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

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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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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Project Overview: EPCC Scope of Work

COMPLETE INDUSTRIAL FACILITY FROM GRASS ROOT TO OPERATION

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Process Facilities Area

Inlet

Utilities

Power Generation

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LNG Production Train Area

Gas Pretreatment

Liquefaction

NGL Recovery

NGL Fractionation

FUTURE TRAIN AREA

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Building Area

Main Control Room,

Warehouse,

Workshop, Safety,

Administration

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Cryogenic Tanks Area

LNG (2x160,000 m3)

Propane (56,000 m3)

Butane (12,000 m3)

BOG Recovery

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Marine Works Area

Breakwater

Jetty

Near-shore Flares

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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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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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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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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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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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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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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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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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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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Construction Challenges: Air Coolers Installation Sequence

LIFTING SLIDINGRAIL POSITIONING

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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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Construction Challenges: Cryogenic Storage and Marine Works

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LNG TANKS

H=50m, OD=85mCapacity=160,000 m3

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HP FLARES

H=140mCapacity:Cold 2400 Tons/hWarm 1300 Tons/hCauseway = 250 m

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JETTY CAUSEWAY

L=400mRubble Mounded

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JETTY TRESTLE

L=500mCaissons

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BREAKWATER

L=760mCaissons

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TEMPORARY DOCK

L=250m

RECLAIMED AREA

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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 8Mechanical 33Instrumentation 50 Electrical 27

TOTAL: 210

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

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