Défis, difficultés et succès. Directeur de Projet

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Défis, difficultés et succès

des grands projets.

Le défi GNL au Qatar

Stephane LAGRANGE

Step a e

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T

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Technip Today

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Qatar, a Key Player in the LNG World

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Ras Laffan Industrial City and the 3 Mega LNG Projects

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Challenges of Qatar Mega LNG Projects

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New technologies

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Worldwide work locations

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Human factors

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Security/safety

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Camps

p

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Logistics

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Construction

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Start-up

Sta t up

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Technip Today

Worldwide leader in engineering project management and technologies

Worldwide leader in engineering, project management and technologies,

serving the oil & gas industry for more than 50 years

►

A regular workforce of 23,000 in 48 countries

►

Industrial assets on all continents a fleet of 17 operational vessels (19 vessels by

►

Industrial assets on all continents, a fleet of 17 operational vessels (19 vessels by

2011)

►

2009 revenue: €6.4 billion

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Technip delivered major energy projects in 2009 / 2010

250

300

llio

n

s

)

QGX

QCS

200

h

ous

(

M

i

RGX

100

150

tio

n

m

a

n

h

Yemen

LNG

Khursaniyah

50

C

ons

tr

u

c

t

Millau

Viaduct

Yansab

Ethylene

3

0

C

Ethylene

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Technip Today

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Challenges of Qatar Mega LNG Projects

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New technologies

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Human factors

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Security/safety

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Camps

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Construction

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Record LNG TRAIN CAPACITY (existing or under construction)

Mt/y

7 8 9 _{Qatar mega} Trains

Mt/y

5 6 7 2 3 4 Yemen 0 1 2 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 5

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Estimated World liquefaction capacity (Mt/y)

77 Mt/y

0 20 40 60 80 100 Malaysia Qatar Indonesia

77 Mt/y

Egypt Australia Trinidad & Tobago Nigeria Algeria Libya United States Abu Dhabi Brunei Oman In operation Feb, 2010

Under construction Future projects

Iran Eq Guinea Norway Russia Yemen

Qatar – The largest LNG

producer since 2008

6

Peru

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Start-up

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Qatar Mega LNG Projects site of Ras Laffan

-IRAN South Pars Gas Field Oil Field Umm Al Irsham N h Fi ld QATAR

Ras Laffan

Maydan Mahzan Idd El Shargi Halul Is. North Field

Dolphin Gas Pipeline Project

Q DOHA Al Wakrah Dukhan A Structure (North) Bunduq Idd El Shargi (South Dome) Bul Hanine dd S a g (North Dome) 8 Messaied A Structure (South) (North) Bunduq

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Ras Laffan Industrial City

1

North Field

Exports through RL Port

LNG trains

LNG

GTL products

GTL plants

Ras Laffan Industrial City: 250 km2

gas

Condensate DSC LSC PC

R

Condensate

Refinery Refined products_{Naphtha, Gasoil, Kerosene}

Export IPP1&2 Oryx Local

Gas projects

Naphtha, Diesel, LO, Paraffins

GTL plants

DSC, LSC, PC Sulfur Raw gas pipeline

Sulfur

Ethane

Petrochemicals

Crackers

LPG

LPG_{C3, C4} IPP1&2 Fuel gas Lean gas pipeline Ethane pipeline

Petrochemicals

Polyethylene, glycols PE units Ethylene pipeline p p Lean gas

export line EXPORT

9 MESSAIED

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Ras Laffan Site View East side

-5 LNG Storage tanks ► Qatargas II (QP/ExxonMobil/Total) 5 LNG Storage tanks ► Qatargas II (QP/ExxonMobil/Total)

• 2 trains of 7.8 Mta LNG

• APCI AP-X

• EPC Contract signed Q4/2004

► Qatargas III (QP / ConocoPhillips)Q g (Q p ) Qatargas IV (QP / Shell)

• APCI AP-X

2.5 km

► Al Khaleej Gas Phase 2 (AKG-2) ► RasGas III QP/Exxon Mobil

• APCI AP-X

j ( )

• RasGas, on behalf of ExxonMobil

• 1.25 Bscfd sales gas

• Ethane recovery

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The largest LNG trains and the largest LNG terminal in the world

► CLP -“Common LNG Storage” QGII RGIII QGIII/IV

• New process APCI “AP-X” _{QGII; RGIII; QGIII/IV}

•

5+2 x 140 000 m3 tanks

•

6 BOG compressors

•

3 new berths

New process, APCI AP X

• 6 trains: 7.8 Mta - very large train capacity

• 99% C3+ recovery

• New compressor drivers (GE Fr 9)

• Large utilities and offsites

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14 000 m3/h/berth

•

2 x 36” lines/berth

•

Simultaneous loading to 2 berths 11

g

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Qatar, a Key Player in the LNG World

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New Air Products AP-X Process

3 refrigerant cycles

each

with GE Frame 9E

driver

C3 Refrigerant string

All exchangers in C3/Pre-cooling section

13 Mixed Refrigerant string Nitrogen Refrigerant string

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New – GE Frame 9E in Mechanical Drive

Frame 9E Incentives

• High Power - 100 MW site rating (49o_{C day)}

• 3000 RPM - better compressor speed match Fl t LNG d ti

Customized for LNG

• Flat LNG production

Frame 9E

• 130 MW ISO

Service

• Speed range 96%-102% • Continuous duty, base load • Extended maintenance

intervals

• 210,000 kg package • 50,000 kg rotor

intervals

• Meets Qatar Environmental requirements using DLN1

Motor/Generator

• 45MW

• 60MW during peak

• C3 & N2 send power to MR

275 MW Total Refrigeration

Power Required

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Challenges of Qatar mega LNG Project

CTJV Yokohama Office

♦Overall Project

Paris, France

Worldwide work locations

& Technip Abu Dhabi Chennai ♦Overall Project

Management and Implementation

♦Engineering for Process Area

CTJV Paris Office

♦Engineering for Common, Utilities, Offsite and a part of Process Areas

Yokohama , Japan

& Technip Abu Dhabi, Chennai, Chiyoda Milano, Philippines…

And all our suppliers around the World

♦Overall Procurement Management and Execution

Ras CTJV SITE Office – Qatar

-♦ All Construction and Site Prefabrication Work

♦ Pre-mechanical Completion Work

CTJV Doha Office

♦Administrative Work

♦Interface with National and Local

Doha, Qatar Ras Laffan, Qatar

♦ Pre mechanical Completion Work

♦ Field Engineering

♦ Procurement Services in Qatar and Other Surrounding Gulf Countries

♦ Customs Clearance Coordination at Ras Laffan Port _{Government Authorities}

♦Customs Clearance Coordination at Doha Port and Logistics

Coordination

Qatar

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People : A mosaic of cultures and religions

¾

Some Illustrating Key Figures

More than 200 000 persons who have worked on one of the 3 Qatar Mega LNG Project

Sites

More than 75 000 persons mobilized together at the peak

86 Nationalities

¾

A mosaic of cultures and religions

For each different culture a different perception and behaviors

For each different culture, a different perception and behaviors

¾

TECHNIP’s approach: understand

Assessing the expectations of the different cultural or religious groups

Identifying the common elements between the different groups and the elements that can y g g p potentially cause issues

¾ There is a real need to uncover and deal with the differences during the project start-up process and to continuously or periodically take account these matters during the project

implementation.

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S

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Security : approach and dedicated measures

¾

Each stage of project presents different risks

¾ Mobilization phase: set up of security measures

¾ Various construction phases: increase of the risks with number

¾ Various construction phases: increase of the risks with number of workers and equipment on site, riots, …

¾ Commissioning phase: increasing sensitive areas on site, with specific needs

¾ Demobilization phase: Ensure people leave the site voluntarily and smoothly.

¾

Specificity of the 3 Qatar LNG Mega projects:

Due to such extraordinary mass of workforce (75000 persons

at peak and 86 nationalities),

p

)

Technip had implemented a

specific security system on site

including:

- a staff of security personnel (300 persons at peak)

- Implementation of the Joint Operation Center (JOC) with Client and Contractor in charge to coordinate any Emergency Response Plan

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Challenges of Qatar mega LNG Project

S f

/

i i

f W kf

Safety / training of Workforce

¾

Safety level on a construction site depends on the

behaviors of your workers, so it is directly depends on

the skill level of the manpower and their safety

awareness.

So maintaining an high level of safety performance has been

a real challenge.

¾ Global ratio of 1 safety personnel for 50 workers

¾ Intensive training program in 14 different languages:

¾ More than 200 000 HSE induction trainings

¾ More than 27 000 Training sessions including various safety Training, Work at height, H2S, etc and craft trainings

¾ High level of Safety equipment provided to the workforce

As result an overall outstanding safety performances in regards

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As result, an overall outstanding safety performances in regards

to the size of the construction sites and number of people

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From the desert to camps facilities for 60 000 persons

Number Capacity Contractor Capacity Subcontractors

Number of Camps Capacity Contractor Camps p y Camps QGX 4 1311 21194 QCS 4 1146 16114 RGX/AKG2 6 1706 21370

Nov 2004

RGX/AKG2 6 1706 21370 Total 14 4163 58678

Camps Utilities

Jan 2006

Average Water Consumption : 350 liters/Day/Person

Average Power Peak:

Camps Utilities

Average Power Peak: 1.8 kW/person

Average Sewage Disposal: 340 liters / day / person

March 2008: Trees have grown up…

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A

h

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f f i h

Among the world’s largest projects in terms of freight movements

to a single place

¾ A i ti 3 Milli F i ht T f i t d t i l i d i Q t

¾ Approximative 3 Millions Freight Tons of equipments and material receivedin Qatar Ports, without major incidents or issue

¾ More than 20 000 TEUs (Twenty feet equivalent unit) containers received and delivered through Doha Port

through Doha Port

Main Challenges:

¾ Congested schedule of Ras Laffan Port operations

¾ Heavy flow of air shipment against limited capacity of Doha Airport

¾ Shortage of container storage capacity in Doha Sea Port

¾ Other regional main ports congestions and delays

25 ¾ Shortage of feeder vessels from Mother ports to Doha Port

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Ship arrival for 3 LNG Mega Projects

20 25

Nb of Vessels

15 20 5 10 0

¾

450 vessels in 43 months

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Challenges of Qatar mega LNG Projects

C

i

Construction

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Huge quantity of materials & equipment

•

700 000 m3

of concrete

137 000 t

f t l f

k (14 ti

Eiff l t

)

•

137 000 tons

of steel framework (14 times Eiffel tower)

•

270 000 tons

of machinery (950 Airbus A380 planes)

•

180 000 tons

of piping

•

20 000 km

of electrical and instrumentation cable

•

The highest flares are

200 meter high

¾

500 000 m2

(66 soccer fields)

for each of the 3 projects

¾

75 000 people at peak

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75 000 people at peak

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700 million construction man-hours

¾

Sheer size required new construction methods

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At construction peak: about 5300 equipment on site

35 Transit Mixers 62 Tower cranes 682 Crawler & Mobile cranes cranes 3646 Welding machines 79 E t

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797 Buses Excavators

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Qatargas II - Erection of AGRU Absorber, Feb 2007

¾

1 absorber per train,

6 in total

¾

1,450 Tons each

Height = 45 7m

Height = 45.7m

Diameter = 7.4m

¾

Lifted with Platform Ringer

Crane, Capacity 2,000T

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Fresh water closed loop cooled with sea water

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Challenges of Qatar mega LNG Projects

B t l

But also….

¾

Shortage of resources in Qatar and in the Gulf

: specialized manpower,

supervision

¾ Construction subcontractors low productivity

¾

Shortage of raw material

(cement, washed sand, argon gas, diesel ...)

¾ For the Argon Gas, TECHNIP has developed in partnership with a Gas supplier, a Argon Gas Station to supply all the 3 LNG projects and Ethylene Projects

Gas Station to supply all the 3 LNG projects and Ethylene Projects

¾

Aggressive schedules and simultaneity of 4 mega projects

¾ inter-project dependencies

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Infrastructure limitation

:

¾ Port congestion, Road traffic congestion in RLIC, supply of water at risk

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Start-up: the challenges of the World’s Largest LGN train

¾

I t

i

f

ti

f

t

i l /

i

t d

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th l

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Intensive program of preservation of material /equipment during the long construction

phase with a dedicated team

¾ Protection of the valves

¾ Protection of all rotating equipment

¾

Implementation of High Pressure Leak test with Helium Leak Detection (HLD) :

The Helium Detection process when combined with nitrogen as the pressurization medium can identify leaks to the order of 0.1 standard cubit feet of gas per year.

1.

This helps to save lost production, time and costs compared to repairing leaks after start up. 2. This ensure a safe start up and operation with the Sour feed Gas

¾

High velocity in Gas lines:

Due to the exceptional size of the plant, the flare design is about 3500 t/h !

This required to adopt advanced method of sizing of the flare system

35

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TODAY

¾

4 Trains in full operation in Qatargas and Rasgas

¾

1 Train on Qatargas 3: in start up phase

¾

The last Train of Qatargas 4 will be in operation by end of 2010

Qatar will celebrate the 77 MT/y

of LNG Capacity production

on Dec 13, 2010

in presence of The Emir of Qatar

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Qatargas II – View from Flare stack 24th May 2007

Qatargas– View as of mid 2009

Qatargas II – View from Flare stack 24th May 2007

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QATARGAS LNG Projects – TECHNIP Staff – October 2009

Q

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Questions ?

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Thank you!