Abu Dhabi Site Visit 2010 - Mr. Sale_Gasco Project

ABU DHABI
SITE VISIT 2010
Giovanni Sale
Tecnimont – Head of Plant Operations
11 October 2010
11 October 2010
Abu Dhabi Site Visit
AGENDA
1.
Plant Operations
2.
GASCO Project overview
11 October 2010
Abu Dhabi Site Visit
2
PLANT OPERATIONS:
AT THE CENTER OF PROJECT EXECUTION
Engineering
HSSE
Procurement
Quality
Assurance
Plant
Operations
&
Construction
Control
Project
Commissioning
Control
11 October 2010
Abu Dhabi Site Visit
3
MAIRE TECNIMONT’S EXECUTION APPROACH
•
Integrated EPC Project Task Force (A-management team)
•
Common infrastructure and working methods
•
Integrated Information Business Management System
•
Work allocated where optimal technical offerings and cost
efficiencies exist
•
Project management teams always oriented to meet client and
specific requirements of each project
11 October 2010
Abu Dhabi Site Visit
4
PLANT OPERATIONS: CRITICAL POINTS
•
Selection of Project Managers
- Selection of A- Team
•
Coordination of procurement and logistics
•
Selection of Sub-Contractors
•
Constant Control of project advancement with monthly
meetings with clients
- Resolution of bottlenecks
•
Construction execution plan
•
Commissioning/start up execution plan
11 October 2010
Abu Dhabi Site Visit
5
HEALTH SAFETY SECURITY ENVIRONMENT (HSSE)
•
Identify project specifics and risk areas
•
Develop programs and specific plans
•
Set targets and KPIs across all levels of project staff
•
Develop plans, monitor, report and improve
•
Visible leadership
•
Ensure execution plans embody safety
•
Entire project team is responsible for safety
•
“Constructability” reviews include safety aspects
11 October 2010
Abu Dhabi Site Visit
6
HR SAFETY STANDARDS ACHIEVED
•
Home Office Engineering Manhours:
– 4.7 million (including subsidiaries;
Jan-August 2010)
•
Safety achievements :
– 0.01 LTI frequency (significant
improvement with respect to
2009);
(1/11th of OGP* industry
benchmark).
– Achieved on more than 18 million
Construction Manhours on O&G,
Chemical/Petrochemical and Power
Plants (thru 30th April 2010)
* OGP is the International Association of Oil & Gas Producers.
11 October 2010
Abu Dhabi Site Visit
7
AGENDA
1.
Plant Operations
2.
GASCO Project overview
11 October 2010
Abu Dhabi Site Visit
8
INTRODUCTION TO GASCO
THE CLIENT
•
Abu Dhabi Gas Industries Ltd. (GASCO): operating company
responsible for the processing of natural and associated gas
onshore oil operation in UAE.
•
GASCO:
– one of the biggest industrial complexes in the UAE but also one
of the largest gas processing companies on the world
– processing capability in excess of 4 bn standard cubic feet /day
(scfd), producing 140,000 barrels of condensate - 4,000
tonnes of sulphur, 18,000 tonnes of NGL/day.
•
Lean Gas (methane) delivered into the gas distribution network is
mainly used as fuel (for power generation and water desalination)
and feedstock for ADNOC’s field, refinery & petrochemical plants
and other facilities.
11 October 2010
Abu Dhabi Site Visit
9
INTRODUCTION TO GASCO
IGD PROJECT LOCATION
11 October 2010
Abu Dhabi Site Visit
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INTRODUCTION TO GASCO
OVERALL PROJECT SCHEME
•
•
New Habshan 5 project developed to accommodate additional
Offshore Gas production and additional associated gases that
will become available as a result of the expansion of ADCO’s
onshore oil production.
The Habshan 5 facilities consist of:
– Two trains of feed gas compression for the new associated
gas feeds
– One train of condensate stabilization
– Four gas sweetening and dehydration trains
– Two rich gas NGL recovery trains
– Four sulphur recovery units (99.9% sulphur recovery)
11 October 2010
Abu Dhabi Site Visit
11
GENERAL CONCEPTS
Plant Capacity：
• Gas Treatment Capacity = Total 2,150 Million Standard Cubic
feet per day (equivalent to 66 Million
Standard Cubic metres per day)
• Sulphur Product = Total 5,200 Tons per day
Plant:
• Feed Gas Compression JGC
• Acid Gas Removal Tecnimont
• NGL Recovery JGC
• SRU & TGTU Tecnimont
• Flare JGC
Tecnimont
Area
SRU
AGR
Flare
JGC
YOC
Area
NGL
11 October 2010
Abu Dhabi Site Visit
Feed
Compression
MOC
12
GAS PROCESSING TRAIN
To sales
gas pipeline
Ethane
Source: Wikipedia
11 October 2010
Abu Dhabi Site Visit
13
MANPOWER ESTIMATE
Home Office
Tecnimont Milano HO
Unit
Total
MM
Peak
250
9,200
Tecnimont India Eng
MM
350
Expected Peak period is between May’10 – Sep’10
Site Construction
Tecnimont site
Unit
Total
Avg. Peak
MM
160,000
9,000
Expected Peak period is between Sep’11 – Mar’12
11 October 2010
Abu Dhabi Site Visit
14
PROJECT OVERVIEW
Major Construction Quantities (by Operation Center)
Discipline
Unit
Yokohama
Milan
Total
Concrete
M3
40,000
120,000
160,000
Steel Structures
MT
33,000
37,000
70,000
Equipments
MT
21,000
49,000
70,000
Piping
MT
24,000
31,000
55,000
Piping
ID
1,300,000
2,000,000
3,300,000
M3: Cubic Metres; MT: Metric Tonnes ID: Inch Dia (Welding)
11 October 2010
Abu Dhabi Site Visit
15
WORK FORMATION
COMPANY HQ
COMPANY
Resident Team
(Tecnimont)
COMPANY
Resident Team (JGC)
Communication
JVPMB (JGC)
Communication,
Information In/Out
Tecnimont
Project Taskforce Team
(TCM - Milan)
JGC
Project Taskforce Team
(JGC - Yokohama)
Tecnimont
Site Team
11 October 2010
JGC
Site Team
Abu Dhabi Site Visit
16
OPERATING CENTERS
MOC
Tecnimont Milan
Tecnimont KT
Rome
YOC
JGC Yokohama
JGC Philippines Inc.
Manila
SOC
GASCO PJ Site Office
Tecnimont, ICB
Mumbai
11 October 2010
JGC Descon
Lahore
Abu Dhabi Site Visit
17
EPC CONTRACT
•
Effective Date: 29 July 2009
•
Contract Value (JV): 4.7 billion US$
•
Tecnimont scope of work: Engineering, Procurement, Construction,
–
•
Pre Commissioning and Testing plus 2 Years Operation Spare Parts
Main Contractual Dates:
– Phase 1 Mechanical Completion – Q1 2013
– Phase 2 Mechanical Completion – Q2 2013
– Phase 1 Test Run - Q2 2013
– Phase 2 Test Run – Late 2013
11 October 2010
Abu Dhabi Site Visit
18
PROJECT CHALLENGES
• Giant Project Involving Huge Bulk Quantities
–
•
Very Tight Project Schedule
–
–
•
Involvement of Tecnimont KT (former Technip KTI)
Revival of Material Booming (Prolonged Delivery)
–
•
Comprehensive Project Control
Construction/Commissioning Driven Schedule
Sulphur Recovery Unit (SRU) exceptionally large scale
–
•
Avoidance of Recycling Engineering & Procurement
Early Purchase Commitments
Tight Construction Market (Shortage of Skilled Labour)
–
11 October 2010
Early Subcontracting
Abu Dhabi Site Visit
19
VISIT ROUTE
SRU & TGTU
AGRU
Flare
NGL
Feed Gas
Compression
11 October 2010
Abu Dhabi Site Visit
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PROJECT OVERVIEW
Interconnecting Pipe Rack Erection
Construction Sulphur Pit Unit 550
11 October 2010
Abu Dhabi Site Visit
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