Enhance CAPEX and Reliability by Optimizing Replacement of Refrigeration Unit

Abstract Objective/Scope One of the main concerns and factors of Oil & Gas Plants is how to ensure plant operation, maintainability, and reliability. At one of our process plants, there was a concern in one of the main refrigeration units which cooling the Instrument Air Compressor lube oil system were reported continue tripping during summer peak time. This paper presents a number of solutions and innovative practices that were adopted to solve the issue of performance for refrigeration units. Methods, Procedures, Process Initial study was performed as per code and standard to evaluate the issue of refrigerant unit performance which concluded existing unit is inadequate and will require replacement. However, due to the high cost, the approach was revisited, and an in-house technical study was conducted. The following activities were carried out as part of study evaluation. Results, Observations & Conclusions Based on available operating data, evaluation proposed new condenser unit running with R-134A taking into consideration original design data and actual data recorded during system refrigerant retrofitting in August 1997. The study concluded that to propose a new condenser unit capacity of 16TR total instead of the original capacity of 8TR. Based on in-house study, below aspects were recommended Implementation of above unique and innovative approach were carried-out by completing installation/commissioning of two condenser units and evaluating overall system performance based the data recorded at site during month of August 2023 and found chiller has performed at high ambient temperature (48ºC) without mechanical failure. Further analysis confirmed the performance of modified chiller even with ambient temperature of 53ºC. Finally, implementing the new condenser replacement potentially achieved CAPEX saving by $1.7M for two units while at the same time improving chiller performance, reliability and ensure plant maintainability. Novel/Additive Information In line with ADNOC way by sustaining plant operation, ensure reliability, and maintainability, initiative was taken to explore all possible life extension options by adopting system retrofitting instead of full replacement which can enhance CAPEX/OPEX efficiency while ensuring reliable performance. The project also addressed other ADNOC values and resulted in intangible benefits in respect of ICV enhancement, people development and being responsible/resilient. This approach can be followed by other operator companies to realize benefits.