Enhance the Operating Capacity - Maximize the Revenue

Abstract

To explore the opportunity for maximum utilization for one of gas processing facilities in line with ADNOC strategy to enhance profitability and asset utilization. A Technical study was conducted to increase the processing capacity up to 115% of its design limit. This was to identify the potential bottlenecks in the facility and suggest debottlenecking options with a reasonable investment. The Technical study covers the following activities: Rigorous process simulation including the licensor units of NGL & AGRU.Line sizing adequacy check and detailed hydraulic evaluation of the major piping.Equipment adequacy check.Relief & blowdown and flare system adequacy check.Proprietary equipment/design evaluation of licensed units.Adequacy check for In-line instruments like control valves, flow elements/transmitters, ThermowellsRotating equipment adequacy checks performed with the concurrence from OEMs.Obtained Endorsement of NGL licenser (Ortloff) for the methodology of 115% adequacy check, with a recommendation to gradually increase the plant rate in 1% at a time and monitor the performance until achieving the required targetRisk assessment was conducted before the capacity testActual plant capacity test run to verify the study findings. The study has concluded the following observations for processing 115% of the design capacity: High flow alarms set points need to be changed at some locations due to increase gas flow rates.550 oo 1133 of thermowell are not adequate based on new design CODE. These thermowells are to be replaced for the continuous operation.6 Filters to be upgraded with required capacity. A Successful two days Test-run was conducted in June 2018 and there are no additional limitations identified other than identified in the study. Following are the outcome. Reduction of the C2 recovery by 1.2 % with no significant change in C3 recovery level.Increase in Residue Gas by 30 MMSCFD per trainIncrease in NGL by 235 TPD per trainIncrease in condensate by 2100 BPD per train Overall Product wise revenue per train was identified at a sum of 62.5 MMUSD/Y.