Innovation of LNG Carrier-Propulsion and BOG handling technology (LNG Warring State Period)
- 1. Prepared by Cargo Master, Benedict Song, Ph.D. Propulsion & BOG Handling Technology 2019-08-31 Rev01
- 2. INDEX Chapter 1. Introduction Chapter 2. MEGI + GMS CONFIGURATION Chapter 3. XDF + GMS CONFIGURATION Chapter 4. BOG HANDLING TECHNOLOGY
- 3. • LNGC Market Trend • LNG Property • Type of LNGC Propulsion system • Innovation & of LNG Propulsion
- 4. LNGC Market Trend Active Fleet: 499(by end of 2018) Order Book: 130+(by end of 2018)
- 5. LNG Property LNG Composition Range (Mol%) Standard (Mol%) Nitrogen(N2) 0.04 – 1.00 0.35 Methane(CH4) 86.70 – 90.40 88.0 Ethane(C2H8) 7.00 – 8.50 7.8 Propane(C3H6) 1.10 – 3.10 2.8 Butane(C4H10) 0.10 – 1.15 1.0 Pentanes and Heavier 0.007 – 0.10 0.05
- 6. LNG Property Physical Properties Methane Ethane Propane Butane Pentane Nitrogen CH4 C2H6 C3H8 C4H10 C5H12 N2 Molecular weight - 16.042 30.068 44.094 58.120 72.150 28.016 Boiling point at 1 bar absolute (0.1 MPaA) °C -161.5 -88.6 -42.5 -5 36.1 -196°C Liquid density at boiling Point kg/m3 426.0 544.1 580.7 601.8 610.2 808.6 Vapour SG at 15 °C and 1 bar absolute (0.1 MPaA) - 0.554 1.046 1.540 2.07 2.49 0.97 Gas volume/liquid volume ratio at boiling point and 1 bar absolute (0.1 MPaA) - 619 413 311 311 205 649 Flammable limits in air by volume % 5.3 to 14 3 to 12.5 2.1 to 9.5 2 to 9.5 3 to 12.4 NA Auto-Ignition temperature °C 595 510 468 365/500 - - Gross heating value at 15 °C Normal: Iso : kJ/kg 55,559 51,916 50,367 49,530 49,404 49,069 48,944 - Vaporisation heat at boiling point kJ/kg 510.4 489.9 426.2 385.2 357.5 199.3
- 7. Temperature – Pressure Graph -165 -160 -155 -150 -145 -140 -135 -130 -125 -120 -115 -110 -105 -100 -95 -90 -85 -80 -75 -70-65-60-55-50 -40 -30 -20 -10 0 25 50 75 100 -165 -160 -155 -150 -145 -140 -135 -130 -125 -120 -115 -110 -105 -100 -95 -90 -85 -80 -75 -70-65-60-55-50 -40 -30 -20 -10 0 25 50 75 100 60 50 40 30 20 10 9 8 7 6 5 4 3 2 1 0.9 0.8 0.7 0.6 TEMPERATURE( C)0 PRESSURE bar(absolute) Methane Ethylene Ethane Propane 2mol%Ethane Propylene Propane Butadrene 1.3 N. Butane
- 8. Propulsion System of LNG Carriers Boiler + Steam Turbine BOG Re-liquefaction +Slow Diesel DFDE Generator + Electrical Motor ~ 2006 ~ 2012 ~ 2018 MEGI engine (2 stroke Diesel Cycle) XDF engine (2 stroke otto Cycle) ? ? Operation & Maintenance Fuel Consumption Operation Cost Boil Off Gas Handling Shipbuilding Cost Crew Training Environment Issue
- 9. Thermal efficiency of propulsion system
- 10. Propulsion Type and Characteristics Characteristic Boiler DFDE MEGI XDF FG Pressure 0.7 ~1.0 barg 6 barg 300barg 15barg FG Consumption (tonnes/day) 175 130 110 108 Boiler + Steam Turbine DFDE + El Motor MEGI (2 stroke Diesel) XDF (2 stroke OTO) Note: LNG fuel consumption figures In the table above are at designed service speeds. Source: HIS Markit
- 11. Conventional LNGC propulsion System
- 12. To GCU + 2 Stroke Diesel Engine (Fuel ONLY) LNG Re-Liquefaction (N2 Compander)+ Slow Diesel World 1st LNGC Re-Liquefaction
- 13. DFDE is best solution for FSRU DFDE Electrical Propulsion System In-line Mixer After Cooler No.1 Vent Mast Mist Sep. No.3 LD Comp. No.2 LD Comp. No.1 LD Comp. ForcingVaporiser Cargo Tank 4 Cargo Tank 3 Cargo Tank 2 Cargo Tank 1 From HD Comp./ Heater To Regas Recondenser GCU DFE (P) DFE (S)CG586 CG536 CG415 CG534 CG451 CG535 CG538 CG405 CG106 CG406 CG408 Spray Main Vapour Main
- 14. MAN B&W MEGI Diesel Cycle Auto-ignition Temperature(‘C) DIESEL 210 METHANE(CH4) 540
- 15. WINGD X-DF Dual Fuel Design(OTTO Cycle) The low-pressure X-DF technology concept Low-pressure X-DF technology is based on the lean-burn principle (Otto cycle), in which fuel and air are premixed and burned at a relatively high air-to-fuel ratio – a concept already used widely on medium-speed engines. Such a concept on the X-DF engines provides the following benefits: - Low-pressure gas supply means maximum simplicity, low investment costs and low power consumption - Very small pilot fuel quantity, below 1% of total heat release - X-DF engines can be operated on gas down to very low loads - Low NOX emissions, close to zero SOX emissions, IMO Tier III compliant without exhaust-gas after-treatment - Particulate matter emissions significantly reduced. The X-DF principle with gas admission (left) and ignition (right)
- 16. DIESEL Cycle vs OTTO Cycle
- 17. Innovation of LNGC Propulsion System Boiler + Steam Turbine LD Compressor PropulsionCargoGMS DFDE + Electric Motor BOG(LD) Compressor MEGI Engine 2-Stroke (MAN B&W) XDF Engine 2-Stroke (Win GD) HP Fuel Pump + FG Compressor (Re-Liquefaction) Re-Liquefaction (PRS/FRS/C3-MR) Re-Liquefaction (PRS/MRS/C3-MRl) FG Compressor Innovation of LNGC Waste Steam Dump GCU
- 18. MEGI / WINGD + BOG Control issue Low Fuel Consumption LOW BOR BOG Control FRS SUBCOOL C3-MR HICOM HIVAR MRS PRS
- 19. • MEGI Configuration • MEGI + HICOM • MEGI + HIVAR • HICOM (Burchardt Compressor) • HIVAR fuel pump • GVT
- 20. MEGI(LNG to 2 Stroke Diesel Engine) MEGI 2 Stroke Diesel Engine Fuel Gas
- 21. HICOM & HIVAR for MEGI
- 22. MEGI + HICOM/HIVAR(CASE A)
- 23. MEGI + HICOM/HIVAR(CASE B) No.4 Cargo Tank No.3 Cargo Tank No.2 Cargo Tank No.1 Cargo Tank CS905 FBOG Mist. Sepa. CS906 CL903 Spray Pipe Spray Pipe CS962 LP Forcing Vaporiser PV-057 PV-058 No.1 HP Pump 5 Stage HP Compressor Fuel Gas Pump Fuel Gas Pump GW Exp. Tank CG985 CG986 No.2 HP Pump FBOG Heater GW/Steam Heater No.1 GW Circ. Pump No.2 GW Circ. Pump CG941 PV-018 PV-038 PV-028 CG920 CG965 CG938 ESD CG942 CG939 ESD ME-GI GVT ME-GI Engine GCU GVU GCU DFG GVU DF Generator HP Forcing Vaporiser
- 24. MEGI Operation Mode HICOM Only HIVAR Only • Tank Pressure Control by NBO (Natural Boil Off) Gas - SDF(Specified Dual Fuel) mode - Cruise control • Excessive BOG to FRS or GCU • FBO(Forced Boil-off Gas) made from LNG. Parallel Mode • HIVAR MEGI / HICOM DFGEs • HIVAR & HICOM MEGI / HICOM DFGE
- 25. HICOM (Burckhardt Compression) LABY-GI COMPRESSORS
- 26. HICOM (Burckhardt Compression) Specification Maker Burkhardt Compression Model Vertical in-line reciprocating compressor (6LP190-5C_1) Number of sets 1 Suction pressure 0.103 MPa A Suction temperature -90 °C Discharge pressure 30.6 MPa A Discharge temperature 43 °C Standard volume flow 4,880 Nm3/h Inlet volume flow 3,233 m3/h Shaft power (coupling) 1,190 kW Electric motor rating 1,500 kW Rotation speed 712 rpm Electric Power Supply 6.6 kW / 60 Hz / 3Ph
- 28. BOG High Pressure Compressing Process
- 29. BOG Compressor(Burckhardt Compression) Compressor Off No Step 2 Auto Start Utilities - Start Oil pump / Stop space heater- Open Bypass valve - Close automatic vent valve - Open Inlet Isolation valve of compressor package - Set suction valve unloaders 50% Condition OK And And 1 Step 1 Ready for Start-Sequence Pre-Start condition Ready for Start-Sequence RunStart Command Pre-Start Interlock (SI) Step 5 Main Motor Running - Main Motor Start Command to MCC And Step 6 Main Motor Runinng Step 7 Controlled Operation And Step 4 Cyl. Lubricating - Main Motor Start Command to MCC Compressor Running - Cylinder Lubricating Pump - Open discharge isolating valve - Start Command to MCC- - Cylinder lubricating pump feedback- Cylinder - Pre-Lubrication- - Start Interlocks (SI) Main Motor Feedback Start-Up Delay Compressor Run Step 3 Cylinder Lubrication And Ready for Cyl. Lubrication RunStart Command
- 30. HIVAR System
- 31. HIVAR – Fuel Pump
- 32. HIVAR – Fuel Pump HP Pump & Motor Maker Cryostar S.A.S Model & Type HPP3-65/90 & Reciprocating Pump Number of Sets 2 Process Data Fluid: LNG Fluid temperature: -160 °C Density (at fluid temp.): 0.5 kg/dm3 Suction pressure (max operating pressure): 0.8 MPaG Suction pressure, design: 1.2 MPaG Operating Data Flow: 9.0 m3/h with SG=0.5, 4,500 kg/h Max allow. discharge pressure: 31.5 MPaG Discharge pressure, design: 37.0 MPaG Shaft power: 64.0 kW Pump speed: 230 min-1 NPSP, required (pump inlet): 1.5 to 2.5 m Drive Data Motor Size: 160 kW Voltage, phase, frequency: 440 V/60 Hz/3-Phase Motor speed: Variable speed
- 34. HIVAR – Vaporizer HP Vaporiser Maker DongHwa Entec. Type BEU Number of Sets 1 Shell Side Fluid: Glycol Water Fluid Quantity: 20942 kg/hr Design pressure: 10.0 bar(g) Operating pressure: 8.0 bar(g) Design temperature: 110 °C Operating temperature(In/Out): 90/50 °C Tube Side Fluid: LNG Fluid Quantity: 4740 kg/hr Design pressure: 350.0 bar(g) Operating pressure: 320.0 bar(g) Design temperature(In/Out): -165/120 °C Operating temperature(In/Out): -145/45 °C
- 35. Gas Valve Train GVT • Supply gas to the ME-GI engine • In case of normally shut down or emergency shutdown, to stop the gas supply to engine and send gas from the pipe systems and GVT_SL to the vent header • Purging of the pipe system between the GVT_SL and ME-GI • Purging of the pipe system between the GVT_SL and FGS System • Secure slow filling of pipes at twin engine operation
- 36. • XDF Configuration • BOG Compressor • BOG Control Mode
- 37. XDF Typical Configuration LD Comp. No.1 LD Comp. No.2 Cargo Tank 2 Cargo Tank 1 Cargo Tank 3 Cargo Tank 4 No.3 DFGE No.4 DFGE No.1 DFGE No.2 XDF No.1 XDF No.2 DFGE No.2 Water Rec. Cooler Mist Sep. ForcingVap. No.2 Inter Cooler No.2 After Cooler No.1 Water Rec. Cooler No.1 Inter Cooler No.1 After Cooler OverPressure Valves Free Flow Line GCU
- 38. BOG Compressor(6 stage) Performance data Unit 90 % CH4 Molecular weight Kg/kmol 17.24 Volume flow m3/h 4250 Mass flow kg/h 5000 Inlet pressure bar A 1.03 Outlet pressure bar A 17.00 Inlet temperature °C -90.0 Outlet temperature °C 45.0 Shaft speed rpm 29235 Shaft power kW 881 Coupling power kW 1049
- 40. FG COMPRESSOR Specification Maker KOBELCO Model KS40STX Compressor Item No: C-101A (No.2 FG Compressor) C-101B (No.1 FG Compressor) Type Screw, electric motor driven Number of Sets 2 Suction temperature at compressor (°C) -40 ~ 43 Design flow rate (kg/h) 4,550 8,000 Design inlet volume (m3/h) 6,607 6,957 Discharge pressure (MPaA) 1.7 3.2 Discharge temperature (°C) 43 ~ 32 Pressure ratio 16.425 Total BHP (kW) 1,086 1,915 Speed (rpm) 3,550
- 41. Tank Pressure Control (SLNG Mode) Pressure Setting Table in LNGC Mode Ballast Voyage Laden Voyage 25 Safety Vent Open (Local) Vapour Header Pressure 23 Vent Valve Open (by IAS) (CG106) 22 Safety Valve Close (Local) 21 Vent Valve Close (by IAS) 20 LNG Vaporiser Trip Forcing Vaporiser Trip PAHH PAH PAL PALL PAVL 19120.3 kPaA 102.8 kPaA 108.3 kPaA 105.3 kPaA Ballast Voyage Laden Voyage 130.3 kPaA 126.3 kPaA 108.3 kPaA 105.3 kPaA kPag kPag GCU Start Request Alarm 17 LNG Vaporiser Stop Request Alarm 15 11 7 0 5 GCU Stop Request Alarm 4 LNG Vaporiser Start Request Alarm X-DF Gas Flow Rate Limit Control (Optional) (by IAS Cargo Tank Low Pressure Controller) 3 DFGE Sequenctial Changeover to MDO/LSMGO Mode (5 Min Delay) (by IAS) 2 All DFGE Changerover to MDO/LSMGO Mode (30sec. Delay)(by IAS) X-DF Gas Flow Rate Limit to Zero (by IAS) (Optional) No.1/No.2 FGC Stop 0.3 By ESDS (GH018) -1 Vacuum Relief Valve Open (Local) Pressure Setting Table in SLNG Mode 35 Safety Vent Open (Local) Vapour Header Pressure 33 Vent Valve Open (by IAS) (CG106) 32 Safety Valve Close (Local) 31 Vent Valve Close (by IAS) 30 LNG Vaporiser Trip Forcing Vaporiser Trip PAHH PAH PAL PALL PAVL 29 GCU Start Request Alarm 27 LNG Vaporiser Stop Request Alarm 25 21 14 7 0 5 GCU Stop Request Alarm 4 LNG Vaporiser Start Request Alarm X-DF Gas Flow Rate Limit Control (Optional) (by IAS Cargo Tank Low Pressure Controller) 3 DFGE Sequenctial Changeover to MDO/LSMGO Mode (5 Min Delay) (by IAS) 2 All DFGE Changerover to MDO/LSMGO Mode (30sec. Delay)(by IAS) X-DF Gas Flow Rate Limit to Zero (by IAS) (Optional) No.1/No.2 FGC Stop 0.3 By ESDS (GH018) -1 Vacuum Relief Valve Open (Local)
- 42. • PRS/FRS • MRS • C3MR • ecoSMRT
- 43. MEGI + FRS(Full Reliequefaction System)
- 45. FRS Heat Balance(DCHE/J-T Valve)
- 46. FRS Heat Balance
- 47. XDF + PRS(Partial Re-liquefaction System)
- 48. FG COMPRESSOR Specification Maker KOBELCO Model KS40STX Compressor Item No: C-101A (No.2 FG Compressor) C-101B (No.1 FG Compressor) Type Screw, electric motor driven Number of Sets 2 Suction temperature at compressor (°C) -40 ~ 43 Design flow rate (kg/h) 4,550 8,000 Design inlet volume (m3/h) 6,607 6,957 Discharge pressure (MPaA) 1.7 3.2 Discharge temperature (°C) 43 ~ 32 Pressure ratio 16.425 Total BHP (kW) 1,086 1,915 Speed (rpm) 3,550
- 49. BOG BOOSTING COMPRESSOR Specification Maker: KOBELCO Model KR50V-2 Type Reciprocating, electric motor driven Number of Sets 1 Capacity 3,500 kg/h Inlet temperature +43 °C Inlet pressure 1.67 MPaA Discharge pressure 15.1 MPaA Discharge temperature 43 °C Rated output 610 kW Speed/No. of pole 440 rpm/16 pole Power 6.6 kV, 60 Hz, 3 Phase
- 51. XDF + PRS/MRS
- 52. XDF + MRS(Methane Re-liquefaction System)
- 54. On-Shore LNG Plant Technology to LNGC
- 55. On-Shore LNG Plant Technology to LNGC MR Compressor of Standard Oil-Injected type – Working Principle
- 56. C3-MR Re-Liquefaction System 25HV1001 25PV1005 40PV1365 25PV1075 25TV1035 25LV1040 40LV1607 40LV1605 40PV1608 40PV1615 25TV1030 40PV1325 40LV1320 From LD Compressor To Liquid Main To Cargo Tanks Propane Storage Tank Propane Separator MR Expansion Drum Economiser Vent Gas Separator BOG Recondenser BOG Precooler MR Precooler MR Comp. Skid Propane Condenser Propane Condenser Skid MR Comp. Aftercooler Coalescer MR Separator PFD Stream Number Medium Vapour Fraction Molecular Weight Temperature Pressure Mass Flow Molar Flow Mass Density Actual Volume Flow Mass Enthalpy Viscosity LNG in - Tank C bar kg/h kgmole/h kg/m3 m3/h kj/kg cP LNG 0.000 16.6 162.2 1.06 436.15 237.08 0.122 BOG 1 1.000 17.9 45.0 6.50 3066 170.9 4.45 689.10 -3481.4 0.013 BOG 2 1.000 17.9 -10.0 6.20 3066 170.9 5.17 592.80 -3589.3 0.011 LNG 3 0.000 17.9 -160.4 6.09 3066 170.9 467.88 6.55 -4280.8 0.102 BOG 4 1.000 25.3 -160.3 4.75 0.0 0.0 14.08 0.00 -903.0 0.007 LNG 5 0.000 17.9 -160.3 4.75 3066 170.9 467.62 6.56 -4280.8 0.101 LNG/BOG 6 0.040 17.9 -163.9 3.50 3066 170.9 136.19 22.51 -4280.8 0.131 MR 7 1.000 40.0 10.0 22 18230 675 25 718 -1967.0 0.012 MR 9 1.000 -23.8 -10.0 22 13316 561 27 489 -2040.2 0.011 MR 10 0.000 -43.0 -10.0 22 4914 114 527 9 -2448.5 Empty MR 11 0.269 43.0 -39.2 3 4914 114 22 219 -2448.5 Empty MR 12 0.000 23.8 -160.4 22 13316 561 568 23 -2697.7 0.255 MR 13 0.064 23.8 -164.9 3 13316 561 99 134 -2697.7 Empty MR 14 1.000 27.0 -14.0 2 18230 675 3 5746 -2033.8 0.010 MR 15 1.000 27.0 -13.5 2 18230 675 3 5886 -2033.8 0.010 MR 16 1.000 27.0 95.7 22 18230 675 21 975 -1853.5 0.014 MR 17 1.000 27.0 40.0 22 18230 675 25 718 -1967.0 0.012 Propane 18 1.000 44.1 13.0 3 11029 250 7 1615 -2427.3 0.007 Propane 19 1.000 44.1 63.0 16 15239 346 31 493 -2327.2 0.010 Propane 20 0.000 44.1 44.7 15 15239 346 459 33 -2663.2 0.082 Propane 21 0.274 44.1 44.7 6 15239 346 459 33 -2663.2 Empty Propane 22 1.000 44.1 10.2 6 4173 95 14 302 -2399.9 0.008 Propane 23 0.000 44.1 10.2 6 11066 251 515 22 -2762.5 0.115 Propane 24 0.149 44.1 -13.0 3 11066 251 43 256 -2762.5 Empty Propane 25 0.000 44.1 -13.0 3 12209 277 546 22 -2821.0 0.145 Propane 26 0.000 44.1 -13.0 3 1202 27 546 2 -2821.0 0.145 Propane 27 0.694 44.1 -12.7 3 12209 277 10 1225 -2547.3 Empty Propane 28 0.626 44.1 -12.7 3 1202 27 11 109 -2574.0 Empty 4 5 6 13 12 9 14 11 25 27 26 28 18 19 20 24 23 15 16 17 1 8 7 3 2
- 62. LNGC Warring State Period
- 63. Survive in the new era of LNG technology along with VMT