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Dynamic Simulation For FLNG Operation

Kongsberg Oil & Gas Technologies

WORLD CLASS – through people, technology and dedication


Agenda
• FLNG Technology : Challenges and way forwards
• Dynamic Simulation : Essentials
• KONGSBERG - FLNG Simulation capabilities
• Simulation Tool Specification
• References : Integrated Process and Marine Simulation
• LNG Project References
• FLNG Simulation Architecture

/2/ WORLD CLASS – through people, technology and dedication


FLNG Technology - Challenges
• New-to-date : As of today there are no operating projects
• Weight and Space Limits : Risk and safety implications
• Inventory of flammable compounds
• Reliability and Safety of operation in changing and occasionally harsh
marine environments
• Interaction of subsea operation on liquefaction process
• Tilt motion and its effects on operation and control
• Liquid sloshing and its effects on operation and control
• Product off-loading in open ocean and its impact on operability
• Availability and reliability are highly uncertain
• High chances of estimate error, which might dilute the economical
advantages

Page 3 WORLD CLASS - through people, technology and dedication.


FLNG Technology - Major Challenges of
Tilt motion:
Effect on Control design and Performance of separation
so plant operation processes & rotating
equipment

Page 4 WORLD CLASS - through people, technology and dedication.


FLNG Technology - Major Challenges of
Tilt motion:
Performance of Distillation Heat Exchanger performance
operation
Uneven exposure of fluid across the
heat transfer surface, in any heat
exchanger (specifically in case of
cattle type and shell and tube type
exchanger or heat integration in
vessel by coil).

Efficiency of exchanger get effected


by the motion effects

Page 5 WORLD CLASS - through people, technology and dedication.


FLNG Technology - Way forward
• Need to understand the impact of interaction between subsea
production and floating LNG operation

• Assessment of LNG technology in offshore environment for


identification and mitigation of risk

• Validation of process and control system design, developed to


meet the compact space availability

• Evaluation of robustness of Process & Control design and operation


for transient phases

• Evaluation of Operational safety, reliability and operability for


entire life of operation

• Certainty of commercial advantage with new technology

Page 6 WORLD CLASS - through people, technology and dedication.


Dynamic Simulation : Essentials
• Need to integrate Subsea operation with Floating LNG
Unstable three phase production
Uncertain well stream composition
• Need to integrate offshore environment with Floating LNG
operation
Wind
Ocean currents
Sea waves
• Need to integrate dynamics of floater with subsea and
Liquefaction operation
Dynamic load balancing
Dynamic orientation of floater

Page 7 WORLD CLASS - through people, technology and dedication.


Dynamic Simulation Tool: Specifications
• Simulator modules must have two level of co-ordinates to specify the
positioning of equipment
3 body (ship) fixed co-ordinate ( to specify the mounting w.r.t.
ship
3 world frame co-ordinate (to specify the dynamic position w.r.t.
positioning of ship at every instance)

• Interfacing Module should be present to translate the Marine simulator


data to a topside process simulator

• The tool should have an interface to EFMS (MIS/MAS) & LMS system
along with seamless integrity with multiphase simulator

• Equipment performance and efficiency correlation with their orientation

• Should be capable to interface with a virtual plant 3D part to impart the


facility familiarization training on an integrated platform

Page 8 WORLD CLASS - through people, technology and dedication.


Dynamic Simulation : Structure
Feasibility Concept
FEED
study selection

Engineering Simulator (K-Spice®)


Subsea Topside and ballast
Hull model
Subsea LedaFlow®
wells LT
Riser

LC
Flowline
Dynamic
Elevation

Roll
Emulated
Pitc
[K-Spice®] h
Ballast Control Draft
System
(x,y,z)

Page 9 WORLD CLASS - through people, technology and dedication.


Objective and Results
@ FEED

Objective Results

• Interaction of offshore processing and • Better understanding of offshore


topside operation in “open sea” environmental effects (tilt and liquid
environment sloshing) on operation

• Validation of topside process performance • Reliable process and control design

• Derivation of efficient control philosophy • Better safety system design

• Better understanding of required excess • Better layout of processing plant


design margin
• Efficient and more meaningful HAZOP of
• Conducting sensitivity analysis of process design
and control system design
• Confidence in deliverable of the stage will
• Development of reliable safety system ensure certainty on preceding stages

/ 10 / WORLD CLASS – through people, technology and dedication


Dynamic Simulation : Structure
Feasibility Concept
FEED EPC
study selection

EngineeringK-Spice®
Simulator (K-Spice®) Check-out Simulator
Subsea Topside and ballast Control
System Control
LedaFlow® Hull model
Subsea
Interface System
wells LT LI
Riser

LC
Flowline OPC link XY

Dynamic
Elevation LY LIC

Ballast
Emulated Ballast
tank
Ballast Control Control
level
System System

Hydrostatic Ballast Roll


Load
Model Pitch
M’ment Wind
Draft
System Current
(x,y,z)
Wave

Page 11 WORLD CLASS - through people, technology and dedication.


Objective and Results
@ EPC
Objective Results
• Control system design and implementation can • Reliable control system
be verify on realistic platform implementation

• Detailed analysis of safety system design and • Better safety implementation


implementation
• Better knowledge of risk mitigation
• Sensitivity analysis of control system on process and risk handling during operation
disturbances
• Better understanding of ballasting
• Realistic derivation of operating envelop for operational requirement during
different production cases and different mounting of key process package
emergency scenarios

• Fine tuning of risk marginalization by bargain


between control system and ballasting
operation

• Realistic HAZOP studies

/ 12 / WORLD CLASS – through people, technology and dedication


Feasibili
Dynamic Simulation : Structure
Concept
FEED EPC Commissioning
ty selection
study

EngineeringK-Spice®
Simulator (K-Spice®) Validation Simulator
Subsea Topside and ballast Control
System Control
LedaFlow® Hull model
Subsea
Interface System
wells LT LI
Riser

LC
Flowline OPC link XY

Dynamic
Elevation LY LIC

Ballast
Ballast
tank
Control
level
System

Hydrostatic Ballast Roll


Load
Model Pitch M’ment Wind
Draft System
(w.r.t. x,y,z) Current
Wave

Page 13 WORLD CLASS - through people, technology and dedication.


Dynamic Simulation : Structure
Feasibili Concept
FEED EPC Commissioning Operation
ty selection
study

EngineeringK-Spice®
Simulator (K-Spice®) Training Simulator
Subsea Topside and ballast Control
System Control
LedaFlow® Hull model
Subsea
Interface System
wells LT LI
Riser

LC
Flowline OPC link XY

Dynamic
Elevation LY LIC

Ballast
Ballast
tank
Control
level
System

Hydrostatic Ballast Roll


Load
Model Pitch M’ment Wind
Draft System
(w.r.t. x,y,z) Current
Wave

Page 14 WORLD CLASS - through people, technology and dedication.


Objective and Results
@ Pre-Commissioning
Objective Results
• Development, validation • Short and smooth start-up, Stable and safe operation &
and fine tuning of Standard Increased uptime of production
Operating Procedure
• Concrete and validated SOP for commissioning
• Ballasting operation training
before sail away • Realistic and reliable simultaneous training on handling
safe operation in harsh offshore environment
• Pre tuning of controllers for
different offshore conditions • Confident and well trained personnel

• Gain scheduling • Readiness for handling any emergency scenario

• Cross checking of start-up • Knowledge in ballast control can be acquired without


override provision hazardous and devastating consequences.

• Estimation of start-up time • Better contracting for start-up offshore


to normal production
• Familiarized of plant lay out well in advance before the
start-up & even before the actual facility available

/ 15 / WORLD CLASS – through people, technology and dedication


Summary:
• Cohesive development of knowledge across different disciplines in
organization
• Identified and mitigating processing risks at the early design stages
of development by performance based approaches to ensure
development of a safe FLNG design
• Operational and commercial risk can be reduced to levels – “As Low
As Reasonably Practicable” (ALARP)
• Provides increased safety through realistic training in a safe
environment for operators and crew
• Proves to be an ideal platform to have Reliability, Availability and
Maintainability (RAM) analysis
• Increase confidence in investment and certainty in return on
investment
• Better medium to realize and maintain the commercial advantage
of technological development
• Simulation well suited for testing and verification of new concepts

Page 16 WORLD CLASS - through people, technology and dedication.


Integrated Process and Marine Simulator
References
• Chevron’s Jack St. Malo (Biggest deep water Semi-submersible
platform in Gulf of Maxico)
• Chevron’s Big Foot (TLP in Gulf of Maxico)

/ 17 / WORLD CLASS – through people, technology and dedication


LNG References
Project Name Client Scope of Work
LNG Re-Liquefaction Moss Maritime Dynamic Simulation Studies
Process
Snøhvit LNG Plant Statoil Dynamic Simulation Studies
Dynamic Bench- Marking
Model
LNG Re-Liquefaction Moss Maritime / ENI-Saipem Dynamic Simulation Studies
System Dynamic
Simulations
LNG Boil-Off Gas Confidential Dynamic Simulation Studies
Condenser Study
Isle of Grain LNG Grain LNG / hessoe O&G Engineering Simulator
Terminal Simulation and Operator Training
Simulator
Dragon LNG Import Whessoe Oil & Gas Dynamic Simulation Studies
Terminal
Snøhvit LNG Statoil, Norway Engineering Simulator
Operator Training Simulator
Online PMS (Production Management
System)
Training courses (80 persons)

/ 18 / WORLD CLASS – through people, technology and dedication


LNG References
Project Name Client Scope of Work
Glenmavis National Grid, UK Engineering Simulator
Simulation and Operator Training
Simulator

LNG Heat Exchanger Study Statoil Dynamic Simulation Studies

Atlantic LNG Facilities Atlantic LNG Dynamic Simulation Studies

LNG Heat Exchanger Study Statoil Dynamic Simulation Studies

LNG Re-Gasification Moss Maritime Dynamic Simulation Studies


Simulations
LNG Dual Fual Slow Speed MAN Diesel/Buckhardt Dynamic Simulation Studies
DSS Comp
Fujian LNG CNOOC, China Operator Training Simulator
Online PMS (Production
Management System)

/ 19 / WORLD CLASS – through people, technology and dedication


FLNG Simulation Architecture

Page 20
FLNG Simulation Architecture

Page 21
FLNG Simulation ideal for better operation
Coupled Simulators for
operation and offloading
training

Process Simulator Marine Ballast Simulator

Virtual Reality Simulator Offshore Simulator


• Ship’s Bridge
• Crane Simulator
• Anchor Handling
• Dynamic Positioning
• Buoy lifting

Page 22 20/05/2014 WORLD CLASS - through people, technology and dedication.


Conclusion:
Easy extension of offer for FPSO/FSRU operation, operating at location
having adverse oceanic conditions

Proven for Semi-submersible platform and TLP operation

Current capabilities (official release of K-Spice) covers the open sea


operation on topside processing in terms of hydrodynamics effects

Features can easily extend to equipment performance (efficiency) as a


function of their orientation (tilting effect) as frame work is already
there in existing K-Spice

Product not only saves CAPEX but also OPEX

Page 23 WORLD CLASS - through people, technology and dedication.


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