MLNG REJUVENATION

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MLNG REJUVENATION AND MLNG/MLNG DUA REVAMP
PROJECT (MRR PROJECT) SUCCESSES, CHALLENGES AND
LESSONS LEARNT 23 MARCH 2004
Pau Kiew Huai
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PETRONAS LNG COMPLEX
PETRONAS LNG COMPLEX, BINTULU
KUALA LUMPUR
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PETRONAS LNG COMPLEX

• PETRONAS LNG COMPLEX has 3 LNG plants
• 
  Start-up Capacity
• MLNG 1983 8.4
• MLNG DUA 1995 7.8
• MLNG TIGA 2003 6.8 Total 23MMTPA

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PETRONAS LNG COMPLEX
MRR Project for 1st 2nd plants only
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WHY REJUVENATION?

• MLNG have completed 20 years operation since
  1983.
• (Modules 1,23 Utilities Common
  Facilities)
• The rejuvenation project objectives are to-
• operate a further 20 years.
• sustain reliability of plant.
• retain integrity of facilities.

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WHY REVAMP?

• MLNG MLNG DUA future feed gas composition
  contains higher CO2 content
• To maintain current MLNG MLNG DUA production
  capacity
• Upgrade plant utilities to support revamped plant
  requirement.

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REJUVENATION SCOPE
Painting and Insulation, 40 of rejuvenation
scope Repair and Replacement of Corroded Pipe
Lines, Steel Structures and Equipment.
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REJUVENATION SCOPE
Rejuvenate boilers deaerator Rejuvenate
boiler water polishers
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REJUVENATION SCOPE
replace chlorination unit
replace SCW pump impeller to bigger size
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REJUVENATION SCOPE
Replace all LNG tank heaters with flexible
conduit design Replace instrument junction boxes
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REVAMP SCOPE
2, Dehydration unit revamp
1,Sulfinol Unit revamp
4, Acid Gas Incineration facilities
3, Liquefaction unit revamp
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EXECUTION STRATEGY
Project Stake Holders (Plant Management)
Project Owner's Team
Project EPCM Consultant (Consortium of JGC, KBR,
OGP)
Vendors, 3rd party services
Construction Contractors
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PROJECT EXECUTION STRATEGY

• Project Phases
• Phase 1 - scope definition site investigation
  (1999 - 2000)
• Phase 2 - engineering, procurement and
  construction planning (2000 - 2001)
• Phase 3 - construction (2001 - 2005)

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PROJECT SCHEDULE
2001
2002
2003
2004
2005
MLNG Rejuvenation/ Revamp
Module 1
Module 2
Module 3
MLNG Dua Revamp
Module 6
Module 4
Module 5
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PROJECT COST ESTIMATE

• Initial project cost estimate USD 306 million
• MLNG Rejuvenation USD 230 million
• MLNG Revamp USD 45 million
• MLNG Dua Revamp USD 31 million
• Latest cost projection USD 270million

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CONSTRUCTION

• HSE - strong emphasis
• Daily toolbox Total Safety
• Task Instruction meetings
• Near Miss Reporting
• Loss Prevention Inspection
• Award Scheme
• Red Lead Based Paint Removal Methods

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CONSTRUCTION

• Training
• 18,000 Man-sessions
• (HSE Skill training)
• 41 Different Courses
• - e.g. Safety
• Induction rigging
• lifting

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CONSTRUCTION

• Red lead based paint removal
• Training Personnel Issue PPE
• Blood testing (before, during and after job)
• enclosure of plant equipment

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CONSTRUCTION

• Heavy lifts
• C-1103 - 120 ton 30 m high in middle of the
  Module
• V5701B - 70 ton on high structure

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LESSON LEARNT
Managing 300,000m3 scaffolding demands lots of
supervision / attention
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LESSON LEARNT
Managing blasting in live plant demands strict
control and monitoring.
Furmanite clamp
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LESSON LEARNT

• Interface with Plant Operations
• Involve plant staff for engineering review
  procurement evaluation
• Daily discussion with Operation staff
• Hold regular "Look Ahead" meetings

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LESSONS LEARNT
Sound economical rejuvenation solution

• Rejuvenation engineering need-
• clear rejuvenation criteria
• up-to-date plant informations
• experienced plant inspectors /engineers

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LESSONS LEARNT
Improvement on next shutdown
Promote teambuilding, organise lesson
learnt workshops
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ACHIEVEMENTS

• HSE
• 7 million manhours
• without LTI to date
• Zero environmental
• infringement
• 18,000 man-sessions training conducted

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ACHIEVEMENTS

• Schedule
• all scheduled target dates and shutdown durations
  met
• project is robust
• and flexible to
• meet the frequent
• target date
• changes.

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ACHIEVEMENTS

• Quality
• Sustained current LNG production on revamped
  modules
• minimum flange leaks
• Cost
• On target,
• expect below budget

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AFTER
BEFORE
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Thank You