high quality feed

0

High Quality FEED

in SK E&C

2015.Mar. SK Engineering & Construction LTD. Process Engineering Team

1

CONTENTS

High Quality FEED in SK E&C

A. SK Introduction ------------------------------------ 5 min.

B. FEED in Overall Engineering Cycle ------------------------------------ 5 ~ 10 min.

1) Feasibility Study & Visualization

2) CEP - Conceptual Engineering Phase

3) FEED - Front End Engineering Phase

C. FEED – SK E&C Execution ------------------------------------ 20 min.

A. Project Execution Strategy

B. Optimal Complex Design Strategy

C. Contribution

D. Major Deliverables

E. Tools & Systems

F. Experiences

D. Q&A ------------------------------------ 15 min.

2

SK Group SK is one of the top 3 biz conglomerates in Korea with combined revenue of U$ 149 Bil. and comprised of 80 affiliate companies sharing the SK brand and culture

SK Innovation SK Energy SK Global Chemical SK Trading International SK Gas SK Lubricants

SK Telecom

SK Hynix

SK E&C

SK Shipping

SK Broadband

SK Telink

SK C&C

SK Networks

SK Securities

Walkerhill Hotel

Energy / Chemical

Trading / Service Telecommunication

Group Sales : U$ 149 Bil. Net Profit : U$ 4.3 Bil. Employees : Over 70,000 Korea Economy Contribution :

11% of GDP

*fiscal year 2013

Business Development Center – Oil & Gas Plant -

A. SK Introduction

3

SK E&C

ENR INTERNATIONAL CONTRACTOR (‘14)

BACKLOG ORDERS (‘13)

OF PROVEN SUCCESS SINCE 1977

TOP 43

US$ 20 BILLION

38 YEARS

OF PROJECT EXPERIENCE OVER 30 COUNTRIES

SK E&C, a global leading EPC contractor with many success stories of multi-billion dollar EPC projects, also serves our valuable clients with comprehensive services for Business Development

Business Development Center – Oil & Gas Plant -

A. SK Introduction

4

0.5km 1km

SK Energy (Inchoun Complex) • CDU : 275,000 BPSD (2 Units)

• VDU : 70,000 BPSD

• HCK : 40,000 BPSD

• VBU : 40,000 BPSD

• HPU : 85 MMSCFD

• SRP : 150 T/D x 2 Trains

SK Energy (Ulsan Complex) • CDU : 845,000 BPSD (5 Units)

• VDU : 85,500 BPSD (3 Units)

• RFCC : 57,000 BPSD

• HCK : 45,000 BPSD

• Reformer : 45,000 BPSD

• ARDS/VRDS : 72,000/40,000 BPSD

• HPU : 145 MMSCFD

• SRP : 1,195 T/D

SK Energy

A. SK Introduction

5

Total

Solution

Provider

Overall Engineering Life Cycle :

Comm. &

Start-up (Operation &

Maintenance)

Customer

EPC Engineering

Procurement

Construction

FEED Front End

Engineering

Phase

CEP (Conceptual

Engineering

Phase)

Visualization Feasibility

Study

B. FEED in Overall Engineering Lift Cycle

6

CEP (Conceptual

Engineering

Phase)

FEED Front End

Engineering

Phase

EPC Engineering

Procurement

Construction

Comm. &


Maintenance)

Total

Solution

Provider

Customer


Feasibility

Study Visualization

Objective:

To Evaluate the Feasibility of the project

To Develop Strategies & Configuration to maximize the Economic Value of the project

To Establish Business Opportunities and Risks from the project

Main Phases:

Market Analysis and Price Forecasting

Technology Screening and Ranking

LP Case Configuration and Screening


7

Objective:

To define and finalize “Design Basis” with Client’s confirmation

To select the Optimal Configuration Case

ITB to Licensors & Licensor Technical / Commercial Evaluation

UT/OS Technical / Commercial Evaluation

Select Optimal Licensor(s)

Select Optimal Technologies for UT/OS Design

Total Investment Cost Estimation (ex. +50 and -20% of the actual installed cost)

CEP (Conceptual

Engineering

Phase)

FEED Front End

Engineering

Phase

EPC Engineering

Procurement

Construction

Comm. &


Maintenance)

Total

Solution

Provider

Customer


Feasibility

Study Visualization

Customer


Main Phases :

Select Optimal Configuration Case

Design Basis / Design Criteria / Constraints

Licensor Selection / Technology Selection

Cost Estimation

8

“FEED” stands for Front End Engineering Design.

“FEED” is Basic Engineering which comes

after the Conceptual Design or Feasibility & Visualization Study.

“FEED” focuses

“Technical Requirements”

Reflect all the client project requirements and avoid significant changes during the next execution phase (ex. EPC

phase)

“Investment Cost Estimation for the Project”

Class II or III Cost Estimation to provide accurate data to the Client to enable launching the Project

“FEED” produces the Design Package for

Bidding the Execution Phase Contract (ex. Next EPC phase ITB)

Using as the Design Basis for the Project

CEP (Conceptual

Engineering

Phase)

EPC Engineering

Procurement

Construction

Comm. &


Maintenance)

Total

Solution

Provider

Customer


Feasibility

Study Visualization

FEED Front End

Engineering

Phase


9

SK E&C FEED Execution

Why SK E&C?

SK E&C Execution Strategy

SK E&C Design Strategy

SK E&C Contribution

SK E&C FEED Major Deliverables

SK E&C Tools & Systems

SK E&C Experience

FEED Front End Engineering Design

C. FEED – SK E&C Execution

10


Why SK E&C?



SK E&C Contribution



SK E&C Experience



Hands-on,

Experienced

Personnel

Abundant Project

Experiences

Strong Connection

with Clients &

Licensors

PROJECT

SUCCESS

Schedule Driven for Project

Early PO for LLI through strategic alliance major manufactures

Overlapping between FEED and EPC

Total Guarantee from FEED to EPC work

Optimized O&M Service through organic collaboration with SK Energy from early stage

Client’s cost down through cumulative know-how and creative idea Value Engineering

Acquiring proven Licensor through SKEC’s long term relationship Collaboration

Project Operation

Transparency Collaboration with Client’s engineer

Seamless Work

One stop process by one contractor

Shorten Period No idle time to select bidder for EPC work

Reliability Single Point Responsibility from FEED to EPC

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Why SK E&C?



SK E&C Contribution



SK E&C Experience

COST

Transparency based on mutual trust (Mutually agreed OBE Procedure)

Minimize uncertainty

Execute value Engineering

Lessons Learned Workshop

SCHEDULE

Early freezing of conceptual design

Improvement of approval cycle through joint review meeting

Maximize the utilization of main spec.

Early issuance of MR

Team building Efforts

QUALITY

Design Quality Audit by an independent internal audit team consists of

Senior Expert Group

Involvement of experienced engineers

Execute safety study : HAZOP,SIL,etc

“Complete Reliable FEED Package on-schedule”


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Why SK E&C?



SK E&C Contribution



SK E&C Experience

MANAGING DEVELIVARBLES

OPTIMAL COMPLEX DESIGN

PROJECT EXECUTION

A consistent set of design specifications for the entire complex.

A smooth transition from the Licensors and/or Basic Design Contractors

to the detailed design contractor enabled by early participation by the

contractor as resident engineers.

Minimizing the energy consumption for the site as a whole using process

models and pinch techniques.

Optimizing the Hydrogen Network by optimizing the process conditions for

the hydrogen sources and sinks, hydrogen recovery using process model and

pinch analysis.

Optimizing the individual process units using rigorous process models and

carefully selecting optimal process design parameters and catalyst.

Single point accountability to simplify the contract structure, expedite

decision making and conflict resolution

Coordination and management of all key meeting to expedite design work.

Conducting optimization studies in parallel with the basic design of the

process units.

Developing and Updating conceptual design of the off-sites and utilities

systems in parallel with the process unit designs.

Steering Committee with Senior Project Level for improvement of project

inconvenience regarding project managing and well decision making for

project issue.

“Complete Reliable FEED Package on-schedule”


13



Why SK E&C?



SK E&C Contribution



SK E&C Experience

SKEC will transfer the Client’s requirement

to Licensor to minimize the Rework.

“For the successful completion of the Project, SKEC will involve in the Licensor

Design Work from early stage”

SKEC will proceed the FEED work with Piecemeal Basis Licensor Product and issue the M.R. for Long Lead Equipment as earliest as possible.

SKEC will support Licensor to freeze the plot plan

upon close collaboration with Client.

“SHORTEN THE OVERALL SCHEDULE”

& “ENSURING DESIGN QUALITY”


SKEC will participate in the V.E session of Licensor PDP phase for optimizing CAPEX & OPEX based on SKEC’s EPC experience.

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Why SK E&C?



SK E&C Contribution



SK E&C Experience


1) Project Overview

Project Capacity

Project Operation Mode

Project Products & Required Product Specifications

Market Analysis

Storage Management & Logistics

Potential Location & Conditions

Future Expansion / Future Facility

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Why SK E&C?



SK E&C Contribution



SK E&C Experience


1) Project Overview

- Project Capacity

- Project Operation Mode

- Project Products & Required Product Specifications

- Market Analysis

- Storage Management & Logistics

- Potential Location & Conditions

- Future Expansion / Future Facility

2) What Infrastructure / Utility?

Site acquisition and terrain?

Access to the Site?

Sharing and/or Utilizing the existing infrastructure to be built?

Access to the site and availability of utility such as NG and water?

Viability of Power Plan within complex?

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Why SK E&C?



SK E&C Contribution



SK E&C Experience


1) Project Overview

- Project Capacity



- Market Analysis





- Site acquisition and terrain?

- Access to the Site?

- Sharing and/or Utilizing the existing infrastructure to be built?

- Access to the site and availability of utility such as NG and water?

- Viability of Power Plan within complex?

3) Review and Confirm Refinery Configuration in order to minimize operating risk and maximize product yield.

Any technical argument and/or data flow consistency between basic engineering contractors (ex. Licensor)?

Client requirement including “Alternative Operation Mode” is well incorporated?

Corrosion Control & Mitigation System?

Multi-trains (or process units) design scheme is reasonable?

LPG (CE/C4) Management – All produced LPG is sent to fuel? Or other conversion unit is there?

Minimum use of Hydrogen, while the commercial and environmental aspects have to be considered?

Hydrogen producer? SRP / Off-gas Balance / POx / PSA

Optimal and Safe & Reliable Design for Flare & Vent System?

HP, LP, LLP, Acid, HF, Cold Flare Systems?

Location and Number of Flares?

Grouping considering refinery start-up & shutdown strategy?

17



Why SK E&C?



SK E&C Contribution



SK E&C Experience


1) Project Overview

- Project Capacity



- Market Analysis





- Site acquisition and terrain?

- Access to the Site?

- Sharing and/or Utilizing the existing infrastructure to be built?

- Access to the site and availability of utility such as NG and water?

- Viability of Power Plan within complex?

3) Review and Confirm Refinery Configuration in order to minimize operating risk

and maximize product yield.

- Any technical argument and/or data flow consistency between basic engineering

contractors (ex. Licensor)?

- Client requirement including “Alternative Operation Mode” is well incorporated?

- Corrosion Control & Mitigation System?

- Multi-trains (or process units) design scheme is reasonable?

- LPG (CE/C4) Management – All produced LPG is sent to fuel? Or other

conversion unit is there?

- Minimum use of Hydrogen, while the commercial and environmental aspects have

to be considered?

- Hydrogen producer? SRP / Off-gas Balance / POx / PSA

- Optimal and Safe & Reliable Design for Flare & Vent System?

HP, LP, LLP, Acid, HF, Cold Flare Systems?

Location and Number of Flares?

Grouping considering refinery start-up & shutdown strategy?

4) Licensor (Basic Engineering Contractors) Coordination

Basic Engineering Design Data

• Project Information

• Meteorological Conditions

• Utility Condition

Process Design Basis

• Plant Capacity & Site Location

• Applicable Codes and Standards

• Feedstock Properties

• Operating Mode & Design Case

• Battery Limit Conditions

System Process Design Criteria

• Numbering System

• P&ID Typical Arrangement &

Specification Recommendations

• Guidelines for Equipment &

Instrument Design

Plot Plan : Support for Early Freezing

PFD Review

• Control Scheme Setup

• Operating Condition Review

MSD Review

• MSD Review from the Economic

Point of view

P&ID Review

• Conformity Check against System

Process Design Criteria

• Control Scheme Check against PFD

• Material Review against MSD

• ESD Logic Review

Equipment Datasheet Review

• Conformity Check (H&MB, MSD,

Design Criteria)

• Review of Over-design and Sparing

Philosophy

Licensor Work Stage Licensor Kick-off MTG Stage

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Why SK E&C?



SK E&C Contribution



SK E&C Experience

Process Engineering

• Design Basis

• Process Description

• Process Flow Diagram

• Equipment List

• Process Equipment Datasheet

• Hydraulic Calculation

• Piping and Instrument Diagram

• Process Instrument Datasheet

• Line Designation Table

• Utility Summary

• Effluent Summary

• Relief Load Summary

• Chemical and Catalyst Summary

• Operation Philosophy

• Mechanical Equipment Design

Criteria

• Equipment Datasheet Update

• Equipment Specification

• Equipment Construction and

Installation Specification

Mechanical Engineering

• Instrumentation & Control

Engineering

• Instrument Design Criteria

• DCS/ESD/FGS Specification

• Instrument Datasheet

• Control System Configuration

Diagram

• Instrument Specification for

Mechanical Package

• Typical Standard Hook-up

Drawing

I&C Engineering

• Electrical Engineering Design

Criteria & Philosophy

• Electrical Equipment Datasheet

• One Line Diagram

• Hazardous Area Classification

Plan

• Substation Equipment Layout

• Main Cable Route

Electrical Engineering

• Plot Plans

• Piping Material Specification

• Piping Specification

• Count and List of Piping Material

• Tie in List

• Equipment Location Plan

• HVAC (Design Basis, Spec &

Conceptual Drawing)

Piping Engineering

• Civil Design Criteria

• Structural Design Criteria

• Building Description

• Project Specification

• General Design & Layout Plan

• Site Grading Plan

• Topographic Survey Map

• Soil Investigation Report

CSA Engineering


19



Why SK E&C?



SK E&C Contribution



SK E&C Experience

No. DISCIPLINES TOOLS & SYSTEMS

1

Process & System

ASPEN-Tech. PIMS

2 ASPEN ENGINEERING SUITES

3 AUTOCAD

4 INVENSYS SIMSCI

5 PROMAX

6 SPPID

7

Mechanical

COMPRESS

8 PULSE

9 PV ELITE

10

Piping

MICROSTATION

11 PDS / SP 3D

12 PDMS

13 Electrical

E-TAP

14 SPEL

15

I&C

ANSYS

16 INSTRUCALC (VER 7.1)

17 SPI

18

CSA

REVIT

19 SAP2000

20 STAAD PRO

21 TEKLA

22 Design HSE PHAST RISK VER 6.7

23

Material / Stress / HVAC /

M.W.E

CAESARII

24 FE-PIPE

25 FLOWMASTER

26 HTRI

27 MATHCAD

28 Start-up / O&M SKPCM


20

BM & Convert

SIMS

IMMS Ⅲ / Ⅳ

C-Works

SPF

Building Info

Eng’g Drawing

STAAD

Stl Str Analysis

SPI

Intelligent Instr. Eng’g

e-Draw

Ortho Gen.

BOM Gen.

e-Weld

Weld Control

ISOGEN

ISO Creation

ETAP

Elec. Transient

Intelligent Electrical Eng’g

PDMS

CAESAR II

Pipe Str Analysis

HTRI/HTFS

(File/Full)

HYSYS/PROII

Aspen+

Conceptual Cost Est.

Heat Transfer App. Process Simulator

Process Design

SPPID

Intelligent PID

Engineering Data Warehouse / EDMS / Engineering Integration

Document Management

Integration Batch

Current Future

IEES

i-PAM

Piping Joint

Project Web (SKEC EDMS based on DOCUMENTUM)

SK ACE

Engineering

Module

Construction

Module

Site Procurement

Module

Current

Description of Application

In-House

Estimation

TOMMS

Total Procurement

Description of Application Description of Application

Document

Management

Application

Integration

Engineering Data

Management Workflow

Change

Management

ABE

(Zyqad)

Developing

SPEL SP3D

TEKLA

REVIT

PJCS

Const. Progress

CPRS

Const. Daily

CDRS

BPCM

Stl. Tracking

Client EXTERNAL USER

PMC Joint Venture Subcontractors Site Vendors

EPPM EDPR RPR PPR

ACCE(Kbase)

Elec. Design

IEDS

Ready for project

Description of Application

Intelligent Material Management

SPM

STMS

Spl. Tracking

PDS

Inst. Design

IDPia

SpoolGen

Spl. Drawing

SK-PCM

Comm. task

SSD

System Def.

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