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N°14<br />

autumn 2009<br />

OFFSHORE BENEFITS<br />

The floating solution for LNG<br />

LNG TURBINE EXPANDERS<br />

A flash of <strong>Cryostar</strong> inspiration<br />

DIGGING DEEP<br />

<strong>Cryostar</strong> geothermal technology in German debut


EDITORIAL<br />

<strong>Cryostar</strong> Magazine’s Spring issue celebrated our company’s<br />

long term, core business segment – industrial gases. But it<br />

is also increasingly obvious to those following trends in the<br />

energy industry that both natural gas and liquefied natural<br />

gas (LNG) are fuels to look to in the future. So it should<br />

come as no surprise that <strong>Cryostar</strong> is present and making<br />

use of its technical expertise at critical points all along the<br />

natural gas production and distribution chain.<br />

SUMMARY<br />

3<br />

Offshore Benefits<br />

<strong>Cryostar</strong> regularly supplies the natural gas processing industry<br />

with equipment. For instance, our news pages detail<br />

agreements in Algeria worth over €7m to supply <strong>turbine</strong>s<br />

for natural gas processing plants. Other key technologies in<br />

this area include <strong>Cryostar</strong>’s recent HPP pump technology,<br />

designed with well stimulation applications in mind.<br />

6<br />

8<br />

9<br />

10<br />

11<br />

Liquid Expanders<br />

Geothermal Project<br />

API Standard<br />

BOG Compressors<br />

News<br />

Training Centre<br />

<strong>Cryostar</strong>’s liquid <strong>turbine</strong> is well established in the air<br />

separation market. The company’s next move is to translate<br />

this technology for the LNG audience. A derivative of the<br />

turbo expander installed in natural gas treatment plants,<br />

the new LNG flashing liquid expander based on radial<br />

inflow <strong>turbine</strong> technology has the potential to become yet<br />

another great success in <strong>Cryostar</strong>’s portfolio. More details<br />

can be found on p6.<br />

On the ground, Crystar has developed automatic compressed<br />

and liquid natural gas fuelling station to fill natural<br />

gas vehicles, and is involved in the LNG supply chain via its<br />

truck-mounted transfer pumps. LNG carriers on the ocean<br />

increasingly benefit from built in efficiency thanks to <strong>Cryostar</strong><br />

compressors, a natural choice to recover and transfer<br />

the boil-off gas (BOG) produced as LNG ships unload (see<br />

p10). BOG compressors may also be used during the LNG<br />

storage and transport stages. With further LNG import terminals<br />

planned worldwide, <strong>Cryostar</strong>’s proven technology<br />

is ideally placed to optimise product volume and revenues,<br />

while cutting the environmental impact.<br />

Another instance of <strong>Cryostar</strong> is leading the pack is showcased<br />

in the main article in this edition of <strong>Cryostar</strong> Magazine,<br />

the LNG floating storage and regasification unit (FSRU).<br />

Old-fashioned methods are rapidly falling away as the LNG<br />

industry adapts to new developments in LNG transportation<br />

and cargo handling processes. Moored at sea to take<br />

on LNG, the FRSU is not only more cost-effective but also<br />

gets around the issues associated with building terminals<br />

on-shore. <strong>Cryostar</strong>’s EcoVAP regasification system is undergoing<br />

final testing now.<br />

<strong>Cryostar</strong>’s technologies for natural gas and LNG are found<br />

in a number of the company’s business segments, but the<br />

common theme is taking proven ideas and re-creating them<br />

to stay one step ahead of tomorrow’s customer. If you want<br />

to take a guess at the gas industry of the future, ask <strong>Cryostar</strong>.<br />

We’re already there.<br />

Daniel MEYER<br />

President<br />

2<br />

Autumn 2009


OFFSHORE BENEFITS<br />

Offshore <strong>benefits</strong><br />

The traditionally conservative LNG industry has recently embraced many changes<br />

and new developments in LNG transportation and cargo handling processes.<br />

The LNG floating storage and regasification unit (FSRU) is one of the latest<br />

technologies to enter the fray, resolving issues associated with cost and approvals<br />

required for on-shore receiving terminals<br />

Why an FSRU?<br />

Onshore receiving terminals have three primary<br />

requirements:<br />

● A suitable site<br />

● A large capital investment in storage tanks,<br />

receiving jetties, vaporisation plant, pipework<br />

and a means to treat the boil off gas (BOG)<br />

during periods of low or no sendout<br />

● Appropriate approvals from local authorities<br />

and, more importantly, the local population<br />

When compared to onshore terminals, FSRU<br />

technology has a number of advantages.<br />

Offshore terminals are located some distance<br />

from the coast, which tends to reduce opposition<br />

by local residents and make it easier to<br />

gain local authority approvals. In addition,<br />

construction time is relatively short and<br />

considerably less expensive, making FSRUs<br />

a good solution for fast capacity growth, or<br />

short-term capacity requirements. Operators<br />

moor a floating buoy <strong>offshore</strong> and connect a<br />

suitably equipped LNG carrier/FSRU to feed<br />

vaporized LNG into an undersea pipeline<br />

linking the buoy to the NG distribution network.<br />

Many regasification solutions are available<br />

for onshore receiving terminals, whereas<br />

the possibilities for <strong>offshore</strong> regasification<br />

are limited. Offshore systems may use heat<br />

from seawater for this process, but in some<br />

areas this is banned and in others the sea is<br />

relatively cool, making the plants larger and<br />

more expensive.<br />

<strong>Cryostar</strong> has developed three different technologies<br />

using steam generated on board or<br />

seawater as heating medium:<br />

● EcoVAP GW – Steam/glycol water in an<br />

intermediate loop system<br />

● EcoVAP DST - A directly steam heated<br />

water-bath<br />

● EcoVAP SW - Sea water/propane intermediate<br />

loop (patented).<br />

<strong>Cryostar</strong> offers tailored processes to meet<br />

the market’s needs, and to adapt to different<br />

conditions of an <strong>offshore</strong> regasification<br />

terminal location, especially local seawater<br />

temperatures.<br />

In simple terms LNG regasification is a<br />

vaporization process<br />

that requires<br />

energy. When this<br />

energy is provided<br />

by the vessel itself<br />

the regasification<br />

system is referred<br />

to as a closed-loop<br />

system because<br />

it re-uses energy<br />

generated by the<br />

FSRU. When the<br />

heating energy is<br />

provided by an<br />

external source<br />

(e.g. sea water),<br />

the system is<br />

referred to as an<br />

open-loop system.<br />

Autumn 2009<br />

3


OFFSHORE BENEFITS<br />

Fully operational<br />

Discharge pressure of 100 to 120 bars is typically<br />

required for <strong>offshore</strong> regasification. Determined<br />

by onshore grid consumption, send-out rates will<br />

require one or more regasification units. Units<br />

are designed so that 16 to 100 percent of the<br />

send-out range can be covered.<br />

1 Module 2 Modules 3 Modules<br />

1200<br />

1000<br />

800<br />

600<br />

400<br />

200<br />

LNG Flow (m3/h)<br />

<strong>Cryostar</strong>’s EcoVAP system is equipped with the<br />

following modules:<br />

- LNG drum module, to feed the high pressure<br />

pumps with LNG<br />

- Booster pump module, to bring the LNG from<br />

atmospheric storage pressure to the required high<br />

pressure<br />

- Vaporization module, to vaporize the high pressure<br />

LNG<br />

- Heating module, to adjust the required NG<br />

temperature<br />

Typical redundancy requirements provide for n+1<br />

regasification units. So for three units in normal<br />

operation, a fourth unit is supplied as backup.<br />

This also allows maintenance on one unit without<br />

interrupting delivery.<br />

Lets go into more detail:<br />

LNG drum module<br />

The LNG drum module has three roles. It acts<br />

as a buffer to damp process variations in case of<br />

a cargo pump trip, ensure sufficient NPSH (net<br />

positive suction head) for the booster pumps and<br />

to function as a re-condenser for excess BOG<br />

flow.<br />

Booster pump module<br />

Increasing natural gas pressure is far more efficient<br />

while it is still in the liquid phase.<br />

The booster pump module’s duty is therefore to<br />

increase the pressure of the LNG to the required<br />

pressure before vaporization takes place.<br />

A typical booster pump module is equipped with<br />

two 50 percent pumps having a total operation<br />

range of 50 to over 120 bar discharge pressure,<br />

with flow range of 120 to 500 m 3 /h. These pressure<br />

and flow ranges are adjusted to customer<br />

requirements.<br />

The booster pump module is equipped with the<br />

necessary lines, valves and instrumentation to<br />

ensure smooth start-up and safe cool-down.<br />

<strong>Cryostar</strong> equips Booster Pump Modules with<br />

one or two booster pumps, although for added<br />

5<br />

From Booster<br />

Pumps<br />

1<br />

LOOP A<br />

Propane / LNG<br />

Vaporizer<br />

LC<br />

Number of Operating Modules<br />

flexibility, two pumps per module are generally<br />

preferred. This configuration enables an operating<br />

range from 10 percent to 100 percent of<br />

design send-out rates.<br />

Vaporization and heating<br />

The Vaporization module performs the LNG<br />

phase change, while the heating module adjusts<br />

the send-out temperature to the required levels.<br />

Typical send-out temperatures are 0 to 10°C, but<br />

customers can also request higher temperatures.<br />

The heating medium for this process is seawater.<br />

The set up uses propane in an intermediate loop<br />

to avoid direct contact between LNG/NG and<br />

seawater.<br />

Vaporization and heating loop schematics<br />

4<br />

3<br />

2<br />

LOOP B<br />

Propane / NG<br />

Heater<br />

LC<br />

Send-out<br />

Propane Loops<br />

Sea Water Loop<br />

In the loop<br />

Propane Loop A performs the phase change from<br />

LNG to NG. In each loop, a seamless pump circulates<br />

liquid propane, which then enters a plate<br />

heat exchanger going against the seawater<br />

current. Within the heat exchanger, the propane<br />

partially vaporizes. The system is equipped with<br />

a separator that sends the propane vapour to the<br />

LNG/NG loop. From here from, the separated<br />

liquid travels back to the propane tank and recirculates.<br />

Vaporized propane vapour enters a printed<br />

circuit LNG/NG heat exchanger, where heat<br />

4<br />

Autumn 2009


OFFSHORE BENEFITS<br />

from the propane condensation vaporizes the<br />

LNG, and superheats the NG. In the LNG/NG<br />

heat exchanger, the propane in re-condensed and<br />

flows to the propane tank.<br />

Propane Loop B adjusts the temperature to meet<br />

send-out requirements, using exactly the same<br />

process as described above, but with different<br />

operating set points. Apart from propane inventory<br />

storage, the propane tank provides a suitable<br />

NPSH for the circulation pumps.<br />

System control<br />

During transient operations - such as stand-by,<br />

start-up and stop - the propane loop process selfregulates<br />

and pressure in the propane loop will<br />

float according to the thermal load (flow and<br />

pressure) of both LNG and sea water.<br />

In stand-by mode, the propane loop pressure will<br />

vary according to the ambient conditions. For<br />

example, at 30°C the propane loop will settle to<br />

around 11.5 bar, as shown on the graph on the<br />

right.<br />

(HAZOP), a dynamic simulator and pilot plant<br />

testing during 2009.<br />

To demonstrate the new process to customers,<br />

<strong>Cryostar</strong> invested in a 1 MW regasification test<br />

plant. This unique situation allows full process<br />

testing and validation of its control philosophy,<br />

on a reasonably large scale. This pilot also helps<br />

to optimise full-size plant performance by carrying<br />

out dedicated testing of heat exchangers,<br />

flow, transient operations and other special<br />

conditions.<br />

A team of over 30 people was dedicated to this<br />

project to fast track testing to October 2009.<br />

After demonstration to shipyards, ship owners,<br />

charterers and consultants, <strong>Cryostar</strong> will be<br />

able to offer a proven, fully engineered and safe<br />

system.<br />

Winning qualities<br />

● EcoVAP SW is designed to ensure safe regasification<br />

● No direct contact between LNG/NG and sea<br />

water<br />

● Maintainability is one of the key design criteria<br />

● Modular design allows simple process integration<br />

with vessel systems<br />

<strong>Cryostar</strong> boasts<br />

● Over 1000 cryogenic pumps delivered annually<br />

● Over 750 heat exchangers and mist separators<br />

delivered<br />

● Over 900 cryogenic compressors delivered<br />

● Over 30 years experience with <strong>offshore</strong> LNG<br />

operation on LNG carriers<br />

● Experienced team of service engineers, worldwide<br />

based<br />

● Branches and service centres in five countries<br />

and representatives in many more<br />

Proven design<br />

<strong>Cryostar</strong> embarked on a complex process to ensure<br />

its fully developed and qualified technology<br />

was market-ready.<br />

The first step was to work closely with DNV to<br />

achieve New Technology Qualification status.<br />

This process includes hazard identification<br />

studies (HAZID), failure mode and effects<br />

analysis (FMEA), hazard and operability studies<br />

Pilot plant vital statistics<br />

Regasification Duty…<br />

● 12 tons/h – 1/15 of real plant size<br />

● 1MW vaporization unit – 1/40 of real plant size<br />

Additional Equipment planned for the test<br />

● 50m 3 LN2 tank<br />

● 5m 3 Propane storage tank<br />

● Booster pump unit built in addition to the vaporization<br />

system<br />

● Water supply system<br />

● Pilot plant controlled through I/O system (similar to<br />

IAS used on LNG carriers)<br />

● Process control station (multi-screen data acquisition<br />

station with direct pressures, flows, temperatures and<br />

levels)<br />

CRYOSTAR EcoVAP,<br />

A Step Change in LNG HP Distribution……<br />

Autumn 2009<br />

5


LIQUID EXPANDERS<br />

More efficiency in a flash<br />

Now that <strong>Cryostar</strong> has successfully<br />

established its liquid <strong>turbine</strong> in the air<br />

separation plant market, the company’s<br />

next move is to offer a similar <strong>turbine</strong><br />

to the liquid natural gas (LNG) industry.<br />

The new LNG version is a derivative<br />

of the turbo expander installed in<br />

natural gas treatment plants. It’s clear<br />

that this new product has the potential<br />

to become yet another great success in<br />

<strong>Cryostar</strong>’s portfolio.<br />

Air separation inspiration<br />

The air separation industry has often taken the lead<br />

in developing cryogenic equipment that was later successfully<br />

applied in an LNG industry context. Not<br />

surprisingly, liquid <strong>expanders</strong> were first operated<br />

in an air separation plant in the mid 1980s before<br />

they were installed in a LNG plant about 10 years<br />

later. <strong>Cryostar</strong> argues that the LNG industry can<br />

take inspiration once again from the air separation<br />

community when considering liquid expander installation<br />

in an LNG plant. <strong>Cryostar</strong>’s liquid <strong>expanders</strong><br />

are based on the radial inflow <strong>turbine</strong> technology.<br />

The advantages of using a liquid expander in parallel<br />

with a Joule Thompson valve are well known and<br />

documented. Two liquid expander applications are<br />

possible in a LNG production plant. The first is to<br />

expand high pressure LNG (from production) to low<br />

pressure LNG (for storage). This application results<br />

in pressure ratios over the expander in the range of<br />

20 - 60. The second use is in the cooling medium loop<br />

(mixed refrigerant). This application results in pressure<br />

ratios over the expander in the range of 10 – 15.<br />

Currently the only liquid <strong>expanders</strong> operating in<br />

LNG plants are installed in series with a downstream<br />

pressure control valve. These liquid <strong>expanders</strong> are<br />

a derivative of submerged pumps, a technology<br />

<strong>Cryostar</strong> knows well. Liquid <strong>expanders</strong> based on<br />

this technology must avoid flashing at the expander<br />

discharge. Flashing occurs when the liquid expands<br />

rapidly to a pressure below the saturated liquid line.<br />

The phenomenon can be illustrated by gas that is<br />

released when opening a soda water bottle or when<br />

popping the cork on a previously shaken bottle of<br />

champagne.<br />

The liquid <strong>expanders</strong> derived from submerged pumps<br />

are designed in a multistage configuration with a<br />

single shaft. These liquid <strong>expanders</strong> are particularly<br />

unsuited for a flashing liquid because the flashing will<br />

considerably upset the flow path. Flashing in a liquid<br />

expander based on submerged pump technology<br />

could lead to efficiency deterioration and flow choking.<br />

This is why the purpose of the downstream valve<br />

is to ensure that the liquid expander always operates<br />

at a safe distance from the saturated liquid pressure<br />

line.<br />

Recent studies by <strong>Cryostar</strong> have shown that radial<br />

inflow expander technology is much better suited for<br />

the purpose of flashing liquid expansion. <strong>Cryostar</strong>’s<br />

6 Autumn 2009


LIQUID EXPANDERS<br />

liquid <strong>expanders</strong> are always designed in a single stage<br />

configuration regardless of the pressure ratio. In its<br />

behavior, a flashing liquid expander is closer to a<br />

turbo expander operating with a saturated gas than<br />

a reverse pump operating with a liquid. The turbo<br />

<strong>expanders</strong> are generally designed and manufactured<br />

to chapter four of American Petroleum Institute<br />

standard API 617 (also see p9 for an article in this<br />

issue on API 614) and are well known to the natural<br />

gas treatment and ethylene industry. The <strong>expanders</strong><br />

could be successfully applied to the LNG industry too<br />

- installing a flashing liquid expander could eliminate<br />

the downstream pressure control valve and result in<br />

more efficient heat extraction from the process fluid.<br />

<strong>Cryostar</strong> offers a wide range of liquid <strong>expanders</strong> with<br />

and without flashing at <strong>turbine</strong> discharge. The success<br />

of this innovative engineering product is based<br />

on the same components used in turbo <strong>expanders</strong><br />

that have proven their reliability over thousands of<br />

operating hours.<br />

Cash expander<br />

For a typical LNG plant with a production of four<br />

million tons of LNG per year, installing a liquid<br />

expander without flashing in the LNG stream would<br />

improve the plant throughput by about four percent<br />

compared to the installation of a Joule-Thompson<br />

valve. The installation of a liquid expander with<br />

flashing in the LNG stream enhances this improvement<br />

by yet another percentage point, resulting in<br />

a total increase of plant throughput of about five<br />

percent compared to one with a Joule-Thompson<br />

valve. The difference of one percent LNG throughput<br />

corresponds to 40,000 tons of LNG per year for the<br />

above-mentioned LNG plant. At the LNG price of<br />

€10/MWhr (approximately $4/MBTU) this adds up<br />

to extra sales worth more than €6m per year.. This is<br />

an increase in sales that is only due to the installation<br />

of a single stage flashing liquid expander delivered by<br />

<strong>Cryostar</strong>.<br />

As well as offering clear advantages for all new LNG<br />

plants, flashing liquid <strong>expanders</strong> can also be considered<br />

to upgrade certain existing plants too.<br />

Autumn 2009 7


GEOTHERMAL PROJECT<br />

<strong>Cryostar</strong> turns up the heat in Unterhaching<br />

When Unterhaching Community Council decided<br />

to install a safe and reliable CO 2<br />

-free energy source<br />

<strong>Cryostar</strong> was naturally interested. A technology<br />

leader in cryogenic rotating machine design for several<br />

decades, <strong>Cryostar</strong>’s expansion <strong>turbine</strong> is an ideal<br />

fit for the new geothermal project, which involves<br />

converting thermal water energy into electrical<br />

energy, and using the geothermal water in parallel<br />

for district heating.<br />

Geothermal energy uses heat present <strong>deep</strong> in the<br />

earth. Pumps bring hot water up from an aquifer<br />

source, and this natural heat then vaporizes an appropriate<br />

working fluid mixture with a boiling point<br />

below 100°C. The vapour is expanded through a<br />

radial inflow <strong>turbine</strong>, which drives a generator and<br />

delivers electricity to the grid. The low-pressure vapour<br />

condenses with an existing cold source, and the<br />

pump returns the liquid to the evaporator to begin<br />

the cycle again. Uses for the hot geothermal water<br />

include district heating or electricity supply, before<br />

it returns underground. The inlet geothermal water<br />

begins the cycle at 122°C and the outlet temperature<br />

is 60°C.<br />

The Unterhaching Community Council also elected<br />

to install a Kalina-based power plant cycle, supplied<br />

by Siemens. A Kalina cycle is a closed cycle using a<br />

mixture of ammonia and water. The patented Kalina<br />

technology helps to produce CO 2<br />

free energy.<br />

For this project, Unterhaching asked <strong>Cryostar</strong> to<br />

supply a TG-500 type expansion <strong>turbine</strong>, capable of<br />

producing up to 3.7 MW of electricity from geothermal<br />

heat. This <strong>turbine</strong> was adapted from the <strong>Cryostar</strong><br />

range of turbogenerators originally developed<br />

for operation with natural gas in pressure let down<br />

applications, ammonia/water mixtures for Kalina<br />

applications or organic fluid for organic Rankine<br />

cycle (ORC) applications.<br />

The process fluid for the project contains 92 percent<br />

8 Autumn 2009<br />

ammonia and eight percent water. <strong>Cryostar</strong> experts<br />

designed the TG 500 expander carefully to suit the<br />

application in the form of a radial inflow <strong>turbine</strong>,<br />

able to handle this corrosive mixture with a very low<br />

consumption of sealing gas. In design conditions, this<br />

<strong>turbine</strong> is capable of producing up to 3.5 MW with<br />

the fluid flowing at 2100 ls-1 and a gas expansion<br />

from 122°C at 20 bars to 6.9 bars. In addition to<br />

increased efficiency, another great benefit of using a<br />

radial inflow <strong>turbine</strong> lies in its standard execution<br />

using variable inlet nozzles. This allows for smooth<br />

seasonal variations inherent to a geothermal process,<br />

and maximizes the power recovered throughout the<br />

year.<br />

Everyone now recognizes that we need to produce<br />

energy without harming the environment. Using<br />

its 3O-years of industrial gas experience, <strong>Cryostar</strong><br />

plans to further grow its business in this area, with<br />

the development of its Lo-C (Low Carbon) clean<br />

energy product line.<br />

Photos (c) Geothermie Unterhaching GmbH & Co KG


API STANDARD<br />

Oiling the wheels<br />

Important components in <strong>Cryostar</strong>’s engineering, oil systems are governed by industry-wide standards. Fortunately,<br />

the company’s engineers know these standards inside out.<br />

Most of <strong>Cryostar</strong>’s <strong>expanders</strong> are equipped with oil-lubricated tilting pad bearings.<br />

Oil systems are engineered according to application specifics, and are adapted to suit customers’ requirements<br />

(customer specifications, specific local codes and standards).<br />

The American Petroleum Institute (API) gives the recognized standard for oil<br />

systems. For hydrocarbon applications, <strong>Cryostar</strong> strictly follows API 614, which<br />

covers lubrication, shaft sealing and oil control systems and auxiliaries. The<br />

U.S petroleum industry’s primary trade organization, the API is an accredited<br />

American National Standards Organization (ANSI), which publishes around<br />

500 standards.<br />

<strong>Cryostar</strong> engineers have proven expertise with each of the four API 614 chapters.<br />

The first chapter, ‘General requirements’ gives the minimum requirements<br />

for piping, instrumentation, control, electrical system, inspection,<br />

testing and preparation for shipment. This chapter is used in conjunction<br />

with the other three chapters.<br />

Chapter two is called ‘Special purpose oil systems,’ and is appropriate for equipment<br />

designed for uninterrupted, continuous operation applications in critical service,<br />

where there is usually no spare equipment. That means that all critical equipment (cooler,<br />

pump, filter, control valves, etc.) are double-piped in a parallel arrangement. If equipment has to be isolated for<br />

any reason, the operator can switch over to the stand-by equipment and perform maintenance or repairs without<br />

stopping the expander. In this chapter, design requirements and sizing criteria are specified for all oil system components,<br />

to ensure sufficient safety margins and increase reliability. Therefore, all of the main equipment <strong>benefits</strong><br />

from following the API. This type of oil system is shown in picture one. <strong>Cryostar</strong>’s experience with oil systems<br />

covered in this chapter has been built upon 30<br />

years of oil gas projects, with major players such<br />

as Shell, Exxon, Technip, and JGC.<br />

Chapter three, ‘General-purpose<br />

oil systems,’ covers equipment<br />

usually used as spare or in noncritical<br />

service. That means that the<br />

requirements are less stringent than<br />

for chapter two, and single equipment<br />

philosophy prevails (redundant<br />

equipment can be used upon<br />

request). <strong>Cryostar</strong> generally uses<br />

this chapter as a guideline for<br />

<strong>expanders</strong> in the industrial gas<br />

market. A standard oil system<br />

design using chapter three is<br />

shown in picture two.<br />

Chapter four covers ‘Self acting gas seal<br />

support systems,’ and specifies requirements<br />

for dry gas seals systems.<br />

So in summary, oil systems designed according<br />

chapter two have a larger footprint and a greater<br />

cost than those designed with chapter three,<br />

but they offer a higher availability by enabling<br />

maintenance operations without stopping the<br />

expander. <strong>Cryostar</strong> engineers take a lot of care in<br />

designing oil systems, and the API614 standard<br />

helps to maximize both our <strong>expanders</strong>’ reliability<br />

and availability.<br />

Autumn 2009<br />

9


GREEN BOG COMPRESSORS<br />

SOLUTION<br />

Unloading the <strong>benefits</strong><br />

With plans for new LNG import terminals under discussion<br />

worldwide, <strong>Cryostar</strong> technology offers proven<br />

methods to optimise product volume and revenues,<br />

and minimise the environmental impact at the same<br />

time. Both reliable and efficient, <strong>Cryostar</strong> compressors<br />

are a natural choice to recover and transfer the<br />

boil-off gas (BOG) produced as LNG ships unload.<br />

BOG compressors may also be used during the LNG<br />

storage and transport stages.<br />

Once berthed, LNG ships transfer their product in<br />

liquid form through flexible unloading arms. The<br />

unloading header transfers LNG to the onshore LNG<br />

storage tanks. As the cargo is transferred from the<br />

ship to the storage tanks, radiant heat plus friction<br />

from the pumps adds heat into the pipeline and tank.<br />

This makes some of the liquid boil off and creates<br />

vapour within the LNG tank.<br />

To avoid pressure build up in the onshore tanks,<br />

vapour return blowers connected to the onshore tank<br />

vapour space transfer vapour from these tanks back<br />

to the ship through a vapour return arm. This helps to<br />

minimize vapour pressure increase in the tank, while<br />

maintaining a constant vapour pressure on the ship<br />

during unloading. Depending on pipe diameter and<br />

length, a return gas blower is sometimes needed to<br />

assist this process. <strong>Cryostar</strong>’s integrally geared singlestage<br />

cryogenic compressors have the suitable flow/<br />

head range to fulfil this function.<br />

BOG refers to the LNG vapour produced as a result of<br />

heat input and pressure variations that occur during<br />

various LNG storage and transfer operations. To avoid<br />

loss of product and revenue, while reducing and environmental<br />

impact, <strong>Cryostar</strong> multi-stage centrifugal<br />

compressors recover this BOG, which can then be used<br />

for other purposes. In comparison to reciprocating (or<br />

LNG Tanker<br />

Vapour Return Line<br />

Return Gas Blower<br />

BOG Compressor<br />

Recondenser<br />

screw) compressors,<br />

the multi-stage compressors<br />

are pulsation<br />

free, require very<br />

little maintenance<br />

and are more reliable.<br />

The small amount of<br />

BOG released during<br />

storage is often used as fuel or combined with the<br />

facility’s daily sendout. During transport, although the<br />

cargo compartment is well insulated, a small amount<br />

of LNG vaporizes. Operators can use this boil-off to<br />

auto-refrigerate the remaining LNG, and to supplement<br />

bunker oil as fuel for the tankers. Another alternative<br />

is to recycle boil-off with <strong>Cryostar</strong>’s “Ecorel” reliquefaction<br />

plant back to the storage tanks.<br />

<strong>Cryostar</strong> compressors feature heavy-duty 304 stainless<br />

steel casings with high performance aluminium<br />

or titanium impellers, inlet guide vanes, and a<br />

compact layout incorporating the compressor,<br />

gearbox, drive motor, lube oil and seal gas system<br />

on a single skid. To benefit from lower cost and<br />

shorter delivery times, we recommend choosing<br />

our standard design like the many hundreds of<br />

reference machines already running onboard<br />

LNG ships. <strong>Cryostar</strong> is also happy to offer customised<br />

API 617 execution if required.<br />

LNG Storage Tank<br />

Send-out pumps<br />

10<br />

Autumn 2009


NEWS / TRAINING CENTRE<br />

News<br />

California LNG trucks clean up<br />

This summer saw <strong>Cryostar</strong> complete the first<br />

phase of its Port of Long Beach (POLB) clean<br />

energy fuels project in California. Currently<br />

the largest station of its kind in the world,<br />

POLB fuels up to 300 trucks per day.<br />

POLB together with its neighbour, the Port<br />

of Los Angeles, handles 35 percent of ocean<br />

imports into the US. POLB has implemented<br />

a “Clean Truck Program” which will slowly<br />

eliminate older, polluting trucks from the<br />

port.<br />

Organized and designed by <strong>Cryostar</strong> Automation<br />

(CSA) with support from <strong>Cryostar</strong> USA<br />

(CSUSA), commissioning for the first phase of<br />

the project was carried out during June 2009<br />

and includes the first software developed by<br />

<strong>Cryostar</strong> to control its SubTran LNG submerged<br />

pumps.<br />

<strong>Cryostar</strong> reveals breakthrough LNG technologies<br />

October offers an opportunity for LNG customers to witness <strong>Cryostar</strong> unveiling two new<br />

key products, which the company is confident will revolutionise regasification and fuel gas<br />

supply.<br />

LNG shipping and distribution technology is advancing rapidly, and <strong>Cryostar</strong>’s pioneering<br />

work in this field yields constant <strong>benefits</strong> to customers wishing to stay ahead of the game.<br />

“We are very proud to present and demonstrate two new products to the market on the 14th<br />

and 15th of October 2009, at our headquarters in Hésingue, France,” says <strong>Cryostar</strong>’s Director<br />

Process and LNG, Bernard Mann.<br />

Customers are invited to groundbreaking demonstrations of EcoVap, <strong>Cryostar</strong>’s patented propane<br />

loop regasification process, and also a new HP fuel gas supply system. EcoVap features<br />

a 1MW rated regasification skid with open loop technology, suitable for installation on LNG<br />

RVs and FSRUs.<br />

The HP fuel gas supply system is for two-stroke marine diesel DF engines, and leverages <strong>Cryostar</strong>’s<br />

expertise in supply, installation and control of high-pressure liquid pumping systems.<br />

“These products will change the face of regasification and fuel gas supply as we know it,”<br />

says Mann.<br />

Hydrocarbon <strong>turbine</strong>s for Algeria<br />

June saw <strong>Cryostar</strong> book two major orders worth €7 million for natural gas processing plant <strong>turbine</strong>s for Algerian projects. At El Merk, oil and gas<br />

infrastructure supplier Petrofac put in the order with <strong>Cryostar</strong>, while Italy’s Saipem has bought <strong>turbine</strong>s for project Hassi Messaoud. The orders,<br />

for magnetic bearing <strong>turbine</strong>s model MTC500, will be shipped in the later part of 2010<br />

<strong>Cryostar</strong> Training Centre Catalogue<br />

Scheduled sessions performed at <strong>Cryostar</strong> Training Centre, from January to July 2010:<br />

Jan. Feb. March April May June July<br />

Reciprocating pumps -<br />

Industrial Gases<br />

Reciprocating pumps -<br />

Process Application<br />

week 8<br />

23-25 Feb<br />

week 8<br />

23-25 Feb<br />

week 24<br />

7-11 June<br />

week 24<br />

7-11 June<br />

Centrifugal pumps -<br />

Industrial Gases<br />

Centrifugal pumps -<br />

Process Application<br />

week 4<br />

26-28 Jan<br />

week 4<br />

26-28 Jan<br />

week 18<br />

4-6 May<br />

week 18<br />

4-6 May<br />

TEOB - ECO : Turbo Expander<br />

Oil Bearings - ECO<br />

TEOB - TP : Turbo Expander<br />

Oil Bearings - TP<br />

Compressor loaded expansion<br />

<strong>turbine</strong> - TC<br />

week 11<br />

15-19 March<br />

week 11<br />

15-19 March<br />

week 28<br />

5-9 July<br />

week 28<br />

5-9 July<br />

Turbo expander Magnetic<br />

bearing - MTC<br />

week 17<br />

19-23 April<br />

Other courses (see course chart<br />

on www.cryostar.com)<br />

O N<br />

R E Q U E S T<br />

Specific inquiry O N R E Q U E S T<br />

Autumn 2009 11


© <strong>Cryostar</strong> - all rights reserved<br />

Contact: magazine@cryostar.com<br />

www.cryostar.com

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