CHALLENGING IMPLEMENTATION of REFINERY OFF GAS

CHALLENGING IMPLEMENTATION
of REFINERY OFF GAS PROJECT
at TOTAL ANTWERP REFINERY
IGTC 2015 - 6th International Gas Technology Conference
19-20 February 2015, Dubai
KT - Kinetics Technology, Daniele Paolinelli
SUMMARY
 KT is currently implementing the Refinery Off Gas “ROG” Project at Total Antwerp Refinery.
 KT is willing to present a case study and the related main features of the project with a particular focus
on the key technical challenges and EPC execution challenges imposed by the severe site and schedule
constraints.
 New ROG Unit is going to be built adjacent to operating units and the modularization concept requested
by Owner to minimize site works is extensively endorsed in the execution strategy put in place by KT.
 Execution of ROG project is definitively, through the experience gained during implementation,
strengthening both KT’s technology and process design expertise in gas processing and EPC execution
capabilities
2
KT AT A GLANCE 1/2 1974: KTI was part of an international group of Companies
1988: KTI
Anlagenbau
Group
was
acquired
by
Mannesmann
1999: Technip Italy acquired 100% of KTI SpA changing the name in
Technip KTI SpA
2005: Management Buy-out, 75% of the Company was acquired by
its Management. The remaining 25% was owned by Technip Italy
2010: Maire Tecnimont acquired the 100% of Technip KTI SpA
changing its name in Tecnimont KT SpA
Recently the Company has changed its name into KT – Kinetics
Technology to highlight company historical identity
3
KT AT A GLANCE 2/2 International Process Engineering Contractor, with significant references in the field of Sulphur Recovery
Facilities, Gas Processing, Hydrogen and Syngas Production, and supply of Process Fired Heaters and Cracking
Furnaces
Experienced EPC contractor for Refinery Licensed Catalytic Units as Hydrocracker (HDC), Hydrotreater
(HDT), Delayed Coker (DCU), etc.
Development of new technologies on core business and in the renewable energies sector
TRACK RECORD
More than 40 year’s experience as process
engineer contractor and development of new
technologies for Oil&Gas
Well recognized player in licensing
Hydrogen Technology, with single train
capacity up to 180,000Nm3/h
+120 Hydrogen and Suplphur Recovery unit
projects completed in the last 10 years
Well recognized player in licensing Sulphur Recovery
and Tail Gas Treatment technology with design
capacity of single train up to 1800t/d
4
INDEX
MAIN PROJECT INFORMATION
I.
II.
III.
IV.
BACKGROUND
CONCEPTUAL SCHEME OF THE PROJECT
KEY DATA
ROG UNIT OVERVIEW
TECHNOLOGY OVERVIEW
I.
II.
III.
SAT HC GAS TRAIN BLOCK DIAGRAM
UNSAT HC GAS TRAIN BLOCK DIAGRAM
MAIN PROCESS DATA
EXECUTION CHALLENGES
I.
II.
II.i
II.ii
January 2015
PROJECT CONSTRAINTS
EXECUTION STRATEGY KEY FEATURES
MODULARIZATION
SITE CONSTRUCTION
5
INDEX
MAIN PROJECT INFORMATION
I.
II.
III.
IV.
BACKGROUND
CONCEPTUAL SCHEME OF THE PROJECT
KEY DATA
ROG UNIT OVERVIEW
TECHNOLOGY OVERVIEW
I.
II.
III.
SAT HC GAS TRAIN BLOCK DIAGRAM
UNSAT HC GAS TRAIN BLOCK DIAGRAM
MAIN PROCESS DATA
EXECUTION CHALLENGES
I.
II.
II.i
II.ii
January 2015
PROJECT CONSTRAINTS
EXECUTION STRATEGY KEY FEATURES
MODULARIZATION
SITE CONSTRUCTION
6
BACKGROUND
•
TOTAL RAFFINADERIJ ANTWERPEN is one of Total’s six major integrated platforms globally, and the
crucial link in Total’s integrated petrochemical complex in Belgium.
•
REFINERY OFF GAS “ROG” PROJECT is part of one of the biggest investment schemes in a European
refinery for which the overall value exceeds one billion and follows the recent move by European refiners
and petrochemical producers to lower their cost of production and improve overall operating efficiency by
modernizing and improving existing complexes rather than developing new plant site.
•
The complex produces several refinery off gas streams from different process units that are
currently routed to the refinery fuel gas network. These streams contain valuable components, which
can be upgraded to cracker feedstock and products. The refinery configuration scheme will be modified
by the provision of a new ROG Unit aimed to recover valuable hydrocarbon streams (Ethane, Propane,
Ethylene and Propylene) and the integration of these streams within Existing Naphtha Cracker and thus
increasing the profitability of the complex.
7
CONCEPTUAL SCHEME OF THE PROJECT
BROWNFIELD / LOT A - EPC
ROG TECHNICAL BUILDINGS AND COOLING WATER SYSTEM
NAPHTHA CRACKER MODIFICATION AND
INTERCONNECTIONG / LOT B - EPCm
EXISTING NAPHTHA CRACKER MODIFICATION
NEW ROG UNIT (ISBL)
UNSATURATED OFF GASES SATURATED OFF GASES
EXISTING UTILITIES SYSTEMS
8
KEY DATA •
CONTRACTOR: KT for Lot A & B
•
EFFECTIVE DATE: April 1st 2014
•
PLANNED KEY DATES FOR THE PROJECT IMPLEMENTATION:
1/2
NEW ROG UNIT
 SITE WORKS START : November 2014 (Piling)
 COMPLETION OF DETAILED DESIGN : March 2015
ROG UNIT READY FOR COMMISSIONING: July 31st 2016 (ED + 28 Months)
NAPHTHA CRACKER MODIFICATIONS AND INTERCONNECTING
 COMPLETION OF DETAILED DESIGN : March 2015
 DELIVERY OF MATERIAL FOR PRE S/D WORKS: September 2015
 DELIVERY OF MATERIAL FOR S/D WORKS: Janaury 2016
OVERALL PROJECT
 NAPHTHA CRACKER S/D : September 2016
 MECHANICAL COMPLETION OF NAPHTHA CRACKER MODIFICATIONS: End of November 2016
ROG UNIT and NAPHTHA CRACKER START UP: Early 2017
9
KEY DATA 2/2
OVERALL PROJECT FIGURES (Lot A and B):
MAIN PROJECT DATA 4/4 ENGINEERING MANHORUS :
400,000
CONSTRUCTION DIRECT MANHOURS:
1,200,000
EQUIPMENT WEIGHT:
tons
2,100
STEEL STRUCTURE WEIGHT:
tons
2,050
PIPING WEIGHT:
tons
2,100
PILES:
Nos
1,000
CONCRETE:
Cum
3,300
10
ROG UNIT OVERVIEW
NEW ROG UNIT CONSIST OF THE FOLLOWING BLOCKS:
 PROCESS BLOCK:
SATURATED GASES TREATMENT AND RECOVERY TRAIN
UNSATURATED GASES TREATMENT AND RECOVERY TRAIN
 UTILITIES AND ANCILLARIES BLOCK:
COOLING
TOWERS
ETHILENE
REFRIGERATION
PROPILENE
REFRIGERATION
ELECTRICAL SUBSTATION & ITR
11
ROG UNIT OVERVIEW 2/2 12
INDEX
MAIN PROJECT INFORMATION
I.
II.
III.
IV.
BACKGROUND
CONCEPTUAL SCHEME OF THE PROJECT
KEY DATA
ROG UNIT OVERVIEW
TECHNOLOGY OVERVIEW
I.
II.
SAT HC GAS TRAIN BLOCK DIAGRAM
UNSAT HC GAS TRAIN BLOCK DIAGRAM
EXECUTION CHALLENGES
I.
II.
II.i
II.ii
January 2015
PROJECT CONSTRAINTS
EXECUTION STRATEGY KEY FEATURES
MODULARIZATION
SITE CONSTRUCTION
13
UNSAT HC GAS TRAIN BLOCK DIAGRAM
UNSATURATED GAS TREATMENT AND RECOVERY TRAIN AMINE TREATMENT
IMPURITIES REMOVAL
BEDS
(SULPHUR SPECIES /METALS)
COMPRESSION
CRYOGENIC FRACTIONATION
FUEL GAS TO
REFINERY
C3+ TO ETHYLENE
PLANT RECOVERY
SECTION
C2’s TO ETHYLENE
PLANT RECOVERY
SECTION
UNSAT GASES
FROM
REFINERY
FEED PROCESS GUARANTEES HAVE BEEN
FULLY ENDORSED BY KT
TYPICAL BLOCK DIAGRAM, PROJECT BLOCK DIAGRAM IS UNDISCLOSED
14
SAT HC GAS TRAIN BLOCK DIAGRAM
SATURATED GAS TREATMENT AND RECOVERY TRAIN
COMPRESSION
AMINE TREATMENT
IMPURITIES REMOVAL
BEDS
(SULPHUR SPECIES / METALS)
CRYOGENIC FRACTIONATION
FUEL GAS TO
REFINERY
FEED TO ETHYLENE
FURNACES
SAT GASES
FROM
REFINERY
FEED PROCESS GUARANTEES
HAVE BEEN FULLY ENDORSED BY KT
TYPICAL BLOCK DIAGRAM, PROJECT BLOCK DIAGRAM IS UNDISCLOSED
15
INDEX
MAIN PROJECT INFORMATION
I.
II.
III.
IV.
BACKGROUND
CONCEPTUAL SCHEME OF THE PROJECT
KEY DATA
ROG UNIT OVERVIEW
TECHNOLOGY OVERVIEW
I.
II.
III.
SAT HC GAS TRAIN BLOCK DIAGRAM
UNSAT HC GAS TRAIN BLOCK DIAGRAM
MAIN PROCESS DATA
EXECUTION CHALLENGES
I.
II.
II.i
II.ii
January 2015
PROJECT CONSTRAINTS
EXECUTION STRATEGY KEY FEATURES
MODULARIZATION
SITE CONSTRUCTION
16
PROJECT CONSTRAINTS 1/2
SEVERE CONSTRAINTS ARE IMPOSED FOR THE EXECUTION OF ROG PROJECT :
 NAPHTHA CRACKER 2016 PLANNED TURNAROUND
TIGHT SCHEDULE FOR NEW ROG UNIT COMPLETION: 28 MONTHS
 NEW ROG UNIT IS GOING TO BE ERECTED WITHIN OPERATING UNITS
SITE CONSTRUCTION MANHOURS NEEDS TO BE MINIMIZED
 CONSTRUCTION AREA IS CONGESTED
LAYDOWN IS VIRTUALLY IMPOSSIBLE, CONSTRUCTION PATH IS OBLIGED
17
PROJECT CONSTRAINTS 2/2
EXISTING NAPHTHA CRACKER
ROG PLANT AREA
18
EXECUTION STRATEGY KEY FEATURES
IN ORDER TO MEET PROJECT OBJECTIVES WHITIN GIVEN CONTSRAINTS A TAILORED STRATEGY
HAS BEEN DEVELOPED AND IS NOW IN PLACE:
 MODULAR APPROACH:
MODULAR APPROACH, ALREADY PRESENT DURING FEED, HAS BEEN FURTHER DEVELOPED AND ENDORSED BY KT  MODULARIZATION YARD SELECTION
IN ORDER TO MEET PROJECT SCHEDULE AND OVERCOME SITE CONSTRAINTS MODULARIZATION WILL TAKE PLACE IN ANTWERP, NEARBY REFINERY SITE
 CONSTRUCTION DRIVEN EXECUTION
PROJECT SCHEDULE IS FULLY TAILORED TO MEET THE CONSTRUCTION SEQUENCE DEVELOPED AT EARLY STAGE OF THE PROJECT
19
MODULARIZATION 1/4 TOTAL ANTWERP REFINERY
MODULARIZATION YARD
20
MODULARIZATION 2/4 THE FOLLOWING ACTIVITIES WILL BE EXECUTED
JANUARY AND NOVEMBER 2015
AT MODULARIZATION YARD BETWEEN
 PROCESS MODULES FABRICATION, TESTING AND TRIAL FIT UP
•
N° 14 MODULES
FOR A TOTAL WEIGHT OF 2300 tons
•
HEAVIEST PIECE AROUND 300 tons
21
MODULARIZATION 3/4 THE FOLLOWING ACTIVITIES WILL BE EXECUTED AT MODULARIZATION YARD BETWEEN
MODULARIZATION ACTIVITIES JANUARY AND NOVEMBER 2015
 PIPERACK MODULES FABRICATION, TESTING AND TRIAL FIT UP
•
N° 6 MODULES FOR A TOTAL WEIGHT OF 900 TONS
 PREDRESSING OF COLUMNS
•
N° 8 COLUMNS FOR A TOTAL WEIGHT OF 260 TONS
22
MODULARIZATION 4/4
YARD LOCATION IS BRINGING THE FOLLOWING BENEFIT TO THE PROJECT EXECUTION MITIGATING
THE RISKS ASSOCIATED WITH SITE ACTIVITIES:
 MODULES WILL BE STORED IN THE YARD UNTIL NEEDED AND SENT TO SITE ONLY AT THE TIME
ERECTION
OF
CONSTRUCTION SEQUENCE, WHICH IS OF UTMOST IMPORTANCE FOR ROG AREA, CAN
BE EASILY ACCOMPLISHED;
 TRANSPORTATION RISKS FOR MODULES IS DRASTICALLY REDUCED;
 YARD WOULD SERVE AS LAYDOWN AREA EVEN FOR OFF/MODULES MATERIALS REDUCING SITE STORAGE
REQUIREMENTS TO THE MINIMUM;
 EFFECTIVE MINIMIZATION OF MHRS WORKED ON SITE DUE TO CONVENIENT LOCATION OF YARD;
23
SITE CONSTRUCTION 1/4
MODULES AND PREDRESSED COLUMNS WILL BE TRANSPORTED TO SITE IN ACCORDANCE TO THE
ERECTION SEQUENCE AND BY MEANS OF BARGES AND SPMT
QUAY
SPMT PATH
BARGE PATH
24
SITE CONSTRUCTION 2/4
MODULES AND PREDRESSED COLUMNS WILL BE TRANSPORTED TO SITE IN ACCORDANCE TO THE
ERECTION SEQUENCE AND BY MEANS OF BARGES AND SPMT
ROG AREA
SPMT PATH
NEW GATE C
25
SITE CONSTRUCTION 3/4
 AT THE EARLY STAGE OF PROJECT KT HAS CONSOLIDATED THE ERECTION STRATEGY
BASED ON THE INSTALLATION OF MODULES AND MAIN LOOSE EQUIPMENT IN
SEQUENCE BY MAIN CRANE WITHOUT STORAGE INSIDE THE REFINERY.
 THE ERECTION PATH WILL BE FROM NORTH TO SOUTH WITH THE MAIN CRANE ACTING
IN 4 ERECTION STEPS/POSITIONS
CRAWLER
CRANE
650 T
 THE ERECTION OF MODULES AND MAIN EQUIPMENT IS PLANNED BETWEEN 26 October
2015 and 22 January 2016
26
SITE CONSTRUCTION 4/4
CRAWLER
CRANE
650 T
CRANE
POSITION :
1
2
3
4
27
THANKS FOR YOUR ATTENTION
....any Question
Via Castello della Magliana, 75
00148 Rome
Ph.+39 06 6021.61
Fax +39 06 6579.3002
info@kt‐met.it – www.kt‐met.com
Daniele Paolinelli
Proposal and Sales Manager
d.paolinelli@kt‐met.it
Ph.+39 06 60216.862