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ABSTRACT
Qatar Liquefied Gas Company Limited (II) (Qatargas) and Ras Laffan Liquefied Natural Gas
Company Limited (3) (RasGas) have successfully completed commissioning, start-up and
operation of multiple Frame 9E gas turbine refrigerant strings. These 100+ megawatt compressor
strings provide energy for the propane, mixed refrigerant and nitrogen cooling loops as well as
electrical power to the four largest 7.8 MTA (million tons per annum) LNG Trains in the world at
Ras Laffan Industrial City in Qatar.
This paper will share the commissioning and start-up experience of these gas turbines, which
are included within the LNG liquefaction process and integral to the power generation system of
the LNG plant. The paper specifically addresses the unique and complex operating modes
associated with starting these large gas turbines, along with full and part load operating
conditions. The rigor applied to both static and dynamic commissioning and the success achieved
will be shared. Operating experience on how this unique application of Frame 9E gas turbines
have successfully responded to a wide mixture of fuel compositions and load upsets while
maintaining production and complying with stringent site emissions requirements, mitigated by dry
low NOx (DLN) technology and refrigeration loop pressurized starting, will also be covered.
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SYNOPSIS
The commissioning and start-up of the first Frame 9E driven refrigeration compressor strings
for the new Qatar LNG trains required a unique approach. The parallel execution of multiple
mega-projects, installation of the worlds largest LNG equipment and validation of many new
technologies represented unprecedented challenges to the project partners.
To take on these challenges, Qatargas and RasGas together with ExxonMobil, General
Electric (GE) and their sub-vendors assembled a team of experienced people and applied
structured processes to ensure the technology validation program effectively addressed
remaining risks prior to hand over of the refrigeration compressor strings to operations. To
minimize the risk of reliability problems post start-up, innovative strategies were adopted to
ensure system cleanliness. The entire twelve strings were also thoroughly tested during
commissioning including final validation of the DLN combustion systems and variable frequency
drive (VFD) starter/motor/generators. Consistent with the strategy of using the first mega-train,
Qatargas Train 4, as the leading train for complete refrigeration string design validation testing in
Massa Italy, real-time site implementation lessons learned were also carefully captured and
transferred immediately to the three remaining mega-trains during simultaneous site execution.
INTRODUCTION
Over the last year Qatargas and RasGas, with strong support from its shareholders Qatar
Petroleum and ExxonMobil, have successfully started operation of the largest LNG trains in the
world (7.8 MTA each). At the heart of these LNG trains are twelve of the largest refrigeration
compressor strings manufactured by GE. The function of the three refrigerant strings (per LNG
train) is illustrated in Figure 1. These are the first to be driven by Frame 9E dry low NOx gas
turbines with a combined overall compression power of more than 1000 megawatts (one
gigawatt) and incorporate advanced technologies not previously used in the LNG industry.
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within the different operating companies of Qatargas and RasGas. This created the need for
close coordination of work and the introduction of processes that facilitated real time sharing of
lessons within and across organizational boundaries. These processes were critical in capturing
the full benefit from the execution learnings obtained on Qatargas Train 4.
The complex sequence of commissioning programs across both plants and the extent of
critical activity overlap can be seen in the overall schedule depicted in Figure 2.
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people working together as a team. The role played by these three key elements, as shown in
Figure 3, will be illustrated throughout this paper.
PEOPLE
Successful projects involve highly skilled people working well together toward a common
goal. The leadership of the project management teams of Qatargas (QG-2) and RasGas
Expansion (RGX-2) mega projects set challenging objectives and the site personnel from all
organizations worked together to ensure these were met. Teams at both plants included a wellbalanced mix of young, enthusiastic engineers combined with very experienced engineers. The
result was highly effective teams working in a positive environment.
The commissioning teams for the large compressor strings involved the three primary
stakeholder organizations:
The three primary organizations associated with each project worked together as shown in
Figure 4 below. The site teams were continuously assisted by permanently assigned engineering
and management teams at ExxonMobil Development Company (EMDC) and GE headquarters in
the United States and Italy. CTJV provided much of the general execution support, and
established their own 3LNG Organization to ensure effective sharing and application of lessons
learned between the Qatar mega-train LNG projects. Specialized technical support was provided
by GEs sub-vendors and other specialist organizations from around the globe.
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in addition to the usual technical field support disciplines of Machinery/Mechanical, Electrical and
Instrumentation & Controls.
TECHNOLOGY
The Air Products AP-X liquefaction process requires three independent refrigeration
compressor strings (Propane (C3), Mixed Refrigerant (MR) and Nitrogen (N2)). A schematic of
the string layouts is depicted in Figure 5. Each string utilizes a GE Frame 9E single shaft gas
turbine driving through an Ansaldo Sistemi Industriali (ASI) starter/motor/generator, powered by a
Siemens Variable Frequency Drive (VFD).
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In summary the new technologies incorporated into the 12 compressor strings include:
First mechanical drive variable speed Frame 9E gas turbine customized for LNG
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Dry Low NOx (DLN) combustion system and controls able to accommodate large
variations in fuel gas composition, load demand and ambient temperatures
Active Front End (AFE), capable of generating electrical power at nonsynchronous speed
Integrated gas turbine, VFD, plant process control and power management system
controls
To ensure the success of so many new technologies, complete validation of the final
refrigerant compressor string design was required. Due to practicality limitations this validation
effort was divided into two phases.
First, a prototype of each unique string was built as part of the Qatargas Train 4 project and
full load tested in Italy during the Massa String tests completed in June of 2006. This test program
successfully validated the majority of the new design aspects that would be used on all of the
Qatar mega LNG trains including the operability of the complete strings, functionality of the
redesigned DLN combustion control strategy, the performance and reliability of the VFD drive and
starter/motor/generator system, the pressurized restart capability and the performance of the gas
compressors and dry gas seals.
Second, the remaining technology areas that were not practical to test on the prototypes in
Massa required validation at the site on the actual strings after mechanical acceptance was
achieved. This included:
1. Dynamic full load operation on plant fuel gas with high nitrogen concentration
This validated the DLN combustion system and, in particular the operability and
reliability during rapid changes in fuel gas composition
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PROCESSES
Both RasGas and Qatargas have a proven history of successfully executing large LNG
projects and safely starting-up, and reliably operating and maintaining these complex facilities.
This has been achieved through the use of well proven work processes that govern day-to-day
activities. ExxonMobil and GE are also organizations well known for such structured work
processes, many of which were a valuable contribution.
The proprietary capital project management systems of ExxonMobil and the Operating
Companies guided the development of a structured framework for planning the installation and
commissioning activities associated with these multiple large machinery packages. Experience on
previous Qatar LNG projects led to early design enhancements and also to procedural
improvements integrated into all phases of the project execution.
Red Flag Reviews
GEs Red Flag Reviews are based on project-specific dedicated checklists that are verified
and approved by the site team at critical commissioning stages and become part of the official
project documentation. All sub-systems such as, the lube oil and fuel gas systems are physically
checked at the site for correct assembly, integrity, and adherence to design requirements. A set
of detailed functional test procedures, first developed at the Massa string tests, were validated
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and updated accordingly for site conditions. This process has now become the standard
approach for GE.
Lessons Learned Process Real Time Sharing
Due to the large scope of parallel work execution at two adjacent sites, ExxonMobil and GE
assigned key leadership positions responsible for ensuring real-time capturing and sharing of
lessons across the site boundaries. Initiatives adopted included regular meetings between the
ExxonMobil, Qatargas and RasGas machinery site teams at which general execution learnings
were shared. Dedicated joint meetings were also held to review specific topics such as piping
alignment strategies and duty run procedures. A Lessons Learned Register tracked closure of key
GE learnings from QG-2 that were applicable to RasGas. These were reviewed on a weekly basis
with the RasGas site teams.
Real-time integration of lessons learned across projects brought immediate results with a
reduction in the commissioning time (motor solo-run to first LNG) of many months for QG-2 Train
5 compared to QG-2 Train 4. These lessons learned also enabled a reduction in commissioning
schedule on both RasGas trains.
FMEA Unique Application of an Industry Standard Tool
The traditional Failure Mode & Effect Analysis (FMEA) is commonly used in many industries
to identify and address design deficiencies in the early stages of a product development.
ExxonMobil and GE have also successfully utilized FMEA to identify and prioritize remaining
integrity, schedule and reliability risks that still remained in the latter phases of our most complex
projects. The types of failures in focus included those that could be attributed to incomplete
technology validation during the first phase in Massa and potential execution process problems
during the second phase at site.
The unique use of FMEA for this application was triggered by a comprehensive strategy
initiated by the QG-2 project team to assess and manage the risks of successfully introducing a
large number of new technologies (not limited to the compression strings) on the worlds first
7.8MTA Trains.
Large multi-disciplinary teams from Qatargas, RasGas, ExxonMobil, GE, Siemens and the
other sub-vendors, conducted three independent reviews of the gas turbine package, compressor
packages and Siemens VFD systems to address all aspects of the final as-tested design, the
commissioning and validation plans, and first start-up/operating procedures.
A ranked list of potential risks and mitigating action plans (including hardware and software
changes or specific validation tests) was produced for evaluation and implementation by
GE/Siemens and the two project teams, ensuring all high priority risks were addressed prior to
start-up. The role of the FMEA Reviews is illustrated in Figure 6.
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Revised installation procedures for the hydraulic fit couplings to address possible shaft
damage during installation
Tooling improvements and procedural changes for the installation of the dry gas seals
Validating total string alignment in the field by installing targets at critical reference
points along the string and using optical surveying tools to measure the final installed
shaft offset in the idle and operating conditions
One of the more important and complex issues identified during the FMEA of the Siemens
VFD system was the potential for arc flash related damage: a thermal and/or mechanical effect
created by the sudden, even if relatively small, pressure increase inside the cabinets where the
power equipment is installed.
To minimize this risk a thorough study of the effectiveness of an arc flash detection system
concluded that a well designed system could significantly abate the amount of energy involved in
an arc flash event. Such a system detects the light of the initiating arc flash and cuts the power to
the equipment within a few milliseconds, thus stopping escalation and reducing the extent of
damage.
Qatargas and RasGas installed arc flash detection systems and reinforced the cabinets to
reduce the damage consequence. Siemens calculated the potential pressure rise within the
cabinet which determined the cabinet reinforcement requirements. Pressure release vents were
also built into the cabinet roof to safely release any potential rapid rise in pressure, improving
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safety for any nearby operators and maintenance personnel. Finally, tests were performed in a
laboratory to prove the effectiveness of the adopted measures.
The installation of the arc flash detection system was completed prior to start-up and provided
immediate benefits during site commissioning when the system activated and prevented severe
damage following a 33kV VFD input transformer fault.
In summary, the unique application of the traditional FMEA during project execution was a
critical step in identifying and mitigating risks that would have impacted the success of the startup and subsequent reliable operation of the new Qatargas and RasGas LNG trains.
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might be required to avoid operability/reliability risks. A project specific risk matrix similar to that
provided in Figure 10 provided the focus areas for the later site DLN testing program.
Modified light-off sequence for reliable start-up with variable fuel gas
String acceleration sequence with coordinated control of Frame 9E, helper motor and
process compressor
New control logic for the DLN combustion modes during steady state and transient
conditions: process upsets; start-up; shutdown
Software to calculate remaining gas turbine power available to base load considering
turbine degradation and a wide range of fuel gas compositions
Massa String Testing. The prototype string testing program provided initial validation of the
new control logic while also validating the new combustion hardware performance in an operating
gas turbine.
Fuel Gas System Design Optimization. The RGX-2 and QG-2 fuel systems, designed by
CTJV, utilized the Greenville test results to establish the maximum allowable Wobbe Index rate of
change. The size of the fuel gas mixing drum and the final fuel gas system control strategy were
critical in preventing flame-out as the fuel changed from EFG to FFF and vice versa. Dynamic
simulations of the entire Qatargas and RasGas fuel systems were run to ensure that all scenarios
were covered. The highest risk scenario was a trip of the fuel gas compressor which would result
in a sudden stop of the EFG fuel gas supply as can be seen in Figure 11. This scenario was
tested at the site with the Frame 9s near full load, with no resulting shutdown of the refrigeration
strings.
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refrigeration string torsional resonance, as well as any possible excitation of balance of plant
rotating equipment. This assured that the original design required no external suppression of the
plant electrical system.
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CONCLUSION
Qatargas and RasGas with strong support from the technology and technical teams in
ExxonMobil, and working closely with CTJV and GE, are proud to report the safe installation,
commissioning and start-up of the twelve large refrigeration compression strings within the four
new mega LNG trains in Qatar.
These unique compression strings incorporate many new features that would help reduce
operating costs and the associated impact on the environment.
The economies of scale have been stretched once again, and the challenge to safely
commission and start such a large number of complex facilities in parallel within an eighteen
month period required significant support from all involved organizations. Meeting that challenge
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can be attributed to the quality of the people involved, teamwork and the structured processes
used in bringing this state-of-the-art technology from concept to reality.
Success can be measured by the safe and efficient completion of the comprehensive
commissioning and testing programs on all twelve refrigeration compressor strings and the
minimization of significant post start-up production losses.
REFERENCE CITED
(1) Roy Salisbury et al, Design, Manufacture, and Test Campaign of the Worlds Largest LNG
Refrigeration Compressor Strings, LNG 15, April 2007.
BIBLIOGRAPHY
(1) Ching Thye Khoo et al, Execution of LNG Mega Trains The Qatargas 2 Experience, 24tth
World Gas Conference, October 2009
(2) Mark J. Roberts et al, Large Capacity Single Train AP-X TM Hybrid LNG Process , GasTech
2002, October 2002
DEFINITIONS
AFE
CFD
Refrigeration
Compressor
String
complete machinery package including the Frame 9E Gas turbine driver, helper
starter/motor/generator and process gas compressors
LNG Train
single LNG processing plant that incorporates three refrigeration compressor strings
(Propane (C3), Mixed Refrigerant (MR), and Nitrogen (N2)
LNG Plant
total LNG processing plant that can incorporate numerous LNG trains
Duty Runs
Operation of the gas turbine-driven compressor strings in recycle mode prior to LNG
production commencing
Massa
small town on the west coast of Italy where GE Oil & Gas has a testing site for
completing full scale testing of complete machinery strings
VFD
FMEA
DLN
MTA
CTJV
PMT
MAC
FSNL
Full Speed No Load Early gas turbine test prior to connecting to the process
compressors
Operation of the electric motor when disconnected from the driven equipment
EFG
FFF
Fuel From Feed Fuel gas derived directly from plant feed gas
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BOG
Boil Off Gas Fuel gas derived from LNG boil off
IBH
Inlet Bleed Heating: System used to re-circulate air from the gas turbine facilitating
operation in DLN mode at low loads
v2
measure of gas flowing momentum that includes gas density and velocity
PMS
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