Egbema West AG

In line with Nigerian government’s inclination towards eliminating routine flaring and increasing supply of domestic gas (DOMGAS) to local industries and power plants, the Egbema West AG GHF Project supports this philosophy by gathering, treating and compressing flared gasses to required specification& pressure of 42-43 barg, and routing the resulting gas to the NDPHC EIPP pipeline. Specifically, the Egbema West AG GHF is designed to produce 8 MMScf/d of gas.

The Egbema West fields is located in OML-20, some 75 km North of Port Harcourt and the existing Egbema-West flowstation, commissioned in 1974 comprises of a single bank, three stage 30Mbpd oil and gas separation facility. The Egbema West AG GHF will be built beside the existing flowstation by Makon Engineering and Technical Services (METS) for Shell Petroleum Development Company (SPDC) and Nigeria Petroleum Development Company (NPDC), the end user.

METS scope of work includes the Engineering, Procurement, Construction, Installation, and Commissioning of this facility, with oversight functions provided by both SPDC and NPDC.

The design for the Egbema West AG GHF Project consistent with:

  1. Eliminating flaring of the gas produced from the flowstation.
  2. Supporting operability, maintainability and reducing NPDC’s OPEX.
  3. Supporting sustainable development of host community.
  4. Giving due focus to HSSE standards.
  5. Standardizing design template and equipment packages such that they can be modularised and be adapted for other locations.
  6. The needs for operational integrity throughout the projected minimum 30 years life cycle of the Facilities.
  7. The requirements of the gas customers, as specified in the gas sales contracts.
  8. Meeting the requirements of high availability, cost effective operations, minimum maintenance and environmental sustainability.
  9. Minimisation of site work to reduce exposure of personnel and equipment by driving off-site pre-fabrication and pre-commissioning of equipment packages.
  10. Designs to allow parts of the project to be fabricated and/or constructed as much as possible in Nigeria by Nigerian companies.
  11. Low operator intervention and minimised use of consumables.
  12. Optimum use of existing utilities and infrastructure.
  13. Flexibility with respect to future development scenarios.

Front End Engineering Design (FEED)
FEED completed to SHELL DEP by PROPAK. Oversight functions (review and approval functions) were provided primarily by MAKON and ultimately by SPDC-NPDC. All HAZOP report recommendations and action points completely closed out.

Detailed Engineering Design (DED):
DED being executed to International Standards and has progressed to 6% completion. MAKON and ENERFLEX will be responsible for the design and fabrication of the process-related equipment with SPDC-NPDC performing the oversight functions of reviewing documents& drawings and giving approvals.

The Egbema West AG Project Scope includes Engineering, Procurement, Construction, Installation and Commissioning for

  • Main Process Package
  • Gas Compressor Unit.
  • Inlet Scrubber Unit.
  • HC Dewpoint Control.
  • Gas Metering Unit.
  • Refrigeration Unit.
  • Glycol Unit.
  • Fuel Gas Distribution Unit.
  • Flare Unit.
  • Instrument Air Unit.
  • Others
  • PAS & SIS Panel/ Cabinet Unit
  • MCC/Switchgear.
  • Power Systems and distribution unit.
  • 190 Days Reliability Test.

As a result of the direct derivative of the FEED and DED, Procurement is divided into Major Equipment and Materials (Foreign Long Lead Items and Overseas Bulk items) and Minor Equipment and Materials (Local procurements). Detailed design of process packages are still ongoing and fabrication is yet to proceed.

Fabrication work will be succeeded by Factory Acceptance Tests (FAT), with the Clients SPDC-NPDC and other regulatory bodies such as NAPIMS and DPR in attendance. The procurement/fabrication of other skids and Utility vessels will be done in due course. As a NCD requirement, METS plan to fabricate various components and tanks locally.

Being a green field project, the Egbema West AG GHF Project will involve heavy construction activities. Collectively, a summary of the scope of construction activities for the AG facilities includes but not limited to:

  • Site survey and Geotechnical studies
  • Mobilization and Transport activities
  • Surcharge Removal
  • Mobilisation of Piling Works
  • Piling and Installation of Pile casings in their required positions
  • Prefabricate and install reinforcements on the installed piled casings
  • Pile cap Construction of foundations as required for Piled Equipment
  • Construction of raft foundation for skid and others as per AFC drawings
  • Foundation for Equipment (piled)
  • Construction of Temporary/ Permanent Site Access Roads within the facility
  • Precast of Storm water drains.
  • Precast of Pipe/Cable Sleepers.
  • Fabrication & Installation of Cable Tray Steel Works on Sleepers.
  • Several Excavation, Blinding & Installation activities.
  • Pipe Rack Foundation.
  • Precast Equipment Foundation.
  • Piling for Equipment Foundations.
  • Excavation & Installation of Precast Storm Water Drains.
  • Pour Concrete & Install Rebar for Equipment.
  • Installation of Precast Foundation.
  • Concrete Road Works (All Areas).
  • Erection of process skids, vessels and Equipment unto foundations.
  • Installation of various instrument valves and fittings.
  • Laying of instrument cables plant-wide.
  • Installation and Hook-up of Electrical Buildings.
  • Installation of Electrical Cables plant-wide.
  • Deployment of Telecommunication equipment.
  • Re-assembly of Accessories for Skids.
  • Other miscellaneous activities to ensure mechanical completion.

METS aims to maintain the highest Health, Safety and Environment Standards with no Loss-Time Injury (LTI) when construction proceeds.

Individual Long Lead Equipment (Process Packages, Instrumentation& Control Packages, and Utility Packages) will be pre-commissioned separately before they are finally integration into a single system. To ensure a seamless& successful commissioning, detailed commissioning procedure will be strictly adhered to e.g. sequence of action, closure of punch list items, sign-off of check sheets A,B & C, Lock-in Tag-out to mention but a few. The Commissioning phase will be succeeded by the 90 Days Reliability Testing of the Gas Handling Facility.

At the completion of the start-up process, the plant will be commissioned to run continuously for 90 days for reliability. During the reliability period, the AG facilities will be monitored by a combined team of MAKON and NPDC Operational staff. The SPDC-NPDC staff will be trained in practice and theoretically. At the success of the reliability test run, the entire system is handed over to SPDC-NPDC management and signed of as a completed and commissioned plant.

In order to successfully keep track of all document deliverables expected from MAKON by NPDC, an electronic document transfer system was instituted and references for tracking documents agreed to. This process enabled MAKON and SPDC-NPDC to agree on which document is delivered and which is outstanding. In addition, a virtual File Transfer Protocol (FTP) is created in the cyber space for storage and sharing of documents between METS and NPDC. This FTP is hosted and managed by a third party and access is strictly through the provision of password and codes. This FTP operated by MAKON is called EGNYTE.
(Slider Operations and Maintenance}
Although tentatively not within METS scope of work, it is expected that:

  • Key Personnel of the operations department of SPDC-NPDC will be trained for operation and maintenance
  • A complete set of Operation and maintenance procedures will be given as part of the hand over notes
  • SPDC-NPDC will sign an agreement to have a few of the technical Vendors on hand to provide Facility operations assistance as part of flawless delivery.
  • SPDC-NPDC through the E-SPIR system, Operations and maintenance spare parts stock management will be driven.