233187394-Mammoet-LNG-Modular-Construction.pdf

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Engineered Heavy Logistics: Moving Deadlines Forward

Modular

Construction

SNAME ARCTIC NOVEMBER 20, 2013

PRESENTATION CONTENT

1. Modularization

2. Engineered Heavy Logistics

3. LNG: Australia to British Columbia

4. Lessons Learned

5. Questions

SAFETY MOMENT

The Mammoet Minute, only six steps

in 60 seconds:

– Stop

– Think

– Look around

– Assess the Risk – Take Action

– Start your task.

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

ENGINEERED HEAVY LOGISTICS

HOW DOES MODULARIZATION SAVE TIME?

WHAT MUST BE CONSIDERED

BEFORE WE START TO DESIGN MODULES?

WHERE WILL THE MODULES BE FABRICATED?

AVAILABILITY OF SUITABLE VESSELS

INCORPORATING TRANSPORTATION LOADS IN THEDESIGN OF STRUCTURAL STEEL

WHAT SIZE OF MODULES CAN BE REALISTICALLY MOVED?

INFRASTRUCTURE LIMITATIONS

• 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

LNG MODULAR CONSTRUCTION EXPERIENCE

Australia:

• Darwin LNG• Gorgon LNG

• Ichtys LNG Project

• Wheatstone

• Woodside LNG Train

• Woodside Pluto

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

GORGON SITE OVERVIEW

JETTY / MOF

CAUSEWAY

LNG PLANT

SITE PLAN (EXCL. FLARE + MOF)

ROLL ON / ROLL OFF

TRAIN 1 LNG MODULE (6000+ TE)

2ND LNG TRAIN MODULE (TAJB)

AMINE ABSORBER (1112 TE)

AMINE ABSORBER RIGGING

PIPE-RACK TRANSPORT IMPRESSION

INSTALLATION CHALLENGES

Tight operations Constant changing site conditions Unexpected additional scope

Maintaining delivery schedule Large amount of auxiliary equipment Shortage of laydown area

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

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.

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

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

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

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

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

233187394-Mammoet-LNG-Modular-Construction.pdf

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