indigenization of spare parts and consumables used in the petrochemical industries present by:...

Indigenization of Spare Parts and Consumables used in the Petrochemical Industries

Present by: Rajeev ChowdhryManaging Partner – Alpha International Management Consultants

28th December 2009

PETROCHEMICAL INDUSTRY - SAUDI ARABIA

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An overview of the Oil and Gas and Petrochemicals Industry

Products – Classified into various Categories

Process Flows for Oil & Gas

Capital Equipment and their types

Spares and Consumables

Observation and Inferences

Petrochemical Industry in Saudi Arabia: A Snapshot

Hydrocarbons are the backbone of the Saudi economy The single largest sector of Saudi Arabia’s economy is the extraction of crude oil and natural gas (hydrocarbons), which accounted for 27 percent of real GDP in 2008. Petrochemicals provided 9 percent of GDP last year, up from 7 percent a decade ago.

The dominance of the hydrocarbons sector extends well beyond its direct contribution to economic output: hydrocarbons account for around 90 percent of export earnings, and thereby provides the main source of revenue for the public sector.

The petrochemicals sector offers one of the most promising long term investment opportunities towards economic diversification in Saudi Arabia.

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The Product Chain

Raw Material and Feedstock

Crude Oil, Natural Gas, Methane, Ethane, Propane, Butane, Naphtha

Basic Petrochemicals

Ethylene, Propylene, Butadiene, Benzene, Toluene, Xylene, Amonia

Intermediates & Derivatives

MTBE, Methanol, Vinyl Chloride Monomer, Mono Ethylene Glycol, Polyethylene, Polypropylene etc

End Products

Plastics, Coolants, Cosmetics, Pharmaceuticals, Fertilizers, Packaging, Fibers, Paper, Textiles, Lubricants…

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Basic flow Chart for Oil Production

Refineries can range from simple topping plants with only a crude oil distillation tower to the more complex refinery shown in the flow sheet.

CD – Crude Distillation Tower, REF – Reforming, FCC – Catalytic cracking, COK – Coking, HYT – Hydrotreating, HR – Hydrodesulfurization. 6


Basic flow Chart for Gas Processing

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What do the Petrochemical Companies produce

Feedstock and Petrochemical products produced

Methane Ethylene PropyleneButenes and Butadienes

Benzene Toluene Xylenes

Hydrogen Polyethylene PolypropyleneStyrene-

Butadiene rubber(SBR)

Styrene Benzoic acidPhthalic

anhydride

Ammonia Ethanol IsopropanolMethyl tert-Butyl Ether

(MTBE)Polystyrene

Toluene diisocyanate

Polyesters

MethanolEthylene

glycolPropylene

glycolPolybutadiene Phenol Polyurethanes

Dmethyl terephthalate

Methyl chloride

Vinyl acetate Alkyl chlorideAcrylonitrile-Butadiene-

Styrene (ABS)Cumene Caprolactam

Terephthalate acid

Carbon blackPerchloroEthylene

Acrylonitrile Polybutenes Aniline NylonsPolyethylene terephthalate

AcetylenePolyvinyl acetate

Acrylic acidMethyl ethyl ketone(MEK)

Adipic acid PolyureasDioctyl

Phthalate

Formaldehyde Glycol ethers Epoxy resins Tert-butanol Nylons 8

Acrobat Distiller 6.0 ME.lnk

http://en.citizendium.org/wiki?title=Methyl_ethyl_ketone&action=edit&redlink=1




What are the main Capital Equipment – Petrochemical Industry

The Oil and Petrochemical Industry have a huge array of equipment that it needs for processing the feedstock into various end products. We give below a list of main equipment that each of the stages need.

Oil Exploration and Pre processing

Drilling Rigs, Platforms, Well Head Equipment like Christmas Tree, Oil Pumping equipment, Gas Oil Separation Plants.

Refining & Petrochemical Processing

De-salter units, Distillation Columns, Hydrotreater, Catalytic Reformers. Fluid Catalytic Cracker. Hydrocracker, Visbreaking, Merox unit, Coking units, Alkylation, Dimerization unit, Isomerization unit, Steam reforming unit, Gas treaters, Solvent refining units, Solvent dewaxing units

ALL these are high end complex Plant and Equipment designed by the Process Patent Holders and Technology Providers (OEM’s).

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Specialized Equipment and Systems

Apart from the capital equipment, this Industry needs a lot of highly technical equipment and systems which are designed for the specific highly critical application by highly specialized manufacturers. We list the most important ones below:

Heat Exchangers

Electrical systems including Rotary Drives,

Automation systems incl. Process Controllers

Instrumentation Systems including Gauges

Hydraulic and Pneumatic Systems – both prime movers and control systems

Utility systems like Compressed Air

IT based control and monitoring systems

Safety equipment & systems

Packaging, Shipment and Delivery systems incl. Automatic loading for liquids and batch

loading for solids

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Generic Equipment and Systems

Generic equipment that is used in this Industry, usually produced by local manufacturers and some of them are actually built on site.

Utility units such as Cooling towers, boiler plants and Water treatment Plants

Buildings and shelters for the process equipment

Technology Structural Steel Works both in Stainless Steel and Mild Steel

Flare Stacks and Chimneys

Liquid Product Storage units like Tanks, Spheres and Bullets,

Solid Storage areas like silos

Material Handling Equipment like Cranes, Stackers, Reclaimer etc.

A variety of piping works including cross country piping for product transportation

Lighting systems for the plant

Fire Detection and Fire Fighting systems (for the plant)

Security Systems11


Accessories and Spares Parts

The Petrochemical Industry needs a number of equipment and spares on a regular basis. The total list is huge and so we have tried to group the most important ones as listed below:

Drives and Rotary equipment like compressors, pumps, motors (both Electrical and

Hydraulic), Gear Boxes, actuators etc.

Heat exchangers

Valves – safety valves, control valves etc.

Instrumentation like gauges, sensors, switches etc.

Electronics and Automation spares

Transformers, Circuit breakers and other Power Electrical Items

Piping and lining material

Cables of all kinds

Paints, Solvents, Rust Inhibitors etc.

Spare Parts for Generic Equipment

Lights and other Illumination items

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Consumables

Apart from the Mechanical and Electrical equipment there are a number of consumables that are used in this industry… once again, we try and identify a few important ones

Drilling Mud, Cement and a host of other non metallic solids

Catalyst – both new and processed

Tubing, Linings and Refractory

Chemical additives like Agitators

Packaging Material

Lubricants for various applications

Column Internals like Sieves and Trays

Tubing for boilers

Most of these items are supplied by trading companies who represent International manufacturers in KSA

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Investment Opportunities

The list of possible equipment and spare parts that can be produced locally is very big and we highlight the following 10 equipment, consumables and services. These items actually find use across a broad spectrum of Industry.

Fabricated Steel Products

Valves

Rotary equipment like pumps

Gear Reducers

Catalyst and Chemical additives

Drives like Electric and Hydraulic Motors

Standard Instrumentation parts

Refractory and lining material

Heat Exchangers

Alloy Steel Castings and Forgings

Hydraulic and Pneumatic Systems

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We shortlisted 3 out of these 10 items for a brief study


Investment Opportunities

The rational for selection of these 3 items was based on the highest demand from Saudi Aramco’s estimate on expenditure it would make for various items between 2007 to 2012

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Investment Opportunity No. 1 : Fabricated Steel Products

This is one of most promising industries in the Support Sector in Saudi Arabia and there is absolutely no doubt about the need for a Quality fabrication shop. Local production capacities exist on the lower quality segment and the demand and supply scenario changes drastically from year to year depending on the projects released simultaneously.

The number of projects planned for 2010 – 2013, the industry will face a supply squeeze unless new quality fabrication facilities are not set up.

Saudi Aramco averages nearly US $ 1.5 billion worth fabricated structures a year and estimating that this value would be approx 40% of the total demand, the market size for Structural Steel Fabricated structures would work out to almost US $ 3.7 billion

In terms of tonnage, this would amount to approx 1.5 – 1.7 Million Tons / annum

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Investment Opportunity No. 2 : Valves

Valves are devices that are used to either control, regulate or contain the flow of liquids, gases, slurries, semi-solids or any other flowing material.

Valves can be broadly classified as follows:

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Based on Application Actuation Construction No. of Ports

Control Valves Hydraulic Control There are more than 50 types of

construction like Ball type, Needle Valves,

Butterfly Valves, Bibcock Valves, Leaf

Type etc.

Single Port

Pressure Valves Pneumatic Control Double Port

Solenoid Control Three Port – multi Direction

Manual Levered Four Port – multi Direction

Electric Motor Control

Spring Loaded

Thermostatic Type


Each of these valves have specific applications and OEM companies specialize in different ranges of these valves. Considering the local market, we recommend the setting up of a plant for the manufacture of Pressure Valves as a first step.

Pressure Valves

The factory should produce Pressure Relief Valves for a variety of liquids and Gases and should be designed and tested as per reputed international standards like ASME

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Low Pressure Safety Relief Valve

High Pressure Safety Relief Valve

Pilot ActuatedSafety Relief Valve



Manufacturing Facility

A comprehensive manufacturing facility would include a Steel and Alloy Steel foundry, a Spring Manufacturing unit, a medium sized machine shop, a valve assembly plant, necessary testing facilities and a painting area.

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MachiningCentre

AssemblyShop

PaintingBooth

Testing Centre

PlantOverview



With only Saudi Aramco planning to buy over US1 billion worth of valves each year, the market for valves is huge and diverse.

Recommended way forward for Saudi SME Investors is to form a Joint Venture with any of the worlds leading OEM’s in this field, with an assured off-take by the OEM.

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Pumps are devices used to move liquids, slurries and gases from one place to other.

Pumps essentially have the following components:

A Casing or Body, within which the fluid is moved. A drive or prime mover with or without a gear reducer. A connecting shaft with coupling that connects the pump and the

drive An impellor or ram which actually moves the fluid from the input port

to the discharge port Seals and Bearing that ensure the whole assembly stays together

and operates smoothly without leaks And finally the instrumentation and control panels

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Investment Opportunity No. 3 : Pumps


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Types of Standard Pumps for common industrial uses

Impellor type single stage centrifugal pump

Multiple stage – Diffuser type centrifugal pump

Reciprocating pump

Reciprocating pump Vane type rotary pump

Diaphragm type axial pump



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Typical Production Facility

Electric Arc Furnace / Induction Furnace facility for casting the valve bodiesMould Shop for making mouldsFettling and Cleaning facilities for castingsMachine Shops for machining of various parts like impellor shafts Heat treatment facility for various itemsAssembly shop for mechanical assembly Electrical workshop for assembly of motors and drives Shot Blasting and painting facilities Testing facility Maintenance workshops



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Typical Production Facility

Machine Shop Assembly Shop Valve Testing Shop



We anticipate the market for valves to be over USD 1 billion/year, given the fact that Saudi Aramco by themselves procure an average of US $ 680 million worth of pumps each year. SABIC companies are equally big users of pumps and if you add to that the other big users like SWCC, SEC and other Ministry of Water, the market size exists for a major investment in this field.

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Inferences

Oil and Petrochemical Industry spends billions of Saudi riyal each year for procurement of Spares and Consumables and there exists a very big opportunity for local investors to Locally Manufacture some of this demand.

The way forward recommended is to set up manufacturing plants in Technology partnerships and Joint Ventures with reputed OEM’s, with clear understanding on Technology Transfers and Training of local manpower, then develop core engineering competence within a planned time frame

The Major Players in Oil and Gas Industry on its part “must” support any new ventures by not only providing necessary technical assistance but also getting into suitable “Take Off Agreements” with new Start – Up companies, which will provide the necessary comfort to the local investor.

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Thank You!

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indigenization of spare parts and consumables used in the petrochemical industries present by:...

Documents

petrochemical products

systems generic equipment

oil gas capital equipment

petrochemical companies

oil pumping equipment

head equipment

technical equipment

list of main equipment