GNL-3Z PROJECT: Realizzazione dell’impianto world class ... · S&T Exchangers Big Size Vessels...
Transcript of GNL-3Z PROJECT: Realizzazione dell’impianto world class ... · S&T Exchangers Big Size Vessels...
GNL-3Z PROJECT:Realizzazione dell’impianto world class per la liquefazione di gas naturale ad Arzew, Algeria
Milan, July 2014
Anton Marco Fantolini - LNG Technology Manager
GNL-3Z Project in Algeria
Main Contents
Project Overview Client Targets EPCC execution challenges
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GNL-3Z Project in Algeria
Project Overview
Bid competition with extensive FEED rework
EPCC LSTK Contract award on December 2008
Peak LNG capacity: 5.1 MTPA RATED @ 21ºC, 330 d/y
Cost Effective Design: < 900 $/tpa
Design responsive to Client’s Bid targets
1 LNG train: 4.7 MTPA, APCI C3-SPLIT MRTM
Provisions for future 2nd LNG Train
Grass Root complex inclusive of Infrastructures, Storages, Utilities
CLIENT: SONATRACH
CONTRACTOR: JV BETWEEN SAIPEM (LEADER) AND CHIYODA
WORLD LARGEST TRAINUSING C3-MR TECHNOLOGY
WORLD LARGEST TRAINUSING C3-MR TECHNOLOGY
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GNL-3Z Project in Algeria
Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
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GNL-3Z Project in Algeria
Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Process Facilities Area
Inlet
Utilities
Power Generation
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GNL-3Z Project in Algeria
Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
LNG Production Train Area
Gas Pretreatment
Liquefaction
NGL Recovery
NGL Fractionation
FUTURE TRAIN AREA
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GNL-3Z Project in Algeria
Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Building Area
Main Control Room,
Warehouse,
Workshop, Safety,
Administration
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GNL-3Z Project in Algeria
Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Cryogenic Tanks Area
LNG (2x160,000 m3)
Propane (56,000 m3)
Butane (12,000 m3)
BOG Recovery
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GNL-3Z Project in Algeria
Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Marine Works Area
Breakwater
Jetty
Near-shore Flares
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GNL-3Z Project in Algeria
Project Overview: Plot Area
Offshore flares Liquefaction/Fractionation split Full containment tanks
LIMITED PLOT SPACE (54 Ha)
GNL-3Z - up to 9.4 MTPA
6 Ha/MTPA
0.9 x 0.6 km
Bonny NLNG - up to 30 MTPA
11 Ha/MTPA
2.8 x 1.2 km
Qatar Gas - Ras Gas - 77 MTPA
17 Ha/MTPA
5.5 x 2.4 km
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GNL-3Z Project in Algeria
Project Overview: Novated Items
Main Cryogenic Heat Exchanger (APCI)
Gas Turbines (GE - Nuovo Pignone) Power Generation: n.3 Frame 6 MR/PR drivers: n.2 Frame 7 Helper motors: 17 MW (Siemens)
ITEMS PARTIALLY FABRICATED BASED ON ORIGINAL FEED
IMPOSED TO EPC CONTRACTOR
ITEMS PARTIALLY FABRICATED BASED ON ORIGINAL FEED
IMPOSED TO EPC CONTRACTOR
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GNL-3Z Project in Algeria
Chiyoda, Yokohama
ADVISORY ROLE:Consultancy, Review,Selected experiencedpersonnel supply
Management Challenges: Effective Multi-center Project Execution
Saipem India
Detailed design forStorage, Utilities and Offsites
Engineering Mhrs
Milan
Paris
Chennai
Yokohama
Algèrie
Saipem Algèrie
Logistics support, SubcontractsSite: Construction Supervision,Field Engineering, Commissioning
Saipem Paris
Marine facilities designStorage/loading design
Saipem Milan
OVERALL PROJECT LEADERSHIPLNG Train design Utilities design Procurement
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GNL-3Z Project in Algeria
Management Challenges: Workforce at Site
Company Expats Algerians
Saipem 38% 62%
International SubContractors 30% 70%
AlgerianSubContractors -- 100%
Project Average 27% 73%
PROJECT TARGET: LOCAL CONTENT MAXIMIZATION
7 OUT OF 10LOCAL WORKERS
7 OUT OF 10LOCAL WORKERS
MOBILIZATION: PEAK IN MARCH 2012
Total 11,830
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GNL-3Z Project in Algeria
Engineering Challenges: LNG Capacity Increase
BID COMPETITION TARGET: MAXIMIZE LNG PRODUCTIONABOVE ORIGINAL 4.0 MTPA,USING PRE-COMMITTED EQUIPMENT
MCHE Operating pressure increase MCHE bypass EFG cold energy recovery
Refrigeration Cycles MR composition optimization MR/PR power balance Compressors curves re-design
Additional Items Liquid expanders Auxiliary Propane Cycle EFG system n.1 GTG
TRAIN PEAK NOMINAL CAPACITY WAS INCREASED TO 5.1 MTPA (NOMINAL 4.7 MTPA)
CLOSE COOPERATION WITH GE AND APCI
CLOSE COOPERATION WITH GE AND APCI
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GNL-3Z Project in Algeria
Engineering Challenges: Safety in design
Safety LNG/LPG spillage handling LNG/LPG far from GT’s, furnace and incinerator LPG air coolers emergency isolation in two halves
Environment DLN/DLE for all Gas Turbines Waste Heat Recovery
BID COMPETITION TARGET: IMPROVE HSE DESIGN, REDUCE AUTO-CONSUMPTION
FEED DESIGN EXTENSIVELY REVISED IMPROVING PLANT HSE FEATURES
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GNL-3Z Project in Algeria
Engineering Challenges: Saipem Compact Design Solutions
PROPANE KETTLES ARRANGEMENT
TYPICAL ARRANGEMENT
GNL-3Z SAIPEM COMPACT DESIGN PRO’S
Compact layout, KO drums close to kettles
Maintainability, Accessibility
Material selection: LTCS on HHP-HP kettles
LPG spillage handling
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GNL-3Z Project in Algeria
Procurement Challenges – GNL-3Z Arzew
USAMCHE Liquid Expanders2 Frame 7 GTCsCryogenic Pumps
GERMANYBOG CompressorsCold BoxesActivated Amine
FRANCE4 Frame 6 GTGsMolecular SievesActivated Carbon
ITALYMain Compressors3 Frame 5 GTCsSpecial On-Off ValvesPiping
JAPANEnd Flash CompressorsSpecial Cryogenic Valves
S. KOREAAir Coolers S&T ExchangersBig Size VesselsBig Size Columns
MIDDLE EASTSteel Structures
Main Bulk & Equipment Quantities
UoM TOTAL
Steel Structures T 43,000
Piping T 23,000
E&I Cables km 3,000
Equipment T 26,000
ARZEW,ALGERIA
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GNL-3Z Project in Algeria
Construction Challenges: HSE Performances
THE SAFER, THE BETTER
CONSTANT FOCUS ON HSE LEAD TO A CONTINUOS PERFORMANCE IMPROVEMENT
PERFORMANCE ACHIEVED
2009 2010 2011 2012 2013
2,5
2
1,5
1
0,5
0
TRIFR*
2,19
1,45
1,14
0,82
0,28
Average = 0.89
WORKED MANHOURS
* TRIFR = Total Recordable Injury Frequency Rate
CURRENT MHRS NO LTI> 19,900,000CURRENT MHRS NO LTI> 19,900,000
HSE TRAINING> 230,000 HOURSHSE TRAINING> 230,000 HOURS
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GNL-3Z Project in Algeria
Construction Challenges: Air Coolers Installation Sequence
LIFTING SLIDINGRAIL POSITIONING
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GNL-3Z Project in Algeria
Construction Challenges: De-Ethanizer Column Heavy Lifts
Tower Bridge Operation:
Heaviest Lift
Weight 1150 tons
Tower Bridge Operation:
Heaviest Lift
Weight 1150 tons
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
LNG TANKS
H=50m, OD=85mCapacity=160,000 m3
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
HP FLARES
H=140mCapacity:Cold 2400 Tons/hWarm 1300 Tons/hCauseway = 250 m
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
JETTY CAUSEWAY
L=400mRubble Mounded
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
JETTY TRESTLE
L=500mCaissons
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
BREAKWATER
L=760mCaissons
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GNL-3Z Project in Algeria
Construction Challenges: Cryogenic Storage and Marine Works
TEMPORARY DOCK
L=250m
RECLAIMED AREA
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GNL-3Z Project in Algeria
Commissioning Challenges: from Construction to Operation
SET UP OF COMPLETE TEAM TO DELIVER AN EFFECTIVE PLANT START UP
Management 12 Operation 80 Process 8Mechanical 33Instrumentation 50 Electrical 27
TOTAL: 210
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GNL-3Z Project in Algeria
Commissioning Challenges: Client Team Training
Training Areas Engineering - 30 trainees Operation - 139 trainees Maintenance - 62 trainees Fire Fighting - 13 trainees
Trainees Assessment Initial Assessment On-going Assessment Final Assessment
BUILD UP OF COMMISSIONING, OPERATION & MAINTENANCE INTEGRATED TEAM
CLIENT TRAINING24,000 HOURSCLIENT TRAINING24,000 HOURS
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GNL-3Z Project in Algeria
Commissioning Challenges: Achievements and Way Forward
LNG Storage and Loading systems
First LNG Ship
Increase production at rated capacity
Performance Test
Utilities & Power Generation
Gas Turbines & Compressors Commissioning
Gas Treatment (Warm End)
Defrost of Cryogenic Sections
Propane Import - Auxiliary Propane Cycle
NGL Recovery and Fractionation
Ethane import - Refrigerant Cycles Start Up
Propane/Butane Production, Storage and export
Liquefaction and End Flash
Oct 2013
Nov 2013
Dec 2013
Mid Jan 2014
Jan 2014
Mid Feb 2014
Mar 2014
Jun 2014
Jun 2014
PLANT IS RUNNING SMOOTHLY AT REDUCED CAPACITY
FIRST LNG SHIP IN JULY 2014
FIRST LNG SHIP IN JULY 2014
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GNL-3Z Project in Algeria
Conclusions
SAIPEM, as a JV leader, with the technological support of CHIYODA: have executed the EPC portion of the LSTK Project GNL-3Z are now completing the Commissioning and Start-up Phase
delivering to SONATRACH their largest LNG Production Train.
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