long-lasting benefits.

New Maintenance, Service and Repair Building

S-CON has announced plans for the addition of a separate building to consolidate the maintenance of the considerable equipment inventory utilized by both the Bryan fabrication facility and off-site construction crews. This building will help insure all equipment is serviced and maintained in a timely manner to eliminate unexpected down-times.

New Corporate Office

S-CON is well underway in the construction of a new, corporate office building located at the Bryan, Texas facilities. This new building will house upper management and accounting, leaving the original, three-year old Corporate building available for Engineering, Drafting and Procurement Projects teams.

Paint Booth Systems, State-of-the-Art

S-CON is in the process of installing its new, shot-blast and paint booth systems. This state-of-the-art, EPA approved blasting and painting facility will include:
  • Shot-blast booth large and tall enough to accept the largest, truckable-sized modular skid.
    • Recycled steel grit.
    • Down-draft air filtration system.
    • Automatic opening doors for ease of entry and exit of skids.
  • One paint booth large and tall enough to accept the largest, truckable-sized modular skid.
    • Side, down-draft air curtain with filtration system.
    • Heated paint curing system.
    • Dry chemical fire suppression system.
    • Automatic opening doors for ease of entry and exit of skids.
  • One, slightly smaller paint booth to accept smaller skids and free-standing equipment.
    • Cross-flow air filtration system.
    • Heated paint curing system.
    • Dry chemical fire suppression system.
    • Automatic opening door for ease of entry and exit of skids.
  • Ancillary Equipment for these systems includes:
    • Multiple air compressors with a total of 210-horsepower capacity.
    • Computerized compressor controllers.
    • Refrigerated, air dryer system.
    • Paint mix room with air filters, exhaust and fire suppression systems.
The complete facility should be ready for the first modular skid in early June, 2012.

Lay-Down Yard

S-CON has purchased four acres adjacent to the back of the Bryan facilities. This additional property, already rocked similar to all other open areas of the facility, allows storage room for large pieces of equipment, especially the used processing plants and treating units routinely purchased by S-CON for refurbishment, modification and installation into new applications for S-CON’s customers.