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Best practices for safe & quality turnaround; the story of NLNG train 6 mega turnaround.

Number: 62

Author(s) : EZUGWU K. M., MOMODU H., SULEIMAN Y.

Summary

NLNG is a six-train LNG plant complex harnessing Nigeria's vast natural gas resources to produce Liquefied Natural Gas (LNG) and Natural Gas Liquids (NGLs). At the heart of its commitment to production excellence is the mantra: Goal Zero (zero safety incidents), 95% Utilisation, 97% Availability and 99% Reliability, exemplified by the acronym P-0579, where P represents the People powering performance.
In August 2024, NLNG embarked upon arguably her most ambitious and challenging Turnaround Event since inception, a 66-day planned Shutdown of one of the Trains in the Six-Train Complex as part of the strategy to address extensive corrosion under insulation under an Accelerated Asset Intervention programme.
This paper provides insight into the approach adopted by the Execution team to ensure the health and safety of the people during Train 6 turnaround, with no damage to NLNG assets, environment, and reputation thus delivering a safe and quality turnaround.
In a demonstration of engineering excellence and unparalleled maintenance execution management, the Train 6 Turnaround execution was completed with zero lost time injury, zero Total recordable case, zero First aid case, zero Total Occupational Illness, zero fire incident, zero process Safety incident, zero environmental incident and zero motor vehicle incident. This outstanding performance was achieved with 4,458 personnel on site (peak period), recording over 2.8 million manhours. A total of 37 buses, 19 pick-up trucks, 3 Hiab trucks, 7 Heavy duty vehicles, 19 mobile cranes of varying capacities from 10 Tons to 450Tonnes, 3 forklifts, 2 cherry pickers and 1 Selfpropelled modular transporter (SPMT) were mobilized for the Turnaround with zero motor vehicle incident recorded!
For additional context, the Turnaround required intrusive work on at least 6 Columns, 31 vessels, 34 heat exchangers including the Main Cryogenic Heat Exchanger (MCHE), 78 valves (Actuated, manual and relief type), 102 withdrawable switch gear units, 6 Load break switches and 3 control interface units for the switchboards, 5 switchboards, 4 compressors, 2 gas turbines, 2 helper motors and 2,095 flanges.
During the Turnaround, some work procedures and technologies were revised and deployed for the first time on site, and this will influence the way certain scopes are executed going forward. For the first time in NLNG, high pressure hydro-jetting was employed to remove Chartek* (a brand ofepoxy intumescent passive fire protection (PFP) coatings) on Heat exchangers, and commissioning and start up activities were commenced on circuits while insulation reinstatement on pipelines was still in progress. The cool down of the MCHE was optimized as this was achieved without first precooling.
It is noteworthy to mention the safe execution of about 9,551 square meters of Fabric rejuvenation scope, the most extensive Fabric intervention ever on a turnaround in NLNG.
The Paper highlights the challenges encountered during the planned Mega Turnaround and the innovative approach deployed to overcome in the face of daunting odds and deliver a Safe & Quality Turnaround. The paper accentuates the role of leadership & technology in mega Turnarounds and concludes with the lessons learned from the execution challenges.

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Details

  • Original title: Best practices for safe & quality turnaround; the story of NLNG train 6 mega turnaround.
  • Record ID : 30034675
  • Languages: English
  • Subject: Technology
  • Source: 21st International Conference & Exhibition on Liquefied Natural Gas (LNG2026)
  • Publication date: 2026/02/05

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