Status: COMPLETED 2014
Bonny AGS plant is designed to compress SV, LP & HP gas (ca. 5MMsfd) to 120 barg and route to the BNAG manifold bulk lines at Oloma. The plant is built beside the existing flow station.
The AG compression package is integrated into the Flow station existing shutdown system and the package control system is capable of transmitting process data for viewing status to the NAG plant control system for monitoring AG Plant process conditions.
The overall objective of the Bonny AG Solution project is to execute a profitable, sustainable and optimised technical solution that will:
- Protect 10Mbopd from the Bonny flow station by eliminating routine flaring of produced AG by gathering SV, LP and HP vessels gas and compressing and treating same to sales gas quality.
- Support operability and maintainability and hence reduce OPEX
- Support sustainable development of host communities
- SPDC and MAKON entered into an Engineering, Procurement and Construction agreement to build the 5mmscfd gas gathering facility in Bonny.
MAKON, in order to fulfill her client’s expectation went into a technical agreement with Propak Systems of Canada.
This is subdivided into Front End Engineering Design and Detailed Engineering Design;
Bonny AGS Front End Engineering Design (FEED)was carried out by Propak System of Canada with review by MAKON and final oversight review and approval function by SPDC Discipline Engineers to Shell DEP and international standards
Detailed Engineering Design (DED) was done to Shell DEP and international standards by a combined team of MAKON and Propak System of Canada discipline Engineers, with SPDC performing the oversight review and approval function.
This part of the scope was subdivided into Foreign Long Lead Item which is a direct derivative of the FEED and DED and Overseas Bulk items and Local procurements.
Foreign Long Lead Items which are direct derivatives of the FEED and DED were handled as foreign procurement as described below:
- Propak Systems of Canada provided the AG Compressor Package consisting of the Ariel GJE/4 Compressor, the CAT Engine 3516 driver, the Intercooler & the wing skids A & B. The Unit Control Panel (UCP) was also supplied by Propak systems.
- Enerflex Ltd of Calgary provided the Instrument Air Package & Fuel gas Package.
- The LV Switchgear was provided by Fairburns of United Kingdom
- The UPS was provided by Dale Eskine
- Dexcrest Technical Services Ltd of United Kingdom were contracted to provide various overseas bulk materials such as pipes and fittings, gantry crane and accessories, electrical cable glands, distribution boards, Instrument cable trays, Instrument junction boxes and instrument Tubing and fittings, etc
- De-Coon Services Ltd in conjunction with Enercon of United States of America supplied 2no. Caterpillar gas driven generators rated at 350KVA and 1no. Olympian diesel driven generator rated at 100KVA
This consist basically construction and fabrication consumables, roofing materials, electrical cables, etc as described below:
- The MCC/FAR building fabrication is being under taken by Galba Nigeria Limited. These steel building/ shelter is housing the Low Voltage Switchgear and Delta V system respectively.
- The smokeless Flare package made up of the Flare Stack and its Ignition Panel were fabricated locally by BOSKEL. The Flare Stack bears a specially designed Flare tip.
- System was provided by AOS Orwell and it incorporates the Process Automation System (PAS) and Safety Instrumented System (SIS). The PAS and SIS constitutes the Integrated Control and Safety System (ICSS) which provides centralized monitoring and supervisory control via human/machine interface which serve as the operator’s single window to the entire plant.
- Telecommunication was provided by Catalyst 2000, on behalf of METS whose scope of work entails provision of LAN& WAN Systems, Telecoms Closet, UPS Power Systems, CCTV System, Telephone System, E&L Systems, and Cable Systems.
- Aluminum Towers Limited for roofing sheets
- Orazulike Limited for steel sections for the fabrication of shed stanchions
- Larfage WAPCO Limited for cement for the casting of process equipment foundations
- Host community local suppliers for river sand and granites
- Nigerchin Limited for electrical cables and wires
- Fire and Gas Detection and Protection materials by Draise Energy Ltd.
Construction and Installation
Construction of Bonny AGS Plant consists of the followings:
- Steel fabrications and installations of sheds
- Concrete works for process equipment foundations and other heavy equipment like generators’ foundations
- Mechanical and electrical equipment installations
- Instrumentation, automation and control equipment installations
- Piling/ Excavation/ Blinding/ Re-Barring/ Formworks.
- Concreting/Concrete casting.
- Process lines installations
Pre-commissioning, Start-up & Commissioning
Individual Long Lead Equipment like the AG Compressor, Instrument Air Package, fuel gas packages, Inlet Knockout Separators and Instrument air package on the side process equipment and power systems like Low voltage switchgear , gas and Diesel Generators were first independently commissioned before the final integration into a single system.
To ensure a seamless & successful commissioning, detailed commissioning processes were duly adhered to during this phase. E.g. sequence of action, sign-off of check /punch sheets A,B& C, Lock-in Tag-out, etc.
The Commissioning phase was succeeded by the 90 Days Reliability Testing of the Gas Handling Facility.
90 Days Reliability Test
At the completion of the start-up process, the plant was commissioned to run continuously for 90days for reliability. During the reliability period, the Associated Gas solution facility will be monitored by a combined team of MAKON, the Technical Vendor and Shell Operational staff. The Shell staff will be trained in practice and theoretically.
At the success of the reliability test run, the entire system is handed over to Shell management and signed of as a completed and commissioned plant.
Operations and Maintenance
Key Personnel of the operations department of Shell 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.
Shell will sign an agreement to have a few of the technical Vendors on hand to provide Facility operations assistance as part of flawless delivery. Through the E-SPIR system, operations and maintenance spare parts stock management will be driven.