epc hyundai project structure - fertilizer plan
DESCRIPTION
Hyundai Project Management Structure and Execution for Fertilizer PlantsTRANSCRIPT
EPC Execution Strategy
for Fertilizer Plants
CONTENTS
I. HDEC GENERAL INFORMATION
II. FERTILIZER REFERENCES
III. EXECUTION STRATEGY FOR
FERTILIZER PLANTS
I. HDEC GENERAL INFORMATION
About Us
Company Profile
Key
Profile Business
Lines
√ Established in May, 1947
√ Affiliate of Hyundai Motor Groupas of April, 2011
√ 7,257 Employees as of June, 2011
Top
EPC
Contractor
√ Ranked 1st in Construction Capability Evaluation by the Korean Government
√ Ranked 23rd Largest Int’l Contractor by ENR Report in 2010
√ Plant Works(Oil, Gas, Petrochemical)
√ Power & Energy Works (Power, Transmission & Distribution)
√ Civil & Environmental Works
√ Building Works
√ Investment & Business Development
HSE
√ ISO 9001
√ ISO 14001
√ OHSAS 18001
4th in the Middle East Market 23rd Largest Contractor World-Wide in 2010
2nd in the Power Market
▶ Pearl GTL Project PKG C-5 LPU Unit
▶ Karan GasFacilities Project
▶ Khalifa Port and Industrial Zone Project
▶ Boubyan Sea Port – Ph. 1
▶ Tripoli West 1,400MW
▶ Jurong Rock Cavern Ph.1
▶ Hamad Medical City
▶ KOC Oil & Gas Pipelines
▶ Bitexco Financial Building
Qatar U.A.E
Kuwait
Vietnam
Kuwait
Singapore
Qatar
Saudi Arabia
Libya
▶ QAFCO 5&6 Fertilizer
Qatar
▶ Ras Laffan“C” IWPP
▶ UAE Nuclear Power Plant
U.A.E▶ Habshan 5
Utilities & Offsites
U.A.E
Qatar
53Overseas Sites US$ 24.6 BilTotal Current Value
• Advancing into overseas market since 1965• Total 723 Projects (US$ 80 Bil.)
By Work Categories
US$ 23.4 bil
US$ 12.5 bil
US$ 6.3 bil
(143 Projects)
(192 Projects)
(42 Projects)
(2Prj)
US$ 16 bil
(50 Projects)
US$ 17.3 bil
(235 Projects)
US$ 4.5 bil
(61 Projects)
Others- Manufacturing Plant- Services
Electrical
Civil
Process Plant
Building
Power Plant
8%
16%
20%
5%
29%
22%
8.4%6.7%
6.1% 5.4% 5.2% 4.9% 4.8% 4.4%
1.8%
√ Hyundai E&C has carried out US$ 80 billion overseas projects since 1965.
US$ 443 BIL
US$ 152 BIL (34%)Others :
US$ 443 BIL
US$ 291 BIL (66%)
Top 10 Contractors:
Projects Carried Out By Korean Contractors
80
(Unit : US$ Bil)
3730 27 24 23 22 21 19
8
18%
AA-
A+
A
A-
BBB+
Sep. 2009
Sep. 2004
Jul. 2006
Jun. 2007
Jun. 2008
√ Korea’s top three credit rating agencies, Korea Investors Service (KIS), Korea Ratings (KR) and
NICE Investors Service, upgraded their credit ratings for HDEC’s corporate bonds by one notch
from A+ to AA- as of September 23, 2009.
HDEC Credit Rating (2004 ~ )
AFFILIATES 50 COMPANIES
TOTAL EMPLOYEES 177,000
TOTAL ASSETS
SALES
STEEL MOTORS CONSTRUCTION
FINANCE OTHERSPARTS
U$ 115.6 Bil
STOCK SHARE 34.88%
U$ 135 Bil
PROFIT U$ 10.6 Bil
OUTCOME
Global High Value-Added
Engineering Company
CAPABILITIES SUPPORT
TECHNOLOGY
MARKETING
GLOBALNETWORKING
FINANCING
Hyundai Motor Group plans to invest
US$ 9 Bil in Hyundai E&C within 10 Years
Maintain Competitiveness on Existing Core Business
- Chemical Plant, Power & Water Plant
High-Tech Civil & Building Works, etc.
Develop New Opportunity in Green & Future Business
- Environment Plant, Smart Grid
Renewable Energy, etc.
II. FERTILIZER REFERENCES
QAFCO 5 & 6 Project (Ammonia & Urea) / QATAR
• CAPACITY QAFCO 5:-No. 2 Ammonia plants 2,300 Tons/day each-No. 1 Urea plant 3,850 Tons/day -No. 1 Urea granulation 3,850 Tons/dayQAFCO 6:Urea Plant 3,850 Tons/day
•LOCATIONMesaieed, Qatar
• CLIENTQatar Fertilizer Company (S.A.Q)
• CONTRACT PERIODQAFCO 5: Dec 2007 ~ Jun 2011QAFCO 6: Oct 2009 ~ Sep 2012
PINGDINGSHAN Urea Plant / CHINA
• CAPACITY132,000 MTPY
• LOCATIONPingdingshan City, Henan Province, China
• CLIENTChina National Chemical Construction Corporation(CNCCC)
• CONTRACT PERIOD1995 - 1999
CHISUI Urea Plant / CHINA
• CAPACITY170,000 MTPY
• LOCATIONChishui City, Guizhou Province
• CLIENTChina National Chemical Construction Corporation (CNCCC)
• CONTRACT PERIOD1993 - 1996
National Fertilizer Complex / THAILAND
• CAPACITYP2O5 200,000 TPYNP/NPK 1,000,000 TPY
• LOCATIONMap Ta Phut, Rayong, Thailand
• CLIENTNational Fertilizer Co.
• CONTRACT PERIOD1994 - 1997
SHAANXI Urea Plant / CHINA
• CAPACITY132,000 MTPY
• LOCATIONHuaxian City, Shaanxi Province, China
• CLIENTChina National Chemical Construction Corporation(CNCCC)
• CONTRACT PERIOD1992 - 1995
IRAQ Fertilizer Plant NO. 4 / IRAQ
• CAPACITY1,000 MT/D Ammonia1,750 MT/D Urea
• LOCATIONBaiji, Iraq
• CLIENTMinistry of Industry & Minerals, Iraq
• CONTRACT PERIOD1986 - 1989
Asean Bintulu Fertilizer Plant / MALAYSIA
• CAPACITY1,500 TPD Ammonia1,500 TPD Urea
• LOCATIONBintulu, Sarawak, Malaysia
• CLIENTAsean Bintulu Fertilizer Sdn. Bhd., Malaysia
• CONTRACT PERIOD1983 - 1985
Korea Fertilizer Plant / KOREA
• CLIENTKorea Fertilizer Co.
• CONTRACT PERIOD1966 - 1967
• CAPACITY590 MT/D Ammonia1,000 MT/D Urea
• LOCATIONSeoul, Korea
Honam Fertilizer Plant / KOREA
• CAPACITY200 MTD Ammonia350 MTD Urea
• LOCATIONNaju, Korea
• CLIENTHonam Fertilizer Co., Korea
• CONTRACT PERIOD1959 - 1963
III. EXECUTION STRATEGY FOR FERTILIZER PLANTS
PROJECT MANAGER
PROJECTQUALITYMANAGER
ENGINEERINGMANAGER
PROJECTIT
COORDINATOR
PROJECTCONTROLMANAGER
SITEMANAGER
COMMISSIONINGMANAGER
SITEORGANIZATION
CORPORATEQUALITYMANAGER
COMMISSIONING ORGANIZATION
PROJECTHSE
MANAGER
CORPORATEHSE
MANAGER
PROCUREMENTMANAGER
PROCUREMENTORGANIZATION
ENGINEERING ORGANIZATION
• HDEC will act as single contractual entity and provide single point of
responsibility to OWNER
• The Project Home Office will be located in Seoul, Korea where
OWNER’s Team and Contractor`s Team will be located with an
integrated office-space arrangement
• Project Engineering and Procurement activities carried out in Project
Home Office in Seoul, Korea with support from worldwide offices
• Project control and review activities involving OWNER’s Team will be
conducted in Project Home Office
• HDEC approach to Engineering and Procurement is based on
experience gained during the execution of Fertilizer Projects
• Focus and utmost attention are given to Projects critical factors such
as:
early mobilisation of Licensors
material delivery schedule
constructability
market condition
SAMPLE
- Ammonia plants 2,300 Tons/day X 2
- Urea plant 3,850 Tons/day - Urea granulation 3,850 Tons/day
Project Summary
Engineering ProcurementConstruction/
Commissioning
WBS & Schedule based on Web (Primavera P6)
Status Report Forecasting
Plant Safety Safety Design & Review
Code & Specifications
Engineering Product Quality Integrated & Dedicated Eng’ng Team
Apply Quality Procedure
Project Timeframe Identity interface points
Early mobilization for early Eng’ng Works
Constructability, Operability &
Maintenance 3D Model & Constructability Review
Maximize OWNER’s Profit by
the successful Engineering and
Construction of the Facilities to
be operated in Safe and
Operable ways through the Best
Quality of Engineering
• Design Reviews
Various Design reviews and Studies will be conducted during
engineering stage to ensure and validate the integrity of
engineering;
- P&ID Review
- HAZOP
- PHASER
- SIL
- HSEIA
- 3D Model Review
- Constructability Review
- FRA (Fire Risk Assessment)
- QRA (Quantitative Risk Assessment)
- Human Factor Study
- RAM Study
State-of-the-art computer facilities and industry recognized
engineering software program complying with OWNER’s
requirements will be used
• Engineering Tools
• Field Engineering
The field engineering team will be mobilized to site once the major
engineering is progressed to an advanced stage
• Constructability Review
A dedicative Constructability Coordinator will be assigned to the
Project Team to coordinate the Constructability Program
• 3D Model Review
3D electronic model of the plant will be developed using multi-
disciplinary PDS (Plant Design System from Intergraph) System.
Each discipline will develop its scope of work for and under the
result of the 3D Model Review
• Construction Team
For optimizing performance cost, schedule and quality, the
construction staff will be involved at the early stage of engineering
• Vendor Material Standardization
• Development of Prospective Alternative Vendors for Project
Benefit subject to Approval
• Expediting utilizing overseas procurement offices and
specialist resources
Plant Critical Equipment Planned PO Date Planned On-Site Date
Ammonia Natural Gas Compressor ED + 2 Months ED + 18 Months
Process Air Compressor ED + 2 Months ED + 18 Months
Syngas Compressor ED + 2 Months ED + 19 Months
Ammonia Refrigeration Compressor ED + 2 Months ED + 18 Months
Ammonia Booster Compressor ED + 2 Months ED + 18 Months
Primary/Secondary Reformer ED + 2 Months ED + 18 Months
Ammonia Synthesis Converter ED + 1 Months ED + 20 Months
Waste Heat Boiler ED + 1 Months ED + 19 Months
Co2 Stripping Column ED + 3 Months ED + 18 Months
Co2 Absorber ED + 1 Months ED + 20 Months
Plant Critical Equipment Planned PO Date Planned On-site Date
Urea Co2 Compressor ED + 1 Months ED + 19 Months
Urea Reactor ED + 1 Months ED + 21 Months
Urea Stripper ED + 1 Months ED + 20 Months
HP Synloop Heat Exchangers ED + 1 Months ED + 20 Months
Carbamate Separator ED + 1 Months ED + 23 Months
1st/2nd Carbamate Condensers ED + 5 Months ED + 17 Months
HP Ammonia Pump ED + 1 Months ED + 19 Months
HP Carbamate Pump ED + 1 Months ED + 19 Months
Plant Critical Equipment Planned PO Date Planned On-Site Date
Utility Gas Turbine Generator ED + 4 Months ED + 17 Months
HRSG ED + 4 Months ED + 18 Months
Service Boiler ED + 1 Months ED + 19 Months
C.W Pump ED + 2 Months ED + 18 Months
• Construction work force through direct hiring as well as
subcontracting
• Own construction equipment & resources which will be utilised
• Strict adherence to Time Schedule as well as cost using local
contractors
• Adherence to all the Quality and Health Safety & Environment
Procedures in line with International practice
• Overall construction supervision by HDEC
• Precommissioning / Commissioning stages overlap will be taken
up along with Licensor representatives, Process experts from
HDEC along with OWNER support
• Mobilization of Construction Equipment acc. to Project Schedule
Equipment Object
1,200 Ton Crawler Crane Synthesis Converter
600 Ton Crawler Crane Reactor & Absorber
450 Ton Crawler Crane H/Ex, Vessel
250 Ton & Less Crawler Crane Less than 100 Ton
100 Ton & Less Hydro Crane Less than 20 Ton
Dozer & Loader Civil and Building
Air Comp. & Generator Utility and Electric source
• Official Hand-Over of Plant Area / Camp Sites
& Relevant Bench Marks ED+1M
• Establishment of Site Office with Direct
Communication with OWNER at Site ED+3M
• Prompt Commencement of Early Work in accordance
with 90 Days Work Schedule
- Topographical Survey ED+1M
- Building / HVAC Basic Engineering ED+1M
- Site Preparation of Camp Area ED+3M
- Site Preparation of Plant Area ED+3M
- Camp Construction ED+4M
- Batch Plant Installation ED+5M
MECHANICAL COMPLETION
COMMISSIONING
START-UP&OPERATION
MECHANICAL COMPLETION COMMISSIONING START-UP&OPERATION
TIME
SYSTEM
SYSTEM-1
SYSTEM-2
SYSTEM-3
SYSTEM-4
SCHEDULE SAVING
WITHOUT SYSTEM HANDOVER APPROACH CASE
WITH SYSTEM HANDOVER APPROACH CASE
Ammonia
Storage
Feed in
Ammonia
Service Boiler
Natural Gas
IA, PA,
IG, FW
Boiler Feed
Water
Stabilize and PGT
Feed in
Urea
Steam Blowing
Ammonia
Steam Blowing
Urea
Stabilize and PGT
Cooling Water
GT with HRSG
Bagging
I. Utility
Gas turbine lube oil flushing & Function test
HRSG refractory dry out, boil out and Passivation
Service boiler refractory dry out, boil out and Passivation
Cooling water system flushing and Passivation
Steam Blowing
II. Ammonia Plant
Lube oil flushing of compressors
Steam blowing for steam networks including around comp, turbines.
Air blowing for all process line by using process air compressor
Catalyst loading
(Special requirement for primary reformer and ammonia converter)
High press. N2 leak test for Ammonia synthesis loop
Degreasing chemical cleaning for H2S and CO2 removal system
Primary reformer refractory dry out
Waste heat boiler chemical cleaning and passivation
Urea
Ammonia Storage Tank
Natural Gas (CH4)
H2S Removal Section
1st Reformer
2nd Reformer
CO → CO2 Conversion
← Steam (H2O)
← Air (N2/O2)(By Process Air
Compressor)
CO2CO2 Removal Section
CO/CO2 →
Methanation (CH4)
Ammonia Converter
NH3 Refrigeration
Section N2 + H2 + CO + CO2
N2 + H2 + CO2
N2 : H2 = 1 : 3
NH3
Urea
NH3
CH3OH(Methanol)
NH2CO-NH-CH2OH
(Mono Methylol UREA)
UREA Polymerization
Granulation
Conveyor
Bulk Hall
CH3OH + ½02 →
CH2O(Formaldehyde) + H2O
CH2O + NH2CO-NH2 →
NH2CO-NH-CH2OH
UFC Plant
O2(Air)
UREA CO2 NH3
UREA
CO2 + 2NH3
↓
NH2-COO-NH4 (Carbamate)
↓
NH2-CO-NH2 (UREA) + H2O
Serial. No Acticity Description Duration(day)
1 Start ID/FD Fans 1
2 Start Nitrogen circulation and heat reformer 2
3 Reformer feed in 1
4 Stream drum passivation 2
5 Testing of Steam drum PSV 1
6 HT Shift catalyst reduction & line up 2
7 Feed process gas to CO2 absorber and produce CO2 1
8 Line up CO2 to urea 1
9 LTS catalyst reduction and line up 7
10 Methanator catalyst reduction 3
11 Receive Ammonia 2
12 Commissioning Ammonia compressor 2
13 Commissioning Syn gas compressor 2
14 Syn gas converter reduction 7
15 Commission Ammonia recovery 5
16 Commission Hydrogen recovery 5
17 Stabilization, Ramp up & Controller Tuning of Unit 31
18 Reliability Test 14
19 Performance Test in Ammonia 5 5
43days
Serial. No Acticity Description Duration(day)
1 Commission of CO2 Compressor 6
2 Receive Ammonia & Commission Ammonia booster pump 3
3 Commission HP Ammonia pump 4
4 HP loop heating 1
5 HP Loop bolts hot tightening 3
6 Ammoniation of HP Loop 1
7 Reactor feed in & melt generation 1
8 Line up Urea melt to granulation 1
9 Stablilization, Ramp up & Controller Tuning of Unit 30
10 Reliability test 14
11 Performance Test in Urea 5 5
12 Ramp up to Over Capacity 1
13 Urea 5 Overdesign capacity demo test 1
20days
Serial. No Acticity Description Duration(day)
1 Blank Operation with hot air 3
2 Collect UFC from Qafco Site 0
3 Collect Urea from Qafco Site 0
4 Granulator sprayer test with water 3
5 Urea filling in start up bin 2
6 Solid dry circulation test 3
7 Granulation system commissiong 1
8 Stablilization, Ramp up & Controller Tuning of Unit 30
9 Reliability Test 14
10 Performance Test in Granulation 5 5
11 Urea Transfer from Granulation to Bulk Storage 1
12days
2011 Pearl GTL Project, Qatar 32,000,000
Year Project Hourswithout LTA
2011 Karan Gas Facilities, Saudi Arabia 10,000,000
2010 QAFCO 5 Project(Ammonia & Urea), Qatar 20,000,000
2010 Ras Laffan C – IWPP, Qatar 10,000,000
2009 Khurais Gas Project, Saudi Arabia 13,000,000
2008 New Ethane Recovery Plant, Kuwait 10,000,000
2005 Western Libya Gas Field Development Project, Libya 19,000,000
No 1. Performer among 10 Contractorsin STAR (Site Technical Assurance Review)
conducted by Shell Global Solutions in 2009
and 2010. – Pearl GTL Project / QATAR
ERP
WBS & Schedule based
on Web (P3 Ver 6.0) Project Summary Status Report Forecasting
Engineering
Tag Index – EDIS*/SPF
2/3D Modeling – SPP&ID
PDS/SP3D
BOM & E/R – SPMat
Deliverables –Project Space*
Calculation – Eng. S/W
Procurement
Inquiry – SPMat
PO – ERP I/F(to be)
Expediting – SPMat
Inspection – TOPICS*
Transportation – SPMat
Construction/
Commissioning
Site material – SPMat/IPCS*
Construction – IPCS/WIT*
QC – HCQM*
Pre-Com. – HPCM*
Punch Control – HPCS*
SPPID
SPEL
SP3D
SPIN
SPMat(Procurement status
monitoring and
material control)
Tags for instrument,
equipment and lineProgress report
Source data for
progress calculation
Design data
Tag and basic design data
- Deliverables
- Relation DB with tag
Engineering Document
Procurement Document
Vendor Document
Correspondence
Fax., Letter, E-Mail
Construction Document
Security & Permission
Revision
Internal Workflow
Interoffice Memorendum(IOM)
Design Review & Verification(DRN)
Design Change Notice(DCN)
Correspondence Distribution
External Collaboration
On Line Transmittal for Vendor,
Partner and Client
Request for Information(RFI/TQ)
for Client
Real time Status Monitoring
for Project Document &
Workflow
Transmittal In/Out
(Client, Vendor, Partner)
Correspondence In/Out
DRN & IOM
Delayed Documents &
Workflow
Status Monitoring
Project Collaboration
Project Information
Project Calendar
Project Bulletin
Project Image Bulletin
Messenger
Project Organization
Project Mail System
ㅋProject
Space
Document Control
Progress Report
Drawing & Document Status
Report.
Behind/Look ahead Report
Transmittal In/Out History
Report
Vendor Data Status Report
Etc.
• Material Code
• Spec & BOQ Report
• 3D-CAD Interface
3D-CAD
(PDS/SP3D)
BOM
Control
Material
Take-off
Inquiry PO Expediting Inspection Transportation
Material
Receiving
Warehouse
Control
Material IssueMaterial
Code
BOM Import
Forecasting
& Reservation
C
• Site receiving mgt.
• Forecasting &
Reservation
• Vendor management
• Status monitoring
• Transportation
E
P
Spec Gen.WIT
TOPICS
HCQM
ERP ContractInspection &
Expediting
Welding Inspection
& Test System
Construction
&
Quality System
(to be)
Mechanical Electrical InstrumentPiping
1. Early P&ID Freezing
2. Quality of Detail Design Drawings
1. Timely Placement of Order for LLI Items
2. Vendor Selection of Key Equipment
(Primary / Secondary Reformer, SyngasCompressor, Ammonia Synthesis Converter, Urea Reactor)
1. Bulk Control System
(Concrete, Steel Structure, Piping, Cable)
2. Self Performing Construction Company
(Reformer, Heavy Lifting, E&I)
3. HDEC Owned Construction Equipment
E
P
C