DLN Retrofit in Two Frame 7 Gas Turbines RasGas LNG Company-Qatar

Presenters: Amr Gad Atul Deshpande RasGas, Qatar

Turbo 41 - Houston Texas Date: 27 September, 2012

Contents

Summary of the project DLN1 Fuel Staging & Operational Modes Process Compressors for RasGas Train 3 Requirements for DLN retrofit for Gas Turbines Project Milestones Project Organization Project Details & Results Challenges & Lessons Learned

Summary of the project

Regulations set by Ministry of Environment to achieve NOx emissions of 25 ppm for such turbines.

Two retrofitted units are driving Mixed refrigerant and propane in the LNG refrigeration cycle. Project engineered in years 2009-2010 and implementation done in year 2011 successfully. 1st successful DLN retrofit for Frame 7EA Gas Turbines in an LNG train.

DLN1 Fuel Staging & Operational Modes

Primary Mode
Diffusion Flame 100% Primary Fuel Ignition - 19% Load
Diffusion Diff /Premix

Transfer Mode
Diffusion Flame 100% Secondary Fuel 50% Load

Lean-Lean Mode
Diffusion Flame ~60% Primary / 40% Secondary Fuel 19% - 50% Load

Premixed Mode
Premixed Flame / Diffusion Pilot 81% Primary / 19% Secondary Fuel 50% - 100% Load For IBH machines or 80%-100% Load for machines without IBH
F/A Mixing
Diffusion/Premix Premix

Diffusion

Primary Zone Dual Purpose: 1. Low Load Diffusion Flame 2. High Load Premixing Chamber

Process Compressors for RasGas Train 3

FRAME 7 PROPANE COMPRESSOR HP MR COMPRESSOR

MOTOR

3,600 rpm

Propane Precooled MCR Process

LNG to Storage
Propane Compressor Scrub Column Main Cryogenic Heat Exchanger

Frame 7 Gas Turbine

Feed Gas

C5+ NGL

Mixed Refrigerant Compressors

FRAME 7

LP MR MP MR COMPRESSOR COMPRESSOR
3,600 rpm

MOTOR

Requirements for DLN retrofit

Stable fuel gas supply pressure Rate of change of MWI Contaminant free fuel gas Turbine Control logic upgrades for mechanical drive application

Requirements for DLN retrofit

Fuel Gas Pressure
Adequate & stable fuel gas supply pressure
Increase the fuel gas supply network pressure Fuel Gas Pressure Control Ramp Up Logic :
Considers scenarios of fuel compressor trip or upset Ensures fast make-up from back-up sources of fuel gas i.e. Fuel From Feed (FFF ) or Boil Off Gas (BOG) to sustain the minimum fuel gas supply pressure

Train-3 Fuel Gas Supply System

Train 3 FG Pressure Control Overview
Additional compressor capacity marginal, amps approaching 100% of rated load.
Fuel Gas Compressor

26.50

barg

PC 3003

Wet Gas Flare

16
93-PV3003B

Frame 7 Gas Turbines

36-KT001/004
Fuel From Feed KO Drum
PC 3002

93-E063

93-V062
93-PV3003A C D

Current pressure at Turbine FG skid Inlet = 25.9 barg

38-K001
83000 Nm3/h
FT 0830

5
93-PV3002
FT 0821 FC 307A

93-E052

38-E005
2,3 4

6
28.2
barg

Drier Regen. / Selexol

93-PV3003C/D

31.5
barg

33-FV307A 52000
Nm3/h

PSV's set at 34.5 barg

93-V061 Fuel Gas Mixing Vessel

How to achieve 27.8 barg at PC3003 and 26.3 barg at inlet to turbine fuel gas skid?

Requirements for DLN retrofit

Fuel Gas Quality
Limited changes in the fuel gas Modified Wobbe Index ( MWI ):
Resized the Fuel gas mix drum to meet max. MWI rate of change of 0.3%/sec from existing of 0.5%/sec. The new fuel gas mixing drum is around 25% bigger in volume to meet the rate of change of MWI as above

Requirements for DLN retrofit

Fuel Gas Contaminants
Meets OEM spec for fuel gas in terms of maximum allowable contaminants. LL from existing train indicates presence of Selexol can act as an ignition source & cause fire in fuel gas piping at valve skid in event of passing purge valves. Additional requirements resulted in upgrades in the fuel gas system as follows: Upgraded fuel gas filter skid to meet specs for liquid carry over & particulate size. Upgraded demisters for upstream fuel gas treatment column & KO drum. Provision of demister in the fuel gas mixing drum. Low point drains. Modified fuel gas skid with piping layout to prevent Selexol accumulation.

Requirements for DLN retrofit

Contaminants Free Fuel Gas
Lessons learned from another train:
Selexol carry over for fuel system Auto ignition of accumulated Selexol in presence of hot air from axial compressor discharge No combustion dynamics monitoring

Requirements for DLN retrofit

New Fuel Gas Valve Skid

Train-3 Fuel Gas treatment unit

Demister upgrades
PC 0201

44554 Nm3/h 148.3 ppm 76.4 ppm 27.6 barg SPT 120.0 PV 120.5 m3/h OUT 18.0%
FC 0201

14

33-V010
SPT 29.0 barg 40.1 mbar 39.3 5.4 mbar 39.2 7.4 mbar

Demisters upgrade for Selexol Absorber 33-C010 & Fuel gas KO drum 33-V010

39.6 oC

PV 27.7 barg OUT 0.0%

15

33-C010

38.9 27.2 mbar 38.8 SPT 40.0 PV 40.1

LC 0201

13

27.7 barg

OUT 23.2% PV 36.9

45300 Nm3/h 34.3 oC

38.0

Requirements for DLN retrofit

New Fuel Gas Filter Skid
N II

Filter elements are suitable for maximum operating temperatures 82C. Cartridges elements, made of CS604LGBH1 which is a amine compatible element working as coalescer element.

One coalescer cartridge is shown

N III

NI

New demister tray inside mix drum

N IV
Continuous flow phase Dispersed phase Condensate/ heavy Hydrocarbons

Milestones
Gate-1/ 2: Scope, strategy development, feasibility-technical & economic Pre-Feed & management approval: Aug09. Gate-3: What if Analysis: Aug 10. CDRA: Sep10. HAZOP: Oct10 Cold Eye Review : Nov10. Gate-4: Constructability Readiness Review : Feb11 Detailed Engineering completion & construction readiness: March11 Gate-5: Construction, commissioning & start-up:June11 Gate-6: Close out: & LL: Oct11

Project Organization

RG Project steering committee

RG Project Manger GE Project Team EPCM Project Team

Technical Lead

QA/QC Lead

Construction Lead

Project Engineer

Project Details & Results

Engineering man hours : 30,000 approx. Construction Man hours: 90,000 approx. Excellent safety records during construction. Construction and commissioning meet the plan schedules. Both turbines successfully re-commissioned post DLN retrofit Achieved NOx emission reduction:
Frame 7EA emissions
250.0 200.0 150.0 100.0 50.0 0.0 NOx mg/Nm3 SO2 mg/Nm3 Emissions O2 %

Value

3rd Q 2007 3rd Q 2011

Challenges & Lessons Learnt

Limited train shutdown duration of 22 days (Mechanical) Incorporate lessons learned from other frame 7EA DLN machines result in increase LNG train reliability: Fuel gas contaminant control measures (Filters, demisters, etc) Ramp-up logic for stable fuel gas supply pressure Additional scope for reliability improvement : Combustion Dynamic monitoring system Job Clash: Simultaneous construction with other activities during shutdown (Compressor overhaul, turbine major inspection and heavy lifting activities) Interface management with multiple parties Technical & project management issues Brown field application : Requirements of Smooth startup without production impact.

Thank you

] RasGas Company Limited 2012