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G L O B A L H U B

L O C A L O F F I C E

12 WorleyParsons Annual Report 2005

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WorleyParsons’ experience covers all fi ve phases of an asset’s lifecycle. It is our understanding of what is critical in each one of these phases and our ability to customise our services for each phase and for every customer that has resulted in outstanding project delivery around the world.

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Annual Report 2005 WorleyParsons 13


22 million metric tonnes per year

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LOCAL OFFICE: Atyrau: KazakhstanPROJECT: TENGIZCHEVROIL SOUR GAS INJECTION & SECOND GENERATION PROJECT

This multi billion dollar project will more than double the oil and gas handling facility located at Tengiz fi eld near the Caspian Sea in Kazakhstan, to process over 22 million metric tonnes per year. WorleyParsons’ involvement began in 1998 with conceptual engineering and has continued with front end engineering, detailed engineering and construction management. These services have been delivered through a joint venture relationship with Fluor.

Engineering was accomplished in four design centres – London, Houston, Atyrau and Manila. All design centres were connected electronically with the hub for management and procurement in London. Design centre staff peaked at over 2,000 people worldwide.

Construction is well advanced towards planned 2006 completion. The current 8,500 person workforce is proud of its world class achievement of 52 million manhours worked with a Recordable Case Rate of 0.24. This was accomplished with the active participation of WorleyParsons, the

owner, and over 50 different subcontractors using six different languages to communicate the safety message to every member of the team.

A key objective of the project is to maximise the use of Kazakhstani goods and services. The project has surpassed aggressive utilisation targets set at inception, through extensive collaboration, education and training of local suppliers and workforce to meet exacting western standards for materials, workmanship and quality.

The project had to be innovative in its approach to the movement of materials purchased around the world and delivered to the landlocked, cold weather impacted and remote site. All major equipment required a combination of sea, canal and rail shipment timed around tight weather windows. A highlight was setting a world record for the largest load ever moved by commercial rail at 354 tonnes.

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354 tonnesworld record set for the largest load ever moved by commercial rail

52 millionmanhoursworked



This project involves engineering, procurement, fabrication and installation of two drilling support structures, fi ve production deck modules, one tie-in platform, 18km of 16” and 24” subsea pipelines, expansion of three existing tie-in platforms to

accommodate new scraper receivers, 29 new well hook-ups, two multiphase fl ow meters and

two submarine cables of 7km total length. December 2007 is the scheduled

project on-stream date.

18km of subsea pipelines

In March 2003, the WorleyParsons Petrocon Consortium (WPC) was awarded the Maintain Potential Program by Saudi Aramco. This fi ve year contract, with two possible two year extensions, involves the provision of engineering, procurement and construction management services for upgrading of existing facilities on offshore hydrocarbon installations.

Over the past two years, WPC has executed 15 projects, with capital value ranging from US$20 million to US$375 million and has undertaken a million manhours without a lost time injury, an

achievement recognised by two safety awards. Commitment to achieving tangible Saudisation targets was a contributor to

Saudi Aramco awarding the contract to WPC. The 320 strong team includes 130 Saudi employees, with

professional development being managed through a competency based training

program tailored specifi cally for each individual’s needs.

PROJECT: Offshore Platform Upgrades

Million manhours without a lost time injury

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As a signifi cant philosophy change, foundation fi eldbus technology is being adopted for the fi rst time on a Saudi Aramco offshore facility, on the Zuluf GOSP-2 hub platform. WPC is integrated with the Saudi Aramco Project Management Team for

this key project involving process automation upgrades, new control room building, HVAC

systems and other key packages.

This project, scheduled to go on-stream in January 2007, involves engineering, procurement and installation of 42 electric submersible pumps on seven operating oil platforms. The additional power requirements necessitate the fabrication and installation of six fully loaded VSD / transformer decks to the existing platforms,

installation of 28km of 13.8kV and 69kV infi eld subsea cable and modifi cation and installation of new switchgear at

existing tie-in platforms. Down stream requirements consist of a new tie-in platform, 50km of 42” subsea

trunk line and 20km of 16” infi eld subsea pipelines plus tie-ins.

7 operating oil platforms

Key fi rst time project

These projects involve the engineering, procurement and construction of tower cranes, fi rewater system and

loading control systems to be undertaken concurrently at the Ras

Tanura Sea Islands VVL tanker loading terminal.

Concurrentproject execution

PROJECT: Ras Tanura Sea Islands Upgrades

PROJECT: Safaniya Artificial Lift

PROJECT: Zuluf GOSP-2 Control System Replacement



1,800MW of power

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In 1995, Unit 1 at the Santee Cooper-owned Cross generating station went into commercial operation. WorleyParsons designed Cross Unit 1, a 600MW pulverised coal fi red plant. Today, Units 3 and 4 are being constructed at the South Carolina site and will provide an additional 1,200MW of coal fi red power. WorleyParsons is providing engineering, procurement, construction management, and start-up services for this US$1.4 billion project. The units will feature the latest environmental control technology consisting of low Nitrous Oxide (NOx) coal burners, electrostatic precipitation of particulate, fl ue gas desulphurisation, and selective catalytic removal of post furnace NOx. The design provides for saleable quality of by-product bottom ash, fl y ash and gypsum to the cement and wallboard industries.

The Santee Cooper/WorleyParsons’ project site and home offi ces are linked electronically for sharing common documentation systems. This allows concurrent reviews of designs and expeditious construction support by engineering through video conferencing and online data collaboration.

The project comprises 153 contracts for construction and/or supply. Material and equipment for the project have been sourced worldwide. Project planning and scheduling services include material delivery and expediting services for delivery to match installation and available site storage space.

A challenge early on in the project was designing the plant to code in a very high seismic zone. To accomplish these requirements the plant’s foundation consists of more than 20,000 concrete piles. Another challenge is co-ordinating the 18 month overlapping construction activities on both units in a confi ned site.

Initial operations for Unit 3 are scheduled for late 2006. Unit 4 is scheduled for completion in 2009.

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LOCAL OFFICE: Cross: South Carolina: USAPROJECT: Cross Station Units 3&4

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The objective of this fi ve year program, which encompasses 11 fossil power plants, six combustion turbine sites, and one maintenance facility, is to perform on-site walk-downs of equipment and electrical systems analysis in accordance

with IEEE1584-2002 Industry Standard. Safety is a primary concern for the WorleyParsons fi eld

engineers and TVA engineering and operations personnel who carry out detailed calculations

and assessments to ensure all TVA plants will be safer places in

which to work.

Since 1999, WorleyParsons has supported TVA on a number of projects for coal combustion by-product disposal at various sites within the seven-state TVA power service area. These projects require WorleyParsons’ personnel to work collaboratively with several TVA in-house groups such as engineering, planning, environmental

permitting, construction and project management. The schedule for many of these projects was “fast-tracked” to meet

permitting deadlines, requiring WorleyParsons to be responsive in all project phases: feasibility studies,

engineering design, construction and permit application development.

Seven-state power service area

PROJECT: Coal Combustion By-Product Disposal

PROJECT: Auxiliary Power and Arc Flash Hazard Analysis Program

A safer place to work



WorleyParsons is a partner in a joint project team effort to design, install and test selective non-catalytic reduction (SNCR) systems for NOx reduction at two TVA coal-fi red plants. The SNCR installations are demonstration projects, and will be

installed on additional TVA coal-fi red units if successful.

Demonstration projects

PROJECT: SNCR/NOXReduction

Under a partnering agreement with the Tennessee Valley Authority (TVA), GUBMK Constructors (a joint venture sponsored by WorleyParsons, which includes American Union Boiler and Washington Group International) provides construction modifi cations and supplemental maintenance covering six of TVA’s 11 coal-fi red facilities, all 29 hydro electric facilities (46 dams), one pumped storage facility, and the metal fabrication facility. In total, these assets represent over 10,000MW of generating capacity. WorleyParsons has been providing

engineering, construction support and operations and maintenance support services on approximately 2,000 projects since 1992,

the total value of these construction modifi cation and supplemental maintenance projects exceeding

US$1.3 billion.The contract was extended in October

2004, for an additional four years.

2,000 projects since 1992

PROJECT: Partnering Agreement with

the Tennessee Valley Authority

In providing support for TVA’s fi rst SOIn providing support for TVA’s fi rst SO33 removal removal system (SBS liquid sodium bisulfi te injection system (SBS liquid sodium bisulfi te injection process) at a 500MW unit, WorleyParsons’ process) at a 500MW unit, WorleyParsons’ technical review and coordination of the technical review and coordination of the vendor’s process design and equipment vendor’s process design and equipment

drawings resulted in many changes and drawings resulted in many changes and improvements. It was the vendor’s improvements. It was the vendor’s

fi rst commercial SOfi rst commercial SO33 removal removal system installation.system installation.

First commercial installation

PROJECT: SO3 Mitigation

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M I N E R A L S & M E T A L S

LOCAL OFFICE: Aughinish: Republic of IrelandPROJECT: WorleyParsons Helps Aughinish Alumina Increase Production

Setting new standards for future projectsAughinish Alumina Limited (AAL), a subsidiary of Swiss based natural resources group Glencore, operates an alumina refi nery situated on Aughinish Island on the south side of the Shannon estuary in the Republic of Ireland. AAL identifi ed an opportunity to capitalise on the strong worldwide demand for alumina by increasing the refi nery capacity. They turned to WorleyParsons to provide them with Engineering, Procurement and Construction Management Services because of our internationally recognised expertise for delivering projects in the alumina industry.Teams based in Brisbane and on-site on Aughinish Island have spent the last 18 months implementing the upgrade work based on the scope of works that was jointly developed by WorleyParsons and AAL. In this time a fourth bauxite mill, additional materials handling conveyors and a new day bin have been installed and commissioned. The reliability of processing units within the plant has been enhanced by the provision of additional

equipment and changed process fl ows and alumina quality has been enhanced by the provision of additional fi ltration units. The work will be completed in suffi cient time for AAL to achieve their target of producing more alumina in 2006.Operating alumina refi neries are not easy places to implement projects. Through close working relationships with the AAL engineering, operations and maintenance personnel, WorleyParsons has delivered facilities that have been commended as setting the new standard for future projects at the refi nery from a design and operating perspective. Damien Clancy, AAL Managing Director, has commended our efforts and acknowledged “that WorleyParsons has left the site a safer place”.

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WorleyParsons provides engineering and project services to support WMC Resources Limited (WMC) operations across Australia, with services being provided to Fertiliser Operations in far north Queensland, Olympic Dam Operations in South Australia, Nickel Business Unit in Western Australia and WMC Group Projects. The delivery model involves the use of small teams close to each of the operations serviced, integrated with

WMC’s engineering personnel and working closely with WMC operations and maintenance personnel.

Over 200 WorleyParsons and Maunsell (joint venture partner) personnel deliver

over A$80 million in minor capital projects per annum.

PROJECT: Services to WMC Resources Limited

(A Subsidiary of BHP Billiton Limited)

QFO produces ammonium phosphate fertilisers for domestic and international use, and consists of a sulphuric acid plant at Mt Isa (the largest of its kind in the world), fertiliser plant at Phosphate Hill and storage and ship loading/unloading facilities at Townsville.

The alliance has been in operation since April 2001 and was formed as an integrated team of WorleyParsons, Maunsell and WMC engineering personnel. The alliance manages and delivers approximately A$15 million in minor capital projects per annum and provides support

for maintenance projects, minor engineering works, shutdown works and maintenance drafting. The alliance has a history

of delivering projects successfully, with many of these projects having made a tangible impact on QFO’s plant

production and reliability. The alliance has over this time delivered substantial improvements in

safety performance.

PROJECT: Queensland Fertiliser Operations (QFO)

Tangible impact on production, reliability and safety

Over 200 personnel across Australia

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The ODO copper, uranium, gold and silver production facility is located in South Australia. It is the world’s fourth largest remaining copper resource, the fourth-largest remaining gold resource and the largest remaining uranium resource, accounting for more than one-third of the known global uranium resource.

ODO is the world’s 17th largest copper producer and third largest uranium producer, accounting for 9.4% of current world mine production of uranium oxide.

The WMC ODO alliance has been operating since April 2003. The alliance is an integrated team of WorleyParsons, Maunsell and WMC personnel based in

Adelaide and on-site at Olympic Dam and undertakes EPCM minor capital project work. The alliance team works closely with the client’s operations

and maintenance personnel, delivering up to A$35 million a year in minor capital projects in all areas of the plant, mine, concentrator,

smelter, refi nery and infrastructure modifi cations. The alliance is also responsible for preparation of

annual capital plans for the operation.

PROJECT: Olympic Dam Operations (ODO)

Copper, uranium,gold and silver

WMC is the world’s third largest producer of nickel-in-concentrate, providing 16% of global nickel-in-concentrate production. The company produces nickel concentrate in Leinster and Mt Keith, has a nickel concentrator at Kambalda, a nickel smelter at Kalgoorlie and a nickel refi nery in Kwinana, all in Western Australia.

The WorleyParsons Maunsell joint venture, working with the WMC engineering teams, provides

engineering services and EPCM project delivery across all NBU sites through a preferred

supplier agreement.

16% of global nickel-in-concentrate

PROJECT: Nickel Business Unit (NBU)

WMC Group Projects delivers major capital projects for all the WMC sites. The Group Projects alliance with WorleyParsons and Maunsell was established by WMC in late 2004 to deliver projects in the A$2 million to A$10 million range and to provide support to other major capital projects across all WMC sites.

To date, the alliance has provided support to the Corridor Sands project team, which is undertaking the feasibility study for a

new mineral sands project in Mozambique. The alliance is also currently completing the pre-feasibility study for

the infrastructure component of the Northern Nickel Projects, which involves the development

of new nickel production facilities inWestern Australia.

Major capital projects for all the sites

PROJECT: WMC Group Projects



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LOCATION: Papua New Guinea (PNG)PROJECT: Esso Highlands Limited – PNG Gas Project Infrastructure Design

Challenged traditional optionsIn December 2004, Esso Highlands Limited (a subsidiary of ExxonMobil Corporation), as operator of the PNG Gas Project, announced that EOS (a joint venture of KBR and WorleyParsons) had been selected to conduct the Front End Engineering and Design (FEED) studies for the PNG Gas Project.

This project will develop gas reserves in the Southern Highlands of PNG, process the gas to sales quality and export it to Australia via pipeline. A decision on whether to proceed with the project is expected to be taken in 2006.

The activities in the FEED program include preliminary design for the infrastructure, gas fi eld developments, gas processing and export compression facilities, and the gas export pipeline from the Southern Highlands in PNG to the landfall at Cape York in Australia. The infrastructure design is a signifi cant portion of the project as it is located in a relatively remote area of PNG that is not well served by roads. In order to accommodate the large number of personnel that will be present during the construction phase and then the operation of the project, the existing camps and airport facilities

currently operated by Oil Search Limited and its affi liates will also require upgrading.

The road defi nition involves route selection, detailed design and cost estimation for approximately 345km of roads. This includes 128km of new road through mountainous terrain, together with signifi cant upgrades to a further 217km of roads in varied terrain from mountains through to swamps. The roads will be accessible both to the project and the public. Due to the high rainfall in the area, the roads include many culverts and bridges across fast fl owing rivers. This, together with limitations on available construction materials, has challenged traditional road and bridge options and provided Eos engineers with the opportunity to develop solutions which maximise local labour and materials content.

When complete, the route will signifi cantly reduce the travel distance and times and provide Esso Highlands Limited with direct access to site from the port of Kopi.

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WorleyParsons provides water and wastewater management solutions for customers in the industrial and utilities markets, including identifi cation of subsurface water resources, transportation, treatment

for potable and industrial use, and treatment of wastewater for reuse. These services are

delivered through Burns and Roe Worley in Australia and New Zealand and

by WorleyParsons elsewhere around the globe.

PROJECT: Water and Wastewater Management Solutions

Our broad capabilities

The Perth Reverse Osmosis (PRO) alliance is a world class seawater desalination project being undertaken by the Multiplex–Degremont joint venture for the Water Corporation of Western Australia. The 144 Mega Litres Per Day (MLD) SeaWater Reverse Osmosis (SWRO) desalination plant is currently under construction in Kwinana, and will be the

largest SWRO plant in the southern hemisphere. Burns and Roe Worley and WorleyParsons have provided

the conceptual, preliminary and detailed design for the whole-of-plant concept

in a sub-alliance with the PRO alliance.

Largest in thesouthern hemisphere

PROJECT: Perth Desalination Project

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Over the past 10 years Burns and Roe Worley has provided engineering services to the Water Corporation of Western Australia as an active member of several design panels. Work ranges from preliminary design through to detailed design of large water treatment plants and water supply schemes.

In addition to traditional engineering design services, other projects have included:

• Owner’s Engineer role on the 280MLD Burrup Peninsula Water Supply and associated desalination plants.

• Design and construction services, in an alliance, for the 60MLD Subiaco Wastewater Treatment Plant Odour Control and Plant

Upgrade project.• Design and construction services for the 130MLD

Beenyup Odour Control – Stage 1 project.

PROJECT: Water Corporation Of Western Australia – Alliance Partners, Panels and Owner’s Engineers

Preferred partner at every level of the business

Burns and Roe Worley completed the design, construction and commissioning of the largest membrane fi ltration plant in Western Australia in early 2005. The 45MLD (expandable to 60MLD) drinking water membrane fi ltration plant is located in the remote north west of the state and provides

drinking water to Australian Drinking Water Standards, eliminating turbidity, taste,

odour, colour and disinfectant by-product contaminants.

45MLD drinking water

PROJECT: Membrane Ultrafiltration Plant Harding Dam

WorleyParsons undertook a pilot hydrogeological mapping study of two areas in the United Arab Emirates in 2003 for the Department of Water Resource Studies (DWRS) as a precursor to a whole of country mapping accord and sustainable development plan, which is currently in planning.

WorleyParsons worked in partnership with the DWRS to undertake airborne exploration, hydrogeological

mapping, drill hole ground truthing and to present the results in formal seminars to other

UAE government departments and private agencies.

Whole of country hydrogeological map

PROJECT: Hydrogeological Mapping



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GLOBAL HUB LOCAL OFFICE - worleyparsons.com/media/Files/W/WorleyParsons/... · Yanbu Singapore Singapore Thailand Bangkok ... weather windows. A highlight was setting a ... online