MITIGATION OF SEASONAL PRODUCTION LOSS FOR THREE PARALLEL 4.7MMTPA - - PowerPoint PPT Presentation

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MITIGATION OF SEASONAL PRODUCTION LOSS FOR THREE PARALLEL 4.7MMTPA - - PowerPoint PPT Presentation

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17 th INTERNATIONAL CONFERENCE & EXHIBITION ON 17 th INTERNATIONAL CONFERENCE & EXHIBITION LIQUEFIED NATURAL GAS (LNG 17) ON LIQUEFIED NATURAL GAS (LNG 17) MITIGATION OF SEASONAL PRODUCTION LOSS FOR THREE PARALLEL 4.7MMTPA <Title of

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

MITIGATION OF SEASONAL PRODUCTION LOSS FOR THREE PARALLEL 4.7MMTPA LNG TRAINS

Nicholas White & Divyesh Master RasGas April 2013

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

  • RasGas acts as the operating company for and on behalf of the owners
  • f the LNG projects RL, RL (II), RL 3, AKG Projects and Barzan Gas

Company Limited (Project Owners)

  • RasGas has developed world-class facilities for the extraction, storage,

processing and export of LNG, and a global portfolio of customers

  • RasGas produces approximately 37 million tonnes per annum (MMTPA)
  • f LNG from 7 LNG trains
  • RasGas delivers LNG via a fleet of long-term chartered LNG vessels
  • Major Shareholders:
  • Qatar Petroleum (QP): 70%
  • ExxonMobil: 30%

RASGAS INTRODUCTION

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

PROJECT BACKGROUND AND OBJECTIVE

Background:

  • Train 3 is designed for rich LNG and Trains 4/5 are designed for rich

and lean LNG production of 4.71 MMTPA

  • Due to seasonality impact, LNG production reduces during summer

by ~5%

Project Objective:

To remove the seasonality impact The project consisted of three main aspects:

  • 1. Revision of process conditions
  • 2. Design for more gas turbine power LP/MP-MR string
  • Gas turbine power reduced due to ambient air temperature

and hot air recirculation

  • 3. Design a restaged propane compressor
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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

LNG PRODUCTION SEASONALITY

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

PROJECT TEAM ORGANISATION

Project Team:

  • RasGas (Company)
  • Elliott Group (Compressor OEM)
  • General Electric (GT OEM) and
  • APCI (Refrigeration Licensor)
  • Chiyoda Corporation (EPC Contractor)

Project Management:

  • RasGas Venture Planning department

acts as focal point for RasGas

  • Chiyoda Corporation acts as focal point

for various vendors

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

PR-MR LIQUIFACTION PROCESS

Main Cryogenic Heat Exchanger Helper Motor (12 MW) FCW Feed Gas FCW MR Helper Motor (12 MW)

LNG

Frame 7 GT/MR (75~85 MW) MR/1 MR/2 Frame 7 GT/PR (75~85 MW) PR MR/3 FCW

Inlet Chilling Re-stage compressor

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

STUDY FOCUS AREAS

  • 1. Hot air recirculation to GT
  • 2. Cooling water system
  • 3. Cryogenics
  • 4. Power augmentation
  • 5. PR re-staging
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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

HOT AIR-RECIRCULATION ANALYSIS

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

COOLING WATER CAPACITY EVALUATION

SW In SW Out

SW/FCW Exchanger

All CW users FCW Pump FCW Out FCW IN

  • Existing sea water (SW) and

fresh cooling water (FCW) system subject to additional heat duty

  • SW & FCW system has capacity

to handle the additional heat load to remove seasonality impact

  • Assessment concluded that it is feasible to select centralised or local IAC
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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

CRYOGENICS – ANALYSIS SUMMARY

Case LP-MP MR Required MW LP-MP MR Available MW Power from IAC MW IAC , USRT PR Required MW PR Available MW Comments Summer

84.30 80.26 4.04 800 78.14 79.55 3636 rpm

Minimum LNG required to remove seasonality Summer - max (August)

84.67 80.26 4.40 960 78.34 79.55 3636 rpm

Maximum LNG with 960 USRT Chiller Winter

88.16 88.94 None 64.8 85.50 3534 rpm

Current Winter LNG rate Winter- max (May)

88.26 82.49 5.77 960 74.26 81.18 3616 rpm

LNG production limited by 7% stonewall margin on Propane Compressor Extreme Summer

76.17 73.81 2.36 800 69.58 70.31 3551 rpm

LNG production limited by power available to Propane- HPMR compressor.

Liquefaction Process Licensor Study Results: (Train 4 & 5 – Lean LNG)

Train 4 Re-rating Cases 1, 2 and 3 with modified propane compressor and inlet air cooling on LP/MP-MR turbine

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LNG TRAIN MAJOR COMPRESSION STRINGS

88M8-5 56MB5 88M4 60M4

DLN1, 79 MW Site Rated PR Compressor HP/MR Compressor Helper Motor, 12 MW Rated DLN1, 79 MW Site Rated LP/MR Compressor MP/MR Compressor Helper Motor, 12 MW Rated DLN1, 27 MW Site Rated RGC Compressor Gear Box Helper Motor, 9.7 MW Rated

PR/HP-MR String LP/MP-MR String NGL String (Train 4 & 5)

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LP/MP-MR STRING POWER AUGMENTATION

Local Chiller Plant per GT Unit

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pulse filter cooler coils silencer trash screen

LP/MP-MR STRING POWER AUGMENTATION

GT Air Inlet Filter-house with Cooling Coils

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PROPANE COMPRESSOR LAYOUT AND DESIGN

  • 88M Centrifugal Compressor
  • Horizontally Split Casing
  • 3 Sideloads
  • 4 Stages
  • 5 Impellers
  • Pressure Rise 1.1 to 16.3 bara
  • Temperature Rise -38 to 63 degC
  • Discharge Mass Flow 637 kg/s
  • Total Power Consumed 56.2 MW
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PROPANE COMPRESSOR RESTAGE

Flow Limitation & Previous Impeller Failures

Numerous cases have been reported over the past 10 years of impeller failures for large heavy gas compressors running in the vicinity of overload (stonewall). RasGas has suffered 4 identical failures between 2007 and 2012

Stonewall region

Restaging: Reason 1 – to remove the restriction on LNG production Reason 2 – to enhance the reliability of the compressor and therefore, LNG Train

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PROPANE COMPRESSOR RESTAGE HHP (4th) Stage Results)

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

SUMMARY

  • Seasonality production loss was identified to be caused by:
  • 1. LP/MP-MR string power constraint during summer (Trains 3, 4 & 5)
  • 2. Propane Compressor HHP (4th) Stage Stonewall (Trains 4 & 5)
  • A total investment of approximately 150M$ was estimated, producing an IRR
  • f ~33%.
  • Overall project schedule of 42 months
  • Retrofit of the propane compressor was estimated to require approximately 20

shutdown days to complete

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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

ACKNOWLEDGEMENTS

Authors would like to acknowledge the following for supporting this paper:

  • RasGas Management & Technical Teams
  • Chiyoda Corporation
  • Air Products Inc.
  • Elliott Group
  • ABB
  • General Electric
  • Turbine Air Systems
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<Title of Presentation> By: <Author Name>, <Organization> <Date>

<Title of Presentation>

By: <Author Name>, <Organization> <Date>

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

17th INTERNATIONAL CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)

BACKUP

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LP/MP-MR STRING POWER AUGMENTATION

GT Power Output and Chiller Temperature Reduction

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PROPANE COMPRESSOR RESTAGE HHP (4th Stage Results) Performance and Mechanical Integrity Validation:

  • Detailed CFD study by OEM
  • Impeller Modal Frequency Tests
  • Cold Eyes Review by independent 3rd party
  • Regular contact with OEM and preliminary design review
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PROPANE COMPRESSOR RESTAGE

Redesigned Components:

Stage 2 - diaphragm and return channel Stage 3 - diaphragm, return channel, side load wall and impeller Stage 4 - diaphragm, return channel, side load wall, 2 impellers and volute wall Discharge volute Balance piston