Status: COMPLETED 2017
In support of government’s desire to increase supply of domestic gas (DOMGAS) to local industries and power plants, SPDC submitted a plan to government detailing out steps to increase its contribution to the DOMGAS market between 2008 and 2013; divided into short-term and medium-term supply targets.
The capacity of the Utorogu gas hub will be increased from 360 MMscfd to circa 510MMscfd to urgently address the supply shortfalls in the ELPS/WAGP captive market. Thus, approval was secured to relocate the 150MMscfd GHF earlier planned for Ughelli-East to Utorogu with the Ughelli-East NAG wells re-routed via a bulk line to Utorogu.
A sales gas return line to supply the low-pressure customers in the Ughelli area (e.g. PHCN Delta I - IV, DSC, Beta Glass, etc) will also be constructed. The existing Ughelli-East NAG plant will be subsequently decommissioned.
This 150 MMscfd Gas Handling Facility at Utorogu, Delta State is being built by Makon Engineering and Technical Services (METS) for SPDC handling the Engineering, Procurement, Construction, Installation and Commissioning of this facility.
Project Design Objectives
The design for the Utorogu GHF is consistent with:
- Standardized design template and equipment packages that 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 need for safety and security of personnel and plant with due regard to protection of the internal working and external environments.
- The requirements of the gas customers, as specified in the gas sales contracts.
- The requirement for high availability, cost effective operation and minimum maintenance.
- The needs, concerns and aspirations of host communities.
- Minimisation of site work to reduce exposure of personnel and equipment
- Minimisation of adverse social/environmental impact.
- 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.
- Minimum loss of production during project implementation by off-site pre-fabrication and pre-commissioning of equipment packages.
- Optimum use of existing utilities and infrastructure.
- Flexibility with respect to future development scenarios.
To meet the West African Gas Pipeline and other design requirements, the Utorogu Gas Handling Facility will feature the following major packages:
- Inlet Manifold Packages
- Joule-Thompson Packages
- Condensate Stabilization Packages
- Gas Compression Packages
- Glycol Injection & Regeneration Packages
- Flare Packages
- Fuel Gas Package
- Instrument Air Package
- Hot Oil Package
- Power Generation Package
- Utility Water Pa
- Motor Control Centre
INSTRUMENT AND CONTROL PACKAGES:
- Field Auxiliary Room Package
- Metering Skids
- Control & Automation System
FRONT END ENGINEERING DESIGN (FEED):
The FEED for the Utorogu NAG 2 Project has been completed and was rounded off with Hazard and Operability Studies (HAZOP). Proper documentation has since been concluded including Close-out of HAZOP Recommendation Items.
DETAILED ENGINEERING DESIGN (DED):
The completed Detailed Engineering Design has led to the generation of Bulk Material Take-Off (MTO) for Piping and steel structures and also involves review and approval of Vendor Detailed Engineering Design including General Arrangement Drawings of the Skids, the 3-D Models etc
As a company with international affiliations, METS has technical understanding with various specialist companies whose specialist input are employed to bring about the packages and equipment mentioned.
All the process packages have been completed and Factory Acceptance Tests (FAT) concluded and were witnesses by the Client and other regulatory bodies; NNPC and DPR. The procurement/ fabrication of other skids and Utility vessels are also 100% completed.
As part of METS plan to work to NCD requirements, various vessels and tanks are being fabricated by local companies and they are 100% completed. The piperack (which was also fabricated locally) has been completed as well.
The various Bulk MTO already generated have also been completed and this entails steel structures, valves , Pipes, flanges and fittings, instrument cables and fittings, transmitters, Fire and Gas detection devices, electrical cables and fittings and other field devices items essential to the completion of the Gas Handling Facility. All of these Bulk Materials have already been delivered.
Construction and Installation
Utorogu NAG 2 being a green field entailed a lot of construction activities to be done by Makon. A summary of the scope of Construction for Utorogu NAG 2 Gas Handling Facility includes but is 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 in situ
- Foundation for Equipment (piled)
- Construction of Temporary Site Access Roads (around the process areas)
- Site Access Road (temp./semi-permanent)
- Precast of Storm water drains
- Precast of Pipe/Cable Sleepers
- Fabrication & Installation of Cable Tray Steel Works (on Sleepers NAG 1 & 2)
- Excavate, Blind & Install of NAG2 Sleeper ways/Flare
- Excavate. Blind & Install of NAG 1 Sleeper ways
- 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
To achieve this and also for activities in the Western axis, METS has proceeded to set up a Camp site at Iwherekan Community which is located close to the Utorogu NAG 2 Plant. This has enabled METS to input its quota in the development of the community and engage massive workforce from the localities.
Activities being carried out in this camp site include:
- Concrete works such as Prefabrication of slabs, Road drains, pre-cast foundations;
- Piping works, fit-up and Welding of Pipe Spools;
- Fabrication of Steel structures;
- Material Handling, Storage and Inventory;
- Accommodation for Workers