The Laffan Refinery Venture has celebrated the successful start-up of its new Diesel Hydrotreater (DHT) Project. The first of its kind in Qatar, the new facility was completed without a Lost Time Incident (LTI) and brought in ahead of schedule and under budget cementing the refinery’s reputation for world class execution of hydrocarbon projects.
The start-up itself was declared 3 weeks early on the 10thof April and this was followed by the catalyst activation on the 26thApril with “on-spec” product being delivered from the performance test on the 14thMay.
Qatargas Chief Executive Officer, Sheikh Khalid Bin Khalifa Al-Thani said; “I am extremely happy to welcome this new asset into the Qatargas family. The introduction of ultra-low sulphur diesel to our economy is a major step forward in terms of our commitment to responsible environmental management and is a critical component of the State of Qatar’s 2030 vision.”
In particular I would like to recognize the efforts of our people who have demonstrated exemplary teamwork in order to complete this project safely within the schedule and budget. Perhaps most pleasing of all is the safety record delivered by the team by completing the work without a Lost Time Incident (LTI) in six million man-hours worked. These excellent standards for safety are achieved only with the commitment and professionalism of everyone involved in the work. I offer my congratulations to the Project Management Team, our Operations Development and Asset staff as well as our contractors and sub-contractors.”
The achievement of the start-up this April marks the successful execution of a 32 month schedule.Detailed engineering design for the project began in September 2011 with Samsung Engineering and Construction Ltd (SECL) as the main contractor. The permanent works construction phase commenced in July 2012.
As it enters its operational phase the DHT unit will produce diesel with less than 10 parts per million of sulphur which will exceed the “best in class” Euro 5 Specification. This will make a major contribution towards the State of Qatar’s drive for world class environmental standards. At first it will operate at 50% capacity receiving feedstock from Laffan Refinery 1 and then later at 100% capacity when Laffan Refinery 2 comes on stream. Then, the DHT unit will process 54,000 barrels per stream day of straight run Light Gas Oil feedstock.
On the 8th January 2014 the DHT Project started receiving permanent 20 kV Power from the Laffan Refinery electricity network. Energization of the DHT electrical sub-station marked an important milestone in the DHT Project progress as it preceded another busy period of work packages within the LR1 shutdown.
Speaking about a second successfully delivered project, Salman Ashkanani, Chief Operating Officer – Refinery Ventures said; “Our team has worked very hard to deliver efficiencies and exploit synergies and opportunities within the scope of work. The success of the DHT Project builds on the reputation established previously by the same project team on the Receiving and Loading Facilities (RALF) Project which was also delivered within cost and schedule and also completed with an impeccable safety record.We use proven Qatargas methodologies such as IPMS(Integrated Project Management Solutions) as well as established Company procedures and processes. Execution plans are diligently prepared and then we try very hard to let the plans drive the work. Of course teamwork has played a huge part in the success of the project but I would also attribute the depth of experience within the team as a major factor in our success. We are all very proud of our safety achievement by completing 6 million LTI-free man-hours and 6000 safety observation cards.”
Qatargas’ Project Management Team together with the EPC Contractor adopted an integrated approach to safety on the project that involved working closely with the workforce in a collaborative manner to achieve excellent health and safety outcomes for all employees associated with the activities. Success in ensuring the safety and wellbeing of all staff associated with the work indicates that this co-operative process worked well and has set a solid precedent and foundation upon which to continue this approach on future projects.
Speaking about completing the project with a zero-lost-time-incident record, Hasan Numan, Deputy Project Manager said; “Over the past two and a half years we have invested heavily in our safety processes. The Qatargas ‘Incident and Injury Free’ (IIF) Program, The 10 Life Saving Rules, Heat Stress programs and various safety related initiatives were vigorously implemented with an emphasis, wherever possible on using ‘face to face’ communications ensuring a style and approach that was best fitted the workers’ environment. Nothing has been more central to the organization’s effectiveness than its ability to transmit the safety philosophy in a clear and concise way to the entire work force.”
Lance Pretorius DHT Safety Lead added; “The safety achievement was extremely important for us as our aim was always to finish the project without an LTI. It took maximum concentration from everyone involved to get safely to the finish line. We are proud to reinforce Qatargas’ reputation as a safety leader in the industry and take great satisfaction knowing that the DHT is another positive step towards protecting the environment.”