Poster PO-58

ADVANCED PROCESS CONTROL QATAR GAS —

ONE YEAR EXPERIENCE
Bouchebri El-Hadi
Senior Process Engineer
Benmouley Abdelkader
Head of Process
Qatar Liquefied Gas Company Limited.
Ras Laffan Industrial Area, Doha, Qatar
belhadi@qatargas.com.qa
abenmouley@qatargas.com.qa

ABSTRACT

The objective of this paper is to present the Qatar Liquefied Gas Company one year
experience with the Advanced Process Control Technology. Advanced Process Control
was implemented in the Onshore Facilities with the objective of Maximizing LNG
production and reducing Steam consumption.

The paper will present details of APC configuration, covering not only the
liquefaction facilities but also treating, sulfur recovery, and fractionation units. An
overview will be presented of the actual APC performance improvement both during
acceptance testing and normal operation after implementation.

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I INTRODUCTION

Qatar Liquefied Gas Company is located in Ras Laffan Industrial Area about 90 Km
North of Doha, State of Qatar.

The Qatar Gas company is composed of two major areas i.e. offshore and onshore
Facilities; the offshore facility represents three well head platforms and three gas
treatment (Dehydration) trains. The dehydrated gas and condensate are transported to the
onshore facilities via an 82 km pipeline (32” diameter).

The Company main business objective is to produce Liquefied Natural Gas and
condensate as per design specifications and optimize use of plant facilities.

As part of Qatar Gas Plant optimization effort, Qatar Gas contracted Honeywell Hi
Spec Solution to implement Advanced Process Control (APC) for Upstream, 3 LNG
Process Trains and Acid Gas Enrichment and SRU units at the Ras Laffan facilities in
Qatar.

The three LNG Trains have been de- bottlenecked where a considerable capacity
increase has been reached; an important aspect in the plant operation is that ambient
conditions especially the summer (Day-Night) temperature affects the LNG run down
capacity due to gas turbine limitations.

The APC project second phase implementation was conducted on the Acid Gas
Enrichment (AGE) and Sulfur Recovery Unit (SRU) units; the second phase APC
implementation was initiated after the phase I APC implementation results exceeded the
guaranteed values.

The aim of Advanced Process Control (APC) implementation is to operate the plant at
the best operator conditions all the time without sea line pressure and LNG through put
variation. These new operating conditions were predicted to increase the cumulative LNG
production by 1.0% with the Robust Multi Predictive Controllers Technology (RMPCT)
controllers and additional 0.5 % with the profit Optimizer. The overall steam reduction
(Amine regeneration & fractionation units) was predicted to be reduced by 5 %. For the
SRU and AGE units, the APC objectives were set to increase the sulfur recovery by
0.1%, reduce the SO2 emission by 14.4% and reduce the steam consumption by 5.1% in
the AGE re-boilers units

The project has started in December 14th 2004 for a period of 13 months; the
performance test was conducted from 23 to 29 January 2006 for winter test and from 10
to 17 July 2006 for summer test.

The phase II project was started November 5th 2006, and it’s scheduled for a period of
6 months.

Twenty five (25) RMPCT controllers were connected to the DCS (Foxboro) Platform;
the Profit Optimizer handles the optimization constraints for the all 25 controllers. The
APC was implemented for the following sections:
A. Upstream onshore section
B. Condensate stabilization units

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C. LNG Trains 1, 2 and 3 Acid Gas Removal

D. LNG Trains 1, 2 and 3 Fractionation
E. LNG Trains 1, 2 and 3 Liquefaction units
F. Acid Gas Enrichment units**
G. Sulfur Recovery Units**

**: Controllers in Commissioning Phase

Qatar Liquefied Gas Company Plant General Overview

Qatar Gas Overview

LNG PLANT LNG STORAGE LNG LOADING

1450 MMSCFD
DOWNSTREAM
LNG PLANT SULFUR
UPSTREAM
SEPARATIO
N
OFF-PLOTS / HARBOUR / JETTY
-53M LNG

CD 82 km TANKERS,LNG,
CONDENSATE,
CONDENSATE STORAGE

SULFUR

OFFSHORE ONSHORE

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II- PROCESS OVERVIEW

Qatar Gas onshore plant receives the de-hydrated gas (condensate & Gas) from the
offshore platform via 32” pipeline. A first separation is taking place in the slug catcher
where gas will feed the three LNG Trains and condensate will be stabilized in the three
upstream trains.

The stabilized condensate (under RVP control) will be pumped to storage section
from the bottom of strippers, while the strippers overhead gas will be compressed and
mixed with the slug catcher gas to form the LNG trains Feed Gas.

The three identical LNG Trains are composed of the following section:
Acid gas removal section: removes H2S and CO2 under Amine Absorption reactions;
the rich Amine solution is regenerated at low pressure and high temperature in the
Amine regenerator column where the overhead acid gas is send to the Acid Gas
Enrichment unit for further treatment. The sweet gas is under H2S and CO2 on line
control.
Dehydration section: the sweet gas is dehydrated for moisture removal; the dry sweet
gas is under on line moisture content monitoring.
Mercury removal section: removes mercury for exchanger protection.
Liquefaction section: the treated gas is pre-cooled in HP-MP –LP propane Chillers to
reach -30 Deg C before entering the scrub column. The bottom of the scrub column is
directed to fractionation for further separation while the column overhead is sent to the
Main Heat Exchanger for liquefaction.
Refrigeration section: two main loops are included in this section; Multi refrigerant
MR (N2, C1, C2 & C3) and propane circuits. The MR is compressed in three stages,
cooled in the propane chillers then expanded through two Joule Thomson Valves in
the Main heat exchanger to liquefy the Natural gas via three bundles (warm, middle
and cold).
Fractionation: composed of three columns De-ethanizer, De-Propanizer, De-
Butanizer; the scrub column bottom stream is feeding the De-ethanizer, the de-
ethanizer bottom is feeding the De-propanizer and the De-Propanizer bottom is
feeding the De-Butanizer. The De-Butanizer bottom (mainly C5+) is routed to the De-
Iso- Pentanizer for Iso and Normal C5 separation.
The three columns (De-C2, De-C3, and De-C4) overheads are mixed in a same stream
and pre-cooled in a propane chiller before entering the Main Heat Exchanger and
being mixed with the Natural Gas as an LPG for heating value correction.
Nitrogen section: nitrogen is removed from the LNG to maintain the Heating Value as
per design figure; the nitrogen is extracted at low pressure and temperature from the
LNG in the nitrogen rejection column. The mixture nitrogen-methane from the column
overhead is compressed and mixed with the fuel gas streams
The LNG leaving the nitrogen column at -160 Deg C is pumped to the LNG Storage
tanks.
Helium: the Helium Extraction unit extracts helium from the LNG at low temperature
in a cold box unit; the produced helium is send to Ras Gas Company for storage and
commercialization.

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Acid Gas Enrichment AGE: The Qatar Gas Ras Laffan facility has two Acid Gas
Enrichment (AGE) units or trains, in series with two Sulfur Recovery Units (SRU).
These trains receive sour gas from the LNG Trains 1, 2 and 3 Acid Gas Recovery
(AGR) Units through a common header. The AGE process units include an Acid Gas
Absorber, Amine Solution Regenerator, Reject Gas Incinerator and auxiliary
equipment. The operating scheme uses the concept of Acid Gas Enrichment (AGE) to
achieve the design objectives of sulfur recovery unit, with the advantage of separating
most of the hydrocarbons and CO2 from the H2S in the acid gas from the Sulfinol units
prior to this gas being fed to the Claus plants. This increase of H2S in the acid gas
means that the Claus unit should not be susceptible to coking or other problems caused
by carbon formation. The enriched acid gases from the AGE amine regenerators are
combined in one header and fed to the two existing SRU.
Sulfur Recovery Unit: The SRU units process the enriched acid gas feed from the AGE
units and converts the H2S and other sulfur compounds to high purity sulfur. The
Qatar gas SRU utilizes the SuperClaus-99 process for recovering elemental sulfur
from the acid gas. The operating objective is to recover as much of the sulfur in the
feed as possible. The process scheme consists of three ordinary Claus Reactor stages,
followed by a Super Claus Reactor stage in which H2S is selectively oxidized. The
basic philosophy of the SRU operation is to control the partial combustion of H2S with
the ratio of air to maintain a specified H2S concentration at the outlet of the third stage
Claus Reactor. The main reaction in the main burner is:
3
H 2 S + O2 → SO 2 + H 2O + heat
2
The major part of the residual H2S combines with the SO2 to form sulfur, according to
the equilibrium reaction:
3
2 H 2 S + SO2 → S 2 +2 H 2 O − heat
2
By this reaction, known as the Claus reaction, sulfur is formed in vapor phase in the
main burner (X0901) and combustion chamber .The primary function of the waste heat
boiler is to remove the major portion of heat generated in the main burner. The
secondary function of the waste heat boiler is to utilize the above mentioned heat to
produce HP steam.

III- ADVANCED PROCESS CONTROL (APC) PROJECT

A. Scope of Work:
The project scope of work was decided based on other LNG plants experience as a
guide line and the Qatar Gas Engineers experience in the existing LNG plant.

The scope of work was finalized as follows:

Tuning of all relevant PID controllers.
Full training for Engineers and Operators to be provided.
Provision of all relevant hardware and software.
Performance test over 5 days for both winter and summer conditions.
Performance Guarantee – Based on the benefit study, APC project to guarantee a
minimum of 10 m3/hr LNG increase per train.

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B. Control Objectives and Strategy

1- Upstream
The upstream section optimization philosophy objectives are to maintain the sea line
pressure steady, control the pre-flash drum level at constant value and optimize the
condensate Reid Vapor Pressure (RVP) based on summer & winter limitations.

a) Slug catcher & Pre-flash drum Controller (# 1) Control the Slug catcher
and Pre-flash Drums levels while using the available buffer capacities. Balance the load
among the three strippers by adjusting the individual feed flows. Condensate.
b) Condensate Stripper controllers (# 3) the design of this RMPCT controller
is to control stabilizer bottoms RVP – derived from pressure compensated temperature.
The stabilizer overheads nC5 – derived from pressure compensated temperature, and the
condensate heater process stream passes temperature difference by balancing the
condensate flow from one pass to another to maintain the Delta T Passes as low as
possible. This will eliminate the high coil skin temperature.
2- Downstream
The down stream area optimization philosophy objectives are to maximize the LNG
run down from each train without exceeding any design or safety limit parameters.

To achieve these optimization objectives, the Advanced Process Control philosophy

was divided in three different areas; where the RMPCT Controllers were implemented for
each separate area.

a) Acid gas removal (# 3):

One Profit controller (RMPCT) per train is connected to the Acid Gas Removal unit
(Absorber & Rich Amine Regenerator) to optimize:
Lean Amine Circulation
Re-boilers Steam flow Consumption.
Regenerator reflux to Rich Amine Ratio (as per Vendor recommendations).

Achieving the above optimization targets without exceeding the below constraints:
Sweet Gas H2S & CO2 content as per design limitations.
Regenerator bottom temperature as per vendor specifications.

b) Liquefaction (# 3):
One profit controller (RMPCT) per train is handling the Manipulated Variables (MV)
and the Controlled Variables (CV) for the liquefaction and the refrigeration units to
maximize the LNG production per train. The philosophy is:
Maintain MR gas turbine close to the Machine Limited conditions all the time.
Maintain the Propane gas turbine close to the machine limited conditions all the time.
Maintain the LNG temperature outlet the Main Heat Exchanger constant at a desired
value all the time.
Scrub column overhead C5+ to be controlled at the design minimum value.
LNG Heating Value to be controlled at the desired value.

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End Flash Gas Compressor load to be controlled below the alarm setting.

The above conditions will optimally react to the day-night feed gas fluctuation and
therefore the best operator will be on duty all the time.

c) Fractionation (# 9):
Three profit controllers (RMPCT) per train will be optimizing respectively the De-
ethanizer, De-propanizer and De-Butanizer operating conditions as follows:
Maintain De-Ethanizer Column Pressure & Temperature Profiles constant as per
desired values (Design conditions).
Maximize the De-C2 overhead Ethane recovery.
Minimize the De-C2 Re-boiler steam flow.
Maintain the De-C3 Column pressure & temperature profiles constant as per preferred
values (Design cases).
Maximize the De-C3 overhead propane recovery.
Minimize the De-C3 Re-boiler Steam Flow.
Maintain the De-C4 Column pressure & temperature profiles constant as per preferred
values (Design cases).
Maximize the De-C4 overhead butane recovery.
Minimize the De-C4 Re-boiler Steam Flow.
OptimizetheDe-C4 bottom RVP by inferential calculation

d) Acid Gas Enrichment (#3)

1 Profit controller: is proposed in order to achieve optimum and stable distribution of
the combined acid gas feed from the LNG AGR units using advanced control system

2 profit controllers: This controller is proposed in order to achieve optimum and

stable distribution of the combined acid gas feed from the LNG AGR units using
advanced control system.

e) Sulfur Recovery Unit (#3):

1 profit controller: Optimum and stable distribution of the combined enriched acid
gas feed from the AGE units is an important objective of the advance control system.
Therefore, a single Profit Controller application is specified for distribution of the
enriched acid gas feeds to the two SRU.

2 profit controllers: The SRU units process the enriched acid gas feed from the AGE
units and converts the H2S and other sulfur compounds to high purity sulfur. The
operating objective is to recover as much of the sulfur in the feed as possible. The
process scheme consists of three ordinary Claus Reactor stages, followed by a Super
Claus Reactor stage in which H2S is selectively oxidized, and all associated ancillary
equipment. For the SRU, two Profit Controllers are envisioned, one for Train 1 SRU and
one for Train 2 SRU.

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3 Profit optimizer: The profit optimizer controller is linked to the twenty five profit
controllers, where all the constraints for the overall plant are handled in order to maintain
the total plant at Optimum Conditions (Maximum LNG rundown and minimum
acceptable energy consumption) without violating the design specifications and
equipments characteristics.

The profit optimizer objective function can be presented as follows:

J = − ∑i
P i × Y i + ∑ j
P j × F j + ∑
k
P k × U k

Where
J = the objective function to be minimized (QR/h)
Pi = the marginal value of the i’th product (QR/m3)
Yi = the flow of the i’th product (m3/h)
Pj = the marginal cost of the j’th feedstock (QR/m3)
Fj = the feed rate of the j’th feedstock (m3/h)
Pk = the marginal cost of the k’th utility, e.g. (QR/unit)

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Qatar Liquefied Gas Company APC phase I overview

Profit Controller
Profit Controller

Profit Controller

Profit Optimiser

Profit Controller

Profit Controllers

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Load
Distribution
Controller

Profit Controller 1 Per Train

Load
Distribution Profit Controller 1 Per Train
Controller

IV- Performance Test results

After Profit Optimizer was commissioned, a performance test was conducted in LNG
Train-2 for a period of 6 days; the test was conducted in winter and summer period

The performance test conditions were as follows:

Train-2 Feed gas fixed at 590MMscftd.

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Feed gases for other trains were floating on sea line pressure (Pressure maintained
between 79.8: 80.5 Barg).
Train-2 lean amine flow limited by a fixed high limit value to protect the lean amine
pump from power over load.
Lean Amine to Feed Gas Ratio floating between 1.64 to 1.8 m3/MMscft.

A. Tangible benefits
The below table shows a comparison between the main benefit objectives agreed and
the results obtained during the performance tests conducted during six days respectively
in winter and summer periods.

APC Phase I Winter Test Summer Test Guaranteed Values

% LNG Increase + 6.5 + 3.5 + 1.5
1
%Steam flow - 3.5 -10.8 -5
reduction
% Fuel Gas to - 4.2 - 0.6 Not measured as a
Condensate Heaters guaranteed parameter

1
: steam flow reduction target hasn’t been reached due to the Lean Amine to the Feed Gas Ratio was
set at a wide range (Design R =1.6 m3/MMscft) to avoid any sudden breakthrough of H2S or CO2 at
very high feed rate.

The below table gives the comparison results from 2004 to 2006 respectively pre and
post APC:

APC Phase I 2004 To 2006 Guaranteed Values

% LNG Increase + 4.6 +1.5

% Steam reduction - 7.1 -5

The above results are not only from the APC implementation but also due to:
Full involvement of Operation personnel during the two performance test periods.
Better tuning of the main plant controllers.

The below table gives the APC phase II average guaranteed parameters.

APC Phase II Guaranteed Values

% Sulfur Recovery + 0.1
% Emission Reduction - 14.4
% Steam Reduction - 5.1
Performance test is scheduled during the 2007 first quarter; the results will be
presented during the conference poster session.

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B. Non tangible benefits:

Maintain sea line pressure steady between 79.8 to 80.5 Barg
Maintain slug catcher & pre-flash drum level steady.
Maintain the condensate on- spec RVP steady at a desired fixed value.
Maintain the condensate heater two passes temperature close to each other.
Maintain the Amine regenerator bottom temperature (LNG Trains and AGE units)
constant at a desired fixed value.
Maintain the Amine regenerator column reflux to rich Amine ratio within the vendor
recommended range.
Maintain the Claus and super Claus reactors parameters steady close to design
conditions.

In addition to the above non tangible benefits, a survey results from Operation
Department (End users) is presented in the below table:

Criteria Rating
Overall satisfaction Very Good
Benefit value of APC Very good
Work load Less with APC
Process values meeting the Automatic and will not exceed the fixed ranges
set points
Interface Man-Machine Friendly

V- CONCLUSION
Advanced Process Control Technology Qatar Gas experience is less than 1 Year since
the phase I project commissioning.

The results obtained during the performance are exceeding the guaranteed value
regarding the LNG production.

Results of APC implementation is convincing. APC has helped to maintain sea line
pressure and load distribution among the three downstream trains.

APC has helped to reduce variation in many important parameters such as LNG trains
feed gas day- night variation.

Overall benefit figures in terms of production rise and energy savings are valuable.

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VI- APPENDIX:
A. Performance test Process Data Trends Comparison:
The process data were compared during 6 days performance test before and after APC
implementation.

Trend-1: Winter Test Steam to rich Amine Ratio Pre APC:

Steam To Rich Amine Ratio Pre APC ( Kg Steam / M3 R Amine)

100

95

90

85

80

75
23-Jan-05 24-Jan-05 25-Jan-05 26-Jan-05 27-Jan-05 28-Jan-05 29-Jan-05

Steam To Rich Amine Ratio KgSteam / M3 R Amine

Trend-2: Winter Test Steam to Rich Amine ratio Post APC

Steam To Rich Amine Ratio Post APC (Kg Steam / M3 R Amine)

100

95

90

85

80

75
23-Jan-06 24-Jan-06 25-Jan-06 26-Jan-06 27-Jan-06 28-Jan-06 29-Jan-06

Steam To Rich Amine Ratio KgSteam / M3 R Amine

Trend-3: Winter Test LNG rundown Pre APC:

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2FI805.PV P801A/B LNG Rundown Prduction Flow Pre APC (M3/H)

110.0%
107.5%
105.0%
102.5%
100.0%
97.5%
95.0%
92.5%
90.0%
2005-01-23 2005-01-24 2005-01-25 2005-01-26 2005-01-27 2005-01-28 2005-01-29

2FI805.PV P801A/B LNG RUNDN PROD F M3/H

Trend-4: Winter Test LNG rundown Post APC:

2FI805.PV P801A/B LNG Rundown Production Flow Post APC (M3/H)

110.0%
107.5%
105.0%
102.5%
100.0%
97.5%
95.0%
92.5%
90.0%
2006-01-23 2006-01-24 2006-01-25 2006-01-26 2006-01-27 2006-01-28 2006-01-29

2FI805.PV P801A/B LNG RUNDN PROD F M3/H

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Trend-5: Summer Test LNG Rundown Pre APC:

Summer Test LNG Rundown Pre APC

1000

980

960

940
LNG Rundown M3/H

920

900

Summer Base Line = 937 M3/H

880

860

840

820

800
10-Jul-04 11-Jul-04 12-Jul-04 13-Jul-04 14-Jul-04 15-Jul-04 16-Jul-04 17-Jul-04
Date

2FI805.PV

Trend-6: Summer Test LNG Rundown Post APC:

Summer Test LNG Rundown Post APC

1100

1080

Summer test LNG Increase = 3.49 %

1060

1040
LN G R un do w n M 3/H

1020

1000

980

960

940

920
Summer Base Line = 937 M3/H
900
12-Jul-06 12-Jul-06 13-Jul-06 13-Jul-06 14-Jul-06 14-Jul-06 15-Jul-06 15-Jul-06 16-Jul-06 16-Jul-06
Date

2FI805.PV

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B. 1 Year performance process data comparison:

The process data were compared between year 2004 and 2006, the results are shown
in the following trends.

Trend 7: Year 2004 steam consumption:

Pre APC Total Steam to Total Sulfinol Ratio Kg/M3

130

120

110
Steam to Amine Ratio Kg/M3

100

90

Average Steam to Amine ratio = 107 Kg/M3

80

70

60
2003-12-30 2004-02-18 2004-04-08 2004-05-28 2004-07-17 2004-09-05 2004-10-25 2004-12-14

Year 2004

Total Steam to Total Sulfinol Ratio Kg/M3

Trend 8: Year 2006 steam consumption:

Post APC Total Steam To Total Sulfinol Ratio Kg/M3

130

Steam Consumption reduction =7.14%

120

110
Total SteamTo Total Amine Ratio

100

90

80

Average Steam to Amine Ratio Kg/M3

70

60
2005-12-29 2006-02-17 2006-04-08 2006-05-28 2006-07-17 2006-09-05
Year 2006

Total Steam To Total Sulfinol Ratio Kg/M3

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Trend-9: Total plant LNG rundown year 2006:

Total Plant LNG Production Post APC

3200
4.6 to 5.2 % Increase on total LNG run down
3100

3000

2900
LNG Run Down M3/H

2800

2700

2600

2500

Average LNG run down = 2817

2400

2300

2200
29-Dec-05 17-Feb-06 08-Apr-06 28-May-06 17-Jul-06 05-Sep-06 25-Oct-06 14-Dec-06

Year 2006

Year 2006 total LNG run down

Trend-10: Total plant LNG rundown year 2004:

Pre APC Year 2004 total LNG run down

3200

3100

3000

2900
LN G ru n d o w n M 3/H

2800

2700

2600

2500

2400
Average LNG production = 2657 M3/H
2300

2200
30-Dec-03 18-Feb-04 08-Apr-04 28-May-04 17-Jul-04 05-Sep-04 25-Oct-04 14-Dec-04
Year -2004

Year 2004 total LNG run down

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Trend-11: Condensate heater passes temperature difference Year 2006

Condensate Heater passes post APC

5.00

4.50

4.00
Condensate Heater Passes DT C

3.50

3.00

2.50

2.00

1.50

1.00

0.50

0.00
2005-12-29 2006-02-17 2006-04-08 2006-05-28 2006-07-17 2006-09-05 2006-10-25 2006-12-14
Year-2006

Absolute Heater passes Delta T U-H8100 DEG C Absolute Delta T U-H8200 DEG C

Trend-12: Condensate heater passes temperature difference Year

2004
Condensate Heater Passes Delta T pre APC

5.00

4.50

4.00

3.50
Heater passes DT C

3.00

2.50

2.00

1.50

1.00

0.50

0.00
2003-11-25 2004-01-14 2004-03-04 2004-04-23 2004-06-12 2004-08-01 2004-09-20 2004-11-09 2004-12-29 2005-02-17
Year-2004

Absolute Heater Passes Delta T U-H8100 DEG C Absolute Heater Passes Delta T U-H8200 DEG C

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