Engineered Heavy Logistics: Moving Deadlines Forward in LNG Modular - - PowerPoint PPT Presentation

Engineered Heavy Logistics: Moving Deadlines Forward in LNG Modular Construction

SNAME ARCTIC NOVEMBER 20, 2013

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PRESENTATION CONTENT

• 1. Modularization
• 2. Engineered Heavy Logistics
• 3. LNG: Australia to British Columbia
• 4. Lessons Learned
• 5. Questions

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SAFETY MOMENT

The Mammoet Minute, only six steps in 60 seconds:

–Stop –Think –Look around –Assess the Risk –Take Action –Start your task.

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WHY MODULARIZATION?

• Limited / strained labor force
• Limited workforce accommodation
• Limited equipment availability
• Harsh environment
• Limited plot plan area or greenfield development
• Restricted geographic location
• Environmentally sensitive
• Limited time window

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ENGINEERED HEAVY LOGISTICS

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HOW DOES MODULARIZATION SAVE TIME?

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WHAT MUST BE CONSIDERED BEFORE WE START TO DESIGN MODULES?

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WHERE WILL THE MODULES BE FABRICATED?

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AVAILABILITY OF SUITABLE VESSELS

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INCORPORATING TRANSPORTATION LOADS IN THE DESIGN OF STRUCTURAL STEEL

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WHAT SIZE OF MODULES CAN BE REALISTICALLY MOVED?

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INFRASTRUCTURE LIMITATIONS

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INFRASTRUCTURE LIMITATIONS

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• Limited / strained local labor force
• Access to offshore labor force
• Remote / “Harsh” environment
• Limited plot area / green field development
• Environmentally sensitive
• Schedule / cost / safety driven projects

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LNG MODULAR CONSTRUCTION EXPERIENCE

Australia:

• Darwin LNG
• Gorgon LNG
• Ichtys LNG Project
• Wheatstone
• Woodside LNG Train
• Woodside Pluto

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GORGON PROJECT SCOPE OVERVIEW

• 56 Modules (MOD)

(SPMT)

• Range between 450 – 6500 Tonnes
• 9 Column's (PDR)

(CRANE)

• Range between 138 and 1112 Tonnes
• 233 Pipe racks (PAR)

(SPMT / CRANE)

• Range between 12 and 1500 Tonnes
• 32 Substation Buildings

(CRANE)

• 6 Compressor/Turbine lines

(CRANE)

• 6 Waste Heat Recovery stacks

(SPMT/CRANE)

• Additional scope : 140+ small pre-assembled structures (Load-out / Load-in AMC Yard Perth) <100Te

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GORGON SITE OVERVIEW

MOF JETTY / MOF CAUSEWAY LNG PLANT FLARE

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GORGON SITE OVERVIEW

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SITE PLAN (EXCL. FLARE + MOF)

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ROLL ON / ROLL OFF

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TRAIN 1 LNG MODULE (6000+ TE)

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2ND LNG TRAIN MODULE (TAJB)

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AMINE ABSORBER (1112 TE)

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AMINE ABSORBER RIGGING

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AMINE ABSORBER LIFT

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PIPE-RACK TRANSPORT IMPRESSION

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PIPE-RACK TRANSPORT IMPRESSION

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INSTALLATION CHALLENGES

Tight operations Constant changing site conditions Unexpected additional scope Maintaining delivery schedule Large amount of auxiliary equipment Shortage of laydown area

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LESSONS LEARNED

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LESSONS LEARNED

• 1. 100% engineering completion before start of fabrication
• Failure to accomplish this will result in potential for significant increase in on site direct / indirect hours

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LESSONS LEARNED

• 2. Early involvement of EHL (Engineered Heavy Logistics)
• Including an EHL as an overall advisor will optimise the logistics chain in time and money
• Optimization of sea fastening, grillage and lashing equipment thru smart engineering
• Determine logistics envelop
• Highlight bottleneck for logistics strategy
• Standardize lifting and transport supports as much as possible for all items
• An EHL approaches design from an optimized construction point of view. Historically, in the offshore

industry, modularisation has been a lump sum based execution strategy. Therefore, the EHL will view

• nshore projects from the same mindset.

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LESSONS LEARNED

• 3. Select construction strategy at early stage
• Build high modules (only SPMT)
• Build lower modules (SPMT with cranes)
• Define maximum weights to optimize crane use (i.e. single crane for all lifts)
• Including legs on the modules allows for flexible placement and storage

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LESSONS LEARNED

• 4. Interface management
• Strong technical and operational experience for integration of marine and land contractors
• Involved parties: MWS, marine contractor, customs, Client, site contractor, stevedores, longshoreman,

engineering design contractor, sea fastening fabricator, etc.

• Clearly understand responsibilities of all parties prior to operations

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LESSONS LEARNED

• 5. Management of the unexpected
• We do not live in an ideal world. Always have a plan B (and perhaps even C)
• Prepare for receiving cargo day or night
• Sufficient support equipment (module stands, load spreader mats and miscellaneous equipment)
• Where possible, have 2 discharge locations to reduce potential for expensive demurrage for transport

vessel and equipment

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LESSONS LEARNED

• 6. Module Alignment
• Module Alignment requires strong spotters to ensure proper positioning and no damage to piperacks

and equipment

• There will be misalignment within the module blocks. Differences in temperatures will make every pipe

extend or retrack.

• Make sure you can compensate misalignment of this piping by using sleeves, or spacers and adequate

measuring and shimming equipment is available

• Understand boundaries of approval with all parties

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LESSONS LEARNED

• 7. Shipping / Importation of Equipment
• In environmentally sensitive areas special preparations (cleaning of equipment, customs paperwork,

inspections) are required

• Custom clearance for modules can be significant scheduling
• 8. Local Contractors
• Well versed in local labor regulations and requirements
• Experience with camp based work
• 9. Communication

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MOVING DEADLINES FORWARD

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