In 2010 we saw the end of the year closing with the award of the SEPAT Early Production System by PETRONAS Carigali Sdn Bhd (PETRONAS). The Front End Engineering and Design (FEED) work for the project had been previously carried out by our specialist FEED execution office in Woking, UK.
Located on the East coast of Peninsular Malaysia, the project involved the engineering, procurement, construction, installation and commissioning (EPCIC) for the full scope of the early production system in a water depth of approximately 65 metres. The EPCIC comprised of a mobile offshore production unit (MOPU), a floating storage and offloading (FSO) facility, and all interconnecting subsea pipelines.
To meet the project’s tight schedule of 12 months to first oil, Petrofac presented a fast-track delivery model by using existing vessels for the FSO and MOPU conversions. We formed dynamic alliances with our local partners Kencana HL and Bumi Armada for the combined delivery of the EPCIC scope.
Kencana’s mission was to upgrade a retired jack up rig into a MOPU with a gross capacity of 22,000 barrels per day. Petrofac was able to utilise its global procurement expertise to speed up the delivery of components for the MOPU, by airfreighting gas turbine generators from the US in record time. Working in tandem with Petrofac, Kencana delivered the design, fabrication, installation and commissioning of the MOPU in under nine months.
At the same time in Singapore, Bumi Armada was faced with the challenge of converting, supplying and installing the FSO in the SEPAT oil field in just eight months. Extensive vessel refurbishment and life extension efforts resulted in the FSO SEPAT, which has a crude transfer metering system capacity of 14,000 barrels of oil per hour and a storage hull capacity of 500,000 barrels.
The delivery team faced a significant challenge when the soil survey revealed that the SEPAT seabed was unsuitable to rest the MOPU. Petrofac worked closely with PETRONAS to design the best solution. The problem was resolved within 18 days and involved selection of contractor, permit and dredging.
Petrofac implemented a comprehensive HSE management plan to realise an incident-free and injury free execution. The SEPAT offshore safety campaign was launched in June 2011 during the MOPU sail-away ceremony and at the end of the project, we had delivered two million man-hours without lost time incident.
On 1 December 2011, the Petrofac team reached the ready for start-up (RFSU) stage of the project, ahead of the planned schedule. Subsequently, first oil was achieved ahead of schedule in the same month.
This is our first lump-sum offshore EPCIC in South East Asia. To have delivered first oil ahead of schedule is testimony to the combined efforts from Petrofac along with our partners and the keen interest and involvement from PETRONAS.
2011 was a very exciting and rewarding year for all of us here in the SEPAT project. Under strong leadership, we enjoyed excellent professionalism, co-operation, teamwork and understanding amongst us all.