2007 - INPEX, Kimberley LNG, Australia
Summary
The Kimberley LNG project aimed to process and export natural gas from offshore fields. The facility required an efficient and reliable gas processing system to meet stringent export requirements. The remote location and extreme weather conditions added complexity to maintenance planning and spare parts management.
Challanges
Extreme weather conditions, including cyclones and high humidity, increased corrosion risks and mechanical failures. LNG production required precise temperature and pressure control, meaning any failure in refrigeration or liquefaction systems could lead to significant downtime. The remote location complicated maintenance and spare parts logistics, requiring optimized planning to avoid operational disruptions.
Solution
Conducted RAM analysis and availability modeling to ensure that the liquefaction process had sufficient redundancy in critical equipment such as compressors and heat exchangers.
Implemented risk-based inspection (RBI) and predictive maintenance strategies, reducing the need for reactive maintenance and unplanned shutdowns.
Used Monte Carlo simulations and Fault Tree Analysis (FTA) to model failure probabilities and optimize spare parts inventory, reducing lead times for critical replacements.
Facilitated HAZID and HAZOP workshops, ensuring a proactive approach to identifying and mitigating process safety risks in LNG processing.
