Défis, difficultés et succès. Directeur de Projet

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1 Défis, difficultés et succès des grands projets. Le défi GNL au Qatar Stephane LAGRANGE Step a e G G Directeur de Projet

2 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 Logistics Construction Start-up t 1

3 Technip Today 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 2011) 2009 revenue: 6.4 billion A long term solid partner

4 Technip delivered major energy projects in 2009 / 2010 llions) QGX QCS Construct tion manh hous (Mi Millau Viaduct Yemen LNG RGX Yansab Ethylene Khursaniyah 3

5 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 Logistics Construction Start-up t 4

6 Record LNG TRAIN CAPACITY (existing or under construction) Mt/y 9 Qatar mega Trains Yemen

7 Estimated World liquefaction capacity (Mt/y) 77 Mt/y Indonesia Qatar Malaysia Algeria Nigeria Trinidad & Tobago Australia Egypt Oman Brunei Abu Dhabi United States In operation Feb, 2010 Under construction Future projects Libya Yemen Russia Norway Eq Guinea Iran Qatar The largest LNG producer since 2008 Angola Peru 6

8 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 Construction Start-up 7

9 Qatar Mega LNG Projects - site of Ras Laffan - Gas Field Oil Field South Pars IRAN Umm Al Irsham North Field Ras Laffan QATAR Dolphin Gas Pipeline Project Idd El Shargi (North Dome) Halul Is. Maydan Mahzan Bul Hanine Dukhan Al Wakrah DOHA Idd El Shargi (South Dome) A Structure (North) Bunduq Messaied A Structure (South) 8

10 Ras Laffan Industrial City Ras Laffan Industrial City: 250 km2 Exports through RL Port North Field gas LNG trains 1 GTL plants LNG GTL products Naphtha, Diesel, LO, Paraffins Raw gas pipeline Lean gas pipeline pp Ethane pipeline MESSAIED INDUSTRIAL CITY Gas projects Local Export Oryx IPP1&2 Fuel gas Ethylene pipeline Condensate LPG Sulfur Ethane Lean gas export line Refinery Crackers PE units EXPORT Refined products Naphtha, Gasoil, Kerosene Condensate DSC, LSC, PC LPG C3, C4 Sulfur Petrochemicals Polyethylene, glycols 9

11 Ras Laffan Site View - East side - Qatargas II (QP/ExxonMobil/Total) 2 trains of 7.8 Mta LNG APCI AP-X EPC Contract signed Q4/ LNG Storage tanks Qatargas III (QP / ConocoPhillips) Qatargas IV (QP / Shell) 2 trains of 7.8 Mta LNG APCI AP-X EPC Contract signed Q4/ km RasGas III QP/Exxon Mobil 2 trains of 7.8 Mta LNG APCI AP-X EPC Contract signed Q3/2005 Al Khaleej Gas Phase 2 (AKG-2) RasGas, on behalf of ExxonMobil 1.25 Bscfd sales gas Ethane recovery EPC Contract signed Q2/2006 ORYX GTL 10

12 The largest LNG trains and the largest LNG terminal in the world 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 Large, integrated electrical system CLP - Common LNG Storage QGII; RGIII; QGIII/IV 5+2 x m3 tanks 6 BOG compressors 3 new berths m3/h/berth 2 x 36 lines/berth Simultaneous loading to 2 berths 11

13 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 Logistics Construction Start-up t 12

14 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 with Technip /Wieland PB tubes Mixed Refrigerant string Nitrogen Refrigerant string 13

15 New GE Frame 9E in Mechanical Drive Frame 9E Incentives High Power MW site rating (49 o C day) 3000 RPM - better compressor speed match Flat LNG production Customized for LNG Service Speed range 96%-102% Continuous duty, base load Extended maintenance intervals Meets Qatar Environmental requirements using DLN1 Frame 9E 130 MW ISO 210,000 kg package 50,000 kg rotor 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

16 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 Construction Start-up 15

17 Challenges of Qatar mega LNG Project Worldwide work locations Paris, France CTJV Paris Office Engineering for Common, Utilities, Offsite and a part of Process Areas CTJV SITE Office Qatar - All Construction and Site Prefabrication Work Pre-mechanical Completion Work Field Engineering & Technip Abu Dhabi, Chennai, Chiyoda Milano, Philippines And all our suppliers around the World Procurement Services in Qatar and Other Surrounding Gulf Countries Customs Clearance Coordination at Ras Laffan Port Ras Laffan, Qatar Doha, Qatar Yokohama, Japan CTJV Doha Office Administrative Work CTJV Yokohama Office Overall Project Management and Implementation Engineering for Process Area Overall Procurement Management and Execution Interface with National and Local Government Authorities Customs Clearance Coordination at Doha Port and Logistics Coordination 16

18 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 Logistics Construction Start-up t 17

19 Challenges of Qatar mega LNG Project People : A mosaic of cultures and religions Some Illustrating Key Figures More than persons who have worked on one of the 3 Qatar Mega LNG Project Sites More than persons mobilized together at the peak 86 Nationalities A mosaic of cultures and religions For each different culture, a different perception and behaviors TECHNIP s 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 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

20 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 Construction Start-up 19

21 Challenges of Qatar mega LNG Project Security : approach and dedicated di d measures Each stage of project presents different risks Mobilization phase: set up of security measures 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 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

22 Challenges of Qatar mega LNG Project Safety / training i 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 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 HSE induction trainings More than 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 to the size of the construction sites and number of people 12 21

23 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 Logistics Construction Start-up t 22

24 From the desert to camps facilities for persons Number Capacity Contractor Capacity Subcontractors of Camps Camps Camps Nov 2004 QGX QCS RGX/AKG Total Camps Utilities Average Water Consumption : 350 liters/day/person Jan 2006 Average Power Peak: 1.8 kw/person Average Sewage Disposal: 340 liters / day / person March 2008: Trees have grown up 23

25 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 Logistics Construction Start-up t 24

26 Challenges of Qatar mega LNG Project Among the world s largest projects in terms of freight movements to a single place Approximative 3 Millions Freight Tons of equipments and material received in Qatar Ports, without major incidents or issue More than TEUs (Twenty feet equivalent unit) containers received and delivered 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 Shortage of feeder vessels from Mother ports to Doha Port 25

27 Ship arrival for 3 LNG Mega Projects Nb of Vessels vessels in 43 months Upto almost one vessel per day at peak 26

28 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 Logistics Construction Start-up t 27

29 Challenges of Qatar mega LNG Projects Construction Huge quantity of materials & equipment m3 of concrete tons of steel framework (14 times Eiffel tower) tons of machinery (950 Airbus A380 planes) tons of piping km of electrical and instrumentation cable The highest flares are 200 meter high m2 (66 soccer fields) for each of the 3 projects people at peak 700 million construction man-hours Sheer size required new construction methods 28

30 At construction peak: about 5300 equipment on site 682 Crawler & Mobile cranes 35 Transit Mixers 62 Tower cranes 79 Excavators 3646 Welding machines 797 Buses 29

31 Qatargas II - Manufacture of AGRU Absorber, Mar 2006

32 Qatargas II - Erection of AGRU Absorber, Feb absorber per train, 6 in total 1,450 Tons each Height = 45.7m Diameter = 7.4m Lifted with Platform Ringer Crane, Capacity 2,000T

33 Fresh Fresh water water closed closed loop loop cooled cooled with with sea sea water water Qatargas II- Fresh cooling water loop piping (114 in) 32

34 Challenges of Qatar mega LNG Projects 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 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 World wide raw material, equipments and manpower price increase 33

35 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 Logistics Construction Start-up t 34

36 Start-up: the challenges of the World s Largest LGN train Intensive program of preservation of material /equipment during the long construction ti 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

37 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 on Dec 13, 2010 in presence of The Emir of Qatar 36

38 Qatargas II View from Flare stack 24th May 2007 Qatargas View as of mid 2009 Qatargas II View from Flare stack 24th May

39 QATARGAS LNG Projects TECHNIP Staff October 2009 Le défi GNL au Qatar 38

40 Questions? Le défi GNL au Qatar 39

41 Thank you!