CCI Gets on Board with Belanak FPSO Project

CCI was proud to participate in Conoco Phillips’ Belanak Project, a new, world-class Indonesia oil and natural gas development that will begin delivering field reserves to growing energy markets in Southeast Asia in 2004.

Fundamental to the Belanak Project is the floating production, storage, and offloading (FPSO) vessel. This barge-like vessel, to be located in the South China Sea off Natuna Island and roughly 200 kilometers northeast of Singapore , will be one of the most sophisticated production facilities in the world.

FPSOs offer an innovative alternative to traditional gas processing. Instead of transporting gas from an offshore facility to land for processing, the FPSO allows processing to take place on the floating vessel.

The Belanak FPSO will be the second offshore liquefied petroleum gas (LPG) facility on a floating vessel and the first in the Asia Pacific region. It involves construction of one of the most complex processing systems ever installed offshore. The vessel is expected to produce 7,800 standard barrels per day of butane and 14,700 standard barrels per day of propane plus 430 million standard cubic feet of gas and 100,000 barrels of oil.
CCI supplied seven anti-surge control valves for the FPSO vessel’s LPG unit. These valves are considered the most important control valves on the FPSO because they protect over $20 million worth of compressors. Stringent specification requirements demanded that CCI implement specialized design and control measures, and the valves were custom designed for each application.

For example, while carbon steel is a typical material for these types of valves, CCI used duplex stainless steel for the FPSO valves since this extra-hard material is the best substance available for preventing corrosion in the valve body and bonnet. Corrosion is a significant concern on the FPSO unit because both the highly acidic fluid it handles and the saltwater contribute to corrosion. The duplex material, however, should allow the valves to resist corrosion even when exposed to a salt-air environment.

CCI’s valves were also created to achieve repeatable Class V super-tight shutoff, made possible by the pneumatic actuator providing thrust of over 500 pounds per linear inch. Preventing leakage and boosting overall efficiency, this tight shutoff translates directly into operational cost savings for the FPSO.

Another special feature of the valves supplied by CCI is their fast stroke speed. The valves were designed to stroke in less than one second under trip conditions and less than two seconds in modulation. This stroke speed allows the user to run the compressor close to the surge line for increased efficiency.

Finally, designed with 10 to 16 pressure-reducing stages, the valves feature CCI’s unique DRAG® technology for superior velocity and noise control to eliminate vibration and the possibility of mechanical failure.

Those with the Belenak Project were so pleased with CCI’s performance during the five months of contract execution that they awarded CCI the Belanak Quality Supplier Initiative (BSQI) Supplier of the Month Award for March 2003. According to Mike Zimmerman, Belanak FPSO Project Engineer Topside Valves, “CCI’s handling of drawings, data, and procedures was excellent. During the factory acceptance test (FAT), CCI committed the needed resources to ensure successful completion and delivery.” The Belanak Project also acknowledged CCI’s professionalism, adherence to a tight production schedule, and its willingness to go the extra mile during the FAT period.

In addition, CCI received the BSQI Gold Award for its outstanding performance throughout its scope of supply. The Belanak Project awarded CCI the highest marks in its six performance criteria categories: on-time delivery; high quality; zero cost growth; a commitment to Health Safety Environment (HSE); efficient documentation, information management, and service; and relationship management.

Published in Solutions Winter 2003