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EXTERNAL
2020-07-10 | CIS PETROCHEMICALS CONFERENCE
Sadara Project – Main Automation ContractLowering complexity, improving competitiveness and fostering collaborationSwarandeep Singh, VP, Global Chemicals and Refining Lead
—Critical success factors
July 10, 2020 2
Main Automation Contractor (MAC)
Safety, security, health and environment
Continuity of project teams
Global work practices and standards
Owner collaboration
Simulation for testing and training
Integrated execution centers
Local presence and focus on life cycle costs
—Sadara
July 10, 2020 3
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Source: Google Maps
Sadara project
July 10, 2020 4
Most ambitious petrochemical project ever undertaken
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Graphs: IOGP Safety performance indicators – 2018 data1 Safety Instrumented System
Best in class safety performance
July 10, 2020 5
Total Recordable Injury Rate (TRIR) end of January 2016 was 0.033 “far exceeding” global industrial standards for a project of this size and scopeABB’s multi-dimensional contribution to safety performance:– Safe Products - Integrated Process Control Systems including SIS1
components– Safe Designs – Safely operate, mitigate disturbances and shutdown– Safe Workforce – Safety culture aligned with Sadara, implemented in
ABB offices and at Site
Leave it better than you found it
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Image: Sadara
Unprecedented size and scope
July 10, 2020 6
Creating value through chemistryUS$20 Billion investmentFirst complex to crack Naphtha in Saudi ArabiaLargest chemicals complex ever constructed in a single phase– 26 integrated world scale plants with over 3 million metric tons of capacityDifferentiated product slate– 14 out of the 26 plants are new to Saudi ArabiaConstruction began in 3Q 2011– First products in 2015– Full production in 2017Total project– 18 800xA safety and automation system, over 150,000 IOs– 40 operator consoles across 5 control operator buildings– Foundation field bus
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1PE: Polyethylene; PO: Propylene Oxide; PMDI: Polymeric diphenylmethane diisocyanate; TDI: Toluene diisocyanate; EO: Ethylene Oxide; PG: Propylene GlycolAll capacities indicated in KTA
Key process units and technologies
July 10, 2020 8
Game changer in chemicals
Technology licensors of international repute and experience:– Dow (PE, PO, PMDI, TDI, EO, PG)1
– Technip (Mixed Feed Cracker)– GTC Technologies (Aromatics)– ThyssenKrupp Uhde (Chlorine)– Espanola (Nitric acid)– Noram (MonoNitroBenzene)– Josef Meissner (DiNitroToulene)– Formox (Formaline)– KBR (Aniline)
1500
400
280
134
375220
416 316 400
250 153
200
360
390
400
70
208
400
—Power and Automation from ABB
July 10, 2020 9
Main Automation Process Control, Safety, Code Validation, Operator Training Simulation, Interfaces
Terminal ManagementAutomation of bulk inventory; tank farms, packaging and transport
Operations ManagementMobility and electronic shift operations management
InstrumentationAdvanced flow and level measurement technology
Analytical Systems and Emissions MonitoringProcess analysers
Distribution TransformersMain power distribution
Drives SystemsVariable frequency drive systems
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Only major EPCs are listed above
15 EPCs, 8 countries, One ABB
July 10, 2020 10
TDA
TDI (7)
HNO3
MNB
Aniline
PMDI (8)
Formaline
PMD(A)I
Chlorine (3)
Brine HCU
CA
Olefins (1)MFC
Aromatics (2)
ExtractHydro
HDPE
Plastics (11,12,13,14)
Elastomers
Sol. PE
Sol. PE
SDL (17)
Site Dev
UPI (15, 16)
Util Infra
Power
DNTBGE
EO & Derivatives (4,5,6)
EOA
EAE
Polys
PO & Derivatives (9,10)Polys
PG
Daelim - KR
JGC- S
A
Jacobs - UK
Daelim - KRDaelim - KR
FW - TH
FLUO
R - U
S
Daewoo - SA
DOW - US
Tecnicas - ES
TDI
PO
EO ISS
Fluor – US/UK
PAK (19)
Tank Farm
FW - UK
Tecnimont - IT
Tecn
icas -
ES
FLUOR - UK
—A global ABB team leveraging local presence
July 10, 2020 11
Oslo, NO
Boros, SE
Shanghai, CN
Bangalore, IN
St. Neots, UK
Riyadh, SA
Houston, US
Helsinki, FI
Orchestrating people, process and technologies across continents
Project split
Global supply chain organizationEstablishing frame/ strategic agreements early in the projectIntegrating critical sub-suppliers into planning and execution
Boston, US
Madrid, ES
Materials (65%)Services (35%)
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FEED: Front End Design Engineering LTSA: Long Term Service Agreement CRT: Creditor Reliability TestEPC: Engineering, Procurement, Construction C&SU: Commissioning and Start Up
Project Timeline
July 10, 2020 12
Cra
cker
Fina
l Inv
estm
ent
Dec
isio
n
2H 2011
Con
stru
ctio
n be
gins
2013 2015 2016 2017
Fina
ncia
l clo
se
Firs
t Pro
duct
(P
E)
Rem
aini
ng p
lant
s
FEED EPC
C&SU
Rem
iani
g pl
ants
2012 2018
Cra
cker
CRT
s
2019 2020 2021
LTSA
Rem
aini
ng P
Os
Cra
cker
PO
2014
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1 Piping and Instrumentation Diagrams 2 Process Control Strategy Documents 3 Input | Output4 Heat and Material Balance 5 Unit-based Control (State-based Control) 6 Smart Plant Instrumentation
Project workflow
July 10, 2020 13
Getting it right first time
EPC DeliverablesP&IDs1
PCSDs2
IO3 listsProcess data, H&MB4
…
Software and Hardware Design
Owner DeliverablesFunctional specifications, standards (Licensor’s…)…
FEED DeliverablesHardware typical(s)Software typical(s) (UBC5)Methods | Tools (SPI6)Standard function blocks Standard libraries
Configuration/ Fabrication Testing/ Acceptance
OWNER
ABB EPC
ABB
OWNER
ABB EPC
Objectives
Once-through, high quality configuration and fabrication with minimum rework
No undefined requirements when Software and Hardware specifications are complete
No compromise on safety and quality in design
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—Project management framework
July 10, 2020 14
Characteristics
– A formal project management process is in place and is applied consistently across all projects
– The process is business-focused and addresses the full lifecycle of the project
– Projects move through the process in a series of controlled steps
– Control is assured by the need to meet defined objectives agreed with all major stakeholders and by detailed scrutiny of recommendations and risks and a formal decision review at the end of each step in the process
– Objectives and performance are benchmarked against external industry
Key to managing global projects
Delivering value through quality decisions
4.1 Mobilization and planning 4.2 Basic design 4.3 Detailed
engineering4.4 Fabrication and test
4.5 Installation and mechanical completion
4.6 Commissioning 4.7 Close out
—Delivering world class projects
July 10, 2020 15
Synchronized execution approach
Manageable, Measurable, and Attainable
Planning and governance
Resource management
Standards and controls
Execution capability
Technical capability
Ensuring timely, and uniform sharing of information, decisions and areas of risks and concerns Clarifying accountability, decision-making authority, and escalation paths
Continuity of resources during all phases of project executionFormal and consistent relocation policies facilitate employee movement
A single, standard project methodology, promotes traceability throughout—from requirements to testing to deliveryStrong advocacy and promotion of the standards
Safe and predictable delivery of world
class projects
