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
3Chiyoda CorporationChiyoda CorporationShell Global Solutions Shell Global Solutions
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)
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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
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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
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Fast Track ProjectComparison with Previous Project
Qalhat LNG13 Months till RFSU (As of October 2004)
Previous Project12 Months till RFSU (As of December 1998)
APCI Main Cryogenic Heat Exchanger
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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
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(1stTrain)
Contract Plan forQalhat LNG
Actual for Qalhat LNG
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(1st Train)
Contract Plan forQalhat LNG
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.
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(1st Train)
Contract Plan for Qalhat LNG
Actual for Qalhat LNG
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Fast Track ProjectComparison with Previous Project
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
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Qalhat LNG19 Months till RFSU(As of April 2004)
Previous Project19 Months till RFSU (As of May 1998)
Fast Track ProjectComparison with Previous Project
First Heavy Lifting
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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
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Fast Track ProjectComparison with Previous Project
Qalhat LNG22 Months till RFSU (As of January 2004)
- World Record ? -
Previous Project15 Months till RFSU (As of September, 1998 )
Underground Cable Laying
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Fast Track ProjectComparison with Previous Project
Qalhat LNG18 Months till RFSU (As of April 2004)
Previous Project13 Months till RFSU (As of November, 1998 )
Concrete Pavement
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$$
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
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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.
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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
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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
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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
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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
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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
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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
21Chiyoda CorporationChiyoda CorporationShell Global Solutions Shell Global Solutions
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.
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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
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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)
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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
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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