Power Gen Africa, 17 th July 2015, Cape Town - South Africa Project management excellence with turnkey projects in Africa Marcus Nelle Siemens Energy Solutions Answers for energy.
Project Management Excellence with turnkey projects in Africa Agenda Introduction Challenges in Turnkey Projects References Page 2
Energy Solutions - as part of Siemens Power & Gas - provides power plant solutions Power and Gas Division Large Gas Turbines, Generators (PG GT) Distributed Generation (PG DG) Steam Turbines (PG SU) Compressors (PG CP) Energy Solutions (PG ES) Instrumentation and Electrical (PG IE) Business Units Gas turbines from 100 to 400 MW Electrical generators from 25 up to 2,235 MVA Fuel gasifiers Industrial gas Turbines from 5 to 50 MW Aero derivative gas turbines from 4 to 64 MW Steam turbines from 45 kw to 1,900 MW Steam turbines for industrial applications & power generation Turbo compressors for - Oil & Gas - Industrial applications Compressor packages incl. drives 50Hz and 60Hz Gas turbine power plant solutions CHP* IGCC** Repowering Integrated solar combined cycle HRSG*** Control solutions Electrical solutions Energy management solutions Solutions for distributed and hybrid power generation Business Fields * Combined heat and power ** Integrated gasification combined cycle *** Heat Recovery Steam Generator Page 3
Energy Solutions is a global OEM-EPC with a regional face Regional sales and project execution supported by a global engineering network Greenville, SC Mexico-City Orlando Zoeterwoude/Hengelo Erlangen/Offenbach Finspong Vienna Recklinghausen Gurgaon Rio de Janeiro Lima Johannesburg Dubai Seoul Global headquarters Sales office NEM Regional headquarters Sales and proposal office IPPS main location Global Architect Engineering Singapore Page 4
OEM in-house components engineered to cuttingedge solutions Core Components GT & ST Packages Extended Power Train Power Island Power Block Power Plant Tailor-made solutions from components up to full turnkey power plants.
Typical configurations of gas power plants 50 Hz 60 Hz 1200 MW SCC5-8000H 2x1 SCC6-8000H 2x1 820 MW 880 MW 600 MW 512 MW SCC5-4000F 2x1 SCC5-8000H 1S SCC5-2000E 2x1 Combined cycle SCC6-5000F 2x1 SCC6-8000H 1S SCC6-5000F 1x1 690 MW 410 MW 345 MW 440 MW SCC5-4000F 1S SCC6-2000E 2x1 342 MW 253 MW SCC5-2000E 1x1 SCC6-2000E 1x1 171 MW 307 MW SSC5-4000F 172 MW SSC5-2000E Simple cycle SSC6-5000F 232MW SSC6-2000E 232 MW 112 MW All values: ISO base rating Page 6
Energy Solutions project references USA: Lake Side II Panda Sherman Panda Temple I Panda Temple II Lodi Marsh Landing El Segundo Caithness Longview NRG Cedar Bayou Evander Andrews Otay Mesa Mexico: La Caridad I La Caridad II CCC Norte Carmon Creek CPV Valley Liberty Patriot Oregon Clean Hummel Mattawomen Stonewall Termocentro CC Venezulia: Termocentro SC Termozulia III SC Peru: Santo Domingo Malacas Duke Las Flores Kallpa II Kallpa III Santa Rosa II Simba Argentina: Ensenada SC Brigadier Lopez SC Manuel Belgrano San Martin Termozulia III CC Guiria F4 UTE Maua 3 Belgium: T-Power Gent Netherlands: Hemweg 9 Diemen 34 Enecogen Sloecentrale Ensenada CC Brigadier Lopez CC Guillermo Brown El Campesino France: Toul Emile Huchet Pont sur Sambre Portugal: Pego UK: Severn Power Marchwood Lockerbie Fortuna Italy: Turbigo Livorno Ferraris Algeria: Berrouaghia Morocco: Jorf Lasfar MP Jorf Lasfar PMPTahaddart Germany: Knapsack 2 SPP Lünen Ulrich Hartmann Irsching 5 Herdecke Egypt: Beni Suef Burulus New Cairo El Kureimat Nigeria: Geregu II Jaworzno Plock Austria: Simmering Mellach Timelkam South Africa: OCGT Eskom Slovakia: Malzenice Bandirma II Turkey: Samsun Jazan S.Arabia: Raz az Zawr Tabouk Opt. Tabouk Ext. Shuaibah Kuwait: Az Zour Az Zour Ext. Hungary: Gönyü Azerbaijan:Sumgait Syria: Zayzoun, Nasserieh, Deir Ali Oman: Barka Sohar Yemen: Marib UAE: Jamex Shuweihat S2 Shuweihat S3 Al Aweer Current projects in execution India: Unosugen Sugen Dadri DGEN Pakistan: Rousch Rousch Conversion South Korea: Incheon 2 Andong Dangjin 3 Dangjin 2 Bugok 3 Ansan Daegu City Posco Power 2 Thailand: Chana II Wang Noi Tuaspring Singapore: GMR Energy (PLP) Power Seraya JangMoon Dangjin 4 Wirye Vietnam: Nhon Trach 2 San Gabriel Pengerang Australia: Uranquinty Braemar Neerabup Mortlake Kogan Creek Selection of finished projects since 2009 Status: 2015-07-02 currently 31 new large power plant projects in execution
Project Management Excellence with turnkey projects in Africa Agenda Introduction Challenges in Turnkey Projects References Page 8
Challenges in Turnkey Projects with focus on Africa Country specific requirements Local sourcing / content Labour conflicts Transport / Logistics Changes in requirements Page 9 Performance Guarantees (Technical & Commercial) Unforeseeable events Seasonal conditions T&Cs of privately financed projects Schedule delays EHS Security Customs How to manage these challenges experienced project teams - on site (local) - in the headquarters early local supplier market investigation + qualification maximize local content early transport, soil studies in-house OEM and engineering full value chain to act fast sustainable workforce qualification local Siemens hub contributes to country knowledge empowered site manager quick and clear decision making one responsible General Project Manager to ensure one face to the customer direct access to finance sector People Integration Organisation
Project Management Excellence is part of our culture Siemens has ~150 years of project experience 1867-1870: Telegraph line from London to Calcutta Professional Project Management is a vital factor of success Half of revenues derive from project business More than 15.000 Siemens project managers work for customers worldwide Projects need be managed in an excellent, innovative and responsible way Improve project-related process People Page 10
Energy Solutions: facts and figures Energy Solution: Our people are our asset People Experience of a General Project Manager (GPM) in average: - age: 52 - in power generation: 23 years - in project business: 16 years - in GPM function: 12 years Page 11
Quality and proven experience are in-house Engineering, erection & commissioning, project management Energy Solutions: High quality in-house capabilities for Turnkey Projects - 2.000 in-house design engineers - 1.000 erection experts - 300 commissioning experts - 400 certified project managers - Siemens own project management academy PM@Siemens Integration Page 12
Typical EPC project teams are present in HQ, in the local company and on site General Project Manager Commercial Project Mgr Technical Project Manager Commercial Project Mgr Project Manager General Site Manager Project Engineering Manager Construction Manager Commissioning Manager Commercial Site Manager HSE Manager Project Manager Civil HSE Manager Project Manager Civil Site Manager Civil HSE Manager Scheduler Project Manager Mechanical Scheduler Project Manager Mechanical Site Manager Mechanical Comm. Mgr Mechanical Scheduler Quality Manager Project Manager Piping Quality Manager Quality Manager Contract Manager Project Manager Steam Gener. Contract Manager Site Manager Steam Gener. Contract Manager Administrator Procurement Manager Project Manager Electrical Project Manager Process Administrator Procurement Manager Project Manager Electrical Site Manager Electrical, I&C Comm. Mgr. Electrical Comm. Mgr. I&C Headquarters Local company on site Administrator Organisation Page 13
Stable process is the backbone of successful project management Sales Phase Lead Management PM010 Go / No-Go decision Execution Phase Project Opening / Clarification Opportunity Development Detailed Planning PM020 Bid decision Bid Preparation Purchasing & Manufacture PM040 Bid approval Contract Negotiation Dispatch PM070 Project won / lost Project Handover PM080 Start of project Construction / Installation Standardized milestones with mandatory minimum results PM100 Order receipt clarified PM600 Release for customer accept. PM200 Approval of detailed planning PM300 Dispatch approval PM400 Material & resources at site Commissioning Acceptance Project Closure Warranty PM650 Customer acceptance Warranty PM670 Project closure Warranty PM650 Customer acceptance Project closure PM550 Construction/ install. completed PM670 Project closure PM700 End of warranty clear process framework proven by many successful projects Clear inputs and outputs Quality-Gate systematic Quality Gate Organisation / Process Page 14
Project Management Excellence with turnkey projects in Africa Agenda Introduction Challenges in Turnkey Projects References Page 15
Individual power plant delivered in record time Energy Solution: Fast delivery times not just on paper Selected projects delivered in record time: Tahaddart (MA) in 24 months (CC) Geregu I (NG): in 21 months (OC) Geregu II (NG): in 28 months (OC) Page 16
E-class technology Geregu II in Nigeria Geregu II Nigeria 3x SSC5-2000E Customer Nigeria Delta Power Holding Company Total net el. Power Output 434 MW Plant net efficiency 33.4 % ST Type - - - Generator Type SGen5-100A Special features Date of order 08 / 2010 1 st comm. operation 05 / 2013 Finished within contractual timeframe in challenging environment Key project for power supply in Nigeria Page 17
Geregu II was the last of 11 ordered NIPP projects, but handed over first! April 2011 Site preparation incl. rock blasting May 2013 Plant in operation Page 18
F-class technology Morocco s first CCPP Tahaddart Morocco SCC5-4000F 1S O&M 2005-2014 : Service Factor = 91,9%, Availability Factor = 96,6% Customer Energie Electrique de Tahaddart Total net el. Power Output 385 MW Plant net efficiency > 56.8 % ST Type SST5-3000 Generator Type SGen5-3000W Date of order 02/2003 1 st comm. operation 02/2005 Special features Morocco s first combined cycle power plant Providing ~10 percent of the Moroccan power demand Financed by Siemens Project Ventures O&M contract with Siemens >85.000 eoh Page 19
Turnkey projects in Africa Afam V Nigeria 2 SSC5-2000E Geregu 1 Nigeria 3 SSC5-2000E Geregu 2 Nigeria 3 SSC5-2000E Tahaddart Morocco 1S SCC5-4000F Ankerlig / Gourikwa South Africa 14 SSC5-2000E Turnkey Open Cycle Power Plant Turnkey Open Cycle Power Plant Turnkey Open Cycle Power Plant Turnkey Combined Cycle Power Plant Turnkey Open Cycle Power Plant without civil Berrouaghia Algeria 2 SSC5-4000F Talkha Egypt 2 SSC5-4000F El Kureimat Egypt 2 SSC5-4000F Nubaria I & II Egypt 2x 2 SGT5-4000F Turnkey Open Cycle Power Plant Turnkey Open Cycle Power Plant without Civil Turnkey Open Cycle Power Plant without Civil Turnkey Econopac CC Power Plant Page 20
executing large-scale projects as EHS 1) benchmark Several projects executed without any Lost Time Incident (LTI) La Caridad II Mexico SCC6-5000F 1x1 Fortuna Germany SCC5-8000H 1S Shuweihat S3 UAE 2x SCC5-4000F 2x1 More than 2.5 million man-hours without LTI Wang Noi Thailand SCC5-4000F 2x1 More than 1.5 million man-hours without LTI San Gabriel Philippines SCC6-8000H 1S More than 2.0 million man-hours without LTI Tuaspring Singapore SCC5-4000F 1S More than 8.0 million man hours without LTI 1) EHS: Enivornmental, Health & Safety Page 21 More than 1.5 million man-hours without LTI SHARP-Award* winner for excellent safety and health performance with over 1.0 million man-hours without LTI
Trusted partner for cutting-edge integrated solutions at highest quality Based on over a century of experience we have a long-lasting commitment to the African power sector we can support with a wide range of proven gas turbines and integrate them flexibly into state-of-the art solutions tailored to customer needs excellence in project execution Page 22
AZURA EDO IPP will be the next plant in Nigeria to prove our execution excellence Azura Edo 459 MW - 3x SSC5-2000E GT Geno Cooling DCS Electrical 3x SGT5-2000E 3x SGen5-100A Fin-fan cooling SPPA T3000 Siemens 330 kv Switchyard, interconnection and extension of TCN substation Fuel Natural Gas; Tie-in, interconnecting pipeline, gas receiving station Operating cond. Base Load Page 23
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Backup Page 26
Gas Turbine Portfolio SGT5-8000H 400 MW * Large scale Gas Turbines 50 Hz 60 Hz SGT5-4000F SGT5-2000E SGT6-8000H SGT6-5000F SGT6-2000E 114 MW 172 MW *** 232 MW 274 MW 307 MW ** SGT-800 47/50 MW Small and medium scale Gas Turbines 50/60 Hz SGT-750 SGT-700 SGT-600 SGT-500 SGT-400 SGT-300 SGT-200 SGT-100 36 MW 31 MW 25 MW 19 MW 13 MW 8 MW 7 MW 5 MW * CC ~600 MW ** CC ~440 MW All values: ISO base rating *** CC ~250 MW Page 27
Power Plant Turnkey Competence Overview of configurations Single Shaft Multi-Shaft 1x1 Multi-Shaft 2x1 Multi-Shaft 3x1 Page 28 Tailor-made power plants based on proven standards as Simple Cycle or Combined Cycle with early power