Priolo Ethylene Plant Upgrade -...
Transcript of Priolo Ethylene Plant Upgrade -...
a cura di: Ing. Ivano Giannoni (Versalis)
Ing Francesco Gravame (GE NP)
Ing Riccardo Fabbri (GE NP)
Milano - 10 dicembre 2014
Priolo Ethylene Plant Upgrade
Imagination at work.
IPMA Milano 10th Dec’14
Priolo Ethylene Plant Upgrade IPMA GOLD Award
GE Oil & Gas today From extraction, to transportation, to end use …
3
Subsea Systems Subsea production
systems
Turbomachinery Solutions
LNG, on- and offshore, pipeline
Downstream Technology Solutions
Refinery and gas distribution
Drilling & Surface BOPs and risers,
onshore trees,
Artificial lift
~45,000 employees
Delivering customer solutions by applying
systems-level engineering across the value chain
Measurement & Control Controls, diagnostics
Downstream technology focus
DRAFT Oct 3 4
PRODUCTS &
SERVICES
High Speed Recips
Reciprocating Compressors
Pumps & Valves
Steam Turbines
Compressors
Small-Scale LNG 25k – 600k gal/day
CNG In A Box 10k – 21k GGE/day
Services & Upgrade
SEGMENTS
Industrial
Processin
g
Gas Distribution
& Processing Small CNG
& LNG
Industrial Power
Generation
Ammonia Ethylene
LDPE / HDPE
Urea Refinery
Processing
2006
Beyo
nd
GE
in
sta
lled
base
G
E i
ns
tall
ed
bas
e
200
8
2009
201
0
2011
2012
2013 Large rehabilitation
projects
Beyond F2F
• Engine & Modular
Replacement F2F:
• Rebundle
• NOx
Upgrade Evolution
Plant Upgrade
(Priolo) 2014
OEM System Integrator Plant
Process
GE &IPMA Project Excellence Award
2009
Statfjord - Upgrade
PM: Roberto Zavani
PRIZE
2010
Darwin - Upgrade
PM: Francesco
Gravame
PRIZE
2011
Qatar Gas - CSA
PM: Carlo Gragnoli
AWARD
2012
ALNG - CSA & TAG -
TM
PM M. Ferri & F.
Giuntini
FINALIST
S
2013
Gorgon - TM
BRONZE
Insert Image
2014
Priolo – DTS
Upgrade
PM: Riccardo Fabbri
GOLD
Operational Excellence
Laser-focused on safety and quality
for customers; project execution
and returns
Products & Services
Including upgrades to
optimize production
efficiency in Ethylene
plant
People and Expertise
Investing in our people, dedicated PM Academy and training
path driving execution
Project Execution Timeline
© 2014 General Electric Company - All rights reserved
© 2014 General Electric Company - All rights reserved
Abstracts & Articles Reflective learning Promoting Technical Reference
Contests & Awards Benchmarking Awarding External Recognition
Conventions & Exhibitions Promoting Touch-base with Market Sharing experience
Special Initiatives
Our Journey in IPMA Project Excellence
Application Report
5th May
4th Feb
23rd June
Assess. & Site visit 30th Sep
Award ceremony
Project Management
1. Project Objectives
2. Leadership
3. People
4. Resources
5. Processes
Project Results
6. Customer Results
7. People Results
8. Other parties involved
9. Performance & Results
Project Team &
Sponsor
GPO & Senior Mgt
Customer - Suppliers
Finance - Marketing
Sourcing & MFG
HR – EHS
Quality & MBB
Gala Evening
& Award
Workshops
World Congress in Rotterdam
Teamwork for
Winners’ club
Congress
attendance
© GE Proprietary & Confidential. Internal Use Only. Not for Distribution
Project
Presentation
Feedbacks & Carry-outs
Team di Progetto Occasione di crescita e confronto Occasione di visibilità
Coinvolgimento Diretto Diretto Coinvolgimento di fornitori strategici Diretto Coinvolgimento del cliente ed utente finale Diretto Coinvolgimento di funzioni esterne
Cultura d’Impresa Sugli impatti nella propria Azienda Sugli impatti sul Business e sul Mercato Sulla Comunità Esterna e sull’Ambiente (CSR)
Excellent performance in all aspects, management of the planning, execution and results (from the process).
Go beyond or even against known standards, methods, tools and techniques
Beyond the actual project goals, they enrich businesses, societies, environment
IPMA Excellence Definition
Versalis The voice of customer
Title or Job Number | XX Month 201X See tutorial regarding
confidentiality disclosures.
14
With an integrated industrial platform, versalis – the Italian leading chemical company – offers to the market an extensive portfolio of intermediates, polyethylene, styrenics, elastomers and a new range of bio-based chemicals
Versalis (Eni) at a glance
Headquarters Milan
Plants: 9 in Italy Brindisi Ferrara Mantova Porto Marghera Porto Torres Priolo Ragusa Ravenna Sarroch
4 rest of Europe Grangemouth (UK) Dunkerque (FR) Oberhausen (D) Százhalombatta (HU)
5 R&D centers in Italy
Sales network 18 branch offices and 2 trading companies in Asia (Shanghai and Mumbai)
Licensing and strategic partnerships
5,600 employees
80% Italy, 20% abroad
71 production units for a total
production of 5.8 mln ton 335 patents
5.9 bln € turnover
Versalis business overview
Olefins Aromatics Derivatives Polyethylene Styrenics Elastomers
Ethylene
Propylene
Butadiene
Raffinate 1
Carbon Black
Feedstock
Toluene
o-m-p-Xylene
Pseudocumene
DCPD
Benzene
Phenol
Acetone
Alphametil-
styrene
Cyclohexanone/
Ka-Oil
EB/Styrene
LDPE
LLDPE
VLDPE
HDPE
EVA
GPPS
HIPS
EPS
SAN
ABS
e-SBR
s-SBR
BR
TPR
EP(D)M
NBR
Latex
Monomers and Intermediates Polymers
turnover: € 5,9 bln – production: 5,8 m ton
production to sales: 3,8 m ton
among leading players 6nd in EU
2nd in EU for EVA 3rd in EU 2st in EU
capacities and
market position
end markets
Key factors boosting Priolo Cracking Unit modification
• Increase one production line capacity
• Improve energy index
• Improve plant availability & maintenance interval extension
Versalis has recently been refocusing its strategies on a more market-oriented and diversified
product portfolio, emphasizing R&D, Licensing and enhancing global presence.
As part of its new strategies, Versalis has made changes to its infrastructures and production
facilities. The following describes the changes made to overhaul its largest Cracking Unit at
the Priolo site.
Modifications included state-of-the-art upgrading of components, systems and controls in order
to:
Priolo: Project Description
Planning
• Development of over 600.000 direct m.h. for Plant and
Machinery modification works to be performed during
facilties 10-years m.o. planned to be performed
September – mid November 2013
• FID Q1/ 2012
• Main Contractor Order June 2012
• Machinery order December 2012
• Field works start mid August 2013
• Plant start up end November 2013
PRIOLO
Main modification according to feasibility/basic
studies performed by Main Contractor:
Machinery modification
Charge gas compression system upgrade
Ethylene compression system upgrade
Propylene Syeam turbine replacement
Process Modification
Ethylene Splitter and Demetanizer trays replacement
Replacement of Ethylene splitter condenser with
Core-in-Kettle technology
Constraints
Scope Plant Location
Priolo: general view of plant modification
Item Modified
NEW Item
Item Revamped PROPYLENE TRAIN
ETHYLENE TRAIN
Item Modified
NEW Item
Item Revamped
Priolo: project challenges
• Machines installed at the first mezzanine deck out of
reach of any mobile crane.
• Roof composed by air cooler and air condenser cannot
be removed
• Existing lifting crane both in hot and cold compression
area while perfectly fit for maintenance are not suitable
for handling assembled machines.
• Lube and Seal Oil console on ground floor found
completely embedded in concrete, and again out of
reach of any type of Crane
Machines
location
Conclusions
• Teamwork between GE and Versalis Engineering &
Operation Teams...key to success
• Concurrent Engineering instrumental to flawless design
and project execution
• Deployement of Engineering Teams at site for the entire
duration of the project
• Early Design for installation and availability fully
exploited and applied