GNL-3Z PROJECT: Realizzazione dell`impianto world class per la

GNL-3Z PROJECT:
Realizzazione dell’impianto world class
per la liquefazione di gas naturale ad Arzew, Algeria
Anton Marco Fantolini - LNG Technology Manager
Milan, July 2014
Main Contents

Project Overview

Client Targets

EPCC execution challenges
GNL-3Z Project in Algeria
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Project Overview
CLIENT: SONATRACH
 1 LNG train: 4.7 MTPA, APCI C3-SPLIT MRTM
 Provisions for future 2nd LNG Train
 Grass Root complex inclusive of Infrastructures, Storages, Utilities
CONTRACTOR: JV BETWEEN SAIPEM (LEADER) AND CHIYODA
 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
WORLD LARGEST TRAIN
USING C3-MR TECHNOLOGY
 Design responsive to Client’s Bid targets
GNL-3Z Project in Algeria
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Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
GNL-3Z Project in Algeria
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Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Process Facilities Area
Inlet
Utilities
Power Generation
GNL-3Z Project in Algeria
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Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
FUTURE TRAIN AREA
LNG Production Train Area
GNL-3Z Project in Algeria
Gas Pretreatment
NGL Recovery
Liquefaction
NGL Fractionation
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Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Building Area
Main Control Room,
Warehouse,
Workshop, Safety,
Administration
GNL-3Z Project in Algeria
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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
GNL-3Z Project in Algeria
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Project Overview: EPCC Scope of Work
COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION
Marine Works Area
Breakwater
Jetty
Near-shore Flares
GNL-3Z Project in Algeria
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Project Overview: Plot Area
LIMITED PLOT SPACE (54 Ha)

Offshore flares

Liquefaction/Fractionation split

Full containment tanks
0.9 x 0.6 km
2.8 x 1.2 km
5.5 x 2.4 km
GNL-3Z - up to 9.4 MTPA
6 Ha/MTPA
Bonny NLNG - up to 30 MTPA
11 Ha/MTPA
Qatar Gas - Ras Gas - 77 MTPA
17 Ha/MTPA
GNL-3Z Project in Algeria
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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
GNL-3Z Project in Algeria
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Management Challenges: Effective Multi-center Project Execution
Engineering Mhrs
Milan
Paris
Chennai
Yokohama
Algèrie
Saipem Milan
Saipem Paris
Saipem Algèrie
Saipem India
Chiyoda, Yokohama
OVERALL PROJECT
LEADERSHIP
LNG Train design
Utilities design
Procurement
Marine facilities design
Storage/loading design
Logistics support, Subcontracts
Site:
Construction Supervision,
Field Engineering,
Commissioning
Detailed design for
Storage, Utilities and
Offsites
ADVISORY ROLE:
Consultancy, Review,
Selected experienced
personnel supply
GNL-3Z Project in Algeria
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Management Challenges: Workforce at Site
PROJECT TARGET: LOCAL CONTENT MAXIMIZATION
Company
Expats
Algerians
Saipem
38%
62%
International
SubContractors
30%
70%
Algerian
SubContractors
--
100%
Project Average
27%
73%
7 OUT OF 10
LOCAL WORKERS
MOBILIZATION: PEAK IN MARCH 2012
Total
11,830
GNL-3Z Project in Algeria
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Engineering Challenges: LNG Capacity Increase
TRAIN PEAK NOMINAL CAPACITY WAS INCREASED TO 5.1 MTPA (NOMINAL 4.7 MTPA)
BID COMPETITION TARGET:
MAXIMIZE LNG PRODUCTION
ABOVE ORIGINAL 4.0 MTPA,
USING PRE-COMMITTED EQUIPMENT

MCHE




Refrigeration Cycles




CLOSE COOPERATION
WITH GE AND APCI
Operating pressure increase
MCHE bypass
EFG cold energy recovery
MR composition optimization
MR/PR power balance
Compressors curves re-design
Additional Items




Liquid expanders
Auxiliary Propane Cycle
EFG system
n.1 GTG
GNL-3Z Project in Algeria
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Engineering Challenges: Safety in design
FEED DESIGN EXTENSIVELY REVISED IMPROVING PLANT HSE FEATURES
BID COMPETITION TARGET:
IMPROVE HSE DESIGN, REDUCE AUTO-CONSUMPTION

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
GNL-3Z Project in Algeria
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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
GNL-3Z Project in Algeria
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Procurement Challenges – GNL-3Z Arzew
ARZEW,
ALGERIA
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
GERMANY
 BOG Compressors
 Cold Boxes
 Activated Amine
USA
 MCHE
 Liquid Expanders
 2 Frame 7 GTCs
 Cryogenic Pumps
S. KOREA
 Air Coolers
 S&T Exchangers
 Big Size Vessels
 Big Size Columns
ITALY
 Main Compressors
 3 Frame 5 GTCs
 Special On-Off Valves
 Piping
MIDDLE EAST
Steel Structures
JAPAN
 End Flash Compressors
 Special Cryogenic Valves
FRANCE
 4 Frame 6 GTGs
 Molecular Sieves
 Activated Carbon
GNL-3Z Project in Algeria
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Construction Challenges: HSE Performances
CONSTANT FOCUS ON HSE LEAD TO A CONTINUOS PERFORMANCE IMPROVEMENT
TRIFR*
CURRENT MHRS NO LTI
> 19,900,000
HSE TRAINING
> 230,000 HOURS
2,5
Average = 0.89
2,19
2
1,45
1,5
1,14
1
0,82
0,5
0,28
0
2009
THE SAFER, THE BETTER
2010
2011
WORKED MANHOURS
2012
2013
PERFORMANCE ACHIEVED
* TRIFR = Total Recordable Injury Frequency Rate
GNL-3Z Project in Algeria
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Construction Challenges: Air Coolers Installation Sequence
LIFTING
RAIL POSITIONING
GNL-3Z Project in Algeria
SLIDING
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Construction Challenges: De-Ethanizer Column Heavy Lifts
Tower Bridge Operation:
Heaviest Lift
Weight 1150 tons
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
LNG TANKS
H=50m, OD=85m
Capacity=160,000 m3
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
HP FLARES
H=140m
Capacity:
Cold 2400 Tons/h
Warm 1300 Tons/h
Causeway = 250 m
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
JETTY CAUSEWAY
L=400m
Rubble Mounded
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
JETTY TRESTLE
L=500m
Caissons
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
BREAKWATER
L=760m
Caissons
GNL-3Z Project in Algeria
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Construction Challenges: Cryogenic Storage and Marine Works
RECLAIMED AREA
TEMPORARY DOCK
L=250m
GNL-3Z Project in Algeria
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Commissioning Challenges: from Construction to Operation
SET UP OF COMPLETE TEAM TO DELIVER AN EFFECTIVE PLANT START UP
Management
12
Operation
80
Process
8
Mechanical
33
Instrumentation
50
Electrical
27
TOTAL: 210
GNL-3Z Project in Algeria
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Commissioning Challenges: Client Team Training
BUILD UP OF COMMISSIONING, OPERATION & MAINTENANCE INTEGRATED TEAM

Training Areas





Engineering
Operation
Maintenance
Fire Fighting
- 30 trainees
- 139 trainees
- 62 trainees
- 13 trainees
Trainees Assessment



Initial Assessment
On-going Assessment
Final Assessment
CLIENT TRAINING
24,000 HOURS
GNL-3Z Project in Algeria
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Commissioning Challenges: Achievements and Way Forward
PLANT IS RUNNING SMOOTHLY AT REDUCED CAPACITY
 Utilities & Power Generation
 Oct 2013
 Gas Turbines & Compressors Commissioning
 Nov 2013
 Gas Treatment (Warm End)
 Dec 2013
 Defrost of Cryogenic Sections
 Mid Jan 2014
 Propane Import - Auxiliary Propane Cycle
 Jan 2014
 NGL Recovery and Fractionation
 Mid Feb 2014
 Ethane import - Refrigerant Cycles Start Up
 Mar 2014
 Propane/Butane Production, Storage and export
 Jun 2014
 Liquefaction and End Flash
 Jun 2014
 LNG Storage and Loading systems
 First LNG Ship
 Increase production at rated capacity
FIRST LNG SHIP
IN JULY 2014
 Performance Test
GNL-3Z Project in Algeria
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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.
GNL-3Z Project in Algeria
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