Petrochemicals Capability & Experience
HYDROCARBONS HYDROCARBONS MINERALS,& METALS MINERALS METALS & CHEMICALS
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POWER POWER INFRASTRUCTURE && INFRASTRUCTURE ENVIRONMENT ENVIRONMENT
Corporate Overview WorleyParsons is a leading global provider of professional services to the resources and energy sectors, and the complex process industries. We cover the full asset spectrum, both in size and lifecycle, from the creation of new assets, to services that sustain and improve operating assets. Our business has been built by working closely with our customers through longterm relationships, anticipating their needs, and delivering inventive solutions through streamlined, proprietary project delivery systems. Strong growth continues to characterize our performance both through organic development and through strategic acquisition as we strive to provide tailored services wherever our customers need us.
EcoNomics™ is our range of services and technologies that profitably embed environmental, social and financial sustainability into project delivery, across the asset lifecycle. It is a seamless extension of our established project delivery capability in the key areas of assessment, efficiency, and treatment & mitigation. We are committed to working with our customers to turn their sustainability objectives into good business practice.
Zero Harm is our corporate vision for health, safety & the environment (HSE). We are committed to our vision; it applies to all of our operations, at all times, in all locations, and at all levels of responsibility. We will actively work to align our expectations and behaviors with those required to achieve our vision through a dedication to continuous improvement. The launch of our integrity management framework, OneWay™, enables us to further align and consolidate our global systems and procedures and continue to work with our personnel to reinforce a culture that underpins our drive to achieve our corporate differentiator of industry leadership in HSE performance.
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â–şâ–şHydrocarbons Power Minerals, Metals & Chemicals Infrastructure & Environment
Petrochemicals WorleyParsons’ worldwide presence allows us to unite global capability and local delivery to meet the specific needs of our petrochemicals customers through a wide variety of project delivery services.
40+
types of chemicals and petrochemicals
600+
projects in 30 countries on 6 continents
WorleyParsons has extensive experience in the design of petrochemical units, completing more than 600 projects in over 30 countries. From mega projects in the most challenging and remote locations, to the smallest improvement project next door, we have the capability to support our customers throughout all phases of the project. As a technology-neutral leader with specialists and technologists in petrochemicals, WorleyParsons provides services to our customers beginning with opportunity identification and project development through detailed design, construction, startup, and operations. Our ability to evaluate and work with diverse technologies on an unbiased basis is one of our key strengths. WorleyParsons provides comprehensive solutions to the petrochemicals industry, and our customers can be assured that solutions are managed with responsibility and accountability, supporting their ultimate objective. For all projects, a clear focus is maintained on critical issues such as sustainability; health, safety and environment; budget; schedule; quality; operating reliability; and technical integrity.
WorleyParsons Project Phases
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Capability Overview Olefins WorleyParsons has engaged in the development of 12 new world-scale olefins complexes in six countries on three continents in the last 10 years, with feedstocks ranging from ethane to heavy naphtha. Our team brings a unique blend of technical, managerial, and operating experience to olefins projects that is unsurpassed in the industry. These projects have included conventional crackers and propane dehydrogenation for “on purpose� propylene. In addition, our technology-neutral teams assist with project scope and product definition, licensor selection, site integration, and optimization of utilities and offsites.
Polymers Polymers are the major end-products of the petrochemical value chain and WorleyParsons has the capability to develop world-class polymer plants around the globe. Our breadth of experience encompasses feasibility studies, large capital projects, expansions, revamps, and major grass roots installations. By combining our expertise in olefin and polymer projects, WorleyParsons provides a unique opportunity to enhance the synergy between these plants that form major portions of a Petrochemicals complex. Our polymers project experience includes polyethylene (HDPE, LDPE, LLDPE); polypropylene (homopolymer, random and impact copolymer); polystyrene; poly-methylmethacrylate, and nylon.
Aromatics and Derivatives Maximizing the economic benefit from aromatics production, whether refinery or olefin derived, can have a huge impact on the financial return from a facility. Aromatics and derivative projects, which are critical to the petrochemical value chain, make up a substantial portion of WorleyParsons’ project experience, including one of the largest ethlybenzene (EB)/styrene units ever built. Our project experience includes aromatics recovery from olefin pygas, refinery streams, and chemical units that process recovered aromatics to make everything from ethyl benzene, to phenol-acetone, to bisphenol A.
Speciality and Derivative Chemicals WorleyParsons has essential experience in the design of derivative and specialty units, ranging from acetic acid to xylene crystallization. Our project history ranges from in-plant services to mega projects that involve world-scale process units. Our experience with technologies such as linear alpha olefins, acetic and acrylic acid, methyl methacrylate, acrylonitrile, and others from multiple technology providers, gives us the capability to efficiently and reliably integrate these units into larger complexes.
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Gasification to Syngas In a world of increasing gas and oil prices, petrochemical manufacturers may soon have to find alternative feedstocks. Gasification to syngas opens up the prospect of sourcing many petrochemicals from all manners of hydrocarbon resources. WorleyParsons has experience in the design and construction of gasification process units, including associated CO2 capture, compression and pipeline transport, and the range of issues for deep geological storage or enhanced oil recovery.
Syngas to Chemicals In many parts of the world, traditional feedstocks for petrochemicals are scarce or being depleted. In such locations, hydrocarbons are expensive and gasification can offer a non-traditional route to olefins and petrochemicals. The breadth of WorleyParsons’ capability means that attractive options can be quickly assessed, matched against the preferred process route, and clearly identified in terms of the project’s environmental impact and sustainability. We remain technology-neutral in order to provide an unbiased assessment and implementation of a particular gasification technology to a customer-selected feedstock.
Utilities & Offsites Optimization We are a global leader in providing project management consultancy services, which may include FEED and EPC for selected process units or utilities and offsites (U&O). Our teams work to maximize efficiencies in design for U&O, through all phases of a project, including the evaluation of current systems for modification and revamp. Understanding the financial impact of infrastructure and logistics, WorleyParsons designs packages for customers to minimize overall project cost and schedule.
Licensor Selection With over 50 years experience in licensor evaluation and selection, WorleyParsons is uniquely qualified to assist in this critical undertaking. During the development phase of a project, WorleyParsons can contribute significantly in final licensor selection. Our experience can help assure that all aspects of a selection, such as sustainability, subtle environmental, energy, or operating impacts of each licensor, are considered in selecting a process. We assist by preparing bid tenders such as duty specifications, managing the licensor bidding process, evaluating the proposals, and recommending an award. Petrochemicals Capability & Experience | 7
Select Petrochemicals Select is WorleyParsons’ specialist front-end division, focused on project viability assessment, concept selection, and support for critical front-end planning issues and decision-making. Cost estimates for projects from
$20k-20b total installed cost
2,500+
studies per year
Select brings real world experience into the front-end value-adding phases to maximize investment return and underlying confidence. Through its focus on the critical early phases of projects, it adds technical definition to reduce risk, optimizes the opportunity, and maximizes the inherent value of the project. WorleyParsons can assist customers in creating the business case, assessing lifecycle costs, securing necessary approvals, and preparing for the next phase of the project. Petrochemical projects generally have the highest margins of error within the hydrocarbons industry, which is a result of the many products and product grades and the complexities of the process units for the purest of hydrocarbons chemicals. Our petrochemicals specialists have practical experience designing and operating these complex facilities, and have a thorough understanding of the total business value chain. This first-hand knowledge, leveraged with global resources, allows WorleyParsons to increase certainty of project outcomes and allow customers to make profitable decisions with confidence. WorleyParsons conducts market analysis, financial modelling, technology selection, greenfield site selection, approvals management, new plant configuration, existing plant optimizations, and develops detailed project realization methodologies. These strategic front-end planning skills and services, integrated with extensive project execution capabilities and WorleyParsons’ technological and commercial neutrality, differentiate us for our customers’ benefit. Our petrochemicals experts remain educated on a wide range of technologies which permits WorleyParsons to objectively advise on technology selection and provide optimal project outcomes.
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Project Confidential Customer Confidential Project Location South America Phases This is the largest and first petrochemicals project undertaken by this customer, who seeks to increase petrochemical output by approximately 2 MT/Y using local refinery and natural gas feedstocks, and supply products mainly to the Latin American market. WorleyParsons was selected to coordinate the overall execution of the conceptual engineering phase, manage the technology licensor pre-selection process, and support the generation of a Âą 30% capital cost estimate. The development of a parallel estimate resulted in significant potential savings and cost reductions, and a positive approval decision at the project Phase II gate decision meeting.
Project ChevronTexaco PCEP Customer Chevron Project Location Pascagoula, Mississippi, United States Phases This feasibility study was for development of an Integrated Gasification Combined Cycle (IGCC) cogeneration plant at the site of the Pascagoula refinery using the proprietary gasification technology licensed by an affiliate of ChevronTexaco. The objective in this phase was to examine the feasibility of building a reliable and efficient IGCC plant that utilized petroleum coke in an environmentally friendly manner to produce high value end products such as hydrogen, power, and steam, while reducing the operating expenses for the refinery.
Project Linear Alkyl Benzene Customer Venoco/PDVSA Project Location Venezuela Phases PDVSA and Venoco, a Venezuelan chemical company, examined the potential for producing linear alkyl benzene from refinery aromatics, and was one of very few projects partially funded by the US Trade Development Agency. WorleyParsons conducted a licensor evaluation and completed a project scope definition package that included preliminary P&IDs. The execution involved multiple entities as stakeholders and was done in multiple countries. Following completion of a cost estimate, a complete project economic analysis was conducted. This project was completed ahead of schedule and under budget but the outcome has been since pending due to political uncertainty.
Project MMA-ACN Chain Project Customer SABIC Project Location Jubail, Saudi Arabia Phases SABIC is currently expanding their portfolio of products to move further up the value chain. WorleyParsons was engaged in pre-FEED feasibility project development studies, including licensor evaluation, utility and offsites definition, logistics, and port facilities. Evaluation of site layout options within existing SABIC manufacturing affiliates was completed and WorleyParsons has continued to support the Deliver phase by developing FEED packages out of our Beijing and Singapore locations.
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Deliver Petrochemicals WorleyParsons’ execution teams are focused on utilizing our extensive industry track record to safely deliver innovative solutions and cost effective projects on schedule.
57 petrochemical mega projects world-wide
600+ petrochemicals in 30 countries
We offer a comprehensive range of services for the Deliver phase of project development to customers across the world. Our commitment to local delivery, combined with expertise from our petrochemical global center of excellence in Houston, allow us to provide optimal solutions.
Front End Engineering Design (FEED) Significant emphasis is devoted to FEED at the commencement of the Deliver phase, where WorleyParsons’ operational expertise is rendered. Design is completed with the goal of reducing startup and shutdown time, increasing maintainability, and improving reliability. Program Management Consultancy (PMC) WorleyParsons has extensive experience in providing PMC services, developing bid packages using liscensor technology, and managing the various aspects of these capital intensive projects. Our specialists have a comprehensive understanding of the best contracting strategy for each project which is a result of local expertise and access to global industry resources. Our interdependent method enables operations to accurately assess potential contractors’ capability to meet project requirements. EPCM Our petrochemicals customers can be confident that WorleyParsons will deliver optimal solutions, whether they’re confronted with the toughest challenges of the industry or are seeking innovative solutions to common issues. With more than 1,250 procurement specialists and 5,000 construction managers utilizing our global design, management, and systems capability, WorleyParsons is well positioned to meet the full project delivery requirements for multi-billion dollar brownfield and greenfield projects.
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Project JCP Project - Petrochemical Complex Customer Saudi Chevron Phillips Project Location Al-Jubail, Saudi Arabia Phases The US $1.5 billion Chevron Phillips Petrochemical Complex at Al-Jubail, Saudi Arabia, is based on Saudi Aramco natural gasoline as feedstock. The complex produces styrene monomer, propylene, mogas, and cyclo-hexane and the facilities include the world’s largest single train styrene monomer plant (715 MTPY). As part of an Integrated Project Management Team (IPMT), WorleyParsons provided front-end engineering design, detailed design, and construction management. Global engineering and procurement activities were performed from eight locations worldwide with five different construction work sites with a result of zero Lost Time Incidents. WorleyParsons served as the site utilities integrator on behalf of the owner.
Project COMPERJ Customer Petrobras Project Location Itaborai, Brazil Phases Rio de Janeiro’s Petrochemical Complex will be one of the largest industrial undertakings in the history of Petrobras and Brazil with a total investment of US $8.5 billion. Due to come on-stream in 2013, COMPERJ will have the processing capacity for 150,000 bpd of Brazilian heavy oil and will include first, second, and third generation units. This project will require approximately 4,000 major pieces of equipment and in excess of 2,000 P&IDs, and the site plan will take nearly 25 km2 to accommodate infrastructure and process units. Executed from three of WorleyParsons’ global hubs, key challenges successfully overcome included cultural, language, and regulatory barriers, the large size of the project, and the coordination with the many licensors and FEED contractors involved.
Project Olefins and Polyolefins Complex Customer Abu Dhabi Polymers (Borouge - ADNOC & Borealis JV) Project Location Ruwais, United Arab Emirates Phases WorleyParsons provided project management consultancy (PMC) services for Borouge, a joint venture formed by the Abu Dhabi National Oil Company (ADNOC) and Borealis of Denmark. The scope included management of the FEED for the polyethylene units and marine facilities and the evaluation, award, and management of two major EPC contracts. The total project investment was approximately US $1.4 billion. This prestigious project was completed on schedule and under budget, and included a world-scale 600,000 MTPY ethylene unit, utilities and offsites, two 225,000 MTPY polyethylene process units, product handling facilities including polymer storage and bagging, bagged product warehouses, storage area for containers, and marine facilities.
Project Syngas Project Customer ExxonMobil Project Location Baytown, Texas, United States Phases WorleyParsons’ scope of services included front-end/basic engineering and planning, detailed engineering, procurement, and construction. This two train facility produces 95 MMSCFD of raw syngas from deasphalter rock. The raw syngas is delivered to others “across the fence” for acid gas removal and separation for sales. Some design features of a solids feed gasifier were included to facilitate conversion at a later date. The project was awarded the National ABC Eagle Award for Excellence in Construction in the Mega Project category. It was also completed under budget and ahead of schedule with all project quality goals met, while achieving 1.2 million safe manhours.
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Project Olefins Project Customer National Chevron Phillips (NCP) Project Location Al-Jubail, Saudi Arabia Phases WorleyParsons is providing project management, front-end engineering design (FEED), detailed design, procurement, and construction management services for a US $5.5 billion world-scale grassroots petrochemical complex at Al Jubail, Saudi Arabia. By installing what will be among the world’s largest polymer production lines, the customer will become the lowest cost polyolefins producer in the world through economies of scale. Production of the new facilities includes 1,200,000 tons of ethylene, 1,000,000 tons of polyethylene, and 400,000 tons of polypropylene per annum. WorleyParsons has added value to this project by leveraging the skills, knowledge, and performance history of our project team, and has recently surpassed 93 million manhours without a Lost Time Injury. This achievement is particularly significant considering the adverse site working conditions and the fact that the project employs more than 22,500 employees with approximately 50 different nationalities on site .
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Improve Petrochemicals Improve is WorleyParsons’ service for brownfield operations, focused on improving our customers’ business outcomes. It is a tailored service to meet the needs of individual sites by sustaining assets and improving business performance.
10,000+ dedicated Improve personnel
20,000+ Improve projects per year
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WorleyParsons’ Improve business line includes delivery of capital projects, upgrades, de-bottlenecking and maintenance projects, project portfolio management and support services. It is most often delivered through an alliance contract relationship, aligned with our customers’ requirements and drivers, and delivers a high level of value-add for our customers and their assets. Using the knowledge accumulated from over 230 international alliances or longterm contracts, we have developed a culture and a suite of unique tools, systems and delivery methodologies that incorporate industry best practice to drive innovation, efficiency, and performance. This strong, industry-specific knowledge and long track record of success is underpinned by our performance-based, relationship contracting model. The trust that this generates enables WorleyParsons to deliver maximum value to petrochemicals customers using local teams, supported both locally and globally.
Project Site-Construction/Maintenance and Engineering Services Alliance Customer Eastman Chemicals (formerly Sterling Chemicals) Project Location Texas City, Texas, United States Phases WorleyParsons provides ongoing project delivery services for in-plant, small to medium sized capital and maintenance projects. These services include general engineering services (FEED through detailed design), procurement support, construction management, and field engineering support. The WorleyParsons team is comprised of all disciplines, and all personnel are located at onsite facilities. Typical portfolio turnover is 20 to 40 projects per annum. Projects range in size from US $50 thousand to US $20 million TIC. This alliance is one of the longest standing alliances in the company, and has been in place for almost 20 years.
Project Beaumont Area Projects (BAP) Alliance Customer ExxonMobil Project Location Beaumont, Texas, United States Phases This alliance was made up of a multidiscipline team in excess of 150 people, located both offsite and onsite at the ExxonMobil facilities. The team acted as the primary brownfield EPC provider for sustaining capital projects, expense projects, maintenance projects, and turnaround support. The alliance’s scope included project management, FEED development and support, detailed design and engineering, procurement, and construction management for all facilities in the area which included chemicals, specialty chemicals, polymers, and a refinery. Typical portfolio turnover was 50 to 80 projects per annum. Projects ranged in size from US $50 thousand to US $20 million TIC. The alliance demonstrated flawless safety performance since its inception, reaching 2.8 million safe manhours.
Project Qenos Alliance Customer Qenos Pty Ltd Project Location Altona, Victoria, Australia Phases The Quenos Alliance provides project management and engineering services for up to US $15 million capital projects as well as for expense budget projects (including plant turnaround support) at the Altona facility. This falility is the largest petrochemical facility in Australia and WorleyParsons’ services include engineering, procurement, and construction management for capital projects. Typical portfolio turnover is approximately 40 projects per annum. A key success factor on this alliance has been WorleyParsons’ ability to manage a widely varying workload based on fluctuating capital availability. Another significant factor to the alliance’s success is jointly developing innovative work sharing arrangements that best leverage the key specialists from each company.
Project Global EPCM Alliance Customer DuPont Project Location Canada, China, UK, USA, and Brazil Phases WorleyParsons provides EPCM services for capital projects to support facilities in Canada, China and the United Kingdom, with discretionary opportunities in the United States for projects with an individual value greater than US $10 million, and provision to support work in Brazil. WorleyParsons also provides site based teams and staff augmentation services to support DuPont’s manufacturing facilities. WorleyParsons delivers these services through our global network of offices and by working with DuPont in integrated teams either at manufacturing facilities or in DuPont’s regional centers. This alliance includes approximately 250 WorleyParsons personnel globally.
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Hydrocarbons Capability WorleyParsons’ Petrochemicals capability is complemented by the following Hydrocarbons sub-sectors. Arctic WorleyParsons and INTECSEA are world leaders in design and construction of oil and gas production facilities located in remote, hostile environments. Innovative solutions are required to solve unique challenges associated with projects, above and below the ice. Gas Processing WorleyParsons has designed and built more than 400 gas processing plants around the world. Locations have ranged from the deserts of the Middle East, the jungles of Southeast Asia to the Arctic regions of Canada. Heavy Oil and Oil Sands As the world’s oil resource is getting heavier, producers worldwide must find production solutions for heavy oil and in-situ bitumen production. WorleyParsons is a leader in this area with nearly 40 years of experience. INTECSEA INTECSEA is a global company within the WorleyParsons Group and combines all the group’s capabilities for offshore pipelines, subsea production, marine production risers and floating production systems (including all types of deepwater hulls, tendon and mooring systems). LNG WorleyParsons’ track record in LNG / FLNG production and LNG regas extends from opportunity evaluation studies and concept/technology selection, through Front-End Engineering Design (FEED), and detailed engineering, Procurement and Construction Management (EPCM) for both greenfield and brownfield LNG developments. Onshore Production and Enhanced Oil Recovery With much of the world’s easy to produce oil already recovered, WorleyParsons increasingly assists customers on projects employing a range of secondary and tertiary Enhanced Recovery (ER) techniques.
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Pipeline Systems WorleyParsons’ dedicated Pipeline and Terminals group operates from centers of expertise in onshore pipelines, compressor and metering stations, Geomatics and SCADA systems. Offshore Topsides WorleyParsons has designed offshore topsides ranging from less than 100 tonnes to large integrated topsides with floatover weights exceeding 35,000 tonnes. Our Floating Structures experience (Semi’s, Spars, TLPs, FPSOs and more recently FLNG systems) includes topside tonnages in excess of 50,000 tonnes per facility. Refining With over 55 years of experience, WorleyParsons has completed 23 grassroots refineries including supporting utility systems, product terminals and offsite facilities ranging in capacity from 5,600 bpd to 272,000 bpd. Sulphur Technology Our sulphur recovery units account for approximately 60 percent of the world’s production of recovered sulphur. These facilities include the world’s largest single-train units and apply processes developed and patented by WorleyParsons. Unconventional Oil & Gas Using standardized modular designs known as “field in a box,” WorleyParsons is developing solutions to the unique logistical challenges associated with tight gas, shale gas, and coal seam methane projects across the globe.
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Supporting Capabilities Many of our customers’ complex projects benefit from access to WorleyParsons specialist expertise in other sectors. Infrastructure & Environment This sector provides complete solutions for the transportation, coastal & marine, water & wastewater, resources & energy, municipal and urban infrastructure sectors. The subsectors that provide our Petrochemicals customers with front end project development support and asset management capability include: ►►Industrial Master Planning
►►Transport Logistics
►►Geotechnical Investigations
►►Port and Marine Terminals
►►Environmental Studies
►►Industrial Waste Management and
►►Regulatory Permitting
►►Water Sourcing Transmission and Treatment
►►Community Consultation
►►Restoration
Power This sector specializes in sustainable power and energy through engineering, design , procurement and construction management of clean coal, oil and gas power generation; combined heat and power, and waste heat generation; gas turbine generation using natural gas, syngas and high hydrogen fuels; transmission networks, and substations; and retrofit project solutions from pre-feasibility to asset operation and maintenance. Subsectors of interest to Petrochemicals customers include: ►►Gas Turbine Based Plants ►► Combined Heat and Power
►►Gasification
►► Waste Heat Power and Stream
►►Water & Wastewater
Generation ►►Power Networks
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►►Air Quality Control
►►Carbon Capture, Transport, and
Sequestration
Our Vision
WorleyParsons will be the preferred global provider of technical, project and operational support services to our customers, using the distinctive WorleyParsons’ culture to create value for them and prosperity for our people. Leadership
Agility
• Committed, empowered and rewarded people • EcoNomics™ – Delivering profitable sustainability • Integrity in all aspects of business • Energy and excitement • Minimum bureaucracy
• Smallest assignment to world-scale developments • Local capability with global leverage • Responsive to customer preferences • Optimum solutions customized to needs
Relationships
Performance
• Rapport with all stakeholders • Open and respectful • Collaborative approach to business
• Zero harm • Results for our customers and employees • Creating wealth for our shareholders • World-class resources, capability, and experience
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For further information about our global capability, email petrochemicals@worleyparsons.com
www.worleyparsons.com