INNOVATIVE IDEAS FOR LIGHT MODULES FOR FPSO & FLNG1.) INTRODUCTION ……HERE BACKGROUND OF SELF AND PASTEXPERIENCE WITH MODULES SHALL BE SHARED2) FPSO & FLNG ……CURRENT STATUS3) FUTURE PROSPECTS FOR FPSO & FLNG……..PERSPECTIVEPLANNING & GROWTH PROSPECTS4) CHALLENGES IN DEVELOPING FLNG PROJECTS5) INNOVATIVE IDEAS & APPROACH6) EXPECTED TRENDS IN FLNG / FPSO7) A POSSIBLE WAY FORWARD8) CONCLUSION
1. INTRODUCTIONCANADOIL ENGINEERING CAPABILITIES World Class P W ld Cl Provider Of E i id Engineering S l ti i Solutions
STATE OF ART FACILITIESSTATE OF ART FACILITIESCANADOIL ENGINEERING CONCEPTCANADOIL ENGINEERING CONCEPT
PROJECT ENGINEERING MANAGEMENTGAS TREATMENT PACKAGESGas Treatment Packages Gas Treatment PackagesBudgeted Man hour 60,000 approx HIGHLIGHTS: GAS Sweetening Package, GAS Drying Package and GAS Dehydration packageCE SCOPE: FEED AND DETAILED ENGINEERING;
PROJECT ENGINEERING MANAGEMENTBAGCR PROJECT – GOHT & KHT REFINERY UNIT UPDATEPresent Progress till Dec 09 : 23.5% Present Progress till Dec 09 : 23.5%Budgeted Man hour 1,70,000 approx Man hour spent till end of DEC 09 : 36000HIGHLIGHTS: GAS OIL HYDROTREATER and KEROSENE HYDROTREATER UNITS PART OF 4 BILLION US$ GAS CONDENSATE REFINERY 360000 BPDCAPACITY : 42,000 BARRELS PER DAY x 2 Trains for GOHT & 25,000 x 1 Train for KHT f fLICENSOR: HALDAR TOPSOE / FEED : SNAMPROGETTI LICENSOR: HALDAR TOPSOE / FEED : SNAMPROGETTICE SCOPE: DETAILED ENGINEERING; PROCUREMENT ENGG; FIELD ENGG & COMMISSG.
PROJECT ENGINEERING MANAGEMENTMAHSHAHR PRODUCT STORAGE FACILITY PROJECTBASIC Engineering being finalized by SPG, Germany, Detail Engineering by CEBASIC Engineering being finalized by SPG, Germany, Detail Engineering by CEBudgeted Man hour 1,00,000 approx HIGHLIGHTS: CYOGENIC STORAGE AND HADLING FACILITY FOR C3, C4 and C5+ ProductsCE SCOPE: DETAILED ENGINEERING; PROCUREMENT ENGG; FIELD ENGG & COMMISSG. ASSISTANCE
UNIQUE COMPETITIVE ADVANTAGES GAINED BY UNIQUE COMPETITIVE ADVANTAGES GAINED BY PARTNERING WITH CANADOIL SHORTER DELIVERY TIME INCREASE ENGINEERING KNOW HOW AND INNOVATIVE SOLUTIONS BASED ON PRODUCTION PRE-FABBRICATION DEVELOPMENT OPTIMIZATION OF ENGINEERING SPECIFICATION OF MATERIAL REQUISITIONS THEREFORE AVOIDING OVER DESIGN & OVER COSTS REDUCED RISK OF MULTIPLE CONTACT/CONTRACT MANAGEMENT CLOSER RELATIONSHIP TO MANUFACTURED COMPONENTS OR END PRODUCT
2. FPSO & FLNG CURRENT STATUS…… CURRENTLY @ 100+ FPSO’S UNDER OPERATION ’ ONE FLNG PLANT UNDER EPC AND COUPLE OF THEM UNDER FEED / CONCEPT STAGE MAINLY ONSHORE TECHNOLOGY & PLANT DESIGN CONCEPT APPLIED TO SHIP. ENGINEERING WISE POSSIBLE TO IMPROVE WITH INVOLVEMENT OF ESTABLISHED ENGG COMPANY HAVING BOTH POSSIBLE TO IMPROVE WITH INVOLVEMENT OF ESTABLISHED ENGG COMPANY HAVING BOTHOFFSHORE & ONSHORE EXPERIENCE NEED TO INVOLVE MODULE SUPPLIERS HAVING ENGINEERING BACKGROUND TO ENSURE TROUBLE FREE MODULE TIE UP & OPERATION ON THE SHIPFREE MODULE TIE UP & OPERATION ON THE SHIP CURRENTLY THE FLNG CONCEPT OF FULL LAND BASED PLANT BEING FIXED ON FLOATING HAS SOME CHALLENGES TO ADDRESS ISSUE RELATED TO SLOSHING MOVEMENT, INTER SHIP TRANSFER, OPERATION OF PLANT DURING ROUGH WEATHER CONDITION ETCOPERATION OF PLANT DURING ROUGH WEATHER CONDITION ETC Worldwide need for clean burning fuel • Shortage of large fields near shore leads to high project cost. • The cost escalation has led to floating LNG production on a vessel (FLNG)b) A way to develop stranded gas fields, isolated, remote from land and other Infrastructurec) Alternative to flaring and re-injectiond) Alternative to land-based Greenfield LNG-plants ) pe) Market uncertainty • Improved technology in LNG storage & transfer (sloshing and motion effects) • FPSOs are conventional, over 100 in operation p • Hundreds of offshore gas fields over 0.5 trillion cubic feet, suitable for 1 – 2 MTPA FLNG.
MAIN MODULES, PACKAGES & EQUIPMENTS……….FOR FLNG , Q • ACID GAS ABSORBER : packed column ACID GAS ABSORBER : packed column• SLUG CATCHER • HEAT EXCHANGERS• GAS FILTERATION / SEPARATION GAS FILTERATION / SEPARATION – Coil‐Wound Heat Exchanger (CWHE) – Plate Fin Heat Exchangers (PFHE) • GAS TREATMENT COMPRISING OF – Core‐in‐kettle Core in kettle – Low fin tubes heat exchangers• GAS DEHYDRATION – Printed Circuit Heat Exchangers (PCHE)• GAS DRYING • ROTATING MACHINES – Compressors p• GAS SWEETENING GAS SWEETENING – Turboexpanders – Gas turbines and power generators• MERCURY REMOVAL
3. FUTURE PROSPECT & GROWTH…… DEMAND FOR 150 MILLION TON PER YEAR OF LNG BY 2012 POSSIBLE TO HAVE A MEDIUM SIZE FLNG WITH CAPACITY OF 1 TO 2 MILLION TON PER YEAR REQUIREMENT OF LIQUEFACTION VS CNG TO BE EVALUATED (NOT ECONOMICAL FOR DISTANCE LESS THEN 3000 MILES).
4. CHALLENGES IN DEVELOPING FLNG PROJECTS There are a number of issues that need to be carefully examined when considering a floating LNG facilitya floating LNG facility• Location & sea condition• Survival in storm conditions• Ensuring smooth facility operation in motion & rough sea E i h f ili i i i & h• Suitable sites having available large quantity of Gas which can be trapped subsea• Availability of skilled manpower to build & operate, material and equipments / package modules suitable for operation in marine environment, suppliers, Certifying agency….. y g• Whether we really need such huge FLNG terminals or whether a smaller version can be more productive and economical• Access for export / import vessels (tugs & pilotage)• Type of plant, liquefaction / regasification• Type of plant liquefaction / regasification• Type of vessel & containment• Mooring of the facility• Method of transfer of cargo M th d f t f f• Deck congestion
5. INNOVATIVE IDEAS & APPROACH……FOR MODULARIZATION BENEFITS OF MODULARIZATION MODULARIZATION APPROACH & ISSUES CASE STUDY ZORA CASE STUDY ZORA CASE STUDY SPG CASE STUDY QGII CASE STUDY WITH MODULE SUPPLIERS DISCIPLINE ENGINEERING INVOLVING INNOVATIVE IDEAS FOR LIGHTER MODULES
BENEFITS OF MODULARIZATION FASTER TO BUILT, QUICKER CASH FLOW FRM PRODUCT DELIVERY, EARLY PROD SAFER COST EFFECTIVE (CONST COST SAVING, LESS TESTING ON SITE / SHIP) BETTER QUALITY DUE TO CONTROLLED WORKING CONDITION MINIMIZE IMPACT & FIELD WORK AT FINAL PRODUCTION SITE MINIMIZE IMPACT & FIELD WORK AT FINAL PRODUCTION SITE MINIMIZE LAYDOWN SPACE MINIMIZE IN‐AIR WORK STRUCTURAL / FOUNDATION REQUIREMENT SIMPLIFIED REDUCE DELAYS DUE TO ADVERSE WEATHER FEWER FITTING ERRORS FEWER FITTING ERRORS PROCUREMENT SIMPLIFIED MATERIAL & EQUIPMENT ARE EXPENSIVE & DIFFICULT TO OBTAIN ON TIME SHORTEN SCHEDULES FURTHER BY CONCURRENT PROCESSES SUCH AS FABRICATION, PERMITTING & LOGISTICAL ARRANGEMENTS UNIQUE MODEL OF COMPANY CAPABLE OF LSTK ENGG, FABRICATION, UNIQUE MODEL OF COMPANY CAPABLE OF LSTK ENGG FABRICATIONPROCUREMENT & CONSTRUCTION SERVICES FOR MODULAR PROJECT GLOBAL NETWORK OF ENGG PROCUREMENT CONSTRUCTION RESOURCES ENSURING FASTER DELIVERY
PITFALLS OF MODULARIZATION Bad Management Incomplete planning Incomplete planning Material delivery not synchronized with the module assembly Location of module yard Construction begins too soon Construction begins too soon Decisions during construction are made based on construction completion date not on the basis of the potential incurred cost by incomplete or un‐installed components Case study: y •Typical issue like for one module the EHT (Electric Heat Tracing) had not been designed and they were proceeding with the installation of the Insulation. •The modules were going to be finished and shipped in this state. Someone had made the decision that shipping the modules without the EHT but installing the insulation was the best thing to do. •This decision was a typical example of how the modularization concept can turn from a major cost reduction initiative to a disaster. major cost reduction initiative to a disaster •The insulation and cladding will have to be removed and probably wasted because the size will most likely be larger than installed at the yard •The EHT cables will have to be field installed The EHT cables will have to be field installed •The power points and connections and will have to be field installed •Field costs will be exponentially more as compared to the cost of those at the module yard Commissioning and start‐up will be delayed. g p y • The project will see a major cost overrun.
INNOVATIVE & CORRECT APPROACH FOR MODULARIZATION Modularization concept must start at feed stage Create a strong integrated Management team for the Detailed design Plan the procurement of materials in the order of assembly Pl h f i l i h d f bl The detailed design must be initiated using the module or modules as the basis and the components and equipment must be designed to fit the module not the module designed to suit the equipment Constructability must be done at the planning stage, e.g. the fabricators and y g module assembly team should be involved at the detailed design stage. g Long lead items must be identified and purchased well in advance Module assembly must be done using the 80/20 rule meaning that the assembly does not begin unless 80% of the module materials have been assembly does not begin unless 80% of the module materials have been received and the other 20% have been purchased and are in the process of being delivered. The module assembly yard should be adjacent to the water to avoid The module assembly yard should be adjacent to the water to avoid shipping constraints in terms of size and weight.
INNOVATIVE COST SAVING METHOD FOR MODULARIZATION Standardize the sizes of structural components Meaning that do not over engineer if a common size works, Meaning that do not over engineer if a common size workseven if it is a heaver section than is required the bulk purchase of a common size will result in cost saving g Bulk purchase electrical cable and wire early If there are multiple modules that will be assembled together If there are multiple modules that will be assembled togetheron the vessel, perform all hydrostatic testing in the module yard and use the “In‐Process” inspection system for the joints between the modules. Maximize the work in the module yard and minimize the work performed in the field or on the ship.
QQATAR GAS OFFSHORE & AMINE FILTERATION MODULE……CASE STUDY
TEMPORARY FLARE PACKAGE SUITABLE TO FIT & USE ON 3 DIFF PLATFORMS
ASSEMBLY OF MODULES……MODULARIZATION IDEASDESIGNING GAS/ LNG FACILITIES FOR LOCATION ON FLOATER……AMINE SWEETENING MODULE
ONSHORE PLANT CONVERTED TO MODULE TO BE SHIPPED…….CASE STUDY
TYPICAL GAS DEHYDRATION PACKAGE MODULE…….CASE STUDY
WEIGHT REDUCTION ANALYSIS & OPTIMIZATION OF MODULES FOR OFFSHOREPLATFORM ………..CASE STUDY ZORA PLATFORM
WEIGHT REDUCTION ON THE OFFSHORE ..…..CASE STUDY ZORA PLATFORM
WEIGHT REDUCTION ON THE OFFSHORE ..…..CASE STUDY ZORA PLATFORM
CONTROL ROOM & SWITCHGEAR MODULES IN FLOATING ENVIRONMENT AREQUITE STANDARDIZED AND USED IN PAST FOR POWER BARGE CASE STUDY FPP BARGE.….CASE
6. EXPECTED TRENDS IN MODULARIZATION - PRINCIPLES DRIVING THE MODULEDESIGN…….DESIGN • Safety • Process functions rationale – Central interconnecting pipe rack to feed process modules – Follow logic of flows to minimize piping lengths – Minimize motions of key equipment Minimize motions of key equipment • Modularization philosophy – Well‐defined hull / topsides interfaces – Mechanical completion by function – easier testing & pre‐commissioning – Size / weight of modules selected to enable lifting by conventional means • Addressed technological difficulties Addressed technological difficulties – Process selection / on board floater – Machinery selection – Layout / plot plan / plot plan • Good understanding of technical quantities / cost of facilities • Facility remains « on par » in terms of project magnitude with currently delivered large oil FPSOs • Important commercial potential for medium scale gas accumulations
GAS TURBINES GUIDELINESThe Gas Turbine selected has to be referenced as:• Off shore application (FPSO)• Power generation (Electrical motor)• Mechanical driver (High “power density” and efficiency for big compressors) power density• Aero-derivative (high efficiency)• Machine proven reliability
LIQUEFACTION TECHNOLOGY SELECTION CRITERIA……• TECHNOLOGICAL SELECTION STRATEGY – Selection of a simple and robust liquefaction process, adapted to medium capacity l f l d b l f d d d and marine environment with high inherent safety – Avoid the use of large HydroCarbon (HC) liquid inventory (such as: refrigerants used in onshore LNG plants) – Minimization of two‐phase flows – Minimization of distillation towers – No by‐products (as LPG) to avoid logistics constraints – Use of proven equipment in identical or similar technologies (gas turbines, heat exchangers…) exchangers ) – For utilities and common facilities (sea water cooling, flare …), stay within capacities already in place in large FPSOs. (200,000 BOPD) LNG FPSO OFFSHORE LNG FSRUs
ACID GAS REMOVAL PACKAGE …….• RECOMMENDED INTERNALS IN MOVING ENVIRONMENT : STRUCTURED PACKING – Trays and random packing are not recommended because of liquid channeling and y p g q g efficiency drops – Structured packing is less affected by tilt and motion thanks to an higher hydraulic resistance to sideways flow• MOTION IMPACT ON STRUCTURED PACKING PERFORMANCES – A permanent tilt has an effect on liquid flow repartition. p q p – Periodic oscillations have a natural mixing effect, less damaging on performances than permanent tilt
CRITICAL ISSUES FOR MODULE /EQUIPMENT LOCATIONS…… Q – The column should be located as close as possible from the centre of gravity of the ship to limit liquid maldistribution – Intermediate remixing distributors reduce the consequence of the liquid flow distortion. This leads to an increase of the column length. – Specific distributors, enable to mitigate motion on distribution – experienced vendors to be considered to avoid problems
Typical LNG Offloading yp g– LNG Carrier offloading every three days– Berthing offloading & departure: 18 hours Berthing, offloading & departure: 18 hours– Rate: 10,000 to 14,000 cubic meters/hour NGL Pipeline NGL Pipeline Gas Conditioning Plant LNG Gas Pipelines G Pi li L N G Surface Storage Vaporization
Risk Management for‐LNGTechnology for LNG covers the “Gas Transportation Chain” Propulsion Hull Vibration Maintenance Dual Fuel Containment System Integrity System Integrity Collision and Grounding Structural Terminal Integrity I t it Class/Certification Ice Strengthening and Cold Weather Operations 46