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