Modularization Study Presentation

RELP El Palito Refinery Expansion Project
MODULARIZATION STUDY PRESENTATION

MAY 2009
MODULARIZATION STUDY
PRESENTATION
Milan – MAY 25th & 26th 2009.
1
MAY 2009
PHASES OF WORK
Feb 2009 March 17th April 27th May 18h June 2009 Sept 2009
March 24th May 26h
EPCm Proposal EPCm Proposal

STICK BUILT MODULAR
EXECUTION EXECUTION
Strategy
Basis to Development of Conceptual Project
move to Execution
modules
Outlook to Outlook to
PDVSA PDVSA
Preliminary Modularisation Refined

Modularisation
Module Feasibility Module
Philosophy
Definition Philosophy Definition
PAR 162 PAR 410

PAU 224 PAU 194
Max Wgt 2050t Max Wgt 896t
2
MAY 2009
ESTIMATE DEVELOPMENT
The estimate was developed based on very preliminary information

no BEDP was available no project plot plans nor PFD’s
Past project plot plans used instead volume of defined modules
proportion of manhours in modules / left stickbuilt and weights
preliminary BOQ refined weights
3
MAY 2009
MODULE DEFINITION
MODULE DEFINITION CRITERIA

Developed preliminary module definition criteria based on economic and
logistics parameters
On-site labour cost and availability – impact to schedule if stick built, impact
to cost. This gives strength of drivers to move manhours offsite and
therefore impacts module definition.
4
MAY 2009
Manpower curves for stickbuilt and modular execution
St i ck Bui l t vs Modul e vs St i ck Bui l t ( Mecha. 8, 000 max)

Stick built
manpower curve
20000
18000
Stick built
16000
manpower curve
14000 based on <8000
skilled workers
12000 Ser i es1
available
Ser i es2
Manpower
Ser i es3
10000
(duration
Ser i es4 13
Ser i es5
8000 months
Ser i es6
longer)
6000
4000 Modular execution,

<8000 site skilled
2000
workers available
0 and completes on
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 schedule
Mont h
5
MAY 2009
MODULE DEFINITION

On-site labour cost and availability – impact to schedule if stick built, impact
to cost. This gives strength of drivers to move manhours offsite and
therefore impacts module definition.
Yard locations giving best value to El Palito project
Ship vs barge
Rack modules legs up vs legs down
Items to group into module vs not (e.g. airfans not on PAR’s)
MODULE BOUNDARIES DEFINED

Started with stick built layouts
Marked up module boundaries grouping together process equipment within
systems where practical / possible
6
MAY 2009
MARKED UP PLOT PLAN SHOWING MODULE TYPES
7
MAY 2009
MODULE DEFINITION
Yard locations giving best value to El Palito project
Ship vs barge
Rack modules legs up vs legs down
Items to group into module vs not (e.g. airfans not on PAR’s)
MODULE BOUNDARIES DEFINED

Started with stick built layouts
Marked up module boundaries grouping together process equipment within
systems where practical / possible
Marked up PFD’s
Note : VAU’s (such as dressed columns and airfans), PAB’s (such as satellite
instrument house, substations and analyzer buildings), VPU’s (such as
heaters, furnaces and vendor skids), considered separately. These items
(and others such as civil pre-cast work) are still essential to reduce
site manhours
8
MAY 2009
MARKED UP PFD
9
MAY 2009
SITE SCOPE vs MODULE SCOPE
MAN HOURS IN MODULES

Based on past project experience, module volumes provide proportion of structural,
mechanical, electrical and instrumentation man hours included in the module vs
remaining in stick built scope.
Total volumes and therefore total weights (not individual module numbers and weights)
important for estimate of man hours, module costs and shipping costs.
Module splits only required later to optimise HL&T costs and planning
ADDITIONAL STEEL REQUIRED

Based on extent of steel structures available in the stick built designs, additional steel
quantities added to package up the module components to enable them to be shipped
from the module fabrication yards to site, transported to their installation location and
installed on site.
MODULE WEIGHT DEFINITION

Module weights then calculated based on SB estimate quantities, proportion of work in
modules and extra steel weight.
Module index refined to define optimum size and weight of modules
10
MAY 2009
MODULE INDEX SUMMARY

Item Data
PAR PAS PAU Total Total Total
Quantity Weight (t) Volume
(m3)
Quantity Weight (t) Volume Quantity Weight (t) Volume Quantity Weight (t) Volume
YARD SOW Code (m3) (m3) (m3)
Y1 FWI 21 23 3 660 43 146 3 118 1 970 22 1 852 19 272 48 5 630 64 388
32 7 1 431 17 064 12 759 7 988 19 2 190 25 052
34 6 897 9 936 14 2 915 28 497 20 3 812 38 433
35 7 1 511 12 096 11 1 536 10 860 18 3 047 22 956
36 4 264 3 456 1 73 840 5 337 4 296
81 10 1 643 19 008 20 1 717 17 541 30 3 360 36 549
82 10 1 429 19 008 8 763 8 952 18 2 192 27 960
83 29 6 526 49 560 5 430 10 752 43 3 786 25 380 77 10 742 85 692
92 14 308 12 454 4 300 10 712 18 607 23 166
FWI Total 110 17 669 185 728 8 548 12 722 135 13 699 130 041 253 31 916 328 491
Y1 Total 110 17 669 185 728 8 548 12 722 135 13 699 130 041 253 31 916 328 491
Y2 TOYO 28 10 3 829 30 312 1 25 560 15 2 169 15 160 26 6 024 46 032
29 12 2 762 29 214 3 48 1 071 20 772 7 210 35 3 583 37 495
51 2 258 2 250 1 10 216 4 32 249 7 300 2 715
84 7 548 6 687 6 179 3 972 10 400 4 314 23 1 127 14 972
TOYO Total 31 7 397 68 463 11 262 5 819 49 3 374 26 933 91 11 034 101 214
Y2 Total 31 7 397 68 463 11 262 5 819 49 3 374 26 933 91 11 034 101 214
Y3 TOYO 96 260 18 608 382 617 260 18 608 382 617
TOYO Total 260 18 608 382 617 260 18 608 382 617
Y&V 53 7 1 077 1 383 7 1 077 1 383
54 2 161 2 016 1 10 216 2 47 520 5 218 2 752
55 4 629 840 1 244 288 5 874 1 128
56 1 135 480 1 135 480
58 2 32 720 2 32 720
Y&V Total 9 957 4 056 1 10 216 10 1 368 2 191 20 2 335 6 463
Y3 Total 269 19 565 386 673 1 10 216 10 1 368 2 191 280 20 944 389 080
Grand Total 410 44 632 640 864 20 820 18 757 194 18 442 159 165 624 63 893 818 786
11
MAY 2009
MODULE FABRICATION AND ASSEMBLY

MODULE FABRICATION AND ASSEMBLY COSTS
Module fabrication and assembly costs were developed based on historical fabrication
rates and tonnage of modules.
Yards in the Far East currently provide best value
AG&P module fabrication rates used as have recently been shown to provide best value
for module fabrication for a similar project and similar shipping distances
NUMBER OF YARDS
Based on the total tonnages of modules, the most cost effective module yard split is to
utilise 3 module yards
Total tonnage of modules to be fabricated in the yards is 62,900 tonnes. Duration to
fabricate and assemble is 18 months => ~14,000 tonnes per yard per year < 22,000
Te/annum practical capacity of AG&P sized yards.
YARD SPLIT FOR PRACTICAL EXECUTION

The client may have a preference to fabricate a proportion of the modules in country.
In this case, fabrication resources should preferably be secured outside the local labour
pool with good water access for barge delivery of completed modules to site.
The interconnecting piperack would be a good candidate for this work and designs
should then reflect local capabilities for fabrication detailing, fabrication and assembly.
12
MAY 2009
MODULE FABRICATION AND ASSEMBLY IN VENEZUELA
POTENTIAL MODULES / PRE-ASSEMBLY WORK THAT CAN BE UNDERTAKEN IN

VENEZUELA
Fired heaters
Dressed vessels
Airfan modules including piping
OSBL PAR’s
ADD PROPORTION OF WORK THAT CAN BE DONE IN VENEZUELA AS % OF TOTAL

CAPACITY IN MARACAIBO (as JGC project is using significant capacity in the east of
Venezuela)
13
MAY 2009
LOGISTICS OF MODULE SHIPPING TO VENEZUELA
Budgetary Shipping Costs - Delivery of modules to

SHIPPING COSTS RELP Project (based on total module quantities)
The comparative
$120
cost of shipping
modules from
$100
various yards by
barge and / or ship $80
to Venezuela
Ships will be LOLO $ million $60 Shipping Cost
and have own gear
29 shipments of $40
modules required
$20
over a 14 month
delivery period $0
Modules shipped
ip
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14
MAY 2009
15
MAY 2009
SHIPPING OFFLOAD CYCLE

Average offload times for average modules (~100 tonnes each) from Lift-Off Heavy Lift ship
Module 1 Hook up module 20
SHIP
Lift module to FAS 30

Land on transporter and unhook 15
TNPT
Lash and transport to laydown 40

Offload in laydown and return to ship 30
Module 2 Hook up module 20 Finish to finish link
SHIP
Lift module to FAS Float 30

TNPT

Module 3 Hook up module 20 Finish to finish link
SHIP
Lift module to FAS Float 30

TNPT

Cycle time ~ 85 mins

=> 7 to 8 per day
for 11 to 12 hr days
16
MAY 2009
LOGISTICS OF MODULE SHIPPING TO VENEZUELA

Budgetary Shipping Costs - Delivery of modules to
VALUE TO PROJECT RELP Project (based on total module quantities)
The comparative
cost of fabrication,
assembly and
shipping of
modules from
various yards by Approx fab cost
US$
barge and / or ship Shipping Cost
to Venezuela
Note: US
fabrication data
based on Gulf
Coast costs
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17
MAY 2009
MODULE DELIVERY OPTIONS TO SITE
COST TO SHIP TO SITE VS TRANS-SHIPMENT AT PUERTO CABELLO

Additional barging costs for modules and major equipment ~$47 million
$65 million
$65 million
+$47 million
18
MAY 2009
JETTY OPTIONS AT SITE
1. ADD LOLO AND TRANSPORT DELIVERY CAPABILITY TO PET COKE

JETTY
19
MAY 2009
2. REVAMP AND EXPAND EXISTING RORO JETTY PLUS BUILD NEW RORO
AT END OF GROIN OF PET COKE JETTY (Y&V OPTION 6a is cheapest)
20
MAY 2009

Ship Jetty Option Existing RORO Jetty upgrade
1 Additional cost to upgrade the pet coke = $9,300,000 1 Additional cost to upgrade the existing = $5,000,000
export jetty to accommodate module RORO facility to accommodate sufficient
shipments barge traffic to support the project
2 Reduction in stevedoring costs if modules = (2nd order) 2 Cost of transhipping modules and barging to = $27,060,000
and stick built materials are delivered direct site
to the site jetty
3 Reduction in inland transport costs if stick = ($1,500,000) 3 Cost of transhipping major equipment items = $19,800,000
built materials are delivered direct to the site that are not modules and barging to site
jetty
4 Reduction in port storage costs if stick built = (2nd order) 4 Estimated cost of ship demurrage due to port = $3,750,000
materials are delivered direct to the site jetty congestion and barge utilisation congestion
factors
5 Route upgrade costs from the jetty to the = $4,800,000
new construction site boundary
6
7
TOTAL = $7,800,000 TOTAL = $60,410,000
Cost savings for shipping direct to site jetty = $52,610,000
Note: An additional RORO jetty will be required to manage the
volumetric throughput of modules on the project. This additional
RORO jetty has been incorporated into the pet coke jetty groin
and there is therefore no additional cost element needed in this
21
MAY 2009
LOGISTICS
MODULE INSTALLATION
Modules to be installed primarily by crane
Where practical, offsite PAR modules will be installed direct from the
transporter
The total modules per unit plus major equipment items were identified and
an installation campaign planned for each unit.
Lift studies were undertaken for “crane defining” lifts
22
MAY 2009
23
MAY 2009
LOGISTICS
MODULE INSTALLATION
transporter
Lift studies were undertaken for “crane defining” lifts
Number and type of crane locations then determined per unit
24
MAY 2009
25
MAY 2009
LOGISTICS
MODULE INSTALLATION
Modules to be installed primarily by crane inside the process units
transporter
Lift studies were undertaken for “crane defining” lifts to establish crane sizes
required to execute the lifts
Reactor weight is now 744 tonnes which falls within the range of installation
by the main crane. A strand jack lift is therefore not required for this item.
Main crane and secondary crane required to work in tandem for installation
of dressed vessels
26
MAY 2009
LOGISTICS
MODULE INSTALLATION
transporter
Lift studies were undertaken for crane defining lifts
Number and type of crane locations then determined per unit
Installation campaign durations for main and support cranes were then
developed for each unit (Crane type 2 not shown)
Lift
Module count Equipment count Crane type 1
System
Days to Days per Total Total
Other Days Days Number of Total days
Unit PAU PAR PAS VAU VPU Airfan Heaters mobilize position weeks in months in
equipment lifting lifting positions in unit
into unit move unit unit
2800 17 5 1 26 0 4 0 4 4 75 5 2 89.0 14.8 3.4
2900 20 8 3 20 0 4 0 0 4 71 8 2 91.0 15.2 3.5
3400 11 3 0 6 0 3 0 0 4 26 2 2 34.0 5.7 1.3
3500 9 3 0 5 0 3 1 0 4 22 1 2 28.0 4.7 1.1
3600 1 2 0 1 0 0 0 0 4 5 0 2 9.0 1.5 0.3
5100 4 1 0 7 0 0 0 0 4 19 1 2 25.0 4.2 1.0
5300 6 0 0 7 0 0 0 9 4 20 2 2 28.0 4.7 1.1
5400 2 1 1 1 0 0 0 0 4 6 0 2 10.0 1.7 0.4
5500 1 2 0 0 0 0 0 0 4 3 0 2 7.0 1.2 0.3
5600 0 1 0 5 0 0 0 0 4 11 0 2 15.0 2.5 0.6
5700 0 0 0 1 0 0 0 0 4 2 0 2 6.0 1.0 0.2
5800 0 1 0 3 0 0 0 1 4 7 0 2 11.0 1.8 0.4
8300 37 17 5 20 0 9 2 2 4 99 6 2 115.0 19.2 4.4
8400 10 4 6 8 0 8 0 7 4 36 9 2 58.0 9.7 2.227
9200 3 9 0 1 0 0 0 0 4 14 1 2 20.0 3.3 0.8
9600 0 87 0 0 0 0 0 0
MAY 2009
LOGISTICS
MODULE INSTALLATION
Total crane months were then developed for each crane type required
The total duration of the Heavy Lift campaign (to support the overall
construction schedule) was then used to determine the number of
installation teams required
Lifting schedule by Crane.
Months
Unit 1 2 3 4 5 6 7 8 9 10 11 12 13
9600 Interconnect unit Crane type 1
Crane type 2 TW O CRANES WORKING
8300 Delayed Coker Crane type 1
Crane type 2
9200 Flare Crane type 1
Crane type 2
8100/8200 Vacuum/Crude Crane type 1
Crane type 2
5300 Raw Water Crane type 1
Crane type 2
3200/3300 Amine regeneration Crane type 1
Crane type 2
3400 Sulfur recovery Crane type 1
Crane type 2
5600 Plant/Instrument Air Crane type 1
Crane type 2
5800 Nitrogen Crane type 1
Crane type 2
2800 VGO Hydrotreatment Crane type 1
Crane type 2
2900 Diesel Hydrotreater Crane type 1
Crane type 2
8400 CN Hydrotreater Crane type 1
Crane type 2
3500 Hydrogen Production Crane type 1
Crane type 2
2100/2200/2600 CCR Crane type 1
Crane type 2
5100 LPG Fractionation Crane type 1
Crane type 2
*smaller process units omitted for clarity.
28
MAY 2009
LOGISTICS
PATH OF CONSTRUCTION
The path of
construction
was
developed to
support the
overall
schedule and
give
preliminary
direction to
module
delivery
priorities.
29
MAY 2009
LOGISTICS
MODULE TRANSPORT
SPMT’s will be used to transport all the modules from the jetty to the
delivery location, and will install those modules to be installed direct from
the transporter.
Sufficient axles have been included in the estimate to provide 1 set of
transporters to feed each of the two installation work-fronts, plus one
additional set to offload ships and take modules to the staging area. 3 Total
Individual transporter units can be coupled together to accommodate the
largest loads (744 tonne reactor and modules up to 900 tonnes).
Loads exerted by transporters on the jetty and haul roads will not exceed
7 Te/m2 compared with x for maintenance of jetties.
30
MAY 2009
LOGISTICS
MODULE TRANSPORT
31
MAY 2009
LOGISTICS - COST
COST ESTIMATE DEVELOPMENT

Equipment and labour rates were secured for the mobilasation,
demobilisation and monthly hire of cranes, transporters, direct and indirect
labour and all ancillary support equipment required to undertake the total
work scope of receiving from ship’s gear, transporting, staging where
necessary and installing all modules and major items of equipment.
An equipment schedule, manpower plan for direct labour and indirect labour
and schedule of all preliminary cost items was then developed giving the
total cost to provide these services.
32

Modularization Study Presentation - PDVSA-FOSTER WHEELER-ToYO-Y&amp;V

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RELP El Palito Refinery Expansion Project

Milan – MAY 25th & 26th 2009.

March 24th May 26h

EPCm Proposal EPCm Proposal

Preliminary Modularisation Refined

PAR 162 PAR 410

The estimate was developed based on very preliminary information

MODULE DEFINITION CRITERIA

Manpower curves for stickbuilt and modular execution

St i ck Bui l t vs Modul e vs St i ck Bui l t ( Mecha. 8, 000 max)

4000 Modular execution,

MODULE DEFINITION CRITERIA

MODULE BOUNDARIES DEFINED

MARKED UP PLOT PLAN SHOWING MODULE TYPES

MODULE BOUNDARIES DEFINED

SITE SCOPE vs MODULE SCOPE

MAN HOURS IN MODULES

ADDITIONAL STEEL REQUIRED

MODULE WEIGHT DEFINITION

MODULE INDEX SUMMARY

MODULE FABRICATION AND ASSEMBLY

YARD SPLIT FOR PRACTICAL EXECUTION

MODULE FABRICATION AND ASSEMBLY IN VENEZUELA

POTENTIAL MODULES / PRE-ASSEMBLY WORK THAT CAN BE UNDERTAKEN IN

ADD PROPORTION OF WORK THAT CAN BE DONE IN VENEZUELA AS % OF TOTAL

LOGISTICS OF MODULE SHIPPING TO VENEZUELA

Budgetary Shipping Costs - Delivery of modules to

SHIPPING OFFLOAD CYCLE

Lift module to FAS 30

Lash and transport to laydown 40

Lift module to FAS Float 30

Lash and transport to laydown 40

Lift module to FAS Float 30

Lash and transport to laydown 40

Cycle time ~ 85 mins

LOGISTICS OF MODULE SHIPPING TO VENEZUELA

MODULE DELIVERY OPTIONS TO SITE

COST TO SHIP TO SITE VS TRANS-SHIPMENT AT PUERTO CABELLO

JETTY OPTIONS AT SITE

1. ADD LOLO AND TRANSPORT DELIVERY CAPABILITY TO PET COKE

JETTY OPTIONS AT SITE

JETTY OPTIONS AT SITE

COST ESTIMATE DEVELOPMENT

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