Client
PETRONAS Refinery and Petrochemical Corporation – Utilities and Facilities Sdn. Bhd. (PRPC-UF)
Location
Johor, Malaysia

PETRONAS Refinery and Petrochemical Integrated Development (RAPID)

Petroliam Nasional Berhad (PETRONAS), Malaysia’s national oil and gas company, is developing the $27 billion Pengerang Integrated Complex (PIC) in Johor, Malaysia – one of the largest of the kind in the world constructed at a single time. At the heart of PIC is the Refinery and Petrochemical Integrated Development (RAPID) project with a 300,000 barrels-per-day (BPD) refinery and a petrochemical complex with a combined 3.609 million metric tons-per-year production capacity. Associated PIC facilities include a 1,220 megawatt cogeneration plant, 3.5 million metric tons-per-year regasification terminal, deep water terminal, air separation unit and raw water supply. Fluor, in a joint venture with Technip, is performing engineering, procurement, construction management and commissioning of the Utilities, Interconnecting and Offsites (UIO).



Client's Challenge

The Pengerang Integrated Complex is the largest project ever undertaken by PETRONAS and the largest single construction project in the country of Malaysia. It will occupy an area of approximately 6,242 acres and require an estimated 70,000 craft workers at peak.

The various process units are being executed by numerous contractors based in Malaysia, Taiwan, China, Japan, India, South Korea, Spain and Italy with a workforce originating from over 40 nations.



Fluor's Solution

As the lead of a joint venture with Technip, Fluor is leveraging its worldwide network of highly-qualified local, regional and international resources to execute the engineering, procurement, construction management (EPCM) and commissioning services of utilities, interconnecting and off-sites at the complex.

These works are being lead from a project office established in Kuala Lumpur, Malaysia, with Fluor’s engineering and procurement services being performed from its Manila, Philippines execution center. In addition to leveraging Fluor’s technical experts around the globe, the project is benefiting from the wealth of UIO experience developed in Manila over the last 15 years.

The UIO alone is a megaproject with a scope that includes: central utilities plant; 780 km of piping; 6,300 km of electrical and instrument cabling; a 15,000 person workers village; field erected tanks; 600,000 cubic meters of concrete including 41 km of main storm water drainage – which exceeds 35 m wide at the outfall to the sea; 70 km of underground firewater distribution piping; and more than 70 buildings including two main control buildings, laboratories with more than 1,400 pieces of equipment, fire stations, electrical substations, operator shelters, warehouses, and chemical storage. The scope also includes numerous instrumentation and controls including: distributed controls system supporting over 13,000 I/O points; site-wide telecommunications systems; plant security and surveillance systems; and site wide IT networks.

A Fluor-Technip consortium is also performing Program Management Consultancy services for RAPID since 2013.



Conclusion

PIC is a keystone project in the Malaysian Government's overall Economic Transformation Programme (ETP). It will position Malaysia to capitalize on the growing demand for energy and petrochemical products in Asia as well as further diversify the PETRONAS portfolio beyond upstream oil and gas and into refined fuels and high value petrochemical products.

Fluor is proud to be a trusted partner in this vital project for economic development of Malaysia.