The Qatar Shell GTL Plant, Pearl GTL, is located in Ras Laffan Industrial City, 80 km north of Doha, Qatar and is the world’s largest gas to liquids (GTL) plant.
In 2013, Kentech Qatar was awarded two strategic 5-year maintenance contracts by Qatar Shell GTL. Following the initial award of the HVAC General Maintenance & Engineering Support Services contract in September 2013, Kentech was awarded an additional contract to provide Electrical & Instrumentation Maintenance Services.
Both contracts ran concurrently until their amalgamation into one overall contract in mid-2017. The original completion date for the contract was June 2019, however this was extended to Sept 2020 and then again extended to June 2022, due to the high performance of the execution team.
As of November 2019, we have achieved 4.6 million manhours at site without a lost time incident. And three years consecutive to date without a reportable incident.
Kentech provides the management team, supervision, labour, tools, equipment, spare parts and materials etc. required to carry out the Services The scope involves the provision of preventive (PM) and corrective (CM) Electrical, Instrument & HVAC Maintenance services, in addition to the execution of major full-train turnarounds, MTA1 (2015), MTA2 (2016) and RTA (2017). Kentech also provides the client with project support for reliability modification improvements.
Activities cover the maintenance of switchgear, transformers, motors, UPS and Battery systems, VSDS and plant general power and lighting – in addition to the full instrument scope.
Kentech works with Shell Technical Authorities and Reliability Engineers to perform regular reviews of PM plans in order to optimize for efficient execution. This has seen a reduction in the quantity of PMs required, improved how they are planned & scheduled, and as a result has driven commercial savings for QSGTL.
A major such exercise was conducted During 2017. Kentech and Shell worked together to improve maintenance planning and execution, taking measures to reduce waste (idle time) which saw an increase in measured hands on tools time and improved the efficiency of maintenance execution driving further savings.
Battling the conditions
During the hot summer season, environmental challenges has traditionally restricted the ability to achieve productivity at site. Kentech provides the site with cooling solutions by way of mobile HVAC units, cooled work habitats and rest shelters. This enables all contractor disciplines, Mechanical, Piping, Civil, E&I, to continue work unimpeded by the summer heat and assures productivity is not lost.
There is a continuous drive towards achieving increased HoTT (Hands on Tools Time) at site. Measures taken to date to drive improvement have been:
- Optimizing resource loading planning
- Multiskilling personnel
- De-centralised (field based) permitting
- Direct personnel transport – using Kentech own logistics in tandem with Shell site shuttles
- Identifying & improving QSGTLs own processes to drive up HOTT –
- Challenging training prerequisites
- ePermit improvements – templates
This contract adds to Kentech’s working history on the Pearl GTL Plant. During the construction phase of the plant, Kentech installed the electrical, instrumentation, HVAC and firewater ring main construction and testing works on the Water Treatment Plant, which forms an integral part of the gas to liquids process. We then continued to support Pearl GTL by providing maintenance personnel starting from the commissioning phase of the plant.