CCC CASE STUDY
GASCO IGD Habshan-5 Project
15/12/2011
1
Contents
1.
Introduction
2.
Ongoing Project Narratives
3.
Ongoing Project Status
A.
HSE Status
B.
Project S-Curve
C.
Project Photos
4.
3D History & Background
5.
C3D Implementation
A.
Vision & Principle
B.
U/G Piping
C.
Structural Steel
D.
Equipment
E.
A/G Piping
F.
C3D Implementation on Planning
G.
Other
2
1- Introduction
Speaker Introduction
3
2. Ongoing Project Narratives
Background of the Project
 Economic Growth, Population Increase in Gulf Countries
 Electricity Demand Increase (2 to 3 times more in 2020
in UAE) => Natural Gas, Nuclear Plant are attractive
energy resources.
 UAE is the 5th reserve of Gas in world.
 40％ of remaining Gas is Sour Gas

Sour Gas???
 Contain H2S.
 High Corrosive and Toxic.
 Not developed due to technical/commercial reasons.
4
2. Ongoing Project Narratives
Integrated Gas Development (IGD)
Habshan 5 Process Plant Project
Increase capacity of Gas Treatment, Sulfur and NGL Recovery
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2. Ongoing Project Narratives
 Client ： Abu Dhabi Gas Industries Ltd (GASCO）

Establish 1978

Shared by

Operating Company for Processing Natural Gas and
Associated Gas from On Shore Oil Operation
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2. Ongoing Project Narratives
A）Contract Award
:
B）Contract Amount :
29-July-2009
Lump-sum Portion 4,681 MMU$
(JGC 50％ vs TCM 50%）
C）Contract type
:
EPC+Lump-sum（upto Performance Test）
D）Contractor
:
JGC-TCM Joint Venture
(50/50 Profit AND Loss Share）
E）Duration
:
(1st Phase) : M/C: 42 months
(Jan 2013）
Performance Test 46 months
:
(2nd Phase): M/C: 46 months （May 2013）
Performance Test 50 Months
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2. Ongoing Project Narratives
>> Click Here
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2. Ongoing Project Narratives
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2. Ongoing Project Narratives
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2. Ongoing Project Narratives
BQ
Unit
Concrete
160,000
M3
Burj Khalifa
220,000
１２0,000
Steel
70,000
Ton
Eiffel Tower
10 Towers
18,000
Equipment
80,000
Ton
QE2 (Ship)
One whole ship
30,000
3,200,000
(2,000)
M
(Mile)
Tokyo - Manilla
1879 mile
1,100,000
Elec/Inst
Cables
Reference
Dolphin PJ
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2. Ongoing Project Narratives
Characteristics
 Large Area
: 2 km x 2 km (High Structures, 45m)
 Steel Volume : Pipe rack/Equipment Str with full steel
 Tall Vessels
: Demethanizer > 100 m
 Large Bore and Heavy Pipes:
 Average Size = 8.3 inch (Dolphin = 7.1 inch)
 Average Thick
= 16.4 mm (Dolphin = 7.07 mm)
 PWHT
= 417,000 ID ( 32% of Weld-ID)
 RT
= 577,000 sheet (% OF Weld ID)
 All Cables are Underground in addition to huge networks
of Fire Water, Rain Water and Oily Drainage Lines
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2. Ongoing Project Narratives
Challenges
 JGC / TCM Joint Venture (JGC Leader)
 Mega PJ and Bulky (Bulky, Heavy, Booming, Cold, S/S rich, etc...)
 Very Tight Overall Schedule
 1,300 t/d×4 Train SRU (Biggest Class)
 Gas Treatment = Total 2,150 MMSCFD
 Higher Class Material due to Sour Service



Alloy 825
HIC (Hydrogen Induced Cracking)
Heavy Thickness
 Booming Market in UAE
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2. Ongoing Project Narratives
120,000
100,000
80,000
UAE
CNPP
Chemaweyaat Others
Chemaweyaat Ethylene
Borouge 3 Eth.
GASCO IGD
Ruwais Fertiliser Expansion
Borouge 2 (PE) / (PP)
Umm Shaif Gas Injection
Other PJ
Bab Thamama 'G'++
ADCO/SAS Project (Phase 1)
Shah Gas Development
Takreer Ruwais Expansion
Jul2008 Data
Nov2007 Data
Mar2007 Data
Feb2009 Data
Feb 2009, Data
Chemaweyaat Eth.
CNPP
GASCO
IGD
Jul 2008, Data
Chemaweyaat
Other
60,000
Nov 2007, Data
Bab
Thamama
Borouge 2
40,000
Shah Gas
Umm Shaif
20,000
OTHER PJs
Takreer Exp.
ADCO/SAS
0
Mar2007, Data 2007
2008
2009
2010
2011
2012
2013
2014
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2. Ongoing Project Narratives
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3. Ongoing Project Status
A. HSE
HSE KPI Estimate 93%
 SAFETY KPI
 SAFE MANHOURS = 15.6 Million MH without LTI As
of 23-Nov-2011
 KPIs
-
Fatality = 0
Illnesses / infectious Diseases = 0
LTI Frequency Rate = 0
Severity Rate = 0
Total Recordable Injury Rate (TRIR) = 0.14
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3. Ongoing Project Status
B. Project S- Curve
1
0.9
0.8
0.7
Actual Cumulative
Early Cumulative
Late Cumulative
0.6
0.5
0.4
0.3
0.2
0.1
Overall
Plan : 59.33%
Actual: 57.89%
0
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3. Ongoing Project Status
C. Project Photos
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3. Ongoing Project Status
C. Project Photos
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3. Ongoing Project Status
C. Project Photos
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3. Ongoing Project Status
C. Project Photos
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4. 3D History & Background
3D history in mechanical projects
• Up to early 90’s, 3D models were not
commonly utilized in this part of the world.
Project models were delivered towards the
end of the project in a non metallic
maquette, displayed at a specified location
of the project. Only structures, large bore
A/G piping and equipments were shown in
these early trials.
• U/G activities were completely absent.
• By mid 90’s, 3D models were introduced
to the construction industry but still showing
major structures, large bore A/G piping and
equipment. This resolved many A/G
clashes, facilitated A/G construction but still
showing structure steel as a block and U/G
was completely absent.
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4. 3D History & Background
3D history in mechanical projects
• By 2005, some engineering companies started modeling U/G
civil objects, electrical and piping networks, in addition to detailed
steel structure elements and small bore A/G piping.
• Over and above, 3D modeling completion started to show on
baseline plans of projects where 90% model completion became a
contractual milestone for EPC projects.
• CCC, as explained earlier has utilized its C3D Program to link
the model elements to real life data, again, the time element has
been introduced and our model became live and up to date.
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5. C3D Implementation
A) Vision & Principles
Circumstances
 Cons
 Bulky projects
 Fast track, thus overlap between Engineering, Procurement and
Construction Phases
 Extremely tight budget for office staff especially drawings mark ups
 Shortage of qualified manpower.
 Pros
 Well organized 3D model.
 Design substantially complete.
 No material delivery issues due to early model downloads
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5. C3D Implementation
B) U/G Piping
Vision for U/G Construction
 Literally execute the job in the following sequence :
 Bottom to top.
 South to north.
 No loose ends.
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5. C3D Implementation
B) U/G Piping
Strategy
Bottom to top
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5. C3D Implementation
B) U/G Piping
Multi Disciplines interface
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5. C3D Implementation
B) U/G Piping
Interface and Elevations Complexity
Bottom UP
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5. C3D Implementation
B) U/G Piping
U/G Activities as Represented in the Baseline
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5. C3D Implementation
B) U/G Piping
Tools for U/G
 Geometrical reasoning substitute using C3D.
 Front end loading.
 Multiple discipline simulation.
 Object operation tracking (Talisman).
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5. C3D Implementation
B) U/G Piping
Independent Operation Sequence
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5. C3D Implementation
B) U/G Piping
Combined Operation
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5. C3D Implementation
B) U/G Piping
Building The Relation
Foundation
Most
Shallow
Trenches
Duct Bank
Pressure Pipes
Atmos Pipes
Man-Hole
Deepest
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5. C3D Implementation
B) U/G Piping
Rules
 Every object is identified by its type in the model and
assigned corresponding class in C3D.
 The elevation of object is known from the 3D model.
 The relation between object is established based on their
presence in the volume covering the area.
 Status of every object is available in the progress.
Monitoring system and linked one to one with the 3D object
via C3D.
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5. C3D Implementation
B) U/G Piping
Object Relationship
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5. C3D Implementation
B) U/G Piping
Operation Relation
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5. C3D Implementation
B) U/G Piping
Inputs for Simulation
 The following are input to the simulator:
 All objects within the area to be analyzed.
 Geometrical inter-discipline operation relationship.
 Progress templates for each type of object.
 Crews productivity.
 Available resource and equipment with bench marked
productivity
 Plan requirements.
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5. C3D Implementation
B) U/G Piping
Outputs
 3 weeks look ahead output, per sub-area leader or supervisor.
 Optimal crew composition.
 Current crew productivity control and optimal utilization.
 Greater chances to achieve progress.
 If not achievable, constraints causing short falls are well identified.
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5. C3D Implementation
B) U/G Piping
Actual Tangible Result At Site
 Sub-areas U/G fully completed allowing paving early in the project.
 Smooth access for other disciplines.
 Minimal interference between A/G and U/G activities.
 Cost saving.
Location
C200
C100
C300
Tot
Budget
259
162
100
521
Actual
353
75
40
468
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5. C3D Implementation
C) Steel Structure
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5. C3D Implementation
C) Steel Structure
Steel Structure and Elevations
 Ability to load specific packages in each sub area.
 Packages assigned a green color if released for piping, otherwise red.
 Target spools based on their levels in the case of:


Different crews are responsible for different pipe rack levels.
Scaffolding is not yet present at particular elevations.
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5. C3D Implementation
D) Equipment
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5. C3D Implementation
D) Equipment
 C3D shows the equipments with their current statuses along with the
spools connected to them.
 Once the equipment is released for piping activities a report is issued
containing all the erectable spools connected to that particular equipment.
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5. C3D Implementation
E) A/G Piping
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5. C3D Implementation
E) A/G Piping
A/G Definitions
1. Piping Isometrics: Each pipe line is detailed by at least one isometric which
2.
3.
4.
5.
6.
shows all material, size, weld, and fitting information. The isometric includes all
necessary data identifying the pipe location and where to be installed.
Piping Spool: Piping isometrics are divided into portions to be fabricated on the
ground, then assembled together in its location on site.
Piping FWR: Piping field runs are simply any straight piping whose length is
more than 12 m.
SRV / SIV: Store Receiving Vouchers,Store Issuing Vouchers indicates and
gathers all data of project components (piping, structures, equipment…etc)
including vendor data and material expected / arrival dates.
RFF / RFP : Request for fabrication / painting is a form which gives permission
to start these activities. These reports are one of multi reports used for tracing
material through the different construction phases.
NDT: Non destructive testing is any test on the material where the goal is only
to verify the acceptance of the material to its design purposes.
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5. C3D Implementation
E) A/G Piping
Piping Isometric
Weld
Number
Material Specs
and QTY
Spool
Number
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5. C3D Implementation
E) A/G Piping
Talisman Software
Talisman is an in-house software which simply gathers all the data for piping.
According to the project needs, IT can generate different reports to show the
different statuses for the life cycle of the spool.
Test
Erected
Painted
Fabricated
Release to
Fabrication
Detailed
Engineering
Done
ISO Received
Scope
Status 00 Status 01 Status 02 Status 03 Status 04 Status 05 Status 06 Status 07
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5. C3D Implementation
E) A/G Piping
 3D model linked to live data of the project.
 Components (spools, equip etc) represented with different
colors according to their ‘status’.
 Benefits of 3D model:
 Track progress of the project.
 Extract data of specific components (spools, field material etc..)
 Plan the work front of various disciplines taking advantage of
the components relationship in the model.
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5. C3D Implementation
E) A/G Piping
Hab5 Color Legend
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5. C3D Implementation
E) A/G Piping
The Erectability Study
 Determines perfectly the spools which can undergo
erection and more importantly fitup.
 The role of the erectability study does not stop here.
 It also selects the spools that other departments need to
expedite in order to proceed with line continuity.
 But mainly it targets particular spools that once erected
they give the green light for their succeeding spools,
waiting in the site lay down area, to be erected.
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5. C3D Implementation
E) A/G Piping
Flow Chart: Algorithm of Erectability Study
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5. C3D Implementation
E) A/G Piping
1. Site
 The timeline built on C3D checks for all erected spools and
examines the next ‘n’ spools.
 If the spool is erectable, it’s added into the work order and the
algorithm keeps checking for the next n-1.
 If the spool is not erectable the algorithm stops.
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5. C3D Implementation
E) A/G Piping
Site-2
More than one erectable spools
selected on the same line sequence
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5. C3D Implementation
E) A/G Piping
Complementary Erectability Study
 Selects spools and FR’s in lay down area which do not
have any erected spool for their line continuity, however
their preceding or succeeding spool are also available in
the lay down area or in the final stage of painting.
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5. C3D Implementation
E) A/G Piping
2. Painting
 To increase the work front for site, the ES is applied to
other departments in order to target the spools which will
be most likely available for erection on the week after.
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5. C3D Implementation
E) A/G Piping
3. Fabshop
 The main purpose is to target those spools whose fabrication will
lead to proceeding with line continuity and expanding the work front
for site engineers.
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5. C3D Implementation
E) A/G Piping
Spools Material Received by Month
 To ensure that the material received for spools of one
isometric is not experiencing big delays, the following
timeline assigns a different color for each spool
depending on its material received date.
 In this manner, piping department can monitor the
sequence and position (material spools per level tracking)
of the material received spools.
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5. C3D Implementation
E) A/G Piping
Spools Material Received by Month : Example
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5. C3D Implementation
E) A/G Piping
Work Orders
 Results of the ES are issued every week.
 The work orders
 Comments provided as a punch list.
 Improve coordination between departments.
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5. C3D Implementation
F) C3D Implementation on Planning
Since P3 is loaded with resources in all the schedule activities, we can easily
reload QTY on these activities
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5. C3D Implementation
F) C3D Implementation on Planning
 Engineering can easily identify all information related to
material reserved for fabrication, erection & painting yard.
 Planning can easily identify QTY required on weekly basis
through resources and QTY distribution.
 C3D already identified open fronts unit / area wise for Fab
shop, site and painting.
 Then we can compare what was planned VS what is
achieved on weekly basis, taking into consideration the C3D
study.
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5. C3D Implementation
F) Output of the ES
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5. C3D Implementation
G) Other
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Simulating Results
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End
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