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ABSTRACT
The Yemen LNG Project is on its way now for two years. The paper focuses on the
technical part of the substantial efforts carried out so far by Yemen LNG Company, from
Project Definition through the Call for Tenders Documents.
RESUME
Le projet GNL Ymen est maintenant ltude depuis deux ans. La prsentation est
centre sur la partie technique de limportant travail ralis par la Ymen LNG Company,
depuis la dfinition du projet jusquaux documents dappel doffre.
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In January 1997, MOMR, YGC and TOTAL in conjunction with EYLNG, YHLNG,
and YUKONG, plus associates of some of these companies, signed 7 Agreements as
applicable:
The Gas Development Agreement (GDA)
The Upstream Facilities and Services Agreement
The Subscription & Participation Agreement
The Shareholders Agreement
The Upstream Operating Agreement
The Upstream Joint Venture & Shareholders Agreement
The Feed Gas Delivery Agreement
Both the Gas Development Agreement and the Upstream Facilities and Services
Agreement were ratified by the Parliament of the Republic of Yemen, prior to the issue of
a Presidential Decree in March 1997.
The final closing between the initial and new shareholders also took place in March
1997.
As of year-end 1997, the Front End Engineering Design was complete as was the
preparation of the calls for tender packages. The lists of potential tenderers have been
approved by the Board and MOMR, based on completed prequalification process.
2. SHAREHOLDERS
YLNG current shareholders are:
36
26
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3. PROJECT PHASES
The project will be implemented in three phases :
Phase 1 : The Preliminary Phase, comprising the conceptual design work and the Front
End Engineering Design and preparation of the calls for tenders
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4. PROJECT DESCRIPTION
4.1. The Fields / The Upstream Facilities
Under a Production Sharing Agreement(PSA) with MOMR, Yemen Exploration and
Production Company (YEPC) - the Upstream Operator - is currently operating the fields
of Block 18 , located in the Marib area, approximately 190 km East of Sanaa.
The gas is processed for LPG extraction and condensate C5+ recovery, prior to reinjection, at the production units located at Alif Central Processing Unit (CPU) and at
Kamil Processing Unit (KPU).
Out of the 26 000 bpd of LPG currently produced, 11 000 bpd supply the current local
market, and the surplus is re-injected with the treated gas.
The field reserves have been certified by the certifying independent agent DeGolyer
and MacNaughton, who confirmed that the reserves were ample to support the Project.
A gas analysis campaign performed during the 1996 spring has shown a gas of good
quality, ideal as liquefaction plant feed:
low nitrogen
low carbon dioxide
no hydrogen sulfide nor sulfur components
no mercury
A total of about 2 100 MMscfd (stream day) of gas are currently produced from 15
fields in the Marib area, with the great majority (95 %) coming from major fields: Al Raja
(condensate gas field), Kamil (oil field), Azal (oil field) and Alif (oil field). Some other
smaller gas accumulations, already delineated but not developed yet, will be put on
production at a later stage according to a Long Term Gas Delivery Plan which is being
performed.
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Out of these 2 100 MMscfd, approximately 2 000 MMscfd are re-injected into
different dedicated reservoirs, of which:
1600 MMscfd are processed through four Natural Gas Liquids (C3+) extraction
plants: one lean oil absorption plant and one cryogenic extraction plant at the CPU and
two cryogenic extraction plants at the KPU
400 MMscfd are by-passing these NGL plants.
All along the project life, upstream facilities will be installed and/or modified to meet
the LNG project requirement with respect to the quality and quantity of the feed gas.
At the early stage of the project, the required new Upstream Facilities were identified
as follows:
drying of the NGL Cryogenic plant by-pass (mole sieve unit) in order to avoid any
water condensation in the main line,
minimization of C5+ in the LNG feed gas by processing all or a portion of currently
by-passed gas.
letdown stations in order to deliver the feed gas at the delivery point at sufficient
pressure to enter the mainline,
2 metering stations for custody transfer,
flaring facilities,
all necessary ties-in, manifolding and interconnecting piping.
The studies / modifications to the upstream facilities are performed by YEPC, but at
YLNG costs. Currently, YEPC is performing the studies which are part of the approved
YEPC 1997 Work Program.
4.2. The Pipelines
The project will include three pipelines that will traverse widely varied topography and
elevations:
For the 2 liquefaction train LNG Plant, the 320 km long, 36 diameter Main Line
will transport feed gas from KPU to Bal-Haf at an initial flow rate of approximately
900 MMscfd. Additional flow rate for a potential third liquefaction train at Bal-Haf
can be obtained with the installation of an intermediate booster compression station
located near Mikrab, 40 km North East from Ataq.
Associated with the Main Line, the 26 km long, 20 diameter Transfer Line
transports gas between CPU and KPU through a flat desert area of sand dunes at a
flow rate corresponding to the requirements of the two train LNG plant.
The 200 km long, 14 diameter Spur Line will transport, for MOMR use, gas from
CPU to a delivery point North of Sanaa at an initial flow rate of 100 MMscfd and
with an ultimate potential flow rate of 250 MMscfd by installing future intermediate
compressor stations.
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The pipeline parameters and block valves will be controlled by a System Control And
Data Acquisition (SCADA system); a fiber optic cable installed parallel to the pipeline will
provide communication links.
The electrical power needed for emergency shut down valves, SCADA system, and
permanent cathodic protection by impressed current, will be supplied, for the extremity
sections, respectively from CPU, KPU and the Bal-Haf plant. For each intermediate block
valve station, thermo electric generator units will be installed.
4.3. The LNG Plant
The LNG Plant will be constructed on a 120 hectare site at Bal-Haf.
It will be fully self supporting, independent of any local infrastructure and will include
administrative buildings, process facilities, utilities, offsites and a marine terminal.
Admin Zone
The administrative zone includes a group of buildings, among which are:
administrative building
canteen
medical center
training center
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Dehydration
Liquefaction system
LPG Fractionation for refrigerant make-up and C5+ removal.
Prior to liquefaction, the carbon dioxide content of the natural gas will be reduced to
50 ppmv in an amine type acid gas removal unit. Water content will be reduced to 1 ppmv
in a molecular sieve unit to prevent any freeze out in the cryogenic sections of the plant. A
mercury guard bed will be installed to ensure removal of any trace amounts of mercury,
although none has been detected in the feed to date.
The liquefaction process is based on Air Products and Chemicals, Inc. (APCI)
Propane / Multi Component Refrigerant (MCR) process, which requires a propane
refrigerant cycle multistage centrifugal compressor driven by a Frame 7 - size gas turbine
and a centrifugal / axial compressor for the mixed refrigerant liquefaction cycle, also
driven by a Frame 7 - size gas turbine.
The overall refrigerant power required for a train of 2.65 Mtpa is approximately
115 MW, of which 66 MW are required for the liquefaction cycle.
As a component of their license, APCI are also supplying the spool wound Main
Cryogenic Heat Exchanger (MCHE) for gas liquefaction.
Utilities Area
To support the operation of the LNG Trains, the following common facilities are
required:
Flare systems
Electrical power generation - main and emergency
Cooling media
Heating media
Fuel systems
Nitrogen generation
Compressed air
Fire protection systems
Fresh water
Telecommunications
Surface drainage
Direct sea water cooling will be used, with a sea water flow of 60 000 m3 per hour, for
the two trains. Low pressure steam will be used as heating medium.
Three Frame 6 power generation sets will be installed to supply the power required for
plant operations. The fuel gas required will be supplied from the LNG trains and by the
boil off gas from the storage area. Fuel gas demand represents 10 to 12 % of the total gas
feed to the plant.
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Storage
LNG produced will run down to two storage tanks at a temperature of - 162 degree
Celsius, with a higher heating value (HHV) in the 1 050 / 1 110 Btu/scf range.
The LNG net storage capacity, based on transportation studies, is 250 000 m3. Two
125 000 m3 tanks will be installed.
For safety reasons, we have selected above ground full containment tanks with either a
concrete outer shell and a free standing 9% Nickel alloy inner tank, or a stainless steel
membrane in a concrete outer shell.
Marine Facilities
All the components of a self sufficient LNG marine terminal will be installed, including
a turning basin, a service vessel / tug berth and a marine base. A single berth will be
installed to accommodate LNG carriers in the 45 000 / 140 000 m3 range.
The location, orientation and design of the berth have been considered with due
attention to weather, sea and meteorological conditions, mooring breasting, tug assistance,
access and departure in case of emergency.
Marine Off-loading facilities (M.O.F.) will also be installed for unloading of equipment
for the LNG plant during the construction period.
Off Plot Facilities
In addition to the above, an air strip for Dash 7 type planes, available take-off
950x45 m, for normal day light shift rotation, will be installed at a short distance, North
West of the Plant.
An access road will link the main Al Mukala / Aden road to the LNG Plant and to the
Permanent Camp
Pre investment for a Third Train
In view of a potential 50% increase in the capacity of the liquefaction plant, the
possibility of installing a third process train and a third LNG storage tank, with associated
utilities and plant layout is taken into account in the current design.
Permanent Camp
Its location is on the Bal Haf North Rock situated to the West of the access road to
the LNG Plant, at the crossing with the main AL Mukalla / Aden road, close to the
Construction Camp area of the LNG Plant.
The Operating Organization is not yet finalized, but for current design purposes, it is
assumed that approximately 700 persons will be accommodated in the Permanent Camp,
with 23 000 m2 floor space on a 58 hectare area.
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5. CONTRACTING/IMPLEMENTATION
One of YLNG objective is to finance the Project through non recourse, Project
financing credits and Export Credit Agencies (ECAs).
5.1. General
During the preparation of the call for tender for the Front End Engineering Design
(F.E.E.D.) of the whole facilities (pipelines and liquefaction plant), the following
contracting strategy was envisaged for the construction phase of the works:
to select EPC contractors who will provide their specific LNG experience to design,
procure, supply, erect and commission fit-for-purpose facilities,
to obtain cost effective implementation through competitive bidding,
to maximize non recourse financing by providing to the banking community the
comfort of a frozen project cost guaranteed by sound and capable contractors.
In order to reach these objectives, the following actions have been / will be
implemented:
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refrigeration compressor manufacturers have already been pre-qualified and the call
for tender is in preparation; the issue of this call for tender will be coordinated with
the issue of the LNG Plant call for tender. It is envisaged that separate quotes will be
requested from the turbine manufacturer and from the compressor suppliers, but
with a complete guarantee of the whole package from the compressor supplier.
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the call for tender for the supply of the Main Cryogenic Heat Exchanger (APCI) is
under preparation. The issue of this call for tender will be coordinated with the issue
of the LNG Plant call for tender.
a questionnaire has also been sent to line pipe manufacturers, before issuing the
corresponding call for tender.
In order to minimize the interfaces between YLNG and contractors, these early
contracts will be assigned to the corresponding main EPC contractor.
Permanent Camp
Due to the characteristics of an urban type development, the design and construction
of the Permanent Camp will be done independently of the lump sum EPC contract for the
LNG Plant.
This will allow for taking full benefit of the existence of local resources, with an
evolutive contractual strategy, depending upon the findings of the local contractor surveys
still to be performed, and upon the results of the different calls for tender. Contracts will
be awarded per trade or through a Main Construction Contractor. This will be assessed
during the Detailed engineering / Tender period.
A step like approach will be implemented for the Permanent Camp development:
These different periods will be managed and controlled by the Project Task Force,
with the help of ad-hoc consultants, i.e., 2 Architects / Urban Planners and their
specialized engineering associates. There will be one consultant for Design and Detailed
Engineering, and another, drawing on Yemeni cultural resources, for providing
architectural support, cultural and local inputs, and for assisting YLNG in construction
supervision.
LNG Carriers
Options are being considered by the Marketing Committee for sale of LNG, F.O.B,
C.I.F. and ex ship basis (refer to corresponding definitions in the narrative to be developed
by the shipping group).
For the C.I.F sales, it will be the responsibility of the Shipping committee to develop
the corresponding implementation strategy and determine the organization, resources,
schedule and budget required.
E.P.C. Contract Implementation and Oversight
In addition to their normal EPC activities, contractors will have to implement all the
actions detailed in the Procedures which will be part of the E.P.C. contracts, in particular
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those related to Quality Assurance (QA), Health, Safety and Environment (HSE) and
Project Control.
Although it is contractors responsibility to guarantee and to demonstrate that the
installations they design and construct meet the specified specifications and standards, the
Project Task Force will monitor all their activities through detailed engineering,
construction, pre-commissioning and commissioning. In addition, and according to the
Inspections and Quality Assurance Plans, the Project Task Force will perform audits
relative to such activities.
All commissioning activities will be performed by systems, with a specific hand-over
mechanism whereby such systems, and relevant documentation, are handed over by the
contractor to the Project Task Force, with YLNG Operation team as a witness. The whole
facilities will be transferred to YLNG (Operations) care and custody when the last handover certificate is signed.
6. QUALITY ASSURANCE
Quality Assurance (QA) addresses the implementation of a disciplined approach
toward all activities affecting quality, including verification, where appropriate. It ensures
that each task has been satisfactorily completed, that there is documentary evidence that
the required quality has been achieved and that this level of quality has not been
inadvertently undermined by subsequent change(s).
The concept of quality is normally associated with fitness for purpose, as
evidenced by demonstrable compliance with an approved specification.
Since QA involves all activities affecting quality, very few activities are exclusive to
QA personnel. But the primary responsibility for quality rests with the party responsible
for the work.
To avoid duplication of QA functions within the Project Task Force and with
contractor organizations, and to encourage contractors to exercise fully their contractual
obligations in respect of QA, the Project QA function and its degree of intervention in the
main contractors QA business will be reduced to the minimum consistent with
establishing and maintaining effective quality systems and effective Company auditing
activities.
This requires that only contractors with strong, independent and suitably staffed QA
functions will be considered for the Project. All major contractors will be required to
submit quality plans showing their proposed QA system, the procedures to be used, the
responsibilities and authorities inherent in them and the quality activities and resources to
be allocated. This includes QA/QC of all design activities and change control.
Such plans must include the contractors own schedule of internal reviews and audits,
which will be monitored by the Project QA for both performance and effect.
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safety objectives
environmental quality objectives
acceptance criteria
legislative requirements
statutory / non-statutory requirements
risk assessment
environmental impact assessments
safety requirements
management of changes
The Project Team has already completed, with the help of various survey contractors
and consultants (both for the Pipelines and for the LNG Plant) the Environmental Base
Line Surveys and the Environmental Impact Assessments. Mitigation measures have been
identified and incorporated into the design.
9. CURRENT ORGANIZATION
Incorporated in Bermuda in 1995, YLNG opened Company Offices in Sanaa in 1997
where staffing will be greatly expanded for management of activities relating to Phase 2
(the Construction Phase) and for Phase 3.
During Phase 1, certain services are being provided for YLNG through the lead
shareholder with a team consisting of secondees from the various shareholders under the
direction of a General Manager.
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