session 3 - qatargas - haouari, abdelkader
TRANSCRIPT
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2
Agenda
• Introduction• Safety & Environment• Plant Optimization• Sulphur Recovery Expansion (SRX)• Debottlenecking• Conclusion• The Future
3
Introduction
0
Qatar
(80 Km)32”
North Field
QatargasQatargas
4
Introduction Contd.
Offshore Onshore
5
6
Qatargas Safety Logo
7
Management Safety Tour
8
• Management commitment at highest levels, monthly SHE Committee chaired by CEO.
• Acknowledgement of staff for safe behaviour and practices.
• Contractors were integrated into Qatargas business and safety culture.
• Team work between Operations, Maintenance, Engineering and Safety to highest standards.
Safety Best Practices
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Safety Performance
LTA Vs LNG Production (MT)
02468
10
1999 2000 2001 2002 2003 2004
LNG Production Lost Time Accidents
Near Miss Reporting
0100200300400500600
1999 2000 2001 2002 2003 2004
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• Qatargas considers protection of the Environment, a fundamental part of its vision.
Environment
• The largest environmental improvement to date was the Sulphur Recovery Expansion (SRX) Project, where sulphur recovery was increased to 97% and emission reduced by 35% whilst the production increased.
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Sour Gas and Sulfur Emission Trends
-
0.100
0.200
0.300
0.400
0.500
0.600
0.700
0.800
0.900
1999 2000 2001 2002 2003 2004
Feed
gas
H2S
Mol
%
-
5.0
10.0
15.0
20.0
25.0
30.0
35.0
Sul
phur
Em
issi
on in
Ton
nes
- Dai
ly
Ave
rage
H2S MOL % Sulphur Emission in Tonnes (Total)
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Plant flare
13
Jetty Flare
14
15
LNG Production (MMT) Since Start up
2.32
3.92
5.89
7.05 7.377.82
8.23
9.25
0
2
4
6
8
10
12
1997 1998 1999 2000 2001 2002 2003 2004
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Plant Availability & LNG Yield
0
20
40
60
80
100
1997 1998 1999 2000 2001 2002 2003 200413
14
15
16
17
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Availability LNG Yield
Availability %
LNG Yield (T/MMSCF)
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Objective
The SRX Project was commissioned with the objectives to :
• Comply with current environmental regulations with a minimum of 95% sulfur recovery.
• Improve Sulfur Plant operability and reliability.
EPC Investment cost of 60 million US $.
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AGE Unit Under Construction
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LNG Production and Sulfur Emission Trends
0
5
10
15
20
25
30
35
1999 2000 2001 2002 2003 2004
Sul
fur E
mis
sion
T/d
ay
5
6
7
8
9
10
LNG
Pro
duct
ion
in M
TPA
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Project Summary
• When completed, the debottlenecking project (DBN) will increase the Plant capacity from 7.2 to 9.5 MTPA using the maximum of sea line capacity (1.6 BSCFD).
• The EPC investment cost of US$ 185 million made this Project very cost effective.
• Trains 2 & 3 and related utilities were safely and successfully completed. Train 1 will be completed in 2005.
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Modified Propane Refrigeration Process
LPPropane
MP Propane
HP Propane
Booster
MR/LP C3 Evap.
C3 Comp.C3 DesuperHeater
C3 Condenser
Evaporator Evaporator
FR 5 C
~~
~
~~~
~ ~
~
~MR/HP C3 Evap
~
~~
~~
~
FR 5 C
New equipment or modified
New piping
MR/MP C3 Evap.
MR
Accumulator
Precooler
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Modified Mixed Refrigerant (MR) Process
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Removal of Propane MR LP Evaporator
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Installation of Propane MR LP Evaporator
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Lifting of Propane Compressor
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Lifting of Gas Turbine
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Gas Turbine Upgrading
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Upgrade of the MR compressors
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LNG Train-2 Performance
Rundown (T/H) Before
200
300
400
500
28/0
8/20
03
29/0
8/20
03
30/0
8/20
03
31/0
8/20
03
01/0
9/20
03
02/0
9/20
03
03/0
9/20
03
04/0
9/20
03
05/0
9/20
03
06/0
9/20
03
07/0
9/20
03
08/0
9/20
03
09/0
9/20
03
10/0
9/20
03
Rundown (T/H) After
2 0 0
3 0 0
4 0 0
5 0 0
02/1
1/20
03
03/1
1/20
03
04/1
1/20
03
05/1
1/20
03
06/1
1/20
03
07/1
1/20
03
08/1
1/20
03
09/1
1/20
03
10/1
1/20
03
11/1
1/20
03
12/1
1/20
03
13/1
1/20
03
14/1
1/20
03
15/1
1/20
03
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Conclusion
In Qatargas, success is measured in terms of safety and environment, customer satisfaction, profitability, efficient and reliable operations and maintenance of a high caliber workforce.
Continuous improvement and an open style of management are leading Qatargas towards achieving its vision to be the world’s leading supplier of LNG.
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35
View of Future Qatargas
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EPC Signing Ceremony for Qatargas II
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Maintenance Best Practices
• Shutdown duration reduced from 28 days to 24 days.
• Same shutdown contractor kept for 3 year period extendable to 5 years.
• Effective implementation of lessons learnt.
• Selective equipment inspection.
• Gas Turbine maintenance contracted to OEM under 18 years contract.
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Maintenance Best Practices
• Acquisition of special tools for all critical equipment.
• All trips are logged, analyzed and corrective action developed, followed up until closure.
• Audits conducted internally, by shareholders and specialized maintenance consultants.
• Shutdowns are considered as projects.
• Selection of contractors not on costs only but on performance and safety records.
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Maintenance Best Practices
• Secured spare parts supply through service agreements with local dealers.
• Risk assessment for critical tasks.
• Integrated teamwork across the organization.
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Gas Turbines Inspection Philosophy before & after 2000
LP/HP Modules Replacement (13 days!)
-24,000 (13 days)48,000 (23 days)
12,000 (5.5 days)24,000 (13 days)48,000 (23 days)
CILTPIMI
FutureNowPast
CI – Combustion Inspection
LTPI – Liner Transition Piece Inspection
MI – Major Inspection