Badak LNG Plant started in production in 1977. It was built initially with two trains of LNG plant, i.e: Train-A and Train-B. Each at production capacity of 460 m3/h LNG. First expansion was completed in 1983 with another two trains, i.e: Train-C and Train-D. During that time Badak LNG Plant successfully increasing the plant capacity simply by revamping the CO2 Absorber. After this CO2 Absorber revamping project each train can produce upto 640 m3/h.
LNG demand continued to increase which enabled Badak LNG Plant to expand further by installing Train-E, followed by Train-F. Both with plant capacity of 720 m3/h. These new trains used DCS (distributed control system) for the controller. After successful application of DCS at Train-E and Train-F, Badak LNG Plant decided to retrofit Train-A/B/C/D. The retrofit mostly done online, while some critical tie-ins had to be done during the scheduled shutdown. This retrofit project was very successful. There was no plant trip we experienced during the tie-in or hot cut over. We also have to train our operators to be familiar with DCS (Yokogawa).
To fulfill LNG demand, Badak LNG Plant also conducted a debottlenecking study to Train-A/B/C/D. I was assigned as the company representative working with Bechtel in Houston to conduct the study. New compressor rotor technology were applied to all the refrigerant compressors. Feed gas line size was increased. The dehydration unit was added to reduce pressure drop. The mercury removal bed height was reduced by half. All of these efforts resulted to an increased plant capacity to 720 m3/h. We also have to install flash drums at the suction of the propane compressor. The higher propane circulation rate has caused liquid entrainment from the evaporator to the compressor suction. This is why we need this flash drums to knock out the liquid before feeding to the compressor suction.
Badak LNG Plant continued the expansion by installing Train-G and Train-H. Train-G capacity was 900 m3/h, while Train-H 1200 m3/h. In year 2000 Badak LNG Plant reached its peak performance. We send more than 400 shipments in the year.