Qalhat LNG Project - NTNU...Carillion Alawi NTI 76 0 76 No. of Under Total Training No. of Graduated...

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QalhatQalhat LNG ProjectLNG Project

Gastech Conference, SpainMarch 2005

Shell Global Solutions

2Chiyoda CorporationChiyoda CorporationShell Global Solutions Shell Global Solutions

Q-LNG Project

Project: Qalhat LNG ProjectClient: Qalhat LNG S.A.O.CSite: Qalhat, Sur, The Sultanate of Oman

3rd LNG Train Expansion with associated facilities of existing 2 Trains Grass Root Plant constructed by Chiyoda-Foster Wheeler LLC (1996 – 2000)

Facility- 1 x 3.3 MMTPA LNG Train with debottleneck facility to 3.7MMTPA - 2 x 52 MVA Gas Turbine Generator- 1 x New Sea Cooling Water Intake Outfall- 1 x 1,760KW Instrument Air Compressor- 1 x Air Separation Unit- 1 x Feed Gas Line- 1 x Lean Gas Package

SULTANATEOF

OMAN


Q-LNG Project Special Features

- Fast Track Project34 Months with Long Lead Equipment (Main Cryogenic Heat Exchanger / Refrigerant Compressor) to be ordered after EPC Contract Award. Previous Project: 38 Months until Ready for Start-up (RFSU)Contract Award: 1st February 2003, RFSU: 30th November 2005.

- Flawless Start Up(®Shell Global Solutions International B.V.)Due to short-duration(1 Month) from RFSU till First Shipment, Q-LNG introduced Flawless Start-up.

- Omanisation35% is adopted (Previous Project: 15%).

-HSE High Performance (As of 28th January 2005)Stretched Target Actual

On Site / OverallLTIF : 0.25 0.00 / 0.08 (Previous Project: 0.25) TRCF : 2.50 2.36 / 2.43 (Previous Project: 3.00)


Fast Track ProjectCritical Path

- Full String Test for Refrigerant Compressor is waived due to identical design (Turbine Solo Run and Compressor Mechanical Running Test performed at Shop).

- To maintain Integrity: Extensive Inspection Items are reviewed and conducted.Vendor’s Material Data is merged into Contractor Site Material Management System. Extensive Material Take-Off Data is gathered from Vendor/Subvendors. This allows early finding of missing material at initial phase.

Previous Project

Actual Result Plan ActualMR Compressor w/Driver 9 13 13C3 Compressor w/Driver 10 13 14MCHE 12 12 13

Q-LNGRemaining Months after Erection to RFSU


Fast Track ProjectComparison with Previous Project

Qalhat LNG11 Months till RFSU (As of December 2004)

Previous Project10 Months till RFSU (As of February 1999)

C3 Compressor



Qalhat LNG13 Months till RFSU (As of October 2004)

Previous Project12 Months till RFSU (As of December 1998)

APCI Main Cryogenic Heat Exchanger


2003 2004 2005 2006JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Actual for Train-1/2

Contract Plan forQalhat LNG

Actual for QalhatLNG


0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Actual for Train-1/2(1stTrain)


Actual for Qalhat LNG


0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Actual for Train-1/2(1st Train)


Actual for QalhatLNG

Fast Track ProjectProject Strategy

Overall Engineering

Procurement Construction

Quick take off of Engineering and Procurement to allow same Construction duration as previous project.


0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Actual for Train-1/2(1st Train)

Contract Plan for Qalhat LNG

Actual for Qalhat LNG



Qalhat LNG26 Months till RFSU(As of September 2003)

Previous Project26 Months till RFSU(As of November 1997)

Previous Project24 Months till RFSU(As of January 1998)

Main Pipe Rack


Qalhat LNG19 Months till RFSU(As of April 2004)

Previous Project19 Months till RFSU (As of May 1998)


First Heavy Lifting


Early Underground Completion allows Safe Environment & Good Productivity for Subsequent Mechanical Work (High Risk Area).

Fast Track ProjectConstruction Strategy

Remaining Months until RFSUActual Result Q-LNG

Previous Project Plan Actual

Main Piperack Completion

22 23 23

Process Area Underground Cable Completion

14 21 21

Main Equipment Erection

Completion*

13.5 15.5 15.5

Note*: Except Refregerant Compressor, MCHE



Qalhat LNG22 Months till RFSU (As of January 2004)

- World Record ? -

Previous Project15 Months till RFSU (As of September, 1998 )

Underground Cable Laying



Qalhat LNG18 Months till RFSU (As of April 2004)

Previous Project13 Months till RFSU (As of November, 1998 )

Concrete Pavement


$$

Flawless Start-upPlant performance after Mechanical Completion

Perf

orm

ance

tCSU - first cycle operation

Trouble-free Start-up and OperationExpectation:What performanceshould look like

Historical :Typical plant performancecurve over time with dormant problems fromprevious project phasesnow coming to live.

Historical :Typical plant performancecurve over time with dormant problems fromprevious project phasesnow coming to live.

Improvement 2 :Preparation through Flawless®

Improvement 1 :Preparation through OIP


Scout/BOD/BDPScout/BOD/BDP

45%

Det Eng/Proc/ConstrDet Eng/Proc/Constr

40%

PSPS

10%

Comm/SUComm/SU

5%

Flawless Start-upWhen were these Flaws introduced?

Resolution requires back integration of lessons learned into early project phases….

If flawsIf flaws remain until last project phase severe delay and extra cost

More than 50% of flaws originate from the development phases.More than 90% of flaws originate before Comm/SU.


Flawless Start-upHow does Flawless typically develop?

Development of Flawless.

ProductionPhilosophy

Phase I ofFSI Program

Phase II ofFSI Program

Awareness& Training

ExecutionFSI Program

ReviewProjectLessons Learned

Review FlawlessProcess

Lessons Learned

Commission&

Start-up

InitialProduction

Phase

Development of the project

ProcurementScouting

&Feasibility

Basisof

Design

Detailed Engineering

BasicEngineering

PackagesConstruction

Value improving practices

Site Management

System


Flawless Start-upKey success areas for effective start-up

Coinciding Events

Structure R&R Comp Info Data

Key

suc

cess

are

a ta

rget

sManagement system/controls

TightnessCleanliness

IntegrityOperability

HSE

PrototypesComplexity

TestingExperience


Flawless Start-up Visible Standard

FLANGE PROTECTION SATISFACTORY

ENSURE DESSICANT BAGS AND WOODEN BLOCKS REMOVED

FLANGE PROTECTION INSECURE – RISK OF

DAMAGE TO FLANGES FROM ADJACENT PIPE

SUPPORTS AND SCAFFOLD POLES


Flawless Start-up Campaign

Incentive Scheme for “Q-Start” funded by Q-LNG.- Daily Gift Coupon to Worker- Bi-Monthly (Once every Two Months) Awards to Supervisors

“Q-Start” (Quality Start-up) campaign


Sustainable DevelopmentSpeciality of Q-LNG

Two Big Projects executedin parallel in Sur Area.

1,600 (20%)8,000Fertilizer (Start 2002)

2,90011,500TOTAL

1,300 (35%)3,500Q-LNG (Start 2003)

Omani and Ratio

Peak Worker

Training

Since this scale of skilled Omani workforce is not available in this region. Extensive Training becomes required.

Sur town, Qalhat, Al Ghallilah etc

Sharqiya region like Ibra and Jalan.

other area in Oman like Muscat and Nizwa.

1st priority

2nd priority

3rd priority

1st Priority on Local Region

Concentric Circular Recruiting

Ref. Previous Project: Peak No. of Omani: 1,000 Omanisation Ratio: 15% No of trained Omani : 350


Sustainable DevelopmentAccomplishment of Omanisation

Omanisation Ratio (CFW and Subcontractors) as of 28th January 2005

373,2061,190

%Omani + Expatriate (Manhead)Omani (Manhead)

Omani Off-the-Job Training Program

716206510Total

26297165CAPE EAST Training CentreCAPE EAST

606Al Jaber Training Centre (Abu Dhabi)Al Jaber

808NTIInterbeton

11011NHIWACASCO

350109241TATIBEC (MEI)

303TATIBEC (O&M)

76076NTICarillion Alawi

TotalNo. of Under Training

No. of Graduated

Training InstituteName of Subcontractor


Sustainable DevelopmentOmani HSE Training

93.54%7387893rd

91.10%7378094th

79.00%4705952nd

69.61&4696901st

Attendance%Total attendedTotal Projected

Texts of HSE Training for Omani

Omani refresher course is continuously held in addition ordinary course.Approximately 2,414 Omanis were attended.4 Courses conducted for all Omani at site.


Sustainable DevelopmentKey Performance Indicator (KPI)

Omanisation Measurement

Employing Omani graduated from Off-the-Job trainingKPI 4

Off-the-Job training for Omani peopleKPI 3

Local procurement and/or local subcontract from neighboring village, Sur and Sharqiya region

KPI 5

Employing Omani people from neighboring village, Sur and Sharqiyaregion

KPI 2

Accomplishment of 35 % OmanisationKPI 1


OVERALL PERFORMANCE SCORE IS 93% AGAINST TARGET OF 80%OMANISATION LEVEL 37.3% AGAINST TARGET 35% HIGHEST IN OMAN

(91 - 100) (81 - 90) 80 (0 - 79) As of January 2005

KPI 1 - Accomplishment of 35% Omanisation ( 90.3)

KPI 2 - Sur/Sharqiya Omanis (100)

KPI 3 - Off the Job Trainees (96.3)KPI 4 - Graduated Employed (81.8)

KPI 5 - Local Procurement (100.0)

Scores Chart

Sustainable DevelopmentKey Performance Indicator (KPI)


Sustainable Development Omanisation Award

CFW received an honour for its remarkable effort toward Omanization

Award by H. E. Al Qatabi,President of Consultancy Council(February 11, 2004 at Al BustanHotel, Muscat)

Messrs. Merzian, Nakano and Managers of Q-LNG and CFW

HONOURING CERTIFICATE


Sustainable DevelopmentCerebration with DGM

Celebration Party at Site Office with Director General, Manpower(1st March, 2004)

Award was fully owing to best cooperation of Director General, Ministry of Manpower, MRMEW, ROP in Sur and Q-LNG

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Qalhat LNG Project - NTNU...Carillion Alawi NTI 76 0 76 No. of Under Total Training No. of Graduated...

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