Dfis, difficults et succs

des grands projets. des grands projets.

Le dfi GNL au Qatar Le dfi GNL au Qatar
Stephane LAGRANGE Step a e G G
Directeur 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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
1
Tec hni p 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
A long term solid partner
Tec hni p del i ver ed maj or ener gy pr oj ec t s i n 2009 / 2010
250
300
l
l
i
o
n
s
)
QGX
QCS
200
h
o
u
s

(
M
i
RGX
100
150
t
i
o
n

m
a
n
h
Yemen
LNG
Khursaniyah
50
C
o
n
s
t
r
u
c
t
Millau
Viaduct
Yansab
Ethylene
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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
4
Rec or d LNG TRAI N CAPACI TY (ex i st i ng or under c onst r uc t i on)
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
Est i mat ed Wor l d l i quef ac t i on c apac i t y (Mt /y)
77 Mt/y
0 20 40 60 80 100
Malaysia
Qat ar
Indonesia
77 Mt/y
Egypt
Aust ralia
Trinidad & Tobago
Nigeria
Algeria
Libya
Unit ed Stat es
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
Angola
producer 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 technologies
Worldwide work locations
Human factors
Security/safety
Logistics g
Construction
Start-up
7
Qat ar Mega LNG Pr oj ec t s - si t e of Ras Laf f an -
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
Ras Laf f an I ndust r i al Ci t y
1
North Field
Exports through RL Port 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
INDUSTRIAL CITY
Ras Laf f an Si t e Vi ew - East si de -
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 km 2.5 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
10
ORYX GTL
The l ar gest LNG t r ai ns and t he l ar gest LNG t er mi nal i n t he w or l d
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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
12
New Ai r Pr oduc t s AP-X Pr oc ess
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
with Technip /Wieland PB tubes
New GE Fr ame 9E i n Mec hani c al Dr i ve
Frame 9E Incentives
High Power - 100 MW site rating (49
o
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
3 GE Fr 9 GTs 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 technologies
Worldwide work locations
Human factors
Security/safety
Logistics g
Construction
Start-up
15
Chal l enges of Qat ar mega LNG Pr oj ec t
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
16
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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
17
Chal l enges of Qat ar mega LNG Pr oj ec t
People : A mosaic of cultures and religions People : A mosaic of cultures and religions
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
A mosaic of cultures and religions
For each different culture a different perception and behaviors For each different culture, a different perception and behaviors
TECHNIPs 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
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.
18
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 technologies
Worldwide work locations
Human factors
Security/safety
Logistics g
Construction
Start-up
19
Chal l enges of Qat ar mega LNG Pr oj ec t
S i h d d di d Security : approach and dedicated measures
Each stage of project presents different risks
Mobilization phase: set up of security measures
Various construction phases: increase of the risks with number Various construction phases: increase of the risks with number
of workers and equipment on site, riots,
Commissioning phase: increasing sensitive areas on site, with specific needs
Demobilization 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
22
Chal l enges of Qat ar mega LNG Pr oj ec t
S f / i i f W kf Safety / training of Workforce
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 the skill level of the manpower and their safety
awareness.
So maintaining an high level of safety performance has been
a real challenge.
Global ratio of 1 safety personnel for 50 workers
Intensive training program in 14 different languages:
More than 200 000 HSE induction trainings
More than 27 000 Training sessions including various safety
Training, Work at height, H2S, etc and craft trainings
High level of Safety equipment provided to the workforce
As result an overall outstanding safety performances in regards
12 21
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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
22
Fr om t he deser t t o c amps f ac i l i t i es f or 60 000 per sons
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
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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
24
Chal l enges of Qat ar mega LNG Pr oj ec t
A h ld l j i f f i h Among the worlds largest projects in terms of freight movements
to a single place
A i ti 3 Milli F i ht T f i t d t i l i d i Q t Approximative 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 delivered
through Doha Port through Doha Port
Main Challenges:
Congested schedule of Ras Laffan Port operations
Heavy flow of air shipment against limited capacity of Doha Airport
Shortage of container storage capacity in Doha Sea Port
Other regional main ports congestions and delays
25
Shortage of feeder vessels from Mother ports to Doha Port
Shi p ar r i val f or 3 LNG Mega Pr oj ec t s
20
25
Nb of Vessels
15
20
5
10
0
450 vessels in 43 months
Upto 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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
27
Chal l enges of Qat ar mega LNG Pr oj ec t s
C i Construction
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 projects
75 000 people at peak 75 000 people at peak
700 million construction man-hours
Sheer size required new construction methods
28
At c onst r uc t i on peak : about 5300 equi pment on si t e
35
Transit
Mixers
62
Tower
cranes
682
Crawler &
Mobile
cranes cranes
3646
Welding
machines
79
E t
29
797
Buses
Excavators
Qat ar gas I I - Manuf ac t ur e of AGRU Absor ber , Mar 2006
Qat ar gas I I - Er ec t i on of AGRU Absor ber , Feb 2007
1 absorber per train,
6 in total
1,450 Tons each
Height = 45 7m Height = 45.7m
Diameter = 7.4m
Lifted with Platform Ringer
Crane, Capacity 2,000T
Fr esh w at er c l osed l oop c ool ed w i t h sea w at er
Fr esh w at er c l osed l oop c ool ed w i t h sea w at er
Fr esh w at er c l osed l oop c ool ed w i t h sea w at er
32
Qatargas II- Fresh cooling water loop piping (114 in)
Chal l enges of Qat ar mega LNG Pr oj ec t s
B t l But 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 Projects Gas Station to supply all the 3 LNG projects and Ethylene Projects
Aggressive schedules and simultaneity of 4 mega projects
inter-project dependencies
Infrastructure limitation:
Port congestion, Road traffic congestion in RLIC, supply of water at risk
33
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 technologies
Worldwide work locations
Human factors
Security/safety
Camps p
Logistics
Construction
Start-up Sta t up
34
St ar t -up: t he c hal l enges of t he Wor l ds Lar gest LGN t r ai n
I t i f ti f t i l / i t d i th l t ti Intensive 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
35
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 production of LNG Capacity production
on Dec 13, 2010
in presence of The Emir of Qatar in presence of The Emir of Qatar
36
Qat ar gas I I Vi ew f r om Fl ar e st ac k 24t h May 2007
Qatargas View as of mid 2009
Qatargas II View from Flare stack 24th May 2007
37
QATARGAS LNG Pr oj ec t s TECHNI P St af f Oc t ober 2009 Q G S G j c s C S Oc 009
Le dfi GNL au Qatar
38
Questions ?
Le dfi GNL au Qatar
39
Thank you! Thank you!