E n e r g y t o t h e W o r May 11, 2015 ABU Dhabi Downstream l d Agenda • Facts & Figures • Key Success Strategies 2 Ships are loaded directly from the refinery Jubail -2 SATORP Refinery Jubail -1 I. ISBL – Segment II. OSBL – Segment III. Port Facility - Segment Petcoke Handling Berth Ships are loaded directly from the Refinery King Fahd Industrial Port 3 Saudi ARAMCO TOTAL Refinery and Petrochemicals 400 MBD of Arabian Heavy Refinery Product 90 MBD Gasoline 50 MBD Kerosene 190 MBD Diesel (10 ppm) 2,200 KTA Coke 450 KTA Sulfur 700 KTA Paraxylene 140 KTA Benzene 205 KTA Propylene NO FUEL OIL Full Conversion Integrated with Petrochemical Refined High Value Product Complying with most Stringent International Specification Complying with Royal Commission Environmental Regulation Very sophisticated and Complex Refinery with high level of Automation EDCI = 5550 kbd. Solomon Benchmark Ranking #7 in complexity index among more than 300 Refineries worldwide 4 4 Facts and Figures • 45,000 employees at the peak Piping • 147,000 tones of pipe • 80,000 tones of steel Pipe rack • 4,500 pieces of equipment FO Pump • 1 million kilometers of electrical cable Electrical Cables 5 Facts and Figures (Special Presentation) • Execution started July 2009. 1st Piping product shipment was made in Sept 2013. • Project came under budget Pipe rack • Over 350 Million safe man hours, 7 LTIs FO Pump • Average PQI 89% Electrical Cables 6 Pkg Description 1 Distillation & Hydrotreating (TR) 2A Conversion (Technip) 2B Acid Gas Treatment (Daelim) 3 Aromatics (Samsung) 4 Coker & Merox (Chiyoda/Samsung) 5A Interconnecting/PCS/Elect. (Technip) 5B Plant Utilities (SK) 5C Auxiliary Utilities (Al Khathlan) 6 Refinery Tank Farm (Rotary Engineering) 7 Permanent Infrastructure (Al Osais) 8 Pipelines & Off Plot Facilities (GCC) 9 Port Tank Farm (Dayim Punj loyd) 10 Permanent Communication (Sumitomo) 7 Main Milestone 16.9% Construction 2010 only Start Concrete Foundations Start Cable Pulling Electrical Start U/G Piping Start A/G Installation 2010 Jan Feb Mar Apr May Start of Construction June July Aug Sept Oct Nov Dec Complete Mobilization on site Start of Site Grading TCF Construction Activities Construction Activities Plot 9 Bridge 8 Main Milestone 44.2% Construction 2011 only 50% Concrete Pouring 50% Steel Structure First SS Energization 50% Eq. Erection 2011 Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec 50% Construction 50% U/G Piping 50% A/G Piping Fab. & Erection Peak of Construction 5.3% 9 Main Milestone 35.7% Construction 2012 only Slop Pipelines & Tanks Utilities Distr. Sales Gas P5A, 5B, 8 P5A P5A, 6, 8 2012 Sept Oct Nov Dec Diesel Import Fire Water Flare Tr1 RFISU P5A P5C WWT P5C 10 Main Milestone 2013 CRUDE IMPORT MAY 20 CRUDE IN CDU1 MAY 23 FIRST EXPORT FUEL OIL CRUDE in CDU/VDU2 ALKY and DHC ALL UNITS IN OPERATION TRAIN 1 OPERATION COKER and MHC in OPERATION Diesel in CDU/VDU1 PX OPERATION 2013 Apr May June July Aug Sept Oct Nov Dec Jan FCC in OPERATION CCR TRAIN 2 OPERATION 11 12 Key Success Strategies • Strong FEED documents for all units in plot 9. No significant changes in process • Strong Shareholder alignment • Oversight by BOD & Project Committee – Governance & immediate decision making • Strong teamwork within PMT, with Operation & with EPC’s. (photo) • Strong Material procurement Monitoring and Intervention 13 Key Success Strategies • Adequate PMT Resources – Overseeing performance ensuring compliance to schedule, quality & safety requirements – 120 Secondees All Key Positions – 650 SMPs – 150 Quality – 30 Safety • Independency & Agility to Mitigate poor performance EPCCs - Signed (unit rates) Services Contracts & mobilized resources to support schedule 14 Key Success Strategies • Subcontractor Award Strategy – 2 Subcontractors for all major packages – Prequalification of all subcontractors by PMT • Strong visibility through appropriate Planning and Reporting tools • Risk mapping and management of mitigation plans Commissioning Report 15 Lessons Learned • Small/Medium Contractor not prone to EPCC • Commissioning activities in complex project must weight more (5 ÷ 7%) sometimes it was 0.5% • 3rd Party Interface: SR PM needed – – – – New Off plot access Procedures Marafiq RC & Other Utilities KFIP 16 ICAPS & Phases of the work DETAIL ENG. CONSTRUCTION / PRE-COMMISSIONING COMMISSIONING Mobilization of: Comm. Manager General Preparation Pre-commissioning Preparation Preparation team Commissioning Preparation PRE COM EXECUTION PREPARATION OPERCOM COM EXECUTION FORMS PROGRESS FORMS PRE COM PUNCH LIST COM PUNCH LIST PROGRESS ICAPS ENGINEERING POPULATION REPORTING REPORTING Integrated Commissioning and Progress System 17 ICAPS  Process Units 38  Non Process Units 76  Electrical Substations 40  RFC 5,325  RFSU 4,596  RFISU  Total Pre Comm. Tasks 788,078  Total Comm. Tasks 121,859  Total Punch Items (A/B/C/D) 449,416 114 18 E n e r g y t o t h e W o r l d