EPC02, BLOCK B, Maharaja Lela South Project · 2017-05-30 · • Replacement and decommissioning of 5 km of 18” CS by 18” CRA-clad on the existing 85 km export pipeline, including

EPC02, BLOCK B,Maharaja Lela South Project

CONVENTIONAL PROJECT

Introduction

The Maharaja Lela field is located in Block B, approximately 50 km

offshore Brunei, at a water depth of 65 m. Total E&P Borneo B.V.

(TEPB) has an ownership stake of 37.5% in the field, in partnership

with Shell Deepwater Borneo Limited (SDBL) and PB ExPro (PBE),

whose interests in the field are 35% and 27.5% respectively.

Operatorship of the field is assumed by Total E&P Borneo B.V.

Further expansion and development of the Maharaja Lela field was

executed through the Maharaja Lela South (MLS) project for which

SapuraAcergy was entrusted by TOTAL E&P Borneo B.V. to perform

the entire offshore installation scope of work.

Project Name : EPC02, Block B, Maharaja Lela South project

Location : 50km offshore Brunei

Client : TOTAL E&P Borneo B.V.

Project Type : Engineering, Procurement, Construction and Installation (EPCI)

Water Depth : Approximately 65m

Date Awarded : January 2014

Date Completed : October 2015 (Mechanical Completion)

Vessel Utilised : Sapura 3000 and other marine spread

Scope of Work : • Transportation and installation of a new wellhead platform and tie-in to the existing pipeline system• Decommissioning and replacement of a section of the existing export pipeline • Installation of new CRA pipeline with associated tie-ins• Replacement and installation of a new riser• Installation of a subsea structure at the Wye tie-in location• Pre-commissioning

Project Overview

The Maharaja Lela field is developed via two existing offshore platforms (MLJ1 and MLJ2). Produced effluents from the two platforms are transported through an 18” multiphase pipeline to the onshore processing plant (OPP) where the effluents are separated. Gas is treated and sent to Brunei LNG (BLNG) whereas liquids are sent to Seria Crude Oil Terminal (SCOT) for export.

The Maharaja Lela South project is an extension of the Maharaja Lela field. SapuraAcergy was awarded the Engineering, Procurement, Fabrication, Transportation, temporary Decommissioning and Offshore Installation Works for the Maharaja Lela South project, associated with the installation of a new wellhead platform (MLJ3) and tie-in to the existing pipeline system, the replacement of a 5 km section of the existing 85 km of 18” export pipeline.The new MLJ3 platform and bare line pipe (18” CRA clad) were free issued by Total E&P Borneo B.V.

SapuraAcergy’s detailed Scope of Work:

• Transportation and installation of the new MLJ3 wellhead platform (jacket 1125 mT and topside 1567 mT).

• Installation of a new section of 5 km x 18” CRA-clad pipeline tied back from MLJ-3 to the existing MLJ-1 OPP export pipeline.

• Replacement and decommissioning of 5 km of 18” CS by 18” CRA-clad on the existing 85 km export pipeline, including de-burial and pipeline cutting works.

• Installation of one subsea structure with protection frame at WYE location.

• Replacement of the existing MLJ-1 riser with a CRA-clad riser.

• Cleaning, transportation and disposal of demolished riser and subsea spools.

• Above water recovery of the existing 18” export pipeline to allow the subsea tie-in to the existing pipeline system (18” welded flange).

• Installation of 5 units x 18” subsea spools including one 18” valves spool (saturation diving works).

• Pipeline system pre-commissioning including flooding, cleaning, gauging, hydrotesting, dewatering and nitrogen packing.

• Installation of temporary facilities in OPP for water treatment and disposal during the temporary de-commissioning of the existing MLJ1 pipeline and re-commissioning of the new pipeline system.

Project management, detailed engineering and procurement for the Maharaja Lela South project was delivered by a team of almost 80 dedicated personnel in SapuraAcergy’s head office in Kuala Lumpur. Major services that were successfully subcontracted include onshore fabrication services (subsea Wye structure, tie-in spools, new riser), pipeline anti-corrosion and CWC coating, offshore pipeline welding, diving services, onshore and offshore pre-commissioning, marine transportation and support vessels spread. The Sapura 3000 versatility was fully utilized in the Maharaja Lela South project for delivering heavy lifting, pipe-laying, subsea construction works, davit lift recovery and pre-commissioning support. The vessel was also equipped with an integrated Saturation and Air Diving System to support all subsea tie-in and riser replacement scope of work.

Project Challenges

The Maharaja Lela South project was the first project for SapuraAcergy and the Sapura 3000 in Brunei. Among the outstanding offshore achievements in this project were the successful above water recovery of the existing 18” pipeline at CRA/CS tie-in, the safe replacement of the existing 12” riser on a live gas platform (MLJ1), and the management of 24-hour simultaneous remote operations from the Sapura 3000 to multiple offshore unmanned facilities (MLJ1 and MLJ3 platforms) to perform hook-up and pre-commissioning works.

These achievements, in combination with the seamless execution of all diving works, permitted the safe and timely completion of all works within the 25-day planned shutdown window, one of the key project objectives. With the greatest commitment to safety from both SapuraAcergy and the Total E&P Borneo B.V. project teams, the Block B − Maharaja Lela South project was successfully completed in October 2015 with ZERO LTI after 109 days of operations in the field and 630,000 overall project man-hours.