Amec Foster Wheeler was the EPCm contractor for the monoethylene glycol (MEG) facility on Jurong Island, Singapore, part of Shell’s Eastern Petrochemicals Complex, and for the related modifications at Shell’s Pulau Bukom refinery. The refinery modifications were designed to enable the refinery to provide advantaged feedstock to the petrochemicals complex. We also developed the FEED for both of these elements.
Successfully commissioned and in production in November 2009, the 750,000 tonnes per annum plant is one of the largest MEG plants in the world and, as the largest MEG plant using Shell’s OMEGA technology, it is a flagship project for Shell.
Shell Chemicals advises that the plant has the highest yield of MEG from ethylene whilst reducing CO2 emissions, waste products and steam requirements. The plant design incorporates the latest technological developments to reduce its overall carbon footprint.
The HSE performance on the MEG project was a major success story. Together with the contractors we managed, we achieved more than 13.5 million manhours without a lost-time injury. This was a challenging project, with a diverse multi-cultural workforce, mainly from the Southeast Asian region.
We are very proud that our world-class HSE performance was recognised with the presentation of a SHARP (Safety and Health Award Recognition for Projects) Award presented by the Workplace Safety & Health Council in collaboration with Singapore’s Ministry of Manpower.
The heated marketplace gave us a seriously compressed and challenging time line to construct and commission the MEG plant. In fact, at the start the probabilistic model of success was only 10%!
The early procurement of long-lead equipment, including two huge 1,375-tonne reactors and columns, was pivotal to the success of the pre-dressing and heavy lift programme, which was itself instrumental in the success of the project.
Work on the refinery mods touched 50% of the existing live refinery, with all of the challenges that this brings including extensive site work, interfacing with different refinery process units, and limited activity while the refinery was in operation. Achieving the 99-day turnaround, feed out to feed in, without any lost-time incidents is an achievement of which we are particularly proud.
“This was a complex project executed in a difficult economic climate. The joint project team should be rightly proud of its world-class performance and in particular its excellent safety record.”
Geoff Smethills, Project Manager, SEPC-Bukom Refinery Modifications Project, Shell