43
1

Session 3 - Qatargas - Haouari, Abdelkader

  • Upload
    others

  • View
    10

  • Download
    1

Embed Size (px)

Citation preview

Page 1: Session 3 - Qatargas - Haouari, Abdelkader

1

Page 2: Session 3 - Qatargas - Haouari, Abdelkader

2

Agenda

• Introduction• Safety & Environment• Plant Optimization• Sulphur Recovery Expansion (SRX)• Debottlenecking• Conclusion• The Future

Page 3: Session 3 - Qatargas - Haouari, Abdelkader

3

Introduction

0

Qatar

(80 Km)32”

North Field

QatargasQatargas

Page 4: Session 3 - Qatargas - Haouari, Abdelkader

4

Introduction Contd.

Offshore Onshore

Page 5: Session 3 - Qatargas - Haouari, Abdelkader

5

Page 6: Session 3 - Qatargas - Haouari, Abdelkader

6

Qatargas Safety Logo

Page 7: Session 3 - Qatargas - Haouari, Abdelkader

7

Management Safety Tour

Page 8: Session 3 - Qatargas - Haouari, Abdelkader

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

Page 9: Session 3 - Qatargas - Haouari, Abdelkader

9

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

Page 10: Session 3 - Qatargas - Haouari, Abdelkader

10

• 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.

Page 11: Session 3 - Qatargas - Haouari, Abdelkader

11

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)

Page 12: Session 3 - Qatargas - Haouari, Abdelkader

12

Plant flare

Page 13: Session 3 - Qatargas - Haouari, Abdelkader

13

Jetty Flare

Page 14: Session 3 - Qatargas - Haouari, Abdelkader

14

Page 15: Session 3 - Qatargas - Haouari, Abdelkader

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

Page 16: Session 3 - Qatargas - Haouari, Abdelkader

16

Plant Availability & LNG Yield

0

20

40

60

80

100

1997 1998 1999 2000 2001 2002 2003 200413

14

15

16

17

18

Availability LNG Yield

Availability %

LNG Yield (T/MMSCF)

Page 17: Session 3 - Qatargas - Haouari, Abdelkader

17

Page 18: Session 3 - Qatargas - Haouari, Abdelkader

18

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 $.

Page 19: Session 3 - Qatargas - Haouari, Abdelkader

19

AGE Unit Under Construction

Page 20: Session 3 - Qatargas - Haouari, Abdelkader

20

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

Page 21: Session 3 - Qatargas - Haouari, Abdelkader

21

Page 22: Session 3 - Qatargas - Haouari, Abdelkader

22

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.

Page 23: Session 3 - Qatargas - Haouari, Abdelkader

23

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

Page 24: Session 3 - Qatargas - Haouari, Abdelkader

24

Modified Mixed Refrigerant (MR) Process

Page 25: Session 3 - Qatargas - Haouari, Abdelkader

25

Removal of Propane MR LP Evaporator

Page 26: Session 3 - Qatargas - Haouari, Abdelkader

26

Installation of Propane MR LP Evaporator

Page 27: Session 3 - Qatargas - Haouari, Abdelkader

27

Lifting of Propane Compressor

Page 28: Session 3 - Qatargas - Haouari, Abdelkader

28

Lifting of Gas Turbine

Page 29: Session 3 - Qatargas - Haouari, Abdelkader

29

Gas Turbine Upgrading

Page 30: Session 3 - Qatargas - Haouari, Abdelkader

30

Upgrade of the MR compressors

Page 31: Session 3 - Qatargas - Haouari, Abdelkader

31

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

Page 32: Session 3 - Qatargas - Haouari, Abdelkader

32

Page 33: Session 3 - Qatargas - Haouari, Abdelkader

33

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.

Page 34: Session 3 - Qatargas - Haouari, Abdelkader

34

Page 35: Session 3 - Qatargas - Haouari, Abdelkader

35

View of Future Qatargas

Page 36: Session 3 - Qatargas - Haouari, Abdelkader

36

EPC Signing Ceremony for Qatargas II

Page 37: Session 3 - Qatargas - Haouari, Abdelkader

37

Page 38: Session 3 - Qatargas - Haouari, Abdelkader

38

Page 39: Session 3 - Qatargas - Haouari, Abdelkader

39

Page 40: Session 3 - Qatargas - Haouari, Abdelkader

40

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.

Page 41: Session 3 - Qatargas - Haouari, Abdelkader

41

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.

Page 42: Session 3 - Qatargas - Haouari, Abdelkader

42

Maintenance Best Practices

• Secured spare parts supply through service agreements with local dealers.

• Risk assessment for critical tasks.

• Integrated teamwork across the organization.

Page 43: Session 3 - Qatargas - Haouari, Abdelkader

43

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