Yemen LNGOperational feedbacks

APCI Owners’ Seminar XI – September 2013APCI Owners’ Seminar XI – September 2013

9/3/20131

Yemen LNG - Agendag

1 Yemen LNG general presentation1. Yemen LNG general presentation

2 Feedback on Plant restarts optimization2. Feedback on Plant restarts optimization

3 Other operational feedbacks3. Other operational feedbacks

9/3/20132

YEMEN LNG – GENERAL PRESENTATION Sh h ldShareholders

OPCO / Total Technical Leader (39.6%) OPCO / Total Technical Leader (39.6%)

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YEMEN LNG – GENERAL PRESENTATIONK j t d tKey project data

Yemen largest industrial project 6.9 Mtpa Average 110 LNG cargoes per year

Project Milestones:o 1995: First GDA

2004 FIDo 2004: FIDo 2005: Site construction started Sept.o 2009: Train 1 First LNG on 15 Oct.

Fi t t 7 N 2009

3 Sales Contracts / 20 years

First export on 7 Nov 2009

TOTAL KOGAS GDF SUEZ

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YEMEN LNG – GENERAL PRESENTATION

Transfer lineTransfer line25 km25 km –– 3030””

Upstream Facilities

Gas supply 25 km 25 km 3030

Main line 38’’Main line 38’’320 km320 km

to the LNG plant

LNG Plant: 2 trains & terminal

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YEMEN LNG – GENERAL PRESENTATION38” Pi li fil38” Pipeline profile

PlateauPlateauTransfer Transfer

LineLine 1400 m1400 m1700 m1700 m

0000

DescentDescentAscentAscentSand dunesSand dunes

LineLine

1000 m1000 m

1400 m1400 m

0000

BalHafBalHaf

CPUCPU KPUKPUWadi & sandWadi & sand

Main Main LineLine

BalHafBalHafBasaltBasalt

Plateau Plateau AscentAscent Plateau Plateau DescentDescent

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YEMEN LNG – GENERAL PRESENTATIONM i liMain line

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YEMEN LNG – GENERAL PRESENTATIONP d i tiProcess description

– 2 identical trains design capacity of 6.9 Mtpa (6.7 guaranteed)2 identical trains design capacity of 6.9 Mtpa (6.7 guaranteed)

– Gas Pre-treatment: • AGRU (Amine unit)• Dehydration (molecular sieve)• (Mercury bed)

– APCI C3-MR split processp p

• 2 spool wound type Main Cryogenic Heat exchanger (MCHE) of a guaranteed capacity to produce 428.8 t/h per train (APCI)

• 2 MR and Propane compression packages ( Eliott)

• 4 Frame 7EA turbine packages driving refrigerant compressors (General Electric)

– 2 LNG storage tanks (2 x 140 000 m3)

1 J tt f t 205 000 3 l– 1 Jetty for up to 205,000 m3 vessels

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YEMEN LNG – GENERAL PRESENTATIONF d G C itiFeed Gas Composition

VV Lean V Lean RichComponent (Mol %) (Mol %) (Mol %)

H20 0.000 0.000 0.000H2S 0 000 0 000 0 000H2S 0.000 0.000 0.000N2 0.100 0.090 0.100CO2 0.310 0.170 0.286C1 93 550 93 220 91 920C1 93.550 93.220 91.920C2 5.560 5.090 5.660C3 0.450 1.220 1.482IC4 0.010 0.080 0.128NC4 0.010 0.110 0.239IC5 0.000 0.000 0.040NC5 0.010 0.010 0.047NC6 0.000 0.000 0.015NC7 0.000 0.000 0.083

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HHV 1055.63 (1062.09) 1069.29 (1076.44) 1086.57 (1089.86)

YEMEN LNG – GENERAL PRESENTATIONK FiKey Figures

82% Yemenis in Operations teams82% Yemenis in Operations teamsAverage of 170 expats on site

ISO 17025 certification for Laborator

Indicators Design 1 Jan 31 Jul 2013

ISO 17025 certification for LaboratoryISO 14001 certificationISRS Level 5

Indicators Design 1 Jan- 31 Jul 2013LTIF - 0.54

TRIR - 1.0

RDL Production 445 t/h 465 t/hReliability 99.5% **Availability 95% * 96.0% **Thermal efficiency 90.4% * 90.6% **

9/3/201310

* Target for 2013** Up to 31st July 2013

FEEDBACK ON PLANT RESTARTSSh td tShutdown events

Plant restart duration

17 20

40

8

9MCHE bottom temperature before restart (average 2 trains)

‐52

‐23

7

31

1

‐20

0

6

7

re (d

egC)

‐31

‐60

‐40

4

5

m te

mpe

ratur

mbe

r of d

ays

1.2 days saved

ted)

120

‐100

‐80

2

3

MCH

E bo

ttom

Num

(feed

gas

lim

i

‐160

‐140

‐120

0

1

M

Estim

atio

n

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16001 2 3 4 5 6 7

Note: Plant restart duration is from Pipeline pressurization to the 2 trains at full production

FEEDBACK ON PLANT RESTARTST i l t tTypical start-up sequence

• Restart sequence ≈ 5 days• Restart sequence ≈ 5 days– Pipeline re-pressurization– Trains restart

8h 12h 12h 24 to 36h

1st TrainWarm end restart=> Gas on‐spec 

ready for cold end

Pre‐cooldown=> MCHE @‐30 C 

ready to start MR circulation

Final cooldown=> 1st LNG drop(MCHE @‐144 C)

Ramp‐up=> maximum sustainable production

(optimized process conditions)   

nd

– Train 2 ramp up can be slow down due to Ethane shortage

2nd Train

p p g

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FEEDBACK ON PLANT RESTARTSO ti i ti f th t tOptimization of the restart sequence

Main challenges:- Pipeline re-pressurization - Restart sequence: Not possible to restart 2 trains at the same time (flare design)- Lean gas composition and Ethane inventory limitations

Several axis of progress:

Warm end restart Pre‐cooldown Final cooldown Ramp‐up

Optimization of the “inter-steps”–Pipeline pressurization and warm end restart almost in parallelAnticipation of the restart:

preparation d ring sh tdo nFeedback tools

p–Anticipation of next step

O ti i ti f h St

preparation during shutdown…

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Optimization of each Step

FEEDBACK ON PLANT RESTARTSP t t d I t tPre-restart and Inter-steps

• Reduction of the gap between 2 steps

• Coordination / planning

• PR and MR compressors restart anticipated

• Lessons learnt: Feedback before & after restart

Good improvement : No gap between 2 consecutive steps

G i th ll l i 2 hGain on the overall planning = 2 hours

• Pressurization

• Pressure optimization in the upstream sections < 70 barg

• From upstream and downstream sections at the same time

Improvement = re-pressurization duration reduced by 10 hours

9/3/201314

FEEDBACK ON PLANT RESTARTSMCHE ldMCHE pre-cooldown

MCHE pre-cooldown to -30 degC MCHE pre-cooldown to -30 degC

Optimization of the cool down flow: Flow through MCHE is restricted by PV on shell side

LNG

g y Optimization done by early opening of the JTs and drains Increased feed gas flow Homogeneous cooldown of the MCHE

MCHE

HP MR separator and lines up to MCHE– Early cooldown recommended

FEED GAS

Early cooldown recommended– Done during pre-cooldown – to be ready for final cooldown

Gain on the overall planning = 10 hoursNGL

REINJECTION

HP MR sep

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FEEDBACK ON PLANT RESTARTSMCHE fi l ldMCHE final-cooldown

C iti l t 30 144 d C Critical step: -30 -144 degC Not possible to decrease the duration Nevertheless some optimizations done

VMR

Control of the cooldown rate Material constraint = 28 deg/h maximum Temperature control difficult when the MR

Monitoring with the VMR & LMR

PDI

Temperature control difficult when the MR starts condensing coils PDIs

LMR PDI

Feed Gas flow adjustment

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FEEDBACK ON PLANT RESTARTSEth tEthane management

Major impact on the restart sequence: – Very difficult to start LNG production without C2 in the MR loopVery difficult to start LNG production without C2 in the MR loop– Ramp-up strongly impacted by C2 shortage

Lean feed gas composition– Long time to build C2 inventory Minimum level to be kept in the C2 bullet at any time

Recommendation during restart

C2 make up t di tl f d C2 t MR lsent directly from de-C2 to MR loop

C2 from C2 bullet: Priority for the 1st TrainPriority for the 1 Train To be be re-started as early as possible To produce C2 for the 2nd Train

9/3/201317

FEEDBACK ON PLANT RESTARTSE d fl h it t tEnd flash gas unit re-start

B d i b f th EFG it By design, no by pass of the EFG unit

At least 4 hours required to cooldown the LNG pumps and End Flash drum

Anticipation:– During plant ramp-down:

• maximize the level in the EFG drum– During plant shutdown:

• Monitor level in the EFG drum If required “re filling” operations by reverse flow from the RDL• If required re-filling” operations by reverse flow from the RDL

Gain on the overall planning = 4 hours

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FEEDBACK ON PLANT RESTARTSPl t d d h tdPlant ramp down and shutdown

Pipeline de-pressurization and plant ramp down check list including:

1 train immediately stopped

1 train producing until pressure at CRF is 50 bara 1 train producing until pressure at CRF is 50 bara Minimum to operate the train Ease to PPL re-pressurization

C2 i i i d d i d C2 inventory maximized during ramp-down

Driers sequence stopped at the end of cycle 1 fresh drier ready for restart

Plant shutdown – Amine unit Amine circulation stopped to avoid gas losses through amine flash drum Filtration is kept runningFiltration is kept running

9/3/201319

FEEDBACK ON PLANT RESTARTSR t t ti i ti C l iRestarts optimization - Conclusion

7 t t f b th T i 7 restarts for both Trains Good improvement of the restart sequence, reduced by 1.2 days High level of experience of operators on restart operations

Way forward: Keep the knowledge for next restarts Reduction of the flaring during re-start

MR composition adjustment due to MCHE leak PV at the top of MCHE shell connected to the fuel gas network

Not used because mainly N2 is vented To reduce C1 content in MR loop:

HP MR separator is used Modification on-going to re-route this line to the fuel gas network

(instead of flare)

9/3/201320

OTHER OPERATIONAL FEEDBACKST i 2 l d SD i M 2014Train 2 planned SD in May 2014

The biggest planned shutdown ever planned

• All the initial scope completed (Main: turbines HGPI*)

• 2 days ahead the schedule (6th May to 17th May 2013)

• Zero accident

• Frame 7 Hot Gas Path Inspection: turbines in very good condition

48 V l F d H t h i t d ( j• 48 Vessels, Furnaces and Heat exchangers inspected (no major

issue)

• Inlet orifice replaced on Train 2

• Driers beds changed out

• ESDV-47001 downgraded situation rectified

• Elliot Compressors: replacement of 6 conical start up strainers by

spacers

* HGPI: Hot Gas Path Inspection

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OTHER OPERATIONAL FEEDBACKST i 2 I l t ti f t iTrain 2 – Implementation of new venturi

Benefits of reducing pressure drop:I th i li it• Increase the pipeline capacity

• Bigger buffer effect (packing/depacking)• Fuel gas savings at Upstream

Design flow rate

D i DP

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Design DP

Yemen LNGOperational feedbacks

THANK YOUTHANK YOU

APCI conference – September 2013APCI conference – September 2013

9/3/201323