Istanbul 2012 - IPLOCA · Abu Dhabi ADCO CCC/Tecnicas Reunidas ... Natural Gas Pipeline Laterals of 12 ‐24“ Pigging facilities ... Procedure h) Mobilization of

CCC Pipeline CapabilitiesIstanbul 2012

CCC has constructed approximately 16,500 kilometers

of pipeline which is equivalentto more than 1.5 times the circumference

of the MOON.

Pipeline Record up to 2011

Pipeline Construction

Pipeline Statistics

16,500 KMS PipelinesDiameter greater than 36 in: 4,900 kmsDiameter greater than 16 and smaller than 36: 7,000 kmsDiameter smaller or equal to 16 in: 4,600 kms

Number of Pipeline Spreads

Manual Spreads 18 Nos.Fully Automatic Spreads 12 Nos.

CCC Group Manpower

CCC currently employs approximately 125,000 people in its worldwide operations

CCC Plant & Equipment

CCC owns a large fleet of construction equipment valued at over USD 1bn1,100 pieces of Pipe laying & Earthmoving Equipment

ELECTRIC GENERATORS& LIGHTING TOWERS

675

EARTHMOVINGEQUIPMENT

906 PIPELAYINGEQUIPMENT

201

AIRCOMPRESSORS

454

CIVIL ENGINEERING& CONSTRUCTION EQUIPMENT

1,345WORK/SURVEY BOATS

& STANDARD FACILITIES168

HEAVY DUTYVEHICLES2,319

CRANES977

VEHICLES& LIGHT TRUCKS

2,625

WELDING MACHINES

8,131

TOTAL NO. OF EQUIPMENT:TOTAL VALUE OF EQUIPMENT:

17,800US$ 1,050 MILLION

Current Pipeline Projects

Project Location Client EPC ContractorCCC

Scope of Work

Contract Value

(US$ MILL)

Qusahwira Field 1.8 MMBOPD Project‐ 20", 14“, 8“ totaling 286 km of Pipelines, Transfer

Lines and Flowlines‐ EPC new central degassing station‐ EPC New remote degassing station‐ Water injection clusters‐ Well tie ins

Abu Dhabi ADCO Nat'l. PetroleumConstruction Co.

(NPCC)

C 518

Bab Thammama G & Habshan 2 Development 1.88 MM BOPD ProjectFabrication and erection, laying flow lines and pipelines, EPC field erected tanks, 4 remote degassing stations and BCDS with all associated works, mechanical and E&I works.

Abu Dhabi ADCO Nat'l. PetroleumConstruction Co.

(NPCC)

C 610

Sahil, Asab & Shah (SAS) Full Fields DevelopmentConstruction of 315 km trunklines and flowlines 16" ‐30".Construction and EPC Main Oil Lines to Asab and 8 no. buildings.Upgrade existing CDS and 2 RDS at Shah. Upgrade existing CDS and 1 RDS at Sahil.Demolition of 31 km of pipelines 6" ‐ 30".Connections to well heads at Sahil and Shah.

Abu Dhabi ADCO CCC/TecnicasReunidas

Consortium

EPC 1,200

Current Pipeline Projects

Project Location Client EPC ContractorCCC

Scope of Work

Contract Value

(US$ MILL)

QCLNG Export Pipeline & Collection HeaderDetailed design and construction of 528 km 42“Natural Gas PipelineLaterals of 12 ‐ 24“Pigging facilitiesReceipt station

Australia QCLNG Pipeline Co.

Ltd.(a BG Group

Co.)

McConnell Dowell / CCC JVwith KBR E&P Services S/C

EPC 750

Australia Pacific LNG (APLNG) Pipeline360 km 42“ Gas Pipeline77 km 36“ Gas Pipeline90 km 30" Gas Pipeline

Australia Australia Pacific LNG PTY Ltd.(APLNG)


EPC 940

QCLNG Export Pipeline ‐ Narrows CrossingEPC of 2 Nos. 13 km each 42" Natural Gas PipelineDelivery station2 Nos. 1.3 km HDD drives1.5 km cofferdam in marine clays2.4 km of dredged trench and tow

Australia QCLNG Pipeline Co.

Ltd.(a BG Group

Co.)


EPC 320

Pipelines (Oil & Gas) Location Client StartDate

24” Ambatovy Slurry Pipeline Installation Madagascar Ambatovy Minerals 200830” OAG Onshore Pipelines & Habshan Facilities UAE GASCO 200624”/30” Eastern Gas Distribution System Upgrade UAE Dolphin 200636” Bu Hasa – Habshan Gas 50 km UAE GASCO 200636” Ras Laffan/Mesaieed Sweet Gas 126 km Qatar QP 200424” Mina Al Fahl – Sohar Crude 266km Oman ORC 200432 ”Fahud – Suhar (Oman) 302 km Oman OGC 200148” Maqta – Jebel Ali (UAE) 112 km UAE GASCO 200042” Baku-Tbilisi-Ceyhan (Oil) 443 km Azerbaijan BTC 200242” Georgia Border - Baku (Gas) 443 km Azerbaijan SCPC 200226” Mozambique – RSA (Gas) 860 km Mozambique Sasol 2001Ras Laffan Common Cooling Water Phase I18” Bab- Umm Al Nar Crude Oil Pipeline Project

QatarUAE

QPGASCO

20012002

CCC Performance in EPC PipelinesCCC has a premium record of performance in the

execution of EPC Pipeline ProjectsSelection of Completed Major EPC Pipeline Projects

Pipeline Projects Around the World

Ambatovy Project

Pipeline projects have taken CCC into many distinguished areas around the globe. However, few have been as exotic and challenging as the Madagascar Pipeline

Ambatovy Project

Madagascar is an island in the Indian ocean.Its located 400 KM to the east of AfricaMadagascar is the world's 47th largest country and the 4th largest island. Madagascar is the largest producer of Vanilla in the worldMadagascar is referred to as the red island due to the color of its soil

Ambatovy Project

Madagascar has 5% of the worlds plant and animal Species, 80% of which are not found anywhere else

Ambatovy Project

Madagascar is home to as many as 12,000 plant species, 70%-80% of which are endemic. This makes it one of the most diverse floras on the planet!

Ambatovy Project

Major Exports include Vanilla, coffee, sugar cane, cocoa, peanuts, etc.

Major Imports include Petroleum, Consumer goods and food

Ambatovy Project

Ambatovy Slurry Pipeline Installation

Location: Madagascar

Client: Ambatovy Minerals SA

EPCM: SNC Lavalin

Contract Value: US$ 250 Million

Completion Date: December 2010

Contract Duration: 34 Months

Ambatovy Project

The Ambatovy Nickel Mining Project is a world-class, project in Madagascar that is positioned to be the world’s biggest nickel mine by 2013-2014The mine site consists of an open-pit mining operation and an ore preparation plantSlurried laterite ore is delivered from the mine site via pipeline to a process plant and refinery located near Tomasina

Ambatovy Project – CCC Scope of Work

CCC Scope for the Ambatovy Project was the Construction of :

248 km 24" Carbon Steel ore slurry pipeline from the Ore Preparation Plant to TomasinaValve stationsPressure monitoring stationsWater pipelinesTerminal facility tailings pipelines (HDPE)Fiber Optic Cable

Ambatovy Project – SCOPE OF WORK

Ambatovy Project – Design Basis

Slurry was transmitted through the pipeline by means of gravity15% slope was required to be maintainedA water pipeline was required for purifying the slurry. The water was of high salinity, as such an HDPE liner was usedAll welds were tested by Automatic Ultrasonic Testing

Ambatovy Project – Major Quantities

No. Major Activity Description UOM QTY. at COMPLETION

1 Total Earthworks - Cut / Fill m³ 11,200,000

2 Total Rock Drilled & Blasted m³ 300,0003 Total length of pipes Welded & laid, CS Km 248

4 Total length of pipes Welded & laid, HDPE Km 215 Total Length of Horizontal Directional Drilling Km 46 Total Major Road / Railroad Crossings No 10

7 Total River / Stream / Minor Road Crossings Nos. 3308 Total Reinstatement / Revegetation Km. 530

9 Total Quantity of Saddles [24”,30,36”] No 16,00010 Total Quantity of Concrete Coated Pipes Km 14

11 Total Quantity of Fiber Optic Cable laid Km 215

Ambatovy Project – Major Subcontracts

No. Subcontractor Name Scope of Work

1 Sicon Oil & GasCompleted Detailed & Field Engineering

Works

2 Essar Construction LimitedPipelay on the East Section Slurry

Pipeline

3 Flowtex Egypt Horizontal Directional Drilling

4 UT Quality Inc. Automated Ultrasonic Welding

Ambatovy Project – Challenges

The challenges of constructing a pipeline through the exotic Madagascar region was an extraordinary experience for CCCMany challenges were encountered, such as:– Climate– Mobilization– Early Site Survey– Logistics– Site conditions– Terrain– Local communities– Schedule– IT and Communication– Environmental Protection Measures

Ambatovy Project – Challenges cont’d

ClimateMadagascar has two seasons, a hot wet season and a dry cool season CCC’s experience was none of the above!It was only rain, or pour or rain!Cyclones were frequent (at least 3 major ones per year)The above resulted in CCC revising the execution plan, i.e.Utilization of mini spreadsIncreased number of camps and site facilities and storage yardsSpecial clothing and boots provided for crews to overcome the mud and access the site by means of walking in some areas


Mobilization / Logistics

Non-availability of scheduled shipping linesAll shipping through the crowded South African Durban portChartering flights and vessels for manpower, equipment and material to be used specifically for this jobInland Transportation for personnel and equipmentDistances in Madagascar are measured in Hours not KilometersNon continuous access to site restricted maneuvering between construction site fronts, camps and storage yardsUtilization of huge amount of military trucks to transport our staff and crewsUtilization of articulated trucks to transport project and earthwork materialDelivery of all line pipe material to many stockpiles along the ROW


Early Site Survey

Access to the pipeline was impossible

Route alignment sheets were prepared as a desktop exercise

LiDAR data was not enough for the construction works

CCC carried out the early site survey to define the Center Line utilizing bush rangers along with our survey team


Site Conditions

Adding to the complexity of the construction works was the unusual site conditions encountered such as:

All-year round muddy and slippery ROWRocky mountainsCanyons and gulleyDense tropical forestsMajor RiversWetlands SwampsEnvironmentally sensitive areasCivil unrest

To overcome most of the site conditions challenges, CCC utilized:HDD for non-accessible areasErosion control techniquesUtilization of specialized equipment to work in muddy and swampy areas


TerrainGetting through the harsh and rugged terrains was a major challenge:

The gravity driven design and the 15% slope required deep cuts into the mountains often exceeding 80 meters (equivalent to a 30 story building)Huge amount of earthwork (in excess of 11 million m3) was required to be removed to achieve the ROW The terrain restrictions required CCC to utilize pre-welded pipeline strings in short sections and excessive cold bending


Project Schedule

Overall tight Schedule:

Start Date Mar 2008Completion Date Dec 2010


IT and CommunicationsCommunication facilities in Madagascar are limited

CCC made our own facilities to cater for communication between all site fronts, head office, CCC Area Office, Client and Engineer to ensure all voice and data links are working and reliable at all times


Environmental Protection Measures1. Environmental Protection Steps during the construction phase:

a) Sloping & benching to prevent landslip and minimize soil erosionb) Moving and reservation of top soil for rehabilitation worksc) Building bridges using flume pipes & rocks to cross over streamsd) Protecting the stream banks by stones, upstream & downstream

(rip rap)e) Installation of silt fence & grass filters down stream of the riversf) Installation of Geotextile fence along the rice fields & water

crossingg) Cut & stock pile trees according to the Environmental Protection

Procedureh) Mobilization of large number of specialized environmental officers

with knowledge on Madagascar flora and fauna


Environmental Protection Measures2. Water Management

a) Drain Channels and Crown Ditches along ROW to control water movement during rainy seasons

b) Installation of Decantation Basins at ponds


Environmental Protection Measures3. Soil stabilization and Re-vegetation

a) Soil compaction embankments re-profiled and compacted

b) Re-vegetation and manual seeding of the entire ROW including slopes

c) Mulching and spreading of trees along the ROW

Ambatovy Project – Construction Highlights

Unconventional Pipeline execution strategiesTo overcome all challenges, the execution strategy had to be tackled as follows:1. Continuous survey team on site2. Splitting the pipeline into East and West Portions3. Mobilizing a very strong planning team4. Open as many fronts as possible utilizing self-sufficient mini

spreads5. Utilizing articulated trucks at all times6. Utilizing environmental specialists at all times7. Long term agreements with Airline and Shipping companies8. Mobilizing community liaison officers for every village, town and

city9. Utilizing of local security services10. Full coordination team to interact with the local authorities

Ambatovy Project – Conclusion

Madagascar was a true out of this world challenge and a unique pipeline experienceThe obstacles encountered only served to empower CCC dedicated teamsCCC proved to successfully overcome all challenges CCC Delivered

Consolidated Contractors Company

Ambatovy Project – Conclusion

THANK YOU!

Consolidated Contractors Company

Documents

Istanbul 2012 - IPLOCA · Abu Dhabi ADCO CCC/Tecnicas Reunidas ... Natural Gas Pipeline Laterals of 12 ‐24“ Pigging facilities ... Procedure h) Mobilization of