
PETRONAS Refinery and Petrochemical Integrated Development (RAPID)
Client: PETRONAS Refinery and Petrochemical Corporation – Utilities and Facilities Sdn. Bhd. (PRPC-UF)
Location: Johor, Malaysia
Business Segment: Energy Solutions

Executive Summary
Petroliam Nasional Berhad (PETRONAS), Malaysia’s national oil and gas company, was 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 was 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 included 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. In a joint venture with Technip, Fluor performed engineering, procurement, construction management and commissioning of the utilities, interconnecting and offsites (UIO).
Client's Challenge
The Pengerang Integrated Complex was the largest project ever undertaken by PETRONAS and the largest single construction project in the country of Malaysia. It would occupy an area of approximately 6,242 acres and require an estimated 70,000 craft workers at peak.
The various process units were executed by numerous contractors based in Malaysia, 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, we leveraged our 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.
The work was led from a project office established in Kuala Lumpur, Malaysia, with our engineering and procurement services performed from our Manila, Philippines, execution center. In addition to leveraging our technical experts around the globe, the project benefitted from the wealth of UIO experience that we had developed in Manila over the previous15 years.
The UIO alone was a megaproject with a scope that included: 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 exceeded 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 comprised 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 had also performed program management consultancy services for RAPID since 2013.

Conclusion
PIC was a keystone project in the Malaysian Government's overall Economic Transformation Programme (ETP). It would 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 have been a trusted partner in this vital project for the economic development of Malaysia.

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