This Malabar Biomethane Injection Project Lessons Learnt Report 3 shares lessons related to equipment sizing, procurement, risk management, operational performance, and renewable energy supply.
Report extract
Throughout the Construction Phase of the project, the following learnings were identified:
- Allowance for Biogas Supply Variations: Fluctuations in biogas quality and flow can impact operations. The addition of a biodome buffer improved operational stability, reduced shutdowns, and increased plant lifespan.
- Efficiencies of Modular Fabrication: Pre-manufactured modules facilitated compliance with regulations, simplified installation, and allow for easier future upgrades, reducing facility downtime.
- Management of Hydrogen Sulfide (H2S) Risk: Strict risk controls were implemented due to the flammability and toxicity of H2S. Segmenting plants and modelling dispersion rates are important considerations to minimize risks.
- Recycle of Upgraded High Pressure gas during station trips: Overpressure scenarios caused by reverse flow during emergency shutdowns and station trips were identified late in the project. Future projects should consider applicable process safety for the release or segregation of migrating gas.
- Improved Reliability of GC Sampling: Delays in gas composition analysis caused unnecessary recycling of gas. Relocating sample points reduced delays, improving efficiency and reducing off-spec gas export.
- Supply of Renewable Electricity: Ensuring a reliable supply of renewable energy is crucial for maintaining green gas certification. Considerations include monitoring, validation, and alternative electricity production.
