convegno nazionale ipma italy projectification saipem...
TRANSCRIPT
Convegno Nazionale
IPMA Italy –
″Projectification″
SAIPEM ONSHORE
DIVISION –
Jazan Project
Execution
24 Gen 2019
Pic
ture
by A
gost
ino N
apoli
tano
2
Jazan IGCC Project
Pic
ture
by A
gost
ino N
apoli
tano
CONTENTS
1. Introduction to the
Program
2. Project
Description
3. Project execution
Strategy
3
Program Overview
Saudi Aramco was charged with developing the infrastructure for the first phase of the
Jazan Economic City which includes the Jazan Refinery and Terminal, the Commercial
Seaport, an IGCC Power Plant and major Infrastructures.
These infrastructure will provide a base for investments in heavy and secondary
industries, petrochemicals, mining and other conversion industries.
The main goal of the Economic City is to stimulate manufacturing and industry in the
Kingdom’s southwest region.
• By creating more than 1,000 jobs directly, and 4,000 jobs indirectly, for the local
community.
• Promote training of local people through Jazan Contractor’s Consortium for Training
and Employment – “Maharat” of at least 5,000 young Saudi’s.
Investment for Refinery and IGCC Power Plant range to about 20 USD billions
The awarded value to Saipem is equal 3.1 USD billions
Introduction to the Project
Jazan IGCC Project
4
Project Location
Introduction to the Project
5
Contractor Offices
& Camp
JIGCC
Project Location
Introduction to the Project
6
Refinery , Terminal & IGCC
Introduction to the Project
7
• Gasification and SARU Block (IGCC-EPC-1) - Saipem
• Sulfur Recovery (EPC- 2) - Saipem
• Air Separation (EPC-3) – Air Products
• Power Block (IGCC-EPC-4) - Sepco
• Utilities & Common Area (IGCC-EPC-5) – Tecnicas Reunidas
• Sea Water Facilities (EPC-6) – China Harbour
Saipem EPC-1
Saipem EPC-1
1
Saipem EPC-2
Saipem EPC-2
Air Product EPC-3
Sepco EPC-4
Tecnicas Reunidas EPC-
5
China Harbour EPC-6
IGCC Packages
Introduction to the Project
8
From
Refinery
Oxygen
ASU(by 3rd Party)
AGRRaw
Syngas
Sulfur
AGR Acid Gas
Power
Block
4GW
Treated Syngas
HRU
Tail Gas
Nitrogen
SARU
Waste
Sulfur
SWS Acid Gas
ARU Acid Gas
SWS Acid Gas
Treated
Syngas
TPD
G-SRU
110 MBD
GFU
1,082 TPD
R-SRU(Refinery Plot)
Utilities
& Offsite
Plant/Inst Air
Potable Water
Chilled Water
Fire Water
Sea Water
Fuel Gas
Flare System
Perimeter Roads
Telecom.
Off-plot Drainage
Oxygen
VR from
Refinery
HSFO
Nitrogen To
Refinery
Power
To Grid
Power/Steam
to Refinery
Pure H2 to
Refinery
Steam
Steam
JIGCC Overall Process Scheme
Introduction to the Project
Metal
Ashes
9
Jazan IGCC Project
Pic
ture
by A
gost
ino N
apoli
tano
CONTENTS
1. Introduction to the
Program
2. Project
Description
3. Project execution
Strategy
10
Jazan IGCC Project
Project: IGCC Program – EPC Package 1 & 2
(Integrated Gasification Combined Cycle Project)
Client: Saudi Aramco
Location: Jazan, Kingdom of Saudi Arabia
Contract type: Lump Sum Turn Key
Contract value: 3.1 bn USD
Scope of Work: Engineering, Procurement, Construction,
Pre-commissioning & Commissioning assistance
Summary Data
11
Jazan IGCC Project
Scope of Work
EPC Package 1
Plant Facilities:
GFU - Gasification Unit Unit A01
(4 blocks equal to 2,360,000 Nm3/h - produced Syngas)
HRU - Hydrogen Recovery Unit Unit A02
(2 blocks equal to 184,000Nm3/h - produced H2)
AGR - Acid Gas Removal Unit Unit A03
(4 blocks equal to 2,110,000 Nm3/h - Treated Syngas)
SARU - Soot Ash Removal Unit Unit A06
(4 blocks equal to 788 kg/h - produced Ash)
Project Duration:
44 Months
12
Jazan IGCC Project
Scope of Work
EPC Package 2
Plant Facilities:
Sulphur Recovery Unit for Jazan Refinery Unit J30
(3 trains x 541 t/d sulphur recovered)
Sulphur Recovery Units in IGCC area Unit A07
(3 trains x 509 t/d sulphur recovered)
Project Duration:
44 Months
13
Jazan IGCC ProjectMain Project Quantities
Unit of
Measure
EXECUTION PHASE
QUANTITIES
Equipment No. 1.927
Reinforced Concrete M3 105.810
Steel Structures ton 67.201
Piping Steel ton 45.558
Piping RTR-PVC ton 2.613
Piping Fabrication DIA 2.463.495
Piping Erection DIA 1.393.020
Ele & Instr. Cables km 6.472
Total I/O Num. 53.653
14
Jazan IGCC ProjectMain Project Quantities
Concrete
71,053 m3 of reinforced Concrete Quantity
equivalent to:
45% more concrete of the Empire State Building
15
Jazan IGCC Project
Main Project Quantities
216,398 M2 of Paving equivalent to:
Piazza del Duomo x 13
Concrete/Asphalt Paving
16
Jazan IGCC Project
Main Project Quantities
Steel Structures52,461 tons of Steel Structures equivalent to:
Brooklyn bridge x 3
17
Jazan IGCC Project
Main Project Quantities
Piping Erection (TONS)
35,766 tons of Piping equivalent to:
Giuseppe Garibaldi Aircraft carrier x 2.5
18
Jazan IGCC Project
Main Project Quantities
Piping in Dia-Inches (Fabrication & Erection)
Factorized Inches 3,218,993 equivalent to:
256 km of Linear Welding
(distance miLAN to FLORENCE)
19
Jazan IGCC Project
Main Project Quantities
Electrical and Instrumentation Cable Length
Over 4,652 km of Cable to be
pulled equivalent to:
Milano –jazan ground distance.
20
Jazan IGCC Project
Building the largest gasification plant in the world
Project Magnitude
21
Jazan IGCC Project
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ture
by A
gost
ino N
apoli
tano
CONTENTS
1. Introduction to the
Program
2. Project
Description
3. Project execution
Strategy
22
Jazan IGCC Project
Construction
Procurement
Engineering
Project Management
Project Management in Milan Office and Site
Project Execution Strategy
Project Management Team initially based in
Milan throughout the Home Office activities,
together with Saudi Aramco
Then relocated in Jazan at the beginning of
Construction
23
Jazan IGCC Project
Construction 1
Procurement
Engineering
30% activities in H.O Milan 70% activities in SIP
Chennai
Project Management
2.650.000 Engineering Manhours at the end of the Project
General activities executed at Head Office Milan:
➢ FEED Verification
➢ Process, Utilities, Material & Corrosion, Loss Prevention
Detailed Engineering Equipment:
➢ Supply follow up (after PO) of Critical Equipment managed
in Milan
➢ Supply follow up (after PO) of non critical equipment (e.g.
pumps and static equip.) developed with support of SIP
(Saipem India Projects)
Instrumentation, Civil, Piping, Electrical:
➢ Detail plant engineering, and follow-up of bulk
materials developed with support of SIP.
Buildings
➢ Detailed engineering developed in Al-Khobar
Project Execution Strategy
24
Jazan IGCC Project
Construction 1
Procurement
Engineering
Project Management
✓ More than 1000 Purchase Orders placed
✓ Suppliers selected in 27 Coutries
✓ Around 1.5 USD Billions of Materials Purchased
Sinergy between Package 1 & 2
Project Execution Strategy
25
4%
Jazan IGCC Project
Italy
39%
Saudi Arabia
6%
South Korea
40%
Germany
3%
India
3%
United States
Distribution of Suppliers
26
Construction 1
Construction Execution Plan
Procurement
Engineering
Project Management
Jazan IGCC Project
▪ CONSTRUCTION EXPECTED MANHOURS AT THE
END OF THE PROJECT : 109.000.000
▪ OVERALL MANPOWER AT PEAK : 14.000
Project Execution Strategy
27
Jazan IGCC ProjectConstruction Execution Plan
Manpower curve
6.219 6.320 6.393 6.530 6.902 6.940
7.159 7.330 7.332 7.477 7.380 7.433 7.433 7.399 7.489
7.321 7.289 7.207 7.030
6.788
-
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
10.000
02-16 04-16 06-16 08-16 10-16 12-16 02-17 04-17 06-17 08-17 10-17 12-17 02-18 04-18 06-18 08-18 10-18 12-18
% M
on
thly
To cover both Projects
28
Jazan IGCC Project
Currently on site active 1950 Saipem employees (for Pack 1&2)
0 100 200 300 400 500 600 700 800 900
ALGERIAN
BANGLADESHI
BRITISH
CROATIAN
EGYPTIAN
FILIPINO
INDIAN
INDONESIAN
ITALIAN
JORDANIAN
MEXICAN
NEPALI
NIGERIAN
PAKISTANI
POLAND
PORTUGAL
ROMANIAN
SAUDI
SRI LANKAN
SUDANESE
TUNISIAN
Manpower by Nationality
29
Jazan IGCC Project
0 50 100 150 200 250 300
ALGERIAN
BANGLADESHI
BRITISH
CROATIAN
EGYPTIAN
FILIPINO
INDIAN
INDONESIAN
ITALIAN
JORDANIAN
MEXICAN
NEPALI
NIGERIAN
PAKISTANI
POLAND
PORTUGAL
ROMANIAN
SAUDI
SRI LANKAN
SUDANESE
• Currently on site active 571 Supervision Personnel (for Pack 1&2)
30
Jazan IGCC Project
TCF designed by Saipem team and constructed in Direct Hiring
Laydown Area and Warehouse ViewCamp Area View
SAIPEM CAMP AREA
Project Execution Strategy
31
Jazan IGCC Project
Construction Execution has been a mix of:
DIRECT HIRING (20%)
➢ HRU (A02) Mechanical Works
➢ A51 Interconnecting Piperack Mechanical Works
SUBCONTRACTING (80%)
➢ Other areas, A01, A03, A06
➢ General subcontractors (NSH / CCC)
➢ Specialized subcontractors (CBI / OLAYAN)
Project Execution Strategy
32
Construction Execution Strategy – Subcontracting Plan
Jazan IGCC Project
