design and engineering.pdf

7/27/2019 DESIGN AND engineering.pdf

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DESIGN AND ENGINEERING

Our underlying ability to improve productivity, increase safety and upgrade the working environment

in the offshore sector rests on our engineering skills and development of fit-for-purpose solutions

based on new technology and integrated work processes.

We conduct feasibility, concept and FEED studies, as well as detail design, for both Greenfield and

Brownfield projects. Engineering services are provided on a stand-alone basis or as an integral part of

an EPC or EPCIC contract.

We use the latest technologies and construction methodologies to obtain optimal plant facilities as

well as the latest design techniques including laser scanning, digital photography and video studies,

3D design and 3D modelling.

Feasibility Studies

Feasibility Studies provide a solid foundation for any process led engineering project. Feasibility

studies facilitate informed decisions; often saving companies and investors time, money and effort

throughout the life of a project.

Feasibility studies or Option studies objectively uncover the strengths and weaknesses of an existing

business, technology or proposed new venture. GSAs extensive in-house knowledge and expertise

can be applied to your project, setting the precedent for achieving optimum value while keeping

effective controls on cost and programme.

Conceptual Design

Conceptual Design Studies shape a projects success, strategy and development plans for the future.

This early phase of project planning is quite complex with various decisions being driven by variables

such as; health & safety, security, environmental impact, logistics, technology, complexity,

infrastructure availability and economic evaluations, all of which can have a direct impact on capital

cost.

Front End Engineering Design

Front End Engineering Design packages sets the precedence for achieving optimum value for any

process led engineering project while keeping effective controls on cost and programme.

At FEED phase, various studies are completed to resolve the relevant technical and safety issues and

risks influencing the project. The FEED study fixes the design intent which will be subsequently taken

forward into Detailed Design and Construction.

The Detailed Design and Construction phases of a project tend to represent the largest proportion of

the total project investment (i.e. 60-90%), therefore investing adequate time and effort in a FEED is

essential to ensure the success of a project and reduce operational risks.


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Detailed Design

During Detailed Design the scope defined in the FEED is developed to produce the definitive

information required for construction and installation. During this critical phase the plan developed

during the FEED is worked and key success parameters are closely monitored to maintain project

control.

To provide continuity and avoid lengthy tendering, it is preferable for the engineering team

responsible for the earlier phases of the project to follow it through detailed design into

implementation. This ensures that historical knowledge stays with the project all the way through to

commissioning saving time and money.

EPC/EPCm

Instructing the FEED contractor to complete the project on an EPC/EPCM basis can provide clients

with several major advantages. Most significantly the FEED contractor is fully familiar with all aspects

of the design, project plan and business objectives.

Selecting the most appropriate strategy is key to successful project execution. We have expertise in

contract management strategies and can assist clients during the FEED phase to ensure the most

appropriate execution contracting strategy is selected; this may include EPC or EPCM approach

dependent upon clients requirements. We able to draw on many years of experience for

multidiscipline construction and installation.

MAINTENANCE, MAJOR MODIFICATIONS AND REVAMPS

Cofely Fabricom GDF SUEZ in the UK prides itself in developing and supporting maintenance solutions

to many of the oil, gas power and allied industries. Cofely Fabricom GDF SUEZ understands that the

individual needs of its customers cannot simply be packaged into one product offering. It requires the

understanding, flexibility and commitment to deliver the best operational solution available.

Whether working within a fully integrated team or on a standalone classic term contract, we can

help to maximize the potential of our clients assets.

Activities range from improving safety and meeting compliance and new working environment

regulations on platforms to solutions for increasing reservoir recovery and enhancing process

capacities. Other challenges for which we are implementing solutions include the remote operation

of old platforms, process simplification and improved control systems.

We are also pioneering new ways of working through integrated operations whereby successive

project phases are handled via advanced video communication systems. By using the integrated

operation methodology we have reduced the number of offshore staff, improved cooperation

between the on- and offshore organisations and achieved an impressive safety record.

Specific areas of attention include modifications to increase oil recovery through new production

wells, separation, gas injection, water injection, gas lift and low pressure production.

Other areas are tie-ins of sub-sea satellites and modifications to process facilities and export systems

associated with end of field life. Parallel focus on increased gas production includes gas compression,

export and/or injection.


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MULTIDISCIPLINARY PROJECTS

We offer a full range of services from turnkey multi-disciplinary design and build projects, through

maintenance contracts, to minor repair and revamp projects.

Fabricom Oil, Gas & Power thrives on the fabrication and delivery of structures for offshore platformsand the downstream and industrial sectors. Whether large, complex, or both, we are specialised in

their fabrication and installation. We can respond to a wide range of requests including process

modules and structures necessitating multi-technical expertise in areas such as piping, mechanical,

electrical and instrumentation.

Piping and mechanical installation projects include hook-up of modular units, racks and columns, pre-

and post-turnaround revamp works as well as turnaround projects during shutdowns.

Electrical, instrumentation and automation projects include the calibration and connection of

instruments as well as loop testing and pre-commissioning.

CONSTRUCTIONCofely Fabricom GDF SUEZ has established a reputation as a market leader for quality, reliability and

performance for both on and offshore oil and gas and power industries.

We employ highly skilled and motivated personnel; which enables us to undertake high quality

construction projects of a complex nature and we are able to accommodate all activities associated

with the project management, engineering and construction of process plant and equipment in a safe

working environment.

Our wealth of experience in project management, engineering and construction projects range from

simple piping systems of skid units through to sophisticated and highly complex schemes which

require stringent Quality Control procedures. Cofely Fabricom GDF SUEZ has extensive knowledge of

effective planning, procurement and quality control; together with our extensive in-house resources,

this enables us to rapidly mobilize specialist teams for specific projects.

Our Fabricom Projects and Engineering Centre in Immingham is set up for the manufacture of piping

systems of all grades and modular construction. Our quality piping systems and modules have been

installed by us at some of the largest oil, gas and power projects in the UK.

Examples of modular construction projects undertaken would be the design, construction and projectmanagement of modules for oil, gas and power projects in the UK and Worldwide. Our expertise, along

with the size of our facility allows us to undertake projects to manufacture modularized units in large

numbers and various sizes up to 2,000 tonnes including pipe racks, cryogenic cold boxes, process

plants, columns etc.

With numerous covered workshops, an extensive module assembly area and our own private access

to the deep water port of Immingham for transportation by sea, Cofely Fabricom GDF SUEZ is able to

meet specific timescales for delivery of clients packages of work.


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Examples of some of our module construction projects undertaken:

Pre-assembled Units Pre-assembled Racks Tanks-Vessels Piping Systems Distillation Columns Offshore Assemblies Cryogenic Cold Boxes Skid Units Compressor Skids

FULL MECHANICAL AND EC&I INSTALLATION SERVICE

Cofely Fabricom GDF SUEZ in the UK has the skilled resources and experience to offer a full mechanicaland EC&I installation service. The installation works are managed as a full project with the backing of

our established project management organization and capability.

Our regional operational businesses can provide the competent resources needed to undertake

medium to very large projects, thus enabling us to provide long term, high value services.

In conjunction with our Cofely Fabricom GDF SUEZ partners in Europe, we also have access to proven

European skills to support our UK skills as required by the project.

Our installation teams receive continuous training in line with our core objectives to deliver to the

highest standards of safety, quality and productivity.

POWERWe are increasingly involved in the energy sector, both in new-built and revamp projects, by executing

installation work for the balance of plant and power island sections, electrical equipment supply and

installation, repowering and re-instrumentation.

Fabricom Oil, Gas & Power sees the energy sector as an important market, as substantial investments

are planned in Europe up to 2030 in different kinds of power plants (CCGT, CFPP including cleancoal, IGCC), renewable energy and environmentally friendly technologies (onshore and offshore wind

farms, CCS, AC/DC applications). Fabricom offers services and solutions in compliance with these new

market developments. Our expertise in multi-technical installation, fabrication and modular

construction enables us to offer integrated and innovative solutions for traditional and renewable

energy facilities and applications.

MODULAR CONSTRUCTION

Modular assembly provides safe and cost-effective solutions for awkward and often extremeoperating conditions. Whether such conditions include time constraints, budget constraints, or


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logistical issues, pre-assembling units off-site minimises operational disruptions and increases safety

by reducing the number of people involved in on-site assembly.

Besides traditional destinations for modules like refineries or gas processing plants, Fabricom offersits modular construction expertise for new applications: Carbon Capture and Storage (CCS), modular

HV substations for onshore Oil & Gas facilities, AC / DC onshore and offshore converter stations for

HVDC interconnections, offshore wind farms, etc.

ADVANCED PIPE BENDING EXPERTISE

Our pipe prefabrication workshops in Grimbergen in Belgium and Strijen in The Netherlands operate

several induction bending machines with diameters of up to 64 all of which offer a high degree offlexibility in terms of bend radius, bend angle and bend plane, and being computer controlled, are

able to achieve exceptionally close tolerances.

After bending, especially of heavy wall materials or special alloy steels, heat treatment is used to

restore the mechanical properties. Such treatments include stress relieving heat treatment,

normalising heat treatment, normalising and tempering heat treatment, quenching heat treatment,

and quenching and tempering heat treatment.

Fabricom is able to work with all types of material including seamless or welded pipes in carbon steel

and stainless steel, as well as the most sophisticated alloy steels. Our processes also ensure that

prefabricated components meet the strict requirements of corrosion resistance and superior metal

hardness set by the industry.

OFFSHORE WIND FARMS

The combination of our offshore services and multi-disciplinary competencies is enabling us to

develop modular construction for application in offshore wind farms, where there is rapidly growing

interest in the energy sector. We are, for instance, able to undertake the engineering and construction

of offshore high voltage substations that provide a single cable link between groups of offshore wind

turbines and onshore equipment.

Booster Technology (BOSS concept - Belgian Offshore Substation Solution) is a patent-pending

technology developed by Fabricom in close cooperation with Tractebel Engineering, Pauwels, Trafo

International and Lemants, representing innovative HV infrastructure for offshore wind farms.

Traditionally electrical infrastructure equipment is installed in an offshore HV platform. The BOSS

concept allows minimum equipment to be installed offshore and important, critical equipment to be

placed onshore, in a booster station. This helps to bring down maintenance costs and ensure

maximum reliability of an offshore wind farm. The concept also won the GDF SUEZ Initiative and

Innovations Trophy in 2009.


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FULL PROJECT MANAGEMENT CAPABILITY

Cofely Fabricom GDF SUEZ in the UK has the resources, skills and tools to offer a full project

management capability from the concept through to the completion of the project. We have an

established project management team with the support of our in house resources covering

engineering, project controls, planning, procurement, risk management, construction methodology

and field services. We have a track record of successful delivery of major projects in the UK achieving

first class performance in terms of safety and productivity.

We are a progressive business seeking to innovate and find cost effective solutions to meet client

project needs. Our culture is to work with our clients in the early stages of the development of the

project so that the project can realize the benefit and value of Cofely Fabricom GDF SUEZ knowledge

and experience. For example, the concept of modular assembly is beneficial as this reduces the

resources required on site and allows the pre-assembly of pipework and equipment in a cleaner and

more efficient work environment. Cofely Fabricom GDF SUEZ in the UK has significant experience in

collaborating with customers for the development of pre-assembly module concepts and strategies.

For the management of the contract Cofely Fabricom GDF SUEZ operate bespoke project management

tools such as our Fabricom Project Control System (FPCS) which we employ for the monitoring and

control of major projects. The system is well proven and established in our business for control of

materials, work packs and QA documents throughout the project life cycle up to handover to the end

user.

Active risk management and identification of potential benefits and opportunities is seen as a critical

component of the project management process. Our project execution strategies would include the

development of a comprehensive plan, in conjunction with our customers, to ensure that risks are

managed and mitigated and the joint benefits and opportunities are realized.

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