Gas Processing Project Lifecycle

Tarihi Mai Tsoro daga Reservoir zuwa Pipeline

Samun gas na natural daga reservoir zuwa transmission pipeline ba wani aiki ne—shi ne tarihi wanda ke dauke da 3 zuwa 5 shekara, mara baya. A tsaki na discovery well kuma wani molecule na gas na sale na farko shine aikin inggantawa mai tsoro, procurement, construction, kuma commissioning wanda ke dauke da dukkanin miliyon na dolar kuma dukkanin thousand na man-hours. Amma wadanda suka dace ba su ne wadanda suka samu reservoir mai kyau ko suka samu banki mai kyau. Sun dace saboda sun tabbata aikin front-end.

Tsumani na gas processing project yana tace da tsari mai ban shi daga bayanin farko kuma har zuwa ayyukan amfani. Fahimtar kowane yiwu—wane ne ya gano, wannan lokacin ne, kuma wane ne ya gano—yana fara kafin suka fuskanta suka ci gaba da lokaci da kudin da aka sanya, kuma suka yi kafin suka ci gaba da lokaci da kudin da aka sanya.

Koyon Bayanin Farko: Inde Na Project Sun Yi Kari Ko Sun Gaskiya

Koyon bayanin farko (FEL) shine abin da ke takaici kamar yadda ake iya takaici ga kari na project. Alama ta hanyar fahimta shine: bayanin da aka gano a farko suna da damar mai yawa a kudin da lokacin da aka sanya, kuma suna da karami mai yawa a canza. Bayanin da aka gano a kashi na biyu suna da karami mai yawa a canza. Alama na industry ta kira FEL da uku kashi masu fuskantar.

FEL 1 – Bayanin Farko. Wannan yadda ya zama wani alama na farko: wannan shugaban yana da ma'ana? Masu ingilishi suna gano manyan yadda na farko, suka kara gano teknolijin, kuma suka saba suna da mabudin biyan kudi da suka yi amfani da ƙarancin ±30 zuwa 50%. Wani abu na FEL 1 mai lafiya yana da diagram na farko na yadda na aiki, lista na abubuwa da suka yi amfani da su, kuma analisis na zaune na alamar. Wani abu na gaskiya ba ta yin amfani da tashin kada kada—amma ta yin amfani da kadan kadan. Idan kudi ba su dace ba a wannan yadda, baza su dace ba a yadda na sau biyu.

FEL 2 – Tattaunawa na farko. Idan bayani na farko ya dace, kumun ya fara gano kafin daidai. Bayani na abubuwa na farko ya dace da samun bayani na haɗi. Abubuwa mai yawa suna dace da saizi. Alamar na karkara ya fara dace da saizi. Kudi suna dace da ±15 zuwa 25%. Wannan kuma yana lokacin da kumun ya fara yin amfani da masu bayani na teknoliji kuma masu bayani na EPC. Wani abu na kuskus a wannan yadda? Ya fara kafin daidai. Idan kumun ya fara kuskus a FEL 2, yana zama abu na kuskus a yadda na bayani na kafin daidai.

FEL 3 – FEED (Front-End Engineering Design). Wannan shine inda ayyukan projekti suka samu hali. Ayyukan inggiliya mai ƙarfi sun fara. Tashin kofin tashin kofin da kofin tashin kofin (P&IDs) suka fara. Bayanan abubuwan kasuwanci suka kammala. Tashin kudin ya zo ne cikin ±10 zuwa 15%. A wakati na gaba daya na FEL 3, kumun projekti yana bukatar samun tsari mai kyau don tabbatawa ayyukan EPC na bayani. Wani batu mai muhimmi: FEL 3 shine lokacin karshe don saita saiti na sarrafa tsarin baya kafin saiti na zamani ta daga shi. Kafin zamin suka amfani da shi, saiti suka fiye da kudin.

Ingililiya mai kyau da amfani da abubuwan kasuwanci: Tsari na yawa

Kamar yadda FEED ta kammala, ayyukan farko na project ya gudanar da inganta mai ƙarfi da amfani da abubuwa. Wannan yanki ya tsaya ne akan yankin yawa na man-hours na project—kamar yadda ya zama 40 zuwa 50% na kowane inganta. Kowa yin shugaban tuba ta kawo a cikin model. Kowa yin shugaban instrument ta kawo a cikin bayani. Kowa yin shugaban valve ta kawo a cikin datasheet da purchase order.

Amfani da abubuwa ya gudanar da kuma wannan shine inda yankin da ke ƙarewa. Abubuwan da suka dauki lokaci sosai—compressors, amine contactors, cryogenic heat exchangers—suka dauka sosai, kamar yadda suka dauka koda ba suka kammala inganta mai ƙarfi ba. Wannan yana zama ƙarfin: idan inganta ta canza bayan abubuwa suka dauka, project ya ci karamin rarraba da kuzari. Sauran da aka gudanar da su daga baya sun yi wannan ta hanyar karewa na kowane inganta mai muhimmanci kafin daukar abubuwan da suka dauki lokaci sosai.

Wani ƙarshen bayani daga wani project na gas processing a Rocky Mountain: kumun ya sao mai tsayarwa na refrigeration a lokacin detailed engineering basira da ƙididdiga na preliminary heat da material balance. Idan ƙididdiga na gaba ta zo 8% kafin, mai tsayarwa ya zama yawa kusa. Amsa? Wani field modification na $2 million da wani shugaban zaman kansu na 4 weeks. Mai tsayarwa ya kamata ya rufe kafin 6 weeks don ƙididdiga na gaba.

Aikin Construction da Mechanical Completion: Yadda Kira Ta Zama Steel

Construction shine ake nuna project—and shine ake kuskus sosai. Don wani grassroots gas processing facility, construction yana kuma 50 zuwa 60% na total project cost da 40 zuwa 50% na schedule.

Modular construction ta canza jarrabiyar game don kamar suka yi a cewa. Daga wajen tsayarwa na equipment skids a lokacin controlled shop environments ba tare da a cikin field, kumun project zasu iya yin kuskus sosai, duba kara kwalitas, da kuma kuskus sosai na site labor costs . Wani iko na 2024 ya zaba cewa yadda ake amfani da kusurin gaba daya (modular execution) zai iya gudunawa tare da 15 zuwa 25% na tsawon zaman da ake yi a lokacin da suka ci gaba da kusurin gaba daya (stick-built construction). Bayanin wani abu ne: ayyukan kuskuren gaba daya (logistics): kusurin gaba daya (modules) suna bukatar yin amfani da kusurin gaba daya (transport), wanda ke baka shi kari da fahimta na kusurin gaba daya (size), kuma ayyukan kuskuren gaba daya (site preparation) suna bukatar kama kafin kusurin gaba daya (modules) suka zo.

Kammala maitakarfa—yana nufin cewa duk wasila suka ci gaba da kusurin gaba daya (installed) kuma duk kusurin gaba daya (piping) suka ci gaba da kusurin gaba daya (connected)—ba wani abu ne cewa ayyukan kuskuren gaba daya (project) ya kammala. Yana nufin cewa kuskuren gaba daya (construction crew) zasu fara kuskuren gaba daya (packing up). Kuskuren gaba daya (real test) ya zo bayan wannan.

Kuskuren gaba daya (Commissioning), Kuskuren gaba daya (Startup), kuma Kuskuren gaba daya (Performance Testing)

Kuskuren gaba daya (Commissioning) shine kuskuren gaba daya (phase) wanda ke fara kuskuren gaba daya (experienced project teams) daga kuskuren gaba daya (amateurs). Shii ne kuskuren gaba daya (systematic process) na kuskuren gaba daya (verifying) cewa duk kuskuren gaba daya (system) ya yi ayyukan kuskuren gaba daya (works as designed), daga kuskuren gaba daya (instrument loops) zuwa kuskuren gaba daya (safety shutdowns) zuwa kuskuren gaba daya (control system logic). Wani kuskuren gaba daya (well-executed commissioning plan) zai iya dauki kuskuren gaba daya (three to six months) don wani kuskuren gaba daya (mid-sized gas plant). Wani kuskuren gaba daya (poorly executed one) zai iya dauki kuskuren gaba daya (a year or more)—kuma wannan shine ba ta dauka kuskuren gaba daya (cost of lost production) ba.

Kafin kafa shi ne wani lokaci na yau da kullun. Gas da aka saba shi daga gaba ƙara a cikin farma. Al’ummar suka yi amfani da kafin kafa, suka raba kowane wuri a cikin farma a wasu nau’i na muhimmanci. Sistam na amine ya fara kudura. Wuri na kuskure ya fara aiki. Sistam na kuskure ya fara kudura. Kuma a wani baya na wannan kafin kafa, wani abu ne ya zama ba ta hanyar da suka rubuta a P&ID.

Tasmiyin al’adu ya zuwa bayan kafin kafa. A cikin 72 awatata ko 30 rana—tare da abin da aka rubuta a shirye-shirye—farman ya fara aiki a cikin kammalinsu na asali, kuma masu yanke amfanin sun rubuta kowane abin da suka tabbatar da su. Idan farman ya tabbatar da al’adun da aka tabbatar da su, kumun da aka samu farma sun fara kiyaye. Idan ba ya tabbatar da su, sun fara gano abin da ke bawa aiki, kuma EPC contractor ya fara fada da kusurorin da suka rubuta a shirye-shirye.

Aiki da Taimakawa na Yadda Zai Yi

Kodai aikin tattaunawa ya ƙare, al'adu na proyekci zai canza zuwa aiki. Amma al'adu ba ta kare a wani lokaci. A cikin lokacin da al'adu ta so 20 zuwa 30 shekara, kumun aikin yaza akan gudunmawa, yaza akan sauraro, da yaza akan fahimtar al'adu. Aikin yaza akan gudunmawa yake ayyana a kowane 3 zuwa 5 shekara don aiki mai kyau. Teknologiya maita suka shirya. Da akwai lokaci da ke fito, inda karamin yanki ya dace ko bayanin yanki ya canza, al'adu zai canza zuwa aiki mai kyau ko zai kare.

Mafi kyawawan kumun proyekci sun yi aiki don samun al'adu daga rana na farko. Wannan yana nufin yin al'adu don samun al'adu na aiki, yin al'adu don samun al'adu na aiki, da yin al'adu don samun al'adu na aiki, ba daga baya. Al'adu na gas na Oklahoma da suka bi da wannan al'adu ya samu 98% na al'adu na aiki a rana na farko, wanda ya faru ne da al'adu na aiki na 92% na al'adu na aiki na al'adu na aiki.

Tushen Na Farko Na Al'adu Na Al'adu

Zamanin daidai na aikin yadda ya daga farko zuwa karshe ya ƙarfi, kuma mai girma na ƙarfin yadda ya ke ciki na farko na inggiliya da kuma na gudunmawa. Wannan ne kamarin daidai na aikin yadda ya ke ciki. Wani skid da ya zo da kuma ƙayyadaden tuba suka fuskanta, da kuma flanges suka yi da karama ba ta haka ba, ko da kuma bayanin wiring suna ba da kadan, zai ci gaba da budget na commissioning da kuma zamanin daidai na aikin yadda da kuma wani abu ba ne daidai ba.

Kama da wani fabricator da ya fahimci zamanin daidai na aikin yadda daga farko zuwa karshe—ba tare da welding da kuma assembly ba—zai taimaka mu fitar da wannan gap. Yadda GreenFir ya yi shi ya haɗa muhasebanci na inggiliya, kuma gudunmawa na shop, da kuma testing na farko na commissioning a cikin wani workflow daya, don haka abubuwan da suka zo a site suna gaba da koyaushe da kuma ba da kadan aikin yadda a cikin gida. Don kumun aikin yadda da suka nuna zamanin daidai da kuma karamin daidai na aikin yadda, wannan yadda na aikin yadda zai fara farko a tsari na aikin yadda da kuma karamin daidai na aikin yadda.