Priolo Ethylene Plant Upgrade

Transcription

1 Priolo Ethylene Plant Upgrade a cura di: Ing. Ivano Giannoni (Versalis) Ing Francesco Gravame (GE NP) Ing Riccardo Fabbri (GE NP) Milano - 10 dicembre 2014

2 Priolo Ethylene Plant Upgrade IPMA GOLD Award IPMA Milano 10 th Dec 14 Imagination at work.

3 GE Oil & Gas today From extraction, to transportation, to end use ~45,000 employees Drilling & Surface BOPs and risers, onshore trees, Artificial lift Downstream Technology Solutions Refinery and gas distribution Subsea Systems Subsea production systems Turbomachinery Solutions LNG, on- and offshore, pipeline Measurement & Control Controls, diagnostics Delivering customer solutions by applying systems-level engineering across the value chain 3

4 Downstream technology focus PRODUCTS & SERVICES SEGMENTS Reciprocating Compressors Steam Turbines Ethylene LDPE / HDPE Ammonia High Speed Recips Pumps & Valves Urea Refinery Processing Compressors Services & Upgrade Industrial Processin g Industrial Power Generation CNG In A Box 10k 21k GGE/day Small-Scale LNG 25k 600k gal/day Gas Distribution & Processing Small CNG & LNG DRAFT Oct 3 4

5 Beyond GE installed base Upgrade Evolution GE installed base OEM System Integrator Plant Process Plant Upgrade (Priolo) 2014 F2F: Rebundle NOx 2006 Beyond F2F Engine & Modular Replacement Large rehabilitation projects

6 GE &IPMA Project Excellence Award PRIZE AWARD BRONZE 2009 Statfjord - Upgrade PM: Roberto Zavani 2011 Qatar Gas - CSA PM: Carlo Gragnoli 2013 Gorgon - TM PRIZE FINALIST S GOLD Insert Image 2010 Darwin - Upgrade PM: Francesco Gravame 2012 ALNG - CSA & TAG - TM PM M. Ferri & F. Giuntini 2014 Priolo DTS Upgrade PM: Riccardo Fabbri

7 Operational Excellence Laser-focused on safety and quality for customers; project execution and returns Products & Services Including upgrades to optimize production efficiency in Ethylene plant People and Expertise Investing in our people, dedicated PM Academy and training path driving execution

8 Project Execution Timeline 2014 General Electric Company - All rights reserved

9 Special Initiatives Abstracts & Articles Reflective learning Promoting Technical Reference Contests & Awards Benchmarking Awarding External Recognition Conventions & Exhibitions Promoting Touch-base with Market Sharing experience 2014 General Electric Company - All rights reserved

10 Our Journey in IPMA Project Excellence Project Management 1. Project Objectives 2. Leadership 3. People 4. Resources 5. Processes Project Results 6. Customer Results 7. People Results 8. Other parties involved 9. Performance & Results Application Report Assess. & Site visit Award ceremony 30 th Sep 4 th Feb 5 th May 23 rd June Project Team & Sponsor GPO & Senior Mgt Customer - Suppliers Finance - Marketing Sourcing & MFG HR EHS

11 World Congress in Rotterdam Workshops Teamwork for Winners club Congress attendance Project Presentation Gala Evening & Award GE Proprietary & Confidential. Internal Use Only. Not for Distribution

12 Feedbacks & Carry-outs Team di Progetto Occasione di crescita e confronto Occasione di visibilità Coinvolgimento Diretto Diretto Coinvolgimento di fornitori strategici Diretto Coinvolgimento del cliente ed utente finale Diretto Coinvolgimento di funzioni esterne Cultura d Impresa Sugli impatti nella propria Azienda Sugli impatti sul Business e sul Mercato Sulla Comunità Esterna e sull Ambiente (CSR)

13 IPMA Excellence Definition Excellent performance in all aspects, management of the planning, execution and results (from the process). Go beyond or even against known standards, methods, tools and techniques Beyond the actual project goals, they enrich businesses, societies, environment

14 Versalis The voice of customer Title or Job Number XX Month 201X See tutorial regarding confidentiality disclosures. 14

15 Versalis (Eni) at a glance Headquarters Milan With an integrated industrial platform, versalis the Italian leading chemical company offers to the market an extensive portfolio of intermediates, polyethylene, styrenics, elastomers and a new range of bio-based chemicals Plants: 9 in Italy Brindisi Ferrara Mantova Porto Marghera Porto Torres Priolo Ragusa Ravenna Sarroch 4 rest of Europe Grangemouth (UK) Dunkerque (FR) Oberhausen (D) Százhalombatta (HU) 5 R&D centers in Italy Sales network 18 branch offices and 2 trading companies in Asia (Shanghai and Mumbai) 5,600 employees 80% Italy, 20% abroad 5.9 bln turnover Licensing and strategic partnerships 71 production units for a total production of 5.8 mln ton 335 patents

16 Versalis business overview turnover: 5,9 bln production: 5,8 m ton production to sales: 3,8 m ton Monomers and Intermediates Polymers Olefins Aromatics Derivatives Polyethylene Styrenics Elastomers Ethylene Propylene Butadiene Raffinate 1 Carbon Black Feedstock Toluene o-m-p-xylene Pseudocumene DCPD Benzene Phenol Acetone Alphametilstyrene Cyclohexanone/ Ka-Oil EB/Styrene LDPE LLDPE VLDPE HDPE EVA GPPS HIPS EPS SAN ABS e-sbr s-sbr BR TPR EP(D)M NBR Latex capacities and market position among leading players 6 nd in EU 2 nd in EU for EVA 3 rd in EU 2 st in EU end markets

17 Key factors boosting Priolo Cracking Unit modification Versalis has recently been refocusing its strategies on a more market-oriented and diversified product portfolio, emphasizing R&D, Licensing and enhancing global presence. As part of its new strategies, Versalis has made changes to its infrastructures and production facilities. The following describes the changes made to overhaul its largest Cracking Unit at the Priolo site. Modifications included state-of-the-art upgrading of components, systems and controls in order to: Increase one production line capacity Improve energy index Improve plant availability & maintenance interval extension

18 Priolo: Project Description Plant Location Scope Main modification according to feasibility/basic studies performed by Main Contractor: PRIOLO Machinery modification Charge gas compression system upgrade Ethylene compression system upgrade Propylene Syeam turbine replacement Process Modification Ethylene Splitter and Demetanizer trays replacement Replacement of Ethylene splitter condenser with Core-in-Kettle technology Planning FID Q1/ 2012 Main Contractor Order June 2012 Machinery order December 2012 Field works start mid August 2013 Plant start up end November 2013 Constraints Development of over direct m.h. for Plant and Machinery modification works to be performed during facilties 10-years m.o. planned to be performed September mid November 2013

19 Priolo: general view of plant modification Item Revamped Item Revamped PROPYLENE TRAIN Item Modified Item Modified NEW Item NEW Item ETHYLENE TRAIN

20 Priolo: project challenges Machines location Machines installed at the first mezzanine deck out of reach of any mobile crane. Roof composed by air cooler and air condenser cannot be removed Existing lifting crane both in hot and cold compression area while perfectly fit for maintenance are not suitable for handling assembled machines. Lube and Seal Oil console on ground floor found completely embedded in concrete, and again out of reach of any type of Crane

21 Conclusions Teamwork between GE and Versalis Engineering & Operation Teams...key to success Concurrent Engineering instrumental to flawless design and project execution Deployement of Engineering Teams at site for the entire duration of the project Early Design for installation and availability fully exploited and applied