Challenge Overview
Tokyo Gas operates a high-pressure natural gas pipeline network spanning approximately 300 km from its Sodegaura LNG terminal. The network includes multiple pressure control valve (PCV) stations at Sodegaura, Kitano, and Souka. When a new pipeline segment and PCV were added at the Souka station, engineers faced a critical question: would the new valve interact with existing controls in ways that could cause pressure instability, flow imbalance, or unsafe conditions during start-up and emergency scenarios?
Manual on-site PID tuning was not a viable option. The operational and safety risk was too high.
What You Will Learn
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How CHEMCAD dynamic simulation was used to model a full 300 km high-pressure gas pipeline network with multiple active PCV stations
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How the Internal Model Control (IMC) method was applied within CHEMCAD to calculate optimized PID parameters before plant commissioning
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How simulated results were validated against actual operational data, including pressure, flow rate, and valve opening behavior
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How the model predicted and confirmed minimal interaction between the new Souka PCV and existing pressure control valves under normal and emergency operating conditions
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How pre-commissioning simulation reduced on-site tuning time and operational risk
Key Results
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Dynamic simulation matched actual plant data after initial transient conditions, confirming model accuracy
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Pressure stability was maintained across the entire 300 km network during normal operation
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Simulated emergency scenarios (including Sodegaura PCV closure) confirmed automatic compensation by remaining valves
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PID parameters were calculated and verified in simulation before any live testing, reducing commissioning risk
Case Study Snapshot
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Product: CHEMCAD
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Industry: LNG / Natural Gas
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Region: Japan
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Application: Dynamic simulation, PID optimization, pipeline control validation
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Key Methodology: IMC-based PID tuning, transient simulation, model validation against operational data