Slide 1

Dynamic Simulation in Design of LNG

Liquefaction Plants

Abhilash Nair, Invensys

© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
 Acknowledgements

• Fujii Takayoshi, JGC Corporation

• Kuroda Toshiyuki, JGC Corporation

• Nakagawa Tatsuji, JGC Corporation

• Charles Rewoldt, Invensys

• Kinya Taguchi, Invensys

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 Agenda
• Background
• LNG Lifecycle
• Design Challenges
• Dynamic Simulation
• Case Study - DYNSIM
 Modeling of Liquefaction process
 Controls
 Scenarios
 Results
• Conclusion
• Q&A

Slide 4
 LNG

• Natural Gas – a principle

energy source
• Supply-Demand imbalance
• Transportation requires
Liquefaction
• 1/600th volume
• High Energy Density

Image from : http://www.fossil.energy.gov

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 Natural Gas Lifecycle
Production

Liquefaction Unit

Transportation

Re-gasification Terminal

Distribution

Consumption

Images from : http://www.fossil.energy.gov

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 LNG Industry - Global

Existing:
•26 terminals –export LNG
•31 Liquefaction plants

•60 terminals –import LNG

Proposed:
•65 export(14 in NA)
•60+ Liquefaction plants

•180 import terminals(13 in NA)

Data source: Federal Energy Regulatory Commission

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 LNG Liquefaction
• Condensing Natural Gas
• Refrigeration cycles
• Four main processes
• C3MR process (APCI) – Most common
• Conoco-Philips
• Shell
• Linde

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 Design Challenges
• Unit requires high availability
• Reliable controls and Safety systems
• Expensive turbo-machinery equipments
• Natural Gas flaring

• Cryogenic service
• Expensive piping metallurgy

• Complex heat transfer equipments

• Heat integration and interaction between
refrigeration loops

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 Design Challenges

Limitations in steady state design

Impact of controls

Understanding the dynamics - critical

Dynamic Simulation - best available technology

Invensys SimSci-Esscor’s – DYNSIM

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 Dynamic Simulation - DYNSIM
• Process Simulation Tool
• System hold-up dynamics
• Control dynamics
• Process variables Vs Time
Time
• Applicable through a Project Lifecycle

Validate Checkout Train Improve

Design Controls Personnel Performance

PROCESS DCS / PLC INITIAL PLANT

DESIGN CONFIGURATION START OPERATION
Dynamic Simulation in Project Lifecycle

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 DYNSIM in LNG Applications

Production

Liquefaction Unit

Transportation Engineering Studies

Operator Training Simulators
Re-gasification Terminal

Distribution

Consumption

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 Case Study – LNG Liquefaction Plant

• Dynamic Simulation Study - DYNSIM

• 2.1 MMTPA LNG Liquefaction Unit
• JGC, Yokohama, Japan - EPC

• APCI – C3MR Process

• Mitsubishi (MHI) Compressors
• CCC Compressor Controls

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 Objectives
• Verify compressor controls
• Verify anti-surge valves’ design
• Verify cold bypass valves’ design
• Verify isolation valves’ design
• Verify settle out pressures and re-start
• Verify start-up/shutdown scenarios
• Evaluate “What-if?” scenarios
• Trip
• Discharge/Suction blockages
• Load changes etc…

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 C3MR Process (APCI)

• Feed Treatment
• Liquefaction
• Two refrigeration loops
• C3 (Propane) – Pre-cooling Natural Gas
• MR (Mixed Refrigerant) – Condensation/Sub-cooling
• Two refrigeration compressors
• Loops are heat integrated

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 C3MR Process (APCI)

• Main Cryogenic Heat Exchanger (MCHE)

• MR and Pre-cooled Natural Gas
• Condensation/Sub-cooling of Natural Gas

• Chillers
• Propane Boilers
• Pre-cooling Natural Gas feed
• Condensation of MR

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C3MR Process (APCI)
C3 LOOP

MR LOOP

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 Modeling Notes - DYNSIM
• Compressors
• Performance maps, MW
changes

• System volume and

resistance
• Isometrics, Pipe fittings
• GA drawings, data-sheets

Curves Validation

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 Modeling Notes - DYNSIM
S07

S11

• MCHE
VL02
S06
S10
S03

• Multi-exchanger, VL03

metal mass, HMB S09 VL01

S02

• C3 Chillers S08
S01

• Non-equilibrium
S05

LNGHX01

scenarios S04

• Compressor controls
• Basic CCC Controls
modeled in DYNSIM
• Non-dimensional
operating maps

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 Scenarios
• 2 steady state ICs
• 4 startup ICs
• 35 case scenarios
• Trip cases
• Startup cases
• Load Change cases
• Process upsets

• Two Phases List of Scenarios

• FEED
• EPC

Compressor Trip
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 Results– FEED Stage
• ASV Sizing
• Compressor trip case
• C3 MP Surge
• Original design of C3 LP ASV
was oversized
• Original design of MP ASV
was under-sized

• C3 Compressor
isolation valves
• Stroke time reduced to
route more flow to recycle
loop

Compressor coast-down

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 Results- EPC stage
• Start-up scenarios
• Available driver power verified
Speed
• Helper motor design verified
• ASV Sizing verified
• Bypass valves’ design verified
• Controls verified

Start-up scenario

Control Lines

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 Results- EPC stage
• Increase stroke time on
cold bypass (CBP) valve
• Capital Savings

• Coast-down scenarios
• Vacuum on C3 suction
• Drop C3 speed to 75% if one of
MR compressors trip
• Low Press override/ Cascade to
ASC required on C3

• HPMR Suction temperature

• Additional logics required
while opening ASV

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Conclusion
Dynamic Simulation in Liquefaction Plant
Design helps:

•Add value to the steady state design

•In FEED, EPC phases and beyond…
•Identify hidden design issues in early stages
•Verify start-up and shutdown procedures
•Excellent platform for the unit OTS system

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 Q&A

Slide 25
 Thank you

Abhilash Nair
Principal Consultant
Invensys SimSci-Esscor
Carlsbad, California CA 92008
+1 760-268-7748
Abhilash.Nair@invensys.com

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C3MR Process (APCI)

ASV Opens

Hot C3 Vapor

C3 Boilers
Cryogenic C3 Liquid

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