All Employee Meeting - Template

Priolo Ethylene Plant Upgrade
a cura di:
Ing. Ivano Giannoni (Versalis)
Ing Francesco Gravame (GE NP)
Ing Riccardo Fabbri (GE NP)
Milano - 10 dicembre 2014
Priolo Ethylene Plant Upgrade
IPMA GOLD Award
IPMA Milano 10th Dec’14
Imagination at work.
GE Oil & Gas today
From extraction, to transportation, to end use …
~45,000 employees
Downstream
Technology
Solutions
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PRODUCTS &
SERVICES
Reciprocating
Compressors
High Speed Recips
Compressors
CNG In A Box
10k – 21k GGE/day
SEGMENTS
Ethylene
LDPE / HDPE
Ammonia
Pumps & Valves
Urea
Refinery
Processing
Services & Upgrade
Industrial
Processin
g
Industrial Power
Generation
Gas Distribution
& Processing
Small CNG
& LNG
Steam
Turbines
Small-Scale LNG
25k – 600k gal/day
DRAFT Oct 3
4
GE installed base
Beyond GE installed base
Upgrade Evolution
Plant Upgrade
(Priolo)
2014
2013
Large rehabilitation
projects
F2F:
• Rebundle
• NOx
2006
OEM
Process
Beyond F2F
• Engine & Modular
Replacement
2009
200
8
System Integrator
2011
201
0
Plant
2012
GE &IPMA Project Excellence Award
PRIZE
AWARD
2009
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PM: Roberto Zavani
2011
Qatar Gas - CSA
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PRIZE
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FINALIST
S
GOLD
Insert Image
2010
Darwin - Upgrade
PM: Francesco
Gravame
2012
ALNG - CSA & TAG TM
PM M. Ferri & F.
Giuntini
2014
Priolo – DTS
Upgrade
PM: Riccardo Fabbri
Products &
Services
Operational
Excellence
Laser-focused on
safety and quality
for customers;
project execution
and  returns
People and
Expertise
Investing in our
people, dedicated PM
Academy and training
path driving
execution
Including upgrades to
optimize production
efficiency in Ethylene
plant
Project Execution Timeline
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Our Journey in IPMA Project Excellence
Project Management
1. Project Objectives
2. Leadership
3. People
4. Resources
5. Processes
Project Results
6. Customer Results
7. People Results
8. Other parties involved
9. Performance & Results
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IPMA Excellence Definition
Excellent performance in all aspects, management of
the planning, execution and results (from the process).
Go beyond or even against known standards, methods,
tools and techniques
Beyond the actual project goals, they enrich
businesses, societies, environment
Versalis
The voice of customer
Title or Job Number | XX Month 201X
See tutorial regarding
confidentiality disclosures.
14
Versalis (Eni) at a glance
Headquarters
Milan
With an integrated industrial platform, versalis – the Italian leading chemical company – offers to the market an
extensive portfolio of intermediates, polyethylene, styrenics, elastomers and a new range of bio-based chemicals
Plants:
9 in Italy
Brindisi
Ferrara
Mantova
Porto Marghera
Porto Torres
Priolo
Ragusa
Ravenna
Sarroch
4 rest of
Europe
Grangemouth (UK)
Dunkerque (FR)
Oberhausen (D)
Százhalombatta (HU)
5 R&D centers in
Italy
Sales network
18 branch offices and 2
trading companies in Asia
(Shanghai and Mumbai)
Licensing and
strategic
partnerships
5,600
employees
80% Italy, 20% abroad
71
production units for a total
production of
5.8
mln ton
5.9
bln € turnover
335
patents
Versalis business overview
turnover: € 5,9 bln – production: 5,8 m ton
production to sales: 3,8 m ton
Monomers and Intermediates
Olefins





Ethylene
Propylene
Butadiene
Raffinate 1
Carbon Black
Feedstock
Aromatics





Toluene
o-m-p-Xylene
Pseudocumene
DCPD
Benzene
Derivatives





capacities and
market position
end markets
among leading players
Polymers
Phenol
Acetone
Alphametilstyrene
Cyclohexanone/
Ka-Oil
EB/Styrene
Polyethylene





LDPE
LLDPE
VLDPE
HDPE
EVA
2nd
6nd in EU
in EU for EVA
Styrenics





GPPS
HIPS
EPS
SAN
ABS
3rd in EU
Elastomers







e-SBR
s-SBR
BR
TPR
EP(D)M
NBR
Latex
2st in EU
Key factors boosting Priolo Cracking Unit modification
Versalis has recently been refocusing its strategies on a more market-oriented and diversified
product portfolio, emphasizing R&D, Licensing and enhancing global presence.
As part of its new strategies, Versalis has made changes to its infrastructures and production
facilities. The following describes the changes made to overhaul its largest Cracking Unit at
the Priolo site.
Modifications included state-of-the-art upgrading of components, systems and controls in order
to:
• Increase one production line capacity
• Improve energy index
• Improve plant availability & maintenance interval extension
Priolo: Project Description
Plant Location
Scope
Main modification according to feasibility/basic
studies performed by Main Contractor:
PRIOLO
Machinery modification
 Charge gas compression system upgrade
 Ethylene compression system upgrade
 Propylene Syeam turbine replacement
Process Modification
 Ethylene Splitter and Demetanizer trays replacement
 Replacement of Ethylene splitter condenser with
Core-in-Kettle technology
Planning
•
•
•
•
•
FID Q1/ 2012
Main Contractor Order June 2012
Machinery order December 2012
Field works start mid August 2013
Plant start up end November 2013
Constraints
•
Development of over 600.000 direct m.h. for Plant and
Machinery modification works to be performed during
facilties 10-years m.o. planned to be performed
September – mid November 2013
Priolo: general view of plant modification
Item Revamped
Item Revamped
PROPYLENE TRAIN
Item Modified
Item Modified
NEW Item
NEW Item
ETHYLENE TRAIN
Priolo: project challenges
Machines
location
• Machines installed at the first mezzanine deck out of
reach of any mobile crane.
• Roof composed by air cooler and air condenser cannot
be removed
• Existing lifting crane both in hot and cold compression
area while perfectly fit for maintenance are not suitable
for handling assembled machines.
• Lube and Seal Oil console on ground floor found
completely embedded in concrete, and again out of
reach of any type of Crane
Conclusions
• Teamwork between GE and Versalis Engineering &
Operation Teams...key to success
• Concurrent Engineering instrumental to flawless design
and project execution
• Deployement of Engineering Teams at site for the entire
duration of the project
• Early Design for installation and availability fully
exploited and applied