Modular LNG Projects Put Greater Pressure on Control System Reliability

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Modular LNG Projects Put Greater Pressure on Control System Reliability
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Modular LNG Projects Put Greater Pressure on Control System Reliability

Jan 30, 2026

LNG Project Execution Is Moving Off-Site
In recent LNG projects, the discussion is no longer limited to capacity or nameplate output. More attention is now being paid to how quickly a facility can be built and how predictable the execution process can be. Modularization has become one of the most practical responses to these pressures.
The Commonwealth LNG export project in Louisiana follows this direction. Honeywell’s modular pretreatment and liquefaction technologies allow major process units to be fabricated and tested off-site before delivery. This approach reduces the amount of field work required and limits the risks typically associated with large construction crews and extended on-site schedules.
For project owners, the benefit is straightforward: fewer unknowns during construction and an earlier path to commissioning.

Coil Wound Heat Exchangers Remain a Proven LNG Core Technology
The facility design includes six modular coil wound heat exchangers using a single mixed refrigerant process, targeting an annual production level of around 9.5 million tonnes of LNG.

CWHEs have been used in LNG service for decades, largely because they handle high gas throughput while maintaining mechanical stability. Their compact structure helps simplify plot layout and pipe routing, which becomes increasingly important as LNG plants grow in scale. From an operational perspective, CWHEs are also valued for consistent thermal performance and predictable maintenance behavior over long operating cycles.

Pretreatment Stability Depends on Automation Performance
Feed gas pretreatment is often underestimated in LNG discussions, yet it has a direct impact on downstream reliability. Technologies such as Honeywell UOP SeparSIV® are designed to remove moisture and heavier hydrocarbons under changing feed conditions, protecting cold section equipment from upset and damage.
However, pretreatment efficiency is not defined by process design alone. It relies on accurate measurement, stable control logic, and dependable safety interlocks. Distributed control systems and safety controllers provide the structure needed to keep pretreatment units operating within defined limits, especially during start-up, load changes, and abnormal conditions.
In practice, automation quality often determines whether theoretical process performance can be maintained in daily operation.

Honeywell Control Systems Across LNG Facility Lifecycles
Many LNG facilities continue to operate Honeywell control platforms installed years ago, alongside newer system expansions. Experion PKS is commonly used for integrated control and visualization, while TDC 3000 systems remain in service at a number of established plants.
Safety-critical functions are typically handled by Honeywell Safety Manager and FSC (Fail Safe Controller) hardware. These systems are designed for long operational life, which means hardware availability and replacement strategy become part of day-to-day reliability planning.
As a long-term DCS module supplier, we support LNG and process industry customers with DCS spare parts and Distributed Control System replacement parts, helping maintain system continuity without forcing premature migrations.

Spare Parts Availability Becomes an Operational Strategy
Once an LNG plant enters steady operation, unplanned downtime is rarely caused by process design. More often, it is linked to component failure, delayed replacements, or limited access to compatible automation hardware.
Effective spare parts management reduces these risks by ensuring that critical control and safety components are available when needed. For Honeywell-based systems, access to reliable industrial spare parts and industrial automation parts supports maintenance planning and shortens recovery time after faults.
In large LNG facilities, stable production depends not only on advanced process technology, but also on the practical ability to keep control systems running as designed, year after year.