EngineeredHeavyLogistics:MovingDeadlinesForward

inLNGModularConstruction
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
J ETTY / 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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2
ND
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
onshore 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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