534 Automation and Safety Solutions of LNG Plants Today Using DeltaV Platform[1]

8/22/2019 534 Automation and Safety Solutions of LNG Plants Today Using DeltaV Platform[1]

http://slidepdf.com/reader/full/534-automation-and-safety-solutions-of-lng-plants-today-using-deltav-platform1 1/49

Automation and Safety Automation and Safety

Solutions of LNG plants today,Solutions of LNG plants today,using DELTA V Platformusing DELTA V Platform

Romel Bhullar

Technical Director/ Fellow

Fluor Corp.

Aliso Viejo, California.



Acknowledgement Acknowledgement Acknowledgement

• All trademarks and trade names used belong tothe respective entities and organizations.

• Some data used is from the presentations of the“LNG 15 International Conference”, and moreinformation can be found at their web site.

www.LNG15.org or the proceedings of theconference.

http://www.lng15.org/

http://www.lng15.org/



Natural Gas - A Fuel of ChoiceNatural GasNatural Gas -- A Fuel of Choice A Fuel of Choice

• Abundance

• Clean Burning

• Large AvailableInfrastructure

• Major Energy Source for

– Power

– Petrochemical

– Industry

– Domestic Use



Where can we get gas ?Where can we get gas ?Where can we get gas ?



Present statusPresent statusPresent status



Looking aheadLooking aheadLooking ahead



Natural Gas Supply ChainNatural Gas Supply ChainNatural Gas Supply Chain

• Gas Production

• Liquefaction

• Gas Transport

• LNG Regasification

• Producers and Consumersare geographically apart.



LNG SUPPLY & DEMAND CHAINLNG SUPPLY & DEMAND CHAINLNG SUPPLY & DEMAND CHAIN



Upstream Gas Production – Qatar FacilitiesUpstream Gas ProductionUpstream Gas Production – – Qatar Qatar FacilitiesFacilities



Qatar offshore/onshore facilityQatar offshore/onshore facilityQatar offshore/onshore facility



Have LNG – will unload anywhere!!Have LNGHave LNG – – will unload anywhere!!will unload anywhere!!



LNG REGASIFICATION FACILITIESLNG REGASIFICATION FACILITIESLNG REGASIFICATION FACILITIES



LNG REGASIFICATION TERMINALLNG REGASIFICATION TERMINALLNG REGASIFICATION TERMINAL

Unloading System

Vapor Handl ing/Send-out system

LNG Carrier

BOG

LNG

Vaporizers

BOG Re-condenser

Users

BOG Compressors

KO

Drum

Vapor return line

Vapor return

blower

Fuel gas

Fuel gas

LNG unloading line

In-tank

Pumps

LNG Storage Tanks

Vapor return / Unloading arms

Recirculation line

Send-out

Pumps



Significant Major Emerging TrendsSignificant Major Emerging TrendsSignificant Major Emerging Trends

• Major producers are doubling production capacity–Qatar, Algeria, Malaysia,

• Capacity of the trains increasing to 7 -10 Mt/year –Super super large –super problems

• LNG terminals numbers will triple – yes not in my

backyard• Need 60 new LNG terminals for Europe alone

• Development of Supertankers - >300 k M3

capacity• Offshore gasification ?



Automation Needs of LNG plant Automation Needs of LNG plant Automation Needs of LNG plant

• Simple but highly complex

• Highly automated –MINIMUM HUMAN

INTERVENTION

• Automation systems has to meet the needs of many stake holders.

• Besides process controls and safety systemstypical LNG plant has more than 30 subsystems to

harmoniously integrate.• Include ERP, supply chain and customer relation

management systems, and it gets exciting.

T diti l D i C id ti



Traditional Design Considerationfor Automation of a process plantTraditional Design ConsiderationTraditional Design Considerationfor Automation of a process plantfor Automation of a process plant

• Safety

• Reliability

• Availability

• Minimum Capital Costs

• No life cycle considerations• No Consideration for integration with business,

supply chain, enterprise or customer systems.



New trends for automation systems –Business Drivers of industryNew trends for automation systemsNew trends for automation systems – –Business Drivers of industryBusiness Drivers of industry

• Design for Flexibility, Flexibility ..

• High turndown for throughput

• Extremely Rapid Response to demands

• Stable, Robust, and highly Reliable

• Minimum Inventories• Extreme safety and audit trail

• Tougher Regulatory requirements

• Completely Integrated within Enterprise, Upstreamand downstream customers.



Emerging Technical trendsEmerging Technical trendsEmerging Technical trends

• Use of APC upstream

• Mega drivers for compressors

• Total supply chain integration

• Increased awareness on safety

• Integrated LNG terminals with district cooling, maxthermal efficiency- like combined cycle in powerindustry.



Automation Systems for New LNG plants Automation Systems for New LNG plants Automation Systems for New LNG plants

• Design for Flexibility, Flexibility ..

• High turndown for throughput

• Extremely Rapid Response to demands

• Stable, Robust, and highly Reliable

• Minimum Inventories• Extreme safety and audit trail

• Tougher Regulatory requirements

• Completely Integrated within Enterprise, Upstreamand downstream customers.



Automation Solution for LNG plants Automation Solution for LNG plants Automation Solution for LNG plants

• No such thing as one shoe fits all

• Use application based “BEST OF THE BREED”

solutions.• Reliable and Proven Technologies

• NO ONE VENDOR CAN NOT PROVIDE ALL THE SOLUTIONS.



ALTAMIRA LNG Terminal Project ALTAMIRA LNG Terminal Project ALTAMIRA LNG Terminal Project

• First LNG terminal in Mexico –On line 9/2006

• Owned by Multinational Consortium

• Engineered and Constructed by MultinationalConsortium

• Built to best technology and world standards in aremote location

• Highly automated

• A world class project



GNL Infrastructure in MexicoGNL Infrastructure in MexicoGNL Infrastructure in Mexico

OVERVIEW OF AUTOMATING A LNGOVERVIEW OF AUTOMATING A LNGOVERVIEW OF AUTOMATING A LNG



OVERVIEW OF AUTOMATING A LNGPLANTOVERVIEW OF AUTOMATING A LNGOVERVIEW OF AUTOMATING A LNGPLANTPLANT

• CONTROL PHILOSOPHY

• LEVEL OF AUTOMATION

• STAKEHOLDER NEEDS THROUGHOUT THEENTERPRISE

• TRANSLATE NEEDS INTO SYSTEMS AND

SUBSYSTEMS• FUNCTIONAL REQUIREMENTS,

SPECIFICATIONS, IMPLEMENTATION

• TESTING AND COMMISSIONING THEAUTOMATION SYSTEMS.

INTEGRATED PROCESS CONTROLINTEGRATED PROCESS CONTROLINTEGRATED PROCESS CONTROL



INTEGRATED PROCESS CONTROLSYSTEMINTEGRATED PROCESS CONTROLINTEGRATED PROCESS CONTROLSYSTEMSYSTEM

• ONE SYSTEM DOES NOT DELIVER WHAT ISNEEDED.

• NEED BEST OF THE BREED TECHNOLOGIES• LINK TOGETHER SEVERAL COMPLEX,

INDEPENDENT AND PROPRIETAY SYSTEMSAND TECHNOLOGIES

• MMS

• IMCS• IPSS ETC.

Alt i LNG Pl t A t tiAlt iAltamira LNG Pl t A t tiLNG Plant Automation



Altamira LNG Plant AutomationSystems and subsystems

Altamira Altamira LNG Plant AutomationLNG Plant AutomationSystems and subsystemsSystems and subsystems

• Consoles and HMI’s – single window of operation

• Distributed Control System

• System communication and cabling infrastructure• IPS

• FIRE AND GAS• IMCS

• MMS

• ODS

• CCTV

AUTOMATION SYSTEMS ANDAUTOMATION SYSTEMS ANDAUTOMATION SYSTEMS AND



AUTOMATION SYSTEMS ANDSUBSYSTEMS contd.

AUTOMATION SYSTEMS AND AUTOMATION SYSTEMS ANDSUBSYSTEMS contd.SUBSYSTEMS contd.

• MAXIMO

• MECHANICAL PACKAGES

• LOADING ARMS

• SHIP TO SHORE LINKS

• MARINE SYSTEMS• SHIP BERTHING

• METERING AND CUSTODY TRANSFER• OTHERS



ADDITIONAL NEEDS OF AUTOMATION ADDITIONAL NEEDS OF AUTOMATION ADDITIONAL NEEDS OF AUTOMATION

• DIGITAL INFRASTRUCTURE

• ANALOG INFRASTRUCTURE

• CABLING –Fiber, Coaxial, ……

• Cabinets and Marshalling

• Field Device Integration• System Integration



Intelligent Motor Control SystemIntelligent Motor Control SystemIntelligent Motor Control System



LNG PLANT SAFETY SYSTEMSLNG PLANT SAFETY SYSTEMSLNG PLANT SAFETY SYSTEMS

• MOST CRITICAL COMPONENT

• EXTREMELY HIGHAVAILABILITY

• EXTREMELY HIGHRELIABLITY

• TESTING/CERTIFICATION

• AUDITING TRAIL

• REGULATORY REQUIREMENT

• Also referred as IPSS



LNG PLANT SAFETY SYSTEMLNG PLANT SAFETY SYSTEMLNG PLANT SAFETY SYSTEM

• IPSS IS A CRITICAL COMPONENT FOR ANYLNG PLANT

• COMPLIED WITH ALL THE EXISITNGSTANDARDS, BEST INDUSTRIAL PRACTICES,AND REGULATORY AGENCY REQUIREMENTS

• USED BEST OF THE BREED AVAILABLE TECHNOLOGY.

SAFETY STANDARDS FORSAFETY STANDARDS FORSAFETY STANDARDS FOR



SAFETY STANDARDS FORPROCESS INDUSTRIESSAFETY STANDARDS FORSAFETY STANDARDS FORPROCESS INDUSTRIESPROCESS INDUSTRIES

• ISA S-84 1996 HARD WIRES ONLY.

• ISA S84.00.01 ALSO IEC 61511-2003, ALLOWS

A DIGITAL BUS COMMUNICATION.• ISA SP84 WG 1 ON SUPPORT FOR FIELDBUS.

• We implemented all the requirements, includingautomatic partial stroke testing and documenting.

OBJECTIVES OF ISA S 84 WG1OBJECTIVES OF ISA S 84 WG1OBJECTIVES OF ISA S 84 WG1



OBJECTIVES OF ISA S 84 WG1 AREOBJECTIVES OF ISA S 84 WG1OBJECTIVES OF ISA S 84 WG1 ARE ARE

• CERTIFIED SIL LEVEL OF SIS

• INTEROPERABILITY - NON PROPRIETARY

• COEXISTANCE OF SAFETY AND NON SAFETYRELATED DEVICES ON THE BUS

• DIAGNOSITIC REQUIREMENTS

• FAULT TOLERANCE• SECURITY

• HOT REPLACEMENT

• TESTING

• FAST RESPONSE



SAFETY FIELDBUS (W2)SAFETY FIELDBUS (W2)SAFETY FIELDBUS (W2)

• TECHNOLOGY EXISTS TODAY

• STANDARDS ? – DRAFT MAY BE ACCEPTEDBY NOW.

• PARTIAL STROKE TESTING CAPABILITIES ARE THERE.

• HAVE SIMILAR BENEFITS AS CLAIMED BY

FIELDBUS



Integration of IPS with Delta VIntegration of IPS with Delta VIntegration of IPS with Delta V



CONSOLECONSOLECONSOLE

• Single window of display & interaction for allsystems and subsystems.

• Ergonomics• Remote electronics

• Customizable for individual operator use.





Field Device IntegrationField Device IntegrationField Device Integration

• Foundation Field Bus or Profibus

• Remote I/O

• HART Based devices.

• FFB DID NOT PROVIDE US THE FUNCTIONALITY

NEEDED FOR LNG PLANT.• NEED FOR MORE THAN ONE BUS IN THE PLANT.

• Our study based upon cost/benefit and risk analysis did not

favor FFB for our application.

• We chose Remote I/O, digital devices with HART



WHY EMERSON DELTA VWHY EMERSON DELTA VWHY EMERSON DELTA V



PLATFORMPLATFORMPLATFORM

• Technology

• HMI

• Hardware

• Software

• Sub-System Integration• Field Device Integration

• Project Execution• MAC Concept

TURNKEY PROJECTTURNKEY PROJECTTURNKEY PROJECTEXECUTION



EXECUTIONEXECUTIONEXECUTION

• SINGLE SOURCE RESPONSIBILITY

• LUMP SUM PROJ ECT

• EXECUTION CONCEPT OF MAC

• MAC – MAIN AUTOMATION CONTRACTOR

Wh MACWh MACWh MAC



Why MACWhy MACWhy MAC

• Total System and Subsystem integrationresponsibility

• Total technical integrity• Consistency of design, construction, and

implementation

EMERSON AS MACEMERSON AS MACEMERSON AS MAC



EMERSON AS MACEMERSON AS MACEMERSON AS MAC

• WHAT EMERSON BROUGHT TO THE TABLE

PLATFORM SELECTIONCRITERIAPLATFORM SELECTIONPLATFORM SELECTIONCRITERIACRITERIA



CRITERIACRITERIACRITERIA

• CLASSICAL – SPECIFICATION COMPLIANCE,HARDWARE, SOFTWARE,COMMUNICATION,

THIRD PARTY• SPECIAL CONSIDERATIONS

IPCS SYSTEM PLATFORMSELECTION BASISIPCS SYSTEM PLATFORMIPCS SYSTEM PLATFORMSELECTION BASISSELECTION BASIS



SELECTION BASISSELECTION BASISSELECTION BASIS

• CLASICAL BASIS

• SPEC COMPLIANCE

• HARDWARE

• COMMUNICATION

• APPLICATION SOFTWARE

• THIRDPARTY SYSTEM

INTEGRATION• SPECIAL CONSIDERATIONS

– GLOBAL EXECUTION

– LNG EXPERTISE

– INFRASTRUCTURE

– ORGANIZATION

WHY EMERSON DELTA VPLATFORMWHY EMERSON DELTA VWHY EMERSON DELTA VPLATFORMPLATFORM



PLATFORMPLATFORMPLATFORM

• AUTOMATION NEEDS OF THE PROJ ECTREQUIRED BEST OF THE BREED

TECHNOLOGIES, SOME OF THEM WERE NOTAVAILABLE FROM A SINGLE SUPPLIER

• SELECTION CRITERIA AND BASIS OF

DECISION IS TO BE PRESENTED IN THESESSION

INTEGRATION COSTMINIMIZINGINTEGRATION COSTINTEGRATION COSTMINIMIZINGMINIMIZING



MINIMIZINGMINIMIZINGMINIMIZING

• WELL DEFINED INTERFACES

• “TRIED”TO USE STANDARD PROTOCOLS, AND USEDPROPRIETARY PROTOCOLS AS LAST RESORT

• PROVEN AND TEST CONFIRMATION IN FAT.

• ONE PARTY RESPONSIBLE FOR INTEGRATION.

• OPC• MODBUS

• ETHERNET

• PROPRIETARY -

Lessons Learnt and Experiencesith E

Lessons Learnt and ExperiencesLessons Learnt and Experienceswith Emersonwith Emerson



with Emersonwith Emersonwith Emerson

• Details would be shared in the presentation.

• Some were good and some did not meet

expectations and need more attention and focus.

ConclusionsConclusionsConclusions



ConclusionsConclusionsConclusions

• Mexico’s first LNG project, a world class LNGterminal was completed and brought on line inrecord time, within the budget. Technical solutionsfor integrated process controls exceededexpectations. Teaming up with Emerson as MAC,significantly contributed to the success of theproject

Questions ?????Questions ?????Questions ?????



Questions ?????Questions ?????Questions ?????

Documents

534 Automation and Safety Solutions of LNG Plants Today Using DeltaV Platform[1]