17th INTERNATIONAL CONFERENCE & EXHIBITION ON th LIQUEFIED17 INTERNATIONAL NATURAL CONFERENCE GAS (LNG & EXHIBITION 17) ON LIQUEFIED NATURAL GAS (LNG 17)
MITIGATION OF SEASONAL PRODUCTION LOSS FOR THREE PARALLEL 4.7MMTPA > By:By: < Author,> <, Organization > Nicholas White > Master RasGas April 2013
17th INTERNATIONALRASGAS INTRODUCTION CONFERENCE & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17)
• RasGas acts as the operating company for and on behalf of the owners of 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) of LNG from 7 LNG trains
> By:By: < Author<Author Name Name>,> <, Organization<Organization> > • RasGas delivers LNG via a fleet of long<Date<Date-term> >chartered LNG vessels </p><p>• Major Shareholders: </p><p>• <a href="/tags/Qatar/" rel="tag">Qatar</a> Petroleum (QP): 70% </p><p>• ExxonMobil: 30% </p><p>PROJECT17th INTERNATIONAL BACKGROUND CONFERENCE AND & OBJECTIVEEXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>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<Title impact<Title of of Presentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > The project consisted of three main<Date< aspects:Date> > 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 </p><p>LNG17th PRODUCTIONINTERNATIONAL CONFERENCE SEASONALITY & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p><Title<Title of ofPresentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > <Date<Date> > </p><p>PROJECT17th INTERNATIONAL TEAM CONFERENCE ORGANISATION & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>Project Team: • RasGas (Company) • Elliott Group (Compressor OEM) • General Electric (GT OEM) and • APCI (Refrigeration Licensor) • Chiyoda Corporation (EPC<Title Contractor)<Title of ofPresentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > Project Management: <Date<Date> > </p><p>• RasGas Venture Planning department acts as focal point for RasGas • Chiyoda Corporation acts as focal point for various vendors </p><p>PR17-thMR INTERNATIONAL LIQUIFACTION CONFERENCE PROCESS & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>Re-stage compressor </p><p>FCW</p><p>Frame 7 GT/PR PR MR/3 Helper Motor (12 MW) (75~85 MW)</p><p>Feed Gas FCW</p><p>Main Cryogenic MR FCW Heat Exchanger Inlet Chilling <Title<Title of ofPresentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > LNG <Date<Date> > </p><p>Frame 7 GT/MR MR/1 MR/2 Helper Motor (12 MW) (75~85 MW)</p><p>17th INTERNATIONALSTUDY FOCUS CONFERENCE AREAS & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>1. Hot air recirculation to GT 2. Cooling water system 3. Cryogenics <Title<Title of ofPresentation Presentation> > 4. Power augmentationBy:By: < Author<Author Name Name>,> <, Organization<Organization> > <Date<Date> > 5. PR re-staging </p><p>17th INTERNATIONAL CONFERENCE & EXHIBITION HOT AIRON-RECIRCULATION LIQUEFIED NATURAL GAS ANALYSIS(LNG 17) </p><p><Title<Title of ofPresentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > <Date<Date> > </p><p>COOLING17th INTERNATIONAL WATER CAPACITY CONFERENCE EVALUATION & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>• Existing sea water (SW) and fresh cooling water (FCW) SW In FCW IN system subject to additional heat </p><p> duty All CW users</p><p>E S x W c h / a</p><p>F n C g W e r • SW & FCW system has capacity to handle the additional heat< Title<Title of ofPresentation Presentation> > load to remove seasonalityBy:By: < Author<Author Name Name>,> <, Organization<Organization> > impact FCW Out <SWDate< OuDatet > > FCW Pump</p><p>• Assessment concluded that it is feasible to select centralised or local IAC </p><p>CRYOGENICS17th INTERNATIONAL – ANALYSIS CONFERENCE SUMMARY & EXHIBITION ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>Liquefaction Process Licensor Study Results: (Train 4 & 5 – Lean LNG) </p><p>LP-MP MR LP-MP MR Power PR IAC , PR Available Case Required Available from IAC Required Comments USRT MW MW MW MW MW </p><p>79.55 Minimum LNG required to Summer 84.30 80.26 4.04 800 78.14 3636 rpm remove seasonality </p><p>Summer - 79.55 Maximum LNG with 960 max 84.67 80.26 4.40 960 78.34 3636 rpm USRT Chiller (August) <Title<Title of ofPresentation Presentation> > 85.50 Winter 88.16 88.94 0 None 64.8 Current Winter LNG rate By:By: < Author<Author Name Name>,> <, Organization<3534Organization rpm > > </p><p><Date<Date> > LNG production limited by Winter- 81.18 88.26 82.49 5.77 960 74.26 7% stonewall margin on max (May) 3616 rpm Propane Compressor </p><p>LNG production limited by Extreme 70.31 76.17 73.81 2.36 800 69.58 power available to Propane- Summer 3551 rpm HPMR compressor. </p><p>Train 4 Re-rating Cases 1, 2 and 3 with modified propane compressor and inlet air cooling on LP/MP-MR turbine LNG TRAIN MAJOR COMPRESSION STRINGS </p><p>PR/HP-MR String </p><p>88M8-5 56MB5 DLN1, 79 MW Site Rated PR Compressor HP/MR Compressor Helper Motor, 12 MW Rated </p><p>LP/MP-MR String 88M4 60M4 </p><p>DLN1, 79 MW Site Rated LP/MR Compressor MP/MR Compressor Helper Motor, 12 MW Rated </p><p>NGL String (Train 4 & 5) </p><p>DLN1, 27 MW Site Rated RGC Compressor Gear Box Helper Motor, 9.7 MW Rated LP/MP-MR STRING POWER AUGMENTATION </p><p>Local Chiller Plant per GT Unit LP/MP-MR STRING POWER AUGMENTATION GT Air Inlet Filter-house with Cooling Coils </p><p> pulse filter cooler coils </p><p> silencer </p><p> trash screen PROPANE COMPRESSOR LAYOUT AND DESIGN </p><p>• 88M Centrifugal Compressor • Horizontally Split Casing • 3 Sideloads • 4 Stages • 5 Impellers </p><p>• 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 PROPANE COMPRESSOR RESTAGE </p><p>Flow Limitation & Previous Impeller Failures RasGas has suffered 4 identical failures between 2007 and 2012 </p><p>Restaging: </p><p>Reason 1 – to remove the restriction on LNG production Stonewall region Reason 2 – to enhance the reliability of the compressor and therefore, LNG Train </p><p>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). </p><p>PROPANE COMPRESSOR RESTAGE </p><p>HHP (4th) Stage Results) </p><p>17th INTERNATIONAL CONFERENCE & EXHIBITION ON th LIQUEFIED17 INTERNATIONAL NATURALSUMMARY CONFERENCE GAS (LNG & EXHIBITION 17) ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>• Seasonality production loss was identified to be caused by: </p><p>1. LP/MP-MR string power constraint during summer (Trains 3, 4 & 5) 2. Propane Compressor HHP (4th) Stage Stonewall (Trains 4 & 5) </p><p>• A total investment of approximately 150M$ was estimated, producing an IRR of ~33%. <Title<Title of ofPresentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > • Overall project schedule of 42 months <Date<Date> > </p><p>• Retrofit of the propane compressor was estimated to require approximately 20 shutdown days to complete </p><p>17th INTERNATIONAL CONFERENCE & EXHIBITION ON th LIQUEFIED17 INTERNATIONALACKNOWLEDGEMENTS NATURAL CONFERENCE GAS (LNG & EXHIBITION 17) ON LIQUEFIED NATURAL GAS (LNG 17) </p><p>Authors would like to acknowledge the following for supporting this paper: • RasGas Management & Technical Teams </p><p>• Chiyoda Corporation </p><p>• Air Products Inc. <Title<Title of ofPresentation Presentation> > • Elliott Group By:By: < Author<Author Name Name>,> <, Organization<Organization> > <Date<Date> > • ABB </p><p>• General Electric </p><p>• Turbine Air Systems </p><p>17th INTERNATIONAL CONFERENCE & EXHIBITION ON th LIQUEFIED17 INTERNATIONAL NATURALBACKUP CONFERENCE GAS (LNG & EXHIBITION 17) ON LIQUEFIED NATURAL GAS (LNG 17) </p><p><Title<Title of ofPresentation Presentation> > By:By: < Author<Author Name Name>,> <, Organization<Organization> > <Date<Date> > </p><p>LP/MP-MR STRING POWER AUGMENTATION </p><p>GT Power Output and Chiller Temperature Reduction PROPANE COMPRESSOR RESTAGE </p><p>HHP (4th Stage Results) </p><p>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 </p><p>PROPANE COMPRESSOR RESTAGE </p><p>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 </p>
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