concept to completion best practice in delivering complex projects

Foster Wheeler. All rights reserved. Foster Wheeler. All rights reserved.

Concept to Completion Best Practice in Delivering Complex Projects

Damon J Hill Senior Vice President, EMEA Business Development John Payne Chief Static Equipment Engineer


Concept to Completion

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Foster Wheelers Philosophy for adding value to client investments

Best Practice from Investment Concept to Beneficial Operation

Critical Phases of Project Delivery

Applying Common Principles

From multi-million dollar to multi-billion dollar investments

Case Studies Examples of delivering highly complex projects

Expertise in Engineering, Procurement & Construction Logistics

Best Practice in Delivering Complex Projects

Defining a road map

Building Confidence


Expanding Horizons Delivering Long Term Value to Client Investments

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Technical Expertise

Project Delivery

Expertise

O&M Best

Practice

World Leading

Technology

Foster Wheeler seeks to work with clients and partners to deliver long term value to client investments

Foster Wheeler is focused on maximising value by combining our technical, O&M and project delivery expertise with world leading technology

Foster Wheelers Philosophy for Adding Value


Foster Wheelers primary objective is always to make the Clients decision making as simple as possible

Detailed study is essential to optimise the project and confirm feasibility on a robust basis ahead of any significant expenditure

A shortlist of technically feasible options should be generated with economic evaluation of the most promising

Investment planning should focus on all issues affecting project cost and development not just the configuration and technology

Investment Planning can be optimised across multiple assets and multiple units, and phased in accordance with financial constraints

Foster Wheeler is a World Leader in Concept Studies from multi-million to multi-billion dollar investments

Investment Planning / Concept Studies

. Bringing real, practical EPC experience to conceptual investment planning


Greenfield LNG plant and facilities 4.3 Mtpa liquefaction train 240,000 m3 LNG storage Utilities and offsites

Pre-FEED, FEED and EPC FW led JV

Innovation - optimised construction Modular construction technique World class safety record in the Thai

module yard. 35 MM man-hours without LTI

263 modules, totalling 52,000 tonnes, largest ~2000 tonnes

69 module shipments over 16 months. 40MW GTGs modularized

Karratha, Western Australia

Woodside Pluto LNG Project

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Study FEED EPCm PMC Services

Upstream Oil & Gas

LNG & Midstream Refining

Chemicals & Petrochemicals Environmental Power


A brownfield/revamp world-scale integrated refining and petrochemical project

Project value in excess of US$10 billion One of the largest integrated refining and

petrochemical projects built in one phase Over 226,000,000 site man hours The new facility processes 400,000 bpsd of

atmospheric residue from the existing refinery Capacity:

Refinery upgrade 400,000 bpsd Ethylene 1,300 ktpa Propylene 300 ktpa Polyolefins, solids and liquids 2,300 ktpa

Rabigh, Saudi Arabia

Petro Rabigh Refinery / Petrochemicals

Study FEED EPCm PMC Services

Upstream Oil & Gas

LNG & Midstream Refining

Chemicals & Petrochemicals Environmental Power


An holistic philosophy: maximising benefit from refinery upgrades Unparalleled Process, Engineering and

Construction expertise for the whole refinery: Working with the client to define the key

upgrade objectives clear terms of reference for the planned investment

Maximizing technology feedstock flexibility and yield benefits together with operability and reliability improvements through application of expertise and best practice

Identifying constraints and impact on other refinery units and providing low cost solutions

Energy optimisation applying Foster Wheelers holistic approach in parallel

Engineering and Construction logistics total implementation expertise to minimise shutdown duration and associated risks

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Complex Refinery Upgrades Integrated Expertise

Foster Wheeler. All rights reserved.

John Payne

Chief Static Equipment Engineer

7


Safety Operational reliability Minimum turnaround time and risk to schedule Lowest possible cost Take advantages of process improvements

SO MUST

Maximise pre-turnaround and post-turnaround activities Maximise work done offsite Fit first time Quality of Installation Latest proven technology

Key Factors for all Operators

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Planning Execution E, P & C Logistics


Coke build up in reactor High temperature material degrading Erosion Thermal shock Shell refractory failure, gas tracking, hot spots, spooling Operational upset Cyclone and internals life: 15 to 25 years Expansion bellows life: 10 to 15 years Shell refractory life: 5 to 25 years

FCC Turnarounds

What are the Key Drivers?

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Lost revenue is $1 million to $2 million per day when not operating Typical turnaround time is 35 days or fewer

Run times have grown from 3 to 5/6 years continuous so need to

plan earlier and predict operational reliability a lot further ahead

FCC Turnarounds

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Significant Revenue and Margin Implications


The Project Decision Process for Refinery Upgrades

Project Delivery Excellence: Key Steps in the Study Phase

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Feasible Options

Maintenance Requirement

Process / Technology

Improvements

Planning TAR Duration Cost Estimate

Engineering & Construction

Conclusion & Execution Strategy

Licensor Selection

Risk / What-if Analysis

Client Needs


Study and EPC Timeline

Project Delivery Excellence: Timeline to Turnaround

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3 Years

Study Licensor Equipment Procurement

6 Months 3-6 Months 18 Months Min 3 Months

Equipment Delivery TAR Pre-TAR

3 Months

Foster Wheeler. All rights reserved.

Case Studies Delivering Highly Complex FCC Upgrades

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Case study 1: Stanlow Regen Head & Cyclones

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2009 study started

Cyclones end of life - will have been in service for 25 years

Options for replacing regen cyclones

2010 turnaround allowed cold survey of head cut line


12 pairs of cyclones Cyclones interlinked and

share secondary hangers Full trial assembly of

cyclones at fabricators works

Precision survey of hangers Data used to position

hanger nozzles in head Alignment blocks on

cross-overs

Case Study 1: Stanlow Head & Cyclones

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Use of electronic 3D solid edge model

Demonstrates clearances, access and future maintenance

Input into FEA analysis


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Cyclone assembly in transport CAN leaving fabricators work

Module weight 265te +15m diameter

Height restriction on canal of 12m


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Head c/w refractory being loaded into special barge

Head weight 185te


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Floating crane at Antwerp lifts head onto cyclone assembly

Cyclone hangers then are installed

Special lifting arrangement to equalise loads into the head

All shell deflections have been analysed to avoid any damage to refractory


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Head module on route from dock to Refinery

Motorway closure Probably the

largest head & cyclone assembly to be transported to site as one piece

Movement date of 24 March 2013 set 2 years in advance


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Tree pruning done one year in advance


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Head assembly being transport through refinery

New site entrance created

Head assembly now jacked up to clear piping either side of road


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Final site assembly

Head assembly being lifted onto Dip Leg frame


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Skid Bridge 35m Long over pipe band allows complete head frame assembly to be moved from off plot location to crane



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Final lift of new head at 440Te


Case Study 2: Regen Head & Cyclones

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Methods Studied and Crane Problems

Regenerator Cyclones End of Life, Replace Cyclones complete with Head is normal Extremely Tight Plot Space and Route Restrictions Come up with split head frames Main Crane Remained the problem space and undergrounds


Case Study 2: Regen Head & Cyclones

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Selected Option

Sequence Install Beams to support cyclones Secure cyclones at top Cut and remove head Remove cyclones as pairs Replace in reverse order


Case Study 3: Reactor Internal Riser & Cyclones ?

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Option at start of study

Problem Internal Riser Buckled Normal Head Replacement as

shown would also suggest replace cyclones as towards end of life.


Case Study 3: Reactor Internal Riser & Cyclones ?

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Option Suggested to Client

Option suggested to Client Cut Hole in top Head and replace Riser Only Delay replacing cyclones till next TA, this

gives time to upgrade technology for improved Product Slate


Early start

Its OK to think big

Overall process and mechanical solution

Consider whole refinery

At the end of the study, the client has an independent report that identifies the way forward

Most overall cost-effective solution

No surprises

Fit First Time

Conclusions & Execution Strategy

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Best Practice in Delivering Complex Upgrade Projects


Whatever the challenge, we can help

Foster Wheeler Concept to Completion

Consistent high quality delivered anywhere in the World

Further information: www.fwc.com [email protected]


www.fwc.com

Concept to Completion Best Practice in Delivering Complex ProjectsConcept to CompletionFoster Wheelers Philosophy for Adding ValueInvestment Planning / Concept StudiesWoodside Pluto LNG ProjectPetro Rabigh Refinery / PetrochemicalsSlide Number 7John PayneChief Static Equipment EngineerKey Factors for all OperatorsFCC TurnaroundsFCC TurnaroundsThe Project Decision Process for Refinery UpgradesStudy and EPC TimelineCase Studies Delivering Highly Complex FCC UpgradesCase study 1: Stanlow Regen Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 1: Stanlow Head & CyclonesCase Study 2: Regen Head & CyclonesCase Study 2: Regen Head & CyclonesCase Study 3: Reactor Internal Riser & Cyclones ?Case Study 3: Reactor Internal Riser & Cyclones ?Conclusions & Execution StrategyFoster Wheeler Concept to CompletionSlide Number 33

concept to completion best practice in delivering complex projects

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