YAMAL LNG

EXTREME DESIGN CHALLENGES FOR AN EXTREME PROJECT

Christian Bladanet
Gas Department Manager
Technip
92973 Paris La Dfense Cedex
France

Benoit Laflotte
Process Manager for Yamal LNG Project
Technip
Benjamin Legrand
Senior Process Engineer
Technip
Benoit Delva
Senior Process Engineer
Technip

ABSTRACT

The Yamal LNG project is, in many ways, taking engineering practice beyond the usual
boundaries. In our industry where innovation is often synonymous with a limited number of small
steps forward, the challenges brought by this large LNG plant located in the Yamal peninsula of
the Arctic Circle, require first-of-a-kind technical solutions and the development of innovative
methodologies to manage new designs while keeping costs at a reasonable level.

The harsh weather conditions, and difficult logistics make it even more important than usual
to do it right first time as any carry-over work would impair drastically project execution.

The paper will describe a number of practical examples: parallel and constant speed gas
turbine drivers, each with multiple refrigerant compressor casings in Propane (C3) and Mixed
Refrigerant (MR) services on the same shaft; material selection to resist polar temperatures;
permafrost protection against flare radiation; plant preservation following total power failure (a
remote yet not an impossible event in such an environment). These are some of the issues that
have had to be solved within the time frame of the project with results that ensure safe and
reliable operation.

This article will explore the challenges, the solutions implemented, and the methodology put
in place to ensure that smart ideas pulled out of the process engineers brains are translated into
a flawless and efficient facility.

Owned and presented by Host IGU Member Supporting Association

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INTRODUCTION

The Yamal LNG project is an integrated complex for natural gas and gas condensate
production. The plant will be built in 3 phases each with an LNG production of 5.5. Million tons.

The Yamal LNG complex will receive gas produced from the South Tambey Field, located in
the North-eastern part of the Yamal Peninsula, in the territory of the Yamal-Nenets Autonomous
Okrug. The nearest inhabited locality to the LNG complex is Sabetta settlement.

The final investment decision on the project was made in December 2013 with the planned
launch of first LNG production in 2017.

Yamal

Figure 1. Location of the Yamal LNG plant

The Yamal LNG plant is exposed to harsh ambient conditions. In winter, peak extreme
temperature can be as low as -57C. Maximum wind gusts in winter can be as high as 40 meters
per second (144 km/h). Average annual temperature is about -10.5C with a minimum extreme
temperature of -49C and maximum extreme temperature of 30C considered for the process
design. Due to the extreme North location of the facilities there is almost no natural light during
the 5 winter months, and the sea is frozen seven to nine months per year.

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 These extreme weather conditions along with extreme site remoteness required the project
team to adopt a different mindset compared to a more usual plant design in arid or tropical
areas. Practically, the temperature reference of the design engineers had to be shifted down by
several dozen of degrees, in this territory where water freeze in seconds, and propane is naturally
a liquid.

This raises unusual design issues including material selection, plant preservation under limited
power availability, permafrost and ground stability.

As if such issues where not enough, a novel arrangement of the refrigerant compressors was
selected to allow the C3/MR liquefaction process to attain a much higher capacity, giving new
perspectives to the LNG industry.

Finally, the remoteness of the plant makes corrective actions on site far more challenging.

Yamgaz, the Joint Venture comprising Technip, JGC and Chiyoda, along with the plant owner
team, the process licensors and the main equipment suppliers worked closely to fully analyze the
risks associated with these challenges and to put in place mitigating solutions in the design, to
ensure a safe and flawless start-up and operation of the plant.

MATERIAL SELECTION

In the harsh weather conditions encountered in the Sabetta Peninsula, the selection of the
proper piping and equipment materials of construction has to take into consideration not only
corrosion, and process temperatures typically reached in an LNG plant, but also the extremely
low ambient temperature (down to -49C) which departs widely from the usual Middle-East or
Asian LNG plant. Particularly the calculation of material temperature during emergency
depressurization shall consider the possibility that parts of the plant could have been idle after a
shutdown, and would cool down before depressurization is initiated. The easy answer for this
situation would be to use stainless steel throughout the whole plant. However such an option
would have a dramatic effect on the plant cost, and could compromise the economic viability of
the project.

In order to minimize the extent of use of stainless steel, the Yamgas process team calculated,
for each depressurization system, a Minimum Initiation Temperature (MIT) for which the
temperature reached during the emergency depressurization of this system remains above the
minimum temperature allowable for Low Temperature Carbon Steel.

This is illustrated in Figure 2, where the temperature of a system after a shutdown, through an
emergency depressurization, is plotted over time. The plain curve represents a system which
naturally cools down (shown as a straight line for the sake of simplification), until it reaches the
ambient temperature, and is then depressurized. The dotted curve represents the same event,
however with the depressurization initiated when the system reaches the MIT, itself set to
prevent the system temperature to decrease below the Minimum Design Temperature of
equipment and piping depending on pipe diameter, rating and stress ratio analysis.

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 10

-10
System temperature (C)

-20
Minimum Initiation Temperature
-30

-40
Minimum Design Temperature
Minimum ambient Temperature
-50

-60

-70
0 500 1000 1500 2000 2500
Time (s)
depressurisation from ambient Depressurisation from MIT

Figure 2. Evolution of the temperature in a system, after a shutdown followed by depressurization

In parallel, the speed of cooldown of the systems were calculated for various ambient
temperatures, in order to assess the time at which the MIT would be reached after a shutdown,
for the different piping section and diameter.

From these two studies, we defined which parts of the system were at risk, and depending on
the criticality of the results and the time left for the operator to take action one or more of the
following measures were specified:
Thermal insulation specifically designed to avoid ambient chilling
High reliability (redundant) heat tracing
Use of stainless steel

PERMAFROST PROTECTION

The Yamal LNG flare stacks are installed on foundations built into the permafrost. During
flaring, the permafrost ground temperature will be warmed up by the heat radiation. If the
permafrost temperature rises above zero degree Celsius, there is a risk that significant surface
settlement occurs, resulting in destabilization of the flare foundation.

To evaluate this risk, and to evaluate mitigation measures, a two-dimensional finite element
computer model was build. The model simulates transient, two dimensional heat conduction with
change of phase for a variety of boundary conditions. The heat exchange at the ground surface is
modelled considering air temperatures, wind velocity, snow depth, and solar radiation.

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 To perform this analysis, flaring scenarios were screened to identify likely long terms releases
over the lifetime of the plant. Two extended operational flaring scenarios were defined:
During the start of the first LNG Train an extended period of flaring is considered until
the plant operation is stabilized, and on-spec LNG can be produced.
Subsequently shorter flaring periods, occurring regularly over several years were
considered, corresponding to multiple LNG train start-ups, followed by yearly scheduled
maintenance over the lifetime of the plant.

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 The evolution of the ground temperature, at several depths, and over the lifetime of the plant
were calculated for various systems of protection (several insulation layer thickness, installation
of thermosyphons). The evolution of the ground temperature over 22 years, and 10m and 30 m
depth, with and without permafrost protection is given in Figure 3 and Figure 4 . It clearly shows
that the ground temperature, for shallow ground, increases steadily when no protective measures
are taken. When an insulation layer is installed to reduce the heat input from flare radiation
along with thermosyphons to remove the heat that nevertheless enters the ground, the situation
becomes acceptable, and even improves the permafrost ground temperature. Finally the study
enabled the determination of the density of thermosyphons, and the thickness of the insulation
layers.

0
-0.5
-1
Ground temperature (C)

-1.5
-2
-2.5
-3
-3.5
-4
-4.5
-5
Dec-14

Dec-29
Dec-15
Dec-16
Dec-17
Dec-18
Dec-19
Dec-20
Dec-21
Dec-22
Dec-23
Dec-24
Dec-25
Dec-26
Dec-27
Dec-28

Dec-30
Dec-31
Dec-32
Dec-33
Dec-34
Dec-35
Dec-36
10m 30m

Figure 3. Temperature variation over 22 years, with no permafrost protection

0
-2
-4
Ground temperature (C)

-6
-8
-10
-12
-14
-16
-18
-20
Dec-18
Dec-19
Dec-14
Dec-15
Dec-16
Dec-17

Dec-20
Dec-21
Dec-22
Dec-23
Dec-24
Dec-25
Dec-26
Dec-27
Dec-28
Dec-29
Dec-30
Dec-31
Dec-32
Dec-33
Dec-34
Dec-35
Dec-36

10m 30m

Figure 4. Temperature variation over 22 years with insulation and thermosiphon protection.

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 As described in Figure 5, the thermosyphons are naturally circulating heat exchangers or heat
pipes, installed in the ground to chill the ground during winter time, and balance, on an annual
basis, the heat input from the flare or more generally speaking from the facility. Thermosyphons
are commonly used in permafrost areas where man-build facilities may be endangered by the
melting of the supporting ground.

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 Winter Summer

Warm ground vaporizes As ground is colder than

refrigerant fluid (CO2), ambient air, refrigerant
which is condensed against fluid stays idle in the heat
cold ambient air, removing pipe bottom
heat from the ground

Figure 5. Schematic description of thermosyphon installation and principle.

Figure 6. Thermosyphon heat pipes installed on Yamal LNG site

PLANT PRESERVATION

The Yamal Peninsula climate is hostile to any human activity. Any failure of critical systems
such as power, or utilities in mid-winter will have consequences far more severe than on any
other LNG facility in the world. As is typical for an LNG plant no connection to an external power

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source is available. It is thus of the utmost importance to identify any potential risks of failure of
critical systems and ensure they are properly mitigated.

A risk identification and assessment study was performed to analyze the risk profile of the
LNG complex in case of Loss of Normal Power supply to ensure that the root cause is
independent from the effect and to ensure that the plant can reach a safe and preserved state in
all cases. A brain-storming exercise was done to identify all potential causes of plant black-out.
Once black-out scenarios were identified, the probability of occurrence and the impact on
personnel safety and Plant operation each of the scenarios have been assessed in accordance
with a risk matrix and classified though one of the three following categories :
Acceptable.
Acceptable with preventive / Recovery measures
Unacceptable risk.

For the most two severe criteria, further mitigation studies were performed and if necessary
additional quantitative analysis were ran to confirm the risk rating is actually not as severe as the
qualitative analysis assessed. For example, dispersion studies of gas leaks were run to
demonstrate that it will not escalate towards critical systems, and that the risk associated with
the corresponding scenario can actually be downgraded to an acceptable level.

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 Figure 7 shows the contour of the gas cloud with concentrations higher than 20% LFL across
the plant in case of a major gas leak. It can be seen that this cloud does not reach the
Emergency Diesel Generator located at the far left of the picture. Hence, it demonstrates that this
event will not prevent the EDG to run, and can thus be rated as acceptable.

Figure 7. Views of concentration fields of maximal cloud expansion 20% LFL.

In addition three different preservation scenarios have been studied to ensure that the facility
will be safe and will not suffer unacceptable damage in the event of scheduled or unplanned
overall shutdown:

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 Planned Preservation, defining the action to be put in place for a scheduled, long
duration overall shut down. The plant is stopped unit by unit in a specific order and
brought to a safe preserved mode to maintain full control of the plant until it can stay
safely idle, although with some power available over a long period of time.

Emergency Preservation. This scenario corresponds to an unplanned power generation

shutdown, with only essential power available to maintain heat tracing and essential
utilities. This scenario is similar to Planned Preservation, however, emergency measures
are provided to cater for the unavailability of the main power, and prevent damage to the
facilities, allowing for a relatively quick start-up once the situation is corrected.

Force Majeure Preservation, corresponding to the action to be undertaken before Plant

Evacuation in case of a catastrophic event. Under this scenario the preservation operation
are taken to the ultimate point where the plant can be left idle with no power available,
while ensuring the safety of the operators and personal, and prevent further damage to
the installation.

A COMPLEX, FIRST OF ITS KIND REFRIGERANT COMPRESSOR STRING

Yamal LNG liquefaction unit is based on Air Products AP-C3MR process technology including
a Propane Refrigeration cycle and a Mixed Refrigerant cycle in which the compressors are
arranged in a 2x50% configuration, with all the refrigerant services on the same shaft. All
compressors rotate at the same speed in addition to which the heavy duty gas turbine driver has
limited speed variation. This arrangement was a novelty due to the complexity of the shaft
configuration and process control involved whereas refrigerant compression is at the heart of an
LNG process and critical to operations. Very early on in the project, it was jointly agreed with the
plant owner to adopt a multi-disciplinary surveillance program addressing the technological issues
and defining milestones critical to the plant design: process, geotechnical, civil, mechanical from
engineering up to commissioning & start-up phases. The main objective of this program was to
confirm that all aspects related to design robustness, testing and safe operation were addressed
and that potential risks for the project were mitigated.

A process was also needed to manage the multiple entities working together with the
objective of converging on a single consistent design solution and control philosophy.

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Compressor Design

The YAMAL LNG refrigerant compressor shafts are unusually long (more than 40m) and
comprise 5 pieces of rotating equipment (C3 compressor casing, LP and HP MR compressor
casings, Frame 7 gas turbine, and Electrical starter/helper motor of 24MW).

Fr 7 LP MR A C3 A HP MR A M

Fr 7 LP MR B C3 B HP MR B M

Figure 8: Schematic representation of the Yamal refrigerant compressors and drivers.

Figure 9. 3D rendering of the Refrigerant compressor and associated driver assembly (Image courtesy of
GE Oil & Gas)

To validate the mechanical feasibility and robustness of the assembly, a thorough train
torsional analysis was performed on the shaft, as well as CFD simulations of the propane
compressor inlet side streams.

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Figure 10. Streamline distribution in two of the propane compressor sidestream (Image courtesy of GE Oil
& Gas)

Figure 10 shows the gas velocity, with a relatively even distribution at the first and second
propane compressor side streams.

In addition to computational design validation, the first compressor train underwent a full
speed full load test at the GE Oil&Gas test facility in Massa, Italy, to fully validate the
performance and behavior.

Figure 11. String test facility at GE O&G workshop (Massa Italy) for Yamal LNG (Photo courtesy of GE Oil
& Gas).

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Dynamic behavior of the process

To assess the behavior of the process during transients, several dynamic simulations were
performed. Air Products (the liquefaction process Licensor) ran the overall dynamic simulation,
and GE Oil&Gas (the refrigerant compressor manufacturer) performed a more detailed one,
centered on the compressors.
Three scenarios were explored:
Unplanned shutdown of one compression string
Restart of the second compression string while the first one is in operation
Feed gas booster compressor trip

In addition, GE Oil&Gas performed detailed dynamic simulations to specify the additional

hardware and software to achieve safe start-up and stability of the compressor trains during the
following shutdown and anti-surge operation:
Start-up,
Emergency and normal shut down.
Anti-surge system sizing and functionality
Detail design of the Hot By-Pass arrangement

One of the main difficulties that had to be overcome was the coordination and integration of
the two dynamic simulations, which had to be consistent at their respective battery limits, but
also which had to be fed by each other findings. This was achieved through workshops organized
between all the parties to understand each others position, technological constraints, and
experience.
Time dependent boundary conditions resulting from the process dynamic simulation run by Air
Products were used as input for the compressor simulation. After a few iterations the two studies
reached convergence.

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 Figure 12 and Figure 13 illustrate the start-up sequence of the second MR compressor
(Compressor B) with the Compressor A in operation. Particularly, it shows the transfer of MR from
String A to String B, which in addition to MR make-up, is used to pressurize the MR compressor
B, before opening the suction valve.

1.1

String A
1.0

0.9

0.8
Normalized Pressure

String B
0.7

Start of ramp up of LNG production

0.6

0.5

0.4 Start transfer from compressor A cross

connection line to compressor B and
0.3
open compressor B make up valve
0.2
Time

Figure 12. MR compressor suction pressures

1.1
String A
1.0

0.9

0.8
MR Make-up closes
Normalized Pressure

0.7
String B
0.6

0.5

0.4 Cross connection line closes

0.3

0.2

0.1

0.0
Time

Figure 13. MR compressor discharge pressures

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CONCLUSION

The challenges raised by extreme weather conditions, extreme remoteness of the Yamal
peninsula and an innovative refrigerant compressor arrangement have been objectively evaluated
and analyzed from the early stages of the project. The risks identified have been captured, and
mitigation plans have been implemented.
Yamgaz, the Joint Venture comprising Technip, JGC and Chiyoda, along with the plant owner
team, the process licensors and the main equipment suppliers worked closely to implement
mitigating solutions in the design, to ensure safe and flawless start-up and operation of the plant
under exceptional scenarios.
These mitigation plans required an exceptional number of studies and the use of the latest
design and innovation management tools. Other developments required the set-up and follow
through of processes to force out-of-the box thinking.
The road toward the first drop of LNG may still be long and bumpy, but every opportunity has
been taken to ensure smooth delivery of the plant and to meet the owner expectations.

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