Concept to Completion Best Practice in

Delivering Complex Projects

Damon J Hill Senior Vice President, EMEA Business Development

John Payne Chief Static Equipment Engineer

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Concept to Completion
Best Practice in Delivering Complex Projects

Foster Wheelers Philosophy for adding

value to client investments

Best Practice from Investment Concept

to Beneficial Operation

Defining a road map

Critical Phases of Project Delivery

Applying Common Principles

From multi-million dollar to multi-billion
dollar investments

Case Studies Examples of delivering

highly complex projects

Building Confidence

Expertise in Engineering, Procurement &

Construction Logistics

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Foster Wheelers Philosophy for Adding Value

Expanding Horizons Delivering Long Term Value to Client Investments
Foster Wheeler is focused on
maximising value by combining our
technical, O&M and project delivery
expertise with world leading technology
Technical
Expertise

O&M
Best
Practice
Project
Delivery
Expertise

World
Leading
Technology

Foster Wheeler seeks to work

with clients and partners to
deliver long term value to
client investments
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Investment Planning / Concept Studies

Foster Wheeler is a World Leader in Concept Studies
from multi-million to multi-billion dollar investments

Foster Wheelers primary objective is always to make the Clients

decision making as simple as possible

Detailed study is essential to optimise the project and confirm

feasibility on a robust basis ahead of any significant expenditure

A shortlist of technically feasible options should be generated with

economic evaluation of the most promising

Investment planning should focus on all issues affecting project

cost and development not just the configuration and technology

Investment Planning can be optimised across multiple assets and

multiple units, and phased in accordance with financial constraints
. Bringing real, practical EPC experience to conceptual investment planning
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Woodside Pluto LNG Project

Karratha, Western Australia

Greenfield LNG plant and facilities

Study

FEED

EPCm

PMC

Services

Upstream
Oil & Gas

LNG
& Midstream

Refining

Chemicals &
Petrochemicals

Environmental

Power

4.3 Mtpa liquefaction train

240,000 m3 LNG storage
Utilities and offsites

Pre-FEED, FEED and EPC

FW led JV

Innovation - optimised construction

Modular construction technique
World class safety record in the Thai
module yard.
35 MM man-hours without LTI
263 modules, totalling 52,000 tonnes,
largest ~2000 tonnes
69 module shipments over 16 months.
40MW GTGs modularized

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Petro Rabigh Refinery / Petrochemicals

Rabigh, Saudi Arabia
Study

A brownfield/revamp world-scale integrated

refining and petrochemical project
Project value in excess of US$10 billion
One of the largest integrated refining and
petrochemical projects built in one phase
Over 226,000,000 site man hours
The new facility processes 400,000 bpsd of
atmospheric residue from the existing refinery
Capacity:
Refinery upgrade
Ethylene
Propylene
Polyolefins, solids and liquids

FEED

EPCm

PMC

Services

Upstream
Oil & Gas

LNG
& Midstream

Refining

Chemicals &
Petrochemicals

Environmental

Power

400,000 bpsd
1,300 ktpa
300 ktpa
2,300 ktpa

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Complex Refinery Upgrades Integrated Expertise

An holistic philosophy: maximising benefit from refinery upgrades

Unparalleled Process, Engineering and

Construction expertise for the whole refinery:

Working with the client to define the key

upgrade objectives clear terms of
reference for the planned investment
Maximizing technology feedstock flexibility
and yield benefits together with operability
and reliability improvements through
application of expertise and best practice
Identifying constraints and impact on other
refinery units and providing low cost
solutions
Energy optimisation applying Foster
Wheelers holistic approach in parallel
Engineering and Construction logistics total
implementation expertise to minimise
shutdown duration and associated risks
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John Payne
Chief Static Equipment Engineer

Foster Wheeler. All rights reserved.

Key Factors for all Operators

Planning Execution E, P & C Logistics

Safety
Operational reliability
Minimum turnaround time and risk to schedule
Lowest possible cost
Take advantages of process improvements

SO MUST

Maximise pre-turnaround and post-turnaround activities

Maximise work done offsite
Fit first time
Quality of Installation
Latest proven technology

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FCC Turnarounds
What are the Key Drivers?

Coke build up in reactor

High temperature material degrading
Erosion
Thermal shock
Shell refractory failure, gas tracking, hot spots, spooling
Operational upset
Cyclone and internals life:
15 to 25 years
Expansion bellows life:
10 to 15 years
Shell refractory life:
5 to 25 years

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FCC Turnarounds
Significant Revenue and Margin Implications
Lost revenue is $1 million to $2 million per day when not operating
Typical turnaround time is 35 days or fewer
Run times have grown from 3 to 5/6 years continuous so need to
plan earlier and predict operational reliability a lot further ahead

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The Project Decision Process for Refinery Upgrades

Project Delivery Excellence: Key Steps in the Study Phase

Client Needs

Process /
Technology
Improvements

Maintenance
Requirement

Feasible Options

Licensor
Selection

Cost Estimate

Engineering &
Construction

Planning TAR
Duration

Risk / What-if
Analysis

Conclusion &
Execution Strategy
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Study and EPC Timeline

Project Delivery Excellence: Timeline to Turnaround

3 Years

6 Months

Study

3-6 Months

Licensor

3 Months

Equipment
Procurement

18 Months

Equipment
Delivery

Min
3 Months

Pre-TAR

TAR

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Case Studies Delivering Highly Complex

FCC Upgrades

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Case study 1: Stanlow Regen Head & Cyclones

2009 study started

Cyclones end of life will have been in
service for 25 years
Options for replacing
regen cyclones
2010 turnaround
allowed cold survey of
head cut line

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Case Study 1: Stanlow Head & Cyclones

12 pairs of cyclones
Cyclones interlinked and
share secondary hangers
Full trial assembly of
cyclones
at fabricators works
Precision survey of hangers
Data used to position
hanger nozzles in head
Alignment blocks on
cross-overs

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Case Study 1: Stanlow Head & Cyclones

Use of electronic 3D
solid edge model
Demonstrates
clearances, access and
future maintenance
Input into FEA analysis

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Case Study 1: Stanlow Head & Cyclones

Cyclone assembly in
transport CAN leaving
fabricators work
Module weight 265te
+15m diameter
Height restriction on
canal of 12m

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Case Study 1: Stanlow Head & Cyclones

Head c/w refractory

being loaded into
special barge
Head weight 185te

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Case Study 1: Stanlow Head & Cyclones

Floating crane at Antwerp lifts

head onto cyclone assembly
Cyclone hangers then are
installed
Special lifting arrangement to
equalise loads into the head
All shell deflections have been
analysed to avoid any damage
to refractory

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Case Study 1: Stanlow Head & Cyclones

Head module on
route from dock to
Refinery
Motorway closure
Probably the
largest head &
cyclone assembly
to be transported
to site as one
piece
Movement date of
24 March 2013
set 2 years in
advance

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Case Study 1: Stanlow Head & Cyclones

Tree pruning
done one year
in advance

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Case Study 1: Stanlow Head & Cyclones

Head assembly
being transport
through refinery
New site entrance
created
Head assembly
now jacked up to
clear piping either
side of road

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Case Study 1: Stanlow Head & Cyclones

Final site
assembly
Head assembly
being lifted onto
Dip Leg frame

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Case Study 1: Stanlow Head & Cyclones

Skid Bridge 35m Long over pipe band allows complete head
frame assembly to be moved from off plot location to crane

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Case Study 1: Stanlow Head & Cyclones

Final lift of new head at 440Te

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Case Study 2: Regen Head & Cyclones

Methods Studied and Crane Problems

Regenerator Cyclones End of Life, Replace Cyclones complete with Head is normal
Extremely Tight Plot Space and Route Restrictions
Come up with split head frames
Main Crane Remained the problem space and undergrounds

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26

Case Study 2: Regen Head & Cyclones

Selected Option

Sequence
Install Beams to support cyclones
Secure cyclones at top
Cut and remove head
Remove cyclones as pairs
Replace in reverse order

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Case Study 3: Reactor Internal Riser & Cyclones ?

Option at start of study

Problem Internal Riser Buckled

Normal Head Replacement as
shown would also suggest replace
cyclones as towards end of life.

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Case Study 3: Reactor Internal Riser & Cyclones ?

Option Suggested to Client

Option suggested to Client

Cut Hole in top Head and replace Riser
Only
Delay replacing cyclones till next TA, this
gives time to upgrade technology for
improved Product Slate

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Conclusions & Execution Strategy

Best Practice in Delivering Complex Upgrade Projects
Early start
Its OK to think big
Overall process and mechanical solution
Consider whole refinery
At the end of the study, the client has an
independent report that identifies the way forward
Most overall cost-effective solution
No surprises
Fit First Time

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Foster Wheeler Concept to Completion

Consistent high quality delivered anywhere in the World

Whatever the challenge, we can help

Further
information:
www.fwc.com
refining@fwc.com

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www.fwc.com

Foster Wheeler. All rights reserved.