Resilient Operations to Deliver Energy 26 October 2016

Cryogenic Heat Exchanger ... AFC Motor Replacements HAR Shielding C 3 PRV Re-setting (TAR) Turbo Expander Repair AGI Repair Build Temporary & New Perm...

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TANGGUH LNG

Resilient Operations to Deliver Energy 26 October 2016 Dharmawan Samsu & PD. Supriyadi

SKKMIGAS 26 October 2016

Outline

TANGGUH LNG

 Tangguh LNG Operations • Operating Management System • Safety Culture

 The Technology • • • •

Inherently Safe Design Gas Production Facilities Dual Flash Energy Efficient Gas Treating Propane Precool Split MR Refrigeration Energy Efficient & Environmentally Friendly LNG Plant

 The Challenges: A Never Give up Journey to Achieve Name Plate  Operations Performance  Q&A 2

TANGGUH LNG

Tangguh LNG Operations

Operating Management System & Safety Culture

TANGGUH LNG

1. How We Operate 2. Operating Discipline • • •

Follow the rule Finish what we start Follow up

3. Safety Leadership • •





Operating Management System OMS is a structured set of processes designed to keep operations safe, compliance, reliable and efficient.



Will relentlessly pursue the ultimate objective of an injury free workplace Will not compromise our focus on safety in order to achieve any other business objective Believe that our safety actions are most effective when we genuinely care about each other Will maintain an environment for open and transparent reporting and recognize behavior which is consistent with our values Will hold to account for those who knowingly disregard the rules

Vision: OneTeamTangguh to be the best Safety:

People:

Performance:

“We will be the leader in personal and process safety”

“We build capability and energize our Team”

“We will be the best-in-class high-reliability LNG Operator”

• Compliance with legal and BP requirements • Rigorous application of procedures and practices • Process safety definition and standards understood by all • Immediate reporting, and deep follow-up on all incidents and upsets • High-quality HSE programs and inputs • Plant integrity is managed to the highest standards and corrosion is prevented

•Provide high quality training to deliver great performance •A clear organization, filled with competent people •Clear targets for localization are set and performancemanaged •Roles & responsibilities for every position: personal objectives we are held to •Reward and progression are earned by performance •People are proud to be part of BP and OneTeamTangguh

• We meet all our cargo commitments: right-ontime • We demonstrate Continuous Improvement in production efficiency • Rigorous Plant Upset Reporting: we anticipate and prevent losses • We manage costs carefully, never compromising safety or integrity

People look for, and immediately report hazards: take action, and learn from incidents

A place where people choose to work, and are able to do their best work ever

A culture where we hunt for defects, drive them out, and recognize this as success

TANGGUH LNG

Continuous Improvement “We reduce risk and increase efficiency in our work, every day” • OMS is applied with rigor by Line Leadership: we use PIC to close our gaps • We complete Risk Reviews every 6months, and link the actions to OMS score • Activity Planning is implemented strictly: we only do work we’re ready to do well • Our Continuous Improvement projects are owned, and deliver risk reduction • We use every incident to understand our systems better, and to improve them • We use Lessons Learned: we react to them on time and implement them properly

Tomorrow is safer and more efficient than today: our systems improve year-on-year

Tangguh LNG Overview Tangguh Overview BP operated LNG business in Asia BP (37.16%) with 6 Tangguh Partners: CNOOC (13.90%), MI Berau (16.30%), Nippon Oil (12.23%), KG (10.00%), LNG Japan (7.35%) and Talisman (3.06%) Full value-chain: wells, reception facility, LNG plant, export 2 offshore platform: 250 mboed 2 x LNG trains, 7.6 mtpa 116 standard LNG cargoes/year

220 BP staff

800 contractors

94% national staff 24% female on track to deliver 85% Papuan by 2029

EMS:ISO 14001 PROPER: 5X Blue

TANGGUH LNG

Tangguh Integrated Facilities Tangguh LNG Process Block Diagram VR-A LNG Process Block Diagram Tangguh VR-B GAS



WELLS

PIPELINES

CO2

GAS WELLS H2S

H2O PIPELINES

RECEIVING RECEIVING FACILITIES FACILITIES

GAS GAS TREATING TREATING UNIT UNIT

RECEIVING RECEIVING FACILITIES Hg FACILITIES CONDENSATE CONDENSATE STABILIZER STABILIZER

CO2

H2S

LNG LNG H2O LIQUEFACTION LIQUEFACTION UNIT UNIT

GAS GAS TREATING TREATING UNIT UNIT



LNG LNG LNG LNG LIQUEFACTION LIQUEFACTION UNIT UNIT

LNG

FRACTIONATION FRACTIONATION UNIT UNIT

Hg

CONDENSATE CONDENSATE STABILIZER STABILIZER

 FRACTIONATION FRACTIONATION UNIT



2 X Normally Unmanned Platforms (14 Producing Wells)



2 X 3.8 MTPA LNG



ca 6,000 bpd Condensate



2 X 170,000 m3 LNG Tanks



1 X 120,000 bbl Cond Tank



3 X 35 MW Steam Turbine Generator

Green Design •

Normally No Flaring



Acid Gas Incinerated



Less CO2 Emission

Energy Efficient •

CONDENSATE CONDENSATE UNIT

 Utilities UtilitiesSupporting SupportingTwo TwoTrains TrainsOperation Operation •Power, Steam, Water, Air, •Power, Steam, Water, Air,Nitrogen, Nitrogen,Fuel Fuel •Waste •WasteTreatment Treatmentand andDisposal Disposal •Fire •FireFighting Fighting Utilities UtilitiesSupporting SupportingTwo TwoTrains TrainsOperation Operation •Power, •Power,Steam, Steam,Water, Water,Air, Air,Nitrogen, Nitrogen,Fuel Fuel •Waste •WasteTreatment Treatmentand andDisposal Disposal •Fire •FireFighting Fighting

Facilities

CONDENSATE

Combine Cycle Power Generation

Proven Technology •

APCI Propane pre-cooled (80% used in base load LNG Plants)

TANGGUH LNG

The Technology

Inherently Safe Design Gas Production Facility NUI with no overnight accommodation to avoid personnel exposure

No helicopters philosophy to minimise hazards

TANGGUH LNG

Topsides rated for WHSP to simplify and avoid overpressure

CRA piping to eliminate corrosion

No platform power generation to avoid hazardous storage and operations

Open layout and grated decks to increase gas dispersion

Export riser located within structure

No hydrocarbon processing to reduce leaks and inventories

Production Wells • 2 Normally Unmanned Installation Platforms (VRA & VRB) • Each Platform has dedicated 24” subsea flowline • Integrated on Onshore Receiving Facility as inlet to 2 LNG Train • VRA: 6 wells; VRB: 8 wells − 7” monobore ; Super Chrome Tubing − Cased hole & perforated completions − Initial production limit to 240 MMSCFD Real time surveillance data could be accessed from onshore Dual Stream I Advanced Metering

Acoustic Sand Detector

Remotely Controlled Downhole Pressure Gauge Xmas Tree & Adjustable Choke

Dual Flash Energy Efficient Gas Treating

• Feed gas: 720 MMSCFD & CO2: 11.5% • Solvent : aMDEA (BASF) • The Low Pressure flashing significantly reduces the CO2 in the rich amine • Less steam consumption for acid gas stripper (around 70% energy saving compared to Single Flash). 11

TANGGUH LNG

APCI Propane Precool MR Refrigeration

Natural Gas Liquefaction Process • Sweet & dry gas precooled to – 35C by propane refrigerant • Heavier component removal at scrub column • Liquefaction and subcooling at Main Cryogenic Heat Exchanger • Subcooled LNG product flows by its pressure to LNG tank 12

TANGGUH LNG

Mix Refrigerant Composition N2 : 8% Methane : 44% Ethane : 40% Propane : 8%

Refrigerant Compressor System 54 MW

TANGGUH LNG

27 MW • Required Power: 80.5 MW • Driver : - Gas Turbine : 68.9 MW - Steam Turbine : 19 MW

Propane Precooled Split MR Benefit • Optimize power utilization of GT & ST with identical engine which simplified maintenance, spare part and operations • Higher thermal efficiency with combine cycle configuration of GT-HRSG-ST and back pressure ST which produce LP steam for AGRU reboiler.

61 MW

17 MW • Required Power: 78.5 MW • Driver : - Gas Turbine : 68.9 MW - Steam Turbine : 13.5 MW

13

Energy Efficient & Environmentally Friendly LNG Plant Combine Cycle, Boil Off Gas Recovery, Dry Low NOx GT

Combine Cycle Energy Saving • Each HRSG produces 130 t/h steam • Equivalent with 48 MMSCFD LP fuel saving (2 Trains ) 14

Environmentally Friendly • Less CO2 emission • Very low NOx ~12 – 20 ppm

TANGGUH LNG

TANGGUH LNG

The Challenges

TANGGUH LNG

First Year Operating Challenges – A Never-Give-Up Journey to Achieve Name Plate Capacity

HAR Shielding C3 PRV Resetting (TAR) Choke Replacement Program (TAR) Choke Oversize

Subsea Pipeline VRA Subsea Pipeline Leak Pipeline Repair

On-shore Receiving Facilities (ORF) HC Liquid CarryOver

D-1004 Modification (TAR)

AGRU Low Performance due to HC Carry-over Vortex Breaker Modification (TAR)

First Year Operation Challenges • Facing Many Design Problems • Executing 25++ Major Modifications & Repairs • Synergizing New Teams with various nonBP and non Oil & Gas back-grounds • Managing remote area PSCM challenges • Managing stable Operations 16

Dry Gas Seal (DGS) Problem

Hot Air Recirculation Refrigeration Problem C3R

AGI Repair Acid Gas Incinerator (AGI) Refractory problem Gas Sweetening (AGRU)

DGS Temporary & Fix Repairs

AFC Motor Replacements

HPMR Repair

HPMR Big O-Ring Failure

Gas Treating

Tank-2 Repair

MR

Tank-2 Roof Rupture

C3R MR Fuel

LNG Storage Tanks

Liquefaction

(H2O & Hg Removals)

Expanders No C2/C3 Manufacturer Production Dryer Bed Defect Failures

Dryer Repair & Hg Catalyst replacement

Scrub Column Modification (TAR)

BOG Repair BOG DGS Problem BOG Comp.

Fuel Utilities

LNG Loading

LNG

Turbo Expander Repair

Power Cooling Water Waste Water Treatment PWT Under Design Build Temporary & New Permanent PWT Plant

Key Achievements • Completed Major Repairs and Modifications Safely • Increasing name plate and Operating Efficiency • Maintain Team Endurances

TANGGUH LNG

Journey to 100% Name Plate Capacity 110%

Train 1&2 Forecast

100% = NamePlate

Train 1&2 Actual

= 1054m3/hr to tank = 1174m3/hr rundown

100%

100%

100%

100% COMPLETED Enriched amine top up. Turbo Expander Running Tr-2. Increasing temp. of feed gas. Adjusted lean amine temp.

94% 91%

89%

90%

90% 89%

95% 95% 95%

COMPLETED: TAR-2 (Train-2) Propane PSV adjust/change D1004 internals modifications Amine Absorber internals mod. HP Flash Drum internals mod.

86%

80%

80%

81%

82%

82%

75%

COMPLETED: TAR-1 (Train-1) Propane PSV adjust/change D1004 internals Amine Absorber internals HP Flash Drum internals ethane production

70%

60%

56% 54%

COMPLETED Hot air recirculation shielding Air Fin Cooler upgrades (fans & motors) ethane production from Train-2

50%

50%

Tank-2 repair and re-commissioning C3 operating pressure increase

40% 2009

2010

2011

2012+

“We will be the best-in-class high-reliability LNG Operator” 17

Lesson Learned: Scrub Column Design & Operations Deficiencies What happened: • Lean feed gas composition with very little ethane and propane component • Insufficient reflux liquid to allow continuous production of C2 and C3 • The bottom section initially run with total dry bottom and hence poor separation efficiency • Ethylene to be imported to support LNG production which is a new operations hazards What are the root causes • The overall system design is not robust to cater wide range feed gas composition including extreme lean feed gas • Design optimization by 2 separate sections introduces complexity to the hydraulics of the column which have influenced performance Solution • Install external C4 reflux at bottom section • Change tray type and internal column modification 18

TANGGUH LNG

TANGGUH LNG

Operations Performance

Wind Rose and Yearly Production Profile

• AFC is designed based on wind speed 4.2 m/s with prevailing wind direction from south to north • Production is impacted by ambient conditions 20

TANGGUH LNG

Tangguh Operations Performance DEVELOPING CAPABILITY On-Track to deliver 85% Papuan in 2029 Intervened on graduate-hire and contract-management Now have Papuan internship program to feed Challenge

TANGGUH LNG

INCREASED PRODUCTION Increase

1 Std Cargo LNG Cargo from

2014

2015 : 116 Cargo

LESS INJURY FREQUENCY

Modified Plant & Achieved NamePlate (2010-2011) MCHE Optimization (2012) Ran Colder LNG, Optimized BOG (2013) Optimized Inventory & Shipping Schedule (2013)

4-Points Intervention started Mar-2012 Reinforced How We Operate 2012-2013 Authorization To Operate (ATO) started 2013

IMPROVED RELIABILITY

PROCESS SAFETY INCIDENTS

PEI meeting started in July 2010 Reinforced PUR & 5 Whys Quality in 2011-2013 Top-10 Bad Actors Identification started 2012 Used PEI Score Card & Top-10 Vulnerabilities- 2013 Defect Elimination Campaigns (EX, F/F bearing, etc.) Vibration Survey & Remediation Works started 2013 Improved Attainment & PM Completion (2012-2013)

Learned, Mitigated, Fixed

2015 OE: 92.9%

2015 : Zero AGRU system fixed for Train-1 & 2 – 2011 & 2012 TAR Train-2 Fire recovered in one month – Dec 2012 Loading Line system fixed on Dec-2013 Cold-venting lesson learned implementation is on-going

REDUCED LEAKS 80% Reduction from 2010 30% Reduction from 2012 2015 : Zero

IMPROVED EFFICIENCY 2015: 91% Plant Thermal Eff. Reduced Flare through Seal Gas Mod. & Tanker Cooldown and Start-up processes optimization (2011-2013) Ran colder LNG, Optimized BOG (2013)

Leak Detection and Repair (LDAR) Program started 2011 Reinforced rigor LDAR program on 2013

LESS FLARE 10% reduction of flare from 2014 2015 : 0.4% of Feed Gas Weekly Tracking at PEI Meeting since 2010 Start-up Procedure Optimization – 2011 Seal Gas back-up line re-routing – 2012-2013 Cool-down procedure optimization - 2013

21

LESS COST /MMBTU 6% Less Cost /MMBTU from 2014 9% Less Cost /MMBTU from 2013 Flat Actual Cost Delivered More Cargos (2012-2013) Waste Reduction Campaign started 2013 Clear activity-based cost assumptions & tracking

TANGGUH LNG

End