Z Energy Biodiesel
Biodiesel is biodegradable and is considered a green fuel because of its significantly lower carbon dioxide emission during combustion. It is also a sustainable fuel due to it being derived from renewable resources. Beef tallow is the feedstock of choice because it is a low value by-product of the NZ meat processing industry.
Z Energy biodiesel decided to build its first biodiesel production plant in Wiri, Auckland with a production rate of 20 million litres per annum, with capacity to upgrade to 40 million litres per annum.
Fitzroy was engaged by Z Energy in July 2013 to perform the FEED study to estimate the capital cost for building the biodiesel plant. The comprehensive costing exercise was completed by December 2013 and presented to Z Energy’s board of directors for review. In March 2014, this obtained the green light to proceed and in June 2014, Fitzroy was awarded the EPCM contract to execute the project. The Z Energy biodiesel production plant was completed in December 2016 with an initial production rate of 20 million litres of EN 14214 quality biodiesel per annum.
Z Energy Biodiesel plant.pdf
Fitzroy Engineering were EPC contractors for the design, fabrication and delivery of the Yolla accommodation & utilities modules which were delivered and installed onto the Yolla offshore gas platform in the Bass Strait in Australia.
The Yolla “megamodule” is a 650 tonne, 19m high unit designed and fabricated to be installed on the Yolla - A offshore gas platform to house the platform’s 40+ person crew. It was Taranaki’s largest ever single engineering fabrication and was delivered to site mid November 2011.
The project was originally destined to be fabricated and delivered as nine individual modules then each one erected and assembled onto the platform. Due to project requirements and cost savings it was later decided that the modules should be assembled, tested and commissioned inside the Fitzroy workshops then transported as one unit to site.
Detailed design was undertaken by two Fitzroy managed design engineering teams based in New Plymouth and Melbourne, who came up with structural additions to allow for the total lift and developed shipping and delivery plan which involved the heavy lift ship Jascon 25. The finished product is the result of over 100,000 man-hours of work for Fitzroy Engineering, along with full commissioning and operator training.
The project owner recognised that Fitzroy possessed unequalled Australasian expertise in offshore installations and so in a separate contract Fitzroy Engineering partnered with Downer Australia to enable the erection of the megamodule onto the offshore platform. We provided personnel who worked in the Downer offices to establish the workpacks and logistics details which allowed Downer labour to carry out the works.Yolla (Oct 13).pdf
Naval Fuel Installation
Fitzroy Engineering Group were awarded the Engineering, Procurement, Construction, Project Management, Commissioning and Training contract for these two concurrent Naval upgrade projects – the Navy Fuel Installation Project (NFI) and the Waste Treatment Plant Project for Oily Bilge Water (OBW).
The NFI Project required the storage of 2.2 million litres of NATO Marine fuel and 750,000 litres of NATO Aviation fuel, unloading and loading capabilities between wharf fuel bunkering stations and storage facilities via under-wharf, under-ground and above ground pipes, unloading and loading capabilities between road tankers and storage facilities, treatment of fuel using filtration and separation filters.
The OBW project required the storage of 150,000L of Oily Bilge Water at a plant located near the fuel facility, unloading and loading capabilities between wharf OBW bunkering stations and storage facilities via under-wharf, under-ground and above ground pipes, automatic skimming of oil layers in tanks, dissolved air floatation treatment of the dirty aqueous bilge water, recovery of waste oil for sale, discharge of treated effluent to local sewer system.
The fuel storage system is located inside underground bunkers, typically 8 m diameter and varying lengths from 45m to 60m. All the fuel tanks are located inside these bunkers and access to them via connecting tunnels of 3m diameter.
These fuel storage tanks of cylindrical horizontal configuration with dimensions of 2.4 m ID x 12m long, 2.4m ID x 24 m long, 2.4m ID x 60 m long, 5.5 m ID x 65 m long and 5.5m x 45 m long were constructed in place inside the bunkers. The fuel treatment and pumping facilities are located outside the bunkers in the main access tunnel. The control room is also located in the same access tunnel.
- Process design and development & HAZOP of P&IDs for both projects
- Calculations for fluid flow, pump and pipe sizing
- Development of process and plant operating procedures
- Development of all process functional descriptions and ladder logics for software programming, development of all PLC screen displays
- Supervision of software programming, dry-run, simulation and factory acceptance test
- Development and design of all process control systems
- Selection, specification, procurement of all plant
- Development of all plant, above round/underground/under- wharf pipework layouts and production of detailed construction drawings including pipe stress analysis
- Design and Calculation of all storage tanks to PD 5500, API 650, NZ Seismic Codes and application of Finite Element Analysis
Kinleith Seismic Isolation
Lump Sum Project
Fitzroy Engineering Group Ltd completed installing new earthquake isolation bearings underneath the 800-tonne Number 8 boiler at Kinleith for Carter Holt Harvey and Beca AMEC.
This difficult project involved lifting the entire structure, removing the existing bearings and replacing with the new base plates, thermal pads and seismic isolation bearings. An extremely comprehensive work plan was developed with many interfaces and there was considerable potential for lost time if the plan was not followed.
Pre-works included the erection of scaffolding, cutting out support beams and tie-ins, removal of instrument and electrical equipment and wiring, and removal of some exterior cladding.
During the process the boiler was exposed to a greater than usual risk of earthquake activity so it was necessary to install temporary restraints and anchors before the preparation and installation of the jacking beams and ancillary equipment to each of the four main columns.
Fitzroy were also required to install a new Kablitz grate to the underside of the boiler firebox that included the removal of fusible links, cladding around headers, and a great deal of welding, fabrication and installation in confined space areas.
However, the key to this project was the successful completion of the pre-works so that the boiler was offline only for the shutdown period of two weeks. Fitzroy crews worked in shifts around the clock for a total of 14,500 man hours so that the completed project was handed over on time.
Shell Catalytic Reactor
Lump Sum Project
In 2006 Fitzroy were awarded the contract by Shell Refining Australia to design, procure, fabricate and deliver a new catalytic cracking unit, including reactor and stripper vessels, cyclone crossover and refractory, site supervision and erection of columns for the Clyde Refinery in Parramatta Sydney. The Clyde Refinery supplied about 40 percent of Sydney's petroleum requirements and about 50 per cent of New South Wales’ needs.
This is the largest and most detailed pressure vessel ever fabricated in New Zealand. The catalytic reactor is made up of several interconnected vessels to a total project weight of over 455 tonnes and was fabricated from chrome molybdenum steel up to 60mm thick. All internal items were lined using either erosion resistant refractory or 410 stainless cladding to protect the steel pressure retaining parts from erosion.
A major component of the overall project was the installation of the refractory anchors which were designed by Fitzroy and their subcontractors. This was a time consuming but essential element as any failures of the refractory lining puts the pressure shell at serious risk. All of the refractory material – a high aluminium, low cement and chemically bonded compound – was applied by hand by a team of specialists, a process that took four months in total.
The reactor operating temperature is 550°C and all weld areas had to be completed with preheats to 150°C. Once complete each weld was heat soaked for three hours at 350°C before being cooled and X-rayed or ultrasonically tested to ensure weld integrity. Final heat treatment was at 700°C in Fitzroy’s onsite heat treatment facility.
The main reactor column was fabricated from nine sub-assemblies to form a single transportable component over 46m long, 5.5m in diameter and weighing in excess of 360 tonnes.
The vessel was delivered fully dressed out with ladders, platforms and access ways in place to ensure minimum work was required on site. All components were transported by specialist heavy duty trailers to Port Taranaki then loaded onto a heavy lift barge, towed to Sydney Harbour and up the Parramatta River to the Clyde Refinery.
- Total project fabrication duration 15 months
- Fabricated from chrome moly to design code AS1210
- Refractory lining weighed 60t with 40t in the main vessel
- Four major components - primary reactor vessel, stripper column, cyclone arrangement, crossover
Shell Diesel Gantry & Pipework Expansion
Lump Sum Project
Fitzroy Engineering Australia was awarded the principal contract to complete an upgrade of the existing Shell Terminal, Mackay, North Queensland. The upgrade involved expanding the existing facilities by adding a new road tanker loading gantry, including a new dedicated 4 arm diesel gantry which increased the loading capacity. The contract included management of all disciplines, civil, structural, mechanical piping, electrical & instrumentation.
The new gantry was designed for the potential to implement biodiesel blending with existing diesel products.
One of the project constraints was that the existing gantry needed to be kept operational for the duration of the project. Dedicated hot work windows were incorporated into the schedule to achieve this. The project involved a crew of 16 trades people over a six month period for a total of 9000 hours with zero environmental or personal incidents.
Civil and structural works for the diesel gantry expansion involved the construction of a new gantry bay attached to the existing gantry bay, and all associated civil works.
Fitzroy Engineering's scope included management of all civil works, I&E aspects and all mechanical and piping components.MacKay Terminal (2013).pdf
Methanex NZ - Waitara Valley
Lump Sum Project
In January 2013 Methanex NZ Ltd formed a project team with the objective of restarting their Methanol production facility in the Waitara Valley. The plant had been shutdown in 2008 due to gas supply issues.
Methanex adopted an integrated team approach, which resulted in selected Fitzroy personnel filling key project roles. Based on previous restart project works at Motunui, Fitzroy were also selected to supply the overall mechanical construction team, and scaffolding and site painting services.
Project tasks were awarded to specialist contractors and off-site fabricators, and Fitzroy provided new heat exchanger shells and tube bundles.
A Fitzroy Project Manager was seconded to the Reformer Lead role, responsible for the management of the Reformer Restart, which included a number of small complex projects:
- Refractory repairs in Reformer cells and Waste Gas Boilers
- Refurbishment and replacement of 312 burner boxes
- Replacement of Waste Gas Economiser channel end flanges
In addition to the restart project, the scope of work also included all of the typical Turnaround activities, such as dismantling, inspection and testing of equipment to allow for the continued operation of the plant.
Fitzroy planners prepared mechanical work packs. The activities were based on previous Turnarounds, and incorporating scheduled and restart tasks.
Fitzroy HSE staff were included in the Responsible Care (RC) team, representing Methanex and providing advice to the wider project team.
- Successful plant restart completed in September 2013
- Fitzroy contributed to the planning team, preparing over 1,000 work packs
- Flexible approach, with supervision and site services supplied to suit project demands
- Fabrication support from Fitzroy’s workshops
- Site Manhours approx 174,000
Methanex NZ - Distillation Plant Turnarounds – D3/D4
Lump Sum Project
In September 2013 the Motunui Major Projects (MMP) team executed plant turnarounds on the Distillation D4 and D3 plants at the Methanex NZ Ltd Motunui production facility. The plants had been operating since the restart projects in 2011 and 2012.
Methanex had planned these turnarounds over the previous 12 months, procuring from Fitzroy a number of replacement heat exchanger tube bundles. Fitzroy Engineering supervisors filled the construction planning roles prior to the turnarounds.
Fitzroy were awarded the contract to execute the mechanical work packs, with Methanex employing a dedicated Turnaround Manager to liaise with the Fitzroy team. Our scope including erection and dismantling of all associated scaffolding.
The turnaround schedule was based on the defined scope of work, and included a small weather contingency. Work was sequenced to execute the D4 turnaround, allow Methanex to complete start-up, and operate reliably prior to executing the D3 turnaround.
Repeating the work scopes in close succession provided an opportunity for lessons learned, and resulted in an improved efficiency of the second turnaround.
The project structure required the Fitzroy team to interface with specialist contractors at all levels, including inspection, NDE, scheduling, crane services and bundle pulling.
HSE staff were included in the Responsible Care (RC) team, representing Methanex and providing advice to the wider project team.
- Successful turnarounds completed in 26 and 24 days respectively
- Fitzroy managed the construction planning
- Flexible approach, with supervision and site services supplied to suit project demands
- Fabrication support from Fitzroy’s workshops
- Site Manhours approx 58,000
- Total Recordable Injury Frequency Rate (TRIFR) of 0
Aica NZ - Condenser Repair
Lump Sum Project
AICA supply wood resin for use in the manufacture of MDF (Medium Density Fibreboard) and LVL (Laminated Veneer Lumber).
The Dowtherm Condenser vessel is a critical piece of equipment in the manufacture of Formalin – a key ingredient in the production of wood resin, and was fabricated in 2007 by Fitzroy Engineering as a replacement to the plant's original vessel.
In April 2014 AICA NZ Ltd noted some steam leaks from the Dowtherm Condenser and close inspection identified a total of 7 transverse cracks in the tubesheet to shell attachment weld.
The project was originally considered as a straightforward weld repair - excavating and burr grinding to remove cracks, followed by re-welding. The excavation of the cracks proved difficult and the cracking was extensive. It was proposed that the affected shell section be removed and a new patch installed. On the same day as the decision was made, the patch had been cut, rolled and dispatched for next day delivery.
Fitzroy mobilised a team of welders, led by an experienced QC Welding Inspector. A team of Heat Treatment Technicians were also mobilised to provide controlled pre-heating for welding. Due to the critical timing, the project was operated on a 24 hour basis. As the tubesheet cracks were removed and inspected, then the tubesheet was built-up and dressed to create the correct weld preparation profile.
A Statutory Inspector was present for the project and was regularly consulted on the repair strategy. When the patch was fully welded and all temporary attachments removed, then the repaired section was wrapped in insulating material and left to cool slowly. When at ambient the vessel was subjected to a hydrostatic test, and after a 24 hour stand down (for possible hydrogen cracking), NDT was repeated, followed by handover.
The fast response and successful repair were greatly appreciated by the AICA management team, who managed to keep the supply of wood resin to their key client.Aica, Nelson (May 14).pdf
Pohokura Gas Re-injection
Joint Venture Project
Fitzroy Engineering Group and Transfield Worley formed a joint venture to complete the EPC development of the Pohokura Gas Re-injection Project for the owners Shell Todd and OMV NZ.
The project scope consisted of detailed design, engineering and all project management. This included the provision of construction services, procurement and management of subcontractor services, procurement of non-client supplied materials, plant and equipment, civil, mechanical, electrical, process control and instrumentation works.
The JV also completed the process piping and utilities tie-ins to the existing operating plant, modifications to an existing glycol contactor column (TEG Contactor), installation and pre-commissioning of a gas re-injection compressor and associated plant and equipment including; the 4MW reciprocating compressor, variable speed drive, suction and discharge scrubbers, inter-stage and after-coolers, process inlet cooled heat exchanger and coalescer vessel.
Northern Oil Refinery
In a negotiated agreement Fitzroy Engineering was selected as the engineering, procurement and construction (EPC) contractor for the new oil re-refinery project for Northern Oil Refineries in Gladstone, Queensland. We have completed the installation and commissioning phases of the construction and have been working with the owners of this project since the outset, carrying out preliminary design of pressure vessels, columns, and modules with a view to achieving both cost and schedule efficiencies. The plant is now fully operational and performing in excess of expectation.
The design phase of the large process module which was fabricated in New Plymouth, was completed utilising the state of art computerised 3D modelling. These models provided us a complete understanding of the end product and allowed isometric drawings to be taken directly from the 3D models to enable better fabrication of pipe spools and structural steel works in an efficient manner.
The fabrication for the Northern Oil Refinery was allocated on a best-for-project basis to the various construction workshops administered by Fitzroy Engineering;
- Piping, pipe racks and steel structures were completed by Fitzroy Engineering in Brisbane and transported to site for installation. Fitzroy in Brisbane also constructed a 3 million litre tank on site in Gladstone.
The refinery process module was the largest and most complex fabrication assembly and accordingly was assigned to the primary workshops in New Plymouth.
34 storage tanks varying in size from 50,000 litres to 400,000 litres were fabricated at the large lower cost facility in Kuala Lumpur operated by parent company Dialog Group and successfully barged to Gladstone.
All fabrication was overseen by Fitzroy project management staff from either Brisbane or New Plymouth who ensured Australian standards for quality control and statutory assurance were applied and adhered to.
Site installation and construction was carried out by staff from Fitzroy Australia. They have also interfaced with instrumentation and electrical engineers to install the hot oil heater and oxidiser and associated equipment.
The modularisation of this project was fundamental to its affordability, all components were assembled and trial tested prior to leaving the workshops meaning that once on site the completion was essentially be ‘plug and play’ minimising on site commissioning costs.NOR.pdf
Maari Platform Free Fall Lifeboat Installation
In 2013 Fitzroy Engineering were awarded the contract to fabricate and install a new free fall life boat system on board the existing wellhead platform (WHP) at the Maari Oilfield offshore in the Taranaki Basin, and operated by OMV.
The Maari WHP is situated in 100m of water at the edge of the region of strong westerly winds (the Roaring Forties) and is configured to remain serviceable in 20m high waves and wind gusts to 160km/h. The work was timed for June, in the middle of the winter conditions.
Access to work was always going to be very difficult due to the size of the work area and required compliance to OMV’s strict rules regarding working over water and at height in daylight hours only.
Project engineers Transfield Worley and the Fitzroy Scaffolding & Rigging division worked co-operatively to establish an access concept, phased to align with the various stages of the structural installation onto the WHP hull.
The concept allowed for constructing two 9m high towers and one 12m high tower on the WHP deck, from where they were lifted with the WHP crane into position onto the six fingers which protruded from the wind wall of the hull. With this concept, working over water was kept to a minimum and was only required during the landing of the towers onto the fingers and making the bolted connections.
Once the three towers were installed access to the work area was down through the 12m tower which was fitted with hatches and ladders accordingly. Landings were installed between the two 9m towers which were set apart to match the Layher component landings. Two levels of truss were installed where the span exceeded 6m and working platforms built on top of these.
During the installation of the project steelwork the scaffold was modified as the team rigged structural sections into position, built habitats and welded components to the hull. The project recorded very little lost time because the scaffold phased easily due to its design.
The free fall life boat structure was installed and commissioned safely and on time with the major contributing factors being the innovative and efficient access scaffolding provided and the easy interface between the Fitzroy Scaffolding and Mechanical teams.Maari Free Fall Life Boat (Jan 14).pdf
Papua New Guinea
Puma energy - napa napa refinery
Fitzroy Engineering's contract with Puma Energy was based on a predefined scope to prepare a shutdown budget and include a review of the client’s Turnaround & Inspection (T&I) scheduled shutdown requirements. This resulted in Fitzroy completing the planning, management and execution the 2014 scheduled T&I turnaround at the 28,000 b/d oil refinery at Napa Napa on the western shore of Port Moresby Harbour in Papua New Guinea.
This required the compilation of a high level execution plan, development of an HSSE plan and controls, all quality documentation, execution work packs, JSA\'s, equipment lists, identification of replacement parts for procurement and development of expenditure budgets. All were submitted to the client for pre-approval before final development of the T&I execution plan and final documentation.
The planning phase required three site visits to PNG during the pre-shutdown phase by our T&I manager, senior planner and a shutdown supervisor. This occurred over a 12 month period on a part time basis with the majority of the work carried out in NZ by our planning team. Included in the work scope was management of all of the pre-shut activities such as scaffold erection, blind points tagging, insulation, cladding removal, and alternate hot unbolting of column and vessel man-ways and heat exchanger nozzles.
This was overseen by our T&I manager and a small contingent of supervisors starting on site two weeks before the shut start date.
The shutdown was managed by our expat team of T&I Manager, one planner and eleven supervisors supported by the Puma operations staff. It was a 12 hour per day operation for 31 days with rostered days off for fatigue management and some critical activities on a two shift basis. During the shut some 68 pressure vessels, columns, heat exchangers, fin fan coolers, heaters and tanks were opened and inspected, cleaned and repaired as necessary along with all pressure safety valves, shutdown valves and control valves. The shut heat exchanger programme involved opening all vessels and in most cases pulling the tube bundles out for cleaning, inspection and some bundle replacements. For this we employed Fitzroy’s own 25 tonne aerial tube bundle puller.
- Project value for Fitzroy approx $2m
- Total peak manning number 180
- 60,000 man hours with ZERO lost time injuries
The shutdown was programmed and work packs developed using Fitzroy’s proprietary Dialog Intelligent Planning System (DIPS). This is a powerful and fully comprehensive integrated software package which allows us to plan & prepare, schedule, cost, execute and manage turnarounds, while providing real time progress and cost reporting for our clients. DIPS incorporates all Job Methodologies and Job Safety Analyses, subcontractor and asset allocation, and generates valuable retrievable information for use in future work.Napa Napa Refinery.pdf
Todd Energy - McKee
MET2 PLANT – FIRST SHUTDOWN
Todd Energy engaged Fitzroy Engineering’s Construction Group to plan, manage and assist with the execution of the first shutdown for their year-old Mangahewa Expansion Train 2 [MET2] plant at their production facility at McKee.
Todd Energy selected Fitzroy Engineering based on the opportunity to use the Dialog Intelligent Planning System (DIPS), and their commitment to develop an automated time recording system that would deliver the ability to monitor the shutdown status, and provide timely and accurately progress reports.
The project was based on an agreed scope of inspection works, some repainting work (due to failed paint systems), some corrective maintenance tasks and a number of Plant Change Requests (PCRs).
Fitzroy were also awarded the contract to execute the erection and dismantling of access scaffolding, and to assist with the mechanical works to facilitate the statutory equipment inspections.
A large number of Emergent Work Requests were raised during the execution phase, and all were minor in nature.
Site labour resources were recorded in TimeClock. Time entry for the main labour groups was automated, using a swipe system and touch screen interface to select shift details and allocated Work Order. These time entries were reviewed by the area supervisors to ensure correct time allocation, and then approved by the client. All other site hours were manually loaded into TimeClock from paper timesheets.
On completion, the actual hours were compared with the baseline planned hours.
The project schedule activities were used to monitor and record progress, and synchronised daily with DIPS and an S-curve progress report was provided against the baseline planned progress. This was available for the overall shutdown; or for the specific plant area; or for a specific equipment item.
- Successful shutdown completed 2 days ahead of schedule
- Fitzroy managed the planning and execution phases
- Site man hours approximately 21,000
- Innovative shutdown progress monitoring and reporting