2005 - ORYX – Gas-To-Liquids (GTL) Plant, Qatar
Summary
The ORYX GTL plant is a major facility designed to convert natural gas into high-value liquid fuels, including diesel and naphtha. The project required advanced process reliability studies to ensure that the highly integrated chemical conversion systems operated efficiently with minimal downtime.
Challanges
GTL plants operate at high pressures and temperatures, increasing the risk of equipment degradation and unplanned shutdowns. The complexity of reactor operations and catalyst performance added further challenges in maintaining plant uptime and efficiency.
Solution
Conducted RAM studies to optimize plant availability and identify potential failure points in reactors and heat exchangers.
Implemented FMECA to prioritize maintenance activities based on equipment criticality and failure risks.
Developed a functional safety management plan in accordance with IEC 61508, ensuring safe operation of critical process control systems.
Designed a spare parts strategy that balanced cost efficiency with operational reliability by forecasting long-lead spare requirements.
