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TRANSCRIPT
Défis, difficultés et succès des grands projets.des grands projets.
Le défi GNL au QatarLe défi GNL au Qatar
Stephane LAGRANGE Step a e G GDirecteur de Projet
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
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Technip TodayWorldwide leader in engineering project management and technologiesWorldwide 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
A long term solid partner
Technip delivered major energy projects in 2009 / 2010
250
300
llion
s) QGXQCS
200
hous
(Mi
RGX
100
150
tion
man
h
YemenLNG
Khursaniyah
50
Con
stru
ct Millau Viaduct
YansabEthylene
3
0
C Ethylene
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
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Record LNG TRAIN CAPACITY (existing or under construction)Mt/y
7
8
9 Qatar megaTrains
Mt/y
5
6
7
2
3
4 Yemen
0
1
2
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 20151960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015
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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
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Peru
Angolaproducer since 2008
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyLogisticsgConstructionStart-up
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Qatar Mega LNG Projects - site of Ras Laffan -
IRAN
South Pars
Gas Field
Oil Field
UmmAl Irsham
N h Fi ld
QATAR
Ras LaffanMaydanMahzan
Idd El Shargi
Halul Is.
North Field
Dolphin Gas Pipeline Project
Q
DOHA
AlWakrah
Dukhan
A Structure (North) Bunduq
Idd El Shargi(South Dome)
BulHanine
dd S a g(North Dome)
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Messaied A Structure (South)
(North) Bunduq
Ras Laffan Industrial City
1North Field
Exports through RL PortExports through RL Port
LNG trains LNGGTL productsGTL plants
Ras Laffan Industrial City: 250 km2
gas
CondensateDSC LSC PCR
Condensate
Refinery Refined productsNaphtha, Gasoil, KeroseneExport
IPP1&2Oryx
LocalGas projects
Naphtha, Diesel, LO, ParaffinsGTL plants
DSC, LSC, PC
Sulfur
Raw gaspipeline
SulfurEthane
PetrochemicalsCrackers
LPG LPGC3, C4
IPP1&2Fuel gas
Lean gaspipeline
Ethanepipeline
PetrochemicalsPolyethylene, glycols
PE units
Ethylenepipeline
p p
Lean gasexport line
EXPORT
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MESSAIEDINDUSTRIAL CITY
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)• 2 trains of 7.8 Mta LNG• APCI AP-X• EPC Contract signed Q4/2005
2.5 km2.5 km
► Al Khaleej Gas Phase 2 (AKG-2)
► RasGas III QP/Exxon Mobil• 2 trains of 7.8 Mta LNG• APCI AP-X• EPC Contract signed Q3/2005
j ( )• RasGas, on behalf of ExxonMobil• 1.25 Bscfd sales gas • Ethane recovery • EPC Contract signed Q2/2006
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► ORYX GTL
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
• 14 000 m3/h/berth • 2 x 36” lines/berth• Simultaneous loading to 2 berths 11
g• Large, integrated electrical system
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
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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
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Mixed Refrigerant
string
Nitrogen Refrigerant
string
with Technip /Wieland PB tubes
New – GE Frame 9E in Mechanical Drive
Frame 9E Incentives• High Power - 100 MW site rating (49oC 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
3 GE Fr 9 GT’s per train 14
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyLogisticsgConstructionStart-up
15
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
RasLaffan,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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♦ Customs Clearance Coordination at Ras Laffan Port
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
17
Challenges of Qatar mega LNG ProjectPeople : A mosaic of cultures and religionsPeople : A mosaic of cultures and religions
Some Illustrating Key FiguresMore 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 peak86 Nationalities
A mosaic of cultures and religionsFor each different culture a different perception and behaviorsFor each different culture, a different perception and behaviors
TECHNIP’s approach: understandAssessing 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 ppotentially cause issues
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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T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyLogisticsgConstructionStart-up
19
Challenges of Qatar mega LNG Project
S i h d d di dSecurity : approach and dedicated measures Each stage of project presents different risks
Mobilization phase: set up of security measuresVarious construction phases: increase of the risks with numberVarious construction phases: increase of the risks with number
of workers and equipment on site, riots, …Commissioning phase: increasing sensitive areas on site, with specific needsDemobilization phase: Ensure people leave the site voluntarily and smoothly.
Specificity of the 3 Qatar LNG Mega projects: Due to such extraordinary mass of workforce (75000 persons at peak and 86 nationalities), Technip had implemented a p )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 kfSafety / training of WorkforceSafety level on a construction site depends on the
behaviors of your workers, so it is directly depends onthe skill level of the manpower and their safetythe skill level of the manpower and their safetyawareness.So maintaining an high level of safety performance has been a real challenge.
Global ratio of 1 safety personnel for 50 workersIntensive training program in 14 different languages:
More than 200 000 HSE induction trainingsMore than 27 000 Training sessions including various safety
Training, Work at height, H2S, etc and craft trainingsHigh 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
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
22
From the desert to camps facilities for 60 000 personsNumber Capacity Contractor Capacity Subcontractors Number
of CampsCapacity Contractor
Campsp 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 2006Average 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…23
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
24
Challenges of Qatar mega LNG Project
A h ld’ l j i f f i hAmong the world’s largest projects in terms of freight movementsto a single place
A i ti 3 Milli F i ht T f i t d t i l i d i Q tApproximative 3 Millions Freight Tons of equipments and material received in Qatar Ports, without major incidents or issue
More than 20 000 TEUs (Twenty feet equivalent unit) containers received and deliveredthrough Doha Portthrough Doha Port
Main Challenges:
Congested schedule of Ras Laffan Port operationsHeavy flow of air shipment against limited capacity of Doha AirportShortage of container storage capacity in Doha Sea PortOther regional main ports congestions and delays
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Shortage of feeder vessels from Mother ports to Doha Port
Ship arrival for 3 LNG Mega Projects
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25Nb of Vessels
15
20
5
10
0
450 vessels in 43 monthsUpto almost one vessel per day at peak 26
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
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Challenges of Qatar mega LNG Projects
C iConstruction 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
500 000 m2 (66 soccer fields) for each of the 3 projects75 000 people at peak75 000 people at peak700 million construction man-hoursSheer size required new construction methods
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At construction peak: about 5300 equipment on site
35Transit Mixers
62Towercranes
682Crawler &
Mobile cranescranes
3646Welding
machines79E t
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797Buses
Excavators
Qatargas II - Manufacture of AGRU Absorber, Mar 2006
Qatargas II - Erection of AGRU Absorber, Feb 2007
1 absorber per train,6 in total
1,450 Tons eachHeight = 45 7mHeight = 45.7mDiameter = 7.4m
Lifted with Platform Ringer Crane, Capacity 2,000T
Fresh water closed loop cooled with sea waterFresh water closed loop cooled with sea waterFresh water closed loop cooled with sea water
32Qatargas II- Fresh cooling water loop piping (114 in)
Challenges of Qatar mega LNG ProjectsB t lBut also….
Shortage of resources in Qatar and in the Gulf: specialized manpower, supervision
Construction subcontractors low productivity
Shortage of raw material (cement, washed sand, argon gas, diesel ...)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 ProjectsGas Station to supply all the 3 LNG projects and Ethylene Projects
Aggressive schedules and simultaneity of 4 mega projectsinter-project dependencies
Infrastructure limitation: Port congestion, Road traffic congestion in RLIC, supply of water at risk
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World wide raw material, equipments and manpower price increase
T h i T d• Technip Today• Qatar, a Key Player in the LNG World• Ras Laffan Industrial City and the 3 Mega LNG Projects• Challenges of Qatar Mega LNG Projects
New technologiesWorldwide work locationsHuman factorsSecurity/safetyCampspLogisticsConstructionStart-upSta t up
34
Start-up: the challenges of the World’s Largest LGN train
I t i f ti f t i l / i t d i th l t tiIntensive program of preservation of material /equipment during the long construction phase with a dedicated team
Protection of the valves Protection of all rotating equipment
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
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
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of the flare system
TODAY
4 Trains in full operation in Qatargas and Rasgas
1 Train on Qatargas 3: in start up phase
The last Train of Qatargas 4 will be in operation by end of 2010
Qatar will celebrate the 77 MT/y
of LNG Capacity productionof LNG Capacity production
on Dec 13, 2010
in presence of The Emir of Qatarin presence of The Emir of Qatar
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Qatargas II – View from Flare stack 24th May 2007Qatargas– View as of mid 2009
Qatargas II – View from Flare stack 24th May 2007
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QATARGAS LNG Projects – TECHNIP Staff – October 2009Q G S G j c s C S Oc 009
Le défi GNL au Qatar
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Questions ?
Le défi GNL au Qatar
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Thank you!Thank you!