Alakiri NAG

Alakiri Non-Associated Gas (NAG) Handling Facilities Upgrade and Revamp project is located in the Alakiri field in OML-18. The field location is in the swamps, about 18Km southeast of Port Harcourt.

Desirous to increase the capacity of the failing gas facility to a capacity of 120Million Standard Cubic feet per day, SPDC went into an agreement with MAKON to provide services linked to the engineering, procurement, installation, commissioning, operation and maintenance activities under the Contract for DOMGAS PROJECT.

  • The overall objectives of the Alakiri NAG Plant Refurbishment are to execute a profitable, sustainable and optimized technical solution for existing faculties that will:
  • Keep Alakiri NAG plant running for another 20 years and secure the gas volume of 100 - 120MMscf/d to Eastern Domgas network and allow full swing to NLNG during NGC outage.
  • Support operability and maintainability and enhance reduced OPEX.
  • Support sustainable development of host communities.
  • Give due focus to HSE standards.

The scope of works includes the following:

  1. Upgrade of the chemical injection system for corrosion inhibition
  2. Upgrade the obsolete SPEC 200 plant control system to a Process Automation System based on Foundation Field bus Technology and redesign/upgrade the Safety Instrumentation System (SIS) to be housed in a new control centre.
  3. Replacement of field instrumentation to Foundation Field Bus (FF) capable instrumentation
  4. Replace the glycol injection and regeneration system
  5. Replacement of gas fired water bath heaters and heat exchangers
  6. Upgrade plant utilities – instrument air compressor and power supply and distribution systems.
  7. Saver pit and environmental upgrade.
  8. Installation of new off gas compressor to collect off gas from condensate Stabilization Vessel and inject into processing facilities for gas export.
  9. Inspect with intent to confirm integrity and replace as necessary existing condensate disposal line to Alakiri Flow station and tie in to Truck line.
  10. It is intended to carry out a load analysis of additional equipment to be installed and determine capability of existing power supply system to cope with the additional load and upgrade power supply system if required.

In view of METS commitment to deliver quality, optimized and cost effective solution the resources of the Local and International technical partner come in handy. Some of the key partners include: ABB Automation; Dexcrest Consulting Engineers, UK; Decoon Services; Frames Process International BV; ODS Metering, the Netherlands; ENERFLEX Ltd, Canada.

In realization of the overarching objectives of the Project, the project has been designed to meet the following sub objectives:

  • To meet the need for safety and security of personnel and plant with due regard to protection of the internal working and external environments.
  • To minimize site work thereby reducing construction duration and associated cost such as oil production deferment and social/environmental impact of the project
  • To employ modern but proven technology in achieving a plant performance which meet International and National standards?
  • To consciously define components and design to allow suitable part of the projects to be fabrication and/or constructed in Nigeria and by Nigerian Components.
  • To prioritize flexibility, robustness, operability and reliability over energy conservation and technical sophistication.
  • To aim for low-intervention and minimize use of consumables
  • To standardize design and equipment packages with other Domgas projects within SPDC.
  • Give due consideration to the needs, concerns and aspirations of host communities with a view of maintaining a conducive operation environment.

Alakiri Front End Engineering Design (FEED) was carried out by SPDC and METS to outline the Functional Design of the plant.
Detailed Engineering Design (DED) was done to Shell DEP, Regulatory and relevant International standards using the expertise of METS Engineering Team, specialized Technical partners and OEMs. Detailed Engineering has currently reached 86%.

Procurement is currently at 94% completion with a bulk of the Long lead Equipments and Materials in the original scope completed or near completion.
The key Equipments & Materials in this scope are as follows:

  • Glycol Injection and Regeneration system (by FRAMES, Canada): This includes the Glycol Regen Skids (2no.), the Flash drum skids(2no.), Water Bath Heater skids(2no.), Glycol Reboilers, Coalescer package and accessories
  • Off Gas Compressor package (by ENERFLEX, Canada): This includes the GAS Compressors, Inlet Knockout separator, with control panels and accessories.
  • Power Generators (by De-coon Nig) consisting 2MVA Gas Generators (2no.), 1MVA Diesel Generator (1no) and accessories.
  • Instrument and Power control systems, including the Electrical Control Buildings and Switch Gears (by ABB, England); and Plant Automation System and Safety Instrumentation Systems (by ECNL/AOS Orwell)
  • Utility Air packages including the Instrument Air Compressor, Unit Control Panels and Accessories (by Airpack, Netherlands) and The Start Air Receiver Vessel (by EWT Nig Ltd).
  • Sales Gas Metering system including Metering Skid, Analyzer House package, HVAC and accessories (by ODS Metering, Netherlands)
  • Bulk Piping materials, Valves and Fittings (by Dexcrest Technical Services and others)
  • Structural Bulk Material & Gantry Cranes (by DTS and Local Vendors)
  • E, I & C Cables, Field Instruments, Valves & UPS (from Kentz)
  • Fire & Gas Systems and Special Tools (by Makon)
  • 2 year spares have been developed for procurement; awaiting SPDC approval for procurement

METS mobilized to site for construction in 2011 and Completed Piling works. Foundation Works is in progress while preliminary works have also been done for the Mechanical, Electrical and Instrumentation scope.
Structural and Piling materials have been procured preparatory to commencement of prefabrication.

METS Completion team consisting of Nigerian and Expatriates has already in place. Apart from developing and optimizing the completion plans and documentation, the team intervenes as necessary in other scopes with the ultimate aim of achieving a Flawless Start-up.

For internal Management of Deliverables and Documents generated by the various units METS deployed the EGNITE, a virtual File Transfer Protocol hosted by a third party. This system is well suited for Transfer, Storage and Sharing of Documents among the various Projects, Department and Functions and come with the necessary Security and Access restriction.
The METS DOCUMENT MANAGEMENT SYSTEM is generally agreed by SPDC. It includes systems to ease Tracking of the status of deliverables.
METS DDMS has interfaces with Shell’s LIVELINKS where deliverables are uploaded for SPDC attention.