The Manifa program will support Saudi Arabia's plan to raise production capacity beyond the 12.5 million b/d from just above 11 million b/d. Manifa project will have a capacity to process 900,000 barrels/day crude oil, 120 million cubic feet of associated sour gas and 50,000 b/d of condensate.
The Manifa Project is both an Offshore and Onshore development. The Manifa Field is located in shallow waters and the development involved the construction of 27 drilling production islands and 2 water injection islands linked by a Causeway to the new Onshore Processing Facilities. The scheme also includes the construction of associated pipelines and a water supply system.
The Arabian Heavy crude will be exported from Aramco's Al-Juaymah and Ras Tanura terminals, while the gas and the condensate will be processed at the Khursaniyah gas plant, which is being expanded as part of the Manifa program.
Engineering and Construction
The first of the major LSTK packages was awarded to Jan de Nul to contruct the drilling islands and causeway, and J. Ray McDermott to to engineer, procure, construct, install, hook-up and commission the Manifa Field Facilities.
The Causeway Package was the first Lump Sum Turn Key (LSTK) contract awarded for the Manifa Programme. The scope of this project included the design and construction of 41km of main causeway and associated lateral secondary causeways to provide vehicle and service access to 25 drilling/production islands and two water injection islands. The works included bridges and culverts, dredging works, berthing areas, roll-on/roll-off facilities and the partial demolition and clearance of existing subsea pipelines.
The causeways support a roadway and facilities/zones for the future installation of pipelines, electrical cables and associated facilities. The form of construction is sand fill with armour protection and surfacing for the causeway, while the island construction is sand fill with armour protection and a compacted, bladed island surface.
The construction of the causeway also included a 2.4km long bridge at the southern end of the main causeway together with five short (180m) bridges and eight banks of culverts spaced along the causeways. Dredging works were carried out to provide access channels for vessels, shore approaches for cables and subsea pipelines, subsea pipeline crossings of navigation channels and borrow areas for the collection of sand for reclamation. Berthing areas were constructed to the causeway to accommodate Saudi Aramco vessels, including quayside and fixed ro-ro ramps.
Manifa Field Facilties
J. Ray McDermott was awarded the package to engineer, procure, construct, install, hook-up and commission the Manifa Field Facilities. The scope of works included the fabrication of platforms, with a combined weight of over 16,700 metric tons.
The project also includes modification work including design, procurement, installation, hook-up and commissioning of communication packages on 26 existing platforms.
Manifa Crude Processing Facilties
A Feed and Project Management Contract (PMC) was awarded to Foster Wheeler in November 2006. Under the contract Foster Wheeler's scope of work included the development of front end engineering design for the Central Process Facitlies, Utilities and Cogeneration packages, ordering of long-lead equipment, coordination of FEED across the all project packages and the development of the bid final package for the engineering, procurement and construction ( EPC) phase.
The key EPC contracts for the onshore facilities were awarded to SAIPEM (Snamprogetti) for the Central Processing Facilties package, JGC Corp. for the Utilities package and Tecnicas Ruenidas for the Cogeneration package. The telecommunications package was awarded to Sumitomo Corp.
The Manifa Crude Processing Facilties has a production capacity of 900,000 barrels/day and comprises of 3 gas oil separation trains (GOSP) with a capacity of 300,000 barrels each, gas hydration, crude inlet manifolds and flare gas system
The Cogeneration Facilities include a Combustion Gas Turbine Generator (CGTG), Heat Recovery Steam Generator (HRSG) and Steam Turbine Generator (STG). Tecnicas Reunidas, the EPC Contractor for this package also contracted Foster Wheeler for the design and supply of two heat recovery steam generators (HRSG) and two package-type steam generators