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© 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. Dynamic Simulation in Design of LNG Liquefaction Plants Abhilash Nair, Invensys

Slide 3 Acknowledgements Fujii Takayoshi, JGC Corporation Kuroda Toshiyuki, JGC Corporation Nakagawa Tatsuji, JGC Corporation Charles Rewoldt, Invensys Kinya Taguchi, Invensys

Slide 4 Agenda Background LNG Liquefaction Process Design Challenges Dynamic Simulation Case Study - DYNSIM  Modeling of Liquefaction process  Controls  Scenarios  Results Benefits and Conclusion Q&A

Slide 5 LNG Natural Gas – a principle energy source Supply-Demand imbalance Transportation requires Liquefaction 1/600 th volume High Energy Density Image from :

Slide 6 Natural Gas Lifecycle Production Liquefaction Unit Transportation Re-gasification Terminal Distribution Consumption Images from :

Slide 7 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

Slide 8 LNG Liquefaction Condensing Natural Gas (NG) Refrigeration cycles Four main processes C3MR process (APCI) – Most common Conoco-Philips Shell Linde

Slide 9 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

Slide 10 Design Challenges  Limitations in steady state design  Impact of controls  Understanding the dynamics is critical  Dynamic Simulation - best available technology Invensys SimSci-Esscor’s – DYNSIM

Slide 11 Dynamic Simulation - DYNSIM Process Simulation Tool System hold-up dynamics Control dynamics, Thermodynamics Process variables Vs Time Applicable through a Project Lifecycle Time PROCESS DESIGN DCS / PLC CONFIGURATION INITIAL START PLANT OPERATION Improve Performance Validate Design Checkout Controls Train Personnel Dynamic Simulation in Project Lifecycle

Slide 12 DYNSIM in LNG Applications Production Liquefaction Unit Transportation Re-gasification Terminal Distribution Consumption  Engineering Studies  Operator Training Simulators

Slide 13 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

Slide 14 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…

Slide 15 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

Slide 16 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 C3MR Process (APCI)

Slide 17 C3MR Process (APCI) C3 LOOP MR LOOP

Slide 18 Modeling Notes - DYNSIM Compressors Performance maps, MW changes System volume and resistance Isometrics, Pipe fittings GA drawings, data-sheets Curves Validation

Slide 19 Modeling Notes - DYNSIM MCHE Multi-exchanger, metal mass, HMB C3 Chillers Non-equilibrium scenarios Compressor controls Basic CCC Controls modeled in DYNSIM Non-dimensional operating maps

Slide 20 Scenarios 2 steady state ICs 4 startup ICs 35 case scenarios Trip cases Startup cases Load Change cases Process upsets Two Phases FEED EPC Compressor Trip List of Scenarios

Slide 21 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

Slide 22 Results- EPC stage Start-up scenarios Available driver power verified Helper motor design verified ASV Sizing verified Bypass valves’ design verified Controls verified Start-up scenario Speed Control Lines

Slide 23 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

Slide 24 Benefits and Conclusion Add exceptional value to the 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 Dynamic Simulation in Liquefaction Plant Design helps:

Slide 25 Q&A

Slide 26 Thank you Abhilash Nair Principal Consultant Invensys SimSci-Esscor Carlsbad, California CA

Slide 27 C3MR Process (APCI) Hot C3 Vapor ASV Opens C3 Boilers Cryogenic C3 Liquid