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Cenovus TL ULC
Telephone Lake Project
Volume 1 – Project Description
December 2011

SECTION 6.0 – FACILITIES


TABLE OF CONTENTS

PAGE

6.0  FACILITIES .................................................................................................................... 6-1 


6.1  Central Processing Facility ................................................................................. 6-1 
6.1.1  Overview ............................................................................................ 6-1 
6.1.2  Flow Rates ......................................................................................... 6-2 
6.1.3  CPF Process Description ................................................................... 6-3 
6.2  Sulphur Recovery ............................................................................................. 6-16 
6.2.1  Sulphur Scavenger Unit ................................................................... 6-17 
6.3  Top Water Handling Facilities .......................................................................... 6-17 
6.4  Off-sites ............................................................................................................ 6-18 
6.4.1  Horizontal Well-Pairs ....................................................................... 6-18 
6.4.2  Production Well Pad Facilities ......................................................... 6-18 
6.4.3  Top Water Dewatering Facilities ...................................................... 6-19 
6.4.4  Gathering/Distribution System ......................................................... 6-20 
6.4.5  Roads............................................................................................... 6-20 
6.5  Blend and Diluent Pipelines ............................................................................. 6-21 
6.5.1  Blend System ................................................................................... 6-21 
6.5.2  Diluent System ................................................................................. 6-21 
6.6  Literature Cited ................................................................................................. 6-21 

LIST OF TABLES

Table 6.1-1: Telephone Lake Cumulative Flow Rates ......................................................... 6-3 


Table 6.1-2: Bitumen, Water and Gas Rates from Production Wells ................................... 6-3 
Table 6.1-3: Project Energy Balance.................................................................................... 6-8 
Table 6.1-4: Lower Heating Value ........................................................................................ 6-8 
Table 6.2-1: Alberta Sulphur Recovery Guidelines ............................................................ 6-16 
Table 6.2-2: Design Sulphur Rates .................................................................................... 6-16 

Table of Contents
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Cenovus TL ULC
Telephone Lake Project
Volume 1 – Project Description
December 2011

6.0 FACILITIES
6.1 Central Processing Facility
6.1.1 Overview
Cenovus TL ULC (Cenovus) intends to construct the Telephone Lake Project (Project) in two
phases (Phase A and Phase B). Each phase produces a nominal 7,154 m3/d (45,000 bbl/d) of
bitumen; the total nominal bitumen production for two phases will be 14,308 m3/d (90,000 bbl/d).
The stream day capacity of each phase is 7,615 m3/d (47,900 bbl/d). The bitumen is blended
with diluent and treated to meet the sales oil specification. The sales oil, which is diluted
bitumen, is delivered to market by pipeline.

For Phase A, there are four once-through steam generators (OTSGs) and one heat recovery
steam generator (HRSG) with gas turbine. The design injection steam rate for each phase is
16,753 m3/d cold water equivalent (CWE). The first-stage steam generators consist of three
OTSGs and one HRSG operating in parallel. The second-stage OTSG utilizes the blowdown
from the first-stage steam generators as boiler feed water. The total steam injection capacity will
be further increased to 33,506 m3/d (CWE) for Phase B by adding four OTSGs and one HRSG
in the same configuration. The facility has a fixed maximum steam rate based on the number of
steam generators, while the maximum bitumen production rate depends on the actual steam-to-
oil ratio (SOR).

The Project is designed to use top water for make-up water as described in Volume 1,
Section 5.6.2. As described in Volume 1, Section 3.5, there is virtually no brackish water in the
region. In addition, surplus top water will be available from the dewatering process (Volume 1,
Section 4.3); therefore, there is no need to divert groundwater from a high quality, non-saline
source (e.g., Quaternary Upper Sand (S2)). Make-up water may be required due to water losses
in the bitumen treating process, such as boiler blowdown and ion exchange wastes to disposal
wells. During conventional steam assisted gravity drainage (SAGD) operations on a CWE basis,
produced water will exceed steam injected; thus, no make-up water will be required.

All the produced gas is used as fuel gas and burned in the OTSGs and HRSG duct burners.
The produced gas contains hydrogen sulphide, and sulphur recovery is required to reduce the
hydrogen sulphide content before combustion.

Cenovus has gained substantial experience in SAGD production from the Christina Lake
Thermal Project (CLTP) and the Foster Creek Thermal Project (FCTP). Most of the equipment
for the Project is sized based on proven results at the CLTP and the FCTP. The design of the
Project incorporates this experience as well as technological developments that have occurred
since these projects were designed. It is believed that these design changes will result in a
facility with lower costs, higher reliability, and better operability. The following list highlights the
major changes in the Project’s design:
• dewatering of the top water portion of the reservoir, in advance of SAGD operations, will
minimize changes in water quality within the Top Water Zone, lower the capital cost of
the produced water handling facilities, and minimize SOR;

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Telephone Lake Project
Volume 1 – Project Description
December 2011

• as noted earlier in this section, top water (rather than brackish water, which is not a
viable option for the Project) will be used as make-up water;
• a second-stage OTSG will be added to recover a portion of the blowdown and decrease
or eliminate make-up water required;
• steam injection heaters will be used to heat the make-up water so that it can be treated
by the produced water softening unit. Ion exchange units for the make-up water will not
be required, which will result in lower capital costs and more efficient use of the
produced water treatment units; and
• A “recycle produced water deoiling train” will be installed to process all recycle water
flows such as backwashes, regenerations, etc., as well as the anticipated higher
produced water flow due to the Top Water Zone.

6.1.1.1 Plot Plan


The following plot plan is provided in Volume 1, Attachment 4:
• TL1-44-PLT-01-001-01 (Plot Plan—Central Plant Facilities).

6.1.1.2 Block Flow Diagram


The following block flow diagram is provided in Volume 1, Attachment 5:
• TL1-42-BFD-01-010-01 (Block Flow Diagram—Phases A and B).

6.1.1.3 Equipment List


The following equipment list is provided in Volume 1, Attachment 6:
• TL1-43-EQL-00-001-01 (Equipment List—Phases A and B).

The equipment list shows the equipment that will be required for the central processing facility
(CPF) during Phases A and B. This list, however, does not include equipment such as blow
cases, sample coolers, exhaust fans, unit heaters, seal flush coolers, drain tanks/pumps and
other auxiliary equipment. “HOLD” indicates equipment that may not be required during
Phases A and B; the requirement for this equipment will be confirmed during detailed
engineering.

6.1.2 Flow Rates


Table 6.1-1 shows the expected cumulative Phase A and Phase B flow rates for the central
plant.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

Table 6.1-1: Telephone Lake Cumulative Flow Rates


Phases A and B
Saturated steam to injection wells [m³/d CWE] 33,506
Bitumen from wells [m3/d] 15,230
Produced water from wells [m³/d CWE] 40,084
Produced gas from wells (dry basis) [Sm³/d] 152,300
Gas to well pads1 [Sm³/d] 0
2
Normal make-up water consumption [m³/d CWE] 0
Produced water to steam ratio 1.2
Steam generator blowdown to disposal2 [m³/d CWE] 2,138
Produced water to steam ratio 1.2
Regeneration/neutralization waste/warm lime softener 400
sludge to disposal2 [m³/d CWE]
Produced water to disposal2 [m³/d CWE] 4,014
Produced water to steam ratio 1.2
1
Natural gas is only required during the ramp-up stage. During normal operation,
electrical submersible pumps (ESP) mode, gas is not required.
2
Refer to the block flow diagram (Volume 1, Attachment 5).

6.1.2.1 Bitumen, Water and Gas Rate


Table 6.1-2 shows production rates for bitumen, water and gas from SAGD production wells.
Bitumen Standard Density is 1,020.4 kilograms per cubic metre (kg/m3), or 7.05 API.

Table 6.1-2: Bitumen, Water and Gas Rates from Production Wells
Bitumen Rate Produced Gas Rate
Produced Water Rate
Phase (Dry Basis)
3
(m /d) (bbl/day) (t/d)1
(e3 Sm3/d)
A 7,615 47,900 20,104 76
B 7,615 47,900 20,104 76
Total 15,230 95,800 40,208 152
1
t/d = tonnes per day.

6.1.3 CPF Process Description


6.1.3.1 Oil Treating
The following process flow diagrams for oil treating are provided in Volume 1, Attachment 7:
• TL1-42-PFD-04-001-01 (Oil Treating System—Phase A);
• TL1-42-PFD-04-002-01 (Produced Gas System—Phases A and B);
• TL1-42-PFD-04-003-01 (Desand System—Phases A and B);
• TL1-42-PFD-04-004-01 (Oil Treatment Chemical Injection System—Phase A);
• TL1-42-PFD-04-005-01 (Oil Treating System—Phase B); and
• TL1-42-PFD-04-006-01 (Oil Treatment Chemical Injection System—Phase B).

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Telephone Lake Project
Volume 1 – Project Description
December 2011

Bitumen and produced water are sent from the well pads to the central plant in one pipeline.
Casing gas, which is mainly water vapour with produced gas, is delivered from the well pads to
the central plant in another pipeline.

Emulsion from the well pads is mixed with diluent and cooled in the emulsion/boiler feed water
exchangers (E-4010). The cooled emulsion is sent to the inlet degasser (V-4000). After the
emulsion is degassed, it is distributed to the oil treating trains (one train per phase) consisting of
a free water knockout drum followed by two treaters operating in parallel. Cooling and
degassing the emulsion prevent excessive flashing in the free water knockout drums
(V-4100/4300) and treaters (V-4150/4200/4350/4400) causing diluent losses.

Vapour from the degasser is combined with the casing gas from the well pads and cooled by the
produced gas coolers (E-4040) to condense residual steam and light hydrocarbons. The liquid is
separated from the cooled produced gas in the produced gas slug catcher (V-4030) and sent to
the slop tanks (T-6200/6210/3200/6230). The vapour is compressed by the produced gas
compressor (K-4045) and sent to the sulphur recovery unit.

At the anticipated operating temperature, the density of bitumen is typically heavier or equal to
water. Hence, the emulsion cannot be treated using gravity separation without diluent addition.
Diluent is added to reduce viscosity and density of the bitumen allowing conventional oil/water
separation technologies to be used. The piping from the diluent pump (P-6350) is configured to
allow diluent addition to the following locations:
• upstream of the emulsion/boiler feed water exchangers;
• upstream of the free water knockout drums;
• upstream of the treaters;
• sales oil to lease automatic custody transfer (LACT) unit; and
• any combination of the above locations.

Adding diluent upstream of the emulsion/boiler feed water exchangers reduces fouling in these
exchangers. Reducing the viscosity of the emulsion improves heat transfer performance.

Adjusting the amount of diluent to each free water knockout drum and treater allows the
operators to optimize oil/water separation in each vessel. Operators can monitor and adjust the
amount of diluent required to keep the sales oil within specification. Excessive consumption of
diluent often indicates the need to decant some of the rag layer from a treater. Injecting too
much diluent into the treating train can increase diluent losses.

The heat exchangers downstream of the treaters are designed to cool the sales oil in order to
minimize diluent flashing in the sales oil tanks. Higher temperatures can increase the amount of
diluent lost to the fuel gas system. The oil product leaving the treaters is stored in the sales
oil/off-spec tanks (T-6100/6110).

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Telephone Lake Project
Volume 1 – Project Description
December 2011

If the product from a treater goes off-spec, it is automatically diverted to the off-spec tank. The
off-spec product is recycled back into the oil treating train, sent to the slop oil treating system, or
blended to the LACT unit if conditions are favourable.

The sales oil is pumped to the LACT unit and delivered to market by pipeline. Upstream of the
LACT unit, trim diluent is added to the oil to meet the sales oil density and viscosity
specifications.

Produced water from the free water knockout drums and treaters is cooled to 90°C and sent to
the skim tanks (T-1100/1400/1700). Produced water cooling takes place using two spiral
exchangers:
• produced water/boiler feed water exchangers (E-4110/4310); and
• produced water/glycol exchangers (E-4115/4315).

6.1.3.2 Desanding System


The following process flow diagram for the desanding system is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-04-003-01 (Desand System—Phases A and B).

Over time, sand will accumulate in the bottom of the inlet degasser, free water knockout drums,
and treaters. This sand is periodically removed from the vessels. The vessels are equipped with
internal jetting nozzles and desand slurry drain nozzles. The desand jet water pumps (P-4060)
sends deoiled produced water to the desand jets inside the vessels. The jetting action fluidizes
the sand and the desand slurry drain nozzles draw off the sand. The sand slurry from the inlet
degasser is routed to the free water knockout drums. The sand slurry from the free water
knockout drums and treaters is cooled by mixing with cold top water and sent to the desand
tank (T-4075).

After the sand settles out in the desand tank, the desand tank decant pump (P-4085) sends the
oil to the slop tanks (T-6200/6210/6220/ 6230) or oily water to the skim tanks
(T-1100/1400/1700). The sand is trucked to an approved disposal facility.

6.1.3.3 Heat Integration


The following process flow diagrams are provided in Volume 1, Attachment 7:
• TL1-42-PFD-02-001-01 (Boiler Feed Water and Once Through Steam Generation—
Phase A);
• TL1-42-PFD-02-002-01 (Second Stage Once Through Steam Generator—Phase A);
• TL1-42-PFD-02-004-01 (Boiler Feed Water and Once Through Steam Generation—
Phase B);

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Telephone Lake Project
Volume 1 – Project Description
December 2011

• TL1-42-PFD-02-005-01 (Second Stage Once Through Steam Generator—Phase B);


• TL1-42-PFD-04-001-01 (Oil Treating System—Phase A);
• TL1-42-PFD-04-005-01 (Oil Treating System—Phase B); and
• TL1-42-PFD-06-001-01 (Diluent Tanks—Phases A and B).

The following heat and material balance is provided in Volume 1, Attachment 8:


• TL1-42-HMB-00-001-01 (Phase A and Phase B Heat and Material Balance).

Boiler Feed Water Heating


Heat from the production fluids is transferred to the boiler feed water using heat exchangers.
Heating the boiler feed water decreases the amount of fuel gas required by the steam
generators which, in turn, reduces the overall natural gas consumption and plant emissions.
Transferring the process heat to the boiler feed water also reduces the glycol cooling load.
Process heat recovery by the boiler feed water takes place in these exchangers:
• emulsion/boiler feed water exchangers (E-4010);
• sales oil/boiler feed water exchangers (E-4160/4210/4360/4410);
• produced water/boiler feed water exchangers (E-4100/4310); and
• boiler feed water/blowdown exchangers (E-2355/2375/2655/2675).

Make-up Water Heating


Cold make-up water is sent to the steam injection heaters (E-1020/1030). The injection heaters
transfer heat in the blowdown to the make-up water. The blowdown from the second-stage
OTSG is flashed to generate the low-pressure steam for the steam injection heater. The top
water will be mixed with the produced water and then heated with the steam injection heaters
and sent to the warm lime softener for treatment. This is normally no flow under steady plant
operation.

Diluent Heating
Diluent, the coldest available stream, is the final cooling medium used to cool the sales oil with
the purpose of minimizing diluent losses in the sales oil tanks. The sales oil/diluent exchangers
(E-4170/4220/4370/4420) cool the sales oil by cross heat exchange with diluent. Using diluent
as a cooling medium also decreases the cooling glycol circulation rate.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

Plant Glycol System


The following process flow diagram for the plant glycol system is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-07-003-01 (Glycol System—Phases A and B).

The glycol system uses 60/40 weight percent ethylene glycol/water solution to transfer heat
from process to the utility heating users. The glycol process cooling takes place at these
exchangers:
• sales oil/glycol exchangers (E-4165/4215/4365/4415);
• produced water/glycol exchangers (E-4115/4315);
• blowdown disposal cooler (E-2390, E-2690);
• produced gas cooler (E-4040)
• slop oil treater overhead/glycol exchanger (E-5035);
• slop oil treater effluent/glycol exchanger (E-5030); and
• produced water deoiling tank vapour/glycol exchanger (E-7070).

The hot glycol from these exchangers is sent to the utility heating users. During normal
operation, the heat recovered from the process is sufficient to supply the entire plant’s utility
heating requirement. The glycol heating consumers are divided into critical and non-critical
users. The controls are set up to send hot glycol preferentially to the critical users, with the
remaining hot glycol to the non-critical users for heat integration. The critical heating glycol
users include the following:
• building unit heaters;
• tank heating coils;
• pipe and equipment heat tracing;
• slop oil/glycol exchanger (E-6280); and
• fuel gas/glycol exchanger (E-7010).

Glycol heaters (H-7100/7110) supply heat to the critical users and protect the plant from freeze-
up during a production turndown or shutdown in the winter. These heaters are on standby
during normal operation.

The non-critical heating glycol users include the following:


• OTSG combustion air preheaters (E-2120/2170/2220/2320/2420/2470/ 2520/2620);
• gas turbine air preheaters (E-2270/2570);

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Telephone Lake Project
Volume 1 – Project Description
December 2011

• slop oil treater reheater combustion air preheater (E-5065); and


• diluent/glycol exchanger (E-4020).

A disruption of hot glycol supply to the non-critical users does not significantly impact the plant
operation.

Glycol from the critical and non-critical heating users are combined and routed to the glycol
expansion drum (V-7170), glycol circulation pump (P-7160), and forced-draft aerial glycol
coolers (AC-7180) which remove the excess heat not used by the utility heating consumers. The
cooled glycol, at 45°C, is distributed to the glycol process cooling users.

The glycol piping is configured with bypasses to balance the flows to the different heating and
cooling circuits. The system is equipped with a glycol filter (F-7165) that removes particulates
from the glycol solution. A slipstream of glycol from the discharge side of the circulation pumps
is sent to the filter and returned to the expansion drum.

A facility energy balance and energy efficiency calculation is provided below.

Table 6.1-3: Project Energy Balance


Energy In (GJ/d) Energy Out (GJ/d)
Bitumen 620,609 Bitumen 620,609
Diluent 614,419 Diluent 608,274
Produced Gas 4,443 Net Electric Power 4,049
Purchased Gas 81,840
Total 1,321,311 Total 1,232,932
Energy Efficiency: 93.3%

Notes:
Based on Oilsands Blend A (Suncor) diluent.
Diluent loss to fuel gas is assumed to be 1%.
Based on emulsion inlet temperature of 180°C.
Net Electric Power = Electric Power Produced - Electric Power Consumed.

Table 6.1-4: Lower Heating Value


Heating Value
Bitumen 0.0399 GJ/kg 17,169 Btu/lb
Diluent 0.0426 GJ/kg 18,303 Btu/lb
Produced Gas 0.0295 GJ/kg 30.23 MJ/m3
Purchased Gas 0.0490 GJ/kg 33.55 MJ/m3

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Telephone Lake Project
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December 2011

6.1.3.4 Make-up Water


The following process flow diagrams for the make-up water system are provided in Volume 1,
Attachment 7:
• TL1-42-PFD-02-002-01 (Second Stage Once Through Steam Generator—Phase A); and
• TL1-42-PFD-02-005-01 (Second Stage Once Through Steam Generator—Phase B).

Top water is used as process make-up water because no viable brackish water sources can be
found in the development area. Top water is treated and used as boiler feed water to replace
the following losses:
• strong acid cation regeneration waste;
• water trapped in the spent warm lime softener sludge;
• losses to the oil reservoir;
• vented vapour from the water treatment system;
• vented vapour from the boiler feed water system;
• water entrained in sales oil;
• water entrained in mixed fuel gas; and
• steam generator blowdown losses.

The process make-up water for steam generation is designed to satisfy about 25% of the
normal steam injection rate. During normal operation, make-up water for steam generation is
not required because the produced water rate exceeds the steam injection rate. During initial
plant start-up when produced water is not available, the maximum make-up water required for
the steam generators is 5,000 m3/d.

The process make-up water for utility and seal usage is designed for a peak of 2,000 m3/d per
phase during start-up, but during normal operation the estimated average utility water
requirement is 300 m3/d. Utility water is used to clean process areas and equipment and to
provide seal fluid. Spent wash water from the utility water stations that is collected in sumps will
be returned to the water treatment plant for recycling.

The peak top water make-up volume required per phase is 7,000 m3/d, and this peak will occur
during start-up. This volume includes the water for steam generation (5,000 m3/d) as well as
utility and seal water (2,000 m3/d). After start-up, the make-up water requirement will be zero for
steam generation and 300 m3/d per phase for utility and seal.

Water from the top water handling facilities is delivered to the make-up water tank (T-1000). The
make-up water pump (P-1010) sends the top water to the steam injection heaters (E1020/1030)
which heat the make-up water. The heated make-up water is sent directly to the warm lime
softener for treatment. The steam injection heaters (E1020/1030) eliminate the requirement for
a make-up water ion exchange unit.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

6.1.3.5 Produced Water Treatment


The following process flow diagrams for produced water treatment are provided in Volume 1,
Attachment 7:
• TL1-42-PFD-01-001-01 (Produced Water Deoiling System #1—Phase A);
• TL1-42-PFD-01-001-02 (Produced Water Deoiling System #2—Phase A);
• TL1-42-PFD-01-002-01 (Warm Lime Softener System—Phase A);
• TL1-42-PFD-01-003-01 (Produced Water Treatment System—Phase A);
• TL1-42-PFD-01-004-01 (Produced Water Chemical Injection System—Phases A and B);
• TL1-42-PFD-01-005-01 (Produced Water Deoiling System—Phase B);
• TL1-42-PFD-01-006-01 (Warm Lime Softener System—Phase B); and
• TL1-42-PFD-01-007-01 (Produced Water Treatment System—Phase A).

The produced water is treated in two main steps:


1. Produced Water Deoiling:
‰ skim tanks;
‰ induced gas flotation vessels; and
‰ oil removal filters.
2. Produced Water Softening:
‰ warm lime softener removes hardness and silica;
‰ filtration removes particulates carried over from the warm lime softener;
‰ primary strong acid cation units remove the hardness; and
‰ polishing strong acid cation units remove residual hardness leaked from the
primary strong acid cation units.

Produced Water Deoiling System


The produced water flow rate is 10 to 50% higher than conventional SAGD production due to
the Top Water Zone. For Phase A, a second produced water deoiling train is installed to ensure
that there is sufficient capacity to treat the additional produced water. This second train is also
the recycle produced water deoiling train which processes all recycle water streams, including
backwashes and the additional produced water. Similar to the second-stage steam generator,
the recycle produced water deoiling train is designed for full rates. This train, however, operates
at approximately 50% capacity. The spare capacity will be utilized during upset conditions,
periods of high produced water flow from the well pads. A third produced water deoiling train is
planned for Phase B.

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The skim tanks (T-1100/1400/1700) are designed for bulk oil removal. The partially deoiled
produced water from the skim tanks is gravity-fed to the induced gas flotation units
(V-1110/1410/1710), which further reduce the oil content in the water to approximately
20 ppmw. The induced gas flotation vessel removes oil by injecting gas bubbles into the
produced water stream. The small bubbles adhere to the oil, causing the oil to float to the
surface of the water, where it is removed by skimming. The oil removal filter feed pumps
(P-1130/1430/1730) send the water from the induced gas flotation units to the oil removal filters
(F-1140/1440/1740) for final oil removal.

The oil removal filters, which are Hydromation filters, capture residual oil from the produced
water. The Hydromation filter is a patented process that uses crushed walnut shells as the
filtration media. The Hydromation filter removes dispersed oil from produced water to less than
2 ppmw which is acceptable for the warm lime softeners.

The produced water from the oil removal filters is routed to the deoiled water tanks
(T-1170/1470/1770). These tanks provide surge capacity to accommodate flow fluctuations. The
deoiled water pumps (P-1175/1475/1775) deliver the deoiled produced water to the produced
water softening trains. Any excess produced water is sent to disposal wells.

The skim oil from the skim tanks is collected in the oil recycle tanks (T-1150/1450/1750) and
then pumped to the slop tanks for further treating.

Produced Water Softening System


The deoiled produced water is further treated for reuse as boiler feed water. The warm lime
softeners (T-1200/1500) remove silica and hardness by reacting with magnesium oxide (MgO)
and lime. The warm lime softeners also provide additional benefits by removing trace amounts
of iron, suspended solids, and residual oil.

Addition of MgO triggers the precipitation of magnesium hydroxide and silicon dioxide. The lime
raises the pH of the water to optimize precipitation. A flocculation polymer is injected to promote
flocculation. The water from the warm lime softener is gravity-fed into the clear wells
(T-1270/1570) for storage that allows the warm lime softener to be operated at a constant liquid
level. Then the after filter pumps (P-1280/1580) send the produced water from the clear well to
the warm lime softener after filters (F-1290/1590), which remove suspended solids in the water.

The sludge, which is a suspended particle-slurry in the warm lime softener, is removed to
maintain a proper sludge blanket level in the warm lime softener. The warm lime softener sludge
is sent to centrifuge (C-1230/1530) for dewatering. The sludge from the centrifuges will be
disposed of in an Alberta Environment and Water-approved Class II landfill.

The produced water at the outlet of the warm lime softener has hardness in the range of 25 to
30 mg/L. The hardness must be reduced to less than 0.5 mg/L in order to meet the steam
generator specifications. The primary strong acid cation units (V-1315/1615) soften the

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produced water from the warm lime softener. Then the polisher strong acid cation units
(V-1320/1620) remove the residual hardness to less than 0.2 mg/L before the water is sent to
the boiler feed water tank (T-2000).

The regeneration waste from the produced water softening systems is sent to the Regeneration
Waste Tank (T-1390). From there the waste is pumped to the disposal wells.

6.1.3.6 Water Disposal


The following process flow diagram for water disposal is provided in Volume 1, Attachment 7:
• TL1-42-PFD-01-003-01 (Produced Water Treatment System—Phase A).

For the CPF, regeneration waste from the produced water treatment units, second-stage OTSG
steam blowdown, and excess produced water are sent to the disposal wells.

There are separate top water disposal lines and wells for the surplus top water to avoid
contamination of the top water disposal.

6.1.3.7 Utilities
The following process flow diagrams for utilities are provided in Volume 1, Attachment 7:
• TL1-42-PFD-05-001-01 (Slop Oil Treating System—Phases A and B);
• TL1-42-PFD-06-002-01 (Sales and Slop Oil Tanks—Phases A and B);
• TL1-42-PFD-07-002-01 (Fuel Gas System—Phases A and B); and
• TL1-42-PFD-07-004-01 (Storm Water and Blowdown Ponds—Phases A and B).

Slop Oil Treating


A slop oil treating system will be installed in Phases A and B for processing hard-to-treat
oil/water emulsions—typically from the interface between oil/water phases in the treaters/free
water knockout drums or the degasser. The hard-to-treat oil/water emulsion from the inlet
degasser, free water knockout drums, treaters, and other process vessels is collected and
stored in the slop oil tanks (T-6200/6210/6220/6230). The slop oil treating system is expected to
operate intermittently. The slop recycle pump (P-6270) delivers the slop oil under pressure to
the slop oil treater feed/effluent exchanger (E-5025) which heats the slop oil. The fired slop oil
treater reheater (H-5070) heats the recycle oil from the slop oil treater (V-5000). The two hot
streams are combined and the pressure is let-down to flash the water. The hydrocarbon liquid is
cooled and sent to the sales oil tanks, while the overhead vapour is cooled and sent to slop oil
treater overhead three-phase separator (V-5050). Water is sent to the skim tanks, oil is returned
to the oil treating facilities, and the non-condensable vapour is sent to the vapour recovery
system.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

Instrument Air
There is a common instrument air system for the entire Phase A and Phase B facilities. It
consists of instrument air compressors, instrument air dryers, and an air receiver.

Fuel Gas/Blanket Gas


High-pressure fuel gas from the natural gas pipeline is heated to about 70°C in the fuel
gas/glycol exchanger (E-7010) and delivered to the fuel gas distribution networks. Pre-heating
the natural gas ensures the temperature high enough to prevent ice and hydrate formation as
the pressure is let-down to the fuel gas operating pressures.

Storm Water/Steam Blowdown Ponds


The storm water ponds (Z-7730/7731) receive surface water runoff. The steam blowdown pond
(Z-7700) receives start-up blowdown from the OTSGs (B-2100/2150/2200/2300/2400/2450/
2500/2600) and HRSGs (B-2250/2550).

6.1.3.8 Fluid Storage


The following process flow diagrams for fluid storage are provided in Volume 1, Attachment 7:
• TL1-42-PFD-06-001-01 (Diluent Tanks—Phases A and B); and
• TL1-42-PFD-06-002-01 (Sales and Slop Oil Tanks—Phases A and B).

Sales Oil/Off-spec Storage and Pumps


Oil from the treaters is cooled and stored in the off-spec/sales oil tanks (T-6100/6110). The oil is
pumped from the tanks to the LACT unit. Upstream of the LACT unit, trim diluent is added to the
oil to meet the sales oil viscosity and density specifications.

Diluent Storage and Pumps


Diluent is delivered by the diluent pipeline and stored in the diluent tanks (T-6300/6310). The
diluent pump (P-6350) sends the diluent to the inlet degasser, free water knockout drum,
treaters and the LACT unit. The diluent pump is designed for a wide variety of diluents ranging
from condensate to synthetic crude. The facility will be designed to operate with either
condensate or synthetic crude as diluent, but not both simultaneously. The decision to operate
using condensate or synthetic crude as diluent will be a decision based entirely on economics
and availability of supply.

6.1.3.9 Steam and Power Generation


The following process flow diagrams for steam generation are provided in Volume 1,
Attachment 7:

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Telephone Lake Project
Volume 1 – Project Description
December 2011

• TL1-42-PFD-02-001-01 (Boiler Feed Water and Once Through Steam Generation—


Phase A);
• TL1-42-PFD-02-002-01 (Second Stage Once Through Steam Generator—Phase A);
• TL1-42-PFD-02-003-01 (Boiler Feed Water Chemical Injection System—Phases A
and B);
• TL1-42-PFD-02-004-01 (Boiler Feed Water and Once Through Steam Generator—
Phase B);
• TL1-42-PFD-02-005-01 (Second Stage Once Through Steam Generator—Phase B);
• TL1-42-PFD-02-006-01 (Gas Turbine and Heat Recovery Steam Generator—Phase A);
and
• TL1-42-PFD-02-007-01 (Gas Turbine and Heat Recovery Steam Generator—Phase B).

There are four OTSGs and one HRSG with gas turbine for each phase. The first-stage steam
generators consist of three OTSGs and one HRSG operating in parallel. The second-stage
OTSG utilizes the blowdown from the first-stage steam generators as boiler feed water. The
second-stage OTSG has the same design capacity as the first-stage OTSG and will take 100%
of the blowdown streams from the three first-stage OTSGs and one HRSG. The first-stage
steam generators produce wet steam at 80% quality and the second-stage OTSG produces
70% quality steam.

The wet steam from steam generators (B-2100/2150/2200/2400/2450/2500) and HRSGs


(B-2250/2500) is sent to steam separators (V-2350/2650). The steam condensate is removed in
the steam separators and cooled by cross heat exchange with the first-stage steam generator
boiler feed water. Then the second-stage steam generator feed pumps (P-2360/2660) deliver
the cooled steam condensate as boiler feed water to the second-stage OTSGs (B-2300/2600).
Similarly, the second-stage steam separators (V-2370/2670) remove the steam condensate
(blowdown) from wet steam produced by the second-stage OTSGs. The dry steam from all the
steam separators are combined and sent to the steam pipelines for distribution to the well pads.

A portion of the second-stage OTSG blowdown is flashed to produce steam for make-up water
heating. The remainder is cooled by cross exchanging with second-stage OTSG boiler feed
water and then with glycol. The cooled second-stage blowdown is sent to disposal.

The gas turbine and generator packages (PK-2100/2200) are installed to produce electric
power. The HRSG uses hot exhaust from the gas turbines to produce steam. HRSG duct
burners provide additional heat to the gas turbine exhaust in order to achieve the design steam
production.

Each gas turbine generates 40 to 50 megawatts of power depending on the ambient


temperature. The black-start generator package (PK-7810) supplies emergency power to start-
up the gas turbine generator when the main power supply is not available.

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Telephone Lake Project
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December 2011

Sweetened produced gas from the sulphur scavenger unit, recovered vapour from the vapour
recovery unit, and natural gas from the pipeline are mixed and sent to the OTSGs and HRSG as
fuel gas. High-pressure natural gas is used by the gas turbines.

6.1.3.10 Vapour Recovery System


The following process flow diagram for the vapour recovery system is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-07-001-01 (Ejector System—Phases A and B).

The vapour recovery system will be similar to the CLTP’s vapour recovery system. It consists of
ejector suction scrubbers (7600/7610/7620/7630) and ejectors (M-7602/7604/7612/7614/7622/
7624/7632/7634). The vapours from the following sources are collected by location and
compressed using ejectors:
• slop oil treater system;
• produced water deoiling;
• hydrocarbon storage tank; and
• warm lime softener and clear well.

The ejectors use heated high-pressure natural gas as motive gas to compress the tank vapours.
The ejector discharges are routed to the fuel gas mix drum (V-7010).

Liquid collected in the ejector suction scrubbers is emptied by using low-pressure fuel gas to
push the liquid to the slop tanks.

6.1.3.11 High-pressure and Low-pressure Flare Systems


The following process flow diagrams for the flare system are provided in Volume 1,
Attachment 7:
• TL1-42-PFD-07-005-01 (High Pressure Flare System—Phases A and B); and
• TL1-42-PFD-07-007-01 (Low Pressure Flare System—Phases A and B).

There are two separate flare systems. The high-pressure flare system collects relief valves
discharges from the process vessels; the low-pressure flare system burns the vapour from the
tank when the ejectors are shutdown.

The high-pressure flare knockout drum pump (P-7505) transfers the liquid collected in the high-
pressure flare knockout drum (V-7500) to the slop tanks. Similarly, the low-pressure flare
knockout drum pump (P-7515) transfers the liquid collected in the low-pressure flare knockout
drum (V-7510) to the slop tanks.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

6.2 Sulphur Recovery


Alberta Sulphur Recovery Guidelines, identified in the Energy Resources Conservation Board
(ERCB) Interim Directive ID 2001-3 (ERCB 2001), become more stringent as the sulphur
content increases. Interim Directive ID 2001-3 recovery guidelines are shown in Table 6.2-1.

Table 6.2-1: Alberta Sulphur Recovery Guidelines


Design Sulphur Recovery Calendar Quarter-Year
Sulphur Inlet Rate
Criteria Sulphur Recovery Guidelines
[t/d]
(%) (%)
<1 none required none required
1 to 5 70 69.7
>5 to 10 90 89.7
>10 96.2 95.9

Source: ERCB Interim Directive ID 2001-3 (ERCB 2001a).

For in situ thermal facilities, the sulphur inlet rate refers to the sulphur content of the produced
gas. The produced gas is used as fuel for steam generation. When the inlet sulphur rate
exceeds one tonne per day, the produced gas will be treated before it is used as fuel gas.

For the Project, the design inlet sulphur rates are based on a ratio of 0.3 kg of sulphur in the
produced gas per m³ of bitumen. This ratio is higher, and hence more conservative, than the
current observed ratios at the CLTP and the FCTP. Design sulphur rates for the Project are
presented in Table 6.2-2.

Table 6.2-2: Design Sulphur Rates


Cumulative Bitumen Sulphur Content of Sulphur/Bitumen
Production Produced Gas Ratio
Phase
kg of sulphur /
(bbl/d) (m3/d) (t/d) 3
m of bitumen
Phase A 47,900 7,615 2.28 0.3
Phase B 95,800 15,230 4.57 0.3

Based on sulphur projections, the design sulphur recovery criteria for production cumulative to
Phases A and B is 70%. A non-regenerative liquid scavenger system has been selected to
remove the sulphur from the produced gas.

Although the scavenger system has been identified, the scavenger unit will not be constructed
and installed at the start-up of the Phase A facilities. The scavenger system will be installed and
in operation before the sulphur inlet rate reaches one tonne per day as the sulphur content and
produced gas rate increase with bitumen production. Cenovus’s experience with constructing
and installing scavenger systems has shown that they can be designed, fabricated and installed
in a relatively short period of time. The design values used for sulphur content in the produced
gas are conservative; therefore, Cenovus believes the facility can be operated for a period of
time to establish sulphur levels before the scavenger system is designed and finalized.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

6.2.1 Sulphur Scavenger Unit


The following process flow diagram for the sulphur scavenger unit is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-08-002-01 (Scavenger Unit—Phases A and B).

Produced gas from the produced gas compressor (K-4050) is routed to the scavenger inlet
separator (V-8500) to remove any entrained liquid. Then the produced gas flows up the
scavenger contactor (V-8502) which contains a non-regenerative liquid scavenger. A continuous
make-up of fresh scavenger is also added at the inlet of the scavenger contactor. The produced
gas and spent scavenger leave the top of the tower and enter the scavenger post contactor
scrubber (V-8504). This vessel separates the spent scavenger from the gas. The sweetened
produced gas is sent to the fuel gas mixed drum. The spent chemical is sent to a tank for
temporary storage. The spent scavenger is trucked to an approved facility for disposal.

A bypass is installed around the scavenger unit to allow a portion of the gas to bypass the
system and reduce scavenger consumption while meeting the required overall sulphur recovery.

6.3 Top Water Handling Facilities


The following process flow diagrams for top water handling facilities are provided in Volume 1,
Attachment 7:
• TL1-42-PFD-07-006-01 (Fire Water and Utility Water System—Phases A and B);
• TL1-42-PFD-07-008-01 (Top Water Handling Facilities—Phases A and B); and
• TL1-42-PFD-07-009-01 (Injection Air Compressor Packages—Phases A and B).

The surplus water from top water dewatering facilities is sent to the top water/fire water storage
tanks (T-7700/7300). These tanks provide surge capacity to accommodate flow fluctuations.
T-7300 also serves as the fire water storage tank. The top water is pumped to the top water
deaerator (V-7770A/B) to remove the dissolved air. The deaerated water is pumped to the top
water make-up tank (T-1000) for process make-up water consumption and to utility water tank
(T-7400) for utility water usage. The top water disposal pump (P-7760) sends the surplus top
water to the top water disposal wells. This portion of the CPF will be commissioned
approximately one year prior to the rest of the commercial plant to effectively dewater the first
production areas prior to beginning SAGD production. Because the top water facility can be
operated as a standalone portion of the plant, it will be constructed in a location such that the
rest of the facility can be constructed without interfering with the operation of the top water
equipment.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

6.4 Off-sites
6.4.1 Horizontal Well-Pairs
At the Project’s full production capacity of 14,308 m3/d (90,000 bbl/d), it is estimated that
93 initial well-pairs, located on eight well pads, will be required. The current development plan
(Volume 1, Section 4.5.2) includes an additional 868 sustaining well-pairs located on 82 well
pads over the life of the Project to fully utilize the steam capacity and maintain bitumen
production levels close to the 14,308 m3/d production capacity. Each well pad will have up to
twelve initial well-pairs. During the five-plus years of well-pair life, injection of steam and
downhole pumps are utilized to produce water-bitumen emulsion and produced gas from the
well-pairs.

6.4.2 Production Well Pad Facilities


The following well pad plot plan is provided in Volume 1, Attachment 4:
• TL1-44-PLT-00-002-01 (Typical Well Pad Plot Plan).

The following well pad process flow diagram is provided in Volume 1, Attachment 7:
• TL1-42-PFD-09-001-01 (Typical Well Pad Electrical Submersible Pump).

A typical SAGD well pad consists of the following: twelve well-pairs, a motor control
centre/instrument air building, and a line heater.

The well-pairs have automated chokes on both the inner and outer tubing strings to control the
amount of flow from the production well. There are automated steam control valves to control
the amount of steam injected into the inner and outer tubing of the injection wells. The wells are
designed for start-up, ramp-up, conventional, and blow-down modes of operation.

After the interwell region is sufficiently heated through circulation of steam, the production well is
converted to the conventional mode of operation by installing electrical submersible pumps
(ESPs). At the end of the oil production phase, the production wells are switched to blow-down
mode of operation. When starting up with steam circulation, all produced fluids from the injection
and production wells are directed to the emulsion header. The inner tubing in the production
well is removed when it is converted to ESP. Then, all emulsion fluid is directed from the outer
tubing to the emulsion header and all produced gas from the casing is directed to the casing gas
header. The casing gas header and casing gas pipeline will be commissioned when the wells
are converted to ESP.

At each well-pair, there are meters to measure the steam injection, gas injection, and casing
gas production. The emulsion production is measured with wellhead orifice meters combined
with manual cuts. In addition, test and group piping will be installed for future shared multiphase
metering, if required. No test separators are expected. The proration error for ERCB reporting
purposes is expected to be below 10%.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

An air compressor to supply instrument air is installed at each well pad. Locating the air
compressor at the well pads is more cost effective than installing an instrument air pipeline from
the central plant facility to the well pads.

Power is supplied to each well pad using a 25 kilovolt high line. A transformer is located at each
well pad to supply the required power to the motor control centre. The motor control centre
contains variable frequency drives for the production well ESPs, breakers for the air
compressors, lighting, heat tracing, fans and heaters. A fibre optic line is installed on the power
poles for communication between the pad controllers and the central plant control system.

The fuel gas is supplied from the natural gas pipeline. The gas lines are designed to a minimum
design metal temperature of -45°C, and are, therefore, not heat traced and insulated. Line
heaters are installed at the well pads to heat the natural gas before the pressure is let-down to
the required operating pressure.

6.4.3 Top Water Dewatering Facilities


The following top water dewatering process flow diagram is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-09-003-01 (Typical Top Water Dewatering Facilities).

Portions of the Telephone Lake reservoir have a Top Water Zone located above the bitumen as
discussed in Volume 1, Section 4.3. The top water is removed (dewatered) before the bitumen
is extracted using SAGD technology. Dewatering of the top water portion of the reservoir
reduces the SOR, reduces the capacity of the produced water deoiling facilities, and minimizes
water quality changes in the top water.

The top water dewatering facilities are incorporated as part of the Telephone Lake SAGD well
pad and part of the central plant facilities. A typical top water dewatering facility consists of an
air injection well, three water production wells, and three water injection wells.

Air, production water and injection water will be distributed via a combination of above ground
pipelines where available and buried lines where not.

Air compressors located at the CPF supply compressed air to the air injection wells. A portion of
the produced water from the Top Water Zone is sent to the water injection wells. These water
injection wells are drilled to reinject top water at the perimeter of the planned SAGD bitumen
production area. Several outlying water injection pads will be required where existing SAGD well
pads cannot be used to drill the water injection wells. The number of these pads will be limited
to minimize surface disturbance.

The surplus top water is sent to the top water handling facilities located at the CPF for make-up
or disposal.

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Volume 1 – Project Description
December 2011

6.4.4 Gathering/Distribution System


The pipeline gathering and distribution system will include the following:
• injection steam;
• produced emulsion;
• fuel gas;
• produced gas;
• produced water; and
• injection air.

Where possible, the above ground pipelines will share a common corridor with the road and
power distribution lines. To minimize land disturbance and for ease of maintenance, power
distribution lines will be located across the road from the pipeline.

Cenovus will apply to the ERCB and other regulatory agencies for licenses required for all
pipelines, and other surface facilities associated with the well pads, in accordance with existing
regulations. A steam distribution system, air distribution system, sweet gas distribution system,
sour emulsion gathering system, and sour produced gas gathering system run between the well
pads and the central plant.

The steam, air, gas, emulsion, and produced gas pipelines are above-ground pipelines on a
common pipe rack. Expansion loops are provided for the steam, emulsion, and produced gas
pipelines. To minimize environmental impact, the pipelines will follow existing rights-of-way and
roads where practicable and cost effective. Shut down valves are installed on the emulsion and
produced gas gathering lines at the pad edge to protect the lines from high temperature and
high pressure. The sweet fuel gas and steam distribution pipeline are protected by pressure
safety valves located in the central plant. Pigging facilities are installed on the casing gas
gathering system.

Pipelines have design features to facilitate wildlife crossings. These design features may
include:
• raising pipe in selected areas;
• building wildlife crossing structures;
• making best use of topography to allow for animal passage; and
• locating crossing sites at existing game trails and in areas of high-quality wildlife habitat.

Watercourse crossings are designed to minimize environmental effects. Sediment and erosion
plans will be developed before construction at or near water bodies. Applications for
watercourse crossings will be made to the applicable regulatory bodies before construction
begins.

6.4.5 Roads
Cenovus will combine the road, power line and pipeline rights-of-way to optimize cleared areas
and minimize surface disturbance.

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Telephone Lake Project
Volume 1 – Project Description
December 2011

Watercourse crossings will be designed to minimize environmental effects. Sediment and


erosion plans will be developed before construction at or near water bodies. Applications for
watercourse crossings will be made to the applicable regulatory bodies before construction
begins.

Surface effects for the right-of-way for road access and well pad access will be determined on
an individual basis with the local Alberta Sustainable Resource Development officers.

6.5 Blend and Diluent Pipelines


6.5.1 Blend System
The following process flow diagram includes the blend system and is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-06-002-01 (Sales and Slop Oil Tanks—Phases A and B).

The blend from the facilities Sales Oil Storage Tanks is transferred to a third-party pipeline
transportation provider. Within the Project facility plant site, land will be allocated to the third-
party pipeline transportation provider to locate equipment consisting of a blend pig launcher,
custody transfer metering, a quality assurance skid, and blend transfer pumps capable of
handling the blend volumes. A transportation right-of-way will be established for the third-party
pipeline transportation provider to route blend pipeline from the facilities.

6.5.2 Diluent System


The following process flow diagram includes the blend system and is provided in Volume 1,
Attachment 7:
• TL1-42-PFD-06-002-01 (Sales and Slop Oil Tanks—Phases A and B).

The diluent requirements for the Project facilities will come from a third-party pipeline
transportation provider. Within the Project facility plant site, land will be allocated to the third-
party pipeline transportation provider to locate equipment consisting of a diluent pig receiver,
custody transfer metering, and quality assurance instrumentation capable of handling the diluent
volumes. The diluent will be transferred from the LACT unit to the facilities diluent storage tanks.
A transportation right-of-way will be established for the third-party pipeline transportation
provider to route diluent pipeline to the facilities.

6.6 Literature Cited


Energy Resources Conservation Board (ERCB). 2001. Sulphur Recovery Guidelines for the
Province of Alberta Interim Directive, ID 2001-3. Calgary, Alberta.

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