MARINE WORKS AND TERMINALS

Transcription

1 MARINE WORKS AND TERMINALS ONSHORE ENGINEERING AND CONSTRUCTION PROJECT REFERENCES People, ideas, energy. Saipem S.p.A. Via Martiri di Cefalonia, San Donato Milanese, Milan - Italy Tel Fax saipem.com - A subsidiary of Eni S.p.A.

2 MARINE WORKS AND TERMINALS

3 INDEX SAIPEM TODAY 4 SAIPEM ONSHORE 6 MARINE WORKS 8 AND TERMINALS MARKET SAIPEM EXPERIENCE 10 IN MARINE WORKS MARINE WORKS CENTER 14 OF EXCELLENCE IN PARIS INNOVATIVE GAME-CHANGING 16 ENGINEERED SOLUTIONS INNOVATIVE CONSTRUCTION 20 SOLUTIONS: THE S.L.I.M. APPROACH OIL AND GAS TERMINALS 24 COMMERCIAL PORTS 36 3

4 SAIPEM TODAY SAIPEM TODAY IS A WORLD LEADER IN THE GLOBAL SUPPLY OF ENGINEERING, PROCUREMENT, PROJECT MANAGEMENT AND CONSTRUCTION SERVICES WITH DISTINCTIVE CAPABILITIES IN THE DESIGN AND EXECUTION OF LARGE-SCALE OFFSHORE AND ONSHORE PROJECTS. Saipem has a strong bias towards oil and gas frontiers, namely activities in harsh and remote areas, in deep waters as well as in extremely cold and hot environments, applying significant technological competences in many diverse fields such as gas monetization and heavy oil exploitation. Saipem is organized in three Business Units: Offshore, Onshore and Drilling. 4 5

5 SAIPEM ONSHORE FOLLOWING THE ACQUISITION OF SEVERAL ENGINEERING COMPANIES OVER THE LAST YEARS, MOST PROMINENTLY OF SNAMPROGETTI, BOUYGUES OFFSHORE AND SOFRESID, SAIPEM HAS BECOME ONE OF THE WORLD S LARGEST AND MOST COMPLETE ENGINEERING AND CONSTRUCTION COMPANIES IN THE GLOBAL OIL AND GAS MARKETS ONSHORE. Saipem Onshore offers a complete range of project definition and execution services, particularly for the mega-projects required by the market today: from feasibility and conceptual studies to complex integrated solutions combining design, engineering, procurement and field construction. The integration of our engineering and project management centres in several continents has been completed recently, providing a consistent design and robust execution philosophy on all our projects worldwide. Through the involvement of our four global engineering centres for onshore projects in Milan and Fano (Italy), Paris (France) and Chennai (India), which operate in connection with a growing number of medium size and smaller engineering centres, employing altogether over 7,000 engineers, Saipem balances high project execution quality with a competitive cost and most importantly with a major emphasis on local know-how and content. Saipem today operates in virtually every world market, often in remote locations with harsh environmental conditions and challenging logistics, leveraging on its proven experience across the most significant product lines in the oil and gas upstream, midstream, refining, chemicals, power generation, environmental industries and infrastructure. This new series, therefore, outlines Saipem integrated references in onshore markets, according to individual business and technology lines. 6 7

6 MARINE WORKS AND TERMINALS MARKET DURING THE PAST DECADES, NEW PORT TERMINAL PROJECTS HAVE BECOME INCREASINGLY COMPLEX. THIS IS TRUE FOR ALL COMMERCIAL PORTS, AS WELL AS FOR ADVANCED MARINE INFRASTRUCTURES FOR OIL AND GAS EXPORT OR IMPORT. 8 Much of the newest economic developments over the recent past and most of the new oil and gas production have taken place in emerging markets, which require new port facilities with novel and often very specific requirements. Therefore, terminal developers have faced the challenge of locating new, often very large infrastructural projects in remote areas and often in climactically harsh environments. The design and construction of such world-scale terminals requires specific engineering skills as well as substantial project management capabilities to face the major technical challenges. These competencies are even more important in the oil and gas industry, where the timely delivery of the new marine infrastructure is essential in order to bring on stream the associated new oil and gas production assets. 9

7 SAIPEM EXPERIENCE IN MARINE WORKS THROUGH ITS DEDICATED MARITIME WORKS BUSINESS LINE, SAIPEM CAN DESIGN AND BUILD ANY KIND OF SHORE LINE INFRASTRUCTURE, INCLUDING WHARFS, QUAYS, TRESTLES AND BREAKWATERS, WITH SPECIFIC FOCUS AND EXPERTISE IN GLOBAL GREENFIELD PROJECT DEVELOPMENTS. WITH MORE THAN 35 YEARS OF EXPOSURE TO MARINE CHALLENGES, SAIPEM HAS DEVELOPED ITS COMPETENCES BY UTILIZING THE LESSONS LEARNED FROM ITS MANY PROJECTS WORLDWIDE. Since the acquisition of Bouygues Offshore by Saipem in 2002, the maritime business line expanded its range of activities by merging the maritime division of Bouygues, the French major civil works company, with the professionalism of Saipem, the leading EPC contractor in the oil and gas industry. Following the subsequent integration of these originally separate entities and capabilities into a single newglobal organization, Saipem can now perform with confidence the full range of engineering and project execution services, from preliminary studies to mega-project design and construction on EPC/LSTK or Design and Build bases, for any world class marine infrastructure project

8 In the last 5 years, Saipem has designed and built: More than a dozen large marine infrastructural projects, including pile supported quays, combiwalls, jetties, rubble mound or concrete caisson breakwaters, Roll-On Roll-Off facilities and shore protection together with dredging and backfilling, platform pavements and administration buildings. 6 Oil and Gas jetties, for import or export of LNG, ammonia or crude oil. 6 Commercial Ports for containers, bulk material, passengers or vehicles. Saipem offers today to port developers: Imaginative proposals and often new alternative solutions, based on its own huge experience. Assurance of design and construction operations according to highest international standards, with particular emphasis on HSE, Total Quality and Sustainability. overall project success; or by subcontracting parts of a large project, when appropriate, to local and/or international contractors, always under Saipem s management and overall responsibility. Keys to construction success are: The ability to adapt construction methods to site constraints and local capabilities. Typically, Saipem performs the most critical construction tasks either directly, particularly in those markets where Saipem has strong local operations, thus controlling the 12 The implementation of intensive training programs and the alignment and adherence of the project workforce to Saipem's HSE and quality expectations. 13

9 MARINE WORKS CENTER OF EXCELLENCE IN PARIS WITHIN ITS INTEGRATED ENGINEERING ORGANIZATION, CONTAINING ALL REQUIRED TECHNICAL DISCIPLINES, SAIPEM HAS DEVELOPED IN-HOUSE CAPABILITIES TO DESIGN THE MOST ADVANCED MARINE WORKS AND TERMINALS. ADVANCED TOOLS USED IN THE PARIS CENTER OF EXCELLENCE AND IN ASSOCIATED LABORATORIES: STRUCTURAL DESIGN MODELLING GEOTECHNICAL DESIGN MODELLING HYDRAULIC MODELLING PHYSICAL MODEL TESTING 14 15

10 INNOVATIVE GAME-CHANGING ENGINEERED SOLUTIONS Caisson-based partial breakwater: development and application of the BYBOP concept for low transmission near-surface structure SAIPEM APPLIES AND FREQUENTLY PROPOSES, AS ALTERNATIVE SOLUTIONS, INNOVATIVE GAME-CHANGING ENGINEERED APPROACHES TO IMPROVE THE PROJECT EXECUTION AND TO OVERCOME CHALLENGING LOGISTICS. Original Foundation Principles: combination of submerged gravity structures with steel piles and bridges Low-reflection structures, via optimal use of successive vertical and horizontal perforated walls and slabs 16 17

11 A STRONG DESIGN & BUILD CULTURE DEVELOPS INNOVATIVE SOLUTIONS THROUGHOUT THE ENTIRE PROJECT EXECUTION SEQUENCE: FROM THE CONCEPTUAL DESIGN DEVELOPED AT BID STAGE TO PROJECT CONCLUSION WITH SIGNIFICANT COST SAVINGS AND ARCHITECTURAL BENEFITS. ORIGINAL CONCEPT ALTERNATE DESIGN SOLUTION PROPOSED BY SAIPEM COMPLETED PROJECT 18 19

12 INNOVATIVE CONSTRUCTION SOLUTIONS: THE S.L.I.M. APPROACH SAIPEM HAS DEVELOPED NEW AND ORIGINAL CONSTRUCTION METHODOLOGIES THAT TAKE INTO ACCOUNT: LOCAL PARTNERS LOCAL KNOW-HOW REMOTE AREAS CLIMATE CONDITIONS COUNTRY LIFESTYLE AND TRADITIONS CLIENT EXPECTATIONS. AVAILABILITY OF LOCAL SKILLS. ENVIRONMENTAL CONSTRAINTS. THE IMPLEMENTATION OF THE APPROPRIATE TECHNICAL SOLUTION, TOGETHER WITH EXTENSIVE TRAINING PROGRAMS, LOCAL PARTNERSHIPS AND SUSTAINABILITY EFFORTS ASSURE PROJECT OVERALL SUCCESS. INTENSIVE TRAINING PROGRAMME SIMPLE LOW COST INNOVATIVE METHODOLOGY SAFETY QUALITY ENHANCED SCHEDULE AND PROJECT CONTROL LOCAL ECONOMY BENEFIT LOW COSTS OVERALL CLIENT SATISFACTION 20 21

13 INNOVATIVE CONSTRUCTION SOLUTIONS: THE S.L.I.M. APPROACH Trestle construction from shore with travelling unit: Independent of wave conditions. Quick and performing construction progress thanks to repetitive and optimized construction task organization. On shore prefabrication of concrete caissons: Maximum use of civil construction capabilities. Full control of construction quality. Minimum downtime due to wave conditions

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15 CHEVRON GORGON JETTY BARROW ISLAND (WESTERN AUSTRALIA) Jetty Length: 2,100 m supported on concrete caissons. LNG Carrier Berths: 2 loading platforms and 17 associated dolphins. Site Facilty: 200 m of quay for module offloading and tug pens. Contract: Design & Build. Consortium Partner: Leighton. In execution since November Marine facilities for a LNG plant in a remote and hardly accessible island, requiring solutions based on extensive modularization of superstructures. This project has been awarded on the basis of an innovative alternate solution proposed by Saipem (prefabricated caisson based jetty), which improved schedule and costs, and significantly reduced on-site construction and life cycle environmental impact. SONATRACH ARZEW AMMONIA PLANT MARINE FACILITIES ARZEW (ALGERIA) Trestle Length: 1,200 m. Platform Size: 260 m long x 62 m wide. Contract: EPC LSTK. In execution since February Marine infrastructure for a 7000 T/D plant producing Granulated Urea, allowing berthing and unloading of DWT vessels. As the jetty construction contract was awarded after the design and construction of the Urea complex had already started, in order to save time Saipem proposed an alternate solution to build the jetty with a travelling piling unit performing the incremental construction from jetty extremity

16 SONATRACH GL-3Z LNG PLANT MARINE FACILITIES ARZEW (ALGERIA) Jetty Length: 810 m total, with 500 m pile suported trestle and 310 m causeway. Offshore Breakwater Length: 750 m, founded at 25 m depth. Contract: EPC LSTK In execution since September Construction of the marine facilities of Arzew 3rd LNG Train: 150,000 tof LNG ship berth, protected by an offshore breakwater, and the offshore platform. The new solution based on concrete caisson design developed for the Tangier commercial ports is being implemented for the offshore breakwater and jetty foundations. PERU LNG S.R.L. PAMPA MELCHORITA LNG TERMINAL MARINE FACILITIES CAÑETE (PERU) Approach Trestle Length: 1,350 m. Offshore Breakwater Length: 800 m (concrete cubic blocks for armor). Contract: Design & Build. JV Partner: Odebrecht (JV led by Saipem), in consortium with Jan de Nul. On stream since Marine portion of the Pampa Melchorita LNG Terminal (LNG Berth, Trestle and Dolphins), with rock load out facility, quarry exploitation, access channel dredging. This project applied an innovative construction method using a travelling piling unit to ensure progress rate without being influenced by Pacific Ocean long swell waves

17 GASCO RUWAIS 3RD LNG TRAIN MARINE WORKS ABU DHABI (UAE) Approach Trestle Length: 3,400 m. Contract: EPC LSTK. On stream since Extension of the existing plant: new send out jetty for liquefied propane, butane and pentane gases. Design and construction of trestle, 2 berths with 2 loading platforms, piping, 2 seawater intake lines. This project has been built without interrupting the regular operations of the adjacent existing marine facilities, built earlier also by Saipem. BVT LNG COSTA AZUL - LNG TERMINAL MARINE FACILITIES ENSENADA (MEXICO) Capacity: 1 M.cu.m/d. Access Trestle Length: 100 m. Contract: EPC. JV Partner: GUTSA (JV led by Saipem). On stream since Design and construction of marine facilities and sea water intake for the first LNG receiving terminal on the West Coast of North America. Designed to accommodate 70,000 to 200,000 cu.m LNG carriers

18 BP/CNOOC GUANGDONG LNG TERMINAL MARINE FACILITIES DAPENG (P.R. CHINA) Access Trestle Length: 300 m. Service Quay Wall Length: 150 m, 10 m draft. Dredging: 1.2 M.cu.m. Contract: EPC LSTK. On stream since Design and construction of marine facilities, sea water intake and backfilled platform shore protection for the 3.3 MTPA LNG Terminal. The first maritime construction project by Saipem in China, performed as part of the whole terminal EPC LSTK contract. CASPIAN PIPELINE CONSORTIUM OIL EXPORT MARINE FACILITIES NOVOROSSIRSK (RUSSIA) Subsea Pipeline Length: 9.4 km. Subsea Pipeline Diameter: 42 inch. Contract: EPC. On stream in Design and construction of a small boat shelter and two single point mooring terminals for crude oil carriers. This project was the first marine construction in Black Sea performed by an international Contractor since the 80 s

19 HAZIRA PORT PRIVATE LTD./HAZIRA LNG PRIVATE LTD. LNG TERMINAL MARINE FACILITIES HAZIRA (INDIA) Capacity: 5 MTPA LNG import Rubble Mound Breakwater: 2.3 M.cu.m. Contract: EPC LSTK. On stream since Design and construction of rubble mound breakwater, LNG berth, sea water intake. This project required the transportation of 2.3 millions m3 of material by road, extracted some 150km from the site, and transported by trucks, through existing villages

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21 AGENCE SPECIALE TANGER MEDITERRANEE TANGER MED II TANGIERS (MOROCCO) Backfilled Platform: 15 M.cu.m. Caisson Breakwater: 3,000 m. Rubble-Mound Breakwater: 1,500 m. Container Quays: 2,800 m. Contract: Design & Build. JV Partner: Bouygues, in consortium with Besix and Jan de Nul. In execution since February Design and construction of 5.2 M.TEU capacity container terminal adjacent to Tanger Med I and Tanger Ro-Ro terminals, also designed and built by Saipem. Tangier Med II is the 3 rd project signed over the last 5 years in the area of Tangier and, so far, the biggest in Morocco for the designing and building of marine terminal. SOHAR INDUSTRIAL DEVELOPMENT COMPANY BULK JETTY SOHAR (OMAN) Trestle Length: 800 m, for three conveyors, plus access road. Platform Size: 600 m long x 60 m wide for iron bulk. 295 m x 30 m platform for aggregate export. Contract: Design & Build. JV Partner: AFCONS (JV led by Saipem). In execution since October Design and construction of the marine facility of an iron pelletizing plant, allowing the bulk import, through 400,000 DWT vessels, and the pellets export. This contract has been awarded on the basis of a very tight schedule, to fit with the production start date of the pelletizing plant. 4 jack-ups were mobilized to complete the project on time

22 DP WORLD CALLAO PORT EXTENSION CONTAINER TERMINAL LIMA (PERU ) Berth: 650 m length, 17 m draft. Contract: Design & Build. JV Partner: Odebrecht, in consortium with Jan de Nul. Delivered in Design and construction of pile supported quay, with 20 hectares of reclamation, dredging and container terminal facilities (4500 sq.m of buildings and parkings, 20 hectares of paving). Container terminals built inside an existing port. AGENCE SPECIALE TANGER MEDITERRANEE RO-RO PASSENGERS TERMINAL TANGIER (MOROCCO) Main Breakwater: 1,230 m (500 m rubble mound, 730 m concrete caissons) Lee Breakwater: 1,200 m rubble mound, 8 Roll-On Roll-Off berths Platform Backfilling: 1,610,000 cu.m. Contract: Design & Build. JV Partner: Bouygues. Delivered in Applications of significant technical synergies in the design and construction of the concrete caissons used for the Tanger Med I project for the same Client (page 43). The project execution concept shows synergies with the previous one in the Dominican Republic for the same end user (page 44)

23 PORT AUTONOME DE MARSEILLE FOS 2XL CONTAINER TERMINAL QUAY MARSEILLE (FRANCE) Quay Length: 1,200 m. Dredging: 6.4 M.cu.m. Contract: Design & Build. JV Partner: Vinci, Eiffage in Consortium with Dredging International. Delivered in Construction of combi-wall quay for Post Panamax vessel type. Also this project has been awarded on the basis of an alternative design. AGENCE SPECIALE TANGER MEDITERRANEE MED I CONTAINER TERMINAL BREAKWATER TANGIER (MOROCCO) Main Breakwater Length: 2,070 m. Lee Breakwater Breakwater Length: 510 m. Quay Length: 600 m. Contract: Design & Build. JV Partner: Bouygues. Delivered in Breakwater for a greenfield 3 M.TEU capacity container terminal. Main breakwater, lee breakwater and quay behind the main breakwater. The final execution plan utilized a revised concept design, where home-designed concrete caissons have been implemented instead of a rubble-mound breakwater. Home-performed wave disturbance and navigation studies were instrumental in validating the new concept at bid stage

24 DP WORLD CAUCEDO MULTIMODAL TERMINAL PUNTA CAUCEDO (DOMINICAN REPUBLIC) Combi-Wall Quay: 600 m length, 16 m draft. Rubble mound breakwater Length: 1000 m. Container Yard: 20 ha. Container Terminal: 700,000 TEU. Dredging: 2 M.cu.m. Contract: Design & Build. JV Partner: Bouygues (Saipem Leader). Delivered in An alternative layout was proposed and accepted. The project was executed on a direct hiring basis, through an intensive training program of local labour. Saipem s Value Engineering at bid stage allowed the development of enhanced solutions to improve port operation while reducing the cost of the investment. The project execution was carried out on a direct hiring basis, through an intensive training program of local labor. PRINCIPAUTE DE MONACO CONDAMINE CRUISE PORT EXPANSION (MONACO) Main Concrete Caisson: 60,000 t, 87 m x 41 m x 31 m. Reclamation: 400,000 cu.m. Dredging 80,000 cu.m. Lee Breakwater: BYBOP caisson, 145 x 30 m, foundation at -30 m. Contract: Design & Build. JV Partner: Bouygues, Vinci. Delivered in 2003 The usual breakwater design could not be applied, due to the depth of seabed in the vicinity of the harbor. Innovative designs had to be implemented for the port expansion, with one floating breakwater on one side, and one partial breakwater supported on caissons with foundations 30 meters under sea level. Numerical hydraulic and physical models, on the basis of a Saipem s patented concept, were an integral part of the design development of the partial breakwater

25 MARTINIQUE DDE POINT DES GREVES CONTAINER TERMINAL FORT DE FRANCE (MARTINIQUE) Pile Supported Quay Length: 460 m. Dredging and Reclamation: 1.36 M.cu.m. Contract: Design & Build. JV Partner: Vinci, Boskalis (JV led by Saipem) Delivered in SOLIDERE BEIRUT SEA FRONT WATERFRONT DEVELOPMENT BEIRUT (LEBANON) Main Waterfront length: 1400 m. Rubble Mound Breakwater length: 430 m. Dredging: 3.8 M.cu.m. Contract: Design & Build. JV Partner: Bouygues. Delivered in The construction of a sea water front promenade and marina project has been executed on the basis of an innovative design concept, based also on submerged reef and bi-lobbe concrete caissons, providing multiple chambers to absorb wave energy

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