LNG Carrier Solutions: Integrated Automation System Simulator

Honeywells Integrated Automation System (IAS) Simulator is a powerful solution that can be used for vessel crew training as well as supporting Maritime Academy/University Courses. It can be deployed in a number of different forms to meet specific requirements. The Simulator is based on Honeywells award winning Experion Process Knowledge System (PKS), the most widely used IAS for LNG Carriers and land based processing plants. Using the same technology applied onboard means that the look and feel of the Simulator closely matches that experienced by the vessel crew onboard.

Introduction Honeywell has delivered automation expertise to the LNG Carrier industry for more than 20 years, and is the largest supplier with IAS installed on all types of LNG Carriers Conventional Steam, Slow Speed Diesel with Reliquefaction, Dual Fuel Electric, and Regas Vessels. As industry pioneers, we have developed groundbreaking technology advances that have shaped todays vessel operations. We have made systems easier to install and use, and developed the industrys most reliable and scalable vessel control solutions. In addition to delivering innovations, products and technologies, we also provide the most experienced and dedicated customer and technical support teams.

Deploying Simulation to meet specific requirements The LNGC IAS Simulator can be deployed to suit various environments and requirements balancing portability, the realism required and budget.

Sim1: Single Laptop Operator environment connected to simple process model. Suitable for temporary onboard training by Honeywell or Shipowner Training Manager

Sim2: Multiple PCs each with dual screens and membrane operator keyboard. Each station loaded with its own Operator environment and simple process model used in Honeywell training courses and suitable for Shipowner HQ or Maritime Academy deployment

Sim3: Marine Console with actual Process Controller hardware and some field equipment extension of above system to facilitate hardware maintenance training.

Sim4: same as Sim2, but replacing simple process model with Honeywell UniSim Dynamic Process Model to provide high fidelity realistic plant response provides the greatest level of realism, but at highest cost since a full first principles model has to be built to replicate the actual plant. Sometimes used by shipyards on new designs.

Example of LNGC IAS Operator Training Station

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Overview of Experion PKS Operator Station The Experion PKS IAS is the most advanced delivered to the maritime industry. Operator Stations are PC based Windows 7 nodes, incorporating the latest Microsoft technologies while maintaining a robust environment for shipboard application. The system includes:

Pre-built standard displays (including group, point detail, trend and alarm) to reduce configuration time.

Intuitive and flexible HMI meets even the most demanding needs for ship mimics, display navigation and alarm presentation.

User-configurable pull-down menus and toolbars promote easier, intuitive navigation to vessel data.

Enhanced trending for up to 32 pens simultaneously and event markers provide operators with a comprehensive view of the vessel.

On-board historian collects history and events, enabling instant access to reliable and accurate vessel data.

Open architecture based on commonly used industry standards and the Microsoft Excel add-in provide greater choice in generating reports from vessel data.

Integrated configuration environment enabling offline and online configuration changes minimizes disruption of shipboard operations.

The system is operated from a dedicated membrane keyboard, which provides quick access to specific vessel mimics (left side of the keyboard), as well as the pre-build system displays(middle of keyboard). Dedicated pushbuttons are also provided for operating control loops (right side of keyboard).

Membrane Operator Keyboard layout

Example of Operator Console

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Gas Management System Simulation Overview

The simulation is designed to provide operator training of the IAS Gas Management System of a Dual Fuel Electric LNG Carrier. A simplified model of the Cargo area process equipment, piping and tanks has been developed to provide realistic simulation for the purposes of IAS operator training.

It is based on our Experion PKS R400 server loaded with SimC300 software on Windows 7 environment. Mimics and control modules from actual vessel systems are used to facilitate training of onboard Gas Management System operations.

The following is included in the simulation Manual and Automatic startup sequence for the Fuel Gas Pump in the LNG Tank Cargo Tank Pressure Control Selection of operating modes tank pressure controller, gas disposal selection, venting overrides System valve lineup Operation of the Forcing Vaporiser in Cascade Mode to make Forced Boil Off Gas available for the engines Operation of the Fuel Gas Compressor and after Heater/Cooler Closed loop system Vessel Speed and Tank Pressure Setpoints (SP) are the inputs. Once the GMS is setup

properly by the student, actual Vessel Speed and Tank Pressure (calculated PVs) matches their setpoints.

The Gas Management System is extremely important aspect of LNG Carrier operations. LNG contained in the cargo tanks vaporizes due to:

The heat flux coming from outside, although limited by the cargo tanks insulation, Kinetic energy created by agitation of the cargo by the ships motions

Gas Management System Overview Mimic

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The vaporized gas or Boil off Gas (BOG) increases the cargo tank pressure. This pressure must be controlled. There are three modes that are used onboard for this function and these are simulated in the IAS GMS Simulator

NON: BOG is used by the ships Dual Fuel engines (normal operating mode), GCU: excess BOG is burnt in the Gas Combustion Unit VENT: excess BOG is Vented to atmosphere if gas burning is not possible, and only when the ship is at open sea

Selection of NON / GCU / VENT is provided in the Simulation system and automatically controls the GCU and Vent valves according to the Cargo Tank Pressure requirements. Voyage Mode

The IAS used three (3) types of controllers to calculate how much BOG is to be consumed by the engines or the GCU, or as a last resort, vented to atmosphere.

One of the three (3) controllers will be selected according to the operator selection of the voyage mode (laden or ballast) and the type of pressure transmitter (absolute pressure, gauge pressure).

To keep the vapor main pressure to predetermined setting value, the following 3 PID controllers are applied:

Absolute (ABS) Pressure controller on laden mode (low tank pressure) Gauge pressure controller on laden mode Gauge pressure controller on ballast mode

Forcing Vapouriser Control

The Forcing Vapouriser is used to generate additional gas to supplement Natural BOG. The Forced BOG setpoint is determined by subtracting the amount of Natural BOG available from the Cargo Tanks from the Engine Gas Demand. The student can operate all the valves and control modules of the Forcing Vapouriser, which can be run in Automatic Mode or Cascade Mode(with the Setpoint coming from the Tank Pressure Controller). The below diagram shows the process control chart for operation in Cascade Mode.

Forcing Vaporiser Flow Control Logic

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Fuel Gas Pump Operation The Simulation System includes operation of the FG Pump in Manual and Automated sequence start. Once the Automatic sequence or Manual Start procedure has completed, the Pump Discharge and Tank Return Valves are operated in Cascade mode to control Pump Load Current and Discharge Pressure respectively. This is a similar arrangement for the Main Cargo Pumps and Stripping Pumps, giving students a familiarity with Cargo Unloading operations.

Cargo Tank Mimic and Fuel Gas Pump Load Control Logic

Powerful Trending System Experion PKS trending enables operators to maintain appropriate situational awareness to keep the vessels machinery within desired limits. The trending system is fully available as part of the IAS Simulator, and provides a useful tool for student practice in setting up views and analysis of vessel historical data.

Example Trend with categorized list of events and associated icon marker on the time axis

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Trends can be preconfigured or configured online as necessary by simply browsing the database and selecting the desired point and parameter (up to 32 pens per trend display). Any of the standard history collection intervals can be used as the basis for the real-time and historical trends.

Trends can display data in the following ways: Line graphs Bar graphs Numerical list of historical data X-Y plot of the value of one point against another

Trend functions include:

View events/alarms in combination with trend data Select event and observe marker with description Generate operator-entered events/description Trend zooming, panning and scrolling Hairline readout Configurable trend density

Simple recall of archived history (calendar, time) Trend protection Smart clipboard support for copy/paste of trend

data into Microsoft Excel Flexible time period selectors Auto-scaling

The de-clutter feature enables individual traces on multi-type trends to be temporarily disabled for clearer viewing without having to reconfigure the trace. Real-time and historical data are presented together on the same trend. Archived history may be accessed automatically by entering the time period and time and date using a drop-down calendar with the choice of time selector position (at right, left, center or at both ends). Adding related events to a trend further improves vessel analysis. For example, an operator might want to view the effect of changing a set point or see when an alarm occurred. With Experion PKS, these events are clearly visible within the trend and filters allow listing only event types of interest.

Integrated Alarm and Event Management The innovative alarm management solution in Experion PKS improves the operators ability to minimize vessel impact. Alarms can be generated in the Simulation and provides students with training on the operation of the Alarm subsystem.

The standard Alarm Summary display enables the ships engineers to focus more clearly on the problem at hand.

Features for alarm and event management:

A selectable Location Pane shows extensive alarm condition details, supports rapid alarm filtering and provides summary alarm count details.

Alarm summary columns can be customized to suit individual vessel or engineer requirements. Fields can include the actual trip value and current live value along with many other fields.

A custom alarm summary configuration can be saved and recalled. Custom filters can be applied to each column in the alarm display, enabling rapid attention to be focused on

problems. Alarms can be filtered by priority. Single line alarm processing keeps the Alarm Summary display from filling up with a chattering alarm. A single

alarm includes details of the time that the alarm originally occurred, the time it last occurred and the total number of times the alarm occurred.

Operators can easily add comments to alarms and events from the Alarm Summary display either individually or per page.

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Alarms can be acknowledged on an individual or per page basis from the Alarm Summary display or from custom displays.

Custom alarm priority colors can be configured. The Event Summary display lists system events such as alarms, alarm acknowledgments, return to normal,

operator control actions, operator login and security level changes, online database modifications, communications alarms, system restart messages and many other system events.

Archiving can be configured to store events online or to network servers or removable media for accessing at a later date.

The System Status display provides operators with one place to review the health and status of all components.

Alarm Summary page showing alarms for a particular asset

Engineering Expertise Honeywells global project management methodologies ensure high quality, consistent engineering and professional documentation. Honeywells implementation locations in Korea, China, Japan and Norway have extensive vessel application knowledge and work closely with the shipyards and major equipment suppliers such as engine, generator, boiler and compressor manufacturers to ensure the maximum benefit is realized from automation. Global resources are mobilized to address the toughest challenges. Some of the latest vessel control systems engineered by Honeywell, for example, incorporate advanced Power Management Systems and Automated Ballast Exchange. Honeywell was the first company to achieve certification against the internationally recognized standard of ISO 17894. This certification recognizes the processes and procedures Honeywell has in place are suitable for providing dependable programmable electronic systems for marine use.

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More Information For more information on LNGC IAS Simulation, visit www.honeywell.com/ps or contact your Honeywell account manager. Automation & Control Solutions Honeywell Marine Solutions Honeywell 2500 W. Union Hills Dr. Phoenix, AZ 85027 Tel: +1-602-313-6665 or 877-466-3993 www.honeywell.com/ps

Worldwide Support Honeywell provides a comprehensive support infrastructure to ensure supportability of the IAS throughout the life of the vessel.

Professionally managed automation support includes: 24/365 emergency call center with customer-accessible call management software Central coordination and global availability for spares and services Parts management to reduce onboard spares Remote system diagnostics and technical support via satellite link Training courses for vessels crew Worldwide service personnel have access to electronic copies of ship documentation

IAS Training Center Vessel crews are trained on Honeywell IAS Simulators in various locations around the world. Training is also available in Korea, Japan and China near shipbuilding yards for easier access to ships crews immediately prior to vessel delivery. Customized courses are offered upon request.

Courses have been independently audited Compliance with ISO17894 Compliance with SIGTTO LNG Shipping Suggested Compentency

Standards Meets due diligence requirements for shipowners confirmation that

Honeywell as a training provider has provided training to ensure crew have the necessary knowledge to operate and maintain Honeywells Marine Automation Systems

PN-XX-XX-XXX September 2011 2011 Honeywell International Inc.