Paper PS5-2

APPLICATION OF DYNAMIC SIMULATION FOR DESIGN

AND COMMISSIONING OF LNG PLANTS
(EXPERIENCE IN MLNG TIGA PROJECT)

APPLICATION D’UNE SIMULATION DYNAMIQUE POUR LA

CONCEPTION ET LA COMMISSION D’USINES DE GNL
(EXPERIENCE DU PROJET DE MLNG TIGA)
Encik Norrazak Hj. Ismail, General Manager
Mohd Soffie Ariffin, Senior Engineering Manager
Malaysia LNG Tiga Sdn Bhd
Bintulu, Sarawak, Malaysia
norraz@petronas.com.my
Hidefumi Omori, Senior Deputy Manager
Hitoshi Konishi, Chief Engineer
JGC Corporation
Yokohama, Japan
omori.hidefumi@jgc.co.jp
Scott A. Ray, Senior Process Engineer, LNG
Charles A. Durr, Technology Vice President, LNG
Kellogg Brown & Root, Inc.
Houston, TX, U.S.A.
scott.ray@halliburton.com

ABSTRACT
During the MLNG Tiga project, dynamic simulation was used by the EPC consortium
of KBR and JGC working with project owner Malaysia LNG Tiga Sdn Bhd for several
studies of plant design and verification of the plant performance. This approach proved to
be very effective.
Acceptance of Tested Performance of the Refrigerant Compressors
The as-tested performance curves of the refrigerant compressors were used within
dynamic simulations to verify that the refrigerant compressors, together with the actual
performance of other equipment, would meet the requirements for LNG production.
Unique Power Exchange Concept between Gas Turbines
Both the MR compressor and propane compressor are powered by individual gas
turbines. MLNG Tiga employs a unique power exchange concept between these two gas
turbines. The excess power available from the propane compressor gas turbine is
transferred to the MR compressor via synchronous electric motors/generators. Excess
power can also be fed to the 50 Hz plant electrical distribution system from the 60 Hz
circuit via a Load Commutated Inverter, and vice versa.
Dynamic simulation was performed in order to ensure the robustness of these
integrated electric and process systems during start-up/shutdown,. The simulation model
included a full representation of the propane, MR and the natural gas circuits. The process
model was linked to an electrical simulation of the turbines and synchronous machines.

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Plant Performance Verification

During the plant performance test, dynamic simulation was used to demonstrate the
performance of the plant. Furthermore, the simulations were used to demonstrate that
specified margins are available and to demonstrate that alternate modes of operation are
possible as designed. The data collected during the performance test was reconciled
against the simulation then actual values of key parameters were estimated. These
estimated key parameters, such as tray efficiencies and overall heat transfer coefficients,
were then entered into the simulation and design/alternative cases simulated on a rating
basis and benchmarked against the systems criteria for success.
Through the use of dynamic simulation we can make future plants fit for purpose and
more cost effective.

RESUME
Dans l’exécution du Projet GNL de Tiga, Malaisie, une simulation dynamique a été
retenue tant pour plusieurs études liées à la conception de l’ensemble de l’usine que pour
la vérification de la bonne performance de l’usine. Cette approche s’est révélée très
effective.
Réception de la performance testée des compresseurs de réfrigérant sous l’angle de
la production de GNL exigée
Les courbes de performance des compresseurs de réfrigérant, obtenues à l’issue de
l’essai de performance sur ces machines, ont été utilisées telles quelles pour la mise en
œuvre de simulations dynamiques avec les données de la performance réelle des autres
appareils, afin de vérifier si les compresseurs satisfont ou non aux exigences imposées par
la production de GNL.
Concept d’un échange de puissance de sortie unique entre turbines à gaz
Le compresseur de réfrigérant mixte (MR) et le compresseur de propane sont
entraînés respectivement par une turbine à gaz individuel. Tiga LNG en Malaisie adopte
au projet précité un concept unique consistant à échanger de la puissance de sortie
excédentaire de ces deux turbines à gaz entre elles. L’excès de puissance, disponible, de
la turbine à gaz entraînant le compresseur de propane est transféré au compresseur MR
par moteurs/générateurs électriques synchrones interposés. L’alimentation en cette
puissance en excès du système distributeur de courant de 50 Hz dans l’usine est
également possible à travers le circuit de 60 Hz, grâce à un onduleur de charge (“Load
Commutated Inverter”), et vice versa.
Afin d’assurer la bonne tenue de ces deux systèmes électrique et procédé ainsi
intégrés, une simulation dynamique a été effectuée sur leur démarrage et arrêt. Le modèle
de simulation couvre tous les circuits de propane, de MR, et de gaz naturel. Le modèle de
procédé et le modèle électrique sur les turbines et sur les machines synchrones sont
attelés l’un à l’autre dans la simulation dynamique.
Vérification de la performance de l’usine
Lors de l’essai de performance de l’usine, une simulation dynamique a été effectuée
pour démontrer la bonne performance de l’usine, ainsi que pour démontrer que les marges
de sécurité prescrites sont bien disponibles, mais aussi pour démonter qu’un ou plusieurs
modes d’exploitation alternatifs sont possibles comme prévu dans l’étude. Les données
saisies tout au long de l’essai de performance ont été entrées dans le simulateur afin

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d’estimer les paramètres-clé tels qu’en particulier l’efficacité du plateau et le coefficient

global de transfert thermique, pour simuler aussi bien l’exploitation basée sur les
conditions de calcul, que des cas d’exploitation alternatifs en utilisant les données
obtenues suite à la simulation de l’exploitation nominale et par comparaison à celles-ci,
résultats qui servent alors à base d’établissement des critères de jugement pour les cas
alternatifs.
L’introduction de la simulation dynamique nous encourage encore davantage à
réaliser des usines plus pertinentes et économiques.

INTRODUCTION
The demand for natural gas throughout the world is rapidly increasing.
Simultaneously, economies of the world are becoming more inter-dependent. Therefore it
is important to maintain competitiveness in the global market place. To do so LNG
owners are constantly looking for ways to remain competitive.
An LNG facility enjoys economy of scale such that larger LNG facilities incur a
lower annual cost of production. Therefore, to remain competitive, annual production
capacities of new grassroots LNG facilities are trending upward at a strong pace. At the
same time, innovative ideas have been applied in cost saving initiatives in order to lower
both the capital expenditures and operating costs of these facilities while simultaneously
focusing on health, safety and environmental issues.
The MLNG Tiga project is an excellent example. With an annual capacity of 3.9
million tones per year each, the MLNG Tiga LNG trains are among the largest ever built.
The application of several significant innovative ideas makes this project one of the most
significant achievements in the LNG industry.
The enabling technology for the implementation of these innovations is Dynamic
Simulation. A recently developed set of Dynamic Simulation tools were applied to the
MLNG Tiga project with the goal to reduce design margins, lower project costs, and
visualize the plant operation while still in the design phase.

BACKGROUND
Process simulation of entire integrated systems is a pivotal technology for engineering
designs. Almost a decade ago, it was stated “I see modeling and simulation as a critical,
enabling technology essential today to capture, test, integrate, transfer and institutionalize
knowledge acquired along the value-adding and information supply chain to our
customers and their customers. Those companies that use these tools effectively will
[1]
provide increasing value to the marketplace. Those that do not will be pushed aside.”
The statement was made in a general way regarding all process simulations while users
were primarily focused on steady state simulations. At that time most desktop computers
were not powerful enough to handle dynamic simulations of large integrated process
systems.
In spite of a lack of widely available powerful computers during the early 1990s,
many studies were conducted with dynamic simulation. Used in the optimization of the
control system in gas compressors, dynamic simulation was proven to be a cost-effective
tool.[2] As the methods improved and desktop computers became more powerful, dynamic

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simulation was used successfully to minimize the investment for new and revamp designs.
The gas processing industry used these tools to remain competitive and profitable as they
focused on improving operational flexibility, unit availability and reliability, as well as on
quality of products, tightening of performance guarantees and length of start-up and shut-
down times.[3]
Within the LNG industry in the late 1990’s the use of dynamic simulation became a
standard part of the design. In certain studies the release of refrigerant to the flare was
minimized through the use of these tools, thus reducing the flare size and capturing
associated cost savings. Dynamic simulation was used to reduce the risk of damaging
rotating equipment, as well as to give the owner/operator the confidence necessary to
implement the next generation technologies.[4] An excellent example for study is both the
high pressure MR and propane compressors operated by the same Frame 7 gas turbine on
a single shaft at a constant speed. Dynamic simulation helps to ensure the operability of
[5]
such new designs throughout upset conditions, start-up and shutdown.
Today a typical design philosophy of many LNG facilities is to use equipment with a
minimum of two years proven experience. This is not always possible, particularly when
innovative ideas are applied or single train capacities set new world-class standards. In
these instances, new elements of risk are introduced and must be adequately managed
throughout design, equipment acceptance testing, and plant commissioning and
verification.
Dynamic simulation is the best available method for the analysis of risks introduced
by new designs and innovations. Many of the phenomena that must be understood occur
during upset conditions. Additionally dynamic simulators typically use “simultaneous
solution” methods and are capable of solving steady state “pressure driven” simulations,
such as the multi-level refrigeration systems of the LNG plant. Because typical steady
state simulators are popular, but cannot easily solve the pressure driven system, processes
are often simulated with estimated parameters to simplify the system. However,
simplifying the system introduces error, which can only be overcome by employing a
design margin.[6].
The dynamic tools used on the MLNG Tiga project provide capabilities that are far
superior to what is available from traditional process simulators. For instance, the use of
these dynamic tools can allow the plant to be debottlenecked during the design phase,
increasing the effectiveness and productivity of the installed equipment. Additionally, the
enhanced capabilities allow the designer to analyze margins and design factors of the
sized equipment and to minimize the combined effect, thereby optimizing the owners’
return on investment.

MAIN FEATURES OF MLNG TIGA PLANT

The turnkey engineering, procurement, construction and commissioning work of
MLNG Tiga project and associated facilities was started in 1999 by the consortium of
JGC Corporation and Kellogg Brown & Root. The project has two liquefaction trains,
each with a design LNG production capacity of 3.9 million tones per year. Also included
is a new LNG storage tank, with a capacity of 120,000 m3 and an additional 3rd LNG Ship
Berthing Facility. The MLNG Tiga plant is located on a site adjacent to the two existing
plants, MLNG and MLNG Dua, a total of 6 trains. After start of operation of Train 7 & 8,
that is MLNG Tiga, the Petronas LNG complex in Bintulu will have a total LNG

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production capacity of 23 mtpa, and will be the largest LNG complex in the world in a
single location.
The utility facilities in MLNG Tiga have been designed independent from the existing
MLNG and MLNG Dua plants, but are inter-connected with MLNG and MLNG Dua and
act as a back-up for each other. The LNG storage and loading system is designed for all
three LNG plants (total of 8 trains).[7]
The Petronas LNG complex in Bintulu, consisting of MLNG, MLNG Dua and
MLNG Tiga, looks like a museum of LNG plants where we can see almost all of the
technologies adopted by LNG plants over the years. The major features of these three
plants are identified in Table 1.[8]
Table 1. Features of MLNG, MLNG Dua and MLNG Tiga

MLNG MLNG Dua MLNG Tiga

(Ea.)Train Capacity 2.8 MTPA x 3 2.6 MTPA x 3 3.9 MTPA x 2
(120% of design) (100% of design) (100% of design)
Liquefaction Process C3-Precool MR C3-Precool MR C3-Precool MR
Main Driver Steam Turbine Frame 6 & 7 Two Frame 7
Helper Driver - Steam Turbine Motor
Liquid Expander No Yes Yes
Cooling Media Sea Water Sea Water and Air Air
Heating Media Steam Steam Heat Trans. Fluid

The key equipment in the large LNG plant is the compressor and its driver. These key
pieces of equipment have large impact on the overall facility’s ability to produce the
required LNG.

Large Compressor Configuration

The adopted liquefaction process in MLNG Tiga plant, i.e., propane pre-cooling MR
process, consists of one four-stage centrifugal type propane compressor, one low-pressure
axial type MR compressor and one high-pressure centrifugal type MR compressor. Only
a few manufacturers may produce these large and complex compressors. In this case,
Nuovo Pignone (GEO&G) supplied these machines.
The arrangement of the compressors and its driver is shown in the Figure 1. A special
60 Hz electrical control system (termed as EPCF) is used as a power manager to interact
the LCI units with the gas turbine Mark V control systems (termed as UCP) to load and
unload the VSDS unit.
The propane compressor is driven by General Electric Frame 7-EA gas turbine and a
variable speed starter motor/generator on the common shaft string. The motor/generator
serves a dual purpose, first in providing starting power to bring the compressor/turbine
combination up to 99.5% speed. Second, the motor generates electricity from the surplus
gas turbine power available during normal operation. That electric power is then supplied
to the MR compressor starter/helper motor and any excess power is sent to the grid.

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60 Hz 50 Hz

MR M

TRAIN 7

G
PROPANE

MR
M

TRAIN 8

G
PROPANE

60 Hz 50 Hz

Figure 1. Configuration of Refrigerant Compressors in Train 7 & 8

Gas Turbine and Helper Motor Control Using LCI

Both LP and HP MR Compressors are driven by a common shaft string connected to
a General Electric Frame 7-EA gas turbine and a variable speed starter/helper motor. The
electric starter/helper motor serves a dual role. First the motor provides starter power to
bring the compressor/turbine combination up to 99.5% speed. Second, the motor provides
additional shaft power to the MR compressor set during normal operation. The required
electric power is supplied by the generator coupled to the propane compressor train.
There are three types of operation of the compressors as shown in following figures.

LCI
CONT'L

Σ Pi = 0
Motor Generator
0 MW 10 MW

MR C3
Σ Pi = 0 Σ Pi = 0
COMP COMP

MR GT C3 GT

Figure 2. Operation with LCI

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60 Hz
Σ Pi = 0
Motor
0 MW
Generator

MR C3
Σ Pi = 0 Σ Pi = 0
COMP COMP

MR GT C3 GT

Figure 3. Operation in Island

60 Hz 60 Hz

MR C3
Σ Pi = 0 Σ Pi = 0
COMP COMP

MR GT C3 GT

Figure 4. Independent Operation

During start-up, the gas turbines for MR and propane are controlled in isochronous
mode, this means that the control of gas turbines maintains a fixed speed whatever the
load (Figure 4). At the end of the start-up procedure, the unit is switched to droop mode
and synchronized to the load commutated inverter (LCI) that takes the frequency of 60
Hz. In case of a defective LCI the propane gas turbine will run in the isochronous mode
setting the frequency of 60 Hz and the two compressor trains will work in island mode.
Normally the two compressor trains are electrically coupled running at fixed speed of
3600 rpm. In case of droop mode a speed variation is permitted. The philosophy used for
the electric power production is to maximize the export to the 50 Hz grid (Figure 2). This
strategy is achieved by setting the propane gas turbine to produce sufficient power to
achieve the maximum generator capability while simultaneously the MR gas turbine is set
to unload the MR helper motor as much as possible. The electrical power generated by
propane generator is supplied to MR helper motor and exported to 50 Hz grid. The load
fluctuation will be absorbed by LCI and both gas turbines until they reach their
temperature control limits, then the LCI will cover any lack of power
increasing/decreasing the power imported or decreasing the power exported. The LCI
also absorbs the power fluctuation during transient upsets because of its faster response.

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The control system was designed for maximum delivery of electric power to the 50
Hz grid. Therefore the gas turbines usually operate at the maximum limit that is either
defined by:
• Gas turbine capacity
• Maximum stator current of the synchronous machine
• LCI capacity
The first limitation is applied if the compressor torque is high and/or the ambient
temperature is high so that the temperature controller of the gas turbine limits the fuel
flow. When the gas turbine capacity is high and/or the compressor torque is low so that
the maximum stator current of the connected synchronous machine would be exceeded,
the gas turbine output must be limited by an active power controller regulating the
electric power of the synchronous machine. In order to protect the LCI, frequency control
is automatically taken over by the speed governors of the gas turbines if the LCI reaches
its current limit. These power-controllers drive the system smoothly back to nominal
frequency and reduce the gas turbines output.
In island operation, when the LCI is out of service, power exchange with the 50 Hz
grid is impossible (Figure 3). Therefore, the 60 Hz power balance must be established by
the gas turbines only. In this case, the propane gas turbine speed governor regulates the
frequency of the 60 Hz system by setting the speed governor to isochronous. If in island
operation the gas turbine capacity is not sufficient to cover the compressor load,
frequency is reduced until a new steady state is established. The new steady state depends
on the speed-torque characteristics of the compressors. In this case, frequency support can
only be achieved if the LNG production, and hence the compressor torque, is reduced.
One LCI is provided in each liquefaction train. If one LCI is under maintenance, it is
possible to operate one of the trains in island mode and the other one connected to LCI. It
is also possible to operate all four compressors in parallel through one LCI by configuring
the 60Hz breakers correspondingly.

COMPRESSOR PERFORMANCE
The refrigeration compressors are the driving force of the LNG process. Therefore
their performance is critical to the overall performance of the plant. Relatively small
variations between the compressor design expected and actual performance during the
official witness testing of the equipment translates into changes in the overall plant
operation and could affect LNG production.
Acceptance Criteria
The MR and propane compressor Power Test Code 10 test is a Class III test (ASME
specified procedure). The tolerances for acceptance are :
• Rated head for centrifugal type: +3%/-0%
• Power at rated condition: +/- 1%
In some cases it may be critical that the compressor performance strictly meets the
acceptance criteria. But in other cases this is not actually true. Although process
performance is affected by the differences between the design basis and the as-built

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performance of the compressor, dynamic simulation can often be used to adjust the
process to slightly modified conditions and still meet the overall requirements.

Example
Consider the simple propane refrigeration system illustrated below. This simple
system is not part of the MLNG Tiga plant, but is an example used to illustrate the use of
dynamic simulation. The process flowrate and composition are arbitrarily chosen for this
example. The propane temperatures, pressures and flows are resultant based on that
arbitrary process chosen, the air cooled exchanger area and air flow, and the compressor
performance curves for volumetric flowrate, head, and efficiency.

Receiver

Desuperheater Condenser

Compressor

Subcooler

LIC

Process Heat Exchanger

Figure 5. Example of Simplified Propane Refrigeration Loop

The compressor performance is illustrated in Figure 6 below.

Compressor Performance Case 1

7200 80
6700 75
Head (meters)

Efficiency (%)
Polytropic

6200 70
5700 65
5200 60
4700 55
4200 50
120 130 140 150 160
Inlet Flow ACMH (1000 m3/hr)

Figure 6. Compressor Performance for Process Design

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For this example, we assume the compressor is built and the actual performance of
the tested machine produces 15% more head than expected at the design inlet flow rate.
Of course, if this were a real design, the compressor manufacturer can modify the
compressor by trimming wheels to lower the head and achieve actual performance much
closer to the expected performance. But, for illustration purposes, it is assumed that this
compressor will be considered operating within the plant with 15% higher head and
efficiency at the design operating point. The question is then how will the overall process
respond with this new compressor?

Head Increased by 15% at Operating Point

7 2 0 0 . 0 0

Where is the
New Operating
6 7 0 0 . 0 0

Point?
Head (meters)

6 2 0 0 . 0 0

?
5 7 0 0 . 0 0
?

5 2 0 0 . 0 0
?

4 7 0 0 . 0 0

4 2 0 0 . 0 0

1 2 0 1 3 0 1 4 0 1 5 0 1 6 0

Inlet Flow ACMH (1000 m3/hr)

Figure 7. Questioning System Performance

With all other parameters held constant, the head and efficiency curves for the
compressor are increased within the simulation with the following result.

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Compressor Performance Comparison

7 2 0 0

6 7 0 0
Head (meters)

6 2 0 0

5 7 0 0

5 2 0 0

4 7 0 0

4 2 0 0

1 2 0 1 3 0 1 4 0 1 5 0 1 6 0

Inlet Flow ACMH (1000 m3/hr)

Figure 8. Resultant System Performance – New Operating Point

Table 2 below illustrates the process changes due to the shift in compressor operation.
First notice that the increase in the head curve by 15% has resulted in only a 0.4%
increase in the propane evaporator duty (Table 2, Row B). Therefore the process receives
a relatively small benefit. The total compressor and propane duty, all of which must leave
through the air cooled exchangers, experiences only a small increase of 0.1% (Table 2,
Row C.) Even though the overall duty that must be handled by the air cooled heat
exchangers has increased a small amount, the distribution of duty between the three air
cooled exchangers is significantly changed. (Table 2, Rows E, F, G.)
Table 2. Sample Results Comparison
Process Differences Caused by Compressor
Performance Shift
ROW
Difference LABEL

Compressor & Power MW -1.0% A

Process Duty Propane Evaporator MW 0.4% B
TOTAL MW 0.1% C
D
Desuperheater MW -12.5% E
Air Cooled Heat
Condenser MW 1.46% F
Exchangers
Subcooler MW -3.1% G
Flow rate ACMH 3.6% H
Compressor Flow Rate kg/s 1.75% I
Inlet Temp C -0.65 J
Pressure Bar-a -0.13 K
Compressor Temp C -0.84 L
Outlet Pressure Bar-a 0.18 M

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Along with slightly higher head produced, the compressor operates also at a slightly
higher efficiency. In Table 2, Row A it can be seen that the compressor power was
reduced by 1.0% because of this higher efficiency. The higher compressor efficiency also
produces the lower compressor discharge temperature shown in Row L. The lower
compressor discharge temperature and higher compressor discharge pressure (Row M)
result in a lower Desuperheater duty (Row E) and lower Subcooler duty (Row G) but a
higher Condenser duty (Row F). Some of these resultant changes are not intuitive but are
the result of several interactions.
The small differences shown in the example above illustrates that the change of the
performance of the compressor does not adversely affect the process performance.
Obviously the effects on a complete LNG refrigeration system are much more
complicated than this simple example. But, this simple example illustrates the very basic
and important responses of a propane refrigeration system. When this technology is used
for a complete LNG refrigeration system, the system must be modeled carefully and the
results studied. The results of the MLNG Tiga simulations are far too extensive to present
here, but the example above provides an excellent illustration of the effects. From this
example it can be concluded that many complex but subtle effects determine the final
operating point and overall system effectiveness.

Simulation of LNG Production

The software package has the ability to simulate a system in steady state, and then
also optimize the system, maximizing an objective function based on calculation within
the simulation. For MLNG Tiga’s simulation, the optimization objective was to maximize
the LNG rundown rate within the limits of available compressor driver power. The search
for maximum LNG production was also limited by constraints to keep the search within
reasonable process conditions. The software finds the optimum through a series of steps,
whereby:
• The process simulation is solved for steady state conditions
• The optimizer automatically changes the value of a few key predetermined
variables
• The process simulation is solved again for the new steady state conditions
• The optimization software compares values of the two steady state runs. The
comparison, along with state of the art intelligence, is used to make another step
towards the optimum.
This process is repeated until the LNG production has reached a maximum. The
system simulation includes many detailed models of the various unit operations. Each
piece of equipment is carefully modeled. For instance, every stage of compression uses
vendor supplied polytropic head and efficiency curves, while solving temperature and
pressure calculations, overall energy balance and density calculations. Each heat
exchanger, valve, expander, and flash vessel are modeled to include mass and energy
balances, flash calculations which use calls to rigorous physical properties, and pressure-
flow relationships. All of these equations must be satisfied in order to reach a steady state
solution.
For a complicated system, many of the equations within unit operations are
interdependent and must be solved simultaneously. For instance, the propane system is
dependent on the polytropic head curves. While the head curves remain constant, the

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head produced by a stage of compression is dependent on the inlet volumetric flow. The
inlet volumetric flow is dependent on the previous stage of compression and the propane
vapor flow from the propane vaporizers. The heat exchanger models use a fixed value for
UA in the LMTD calculation, which must retrieve the physical property from the
database. All these equations must be solved simultaneously to arrive at the steady state
solution. In the optimization procedure the steady state solver first completely solves all
the unit operations in the simulation. The optimizer uses first order derivatives with
respect to the objective function for certain variables to determine the direction of the
next step. The optimizer will then change the values of several predetermined variables
and the steady state solver will again solve the system. Each step that the optimizer takes
while searching for the maximum LNG production is a valid steady state solution for the
entire liquefaction system. Each step taken is therefore on the feasible path. While
searching for the maximum LNG production, the optimizer is permitted to manipulate:
• Inlet guide vane angle of LP MR compressor
• Inlet pressure of LP MR compressor
• Outlet pressure of heavy MR expander
• MR composition
These variables are available for the optimizer to manipulate while attempting to
maximize the objective function. The system is also constrained by the following:
• Refrigeration compressor power must be less than or equal to the maximum
allowable power.
• Outlet pressure of heavy MR expander must be 3 bar above the bubble point.
• The angle of the inlet guide vane of the LP MR compressor must be between 10
and –20 degrees.
• All temperature approached in the MCHE must be greater than a predetermined
minimum, typically 1 or 2 degrees Celsius.
By manipulating the variables listed above, and adhering to the constraints, the
optimizer searches for the settings that will produce maximum LNG from this system.
When the compressor manufacturer provided the as-tested performance curves, these
performance curves were used in the dynamic simulation of the MLNG Tiga plant. The
simulator predicted the systems operation and response to the as-tested curves. Then the
simulator was used to shift small amounts of the load between the MR and propane
refrigeration loops in order to optimize the overall operation. A new benchmark
operation was created that optimized LNG production. Although the head of the fourth
stage of the propane compressor exceeded the specified acceptance figure, it was found
that the expected LNG production would be more than the design and it had potential to
produce more LNG than the case of re-wheeling of the impeller. Therefore it was decided
that the as-built performance curves of the refrigerant compressor were “fit for purpose”
and used without any further modification.

POWER EXCHANGE BETWEEN GAS TURBINES

The dynamic study, which included the propane and MR refrigeration compression
systems and an integrated electrical model, was carried out to confirm the following
points.

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• Confirm the performance of the combined operation of the propane and MR

compressor systems integrated with the electrical control system. The study
considered the response of the system from the viewpoint of process, mechanical,
control and electrical, under start-up, normal operation, turndown and upset
conditions.
• Establish that the overall control systems and safety features employed in the
combined propane and MR refrigeration compression system are capable of
ensuring safe operation and machinery/equipment protection during a number of
identified modes of operation including start-up, shutdown, turndown and upset
scenarios.
The verification study above has been performed using actual equipment and system
design data.

Key Aspects of Dynamic Simulation

The study was based on an integrated dynamic simulation model of the combined
propane and MR refrigeration compression system and electrical system including a
simplified model for the Main Cryogenic Heat Exchanger (MCHE) and the LCI. Thus,
the interaction between the two compressor trains and the electric system was determined
by the model. The dynamic simulation software, “OTISS” by Aspen Tech and the
software, “Power Factory” by DigSilent, were integrated together as shown in following
scheme. The torque in the compressor trains is transferred from process system to electric
system and the speed, i.e., the frequency, is transferred from electric system to process
system.

Aspen Tech DigSilent

OTISS Torque Power Factory

Process System & Electric System

Compressors GT & Motor

Speed

The verification studies establish the following:

• Minimize the susceptibility of the process system to electrical disturbances on the
60 Hz system
• Verify the operability of the system at design and turndown conditions
• Verify the response of the anti-surge control systems and associated recycle
piping, hot gas bypass valve sizes and stroke time, and instrument requirements to
protect the compressors from surge or stonewall
• Verify the control system employed in the propane and MR refrigeration
compression trains and confirmation of the minimum number of control loops,
alarms and trips required

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• Verify that control systems are capable of ensuring safe operation and equipment
protection during major upset conditions such as gas turbine trip, helper motor or
generator trips, blocked compressor suction/discharge, LCI trip and electrical
faults.
• Verify that sufficient starter motor/LCI torque capability exists to accelerate in
accordance with the acceleration rate required by MARK V.
• Verify that compressors stay on line under total recycle in the event of an MCHE
trip
• Verify equipment design conditions

Failure Scenario
In order to verify the above conditions, the following upset scenarios have been
assumed in addition to start-up, shutdown and normal operation.
• Sudden blockage of suction or discharge valves
• Trip of starter/helper motor and starter/generator
• Trip of gas turbines
• MCHE trip
• Failure opening of anti-surge control valves or hot gas bypass valves
• Trip of LCI
• Electrical faults

Results of Simulation
The major findings of these test runs are:
• The electric control system can perfectly handle any electrical disturbance and
weak or slow mechanical disturbances.
• In case of very strong and fast compressor-torque variations, for instance caused
by a process disturbance, the corresponding synchronous machines must be
tripped to ensure that stator limits are not exceeded, as well as to maintain
synchronism with the other 60 Hz synchronous machines that are operated in
parallel.
For instance, in case the propane compressor torque was suddenly reduced due to
a process disturbance, e.g., failure opening of the anti-surge control valve or hot
gas bypass valve, depending on the initial conditions, the propane generator
would be tripped by the over-current protection before the control system could
reduce the propane gas turbine power.
Or in case the MR compressor torque was suddenly increased due to a process
disturbance, e.g., discharge blockage of MR compressors, the MR motor would be
tripped by the over-current protection.
• A small minority of failure cases, e.g., discharge blockage of MR and propane
compressors, would lead to subsequent trips of the turbines.

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• The process control system responds well to the normal operation, upsets,
including start-up and shutdown.
• For trip cases requiring a reduction in load on the MR compressor such as helper
motor failure, generator and electric system failure, the IGV on the MR axial
compressor should be closed to an angle of –20 degrees with a rate of 5%/second.
This will reduce the load on the MR turbine, preventing low speed trips.
• In case of an LCI failure, a frequency drop was observed due to limited electric
power generation from the propane generator. Frequency then reached a new
steady state value that depends on the speed-torque characteristic of the
compressors and the available electric power in the island.

PLANT PERFORMANCE VERIFICATION

In a typical LNG performance verification, the plant is subjected to a performance test
to verify that the required LNG production can be met. During the test, plant data is taken
at prevailing conditions and adjustments are made for variances between prevailing and
design conditions in ambient conditions and feed gas composition.
In this case, the MLNG Tiga project wanted to ensure that built in equipment and
system design margins are available for owners’ future use. Therefore, in addition to a
typical performance test, simulations were prepared for systems within the plant. Field
Performance testing was performed for each system during the performance test. The data
from the field performance testing was modeled using the computer simulation and
benchmarked to accurately represent the performance of the as-built system. Then the
computer simulation was run for the appropriate design cases to demonstrate that the
system as a whole has the ability of turndown and alternative modes of operation include
all design cases.

Methodology of Verification
Data taken from this, or any, performance test will have errors of measurement
included in the data. Instruments that have drifted away from calibration or are faulty
may cause these errors. That data will not match the equations within the simulation. For
instance, if we know that A + B = 4, and one instrument reports that A = 2.1 and another
instrument indicates that B = 1.8, it is easy to see that there is a problem between the data
and the equation. In the case of MLNG Tiga, there were hundreds of instruments
reporting data and thousands of equations representing the heat and mass balance,
pressure-flow relationships, and equipment parameters and functions. This data was
entered into the dynamic simulator, which was then run in a data-reconciliation mode.
Using this type of analysis, the computer can determine which variables, if any, are
grossly in error. All variables are forced to conform to the known equations that govern
that system. But, the combined errors between variables and final values are minimized
by the computer program.
The resulting set of data looks very similar to the original test data, but with a small
amount of shifting to ensure consistency with the process equations. That reconciled set
of data is then used to evaluate the performance of the system. Equipment parameters
throughout the system are estimated from the system performance simulation run in a
rating case mode. Those equipment parameters can then be used in a simulation of the
design cases for each system and compared against the benchmark simulation prepared

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early in the project or against the heat and material balance originally developed by the
process licensor. Stating it with different words, the system’s equipment parameters are
estimated based on actual performance in the field. Those estimated parameters are then
used in a simulation of the design cases to determine the performance of the system if the
as-built system was operating with exactly the design ambient conditions and design feed
gas.

Results of Simulation
These simulations performed for MLNG Tiga illustrated that the as-built systems
have the required capability to maintain the specified owners’ margin. The overall system
simulation illustrated that the equipment installed, while operating at the design ambient
conditions with design feed gas composition, could produce an LNG rundown rate
considerably higher than the guaranteed value. Additionally the simulations illustrated
that the various subsystems met or exceeded their expected performance, while
maintaining the owners’ margins.
In the future this simulation will be a valuable tool. When the owner decides to
further debottleneck the plant to achieve the next higher level of production, this
simulation can be used to accurately determine what changes must be made to reach the
owners’ goal. The simulation could also be used for additional studies, what-if scenarios,
and troubleshooting.

CONCLUSION
Dynamic simulation is the best available method for the analysis of risks introduced
by new designs and innovations. The dynamic tools used on the MLNG Tiga project
provide capabilities that are far superior to what is available form traditional process
simulators. For instance, the use of these dynamic tools can allow the plant to be
debottlenecked during the design phase, increasing the effectiveness and productivity of
the installed equipment. Additionally, the enhanced capabilities allow the designer to
analyze margins of the sized equipment and to minimize the combined effect, thereby
optimizing the owners’ return on investment.

REFERENCES CITED
1. Chemical and Engineering News, 73, March 27, 1995, “Process Simulation Seen as
Pivotal in Corporate Information Flow” by James H Krieger. Quote made by James
A. Trainham, director of engineering research and development, DuPont.

2. SPEEDUP Users Meeting, Cambridge, UK, April 1991, “SPEEDUP for Anti-Surge
Control of Gas Compressors” by Mary E. Gill, WS Atkins Engineering Sciences Ltd.,
Woodcote Grove, Ashley Road, Epsom, Surrey England.

3. Petroleum Technology Quarterly, Winter 1996/1997, “Minimising Investment with

Dynamic Simulation,” by Gerbert van der Wal, et. al, Fluor Daniel.

4. LNG 12, Perth, Australia, May 4-7, 1998, “Improved Plant Design and Cost
Reduction through Engineering Development,” by Charles Durr, et. al , KBR,
Houston, TX.

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5. LNG 12, Perth, Australia, May 4-7, 1998, “The 4.5 MMTPA Train – A Cost Effective
Design,” by Victor Perez, et. al.

6. LNG 13, Seoul, Korea, May 14-17, 2001, “A New Tool – Efficient and Accurate for
LNG Plant Design and Debottlenecking,” by Hidefumi Omori, et. al.

7. LNG 12, Perth, Australia, May 4-7, 1998, “The MLNG Project” by Norrazak Hj.
Ismail and Henk Grootjans.

8. LNG13, Seoul, Korea, May 14-17, 2001, “The Malaysia LNG Complex-Sustainable
Growth” by Ahmad Adzha Kasmuni, Goh Ngiang Ann, and Jannes Regterschot.

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