Malampaya Deep Water Gas-to-Power Project: Onshore Gas Plant Value Engineering and Flawless Start Up

摘要

The Malampaya field development comprises subsea wells inrn820 metres water-depth producing via a subsea manifold andrntwo 16 inch diameter inconel clad flowlines to a shallow waterrnplatform 30 km distant. Condensate is removed on thernplatform and the dry gas is then transported via a 504 km longrn24 inch export pipeline to an onshore gas plant at Tabangaorn(Batangas, Luzon Island) for extraction of H2S. Therncondensate is stored in the platform CGS caisson prior tornexport via a short 3 km long 24 inch diameter pipeline andrnCALM buoy.rnThe Malampaya Onshore Gas Plant (OGP) at Batangas is arnvital part of the overall Shell Philippines Exploration B.V.rn(SPEX) Malampaya Deep Water Gas-to-Power Development.rnThe plant design and execution schedule was from the outsetrnextremely tight, mainly due to uncertainties during therndefinition stage on the exact requirements for H2S removal.rnConsequently, the project awarded the main EngineeringrnProcurement and Construction (EPC) contract ahead of finalrndesign optimisation.rnTo ensure an optimised design and to reduce cost withoutrnscarifying the functional requirements, the project executed arnValue Engineering exercise prior to start of detail design. Thernexercise not only resulted in a reduction of overall cost ofrn20%, it also produced a better design.rnIn addition to discussing the benefits gained through thernValue Engineering process, this paper will address the fastrntrack nature of the Project and the application of the conceptrnof Flawless Start-Up to meet the tight schedule. This involvedrnthe necessary up front work in detailed engineering,rnprocurement and construction, as well as commissioning, startrnup planning and risk analysis to support a short and troublernfree start up.rnThe paper also addresses key aspect of HSE managementrnin construction and start up for this green field project inrnBatangas, Philippines. The OGP executed some 11.3rnmanhours without a Lost Time Incident (LTI) utilising mainlyrnlocal, in most cases unskilled, labour. The project was alsorncertified to ISO 14001 from start of construction and throughrnuntil start up and full operation.