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Valve Techbook 2017

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30 | September 2017 | VALVE TECHBOOK: CASE STUDIES A t the mouth of the Congo River sits one of the world's most modern LNG process- ing facilities, capable of supplying 5.2 mil- lion tonnes of LNG to the global market every year: the $10 billion Angola LNG plant. Approxi- mately 175 km to the southwest, the Kaombo offshore project in Block 32 will include two FPSOs, with a combined oil treatment capacity of 230,000 bbl/d, transferring the associated gas collected back to the Angola LNG facility. Both projects are examples of an investment drive in the Angolan oil and gas industry, and both have relied on PJ Valves (PJV) as a key engineer- ing partner in delivering cost-effective, made-to- order valves in a timely fashion to allow for safe and efficient operation. Angola LNG: A natural evolution Angola first discovered oil in 1955 and became the 12th member of OPEC in 2007. In 2014, it was the second largest oil producer in Sub-Saharan Africa, with only Nigeria producing more. However, it hasn't invested as much into harnessing its natural gas resources and in 2012, 91% of its gross natural gas production was re-injected, vented or flared. This wasted gas resource, along with significant untapped reserves (together totalling 6.8 billion m3 per year), promised a significant source of revenue for Angola, as well as a way to meet more if its own gas needs domestically. As such, the decision was made in 2007 to build one of world's most modern LNG processing and storage facilities, and in 2012 con- struction of the Angola LNG project was completed. However, in April 2014 the facility was unexpect- edly shut down and production paused. The plant subsequently underwent a significant refurbish- ment process due to variations in the gas conditions. Refurbishing valves As part of the refurbishment process, a number of the facility's valves needed to be replaced. First contact came from the client in Septem- ber 2014, a few months after the plant had shut down. The priority was for high-integrity, bespoke valves delivered as quickly as possible to mini- mize downtime. PJV's approach was based on pro- viding advice through its accumulated expertise to ensure the solution was fit-for-purpose rather than simply filling an order according to a specification sheet. PJV quickly supplied supporting documentation to prove the integrity of its valves including reference lists, general arrangement drawings, procedures and type test certificates. Crucially, it was able to manu- facture 10% of the valves early so that the client and Angola LNG could witness cryogenic gas testing and be assured of the valves' integrity. Another key reason for PJV winning the contract was pacing. "The project was really in our sweet spot," said Spencer Linsell, sales director, PJV. "The client wanted the deliveries within an 8- to 12-week window, pushing to 14 at the latest. That's very easy if you're selling stock valves off the shelf–anyone can do that– but not many people can make significant numbers of valves to order in that time. On the other hand, if you go to 24 weeks or more and are ordering big numbers, the global manufacturers can step in. There aren't many that can fill orders to spec that quickly. We were receiving inquiries and turning them into quotations overnight." PJV was also able to utilize its stock of more than 2,000 raw forgings, in a wide range of materials up to titanium grades, ready to machine to customer specification on a fast-track basis at its manufacturing plant in Italy. Engineering Angola's Oil and Gas Future By James Moir PJ Valves One company supports the Angolan oil and gas industry by partnering on two major projects.

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