MALAMPAYA / Shell Philippines Exploration B.V. (SPEX)

The Malampaya Deep Water Gas to Power project delivers gas from an off-shore gas field to three power plants near the city of Batangas (100 kilometers south of Manila) in the Philippines. The project consists of an off-shore production platform, a 504 km subsea pipeline, and an on-shore gas treatment plant.

The offshore field contains recoverable natural gas reserves of some 2.7 trillion cubic feet and 85 million barrels of condensate. The gas is extracted from 2,200 meters below the seabed, which is at a water depth of 830 meters. This project to extract natural gas deposits from over 3,000 meters below sea level and transport this to a market over 500 kilometers away posed one of the greatest deep-water challenges in the world and required the use of the latest in gas technology and skills.

Gas from five subsea wellheads is transported via two 30 km flowlines to a production platform that sits in shallow water. On the platform the condensate is removed from the gas and stored for retrieval by tankers using a catenary anchored leg mooring (CALM) buoy. Then the gas is compressed for export to the gas treatment plant through the 504 km pipeline.

For the off-shore platform Yokogawa has delivered all safety systems, including an inherent safe high integrity pressure protection system (HIPPS) that contains SIL4 loops and two PLCs controlling the emergency shut down (ESD) and fire & gas (F&G) functions. As it was a requirement of Shell to standardize on one safety PLC type, the safety functions of the Cooper Rolls gas compressors (2x) and the solar turbines (3x) were implemented on a Yokogawa ProSafe-PLC, in close co-operation with the package suppliers. All Yokogawa safety systems are integrated into one redundant safety network. The engineering work station (EWS) includes a FAST/TOOLS application for maintenance override scheduling. Via a redundant ProSafe-COM MULCOM interface, data is transferred via the OPC (OLE for process control) protocol to the DCS.

For the on-shore gas plant, Yokogawa has again delivered all safety systems, including an inherent safe HIPPS that contains the SIL4 loops, two PLCs for the ESD and F&G functions, and four safety systems for burner management control. The safety functions of the solar turbines (2x) are also implemented on Yokogawa ProSafe-PLC. All Yokogawa safety systems are integrated into one redundant safety network. The EWS includes a FAST/TOOLS application for maintenance override scheduling. Via a redundant MULCOM interface, data is transferred via the OPC protocol to the local DCS.

"Delivered as Advertised" award from Shell Philippines Exploration B.V.

Dick Wismeijer, Principal Process Control, Instrumentation and Telecomm Engineer for the project definition and development, had the following to say about the project: "The technical and commercial challenges for the safety shutdown management concept in this project are considerable, with full and unambiguous compliance to IEC 61508/61511 international standards. With the selection of the Yokogawa ProSafe family, we have been able to pursue a truly network based system across various package units. Yokogawa's commitment to embrace open system architecture through the use of OPC provide seamless integration with foreign process automation systems.h Mr. Wismeijer went on to say: "We will integrate information from the safety shutdown management systems with the comprehensive plant-wide process and equipment monitoring and control areas to provide a single operator window to the entire process. We're using satellite communications to link systems on the platform with an on-shore operations center and beyond. We also will use the diagnostic information from the intelligent HART safety transmitters to insure high overall production system delivery availability with uncompromising process safety integrity, setting a new standard of unprecedented uptime. Asset Management Solutions software will be used to configure, calibrate, diagnose and perform long-term predictive maintenance on the project's instrumentation."

The systems have been engineered and built in Apeldoorn (The Netherlands) and in Houston (USA). Commissioning has been handled by the offices in Apeldoorn, Kuala Lumpur and Manila. The entire project was delivered ahead of schedule.

Through this job, Yokogawa received a "Delivered as Advertised" award from Shell Philippines Exploration B.V. as an extra indication of its appreciation for Yokogawa keeping its promises.

SYSTEM DETAILS

System:	ProSafe-PLC, ProSafe-SLS, ProSafe-COM MULCOM and FAST/TOOLS
Total I/O:	6,350
System Configuration:	2 HIPPS systems, 2 ESD systems, 2 F&G systems, 4 BMS systems, 7 package safety systems, 2 EWS, OPC and HART interfaces
Scope:	Engineering, assembly, safety assessment and commissioning. Project execution completely according IEC61508. Advisory capacity during SIL classification