In an era characterized by swift transformations in the energy sector, the demand for a varied and flexible work ethic within the supply chain has become more critical than ever before. It is imperative for the supply chain to showcase its agility and adaptability in meeting client requirements. This emphasis on responsiveness has now evolved into the necessity that can expedite and execute projects with both efficiency and safety.
This trend is particularly evident in the way countries are proactively addressing global developments. They are not only diversifying their energy sources but also placing significant focus on reducing carbon emissions.
Germany, for example, has embarked on a major undertaking to reduce reliance on Russian gas imports through the development of its Elbehafen LNG Import Terminal at the port of Brunsbüttel. This underscores the increasing need for a supply chain that can swiftly navigate these shifts in the energy landscape.
The commissioning strategy EnerMech has devised places strong emphasis on early involvement ensuring that our team of experienced engineers are engaged, if able, from the very beginning of each project. This approach enables us to work in close cooperation with our client and all stakeholders, from conceptualization to execution, ensuring a comprehensive understanding of project goals and responsibilities. By integrating our skilled experts at the outset, we maximize efficiency, anticipate challenges, and enhance the overall quality of our commissioning process.
Q. What does the Elbehafen project involve?
A. The purpose is to enable the import of large amounts of LNG as quickly as possible to a country that had no direct access to the LNG market. The long-term establishment of the LNG import terminal will help Germany reduce its dependence on Russian energy.
Phase one involved the construction of necessary technical infrastructure at an existing jetty at the port of Brunsbüttel to accommodate a floating storage and regasification unit (FSRU) commissioned by German multinational energy company RWE on behalf of the country’s government. Work on a dedicated new LNG import jetty is also proposed and expected to begin late 2023/early 2024.
Phase two will see the new state-of-the-art jetty, which will accommodate the FSRU on a longer-term basis, come into operation. The third phase will see gas being fed into a newly constructed gas pipeline which will have the capacity to carry 7.5 billion m³ of gas, generated from 12.5 million m³ of LNG per annum.
Q. What is EnerMech’s workscope on the Elbehafen project?
A. EnerMech — a strategic partnership alliance between EnerMech and Offshore Technical Services (OTS) — was awarded a contract by Worley for the provision of pre-commission, commissioning execution and specialist services across the project.
The alliance was awarded the provision of commissioning engineering and execution services added to the specialist services of nitrogen leak testing, flange management, boroscopic inspection for pipeline cleanliness and strength testing of the newly built temporary oil pipeline (original oil offloading facility now being used for LNG import).
At the client’s request, EnerMech was involved in all the main areas in phase one, including design and construction assistance, turnover, construction and commissioning, handover, start-up and operations – meeting the requirement for this to be completed within a timescale that was “as short as possible”.
Prior to the contract award, acting on a verbal agreement only, EnerMech demonstrated its competence and trust by performing the following:
Early systematization and scoping of the project
Development of completions management system database, complete with construction and commissioning completion inspection test records (ITR)
Commissioning schedule and detailed plan
A full commissioning team at Elbehafen has taken the project from the construction/mechanical completion stage through to operations handover, delivering enhanced continuity of planning execution, interface reduction and the project delivery.
Q. What experience and expertise did EnerMech bring to the table?
A. EnerMech has global experience and world-leading expertise in servicing the LNG industry which has generated more than half a billion UK pounds of revenue. That has seen us work across 20 different facilities in a growing geographical spread which includes Australia, Africa, The Americas, Middle East, Caspian, Europe, and Asia – and, as announced earlier this year, Canada.
The Canadian project was a strategically important win for EnerMech as we look to increase our foothold as a specialist services provider for LNG production, storage and loading projects. This award further highlights our growing reputation for our capabilities to deliver specialist and integrated mechanical, electrical and instrumentation services, and equipment to clients in different geographies around the world.
Our track record of work spans the asset life cycle from early engineering to pre-commissioning, commissioning and start-up to operations and maintenance and specialist shutdown and turnaround scopes.
Our experience and the broad range of services we provide has expanded over the years, equipping us with the scope to deliver a broader level of expertise and capability than ever before.
Having this as a solid foundation was key to the industry-leading project delivery of this strategically important project for Germany.
Q. Where did the EnerMech LNG story begin?
A. Our legacy as the premier provider of integrated specialist services in the LNG market stretches back over the last 15 years and has its roots in Australia which led the way in large-scale global LNG projects.
The Gorgon and Wheatstone LNG developments offshore Western Australia were two early flagship projects which continue to supply gas to Australia’s domestic market and exports to China, India, Japan, and South Korea.
Our legacy from working on Australian mega-projects helped introduce our services and expertise to the global LNG market and this has continued to thrive due to our toolbox of specialty services and our integrated approach, allied to our ability to quickly ramp up activity as required by the Market Tier 1 contractors.
Q. What needs to be taken into consideration when fast-tracking projects?
A. Fast tracking a project requires much more than just pulling the timeline forward. Fast-track projects require specific advance planning followed by detailed execution to avoid problems regardless of the reduced timescales and teamwork is essential to ensure project delivery at a safe, accelerated pace.
This means the ability to mobilize quickly with a team that has the specialist skills required, who can be adaptable and flexible in responding to emerging needs and demands of clients and the ability to fulfil a wide variety of requirements through a broad range of specialist capabilities. The partnering and trust between us through engineering, procurement, and construction (EPC) is led by leadership commitment and action, setting the tone for our can-do approach, common purpose and shared motivation.
Q. What is the EnerMech approach to fast-tracked projects?
A. We see communication, cooperation, and coordination as the backbone of safe and successful project completion. Project quality and HSE are equally critical in the delivery process, and this came to the fore at Elbehafen with a 100% safety record with EnerMech incident and injury free. Achieving this safety record emphasized the importance of good communication and ensuring proven and experienced individuals were in place for the more challenging aspects of the work. Accident risks increase when unplanned modifications to the schedule and congestion problems occur therefore underlining the need for meticulous early planning and dedicated reporting at all times.
Q. How important is good teamwork in a project?
A. It is absolutely crucial. For example, different teams might also be working in separate areas simultaneously, which could lead to an increase in safety risks. That means it’s critical that managers and teams communicate well to mitigate risk and ensure safe working conditions. Commitment to SIMOPS workshops (Simultaneous Operations) and RA (Risk Assessment) creation is essential to ensure all parties within the project have complete understanding and buy-in to daily activities.
The fast-paced approach employed by our team highlighted the importance of collaboration and proactive involvement. In contrast to becoming delayed in the workings of contractual documentation, which in some cases does not lend itself to efficient work, the team proactively championed a basis of trust with the client. This resulted in the achievement of a shared goal, thereby successfully realizing the milestone of the first gas production.
As a result, team members were commended by the client for their technical knowledge and also for their ethos and approach to the project. Likewise, it was commented that we brought an agility to Elbehafen that had been in short supply until the team arrived.
Q. What can we expect in the future?
A. The demand for LNG is on a strong upward trajectory as countries around the globe seek alternative forms of energy as they move towards the energy transition. Germany’s example in fast-tracking its access to LNG through the Elbehafen project is a clear indicator that governments are prepared to make significant investment into the development of their LNG capabilities.
Clearly there is an appetite to move projects forward at pace. As an experienced contractor with a solid pedigree of LNG projects successfully completed over many years, coupled with our expertise and capability of handling fast-tracked projects worldwide, EnerMech is well-placed to support the development of these strategically important developments around the globe.