CCC Pipeline Capabilities
Istanbul 2012
Pipeline Record up to 2011
CCC has constructed approximately 16,500 kilometers of pipeline which is equivalent
to more than 1.5 times the circumference of the MOON.
Pipeline Construction
Number of Pipeline Spreads
Manual Spreads
Fully Automatic Spreads
18 Nos.
12 Nos.
Pipeline Statistics
16,500 KMS Pipelines
Diameter greater than 36 in: Diameter greater than 16 and smaller than 36:
Diameter smaller or equal to 16 in: 4,900 kms
7,000 kms
4,600 kms
CCC Group Manpower
CCC currently employs approximately 125,000 people
in its worldwide operations
CCC Plant & Equipment
CCC owns a large fleet of construction equipment
valued at over USD 1bn
1,100 pieces of Pipe laying & Earthmoving Equipment
ELECTRIC GENERATORS
& LIGHTING TOWERS
EARTHMOVING
EQUIPMENT
906
675
PIPELAYING
EQUIPMENT
201
CIVIL ENGINEERING
& CONSTRUCTION EQUIPMENT
1,345
AIR
COMPRESSORS
454
WORK/SURVEY BOATS
& STANDARD FACILITIES
HEAVY DUTY
VEHICLES
168
2,319
CRANES
977
VEHICLES
& LIGHT TRUCKS
2,625
TOTAL NO. OF EQUIPMENT:
TOTAL VALUE OF EQUIPMENT:
WELDING
MACHINES
8,131
17,800
US$ 1,050 MILLION
Current Pipeline Projects
CCC Scope of Work
Contract Value (US$ MILL)
Project
Location
Client
EPC Contractor
Qusahwira Field 1.8 MMBOPD Project
‐ 20", 14“, 8“ totaling 286 km of Pipelines, Transfer Lines and Flowlines
‐ EPC new central degassing station
‐ EPC New remote degassing station
‐ Water injection clusters
‐ Well tie ins
Abu Dhabi
ADCO
Nat'l. Petroleum
Construction Co.
(NPCC)
C
518
Bab Thammama G & Habshan 2 Development 1.88 MM BOPD Project
Fabrication and erection, laying flow lines and pipelines, EPC field erected tanks, 4 remote degassing stations and BCDS with all associated works, mechanical and E&I works.
Abu Dhabi
ADCO
Nat'l. Petroleum
Construction Co.
(NPCC)
C
610
Sahil, Asab & Shah (SAS) Full Fields Development
Construction of 315 km trunklines and flowlines 16" ‐
30".
Construction and EPC Main Oil Lines to Asab and 8 no. buildings.
Upgrade existing CDS and 2 RDS at Shah. Upgrade existing CDS and 1 RDS at Sahil.
Demolition of 31 km of pipelines 6" ‐ 30".
Connections to well heads at Sahil and Shah.
Abu Dhabi
ADCO
CCC/Tecnicas
Reunidas
Consortium
EPC
1,200
Current Pipeline Projects
CCC Scope of Work
Contract Value (US$ MILL)
Project
Location
Client
EPC Contractor
QCLNG Export Pipeline & Collection Header
Detailed design and construction of 528 km 42“
Natural Gas Pipeline
Laterals of 12 ‐ 24“
Pigging facilities
Receipt station
Australia
QCLNG Pipeline Co. Ltd.
(a BG Group Co.)
McConnell Dowell / CCC JV
with KBR E&P Services S/C
EPC
750
Australia Pacific LNG (APLNG) Pipeline
360 km 42“ Gas Pipeline
77 km 36“ Gas Pipeline
90 km 30" Gas Pipeline
Australia
Australia Pacific LNG PTY Ltd.
(APLNG)
McConnell Dowell / CCC JV
with KBR E&P Services S/C
EPC
940
QCLNG Export Pipeline ‐ Narrows Crossing
EPC of 2 Nos. 13 km each 42" Natural Gas Pipeline
Delivery station
2 Nos. 1.3 km HDD drives
1.5 km cofferdam in marine clays
2.4 km of dredged trench and tow
Australia
QCLNG Pipeline Co. Ltd.
(a BG Group Co.)
McConnell Dowell / CCC JV
with KBR E&P Services S/C
EPC
320
CCC Performance in EPC Pipelines
CCC has a premium record of performance in the
execution of EPC Pipeline Projects
Selection of Completed Major EPC Pipeline Projects
Pipelines (Oil & Gas)
Location
Client
24” Ambatovy Slurry Pipeline Installation
30” OAG Onshore Pipelines & Habshan Facilities
24”/30” Eastern Gas Distribution System Upgrade
36” Bu Hasa – Habshan Gas 50 km
36” Ras Laffan/Mesaieed Sweet Gas 126 km
24” Mina Al Fahl – Sohar Crude 266km
32 ”Fahud – Suhar (Oman) 302 km
48” Maqta – Jebel Ali (UAE) 112 km
42” Baku-Tbilisi-Ceyhan (Oil) 443 km
42” Georgia Border - Baku (Gas) 443 km
26” Mozambique – RSA (Gas) 860 km
Ras Laffan Common Cooling Water Phase I
18” Bab- Umm Al Nar Crude Oil Pipeline Project
Madagascar Ambatovy Minerals
UAE
GASCO
UAE
Dolphin
UAE
GASCO
Qatar
QP
Oman
ORC
Oman
OGC
UAE
GASCO
Azerbaijan
BTC
Azerbaijan
SCPC
Mozambique
Sasol
Qatar
QP
UAE
GASCO
Start
Date
2008
2006
2006
2006
2004
2004
2001
2000
2002
2002
2001
2001
2002
Pipeline Projects Around the World
Ambatovy Project
Pipeline projects have
taken CCC into many
distinguished areas
around the globe.
However, few have been
as exotic and challenging
as the Madagascar
Pipeline
Ambatovy Project
Madagascar is an island in
the Indian ocean.
Its located 400 KM to the
east of Africa
Madagascar is the world's
47th largest country and the
4th largest island.
Madagascar is the largest
producer of Vanilla in the
world
Madagascar is referred to as
the red island due to the
color of its soil
Ambatovy Project
Madagascar has 5% of the worlds plant and animal
Species, 80% of which are not found anywhere else
Ambatovy Project
Madagascar is home to as many as 12,000 plant
species, 70%-80% of which are endemic. This
makes it one of the most diverse floras on the planet!
Ambatovy Project
Major Exports
include Vanilla,
coffee, sugar cane,
cocoa, peanuts, etc.
Major Imports
include Petroleum,
Consumer goods
and food
Ambatovy Project
Ambatovy Slurry Pipeline Installation
Location:
Madagascar
Client:
Ambatovy Minerals SA
EPCM:
SNC Lavalin
Contract Value:
US$ 250 Million
Completion Date:
December 2010
Contract Duration:
34 Months
Ambatovy Project
The Ambatovy Nickel Mining
Project is a world-class,
project in Madagascar that is
positioned to be the world’s
biggest nickel mine by 20132014
The mine site consists of an
open-pit mining operation
and an ore preparation plant
Slurried laterite ore is
delivered from the mine site
via pipeline to a process
plant and refinery located
near Tomasina
Ambatovy Project – CCC Scope of Work
CCC Scope for the Ambatovy Project
was the Construction of :
248 km 24" Carbon Steel ore slurry
pipeline from the Ore Preparation
Plant to Tomasina
Valve stations
Pressure monitoring stations
Water pipelines
Terminal facility tailings pipelines
(HDPE)
Fiber Optic Cable
Ambatovy Project – SCOPE OF WORK
Ambatovy Project – Design Basis
Slurry was transmitted through the pipeline by means of
gravity
15% slope was required to be maintained
A water pipeline was required for purifying the slurry.
The water was of high salinity, as such an HDPE liner
was used
All welds were tested by Automatic Ultrasonic Testing
Ambatovy Project – Major Quantities
No.
Major Activity Description
UOM
QTY. at
COMPLETION
1
Total Earthworks - Cut / Fill
m³
11,200,000
2
Total Rock Drilled & Blasted
m³
300,000
3
Total length of pipes Welded & laid, CS
Km
248
4
Total length of pipes Welded & laid, HDPE
Km
21
5
Total Length of Horizontal Directional Drilling
Km
4
6
Total Major Road / Railroad Crossings
No
10
7
Total River / Stream / Minor Road Crossings
Nos.
330
8
Total Reinstatement / Revegetation
Km.
530
9
Total Quantity of Saddles [24”,30,36”]
No
16,000
10
Total Quantity of Concrete Coated Pipes
Km
14
11
Total Quantity of Fiber Optic Cable laid
Km
215
Ambatovy Project – Major Subcontracts
No.
Subcontractor Name
Scope of Work
1
Sicon Oil & Gas
Completed Detailed & Field Engineering
Works
2
Essar Construction Limited
Pipelay on the East Section Slurry
Pipeline
3
Flowtex Egypt
Horizontal Directional Drilling
4
UT Quality Inc.
Automated Ultrasonic Welding
Ambatovy Project – Challenges
The challenges of constructing a pipeline through the
exotic Madagascar region was an extraordinary
experience for CCC
Many challenges were encountered, such as:
–
–
–
–
–
–
–
–
–
–
Climate
Mobilization
Early Site Survey
Logistics
Site conditions
Terrain
Local communities
Schedule
IT and Communication
Environmental Protection Measures
Ambatovy Project – Challenges cont’d
Climate
Madagascar has two seasons,
a hot wet season and a dry
cool season
CCC’s experience was none
of the above!
It was only rain, or pour or
rain!
Cyclones were frequent (at
least 3 major ones per year)
The above resulted in CCC revising the execution plan, i.e.
Utilization of mini spreads
Increased number of camps and site facilities and storage yards
Special clothing and boots provided for crews to overcome the mud
and access the site by means of walking in some areas
Ambatovy Project – Challenges cont’d
Mobilization / Logistics
Non-availability of scheduled shipping lines
All shipping through the crowded South African Durban port
Chartering flights and vessels for manpower, equipment and
material to be used specifically for this job
Inland Transportation for personnel and equipment
Distances in Madagascar are measured in Hours not Kilometers
Non continuous access to site restricted maneuvering between
construction site fronts, camps and storage yards
Utilization of huge amount of military trucks to transport our staff
and crews
Utilization of articulated trucks to transport project and earthwork
material
Delivery of all line pipe material to many stockpiles along the ROW
Ambatovy Project – Challenges cont’d
Early Site Survey
Access to the pipeline was impossible
Route alignment sheets were prepared as a desktop
exercise
LiDAR data was not enough for the construction works
CCC carried out the early site survey to define the Center
Line utilizing bush rangers along with our survey team
Ambatovy Project – Challenges cont’d
Site Conditions
Adding to the complexity of the construction works was the unusual site conditions
encountered such as:
All-year round muddy and slippery ROW
Rocky mountains
Canyons and gulley
Dense tropical forests
Major Rivers
Wetlands
Swamps
Environmentally sensitive areas
Civil unrest
To overcome most of the site conditions challenges, CCC utilized:
HDD for non-accessible areas
Erosion control techniques
Utilization of specialized equipment to work in muddy and swampy areas
Ambatovy Project – Challenges cont’d
Terrain
Getting through the harsh and rugged terrains was a major
challenge:
The gravity driven design and the 15% slope required deep
cuts into the mountains often exceeding 80 meters
(equivalent to a 30 story building)
Huge amount of earthwork (in excess of 11 million m3) was
required to be removed to achieve the ROW
The terrain restrictions required CCC to utilize pre-welded
pipeline strings in short sections and excessive cold bending
Ambatovy Project – Challenges cont’d
Project Schedule
Overall tight Schedule:
Start Date
Completion Date
Mar 2008
Dec 2010
Ambatovy Project – Challenges cont’d
IT and Communications
Communication facilities in
Madagascar are limited
CCC made our own facilities
to cater for communication
between all site fronts, head
office, CCC Area Office,
Client and Engineer to ensure
all voice and data links are
working and reliable at all
times
Ambatovy Project – Challenges cont’d
Environmental Protection Measures
1. Environmental Protection Steps during the construction
phase:
a)
b)
c)
d)
Sloping & benching to prevent landslip and minimize soil erosion
Moving and reservation of top soil for rehabilitation works
Building bridges using flume pipes & rocks to cross over streams
Protecting the stream banks by stones, upstream & downstream
(rip rap)
e) Installation of silt fence & grass filters down stream of the rivers
f) Installation of Geotextile fence along the rice fields & water
crossing
g) Cut & stock pile trees according to the Environmental Protection
Procedure
h) Mobilization of large number of specialized environmental officers
with knowledge on Madagascar flora and fauna
Ambatovy Project – Challenges cont’d
Environmental Protection Measures
2. Water Management
a) Drain Channels and Crown Ditches along ROW to control water
movement during rainy seasons
b) Installation of Decantation Basins at ponds
Ambatovy Project – Challenges cont’d
Environmental Protection Measures
3. Soil stabilization and Re-vegetation
a) Soil compaction embankments re-profiled and compacted
b) Re-vegetation and manual seeding of the entire ROW including
slopes
c) Mulching and spreading of trees along the ROW
Ambatovy Project – Construction Highlights
Unconventional Pipeline execution strategies
To overcome all challenges, the execution strategy had to be tackled
as follows:
1. Continuous survey team on site
2. Splitting the pipeline into East and West Portions
3. Mobilizing a very strong planning team
4. Open as many fronts as possible utilizing self-sufficient mini
spreads
5. Utilizing articulated trucks at all times
6. Utilizing environmental specialists at all times
7. Long term agreements with Airline and Shipping companies
8. Mobilizing community liaison officers for every village, town and
city
9. Utilizing of local security services
10. Full coordination team to interact with the local authorities
Ambatovy Project – Conclusion
Madagascar was a true out of this world challenge
and a unique pipeline experience
The obstacles encountered only served to empower
CCC dedicated teams
CCC proved to successfully overcome all challenges
CCC Delivered
Consolidated Contractors Company
Ambatovy Project – Conclusion
THANK YOU!
Consolidated Contractors Company