Asia’s Largest Offshore Operating Facility

Strengthening Malaysia’s Position as a Regional Deepwater Hub.

The Gumusut-Kakap Semi-Submersible Floating Production System (Semi-Sub FPS)

The successful construction of the Gumusut-Kakap Semi Submersible Floating Production System (Semi-Sub FPS) for Malaysia’s Gumusut-Kakap deepwater field has provided Malaysia with the opportunity and platform to develop its deepwater capabilities and expertise, strengthening the nation’s position as a regional deepwater hub.

The field, Malaysia’s second deepwater development after the Kikeh oil field, is jointly developed by Petronas Carigali Sdn Bhd, Sabah Shell Petroleum Company Limited, ConocoPhilips Sabah Ltd and Murphy Sabah Oil Co. Ltd.

As the Engineering, Procurement and Construction (EPC) contract holder for the project, MISC undertook full project management scope and responsibility, while the construction of the Semi-Sub FPS was undertaken by Malaysia Marine and Heavy Engineering Sdn Bhd (MMHE), a subsidiary of Malaysia Marine and Heavy Engineering Holdings Bhd (MHB) and a member of the MISC Group.

According to Datuk Nasarudin Md Idris, President/CEO of MISC Berhad, "The completion of this project is a testimony to MISC and MMHE’s growing capabilities in the engineering and construction of floating production facilities."

The Gumusut-Kakap Semi-Sub FPS comprises a hull and topsides. The hull was designed by Shell and weighs approximately 19,000 MT. It has a storage capacity of 20,000 barrels of crude oil, 2,582 barrels of methanol, 4,145 barrels of diesel and 7,122 barrels of potable water.

The topsides which weigh around 20,000 MT were designed by Technip GeoProduction (M) Sdn Bhd. The structure comprises four main integrated modules (South, North, East, and West). The topsides are also equipped with a 140-man Permanent Living Quarters, 132-man Temporary Living Quarters and 11 Technical Buildings (including Production, Subsea, Flash Gas Control, Switchgear, Warehouse and Generator Buildings). The topsides can accommodate 19 well slots and has the processing capacity of 150,000 barrels per day of crude oil, 300 million standard cubic feet of gas re-injection per day and 225,000 barrels of water per day.

The four topsides modules were assembled and lifted on shore by a super lift methodology using lifting towers and strand jacks while the hull blocks consisting of column and pontoon were erected in sections at the skid rail adjacent to the topsides modules. The topsides and hull structures were then integrated on land by raising the modules through the super lift frame 45 metres from the ground. The super lift was the largest onshore topsides lift in the world and required the design and fabrication of a special purpose lifting assembly. The hull was then skidded beneath the topsides for all the components to be fully assembled. The topsides modules were then lowered down and secured onto the hull.

This is the biggest structure ever undertaken by MMHE and was successfully constructed utilising approximately 40 million man-hours and the direct involvement of approximately 5,000 personnel.

It was handed over to Sabah Shell Petroleum Company Ltd on 3 June 2013, and then made a 1,480km journey to arrive at the field on 12 June 2013.

The Semi-Sub FPS has been anchored in a water depth of about 1,200 metres and will initially service seven sub-sea manifolds in the Gumusut-Kakap field. Designed to remain on station in the field for 30 years, the Semi-Sub FPS has the potential to act as a hub for other possible sub-sea facilities. It will be the largest offshore operating facility not only in Malaysia but in Asia.

“This project and its achievement is attributed to the collaborative effort of PETRONAS, Shell, Murphy, ConocoPhilips as well as PETRONAS Carigali, supported by the capability and technical know-how of MISC Bhd and MMHE,” said Tan Sri Dato’ Shamsul Azhar Abbas, President & Group CEO of PETRONAS.

The challenging project has provided Malaysia with the opportunity and platform to develop its deepwater capabilities and expertise. The Gumusut-Kakap Semi-Sub FPS leveraged on strengths, resources and infrastructure derived from deepwater expertise already existing in Malaysia, thus strengthening the nation’s position as a regional deepwater hub.