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No. 1 LNG plant construction in the world: Contributed to resource development of Qatar and the global environment with engineering

Tsurumi-Ward, Yokohama-City
Chiyoda Corporation
Other award winners
Kazumi Ikeda, Hiroshi Ogawa, Hitoki Kadono, Isamu Kuroda, Mamoru Nakano, Moritaka Nakamura, Kou Fujisawa, Junichi Masukawa, Tadashi Miyaichi
Recommended by
Engineering Advancement Association of Japan
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Ikeda, Seiichiro  (56)
Vice Manager of the Technical Department (Director for the Qatar gas II project at the time)

The construction of the largest LNG plant in the world was achieved with an advanced design system
summary

Chiyoda Corporation has the largest share of LNG (liquefied natural gas) plant construction in the world. The company received orders of the design, procurement and construction of six series of LNG plants and started the work for the first series in December 2004. The total amount of LNG production of 46 million 800 thousand tons of the six series corresponds to about one-fourth of the its production amount in the world. For the unprecedented scale of the plant construction, the company used most advanced engineering technologies. The company procured equipment and materials for the plants from all over the world and employed workers with different cultures and customs from 86 countries. The project was carried out, maintaining the high quality and reliability while promoting the training for safety and environmental health.

summary

Accepted an order for construction of a LNG plant of an extremely large size that had never been achieved

The amount of carbon dioxide emissions of natural gas, which is used as town gas and fuel of thermal power generation, is less than those of coal and oil, for obtaining the same amount of heat. In addition, it is a clean energy source that does not produce sulfide that causes air pollution. In accordance with the recent increase of environmental awareness, the demand for natural gas has been increased worldwide.
However, because natural gas is gaseous at ordinary temperature unlike oil that is liquid, there are some difficulties about its handling. For example, while natural gas can be exported by pipeline if a natural gas producing country is connected by land to a country that procures the natural gas, if they are separated by the sea, it requires enormous cost to construct a pipeline between the countries.
To solve the problem, a technology that "liquefies natural gas by decreasing its temperature to –162°C to obtain LNG (liquefied natural gas)" was invented. Liquefied natural gas can be put in a tanker and transported to anywhere in the world. The technology for liquefaction of natural gas is essential for Japan that is an island nation and actually, Japan is the country that introduced LNG for the first time in the world. Therefore plant manufacturers in Japan are pioneers and, above all, Chiyoda Corporation boasts the largest share of LNG plant construction in the world.
"Our past performance was recognized and we accepted the order of the construction of the LNG plant attached to the North field gas field. The scale of this plant was the largest in the world that no one else had ever constructed, and the budget of the project was more than one trillion yen."
Previously, the largest scale plant had an annual production capacity of 4.8 million tons. And the company won the contract of the massive plant having an annual production capacity of 7.8 million tons per series, whose scale was 1.6 times that of the former. First, the company constructed two series with annual production capacity of 15.6 million tons.
"If the production amount is increased 1.6 times, roughly speaking, the size of the length, width and height of the plant is increased 1.6 times and the capacity is increased about 4 times. The design levels that are different from those for conventional plants are required for everything including foundation works."

Recruited and trained 75 thousand workers from 86 countries around the world

Since the plant scale was the one nobody else had ever constructed, they could not often use ready-made materials, for example piping materials. In addition, the quantities of the materials required were huge. In this case, they needed to place orders for the piping materials of the same standards and quality with more than one manufacturer of them.
Regarding the ratio of the material procurement, they procured the materials from all over the world, 15% from Japan and 85% from other countries. The incredible scale is also shown in the following remark: "We even chartered a Russian military aircraft to transport materials in order to meet the construction schedule."
"i-PLANT 21," a 3D design/integrated system independently developed by the company, was effective for the large-scale and complicated design and construction. This system is a kind of CAD (computer aided design) that determines the materials such as piping materials and transmission cables that are needed and the quantities of them, based on a 3D model of the plant they designed. Additionally, using this excellent system, they can understand the progress of the construction in virtually real time by inputting the data of orders and deliveries of the materials.
"I think we could not design and construct the plant of such a huge scale if we used the conventional methods, " says Mr. Ikeda.
This was not the only hurdle they had to overcome for the construction of the plant. Although as many as 75 thousand construction workers were required at the peak of the construction, it was impossible to secure human resources near Qatar because of the labor shortage caused by the worldwide rush for construction at the time. So the company recruited the workers from 86 countries around the world, mainly India and Philippines, for the construction in Qatar.
"We hired migrant workers for the construction and hoped that they would earn money and return to their countries without injury. However, it was very difficult to train them for safety and quality because the workers consisted of various races from different countries having diverse cultures and habits."
The first series of the project, which had begun in the summer of 2004, was delivered to the customer at the end of 2008, and the second series was delivered in the summer of 2009, without a major accident, and the largest LNG plant in the world was completed. The company won additional contracts from Qatar for four series of the equivalent scale. Two of the series will be completed by the end of 2009 and the remaining two will be completed in 2010.
Natural gas will be transported worldwide via the extremely huge plants.

Chiyoda Corporation

http://www.chiyoda-corp.com/

Established:
Jan. 1948
Capital:
43, 396.4 million yen
Employees:
1,304 (as of Sep. 2009)
Brief information:
Total management of planning, design, construction, procurement of equipment, and the like for plants of energy, chemical, medical, biotechnology, etc

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Mr. Faisal Mohammed Al Suwaidi, right, CEO of Qatar Gas Operating Company, firmly shaking hands with Mr. Kubota Hiroshi, President of the company

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The workers from 86 countries around the world, mainly India and Philippine, were employed. The colleagues worked in the same site were like family members.

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In order to obtain the production amount 1.6 times that of the conventional plant, the volume that is about 4 times (the cube of 1.6) that of the conventional plant is required. The total amount of LNG production of 46 million 800 thousand tons of the six series corresponds to about one-fourth of its production amount in the world.