Dynamic Simulation Solutions From Well Heads to LNG Terminals: The contribution of Dynamic Simulation to LNG Supply Chain

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Dynamic Simulation SolutionsFrom Well Heads
to LNG Terminals The contribution of Dynamic
Simulation to LNG Supply Chain
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AGENDA

• RSI SIMCON PROFILE
• VIRTUAL PLANT
• CASE STUDIES
• MULTIPHASE FLOW
• COMPRESSOR STUDIES
• CUSTOM SIMULATORS
• CONCLUSION LIFE CYCLE TOOL

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RSI SIMCON PROFILE
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RSI SIMCON PROFILE AN IFP COMPANY

• RSI SIMCON is serving the following industries
  for more than 25 years
• Refining Gas Processing, Naphtha Middle
  Distillates, conversion of residues, Olefins
  Aromatics, Heavy oil Upgraders
• Petrochemicals Steam crackers, Aromatics, Major
  Monomers Polymers
• Onshore/Offshore Oil Gas Industry from Well
  Heads to Topside Facilities and Export
• LNG Supply Chain Liquefaction Plants, LNG
  Carriers, LNG Terminals,
• Coal liquefaction,
• Energy, Water Environment Processing

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RSI SIMCON PROFILE - MAJOR CUSTOMERS
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VIRTUAL PLANT
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Virtual Plant From Design To Operation

• Virtual Plant from Well Heads to Process
  Facilities
• Wells
• Pipelines Network
• Processing Facilities Utilities
• Control Loops Logics
• Sequential Controls
• Emergency Shutdown Systems

Benefits Anticipate and analyze operational
issues by considering the production field in its
entirety Focus on integrated safety, processing
and operational aspects
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Virtual Plant From Design To Operation

• Support all phases of your process life cycle by
  consistently enriching your dynamic model
• Dynamic Engineering Simulator (DES)
• ICSS Commissioning Simulator
• Operator Training Simulator (OTS)
• Production Management Simulator (PMS)

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CASE STUDIES
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LNG Supply Chain
Exploration Production
Liquefaction
Shipping
Regasification
End Users

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South Pars Giant Gas Field

• South Pars is one of the Worlds Largest Natural
  Gas Fields.
• RSI Simcon is fully aware of the innovative
  technical solutions deployed within the onshore
  and the offshore facilities.
• Phases 23 PMS and OTS (Gas Plant)
• Phases 45 OTS (Gas Plant)
• Phases 6,78 PMS
• Pars LNG DES

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South Pars Giant Gas Field

• The reservoir lies more than 3,000 metres under
  the seabed and in 65 metres of water
• Multiphase transport system
• Each phase corresponds to one sea line
• 1 000 MMSCFD of reservoir fluids
• Pipeline length 100 km
• Pipeline section 32 inch (offshore pipeline)

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South Pars Giant Gas Field Phase 4-5

• South Pars Phase 4-5 Gas Plant
• Gas Field
• 2 x 1000 MMSCFD

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South Pars Giant Gas Field Phase 4-5

• Process units
• OTS-1
• Reception Facilities
• Condensate Stabilization
• OTS-2
• Gas Treating
• Gas Dehydration Mercury Guard
• Ethane Recovery
• Export Gas Compression
• OTS-3
• NGL Fractionation
• Caustic Regeneration
• Propane treating
• Butane treating
• Ethane Treating

• OTS-4 Sulphur Recovery
• OTS-5 Propane Refrigeration Cycle

• Control systems
• DCS
• ESD

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South Pars Giant Gas Field Phase 4-5
Unit 105 Ethane Recovery
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South Pars Giant Gas Field Phase 4-5
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South Pars Giant Gas Field Phase 6-7-8

• Statoil / PetroPars
• 3x 1000 MMcft/d multiphase pipelines - 100 km,
  32  inches

• Sea Lines
• 3 x 100 km pipelines

• Off-shore facilities
• 3 wellhead platforms including
• Test Separator for well testing
• 2 x 50 Free Water Knock Out Drums
• 2 x 50 Coalescers
• Oily Water Treatment system
• Fuel Gas system,
• Flare system with a Flare KO Drum to collect
  relieving fluids

• On-shore facilities
• Inlet manifold
• Pig receiver
• Slug catcher
• Gas expansion in pressure letdown control
  station.
• Gas/liquid two phases separation in the HP
  separators

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South Pars Giant Gas Field Phase 6-7-8
Treatment facilities
Pipeline
Pipeline
Pipeline
Production Platform
Production Platform
Production Platform
Simulated with INDISS
Simulated with OLGA
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Sable Island Gas Field

• Exxon Mobil
• Canada

• Off-shore
• platforms
• Revamping
• 425 MMcft/d gas, 20.000 BPD condensate

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Sable Island Gas Field

• Process units
• 4 satellite production
• platforms
• 4 mutiphase pipelines
• 1 central production /
  separation platform
• 1 compression platform
• Cooling Medium / sea water systems
• Heating medium
• MEG TEG regeneration systems
• Fuel Gas system
• LP HP flare system
• Closed drain

• Control systems
• DCS
• ESD
• CCC anti-surge performance controllers

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Sable Island Gas Field
INDISS OLGA PLUG-IN
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Ground Profile Temperature Pressure Oil / water
fraction Gas / water total mass flow
Benefits Investigate Flow Assurance Issues
Decide pigging frequency Optimize procedure
for slug reception MEG inventory management.
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Sable Island Gas Field
Simulated with INDISS
Simulated with OLGA
Separation platform
Production platform
Export pipeline (200 km)
Pipeline
Compression platform
Production platform
Pipeline
Pipeline
Pipeline
Production platform
Production platform
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Zakum Gas Field Production Facilities

• Zakum West Super Complex

• 560 MMSCFD
• New gas treatment platform called Zakum Gas
  Production Facilities (GPF)

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Zakum Gas Field Production Facilities

• Gas Production Facilities (GPF)
• Train 1 2 2-stage compressors
• TEG contactor
• Gas Gathering Platform (GGII)
• Train 1, 2 3 2-stage compressors
• Condensate stripper
• Gas Injection Pilot (GIP)
• GIP train 1 2 2-stage injection gas
  compressors
• CGIP faciIity 2-stage injection gas compressor

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Zakum Gas Field Production Facilities
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Zakum Gas Field Production Facilities

• Simultaneous operation of the GGII and GPF
  compressor trains will lead to complex
  interactions
• Control system stability
• Impact on the compressor plant safety
• Study objectives
• Model all the necessary compressor loops
• Study normal various upset scenarios
• Determine requirement of any special/proprietary
  controller, controller set points, establish
  alarms trip set points
• Confirm the workability of the integrated system
  to meet the production targets

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Hasdrubal Gas Field NGL Extraction

• Hasdrubal NGL Extraction Plant

• 120 MMSCFD 15,000 BPD of stabilized
  condensate
• New onshore facilities

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Hasdrubal Gas Field NGL Extraction

• NGL Extraction Plant
• Warm separator
• Compression discharge cooler
• Turbo Expander package
• Re-compressor after cooler
• Plate fin heat exchangers
• De-Ethanizer
• Simulator objectives
• Check anti-surge controls response to sudden
  changes
• Impact of process behavior on the turbo-expander
  machine
• ESD procedures

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Compressor Studies Highlights

• Compressor studies

• Anti-surge controller tuning / configuration
• Shutdown Settle Out Pressure

• Anti-surge valve size checking
• Hot by-pass requirement / sizing

• Start-up shutdown sequence checking
• Torque analysis during start-up
• Power limitation studies

• HPThermo
• Studies up to 11.000 psi / 760 bar

Benefit Prevent damage multi-million dollar
machinery
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Cryostar EcoRel LNG Carrier

• LNG Carrier BOG
  treatment re-liquefaction

• 3-stage N2 compressor
• Expansion turbine
• 2-stage BOG compressor

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STI - LNG Carrier Cargo / Ballast Simulator
LNG vaporizer
Cargo tank
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STI - LNG Carrier Cargo / Ballast Simulator
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SNC Lavalin LNG Terminal
LNG Terminal OTS
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LIFE CYCLE SIMULATOR
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Yemen LNG Liquefaction Plant

• YEMEN LNG Grass root
  LNG Liquefaction plant

• APCI C3/MCR
• 6.7 Mtpa

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Yemen LNG Liquefaction Plant

• Process units
• Liquefaction train 1 2 including
• Receiving facilities
• Acid gas removal, Dehydration
• Mercury removal
• Feed pre-cooling, Fractionation
• Liquefaction, Refrigeration
• End flash
• Utilities off sites including
• Fuel gas
• Desalinated water
• Power generation
• Steam condensates system
• Sea Water system
• Refrigerant storage, LNG storage, Boil-Off Gas
  Loading Facilities

• Control systems
• PCS Process Control System
• PSS Process Safety System
• SSS Safety Shutdown System

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Yemen LNG Liquefaction Plant

• INDISS Dynamic Engineering Simulator for Technip
• Settle out pressure of compression trains
• Maximum allowable pressure for restart (torque)
• Recommendations to change the control process
  scheme, notably on the anti- surge system
  bypass valves

• Operator Training Simulator for YemGas
• Emulated Operator Training System for early
  delivery
• Stimulated Operator Training System for ICSS data
  base cross checking

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Yemen LNG Liquefaction Plant
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Yemen LNG Liquefaction Plant
OTS
DES 20 PIDS Standard INDISS Control No HMI
EOTS
DES
Refrigeration loops
EOTS 70 PIDS Standard INDISS Control Foxboro HMI
Liquefaction Train 1
Liquefaction Train 2 Offsite Utilities FOX I/A
Connection TRISIM Connection
OTS 200 PIDS FSIM TRISIM Foxboro HMI
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Visit us in
Houston RSI Simcon USA 1880 Dairy Ashford Rd
Suite 685 Houston, TX 77077 - USA Phone 1 832
448 59 00
Beijing RSI Simcon China Chaoyang
District 100029 Beijing - China Phone  86
1064418357
Grenoble RSI Simcon France Parc Technologique
de Pré Millet 38330 Montbonnot France Phone
33 4 76 52 46 00 http//www.simulationrsi.net/
THANK YOU FOR YOUR TIME
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Conclusion - Life Cycle Tool

• LNG Constraints
• Thermodynamics limits of modeling Very low
  temperature ( -160C)
• Multiphase transportation Pipeline
• Multi-stream heat exchangers Heat Integration
• Safety Issues Boil off Gas, Roll Over phenomena
• Simulation is necessary in early phase of LNG
  projects
• Dynamic studies
• use of Operator Training Simulator OTS

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Life Cycle Tool

• Engineering Procurement Phase
• Dynamic studies
• Compressor studies anti-surge system, torque
  analysis
• Cryogenic Heat Exchangers behavior
• Safety studies - HIPPS
• Cooling capacity studies
• Operability controllability
• Early OTS OTS used for process learning

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Life Cycle Tool

• Commissioning Start-up Phase
• Stimulated OTS used for
• ICSS (Integrated Control Safety system)
  database integrity checkout
• Start up optimization and feasibility studies
• Initial training on plant replica before start-up

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Life Cycle Tool

• Operation Phase Use of OTS
• What-if Studies
• ICSS upgrade
• Best practices
• Incident reviews

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Sable Island Gas Field
Feedback

• I would like to thank RSI for all the hard
  work that was done in creating our DES/OTS.
• The dynamic engineering studies that were
  done with RSI have proven very valuable for
  overall engineering and design.
• The OTS is an excellent tool for giving the
  control room operators hands on experience
  prior to start-up of the compression project. The
  work that the operators are doing in the
  simulator will give them a strong foundation for
  their control room training and competency for
  post compression operations.
• The simulator has also proven to be an
  effective aid in teaching new control room
  operators some of the PPB operator functions and
  we have also started using the OTS to help
  validate operating procedures.

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Cryostar EcoRel LNG Carrier
Feedback Cryostar magazine Autumn 2007
INDISS For the EcoRel project Cryostar was
responsible for both rotating machinery
performance and also for the performance of an
entire plant. In order to build the on-board
re-liquefaction plant it was necessary to master
the process of the plant. For this purpose
Cryostar used a high fidelity dynamic simulation
platform provided by RSI Simcon (part of the IFP
group)
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Cryostar EcoRel LNG Carrier
Feedback Cryostar magazine Autumn 2007
The open environment allowed Cryostars
engineers to implement their own proprietary
components of the on-board re-liquefaction
plant. Expanders, compressors, anti-surge
protection and load sharing heat-exchangers and
N2 make-up systems were all coded in the dynamic
plant model. The performance characteristics
of the rotating machinery components of the plant
were cross-checked and adjusted during the open
loop performance test that was conducted at the
Cryostar test facility. The comparison with
the test results allowed an adjustment of the
parameters of the plant model which were
previously based on predictions. During the
full N2 loop test the plant model showed
excellent comparisons with the measurements at
the test bench and provided a useful learning
tool for the operation of the plant.
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LATEST OIL GAS REFERENCES
Project Type Year Location Customer / End user Simulator scope
Kerteh Gas Plants OTS In progress Malaysia Gas Plants Foxboro I/A Honeywell PKS emulation
Hassi Messaoud DES In progress Algeria Flash gas compressor Thermodyn anti-surge emulation
Zakum DES In progress 2005 UAE Offshore Gas Production Facilities (14 compressors)
South Pars 6-7-8 PMS In progress Iran Gas production facilities Yokogawa CS3000 emulation INDISS-OLGA
Ruwais OTS In progress UAE Onshore gas plant Yokogawa CS3000 emulation
Yemen LNG DES OTS In progress 2006 Yemen LNG liquefaction plant Foxboro I/A stimulation
Harad DES 2008 Saudi Arabia 2-stage gas compressor Thermodyn anti-surge emulation
Hasdrubal DES 2008 Tunisia NGL extraction plant
Ofon II DES 2008 Nigeria Offshore slug catchers Riser HIPPS
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LATEST OIL GAS REFERENCES
Project Type Year Location Customer / End user Simulator scope
Juaymah DES 2008 Saudi Arabia Debutanizer HIPPS
El Gamil DES 2007 Egypt HIPPS, Gas Turbine HP compressor
Yadana OTS 2007 Myanmar Offshore oil gas platforms Yokogawa CS3000 emulation
Tunu Peciko 6 DES 2007 Indonesia Gas compressor Thermodyn anti-surge emulation
Hamrin DES 2007 Irak Gas compressor Thermodyn anti-surge emulation
OAG DES 2007 UAE Gas compressor Thermodyn anti-surge emulation
Harweel DES 2007 Oman LP1/LP2/IP1/IP2 compressors Thermodyn anti-surge emulation
Auvers Evry DES 2006 France Gas compressor Thermodyn anti-surge emulation
Volve OTS 2006 Norway Offshore oil gas platform ABB Ind. IT emulation
San Roque DES 2006 Argentina LP compressor Thermodyn anti-surge emulation
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LATEST OIL GAS REFERENCES
Project Type Year Location Customer / End user Simulator scope
Shayabah II DES 2006 Saudi Arabia LP/IP/HP/injection compressors Thermodyn anti-surge emulation
Pazflor DES 2006 Angola Riser HIPPS
OGD III gas expansion project DES 2006 UAE 2-stage Gas Compressor Thermodyn anti-surge emulation
South Pars 4-5 OTS 2006 Iran Gas production facilities Yokogawa CS3000 emulation
Canadon Alpha Aguada Pichana DES 2006 Argentina Gas compressor Thermodyn anti-surge emulation
Rosa DES 2006 Angola Offshore water treatment Hydrocyclones
Cryostar DES 2006 France LNG carrier Boil-off gas treatment
Pars LNG DES 2006 Iran LNG liquefaction plant
Dalia FPSO DES OTS 2006 2005 Angola FPSO, Foxboro I/A stimulation Multi-well control INDISS-OLGA Thermodyn anti-surge emulation
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LATEST OIL GAS REFERENCES
Project Type Year Location Customer / End user Simulator scope
Liquefin DES 2005 France LNG liquefaction plant
Kashagan 2 OTS 2005 Kazakhstan Offshore oil gas platforms Onshore gas plant
Kashagan DES 2005 Kazakhstan HIPPS, Gas turbine Raw gas injection 3-stage compressors CCC emulation
Akpo FPSO DES 2005 Nigeria LP/MP/HP, Gas export Gas injection Compressors Thermodyn anti-surge emulation
Sable DES OTS 2005 2004 Canada Offshore oil gas platforms ABB PBB emulation CCC emulation INDISS-OLGA
Lussagnet DES 2004 France Reciprocating compressor
Carina-Aries OTS PMS 2004 Argentina Gas production facilities Foxboro I/A emulation INDISS-OLGA
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LATEST OIL GAS REFERENCES
Project Type Year Location Customer / End user Simulator scope
Rod DES 2004 Algeria Onshore oil gas complex CCC emulation INDISS-OLGA
Amenam OTS DES 2004 2002 Nigeria Oil gas platforms Foxboro I/A stimulation Multi-well control
Soroosh-Nowrooz OTS 2003 Iran Oil gas platforms Yokogawa CS3000 emulation
South Pars 2-3 OTS PMS 2001 Iran Gas production facilities Yokogawa CS3000 emulation INDISS-OLGA
Ruwais OTS 2001 UAE Debutanizer Yokogawa CS3000 stimulation
Amenam DES 2001 Nigeria Sea water pumps
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