Alaska Gasline Development Corporation Observation on Current Plant Design

Transcription

1 Alaska Gasline Development Corporation Observation on Current Plant Design Revised - June 22, 2018 Keiji Akiyama

2 Discussion topics 2 1. Project Economics Improvement - OPEX 2. Plant Cost Optimization - CAPEX 3. LNG train layout Observation and Potential Issues

3 Project Economics Improvement - OPEX 3 1. Minimize natural gas consumption- GHG emission Process scheme Gas turbine and compressor scheme and model selection Waste heat recovery 2. Improve plant availability Gas turbine and compressor maintenance 3. Increase LNG production capacity Effectively use large temperature difference. Consider production reduction during summer.

4 Temperature Distribution Profile Nikiski Airport 4 Summer and a*ernoon only Air Cooler design Whole year round Hydraulic design

5 Ambient Temperature Profile Nikiski Airport 5 Summer and A+ernoon only Whole year Hydraulic Design Average Air Cooler design

6 GHG Emission Comparison without Native CO2 6 ton- CO2/ton- LNG GTP Pipeline LNG Industrial GT Aero-derivative GT Steam Turbine

7 Waste Heat Recovery to improve energy efficiency 7 Fuel gas consumption is a major portion of plant running cost. Wrt fuel consumption of entire plant, major consumers are Ref. comp. GT (< 70%), not power 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.

8 Plant Cost Optimization - CAPEX 8 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

9 Modularization for on-shore LNG 9 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 and process design phase.

10 Module experience of LNG project to date 10 O n s h o re Project Country Liquefactio n Process Capacity MTPA Trains Operator Status NWS #5 Australia C3MR Woodside In operation Pluto Australia C3MR Woodside In operation Gorgon Australia C3MR Chevron In operation Ichthys Australia C3MR INPEX Under construction Yamal Russia C3MR Novatek In operation GLNG Australia Cascade Santos In operation QCLNG Australia Cascade BG In operation APLNG Australia Cascade CoP In operation Wheatstone Australia Cascade Chevron Under construction 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 O ff s h o re PFLNG1 Malaysia Nitrogen Petronas In operation PFLNG2 Malaysia Nitrogen Petronas Under construction Prelude Australia Shell DMR Shell Under construction Coral Mozambique APCI DMR ENI Just started Cost over run and schedule delay

11 Modularization Key points 11 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

12 LNG train layout - Observation 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 12

13 Optimize large bore, cryogenic piping MR circuit 13 MR 1st stage suction line

14 Optimize large bore, cryogenic piping Propane circuit 14 C3 1st stage suction line

15 Optimize large bore, cryogenic piping MR circuit 15 Pipe rack will be necessary for suction/discharge piping, isolation valves, and safety relief valves. Crane access will be difficult for these air cooler bundles.

16 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. 16

17 GTP Site Layout 17 CO2 Comp 3 AGRU 3 TG Comp 3 TG Comp 1 CO2 Comp 1 CO2 Comp 2 AGRU 2 TG Comp 2 AGRU 1 Power Gen Power Gen Power Gen

18 GTP Site Layout Recommended Concept 18 Recommend grouping together all TG compressors, CO2 compressors and power generators respec;vely considering opera;on and sparing philosophy AGRU 3 AGRU 2 AGRU 1 CO2 Comp 3 CO2 Comp 2 CO2 Comp 1 Dehyd. Dehyd. Dehyd TG Comp 3 TG Comp 2 TG Comp 1 Power Gen Power Gen Power Gen

19 How hot air recirculation occurs? 19 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 most seriously impacted.

20 Prevailing Wind Direction 20 Whole Year Whole Year Prevailing Wind Whole Year

21 Prevailing Wind Whole Year 21

22 Monthly Prevailing Wind Direction - Nikiski NKTA2 Buoy 22 From May to August

23 Prevailing wind - May to August and Afternoon only 23 Prevailing wind direction during summer Prevailing wind direction during summer

24 24 LNG Train Layout Potential Issues Prevailing wind direction during summer Compressor shelter should not be taller than ACHE banks Too close each other. Combine these two banks and line up parallel to prevailing wind Too close each other. Combine these two banks and line up parallel to prevailing wind Ensure sufficient air flow path behind tall columns and structures. Increase gap between main piperack and tall equipment and module

25 Maintenance Access 25 These ACHE should not be located here considering HAR Crane How to access to these ACHE?

26 26 Thank you Akiyama LNG Technology Consultant Office