PROVEN EXCELLENCE

Kutubu Refinery Repair & Upgrade Project

Santos Limited
| Papua New Guinea

Project Overview

Client
Santos Limited
Dates
Dec 2021 to Mar 2024
Location
Kutubu, Southern Highlands, Papua New Guinea
Scope
  • Geotechnical slope stabilisation of earthquake affected zones
  • Crude Oil Storage Tank and transfer Pumps (located at the CPF)
  • 3.2 km cross country Pipeline (AS2885)
  • Integration of Modular Refinery Unit (free issued item)
  • Upgrade and replacements of balance of plant facilities including new Electrical Equipment Room and control system

Following a major earthquake that struck Papua New Guinea (PNG) in February 2018, the Kutubu Refinery ceased production due to ground failures and damage to the production facility. Santos, the plant operator, has since progressed to replace the damaged Kutubu Refinery with a new modular refinery.

The aim of the Kutubu Refinery Repair and Upgrade Project is to reinstate the site civil works, install and integrate a new modular refinery process unit into the existing plant, repair and upgrade the balance of plant equipment, and complete other defined upgrade works to reinstate the refinery as an operating facility.

The project involves tie-in to the existing Central Processing Facility (CPF), supplying stabilised crude to a new crude supply tank and transfer pumps, transfer via a new 3.2km high pressure pipeline to the Kutubu Ridge Refinery. The refinery will process the crude to supply Diesel and Jet A1 product into product storage tanks and delivering to an upgraded truck load out facility.

ROLES & SERVICES

Engaged by Nacap, the EPCM contractor, to deliver:

  • FEED verification and validation, of client engaged consultant, to allow acceptance and transition to detailed design
  • Detailed design for the project scope
  • Technical procurement and expediting of key packages
  • Completions, Commissioning and handover to Santos Operations
KEY CHALLENGES
  • Challenging design and engineering constraints of a multi-terraced site with limited available footprint located in a seismic zone
  • Interfacing with multiple stakeholders to achieve the project objectives within the known constraints
  • Ensuring project change is managed in line with the project’s goals and the client’s strategic objectives
MAJOR ACHIEVEMENTS

Value add engineering with continuation and improvements from FEED, involving significant cost
reduction to geotechnical scope, rationalising civil design and overall improvements to equipment
selection.

QUICK LINKS