Process Solutions. Honeywell s Dynamic Engineering Studies Group Dynamic simulation services for process design, control and troubleshooting

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1 Process Service Note Honeywell s Dynamic Engineering Studies Group Dynamic simulation services for process design, control and troubleshooting Dynamic Engineering Studies Group Capabilities UniSim Design Suite, part of Honeywell s breadth of Advanced capabilities, is the suite of simulation software tools used to perform dynamic modeling and engineering studies. UniSim Design is an essential foundation of Honeywell s ability to provide a variety of detailed dynamic modeling and engineering studies. The appended experience list summarizes the track record for Honeywell s Dynamic Engineering Studies group. Studies the group has executed include: Emergency depressuring and flare relief Compressor and surge control High Integrity Pressure Protection System (HIPPS) Integrated pipeline and production platforms Process design and controllability Let s take a look at what drives these types of studies, as well as review some of the customer benefits. Emergency depressuring and flare relief studies In cases where plant capacity is being expanded, careful consideration must also be given to the plant s flare system capacity to ensure that it meets safety requirements. Detailed dynamic studies of unit depressuring, including dynamic models of the flare system, can determine the existing relief system s ability to handle the new relief loads. In many cases, detailed dynamic studies have shown that the size of the current relief system is sufficient to handle the relief loads of the expanded plant thereby avoiding the need to also expand the relief and flare system. The savings of this avoidance frequently run in the tens of millions of dollars. Compressor and surge control studies Many of today s plant designs rely on large, expensive compressor systems. The expense of damages to compressor systems can quickly run into the tens of millions of dollars, not only due to the cost of the equipment but also to the loss of profits during plant downtime. Further, large compressors are long lead-time items, often requiring two to three years of lead time to replace if the damage is severe enough. For these reasons and others, it is critical that customers are able to rely on their compressor protection systems making certain they are properly designed and are capable of operating correctly in order to protect these valuable assets. Utilizing detailed dynamic compressor system models including such factors as detailed compressor models, surge controllers, valves, and piping to study potential trip events, can identify flaws in the system, or provide the assurance that the compressor system is properly designed and fully protected. High Integrity Pressure Protection Systems (HIPPS) studies Many customers today are implementing HIPPS to provide additional protection to valuable equipment such as separation units and more importantly, to personnel working around these systems in the event of potentially catastrophic plant upsets. It is

2 Dynamic Simulation Services for Process Design, Control and Troubleshooting 2 important to ensure that the system being implemented provides a suitable response to plant upsets. Dynamic studies utilizing detailed dynamic models can validate the timing and effects of events and the trigger points programmed into the HIPPS, thus ensuring that the system works as required. The cost of a failure cannot be predicted, in either dollar terms or liability, but it most certainly would be exceedingly high. Integrated pipeline and production platform studies Modern oil production, especially offshore, relies on pipelines to feed production facilities and transport the dewatered and degassed oil for further processing. One of the main concerns of a typical offshore oil production platform is how well the facility handles slugs in the incoming oil flow. These slugs can be of gas or water intermingled with the normal oil/water/gas flow. The slug catcher size is typically the most important variable in the ability of the system to handle these events. Naturally, the tendency would be to oversize the slug catcher in order to provide a wider safety margin. However, since the weight of the slug catcher vessel impacts the total weight of the platform, not only due to its own weight, but also the structural steel required to support it, the slug catcher size on the platform also greatly impacts cost. A detailed dynamic analysis that includes predictions of slug size and frequency, as well as considers slug catcher control algorithms, is extremely useful for determining the slug catcher size such that it provides the required safety margin at a minimum cost. The potential savings are in the millions of dollars in platform cost. Significant benefits can also be realized by avoiding the need to cut production rates during operation when the slug catcher is sized too small. Further applications of detailed dynamic studies to these types of systems includes controllability and operability issues, and in cases of gas-only production, the utilization of the gas-export line volume and line packing as a storage medium to ensure availability. Process design and controllability studies Detailed dynamic models of new plant designs can be reviewed even before they are constructed in order to determine a particular design s operability. This type of study serves to identify potential control issues before they become native to the plant. Special control algorithms, including advanced process control strategies, can be evaluated and many other issues can be identified long before plant startup. This approach, which is an important part of the modeling lifecycle concept, ensures safer and faster startups. The potential for savings runs in the millions of dollars when considering the cost avoidance of wasted feedstock (or rework) and added profit due to faster on-spec production at startup. Note that these types of studies can be combined with Operator Training Simulator (OTS) projects that, in addition to providing operator training, identify any shortcomings with the Distributed Control System (DCS) and/or logic (interlocks and Emergency Shutdown Systems) configuration. The benefits of such an approach include the added profit and reduced costs due to shorter initial start-ups and peace of mind that the operators will take the desired corrective actions in the event of a plant upset. For More Information To learn more about how Honeywell s Dynamic Engineering Studies services can benefit you visit our website or contact your Honeywell account manager. Honeywell Process 1250 West Sam Houston Parkway South Houston, TX Honeywell House, Arlington Business Park Bracknell, Berkshire, England RG12 1EB Shanghai City Centre, 100 Junyi Road Shanghai, China SV ENG August Honeywell International Inc.

3 Service Note Chevron Houston Engineering Study Scope: Operational assurance on behalf of owner engineering design team for slug catcher, stabilization system, and gas train inlet flow for full range of expected operations over life cycle of plant. Engineering model in UniSim includes integration of flow assurance model used by engineering contractor for FEED. Report ~130 pages Chevron Houston and Australia Engineering Study Gas gathering (wells and inlet flowlines), platform processing (dehydration and compression) and transport to LNG inlet facilities: operational assurance on behalf of owner operations team focused on facility start-up. Engineering model in UniSim includes integration of flow assurance models used by engineering contractor for FEED. Report ~40 pages Technip / Shell Bracknell UK Engineering Study - Shell Prelude Floating LNG Providing Engineering Design Simulation Model comprising of Wells and Sub Sea pipe lines in the OLGA model. Honeywell is responsible for overall modelling including the integration of the OLGA model with the UniSim Design. All Sub Sea controls and Emergency trips will be simulated UniSim design and integrated with OLGA model. Scope of work involve following scenarios: Start of the process from well shutdown condition with Well Choke closed. Circulation of the MEG through the Sub Sea pipeline. Gas sweeping operation to remove any entrapped liquid from the Sub Sea pipe line. Three OLGA model snapshots will created for Rich, Average and Lean Gas feeds to be integrated with UniSim model. Honeywell scope involves FDS, OLGA model testing and FAT of integrated OLGA and UniSim Model. Honeywell scope also includes get updates of OLGA model included on golalater dates. Petroleum Development Oman (PDO) Honeywell UK & Middle- East Engineering Study Integrated UNISIM & OLGA model from reservoir to the trunkline delivered for Operator Training Simulator Application. The model comprises of: Individual well lines, gathering manifolds, Main trunk lines, Test lines etc. in OLGA Reservoir, well riser, gas lift and Onshore process from slugcatchers and beyond in UNISIM LNG Inlet Facilities LNG Wells to Inlet Facilities OLGA integration with UniSim for Floating LNG Qarn Alam Steam Injection Kuwait Oil Kuwait BS132 Dynamic Compressor Study Booster Compressor Station Feb May May Nov Mar Nov Feb

4 Dynamic Simulation Services for Process Design, Control and Troubleshooting 4 Shah Gas Development Samsung, Korea Pan American Energy LLC Valle Hermoso - PC Phase VI Project Qatargas LNG Fluor EPC Statoil Canada SAGD Project Bluestar Adisseo Nutrition Group Abu Dhabi Gas (ADGAS) Development GASCO Saipem Italy Papua New LNG Hides Gas Plant: Papua New LNG Hides Gas Plant: Southern KBR, Houston Oman Gas Galfar Engineering And Contracting SAOG Abu Dhabi, UAE Houston, TX, USA Houston, TX, USA Calgary, Canada China National Chemical Corp (ChemChina) Abu Dhabi, UAE Abu Dhabi, UAE Papua, New Papua, New Kemper County Power Plant Birmingham, USA Muscat, Oman Propane & Cooling Gas Compressors Study Whole plant dynamic engineering study Dynamic Engineering Studies UniSim Design Extension Development for Compressor Systems Boil Off Gas Compressor Dynamic Simulation reduce mill startup time Steam & Flare System Propane & Cooling Gas Compressors Study Whole plant dynamic engineering study Compressor Coast-Down Surge Study Pipeline Compressor Unit Analysing effect of trips on Compressor System Determining Size of Anti-Surge Valve/Knockout Vessels to limit Surge Conditions Stabilisation Unit Analysing effect of High Rates on Stabilisation Unit and Pipeline Dynamic Analysis Shell Nigeria Steady State & Design H&MB SS and Dynamic Engineering Study for Multiphase Pipelines Depressurization Study Woodside Energy Pluto, Karratha, Fuel Gas Wobbe Index Study Analysing effect on Wobbe Index during trips Natural Gas Liquids Production Plant LNG Production Adistar Project Poultry Feed Additive Mill Shah Gas Development (SGD) Project Natural Gas Liquids Production Plant (NGL-4) Gas Plant Gas Plant Integrated Gasification and Combined Cycle NIMR Compressor Station BVS-12 Utorogu-Ughelli NAG Pipeline Project Fuel Gas Unit 2010

5 Dynamic Simulation Services for Process Design, Control and Troubleshooting 5 Western Australia for combined Fuel Gas Header Chalco PingGuo Guang Xi, China DSME Sueol, Korea MR Compressor Control Design Liquefaction Unit Control Design PDO Qarn Alam Oman PDO Qarn Alam Oman Pipeline Study Qatar Petroleum Ras Laffan MW Kellogg, Slough Qatar UK Ras Laffan LNG Sonatrach Sonatrach Suncor Energy Firebag SAGD Project Chevron Ras Laffan, Qatar Bethioua, Algeria Bethioua, Algeria Ft. McMurray, AB Nigeria (Off-Shore) Sales Gas Header Control Study 3 phases GL-1Z Steam Header Study GL-2Z Steam Header Study Dynamic Simulation Dynamic Engineering Study Whole topside process Integration with OLGA Pipeline model Chalco Design Study Conceptual and Basic Design for LNG FPSO Shell Gas to Liquids - Pearl Project LNG Production AKG2 Project 2008 GL1Z Boiler 2008 GL2Z Boiler Agbami FPSO 2007 Oil Production (250,000 BPD) NGL3 Project 2006 GASCO Ruwais, UAE Snamprogetti, Italy Compressor Study Ras Laffan LNG Ras Laffan, LNG Production Qatar Compressor Study Acid Gas Injection 3 phases Ras Laffan LNG Ras Laffan for Compressor LNG Production 2005 Systems AKG Project LNG Train 4 Optimization Sales Gas Ortloft NGL Acid Gas Injection Suncor Energy Edmonton, Sulphur Recovery 2005 Canada Unit ADGAS Abu Dhabi Dynamic Steam 2003 System Model ADGAS Abu Dhabi Auto Steam Load Shedding Consultancy Study LNG Co-generation 2003 System Laminaria Woodside, Production 1998 Australia FPSO Model Ras Laffan LNG Ras Laffan LNG Ras Laffan Ras Laffan Pipeline Model Compressor LNG Train 3 Compressors, Pipeline Pipeline LNG Production 1998 LNG Production 1995

6 Dynamic Simulation Services for Process Design, Control and Troubleshooting 6 Upstream LNG Train 1 Shell Shearwater UK Production 1995 Platform Model Pipeline Model Shell Philippines Philippines Dynamic model for design confirmation, control scheme evaluation, and availability study Topsides and pipelines (Multiple) Multiple Lube Oil System study for design, operability, and control checkout Compressor systems Texas Steam System study for design, operability, and Chemical plant availability SBM Imodco (For Compressor Study for evaluation of surge control FPSO ChevronTexaco) Angola Chevron Texaco Compressor study for surge control evaluation Topsides and FPSO Angola SNC Lavalin (for Ontario Flare relief study Crude Unit Shell Canada) ExxonMobil (for Esso Australia) Australia HIPPS study Oil Movements Facility Conoco Texas Dynamic model for design confirmation, control scheme evaluation, and availability study Topsides and Pipelines Jacobs Engineering (for ExxonMobil) Wyoming Dynamic model for design and controllability study Acid Gas Reinjection Absolut Distillery Sweden Dynamic model for design and control evaluation Vodka Distillery Frito-Lay Texas Dynamic model for control evaluation Food Manufacture Albert Garaudy & Associates (for Mobil Equatorial ) Equatorial Dynamic model for design and controllability evaluation Topsides W.S. Nelson (for Mobil Equatorial ) Equatorial Continuation of design and controllability study Topsides Schlumberger (for Petrobras) Brazil Dynamic model for design and controllability study Oil Movements Platform ExxonMobil URC Unspecified Dynamic model for design and controllability LNG Unspecified Dynamic study for design and controllability Oil Riser Louisiana Compressor and surge control study Ethylene Plant JGC (for Shell JV) China Compressor and surge control study Various ADMA-OPCO Abu Dhabi SS and dynamic model for facility performance Oil Facility monitoring and analysis Jacobs Engineering (for ExxonMobil) Wyoming Dynamic model for design and controllability study Cogen power system British Petroleum Washington Flare relief study Coker PetroCanada Quebec Dynamic model for design and controllability study Hydrogen Plant revamp ExxonMobil Scotland HIPPS study Gas terminal S&B Engineers and Constructors/Shell Global Unspecified Dynamic study for Flare Gas Recovery Compressor System design and controllability analysis Flare System / Compressor British Petroleum Azerbajian Dynamic modeling for well scheduling platform and onshore terminal

7 Dynamic Simulation Services for Process Design, Control and Troubleshooting 7 ExxonMobil Angola Dynamic model for analysis of multi-phase flow in transfer lines Sub-sea wellheads and FPSO Multiphase Confidential Dynamic model for design and controllability study Confidential Inc. Elliot Sakhalin Dynamic simulation study to investigate process LNG process Island operability ExxonMobil Scotland Verification of HIPS system Gas processing plant Siemens Norway Dynamic simulation study to investigate new CO2 Compression compressor installation Statoil Norway Flow line depressurization platform Statoil Norway Compressor operating problems platform Costain Oil and Gas Process England Investigating new compressor installation Gas processing plant Maersk Middle East Gas compression and water injection studies platforms and onshore terminal Unspecified Conceptual study LNG process Kellogg Norway Control system study Gas processing plant Statoil Norway Compressor operation study platform Statoil Norway Flow line HIPPS study platform Statoil Norway Control system study platform Hamilton England Dynamic simulation study platform and onshore terminal Shell Scotland Operational study platform PPCO Scotland Dynamic simulation study platform BG England Dynamic simulation study platform Kvaerner Norway Dynamic simulation study platform AMEC Scotland Dynamic simulation study platform Dresser Rand Scotland Dynamic simulation study Compressor lube and seal oil system HGB England HIPPS study platform Norsk Shell Norway Dynamic simulation study platform Shell USA Dynamic simulation study of offshore process platform Shell USA Dynamic simulation study of offshore process platform Amoco Chemical Belgium Design of power recovery train control system PTA unit Aramco Saudi Arabia Control system design study Gas plant Kellogg Uzbekistan Dynamic simulation study of compressor network Gas plant Pembroke Refining UK Process operation study FCC unit Reliance India Design of power recovery train control system FCC unit Shell USA Dynamic model for operational support 2 phase pipeline Shell USA Dynamic model for operational support Multiphase pipeline network Statoil Norway Compressor control system platform Dresser-Rand USA Compressor operational study LNG