Défis, difficultés et succès des grands projets. Le défi GNL au Qatar Stephane LAGRANGE Step a e G G Directeur de Projet
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
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
Technip delivered major energy projects in 2009 / 2010 llions) 300 250 QGX QCS Construct tion manh hous (Mi 200 150 100 50 0 Millau Viaduct Yemen LNG RGX Yansab Ethylene Khursaniyah 3
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
Record LNG TRAIN CAPACITY (existing or under construction) Mt/y 9 Qatar mega Trains 8 7 6 5 4 Yemen 3 2 1 0 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 5
Estimated World liquefaction capacity (Mt/y) 77 Mt/y 0 20 40 60 80 100 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
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
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
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
Ras Laffan Site View - East side - Qatargas II (QP/ExxonMobil/Total) 2 trains of 7.8 Mta LNG APCI AP-X EPC Contract signed Q4/2004 5 LNG Storage tanks Qatargas III (QP / ConocoPhillips) Qatargas IV (QP / Shell) 2 trains of 7.8 Mta LNG APCI AP-X EPC Contract signed Q4/2005 2.5 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
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 140 000 m3 tanks 6 BOG compressors 3 new berths 14 000 m3/h/berth 2 x 36 lines/berth Simultaneous loading to 2 berths 11
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
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
New GE Frame 9E in Mechanical Drive Frame 9E Incentives High Power - 100 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
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
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
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
Challenges of Qatar mega LNG Project 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 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
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
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
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 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 to the size of the construction sites and number of people 12 21
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
From the desert to camps facilities for 60 000 persons Number Capacity Contractor Capacity Subcontractors of Camps Camps Camps Nov 2004 QGX 4 1311 21194 QCS 4 1146 16114 RGX/AKG2 6 1706 21370 Total 14 4163 58678 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
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
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 20 000 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
Ship arrival for 3 LNG Mega Projects Nb of Vessels 25 20 15 10 5 0 450 vessels in 43 months Upto almost one vessel per day at peak 26
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
Challenges of Qatar mega LNG Projects Construction Huge quantity of materials & equipment 700 000 m3 of concrete 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 700 million construction man-hours Sheer size required new construction methods 28
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
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 each Height = 45.7m Diameter = 7.4m Lifted with Platform Ringer Crane, Capacity 2,000T
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
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
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
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
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
Qatargas II View from Flare stack 24th May 2007 Qatargas View as of mid 2009 Qatargas II View from Flare stack 24th May 2007 37
QATARGAS LNG Projects TECHNIP Staff October 2009 Le défi GNL au Qatar 38
Questions? Le défi GNL au Qatar 39
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