observation on current plant design€¦ · • process scheme • gas turbine and compressor...
TRANSCRIPT
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Alaska Gasline Development Corporation
Observation on Current Plant Design
Revised-June22,2018
KeijiAkiyama
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Discussion topics
1. Project Economics Improvement - OPEX2. Plant Cost Optimization - CAPEX3. LNG train layout – Observation and Potential Issues
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Project Economics Improvement - OPEX
1. Minimize natural gas consumption- GHG emission• Process scheme• Gas turbine and compressor scheme and model selection• Waste heat recovery2. Improve plant availability• Gas turbine and compressor maintenance3. Increase LNG production capacity• Effectively use large temperature difference.• Consider production reduction during summer.
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Temperature Distribution Profile – Nikiski Airport4
Summeranda*ernoononly
Wholeyearround
AirCoolerdesign
Hydraulicdesign
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Ambient Temperature Profile – Nikiski Airport5
SummerandA+ernoononly
Wholeyear
AirCoolerdesign
HydraulicDesign Average
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GHG Emission Comparison – without Native CO26
ton-CO2/ton-LNG
Industrial GT
Aero-derivative GT
Steam Turbine
GTP
LNG
Pipeline
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Waste Heat Recovery to improve energy efficiency
• Fuel gas consumption is a major portion of plant running cost.
• Wrt fuel consumption of entire plant, major consumers are Ref. comp. GT (< 70%), notpower gen. GT (< 30%). Waste heat recovery from the latter is less effective.
• Waste heat recovery unit on Ref. comp. GT may have modularization issue.
• Usage of recovered energy from waste heat will be limited.
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Plant Cost Optimization - CAPEX
To optimize module fabrication and site construction cost,• Minimize large bore piping quantity• Minimize height of pipe rack and steel structure• Minimize site integration work volume (carry over work), particularly
• Electrical and instrument cable installation and termination• Piping/equipment cold insulation and painting• Minimize hydrostatic test of pipe loops at site
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Modularization for on-shore LNG
• Modularization of on-shore LNG plant is different from off-shore application. Recognize“particulars”
• Incorporate uniqueness of module approach from early stage of project, e.g. concept andprocess design phase.
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Module experience of LNG project to dateProject Country Liquefaction Process
CapacityMTPA Trains Operator Status
NWS #5 Australia C3MR 4.2 1 Woodside In operation
Pluto Australia C3MR 4.9 1 Woodside In operation
Gorgon Australia C3MR 5.2 3 Chevron In operation
Ichthys Australia C3MR 4.5 2 INPEX Under construction
Yamal Russia C3MR 5.5 3 Novatek In operation
GLNG Australia Cascade 3.5 2 Santos In operation
QCLNG Australia Cascade 4.3 2 BG In operation
APLNG Australia Cascade 4.5 2 CoP In operation
Wheatstone Australia Cascade 4.5 2 Chevron Under construction
PFLNG1 Malaysia Nitrogen 1.2 1 Petronas In operation
PFLNG2 Malaysia Nitrogen 1.5 1 Petronas Under construction
Prelude Australia Shell DMR 3.6 1 Shell Under construction
Coral Mozambique APCI DMR 3.3 1 ENI Just started
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Issues
Cost over run and schedule delay
Cost over run and schedule delay
Cost over run and schedule delay
Cost over run and schedule delay
Cost over run and schedule delay
Onshore
Offshore
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Modularization – Key points
• Modularize large bore piping around refrigerant compressors. Don’t use “stick built” of gas turbines and compressors.
• Re-visit gas turbine driver model to facilitate modularization
• Review module transportation route and sequence of erection
• Review electrical cable route from substation to large motors
• Ensure proactive project management of module fabrication at yard
• Ensure flexibility of ocean transportation schedule
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• Current design assumes stick built of refrigerant compressor/gas turbine driver, not module.Majority of large bore piping installation & test will also stick built accordingly.
• Optimize layout to minimize large bore piping quantity.• Provide maintenance access, particularly for air cooled exchanger bundles.• Consider cable route from substation to large motors – Location of substations• Consider module transportation route and sequence• To minimize adverse impact due to hot air re-circulation,
• Evaluate distance between LNG trains• Evaluate direction of LNG trains to lined up with prevailing wind.• Evaluate gap between main piperack and tall equipment modules and columns
LNG train layout - Observation12
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MR 1st stage suction line
Optimize large bore, cryogenic piping – MR circuit13
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C3 1st stage suction line
Optimize large bore, cryogenic piping – Propanecircuit
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Optimize large bore, cryogenic piping – MR circuit15
Pipe rack will be necessary forsuction/discharge piping, isolationvalves, and safety relief valves.
Crane access will be difficultfor these air cooler bundles.
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GTP layout - Observation• Recommend grouping together all TG compressors, CO2 compressors and power
generators respectively considering operation and sparing philosophy• Recommend not to rotate 1st train only. Use same design and direction for all trains.• Make sure if AGRU absorber can be integrated in module. Absorber is the heaviest vessel
in LNG plant.
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GTP Site Layout17
CO2 Comp 3
CO2 Comp 2
CO2 Comp 1
TG Comp2
TG Comp3
TG Comp1
Power Gen Power Gen Power Gen
AGRU2
AGRU3
AGRU1
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GTP Site Layout – Recommended Concept18
CO2Comp 2
CO2Comp 3
CO2Comp 1
TG Comp2
TG Comp1
TG Comp3
PowerGen
PowerGen
PowerGen
Dehyd.1
Dehyd.2
Dehyd.3
AGRU 3 AGRU 2 AGRU 1
• RecommendgroupingtogetherallTGcompressors,CO2compressorsandpowergeneratorsrespec;velyconsideringopera;onandsparingphilosophy
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How hot air recirculation occurs?
Hot Air Recirculation will be problematic when• Ambient temperature is high, and• Wind direction is perpendicular to ACHE bank (cross
wind), and• Wind speed is high, say above 3 m/sec.
Propane condenser and sub-cooler will be mostseriously impacted.
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Prevailing Wind Direction20
PrevailingWind
WholeYear
Whole Year Whole Year
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21Prevailing Wind
Whole Year
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Monthly Prevailing Wind Direction - Nikiski NKTA2 Buoy22
From May to August
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Prevailing wind - May to August and Afternoon only23
Prevailingwind
directionduringsummer
Prevailingwind
directionduringsummer
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Too close each other. Combinethese two banks and line up
parallel to prevailing wind
Too close each other. Combinethese two banks and line up
parallel to prevailing wind
Compressor shelter should notbe taller than ACHE banks
Ensure sufficient air flow pathbehind tall columns and structures.
Increase gap between mainpiperack and tall equipment and
module
Prevailingwind
directionduringsummer
LNG Train Layout – Potential Issues
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Maintenance Access25
How to access tothese ACHE?
TheseACHEshouldnotbelocatedhereconsideringHAR
Crane
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Thank you
Akiyama LNG Technology Consultant Office
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