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Early-life debottlenecking: Achieving 7% LNG capacity uplift via zero-capex design margin realization.

Numéro : 11

Auteurs : INDRA HARAHAP M. M., SUDWIYANTO A., SUWARTONO B. S., REKSOPRODJO F. R., TANTO M. E. H. Y.

Résumé

In the newly started-up Tangguh LNG Train 3, the opportunity to optimize capacity shortly after nameplate testing presents both promise and risk. This paper outlines a case study in which a brand-new LNG plant safely increased its production capacity from 1,210 m³/h (original nameplate capacity) to 1,300 m³/h—approximately a 7% gain—without any capital investment. Rather than
physical modifications, the increase was achieved through a deep understanding of the design envelope and a methodical, risk-managed approach to exploring available margins.
The initial basis for evaluating potential capacity margin stemmed from observed surplus in Gas Turbine (GT) power under steady-state conditions. This surplus triggered a broader investigation into system-level design margins across major process units. Given the early life of the plant, the primary risk was not equipment degradation, but the presence of unknown defects or undercharacterized system behaviors that could emerge under increased load. As such, the debottlenecking strategy prioritized cautious, incremental changes supported by real-time monitoring and multidisciplinary validation. Four key process domains were identified as critical for evaluation based on early operational observations and known design sensitivities.
The Onshore Receiving Facility (ORF) exhibited elevated hydrocarbon carryover, raising concerns about foaming in the downstream Acid Gas Removal Unit (AGRU). Targeted anti-foam strategies and tighter operational control were employed to manage this risk.
In the Dehydration Unit (DHU), regeneration system limitations made it difficult to reach and sustain plateau temperatures, increasing the risk of early breakthrough. This was mitigated through extended regeneration cycles and careful dew point trending.
The cold-end performance, particularly in the Main Cryogenic Heat Exchanger (MCHE), was affected by lean feed gas composition, which limited the contribution of the warm-bundle section. Performance tuning and close thermal profiling ensured that cryogenic balance was maintained at elevated rates.
Additionally, mechanical integrity risks, especially in areas prone to vibration, were managed through enhanced condition monitoring and pre-emptive inspection to address any emerging anomalies.
This paper details the analytical and operational techniques used to verify and safely exploit latent design margins—ranging from equipment response characterization to the integration of process safety reviews. The result was a capacity increase that maintained product quality and system reliability, while delivering additional value from an asset still early in its lifecycle.
By demonstrating that measurable performance gains can be achieved shortly after commissioning—without capex and while managing first-operation uncertainties—this case provides a practical model for maximizing the early return on investment in large-scale LNG infrastructure.

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Détails

  • Titre original : Early-life debottlenecking: Achieving 7% LNG capacity uplift via zero-capex design margin realization.
  • Identifiant de la fiche : 30034624
  • Langues : Anglais
  • Sujet : Technologie
  • Source : 21st International Conference & Exhibition on Liquefied Natural Gas (LNG2026)
  • Date d'édition : 05/02/2026

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