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MUSTANG ENGINEERING
02 - CONTENTS
02 - CONTENTS
03 - OUR APPROACH
04 - PROJECT MANAGEMENT
05 - HSEQ
06 - FACILITIES
10 - PROCESS
11 - MECHANICAL
12 - STRUCTURAL
14 - FLOW ASSURANCE
15 - CONCEPT SELECT
December 2008
Mustang exhibiting at Deep Offshore Technology
Conference, Perth.
04 - PROJECT MANAGEMENT
Our Expertise
Project Management
Mustang can provide specialist Project Management services covering
a full range of project types including study managers, senior design
and engineering managers, procurement specialists and construction
managers.
PSM can help project managers work with any Owner's Stage Gate
process. Working closely with project managers and project directors,
Mustang adds the support necessary through our own Stage COACH®
methodology to make your unique project a success.
Project Delivery
• Field development studies
• Concept selection and feasibility studies
• FEED projects
• Detailed design
• Project engineering and management
• Construction management
• Procurement services
• Safety and risk assessments
• Structural integrity and re-assessment
HSEQ - 05
Our Expertise
Total Quality Management
Mustang Australia has Det Norske Veritas HSEQ certification for Quality
Management, Environmental Management and Safety Management as
follows:
HSEQ Communications
Wood Group and Mustang are commited to improving communications
in HSEQ by:
Our Expertise
Facilities Our project teams integrate with our clients to best identify project
drivers and focus the engineering effort where it can provide maximum
value. With access to the worldwide engineering expertise of Mustang
and close working relationships with other Wood Group companies we
can provide complete facilities development and integrated Subsea
completions, Pipeline and Offshore/Onshore Facilities.
• Field development
• Fixed platforms
• Onshore terminals and infrastructure
• Systems engineering
• Rotating equipment
• FPSO / FSO / MOPU topsides design
• Brown-field and green-field developments
• Design review, audits and due diligence
• Project leadership in field development
• Operability, maintainability and reliablility
• Constructability
• Risk management
• Asset management
• Cost estimation
Project Delivery
Mustang integrates design disciplines with a range of other engineering
functions such as:
.......................................................................................................................................................................................................................................................................................................................................................................................................................
NEXUS ONGC Inpex
Crux FPSO FEED Mumbai High North Platform Ichthys Option C Pre-FEED
Timor Sea, Australia India Browse Basin, Australia
.......................................................................................................................................................................................................................................................................................................................................................................................................................
Nexus Energy Limited is the operator of The original Bombay High North (BHN) The Ichthys Field is part of offshore permit
the Crux Gas Field (Block AC/P23) in the platform, a 30 year old 7-storey steel area WA-285-P, located in the Browse Basin
Timor Sea. The block is located in Australian structure, was an oil and natural gas on theNorth West Shelf of Western Australia,
waters and is about 150 km off the coast of processing complex which had a capacity of approximately 440 km north of Broome.
Western Australia. The field water depth is 80,000 bbls/day of crude production.
170 m. The permit encompasses an area of
It was connected to the unmanned NA approximately 3,100 km² with water depth
The Crux Development consists of two drilling platform, the BHF platform and the ranging from 90 to 340 m. Exploration
subsea production wells and three subsea MNW platform via interconnecting bridges. programs have indicated the presence of
re-injection wells. A Floating, Production,
The MHN facility separated oil and gas significant natural gas and condensate
Storage and Off-Loading (FPSO) vessel
carried by risers from the nearby NA and volumes in the permit area.
will recover and store the condensate from
the production wells and re-inject gas into BHF platforms, and sent them onshore by
INPEX is assessing the potential to transport
the reservoir via the re-injection wells. The separate undersea pipelines.
natural gas from the Ichthys field to a
facility was designed for 660 MMSCFD On 27 July 2005, due to a ship impact Liquefied Natural Gas (LNG) plant via a
(Normal) and a peak gas reinjection rate accident and subsequent fire, the BHN subsea gas pipeline. The Ichthys Field
of 900 MMSCFD and nominal condensate platform collapsed into the sea. comprises two gas condensate reservoirs:
production of 25,000 bbl/day. an upper reservoir (Brewster Member) and a
The flow of oil and gas from the affected lower reservoir (Plover Formation).
The integrated FPSO development included wells was shut down through the
subsea production wells, subsea gas sub-surface safety valves, preventing a large Mustang Developed a wax management
injection wells tied back to an FPSO via area of pollution. strategy for this field.
flowlines and flexible risers. The well stream
fluid is separated, stabilised, and stored on The concept for the revival of Key Flow Assurance Involvement:
board the vessel for subsequent export via production from the MHN Field is a
The purpose of the wax management
off-take tankers. Produced gas is processed traditional inter-linked fixed steel jacket and
strategy was to illustrate that wax mitigation
and reinjected into the reservoir with minimal topsides arrangement consisting of the new
and remediation for the upstream facilities
flaring. A small quantity of produced gas is MNP (Process/Riser) and MLQ
can be managed. Issues associated with wax
consumed as fuel gas for onboard systems. (Living Quarters) platforms, and an
that may be a problem for topsides process
Produced water is treated to the required additional remote flare (MNF).
and onshore facilities were identified and
specification and discharged overboard. The strategies developed, based on analogous
Key Facilities Involvement:
FPSO also provides utilities, living quarters, projects for other waxy condensates. The
safety systems and other ancillary systems. Mustang developed a mulit-platform concept key flow assurance issues were:
design to maximise safety, with a seperate
Key Process Involvement: • Fluid Characterisation
LQ platform bridge linked to Utlitiy and
• Topsides process design included Inlet Production platforms
• Wax Characterisation
Separation, TEG Dehydration, a
The number of pipelines linked to MHN was
Turboexpander/Recompressor for gas • Wax Deposition Rate Modelling
a major constraint, as was the need to tie in
dewpointing,
to the remaining functional platform • Cooldown
• Compression systems (Off Gas, Booster
• Wax Management Strategy
and Re-injection Compression) and
Condensate Stabilisation. • Laboratory Testing Programs
• Optimization of condensate recovery given
the power and compression constraints.
• Production of PFDs & UFDs as well as
Equipment sizing for the FPSO.
08 - FACILITIES
.......................................................................................................................................................................................................................................................................................................................................................................................................................
The Zhuhai LPG Phase II Expansion Project Blacktip is a gas field development located in Mustang Engineering Pty Ltd was contracted
intends to replace the LPG storage and the Joseph Bonaparte Gulf offshore Western by ONGC to provide feasibility engineering
handling currently provided by a VLGC with Australia. The facilities include an offshore consultancy services for the conversion of
underground storage and onshore processing wellhead platform (WHP), subsea carbon the ONGC jack-up drilling rig Sagar Samrat
facilities. This will allow the removal of the steel trunkline and an onshore gas plant. to Mobile Offshore Production Unit (MOPU).
VLGC “Gas Bauhinia” which is presently
ENI Australia engaged Mustang Perth to The future intent is to equip the Sagar
permanently moored alongside the terminal
carry out Post-FEED engineering for the Samrat to service the western operations
importing jetty. The existing Terminal was
offshore wellhead platform. The platform area of ONGC in water depths ranging
constructed by JOVO ARCO during 1998 and
consists of a four leg jacket in 50m of water from 60 to 85m. The MOPU conversion
commissioned in 1999. It was designed to
with unmanned topsides and a helideck. will include all of the utilities and support
handle the import and storage of refrigerated
equipment required to accommodate the
propane and butane as well as the distribution The Mustang scope was to confirm primary operating crew and production equipment
and export of pressurised LPG (in River steel sizing from the FEED analysis and capable of carrying out the new operating
Barges, Trucks and LPG Bottles). The terminal perform further analysis work that was not duties.
consists of a jetty with four (4) refrigerated part of the FEED scope.
LPG Loading Arms, four (4) pressurised LPG A defined support frame or deck will be
Loading Arms, and an onshore plant containing The software packages SACS and USFOS provided which will support the initial process
four (4) pressurised storage, eight (8) Tanker (non linear) were utilized by Mustang to facilities to be installed. It will be configured
Bays and a small LPG Bottle Filling Plant. perform the following analyses on the such that it will readily accept facilities of
structure: a similar size and weight or modifications
The Storage Option chosen for further
Key Structural Involvement: to the basic production plant whenever it
development in the FEED was Underground
becomes necessary to relocate the facility
Storage Caverns (capacity of each cavern • Inplace (topsides and jacket) to another field.
to be 100,000m3). BP requested Frontier
Engineering Solutions (now Mustang • Inplace spectral fatigue Facilities will be designed to achieve
Engineering) to proceed with a FEED Study separation of the crude for export to a tanker
• Inplace seismic
for the Zhuhai LPG Phase II Project. Frontier and moored at a SPM and export of gas
worked with various LPG Storage Contractors • Pushover to existing facilities or to a shore based
to determine the preferred storage option, in terminal.
addition to the need to upgrade and expand • Boat impact
the existing LPG Terminal. Mustang’s Involvement:
• On bottom stability
Key Facilities Involvement: Mustang was commissioned by ONGC to
• Floatation, lift and upending provide engineering and consultancy
Further to two site visits, various storage • Static lift (topsides and jacket) services for work including:
options were developed:
• Transport (topsides and jacket) • Specifications and data sheets for major
• Spheres and bullets equipment
• Refrigerated surface storage • Load-out (topsides and jacket)
• Underground storage caverns • Preliminary P&ID’s and line list
• Pile design
Each of these options was developed in some • Equipment layouts
Mustang also assisted ENI in liaisons with
detail, covering tankage, pipework, structural, • Cost estimate
the installation contractor and produced a
electrical, instrumentation and contrast and
primary steel MTO for the platform. • Plan
safety aspects. The underground storage
caverns were found most suitable for BP’s LPG
• Equipment list
strategy and considerable work was carried out
during the FEED Phase to finalise schedule, • Various technical notes and studies
costs and all relevant safety aspects.
FACILITIES - 09
.......................................................................................................................................................................................................................................................................................................................................................................................................................
BHP Billiton Ravensthorpe Nickel Project The Julimar and Rosella Fields are located Mustang has been involved in the Gorgon
(RNP) includes nickel/cobalt bearing laterite off the North west coast of Australia, in design development including the subsea
ore deposits, an ore processing plant, the region of the Varanus Island, on which well control via electo-hydraulic umbilicals up
reagent facilities/plants, and associated Apache has an existing processing facility. to 170 km offshore.
infrastructure. The fields are being developed to meet
future gas sales of up to 600MMscfd. The distance of the Gorgon and Jansz
The ore deposits and processing plant are The field development consist of a gas gas reserves from the gas plant and 50
located approximately 35 km east of the gathering system exporting untreated year design life required a control system
town of Ravensthorpe in the central south production fluids to either an onshore or technique that significantly extends current
coastal region of Western Australia. shallow water platform for processing. The control system and communications
Julimar and Rosella Fields fluids contain technology.
The RNP ore processing plant makes use
of established process steps to upgrade, high concentrations of carbon dioxide and Mustang developed the Barrow Island
extract, purify and produce nickel (and nitrogen, making them unsuitable for sales LNG Plant to offshore subsea umbilical
cobalt) in the form of an intermediate mixed gas without treatment. link and interface including manufacture,
hydroxide product. The mixed hydroxide Mustang’s Involvement: construction, testing and commissioning
product is shipped in containers to the specifications for onshore electrical,
Yabulu Nickel refinery in North Eastern Mustang reviewed the potential technologies hydraulic and fibre optic communications
Queensland. available for the removal of carbon dioxide including the challenges of installation within
and nitrogen from natural gas to produce a Class A nature reserve.
Key Process Involvement: a sales gas capable of meeting the entry
specifications for the Dampier to Bunbury Key Electrical Involvement:
• Designing & implementation of process
isolations under PTOs, PTWs and CSEs Natural Gas Pipeline. • Concept selection of onshore controls
• Ensuring successful energising and wet Mustang’s work included: • LNG plant interfaces
commissioning of critical path systems • Review of the available technologies for • Subsea unbilical interfaces
• Involved in achieving commissioning carbon dioxide and nitrogen removal at any
tollgate compliance through process scale. Included in this was production of a • Construction planning support in
commissioning of critical path systems description of the available technologies environmental sensitive location
to allow an understanding of how each
• Involved in seamless handover of various • Onshore spares philosophy
operates and the utility requirements
process systems to operations and required for operation. • Installation and testing specfications
assisting in production ramp-up
• Review of the available technologies for
suitability in meeting the required sales
gas specification, with advantages and
disadvantages of each was also provided.
• Benchmarking each technology to
determine whether any similar plants are
currently in operation worldwide.
• Review of the suitability of the technologies
for both offshore and onshore locations,
considering layouts and weight estimates.
• A review of the ability to optimise the
processing plant capacities through
investigation of slip-streaming quantities of
the produced gas.
10 - PROCESS
Our Expertise
Our process team considers the entire design of the client’s facility from
the reservoir onwards. They interact closely with the other engineering
disciplines and can facilitate any stage of development through all
phases of a production asset, including;
• Feasibility Studies
• Concept Design
• Front End Engineering Design (FEED)
• Detailed Design
• Operational Troubleshooting
• De-bottlenecking & Asset Expansion
Project Delivery
• Separation, including handling of slugs, wax, hydrates, sand,
asphaltenes, etc.
• Gas dehydration
• Acid gas treatment
• Gas purification, including cryogenic processes
• Gas compression
• Condensate dewatering
• Condensate desalting
• Condensate stabilisation
• Produced water treatment
• Corrosion and erosion
• Start-up, shut down and dynamic control
• Blowdown and operational flaring
• Seawater handling
• Piping design
• Plant layout
Our Expertise
The Mustang team integrates with the client to identify project drivers
and needs. Mustang can provide complete coverage of Mechanical and
Piping needs.
• Safety by design
• Good maintainability
• Optimum constructability
• Careful selection of materials
• Understanding of Design Codes
• Emissions restriced on an ALARP basis
• Cost-effective selection of drivers
• Maximising efficiency where appropriate
• Minimising risks
Project Delivery
• Design of equipment packages
• Rotating Equipment package design
• Onshore and offshore plant layout
• Pipe stress and piping design
• Pressure Vessel design and verification
• Heat Exchange design and verification
• FPSO and FSO Topsides Design and Layout
• Offshore fixed platform design
• Minimum facilities platform design
• RAM (Reliability, Availability and Maintainability) Analysis
• Independent Technical Audits of Equipment and Systems
• Pipeline Receiving Stations
• Finite Element Analysis (FEA)
12 - STRUCTURAL
Our Expertise
Our structural design capabilities cover the lifecycle of projects from
conceptual field development work through to the detailed design of
offshore and onshore structures. Mustang understands the challenges
associated with structural design and has an experienced structural
team backed up by a comprehensive software suite. Mustang has
experience with steel platforms of various sizes in the Australian, SE
Asian and Middle Eastern geographies. Whether a field is in a remote
location, deep water, in geotechnical challenging areas, or tied back to
an existing facility, a mature understanding of the structures plays a key
role in determining a technical and economic field development solution.
Mustang is independent of any proprietary technology and is able to
provide an unbiased appraisal of all potential technologies.
• Production platforms
• Well head / minimum facilities platforms
• Lift or Launch installed jackets
• Lift or Floatover installed topsides
• Platform layouts
• Subsea templates
• Onshore processing terminals
Project Delivery
Service Conditions and Pre-Service Conditions (Offshore)
Topsides, jackets, FPSO / FSP, subsea:
• Site/Plant Layout
• Infrastructure Review
• Foundation Design and geotechnical review
• Structural Design of steel and concrete.
ELECTRICAL, INSTRUMENT, CONTROLS AND TELECOMMUNICATIONS - 13
Our Expertise
Working from project inception through start-up and commissioning, the
EICT group uses state-of-the-art software tools to provide a wide range
of engineering services. Whether the project is a grass-roots
installation or involves the modernization of an existing facility, EICT
works to provide technical solutions that support long-term operability
and ease of maintenance.
Software Tools
For IC we can produce most of our work in an integrated engineering
and design database environment. Intergraph’s Smart Plant
Instrumentation (SPI) software is used extensively in the development
of engineering documentation, technical specifications and design
drawings. Most deliverables are developed from within the SPI
environment including the instrument index, engineering calculations,
instrument specifications, instrument installation details, control loop
diagrams and wiring diagrams.
Project Delivery
• Single Line Diagrams
• System Architectural Diagrams
• P&ID Diagrams (instrument & control portions)
• Control Strategy Drawings or Narratives
• Cause & Effect Matrices or SAFE Charts
• Instrument Loop Diagrams
• Hazardous Area Layouts
• Engineering Calculations
• Equipment Specifications
• Cable Block Diagrams
• Equipment Layout Drawings
• Schematics
• Wiring Drawings
• Installation Details
14 - FLOW ASSURANCE
Our Expertise
Mustang Australia works closely with MSi as an integrated team on
many Flow Assurance projects where the expertise of MSi is beneficial.
Flow Assurance work in Australia is currently contracted through
Mustang. This team combines the flexibility and innovation of a small
company with the strength and additional support provided by Mustang
Houston and MSi.
Deliverability
Impedance
• Hydrates
• Waxes and gel
• Asphaltenes
• Sands and scales
Operability/Stability/Integrity
• Transient analyses
• Severe slugging, hydrodynamic slugging
• Startup, shutdown, cooldown, blowdown
• Pigging dynamics
• Process control dynamics
• Specifications of materials
• Corrosion and erosion
• Thermal transient modeling
Project Delivery
Mustang Australia covers flow assurance in all phases of engineering
studies:
• Concept Screening/Definition
• Front End Engineering and Design
• Detailed Design
• Engineering Consultancy
• Operational Support
CONCEPT SELECT - 15
Our Expertise
At Mustang, concept selection work is carried out with a view to providing
the full service EPCM project delivery at a later stage. Mustang has the
horsepower, commitment and passion to support our clients through all
stages of the “gate” processes providing decision support packages at
every step through project sanction, completion and health checks.
Project Delivery
Mustang provides a comprehensive range of concept selection services
including:
• Feasibility studies
• Process / facility definition
• Cost estimation
• Risk assessment
• Layout studies
• Safety / risk assessment
• HAZOP / HAZID
• Hydrate mitigation and control
• Wax deposition
• Comprehensive Flow Assurance studies
• Systems engineering and analysis
• Production planning
• Operations and maintenance
• Project Management
• Brown-field development options.
16 - RISK AND SAFETY
Our Expertise
Risk Management
• Qualitative Risk Assessments
• Quantitative Risk Assessments
• Pipeline Risk Assessments
• FMEA/FMECA
• Functional Safety Assessments
• Safety Critical Elements SCE Identification
Safety Management
• Safety Cases
• Combined Operations Safety Cases
• Emergency Response
• Fire Safety
• Major Hazard Facilities and Dangerous Goods Safety
• Mine Safety
• Storage and Handling Facilities and Dangerous Goods Safety.
• Dangerous Goods Licencing
Human Factors
Maintaining and improving three types of barriers are the focus of
three campaigns of scrutiny:
• Technical integrity
• Process safety
• Human factors
Project Delivery
Mustang provides safety and risk services across all phases of
engineering:
• Concept Screening/Definition
• Front End Engineering and Design
• Detailed Design
• Engineering Consultancy
• Operational Support
ANALYSIS AND MEASUREMENT - 17
Our Expertise
The Mustang Analysis & Measurement Group works across a broad
range of industries providing solution oriented analysis, measurement
and monitoring services. The group is independent of any proprietary
technology and is therefore able to provide an unbiased appraisal of
all potential solutions for our clients by applying the most appropriate
tools for the job.
Project Delivery
Mustang provides analysis and measurement services in all phases
of engineering:
• Concept Screening/Definition
• Front End Engineering and Design
• Detailed Design
• Engineering Consultancy
• Operational Support
18 - PEOPLE AND PROJECTS
People Oriented
• Heart of Mustang – giving back to the community
Project Driven
• Commitment to Continual Improvement through:
asiapacificsales@mustangeng.com
eastcoastsales@mustangeng.com.au
indiasales@mustangeng.com
www.mustangeng.com
MUSTANG ENGINEERING