Shanghai LNG Company Limited,
China is rapidly developing into a major global economic power. To succeed in its drive to be the center of manufacturing for just about everything, China has an ever growing need for energy. One of the big challenges is securing sufficient gas supplies for the next 25-30 years. Like the country as a whole, Shanghai is undergoing a transformation into a major global economic center.
In January 2007 it was announced that CNOOC Gas and Power Limited, a subsidiary of China National Offshore Oil Corporation, had signed an agreement with Shenergy Group Limited for the development of the Shanghai LNG terminal by Shanghai LNG Company Limited (SHLNG).
The LNG is transported from Malaysia to Shanghai, the economic hub of east China. This is the third LNG terminal in China, with the others being in Guangdong and Fujian. Its current gas production capacity is 3 million tons per year, and a second construction phase starting in 2011 will double that.
The Shanghai LNG terminal is comprised of an LNG dock, three 160,500 m3 receiving tanks, regasification facilities, and a 40 km subsea gas trunk line to Shanghai.
For this project, Yokogawa China successfully installed and commissioned Yokogawa's CENTUM CS 3000 distributed control system (DCS), ProSafe-RS safety instrumented system (SIS), STARDOM network-based control system, OmegaLand operator training system (OTS), Exaquantum PIMS, and PRM asset management system as well as systems from other vendors.
Central control room
The Challenges and the Solutions
Safety is an absolute requirement for this LNG terminal. The ProSafe-RS SIS is fully integrated with the CENTUM CS 3000 DCS, providing operators a unified operating environment in which they can monitor all DCS and SIS loops from the same human machine interface (HMI).
The layout of the central control room is designed with safety in mind. The mimic panel consoles for the fire and gas system and the emergency shutdown system follow the same design. A large screen displays graphics of plant facilities as well as video from CCTV cameras, so operators can easily spot problems and take quick action. All systems throughout the terminal are integrated with the CS 3000 DCS, allowing the Exaquantum PIMS to gather and process data from nearly 1,500 processes and display this in 30 different management level screens that provide information on plant performance, gas demand scheduling, gas production, gas specification, and nomination & allocation.
For added safety, Yokogawa installed its OmegaLand OTS. This simulator is used by both new and veteran operators to acquire and brush up on essential plant operation skills.
Steady gas supply
Shanghai relies on this LNG terminal for 40% of its natural gas, with the remainder coming from the West-East Gas Pipeline and a coal gasification plant.The CS 3000 DCS is the terminal's main control system and its field control stations (FCS) are highly reliable, with an availability of more than 99.99999% (seven 9s). The pipeline delivering gas to Shanghai is accurately monitored and controlled using Yokogawa's STARDOM network-based control system and the FAST/TOOLS SCADA monitoring package. The terminal operates reliably around the clock, 365 days a year.
A room with engineering workstations is located right next to the central control room to facilitate the efforts of SHLNG's engineers to automate the terminal's control loops.Currently more than 90% of the control loops have been automated, bringing tremendous benefits. SHLNG is now considering certain procedural changes that will yield additional improvements in this area, and is using the OmegaLand simulator to optimize each loop's control strategy.
Effective use of asset management system (PRM)
Before plant start-up, each loop was checked to make sure that wiring had been done correctly, signals were being correctly transmitted, field devices were healthy, and valves were responding accurately to controller output signals. By helping to accurately check all these functions, PRM made it possible to complete the plant start-up ahead of schedule. And by monitoring the status of all field devices and issuing an alarm to maintenance engineers when preset conditions are reached, PRM makes possible a proactive maintenance approach that significantly reduces total cost of ownership.
Li Wen, Director of SHLNG's Facility Equipment Department, said, "We completed the first phase of this project and are supplying gas to Shanghai every day without any problems. We supply nearly 40% of the gas used by Shanghai. It follows that this role of providing a stable gas supply is a very important one. We very much appreciate Yokogawa's highly reliable systems and products. We will continue to improve our operations and will work to make more effective use of the OmegaLand OTS, PRM, and Exaquantum. We plan on working with Yokogawa for a long time to come."
Engineering room (DCS/ESD/FGS displays)
Rack room (CENTUM FCS cabinets)
|DCS:||CENTUM CS 3000 (I/O: 1,600 points)|
|ESD:||ProSafe-RS (I/O: 700 points)|
|Pipeline SCADA:||STARDOM (I/O: 600 points)|
|OTS:||Exatif & OmegaLand|
|PIMS||Exaquantum (1,500 points of data on 30 pages)|
|Asset management system:||PRM|
|Fire & gas system:||GE-GMR (I/O: 1,200 points)|
|Fire & gas detector:||CCTV flame, gas detector, beacon, MAC, etc/|
YOKOGAWA's production control systems are operated at 54 LNG receiving terminals around the world, and 2/3 of the terminals in Japan. YOKOGAWA contributes to stable and efficient gas supply at LNG receiving terminal through the total process, loading, storage, regasification, and metering.
YOKOGAWA has been engaging in LNG automation by supplying the latest sensors, analyzers, control and information systems for more than 50 years since LNG was first imported to Japan. YOKOGAWA is one of the biggest automation suppliers to the worldwide LNG supply chain, liquefaction, transportation, and regasification.
Today, many end-users not only in the oil, gas, and petrochemical industries, but also in the LNG/LPG and bulk industries are facing common logistical challenges. Those challenges include shortening the product delivery time, improving loading efficiency, adapting to changes in the manufacturing process, improving safety, increasing administrative efficiency, reducing labor costs, integrating data systems, visualizing operations, managing traffic, and so forth.
Yokogawa has been providing solutions to meet customers’ needs for terminal automation and management for decades.
The brick type model FCJ autonomous controller fulfills the basic requirements of the utility control. It also provides the reliability for the SCADA communication with network redundant capability.
The low power consumption model of the field control node (FCN) autonomous controller meets the demanding requirements at inhospitable remote locations which lack power.
Exaquantum can acquire data from all facets of a process and transform that data into easily usable, high-value, widely distributed information.
The ProSafe-RS is a Safety Instrumented System that is certified by the German certification organization (TÜV) to meet Safety Integrity Level (SIL) 3 specified in IEC 61508.
This compact, high performance and explosion-proof monitoring camera exemplifies Yokogawa's commitment to constructing reliable field instruments that are able to withstand even the most severe environments.
Our distributed control system (DCS) enables automation and control of industrial processes and enhanced business performance. Over 10,000 plants entrust Yokogawa DCS to deliver their production goals.
From process plants to remote locations, our process control PLC and Remote Terminal Unit (RTU) help users maximize operational excellence.