Project Engineering, Procurement and Construction in Russia Andrei Kalyuzhnov General Manager, LLC Foster Wheeler
Global E&C Group Approximately 10,000 E&C personnel world-wide Teesside Hull Glasgow N. D. de Gravenchon Antwerp Reading Clinton, NJ Moscow Calgary Chengdu Woking Basel Paris Walnut Creek, CA Baku Beijing Philadelphia, PA Milan Istanbul Madrid Cary, NC Shanghai South Jordan, UT Al-Khobar Kolkata Vitrolles Dubai Puerto Rico Hanoi Abu Dhabi Bangkok Houston St Clair (Trinidad) Sriracha Chennai Caracas Bogotá Kuala Lumpur Bandar Seri Begawan (Brunei) Singapore Jakarta Rio de Midrand Janeiro Santiago Main engineering centres Global High Value Execution Centre Regional/local engineering centres Sales offices
2010 – 2011 Russian Experience - Timeline Turkmenbashi Refinery Sasol – GTL Feasibility – Uzbekistan 2004 – 2008 Compra Energy – Azerbaijan Turkmenbashi Refinery Siirtec NIGI / Gazprom Nizhnekamsk Refinery – FEED/PMC 1996 – 1999 Naftan Refinery DCU OCA Alliance Khabarovsk 1932-1947 Lukoil – Rostovenefttechimproyekt Marisky Refinery Expansion – FEED Salavatnefteorgsyntez Permnefteorgsyntez TAIF NK Amtorg -Grozny Naftan Novopolotsk Refinery Turkmenbashi Refinery Ufaneftechim Trading JSC Nizhnekamsk Refinery Nizhnekamsk Refinery Novoil First Project in Ufaneftekhim Refinery Yakutgazprom Rosneft-Achinsk Refinery Russia Ukrtatnafta, Kremenchug Belmed Insulin Injectable Plant Mozyr Refinery TNK-BP Ryazan Refinery – PMC, TONAR Waste to Energy Study Novokuibyshevsk Refinery Tech Diligence and Feasibility Study Norsi Oil Refinery Rosneft Syzran Refinery 1979 -1985 Mazeikiu Nafta Refinery Omsknefttekhinproekt for Atyrau -HPU Techmashimport Kazmnunaigaz – Kazakhstan OCA Alliance Khabarovsk Mashinoimport Odessa Refinery Antipinsky Oil Refinery Crude heater Shell Chemicals Servier Safimo - OSD Facility Ministry of Energy Petrochemical Study Russia Novokiubyshevsk Refinery TNK-BP Ryazan Refinery VDU heater Taneco Nizhnekamsk 80 YEARS AND COUNTING 80 YEARS AND COUNTING 2000 – 2003 2009 – 2010 2012 - 1967 -1978 Lukoil – Petrotel / Neftochim Lukoil Nizhegorodnefteorgsintez ONGOING Techmashimport Mozyr Refinery OC Alliance – Khabarovsk Rusvynil – JV Solvay & Sibur 1992 – 1995 Russia/Ukraine/ Turkmenbashi Refinery Taneco FEED OSPL Facilities Novokuibyshevsk Refinery Uzbekistan UKSOIL – Latvia Slaveneft Yaroslavl HPU GAZprom Neftechim Salavat H2 Mazheikiai Refinery Yakutgazprom Ufaneftechim DCU & HPU Antipinsky Oil Refinery-DCU Merloni Progetti NizhnekNeftochim Naftatrans – Krasnodar Marisky Refinery - DD vs FEED Yamburggas Norilsk Nikel Plant ONGC Sakhalin Rosneft Novokuybishevsk Novo-Ufimsky Refinery RVO Zarubzhneft Tukmenbashi Refinery DCU Menarini Berlin Chemie- Kaluga Kremenchug Refinery Slavneft – Yaroslavnefteorgsyntez Orsk Refinery – Visbreaker Mari El Refinery FEED Novokuibyshevsk Refinery Shell – Salym Wissol Zarubezhneft Brod - H2 Novomendeleevsky Chemical Plant TNK – Ryazan Refining Co Mozyr Refinery CDU/VDU/Gas plant PDPs and Lukoil - Permnefteorgsyntez Nishnekamsk Refinery Novoufimsky Refinery FEED and DD CORU for Moscow Rosneft-Tuapse Refinery Shell – LNG Modularization Refinery (Gazpromneft) VietRoss Refinery Eurotek – FEED and DD for BCS Rusvynil -VCM PVC study Rossiyskiy Insulin Shtokman – Development of STC FH – various Clients Slavneft – Yaroslavnefteorgsyntez Shell – Salym
Project Delivery Model 3
Western EPC Contractors work in Russia Common challenges • Well established and mature “Russian design and project execution style” • Difficult to recognise the “reimbursable” concept, most projects are Lump Sum • Time and schedule of project implementation represent an issue • ITBs require provision of documentation and prices in a very short period, in Russian • Construction used to be always local, now some changes start to occur • Most Clients do not speak any foreign language • Changes of written and unwritten rules and regulations 4
Phases of Project Delivery – Critical Issues The cornerstone of any capital project is the preFEED study Detailed Engineering Operation and Feasibility FEED Commissioning Procurement Maintenance (preFEED) (Project Definition) Construction 6 to 26 weeks 6 to 15 months 24 to 45 months 6 months 20 years + Time Line Feasibility Study Front End Engineering Design (FEED) Engineering, Procurement, Construction, Commissioning
Downstream Sector – Scope of Work division The established project development steps for a complex downstream project in Russia are: - Feasibility Study and Basic Design Package by Western Contractor - then Engineering (DD and WD) by local RDIs, - Material Procurement and Construction managed directly by the final Owner Traditional segments of work executed by Western Engineering Companies Feasibility Studies Licenses Consultancies Basic Design Packages PMC Specialist Equipment supply 6
Downstream Sector – Scope of Work division Engineering Volume of Work 10% 90% FS => PDP => PMC FEED => Detailed Engineering These activities are done in accordance to the Western philosophies and norms and Activities on these stages are heavily not much affected by the Russian Rules. affected by the Russian Rules and Norms They can be managed more or less independently by Western Companies 7
Western Service Companies – Downstream Sector Emerging segments of work for Western Contractors - combination of Western and Russian execution steps FEED + DD (former SP) EPC steps: Advanced Engineering E + WD Ps (E+WD)PsCm EPCm EPC 8
Phases of Project Delivery – Critical Issues The cornerstone of any capital project is the preFEED study Detailed Engineering Operation and Feasibility FEED Commissioning Procurement Maintenance (preFEED) (Project Definition) Construction 6 to 26 weeks 6 to 15 months 24 to 45 months 6 months 20 years + Time Line Feasibility Study Front End Engineering Design (FEED) Engineering, Procurement, Construction, Commissioning
Overall Project Implementation Plan Level 0 Schedule: Overall Project Implementation – From Feasibility Study to Start Up
Selected Key Recent Projects in Russia Salavatnefteorgsyntez • Project Description: FCC Complex • Years 2004-2005 • Scope: – Basic Design Package – FEED – Studia Proect – PMC – Beneficial Engineering
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