In the construction of LNG (liquefied natural gas) plants, ensuring precision in assembly and minimizing costly errors is critical. Traditionally, physical mockups have been used to test designs and assembly sequences, but virtual assembly simulators are increasingly becoming a viable alternative. This blog compares the costs and benefits of both approaches.

Physical Mockups: Pros and Cons

Benefits:

Tangible Validation: Engineers can physically interact with components, identifying fit and interference issues more intuitively.

Stakeholder Confidence: Clients and contractors may prefer seeing a real-scale model before approving designs.

No Software Dependency: Avoids potential glitches or limitations of digital simulations.

Drawbacks:

High Costs: Fabricating full-scale mockups is expensive, especially for large LNG modules.

Time-Consuming: Building and modifying physical models delays project timelines.

Limited Flexibility: Changes require rebuilding, increasing material waste and labor costs.

Virtual Assembly Simulators: Pros and Cons

Benefits:

Cost Savings: Eliminates material and labor expenses associated with physical mockups.

Faster Iterations: Design changes can be tested instantly in a digital environment.

Enhanced Visualization: 3D simulations allow for clash detection, ergonomic assessments, and virtual walkthroughs.

Remote Collaboration: Teams across locations can review and optimize assembly processes in real time.

Drawbacks:

Software & Training Costs: Requires investment in simulation tools and skilled personnel.

Hardware Limitations: High-fidelity simulations may need advanced computing power.

Perception Challenges: Some stakeholders may distrust digital models over physical verification.

Which is Better for LNG Plant Construction?

For most modern LNG projects, virtual simulators offer greater cost efficiency and flexibility, especially in the early design phases. However, physical mockups may still be justified for critical components where hands-on validation is irreplaceable.

A hybrid approach—using virtual simulations for most planning and selective physical mockups for high-risk areas—can balance cost, accuracy, and stakeholder confidence.

Conclusion

While physical mockups provide tangible benefits, virtual assembly simulators are transforming LNG plant construction with significant cost and time savings. As simulation technology advances, their adoption will likely become the industry standard, reducing reliance on expensive physical prototypes.