BASED ON EXPERIENCE - TGE Gas · 2016-11-10 · based on experience tge gas engineering epc execution of borealis ethane tank project. ... propylene, lpg, etc. liquefied gas storage

www.tge-gas.com Page 124/10/2016

BASED ON EXPERIENCE

TGE GAS ENGINEERINGEPC EXECUTION OF BOREALIS ETHANE TANK PROJECT


� Overview on the Services and Experience of TGE Gas Engineering GmbH

� Project Overview and Process Description

� Construction Phase

� Pre-Commissioning and Commissioning

� Time Schedule

CONTENT


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.

0

1.000.000

2.000.000

3.000.000

4.000.000

5.000.000

6.000.000

Overallcapacity

LNG Ethylene /Ethane

Propylene,LPG, etc.

LIQUEFIED GAS STORAGE CAPACITY PERFORMED (m³)

Status Sep. 2016

COMPANY PROFILE


� 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

SCOPE OF SERVICES BOREALIS


� Medium

� Liquid Ethane

� Storage Tank

� Full Containment Storage Tank

� Working Volume 52,000 m³

� Design Conditions

� -4.5 to 300 mbarg

� -115°C to Ambient

� Level / Temperature / Pressure Measurement & 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

� DESIGN BASIS

�PROJECT OVERVIEW


�PROJECT OVERVIEW – FLOW DIAGRAM


� Tank Design

� Full Containment Design acc. EN14620

� Insulation Calculations

� Design of Equipment

� Type

� Data Sheets

� Noise Study Compressor Shelter

� Restriction of Noise

� 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 of Safety Valve Sizing

� MAIN PROJECT STEPS

�PROJECT OVERVIEW


� SPECIAL PROCESS DESIGN

�PROJECT OVERVIEW - PROCESS

� 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

� Safety System

� Stop Compressor at low Temperature


PROJECT OVERVIEW - PLOTPLAN


� Duration 26 months (08.14. – 09.16)

� Number of Near Misses: 303

� Total Hours Worked: 292.506

� 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

� STATISTICS � ORGANIZATION

�CONSTRUCTION


� WORKS

�CONSTRUCTION


� 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

� Vendor Checks

� Introduce IA and N2 – Flush & Test

� Service Test FW System – Flush & Test & Drain

� Follow Up Done by PIMS CMS System

� MECHANICAL COMPLETION / PRE-COMMISSIONING

�CONSTRUCTION


� 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 of In-tank Pumps

� Start of Sendout

� Performance Tests

� Taking Over

�PRE-COMMISSIONING / COMMISSIONING


� CHALLENGES

� Integration of:

� New DCS / SM into old DCS / SM

� Equipment into old DCS / SM

� Manual Control for Preheaters during Cooldown

� Sensible Interaction between Components of System forAdjustment

� Observation of Behavior of the Control Systems duringManual Control

� Support

� DCS programming according TGE design

� Adjustment of Control for Preheater System

�COMMISSIONING


�IMPORTANT MILESTONES


THANK YOU FOR YOUR ATTENTION!

Vielen Dank

多谢

cпaсибо большое

Obrigado


TGE Gas Engineering GmbH

Mildred-Scheel-Str. 1

53175 Bonn

Germany

+49 228 60448 0

+49 228 60448 893

www.tge-gas.com

[email protected]

CONTACT


Storages and

Terminals

for LNG

Small-Mid Scale

Natural Gas LNG

Liquefaction Plants

Storage and

Terminals

for Petrochemical/

Chemical Gas

Other

� Package Plants for gas

treatment or elements

of storage product

lines

� LNG as Fuel

� Storage Tank

Design Services

PRODUCT LINES


� 17 Projects in Total (EPC & EP+CS)

� Import Terminals: 9

� Export Terminals: 7

� Import/Export Terminal: 1

� 72 LNG Truck/Container Loading Stations

� Total Regasification Capacity > 13 mio t/a

� Total Production Capacity

Small-Mid Scale LNG > 3 mio t/a

Reference for all relevant International Design Codes:

Tanks: EN 14620, EUROCODE

API 625, API 620, ACI 376

Facilities: EN 1473, NFPA 59a, S

STORAGE TANKS

Storage Tanks installed 30,000 - 160,000 m³

Storage Tanks designed 5,000 - 260,000 m³

Storage Tanks installed in Europe 940,000 m³

Storage Tanks installed in Asia 1,908,000 m³

STORAGES AND TERMINALS FOR LNG

INSTALLED CAPACITY

21 Full Containment Tanks 2,838,000 m³

5 Single Containment Tanks 170,000 m³

TOTAL INSTALLED CAPACITY 3,008,000 m³

FACTS & FIGURES


� 36 Projects in Total (EPC & EP+CS) for

Petrochemical Products: Ethylene, Ethane,

Propylene, Butane, LPG, Ammonia.

STORAGE TANKS

Tanks installed with capacities from

up to3,000 - 120,000 m³

Facilities installed in Europe 327,000 m³

Facilities installed in Asia 1,684,000 m³

STORAGES AND TERMINALS FOR

PETROCHEMICAL GASES

INSTALLED CAPACITY

20 Full Containment Tanks

with installed capacity1,205,000 m³

22 Single Containment Tanks

with installed capacity560,000 m³

TOTAL INSTALLED CAPACITY 1,765,000 m³

FACTS & FIGURES

LARGEST INSTALLED CAPACITY

LPG 120,000 m³ Full Containment

Ethylene 80,000 m³ Full Containment

Ethane 120,000 m³ Full Containment

Propylene 80,000 m³ Full Containment

Ammonia 25,000 ton Full Containment

Documents

BASED ON EXPERIENCE - TGE Gas · 2016-11-10 · based on experience tge gas engineering epc execution of borealis ethane tank project. ... propylene, lpg, etc. liquefied gas storage