Pearl GTL, Ras Laffan, Qatar

2012
Qatar - Ras Laffan Industrial City
Shell
  • Structural Steel and Vessel Skirts

Qatar - Ras Laffan Industrial City

Pearl GTL is a world-scale project located in Ras Laffan Industrial City, 80 km north of Doha, Qatar. With full ramp-up achieved towards the end of 2012, Pearl GTL is the world’s largest source of gas-to-liquids (GTL) products, capable of producing 140,000 barrels of GTL products each day. The $19bn plant also produces 120,000 barrels of oil per day of natural gas liquids and ethane.
  • Category: Integrated gas and gas-to-liquids project
  • Ownership: Development and Production Sharing Agreement with Government of the State Qatar, 100% Shell funding
  • Operator: Shell
  • Development cost: $18 billion-$19 billion
  • Peak: 1,6 bcf/d of gas resulting 
  • Production: 140 Mbpd of gas-to-liquids products (2 trains), 120 Mbpd of natural gas liquids and ethane
  • Total production: 3 billion BOE of natural gas over the life of the project
  • Key contractors: JGC/KBR joint venture 
  • Contractors: Toyo Engineering Corporation (TOYO) and Hyundai Engineering & Construction Co. Ltd. (HYUNDAI)- Joint Venture
  • Installers: Kaefer L.L.C (GTL C5), SFC (GTL C4)


Project

Promat has a strong track record of product and supply performance in Qatar over three decades the Cafco FENDOLITE® system supplied by Promat is the most widely used proprietary passive fire protection arrangement for onshore plant structures.

Promat secured the following packages on Pearl GTL

  • C4 Gas process trains
  • C5 Liquid Processing Unit (LPU)

Challenges

  1. Vessel skirts operating at elevated temperatures (up to 385 deg C)
    Promat method featured mineral wool insulation on skirts before applying FENDOLITE MII on equipment (HPC Reactors, HGU Reactor, CDW Reactor, Hot high pressure separator, Feed surge drum, receiver vessel etc).
  2. Zinc Silicate primer was overcoated with polyurethane topcoat. Promat method featured abrading of P.U topcoat to ensure good mechanical bond with Link coat Cafco®-PSK 101

Technical description

The Shell standard (DEP 34.19.20.11-Gen. December 1999) references the Standard for Safety: ANSI/UL1709 Rapid Rise Fire Tests of Protection Materials for Structural Steel           

Cafco FENDOLITE® MII/TG are commercial brand names the corresponding UL designations are: Type PFM2 and Type PFTG.

Type PFM2 (investigated for exterior use) in design number XR719    

Type PFM2 and Type PFTG are covered by the UL Follow-Up and Inspection Label Service; each bag has the appropriate UL label.

Requirements

  • Promat Cafco FENDOLITE®-MII/ integrated fire protective coating system:
  • Cafco FENDOLITE®-MII is a spray applied, single package factory controlled premix, based on vermiculite and Portland cement.
  • Cafco®-PSK 101 is a single pack, multi-purpose; water based synthetic latex emulsion for use as a sealer and keycoat as a component of the Cafco FENDOLITE® integrated fire protective coating system.
  • Cafco®-Plastic Coated Galvanised Mesh & CAFCO® Helical CD Weld Pin Reinforcement System
  • Cafco®-Topcoat 200 Acrylic Polymer Coating Cafco®-Topcoat 200 is a single pack, water based acrylic polymer for use as a water vapour permeable topcoat with
  • PROMASEAL® Silicon Sealant

Solving the case

Cafco FENDOLITE®-MII is proven and exceeds the design and application requirements specified in the Shell standard whereby Cafco FENDOLITE®-MII is effective and practical in terms of availability, maintainability and reduction of risk.

PRODUCTS

  • Cafco FENDOLITE®-MII