BASED ON EXPERIENCE TGE GAS ENGINEERING EPC EXECUTION OF BOREALIS ETHANE TANK PROJECT

Transcription

1 BASED ON EXPERIENCE TGE GAS ENGINEERING EPC EXECUTION OF BOREALIS ETHANE TANK PROJECT 24/10/2016 Page 1

2 CONTENT Overview on the Services and Experience of TGE Gas Engineering GmbH Project Overview and Process Description Construction Phase Pre-Commissioning and Commissioning Time Schedule Page 2

3 COMPANY PROFILE TGE Gas Engineering GmbH (TGE) is one of the world s leading contractors for projects involving the storage and handling of liquefied gases in the energy and petrochemical/chemical industries. TGE has over 30 years of experience in this field, providing full range of services from concept /feasibility studies through to Lump Sum Turn-Key Project execution. Our target is to provide to customers the added value based on our experience and Know-How in delivering millions of m³ of Liquefied Gas Storages and Handling Facilities. TGE is a technology focused company that is active worldwide with main operating units throughout Europe and Asia LIQUEFIED GAS STORAGE CAPACITY PERFORMED (m³) Status Sep Overall capacity LNG Ethylene / Ethane Propylene, LPG, etc. Page 3

4 SCOPE OF SERVICES BOREALIS Consultancy Technical and Commercial Feasibility Studies Site Selection Conceptual Design Environmental Impact Assessment (EIA) and HAZOP Studies Capital Cost (CAPEX) and Operating Cost (OPEX) Estimation Business Plan for Capital Investments and Operations Basic Engineering and Front End Engineering Design (FEED) Detailed Engineering Procurement/Procurement Services Construction/Construction Services Supervision Services Pre-Commissioning and Commissioning Services Start-Up/Shut Down Services Selection and Training of Operators Operation and Maintenance Services Life-Cycle Engineering Studies and Plant Life-Cycle Optimisation Page 4

5 PROJECT OVERVIEW DESIGN BASIS Medium Liquid Ethane Storage Tank Full Containment Storage Tank Working Volume 52,000 m³ Design Conditions -4.5 to300 mbarg -115 C to Ambient Level / Temperature/ PressureMeasurement & Control Systems Main equipment In-tank Pumps (3 x 50% capacity) Screw Compressor Package (2 x 50% Capacity) Ground Flare System Utilities Design Requirements Unloading Rate Sendout Rate Page 5

6 PROJECT OVERVIEW FLOW DIAGRAM Page 6

7 PROJECT OVERVIEW MAIN PROJECT STEPS Tank Design Full Containment Design acc. EN14620 Insulation Calculations Design of Equipment Type Data Sheets Noise Study Compressor Shelter RestrictionofNoise Natural Ventilation Hazop Review Meeting Safety Discussions Client & Vendors 3D Model Review 30% 3D Model Review Lines 60% 3D Model Review Maintability and Operability 90% 3D Model Review All Layout Safety Review by Inspecta Review of Project Design regarding Overall Safety e.g. Check ofsafetyvalvesizing Page 7

8 PROJECT OVERVIEW- PROCESS SPECIAL PROCESS DESIGN Screw Compressors Preheating of Cold Ethane Vapour Shell & Tube Heater Usage of Hot Compressor Discharge Preheating to-40 C Compressor Inlet Temperature controlled via Bypass SafetySystem Stop Compressor at low Temperature Page 8

9 PROJECT OVERVIEW- PLOTPLAN Page 9

10 CONSTRUCTION STATISTICS ORGANIZATION Duration 26 months ( ) Number of Near Misses: 303 Total Hours Worked: Accidents: 0 Lost Working Hours: 0 Daily Site Coordination Meetings Weekly Meetings with CLIENT and Subcontractors Weekly Safety Walks Toolbox Meetings Involvement of CLIENT and INSPECTA from the beginning Page 10

11 CONSTRUCTION WORKS Page 11

12 CONSTRUCTION MECHANICAL COMPLETION / PRE-COMMISSIONING Deviation into Systems and Subsystems and Testpacks Inspections Line Cleaning System Drying& Inerting Instrument Loop Interlock / ESD Checks PID Checks Electrical Circuit / Motor / Equipment Checks Equipment Installation Mechanical Equipment Checks VendorChecks IntroduceIA andn 2 Flush& Test Service Test FW System Flush& Test & Drain Follow UpDonebyPIMS CMS System Page 12

13 PRE-COMMISSIONING/ COMMISSIONING PRE-COMMISSIONING/ COMMISSIONING Start Half a Year in Advance with first Commissioning Meetings (Scope, Interfaces, Organization) Operator Training Support Dedicated Commissioning Team Full Time on Site Tank Purging with Nitrogen Tank Gassing-up& Start-up Compressors Tank Cool Down Start ofin-tank Pumps Start ofsendout Performance Tests Taking Over Page 13

14 COMMISSIONING CHALLENGES Integration of: New DCS/ SMintooldDCS/ SM Equipment intoolddcs/ SM Manual Control for Preheaters during Cooldown Support DCS programming according TGE design Adjustment of Control for Preheater System Sensible Interaction between Components of System for Adjustment Observation of Behavior of the Control Systems during Manual Control Page 14

15 IMPORTANT MILESTONES Page 15

16 THANK YOU FOR YOUR ATTENTION! Vielen Dank cпaсибо большое 多谢 Obrigado Page 16

17 CONTACT TGE Gas Engineering GmbH Mildred-Scheel-Str Bonn Germany tge-service@tge-gas.com Page 17

18 PRODUCT LINES Storages and Terminals for LNG Storage and Terminals for Petrochemical/ Chemical Gas Small-Mid Scale Natural Gas LNG Liquefaction Plants Other Package Plants for gas treatment or elements of storage product lines LNG as Fuel Storage Tank Design Services Page 18

19 FACTS & FIGURES STORAGES AND TERMINALS FOR LNG 17 Projects in Total (EPC& EP+CS) Import Terminals: 9 Export Terminals: 7 Import/Export Terminal: 1 72 LNG Truck/Container Loading Stations STORAGE TANKS Storage Tanks installed 30, ,000 m³ Storage Tanks designed 5, ,000 m³ Storage Tanks installed in Europe 940,000 m³ Storage Tanks installed in Asia 1,908,000 m³ Total Regasification Capacity > 13 mio t/a Total Production Capacity Small-Mid Scale LNG > 3 miot/a Reference for all relevant International Design Codes: Tanks: EN 14620, EUROCODE API 625, API 620, ACI 376 Facilities: EN 1473, NFPA 59a, S INSTALLED CAPACITY 21 Full Containment Tanks 2,838,000 m³ 5 Single Containment Tanks 170,000 m³ TOTAL INSTALLED CAPACITY 3,008,000 m³ Page 19

20 FACTS & FIGURES STORAGES AND TERMINALS FOR PETROCHEMICALGASES 36 Projects in Total (EPC & EP+CS) for Petrochemical Products: Ethylene, Ethane, Propylene, Butane, LPG, Ammonia. STORAGE TANKS Tanks installed withcapacitiesfrom up to 3, ,000 m³ Facilities installed in Europe 327,000 m³ Facilities installed in Asia 1,684,000 m³ LARGEST INSTALLED CAPACITY LPG 120,000 m³ Full Containment 20 Full Containment Tanks with installed capacity INSTALLED CAPACITY 1,205,000 m³ Ethylene Ethane 80,000 m³ Full Containment 120,000 m³ Full Containment 22 Single Containment Tanks with installed capacity 560,000 m³ Propylene 80,000 m³ Full Containment TOTAL INSTALLED CAPACITY 1,765,000 m³ Ammonia 25,000 ton Full Containment Page 20