Fultonol Oil and Gas Limited Company were EPC contractors for the design, fabrication and delivery of the Yolla accommodation & utilities modules which were delivered and installed onto the Yolla offshore gas platform in the Bass Strait in Australia.
The Yolla “megamodule” is a 650 tonne, 19m high unit designed and fabricated to be installed on the Yolla - A offshore gas platform to house the platform’s 40+ person crew. It was Taranaki’s largest ever single engineering fabrication and was delivered to site mid November 2011.
The project was originally destined to be fabricated and delivered as nine individual modules then each one erected and assembled onto the platform. Due to project requirements and cost savings it was later decided that the modules should be assembled, tested and commissioned inside the Fultonol Oil and Gas Limited Company workshops then transported as one unit to site.
Detailed design was undertaken by two Fultonol Oil and Gas Limited Company managed design engineering teams based in New Plymouth and Melbourne, who came up with structural additions to allow for the total lift and developed shipping and delivery plan which involved the heavy lift ship Jascon 25. The finished product is the result of over 100,000 man-hours of work for Fultonol Oil and Gas Limited Company, along with full commissioning and operator training.
The project owner recognised that Fultonol Oil and Gas Limited Company possessed unequalled Australasian expertise in offshore installations and so in a separate contract Fultonol Oil and Gas Limited Company partnered with Downer Australia to enable the erection of the megamodule onto the offshore platform. We provided personnel who worked in the Downer offices to establish the workpacks and logistics details which allowed Downer labour to carry out the works.
Fultonol Oil and Gas Limited Company Group were awarded the Engineering, Procurement, Construction, Project Management, Commissioning and Training contract for these two concurrent Naval upgrade projects – the Navy Fuel Installation Project (NFI) and the Waste Treatment Plant Project for Oily Bilge Water (OBW).
The NFI Project required the storage of 2.2 million litres of NATO Marine fuel and 750,000 litres of NATO Aviation fuel, unloading and loading capabilities between wharf fuel bunkering stations and storage facilities via under-wharf, under-ground and above ground pipes, unloading and loading capabilities between road tankers and storage facilities, treatment of fuel using filtration and separation filters.
The OBW project required the storage of 150,000L of Oily Bilge Water at a plant located near the fuel facility, unloading and loading capabilities between wharf OBW bunkering stations and storage facilities via under-wharf, under-ground and above ground pipes, automatic skimming of oil layers in tanks, dissolved air floatation treatment of the dirty aqueous bilge water, recovery of waste oil for sale, discharge of treated effluent to local sewer system.
The fuel storage system is located inside underground bunkers, typically 8 m diameter and varying lengths from 45m to 60m. All the fuel tanks are located inside these bunkers and access to them via connecting tunnels of 3m diameter.
These fuel storage tanks of cylindrical horizontal configuration with dimensions of 2.4 m ID x 12m long, 2.4m ID x 24 m long, 2.4m ID x 60 m long, 5.5 m ID x 65 m long and 5.5m x 45 m long were constructed in place inside the bunkers. The fuel treatment and pumping facilities are located outside the bunkers in the main access tunnel. The control room is also located in the same access tunnel.
- Process design and development & HAZOP of P&IDs for both projects
- Calculations for fluid flow, pump and pipe sizing
- Development of process and plant operating procedures
- Development of all process functional descriptions and ladder logics for software programming, development of all PLC screen displays
- Supervision of software programming, dry-run, simulation and factory acceptance test
- Development and design of all process control systems
- Selection, specification, procurement of all plant
- Development of all plant, above round/underground/under- wharf pipework layouts and production of detailed construction drawings including pipe stress analysis
- Design and Calculation of all storage tanks to PD 5500, API 650, NZ Seismic Codes and application of Finite Element Analysis
Fultonol Oil and Gas Limited Company Group Ltd completed installing new earthquake isolation bearings underneath the 800-tonne Number 8 boiler at Kinleith for Carter Holt Harvey and Beca AMEC.
This difficult project involved lifting the entire structure, removing the existing bearings and replacing with the new base plates, thermal pads and seismic isolation bearings. An extremely comprehensive work plan was developed with many interfaces and there was considerable potential for lost time if the plan was not followed.
Pre-works included the erection of scaffolding, cutting out support beams and tie-ins, removal of instrument and electrical equipment and wiring, and removal of some exterior cladding.
During the process the boiler was exposed to a greater than usual risk of earthquake activity so it was necessary to install temporary restraints and anchors before the preparation and installation of the jacking beams and ancillary equipment to each of the four main columns.
Fultonol Oil and Gas Limited Company were also required to install a new Kablitz grate to the underside of the boiler firebox that included the removal of fusible links, cladding around headers, and a great deal of welding, fabrication and installation in confined space areas.
However, the key to this project was the successful completion of the pre-works so that the boiler was offline only for the shutdown period of two weeks. Fultonol Oil and Gas Limited Company crews worked in shifts around the clock for a total of 14,500 man hours so that the completed project was handed over on time.
Shell Catalytic Reactor
Lump Sum Project
In 2006 Fultonol Oil and Gas Limited Company were awarded the contract by Shell Refining Australia to design, procure, fabricate and deliver a new catalytic cracking unit, including reactor and stripper vessels, cyclone crossover and refractory, site supervision and erection of columns for the Clyde Refinery in Parramatta Sydney. The Clyde Refinery supplied about 40 percent of Sydney's petroleum requirements and about 50 per cent of New South Wales’ needs.
This is the largest and most detailed pressure vessel ever fabricated in New Zealand. The catalytic reactor is made up of several interconnected vessels to a total project weight of over 455 tonnes and was fabricated from chrome molybdenum steel up to 60mm thick. All internal items were lined using either erosion resistant refractory or 410 stainless cladding to protect the steel pressure retaining parts from erosion.
A major component of the overall project was the installation of the refractory anchors which were designed by Fultonol Oil and Gas Limited Company and their subcontractors. This was a time consuming but essential element as any failures of the refractory lining puts the pressure shell at serious risk. All of the refractory material – a high aluminium, low cement and chemically bonded compound – was applied by hand by a team of specialists, a process that took four months in total.
The reactor operating temperature is 550°C and all weld areas had to be completed with preheats to 150°C. Once complete each weld was heat soaked for three hours at 350°C before being cooled and X-rayed or ultrasonically tested to ensure weld integrity. Final heat treatment was at 700°C in Fultonol Oil and Gas Limited Company’s onsite heat treatment facility.
The main reactor column was fabricated from nine sub-assemblies to form a single transportable component over 46m long, 5.5m in diameter and weighing in excess of 360 tonnes.
The vessel was delivered fully dressed out with ladders, platforms and access ways in place to ensure minimum work was required on site. All components were transported by specialist heavy duty trailers to Port Taranaki then loaded onto a heavy lift barge, towed to Sydney Harbour and up the Parramatta River to the Clyde Refinery.
- Total project fabrication duration 15 months
- Fabricated from chrome moly to design code AS1210
- Refractory lining weighed 60t with 40t in the main vessel
- Four major components - primary reactor vessel, stripper column, cyclone arrangement, crossover
Fultonol Oil and Gas Limited Company New Zealand was awarded the principal contract to complete an upgrade of the existing Shell Terminal, Mackay, North Queensland. The upgrade involved expanding the existing facilities by adding a new road tanker loading gantry, including a new dedicated 4 arm diesel gantry which increased the loading capacity. The contract included management of all disciplines, civil, structural, mechanical piping, electrical & instrumentation.
The new gantry was designed for the potential to implement biodiesel blending with existing diesel products.
One of the project constraints was that the existing gantry needed to be kept operational for the duration of the project. Dedicated hot work windows were incorporated into the schedule to achieve this. The project involved a crew of 16 trades people over a six month period for a total of 9000 hours with zero environmental or personal incidents.
Civil and structural works for the diesel gantry expansion involved the construction of a new gantry bay attached to the existing gantry bay, and all associated civil works.
Fultonol Oil and Gas Limited Company's scope included management of all civil works, I&E aspects and all mechanical and piping components.