Introduction To LNG & Material Used in LNG Services

Introduction to LNG & Material used in
LNG Services
Trainer : Satyapada Mandal

(Process)
Facilities
Introduction
• Operating Cases
• Turndown
60% - 110%
Facilities
Introduction
Some Useful Definition

• Corrosion Resistant Alloy (CRA) : majority being Type 304/304L SS and 316/316L SS.
• MDMT : due to exposure to the lowest possible operating temperature of the process fluid or environment,
auto refrigeration temperatures during depressurization event.
• Low Temperature Carbon Steel (LTCS) is defined as carbon steel that has been impact-tested
• at a temperature colder than (-29°C) as per ASME/ASTM.
• Environmental Assisted Cracking (EAC) is a brittle fracture mechanism, occurs in ductile materials with
SCC, wet H2S, caustic, amine, etc. Major EAC mechanism found as chloride induced SCC of 300 series SS
and amine cracking of CS.
• Cryogenic Temperature/Service is defined as temperatures below -101°C.

Facilities
Introduction
• Typical Feed
Facilities
Introduction
• The presentation focuses on LNG plant process facilities overview in general.

• Theoretical and Technical aspect of Liquefaction and Refrigeration.
• The following parameters will be discussed
• Design intent
• Mechanism
• Design basis
• Equipment/ system description
• Operating Parameters
• Brief of Nominal Material used
• Any information used here are of typical value/diagram/drawing which may differ
from project to project based on design basis, licensors etc.
Facilities
Introduction
1. Pre-treatment
1. Inlet Facilities
2. Feed Gas Conditioning
3. Acid Gas Removal
4. Gas Dehydration
5. Hg Removal
2. Train Fuel Gas System
3. Liquefaction & Refrigeration
4. NGL Recovery & Fractionation
5. Gas Turbine Power Generators System
6. LNG Storage and Loading System
7. LPG Refrigeration, Storage and Loading Unit
8. Refrigerant Storage System
9. Gasoline system
Utilities, Storage & Effluent
1. Storage
2. Utilities
1. Hot Oil System
2. Cooling Water System
3. Emergency Diesel Generator System
4. Common Fuel Gas System
5. Instrument and Plant air system
6. Nitrogen storage and vaporization system
7. Potable Water System
8. Demineralised and Service Water System
3. Effluent
1. Storage
2. Utilities
3. Effluent
1. Effluent and Wastewater System
2. Flare system
Facilities
LNG Plant Brief Overall Diagram
Facilities
Corrosion and Material Selection
Basis
• Feed gas composition.
• Economic and practical considerations (purchasing, constructability, etc.) – total installed cost.
• Maximum normal operations pressure, temperature, pH, velocity, dew point, phase,
• and process fluid composition including contaminants.
• Start-up, shutdown, and upset conditions
• Cyclic service and steam-out operations.
Facilities
Material Degradation Mechanism for LNG Plant
• Carbonic Acid Corrosion by wet CO2

• Sour service by wet H2S
• Amine Corrosion and Cracking
• Caustic
• Environmental Assisted Cracking - Chloride Induced Stress Corrosion Cracking (CI-SCC)
• Chloride pitting corrosion of stainless steels.
• Microbiological Induced Corrosion (MIC)
• Liquid Metal Embrittlement (LME)
• Brittle Fracture in Low-Temperature Service
Facilities
Exclusions
• Protective Coating and Insulation Selection

• Cathodic Protection (CP)
• Chemical Treatment
Facilities
Wet CO2 Corrosion

If H&MBs indicate significant CO2 conc and liquid water, CS may not be acceptable without increasing the
corrosion allowance, application of pH neutralizers, corrosion inhibitors, dehydrators (glycol, methanol),SS
cladding, or a combination of these mitigating tactics.
Wet H2S
Wet hydrogen sulfide (H2S) service as defined by NACE MR0175/ ISO 15156, occurs when a gas stream H2S
partial pressure exceeds 0.3 kPa. The presence of high or low pH can greatly increase the everity/corrosiveness
of sour environments.
Amine Corrosion and Cracking

• Lean amine and rich amine pose corrosive issues. Rich amine solvents charged with the acid gases are
corrosive.
• CS+3mm and velocity less than 2 meters per second for CS in lean amine service.
• Piping of 300 series (+0.4mm) SS is 4 meters per second. Copper containing alloys should never be used in
the amine treating or regeneration units.
Facilities
Carbon or low-alloy steels susceptible to hot amine solutions above approximately 4% by weight(caustic
embrittlement). For all CS equipment and piping in amine service, PWHT after welding needed to mitigate
caustic cracking.
Caustic
• Carbon Steel
• CS is the material of choice for equipment and piping in caustic service for caustic concentrations
below 50% weight with PWHT requirement. At higher temperature, corrosion rates can increase. At
concentrations above 50% caustic is very corrosive to CS, even at ambient temperature.
• Crevice corrosion is a concern when local high caustic concentrations are produced as a result of
heating and/or solution evaporation. For this reason, care in design of heat transfer equipment
(avoiding crevices) is advisable.
• Caustic cracking of highly stressed (e.g., as-welded or as-bent) CS is not anticipated when exposed to
caustic solutions up to 50% weight, at temperatures below 46°C. In the 46 to 82°C temperature range,
cracking is a function of the caustic concentration. Above 82°C, cracking is highly likely for all
concentrations above about 4% wt.
Facilities
Caustic
Nickel Alloy
• Nickel alloys may be used where higher temperatures and caustic concentrations promote corrosion
• greater than 0.1 millimeter. Nickel base alloys offer the best resistance to SCC in caustic solutions. NACE
SP0403 offers guidance in determining the need for PWHT or Nickel Alloys in caustic environments.
300 series SS
• 300 series SS are not generally recommended for caustic service because they offer little advantage over CS.
Their corrosion resistance is only marginally better, and they are also subject to caustic cracking above
approximately 110°C.
Facilities
Chloride Aqs Solution
• Aggressive under certain conditions.
• Mitigated by use of demineralized water for absorber tower washing and solvent make-up.
• The 300 series SS are susceptible to pitting and under deposit corrosion. However, the most
significant threat is from chloride induced-stress corrosion cracking (Cl-SCC) when the operating
temperature is above the threshold temperature for SCC.
To reduce the potential for pitting and Cl-SCC, the following precautions are recommended for
300 series SS.
• 304L/316L series SS materials (e.g., plates, piping, forgings, fittings, etc.) are typically specified to
be supplied in the solution annealed condition in order to minimize residual stresses that can
contribute to CI-SCC.
• Bulk 300 series SS piping components are generally externally coated
• Hydrostatic testing water quality should be controlled to reduce chloride concentration below 50
mg/l for austenitic stainless steel and 100 mg/l for carbon steel.
Facilities
Microbiological Induced Corrosion (MIC)
• MIC has been found in heat exchangers, in the bottom of water storage tanks, piping with
• stagnant or low flow, and in piping in contact with some soils.
• Using well or ground water is especially susceptible to MIC contamination.
• Appropriate material selection, coating, chemical treatment (chlorine, bromine, ozone,
ultraviolet light, or proprietary compounds) should be considered to minimize MIC. Bleach
(NaOCl) is an effective biocide but must be used in the correct concentration (2 mg/l) to
preclude damage to the MOC.
Facilities
Liquid Metal Embrittlement
• Liquid metal (mercury) wetting are the cause of cause of corrosion.
• The major concern for LME in an LNG Plant arises from exposure of aluminum alloys in the cold
box to accumulated mercury from the feed gas. As long as the cold temperature remains below
the freezing point of Mercury, -38.8°C , no LME problems exist. However, at some point the cold
exchangers will be shut down, and reach ambient temperatures, where mercury melts, exists as
a stable liquid, and LME of aluminum alloys can result.
• Mercury Removal Beds are employed to eliminate mercury in gas streams entering the
aluminum exchangers and the cold boxes.
Facilities
Liquid Metal Embrittlement
• Liquid metal (mercury) wetting are the cause of cause of corrosion.
• The major concern for LME in an LNG Plant arises from exposure of aluminIum alloys in the cold
box to accumulated mercury from the feed gas. As long as the cold temperature remains below
the freezing point of Mercury, -38.8°C , no LME problems exist. However, at some point the cold
exchangers will be shut down, and reach ambient temperatures, where mercury melts, exists as
a stable liquid, and LME of aluminIum alloys can result.
• Mercury Removal Beds are employed to eliminate mercury in gas streams entering the
aluminIum exchangers and the cold boxes.
Facilities
Low-Temperature Service and Potential for Brittle Fracture
• The minimum design metal temperature (MDMT) is defined during design in order to allow
material selection for resisting brittle fracture. This is purely a mechanical design requirement
(no corrosion concern).
• MDMT may be based on consideration of the lowest expected operating temperature of any
condition. MDMT may be established as the minimum exemption temperature allowed by the
applicable engineering code.
• MOC’s will be chosen to meet code requirements for brittle fracture mitigation. The philosophy-
• For temperatures warmer than -29°C, carbon steel (CS) is used

• Where temperature is colder than -29°C but warmer than -46°C, low-temperature carbon
steel (LTCS) or impact tested CS is specified
• For temperatures colder than -46°C, Austenitic Stainless Steel is specified
Facilities
Pre-treatment
Inlet Facilities
Design Intent:
1. To remove liquid and solid contaminants from the raw feed gas by means of a Filter Coalescer.
2. To provide a correct fiscal measure in terms of flow and composition of the feed gas by means of
a Metering System.
3. To provide a back‐up source of fuel gas
4. to provide an emergency source of fuel gas to the flare pilots, LNG and LPG tanks
Equipment/System Design Considerations:
1. Feed Gas Filter Coalescer
• To removal efficiency : 99.7% for >=particle size 0.3 microns.
• The maximum liquid hydrocarbon content at the coalescer outlet is 0.1 ppm w/w.
• The pressure drop across the equipment shall not exceed 0.6 bar.
• MOC : Carbon Steel
2. Feed Gas Metering System
As CS with 1.5 mm to 3 mm and in some cases 6 mm for piping & 6 mm.
Facilities
Pre-treatment
Inlet Facilities –
Typical Sketch
Inlet
Facilities
Facilities
Pre-treatment
Feed Gas Conditioning
Design Intent:
1. Smoothening out the pressure fluctuations of the feed gas pipeline upstream the process
2. To increase the natural gas pressure for Acid Gas Absorption by means of a compression station.

• Feed Gas Compressor Suction K.O Drum
• Liquid removal with the efficiency required by the downstream Compressor (99% removal of 10
μm and larger particles and a maximum liquid carry over lower than 3% of gas mass flowrate).
• MOC : CS (Shell) / SS (Internal)
Facilities
Pre-treatment
• Feed Gas Compressor

• The Feed Gas Compressor is a single stage split casing centrifugal compressor, driven by a
variable speed gas turbine Frame 5 and designed to bring the feed gas pressure from 40.4
bara up to 69.05 bara.
• MOC : ASTM A350 LF2 (Casing)
• Compressor Dry Seal Gas System

• Feed Gas Compressor Aftercooler
• CS (tubes) / CS (Shell)
Facilities
Pre-treatment
• Feed Gas K.O Drum
• liquid removal with an efficiency required of 99% removal of 150 μm and larger particles.
• MOC : CS (Shell) / SS (Internal)
• Mercury Adsorber
• To prevent damage of downstream aluminium equipment.
• The Mercury Adsorbent bed is designed to treat an amount of mercury in Natural Gas of 50
μg/Nm³ and to reduce it to less than 10 ng/Nm³.
• MOC : SA-516-70 (Shell) /SS (Internal)
• Treated Gas Filters
• To remove 99.5% of the entrained particles greater than 5 microns.
• MOC : CS (Shell and welded Internals) /SS (Removable Internals)
Facilities
Pre-treatment

….contd
• Feed Gas Compressor Turbine Driver
• MOC : Mft. Standard
• Fuel Gas Scrubber
• Lube Oil Auxiliary System
• Lube Oil Vapour Separation
• Lube Oil Purifier
• Fire Fighting System
Facilities
Pre-treatment
- Typical Sketch
Feed Gas
Conditioning
Facilities
Pre-treatment
Acid Gas Removal
Design Intent:
1. To reduce the content of CO2 to a concentration lower than 50 ppm vol.
2. To prevent damage d/s equipment since CO2 can freeze at low temperature causing possible
blockages in the cryogenic section.
Facilities
Pre-treatment
Acid Gas Removal
• Absorbent : The aqueous solution of aMDEA.
• May require alloy upgrades, increased corrosion allowances, and process controls to
minimize corrosion.
• For lean amine (prior to exposure to acid gas) service, all CS welds in piping and vessels
should be post weld heat treated (PWHT). The lean amine circuit is fabricated from CS with
3 mm corrosion allowance (CA), and in some cases a larger CA may be specified. In CS
piping, the fluid velocity is limited 1.8 meters/second to reduce flow assisted corrosion.
• Piping in rich amine streams are generally specified as 304/304L SS.
• Material choice should therefore be NACE MR0175/ISO15156 compliant.
Facilities
Pre-treatment
Acid Gas Removal
• Major Equipment
• Acid Gas Absorber
• MOC : CS (Shell) SS 304 / 316(Internals)
• Rich Solvent Flash Drum
• MOC : CS (Shell and Welded Int.) ; SS 304 / 316 (Internals)
Facilities
Pre-treatment
Acid Gas Removal
• Solvent Regenerator
• MOC: CS (Shell) / SS 304 L (Internals - clad for column top section approx. 6 m)
• Regenerator Condenser
• Regenerator Reflux Drum
• MOC : SS 316 /SS 304 / 316 (Internals)
• Regenerator Reboiler
• MOC : CS (Channel) SS 316 (Tubesheet and Tubes) CS + 6 mm (Shell)
Facilities
Pre-treatment
Acid Gas Removal
• Anti-Foam Injection Package
• Lean Solvent Pumps
• MOC : SS 304 (Case) / SS 304 (Internals)
• AGRU Off Gas K.O. Drum
• MOC : SS 316 (Shell) ; SS 304 / 316 (internals)
• Sour Water Drain Pumps
• MOC : 316L (Case) ; 316L (Impeller)
Facilities
Pre-treatment
Acid Gas Removal
• Incinerator Fuel Gas K.O. Drum
• MOC SS 316 (shell) ;SS 304 / 316 (internals)
• Acid Gas Incinerator Package
• MOC : A36 CS (Incinerator Case) ; A36 CS (Burner Chamber & Exiting Duct and Stack)
• Solvent Drain Drum
• MOC : ASTM A516 Gr.70 (Shell)/SS 304 / 316 (Internals)
• Solvent Drain Pump
• Solvent Charged Filter
• Skim Oil Pump
Facilities
Pre-treatment
Acid Gas Removal
CO2 and H2S removal stage

CO2 would not exceed 50 ppm in the natural gas feed. If the composition of CO2 exceeded that
limit it would freeze in the liquefaction process pipelines.
Solvent Selection
Sulfinol does not work well with rich natural gas (rich with heavy hydrocarbons) because it
tends to attract or attach to heavy hydrocarbons and then it drags the heavies to the sulfinol
pump or circulation which leads to allowing the heavy hydrocarbons to vent into the air.
Activated MDEA (BASF) is selected for better selectivity, lower concentration, better absorption
and handling.
Facilities
Pre-treatment
Acid Gas Removal
• AGRU Off Gas K.O. Drum
-Protects the Acid Gas Incinerator Package from any liquid carry over.
• Acid Gas Incinerator Package
-Forced draught type
-Thermally oxidized in the Acid Gas Incinerator by means of fuel gas.
Facilities
Pre-treatment
Acid Gas Removal –Typical sketch
Acid Gas
Removal
Facilities
Pre-treatment
Gas Dehydration
Design Intent
To reduce NG water content (upto 0.5 ppm vol) coming from the Acid Gas Removal system to avoid
freezing of water in downstream cryogenic system. . The natural gas feed should be completely dry,
even from the smallest traces of water molecules (<0.01Microgram/m3), before entering the heavy
duty cooling section of the liquefaction process.
• Major Equipment/packages
• Driers Precooler
• Driers Inlet Separator
liquid removal efficiency of 99% of 10 micron and larger particles, with maximum liquid
content equal to 0.1 ppm (wt), and 0.05 bar maximum allowable pressure drop.
• Molecular Sieve Driers
• Dried Gas Filters
Facilities
Pre-treatment
Molecular Sieve
Design Intent
Used in LNG plant.
Although TEG removes H2O significantly from the natural gas, small amount of water traces still escape this process;
so to insure that these traces do not accompany the natural gas feed, molecular sieves are used to serve this purpose.
Facilities
Pre-treatment
Hg Removal
Design Intent
Hg causes corrosion in the expensive Aluminum LNG heat exchangers used in the liquefaction
process. For example, 10 ng/m3 (nano gram per m3) are enough to cause a catastrophe. The
activated bed filter that is used in the Hg filtration is inexpensive and it is replaced on an average of
once every four years.
Facilities
Pre-treatment
Gas Solid Particle Filtration
Design Intent
To insure that the natural gas feed is free from small solid particles which might cause a clog in the
pipes of the liquefaction process or damage the heat exchangers.
Facilities
Pre-treatment
Gas Dehydration –Typical sketch
Gas Dehydration
Facilities
Pre-treatment
Dehydration
Material of Construction of Major equipment:
Since no CO2 or water is present, CS with minimal corrosion allowance is used for downstream
equipment and piping.
• REGENERATION GAS HEATER : CS (Shell) /CS (Tube)
• REGENERATION GAS COOLER : 2205 DSS (Bare Tubes) CS (Headers) Aluminum (Fins)
• DRIERS AIR PRECOOLER : 2205 DSS (Bare Tubes) / CS (Headers)
• MOLECULAR SIEVE DRIER : SA-516-70N
• REGENERATION GAS K.O. DRUM :SA-516-70 (Shell) ;CS (Welded Int.) SS (removable Int.)"
Facilities
Train Fuel Gas System
Design Intent:
1. HP Fuel Gas supply to
• Regeneration gas for Molecular Sieve Driers, Common fuel gas users
• Feed Gas Compressor GTG
• LP/MP MR Compressor GTG
• Main Propane / HP MR Compressor GTG
• Residue Gas Compressor GTG
• Auxiliary Propane Compressor GTG
2. LP Fuel Gas supply to
• Fuel Gas K.O. Drum for Hot Oil Furnace
• Incinerator Fuel Gas K.O. Drum and Acid Gas Incinerator Package
• Pentane Sidedraw Drum for blanketing purposes
Facilities
System Considerations
Two different fuel gas systems:
• A fuel gas system inside each process train with its own distribution network . Sourced from
• End Flash Gas (EFG) from Liquefaction Unit ;
• Boil Off Gas (BOG) from LNG Storage Unit.
• A fuel gas system common to trains for offsite and common users with its own distribution
network.
• System is designed to supply and distribute to users at their battery limit HP fuel gas at around
25.5 barg and LP fuel gas at 5.0 barg.
• Fuel gas back‐up sourced from
• the feed gas at the inlet of the process train
• the residue gas at the inlet of the Liquefaction unit;
• the fuel gas from the Common Fuel Gas System
Facilities

1. HP Fuel Gas users
2. LP Fuel Gas users
Facilities
Liquefaction & Refrigeration process
Design Intent
The purpose of Liquefaction & Refrigeration is to produce Liquefied Natural Gas (LNG) on specified
markets quality, and a crude helium stream.
System Design consideration

Liquefaction & Refrigeration consists of 4 circuits
1. Natural Gas Circuit
2. End Flash Gas Circuit
3. Propane Refrigeration Circuit
4. Mixed Refrigerant Circuit
Facilities
Typical diagram(brief)
Facilities
Refrigerant fluid choice:

We now turn our attention to the fluids. Usually, one tends to pick pL as low as possible, but not below atmospheric
pressure. Thus, the refrigerant chosen needs to have a normal boiling point compatible with the lowest
temperature of the cycle (usually 10oC lower than the system one wants to cool). The higher pressure needs to be
compatible with the cooling media used for qH. If this is cooling water, then the TH needs to be around 10oC higher
than the available cooling water temperature. The next table shows the existing refrigerants. It is followed by the
boiling temperature and rang of selected refrigerants..
Facilities
Heat
Liquefaction &
Sink Carnot Cycle:
Refrigeration process TH QH=m.q
Ideal in its refrigeration (Carnot COP=qL/w = TL/(TH-TL) (first law)
H
cycle):
d c qL=TL/s, qH=TH. s (2nd law)
d c W(net)=m.
expander w w is also given by the area of the
w rectangle.
a b
compressor COP varies with TL (TH is ambient in
q Prime this case) and the temperature difference
mover in exchangers.
L
m
a b
QL=m.q
Specific TLL
entropy Heat
Sourc
e
Facilities
Real one stage refrigeration cycle : Dry Cycle:

- To be able to achieve the best match
possible with the rectangular shape it is
necessary to operate inside the two
phase region.
- Compression is in this example
performed outside the two phase
region. Creating a “horn”, which is not
thermodynamically advisable, is
mechanically better. For this
reason, this cycle is called “dry” cycle.
Facilities
Wet Cycle:
The expander has been substituted by a throttling
valve. If an expander had been used the line from
d to a would be a vertical line. This is also done
for mechanical reasons.
Facilities
Wet Cycle:
The expander has been substituted by a throttling
valve. If an expander had been
used the line from d to a would be a vertical line.
This is also done for mechanical reasons.
Facilities
Typical Sketch –
Two Stage Refrigeration
Facilities
Natural Gas Circuit
Design Intent
To produce Liquefied Natural Gas (LNG) on specified markets quality, and a crude helium stream.
• Precooling
• Residue Gas / HHP Propane Cooler
• Residue Gas / HP Propane Cooler
• Residue Gas / MP Propane Cooler
• Residue Gas / LP Propane Cooler
• Main Cryogenic Heat Exchanger
• LNG Liquid Expander
• Helium Recovery Drum
• Nitrogen Stripping Column
• LNG Product Pump
Facilities
Natural Gas Circuit
Material of Construction
• No internal corrosion mechanisms are active in this unit. The most critical factor for
MOC will be the MDMT. Brittle fracture has been mitigated by the use of aluminium and
304L SS.
Facilities
Facilities
Facilities
Facilities
Facilities
Facilities
Propane Refrigeration Circuit
Design Intent
To provide cooling to MR and Natural Gas circuit.
Major equipment
• LP Main Propane Suction Drum
• MP Main Propane Suction Drum
• HP Main Propane Suction Drum
• HHP Main Propane Suction Drum
• Main Propane Compressor
• Main Propane Desuperheater
• Main Propane Condenser
• Main Propane Accumulator
• Main Propane Accumulator Top Condenser
• Main Propane Subcooler
Facilities

Major equipment
• Main Propane Subcooler
• Main Propane Drain Pump
• Main Propane Drain Pump Motor
• Main Propane Transfer Pump
• Main Propane Transfer Pump Motor
• Main Propane Transfer Drum
Facilities
3) Liquefaction & Refrigeration process
Material Of Construction
• No internal corrosion mechanisms are expected for the propane system.
• CS piping is restricted to -29°C (-20 °F) whereas LTCS is selected for temperatures below -
29°C.
• For temperatures colder than -45.6°C, 304L SS should be been chosen because of improved
ductile-brittle transition at low temperatures.
• Similarly, aluminum cores are not susceptible to low-temperature to brittle fracture.
• Major MOC
• RESIDUE GAS HHP/ HP/MP/LP PROPANE COOLER : LTCS (Shell) /LTCS (Tube)
• MAIN CRYOGENIC HEAT EXCHANGER : Aluminum
Facilities
• END FLASH COLD BOX : Aluminum
• LP/MP/HP END FLASH COMPRESSOR AFTERCOOLER : CS (Bare Tubes) / CS (Headers)
• NITROGEN STRIPPING COLUMN : 304L SS (Shell) 304L SS (Internal)

• PACKINGS FOR NITROGEN STRIPPING COLUMN : 304L SS (Shell) /304L SS (Internal)
• HELIUM RECOVERY DRUM :304L SS (Shell) /304L SS (Internal)
• END FLASH COMPRESSOR : MOC Manufacturer's standard materials for the intended services
• END FLASH COMPRESSOR Manufacturer's standard materials for the intended services
• LNG LIQUID EXPANDER : MFR STD MAT
• LNG PRODUCT PUMP MFR STD MAT
• LNG PRODUCT PUMP MFR STD MAT
Facilities
Mixed Refrigerant Circuit
Design Intent
Final cooling and sub-cooling service to produce LNG in MCHE.

• LP MR Suction Drum
• LP MR Compressor
• Lube Oil Cooler skid
• LP MR Compressor Intercooler
• MP MR Compressor
• Helper / Starter Motor
• MP MR Compressor Intercooler
• HP MR Suction Drum
• HP MR Compressor
Facilities
Design Intent
Final cooling and sub-cooling service to produce LNG in MCHE.

• HP MR Compressor Aftercooler
• MR/HHP Propane Cooler
• MR/HP Propane Cooler
• MR/MP Propane Cooler
• MR/LP Propane Cooler
• HP MR Separator
• MCHE-MR SIDE
• MR Liquid expander
Facilities
• LP MR COMPRESSOR INTERCOOLER : CS (Bare Tubes)/CS (Headers)
• LTCS
• MP MR COMPRESSOR INTERCOOLER : LTCS (Bare Tubes) / LTCS (Headers)
• HP MR COMPRESSOR AFTERCOOLER : LTCS (Bare Tubes) /LTCS (Headers)
• MR/ HHP PROPANE COOLER : LTCS (Tube) /LTCS (Shell)
• MR/ HP PROPANE COOLER : LTCS (Tube) /LTCS (Shell)"
• MR/ MP PROPANE COOLER : LTCS (Tube) /LTCS (Shell)
• MR/ LP PROPANE COOLER : LTCS (Tube) /LTCS (Shell)
• MAIN PROPANE CONDENSER :LTCS (Bare Tubes) /LTCS (Headers)
• MAIN PROPANE SUBCOOLER : LTCS (Bare Tubes) /LTCS (Headers)
• MAIN PROPANE DESUPERHEATER :LTCS (Bare Tubes) /LTCS (Headers)
Facilities
• LP MR SUCTION DRUM : 304L SS (Shell) /304L SS (Internals)
• LP MAIN PROPANE SUCTION DRUM : LTCS (Shell)/SS (Internals)
• MP MAIN PROPANE SUCTION DRUM : LTCS (Shell) /SS (Internals)
• HP MAIN PROPANE SUCTION DRUM : LTCS (Shell) /SS (Internals)
• HHP MAIN PROPANE SUCTION DRUM : LTCS (Shell)/SS (Internals)
• MAIN PROPANE ACCUMULATOR : LTCS (Shell)/LTCS (Internals)
• MAIN PROPANE TRANSFER DRUM : LTCS (Shell)/LTCS (Internals)
Facilities
• HP MR SUCTION DRUM : LTCS
• MAIN PROPANE ACCUMULATOR TOP COLUMN : LTCS
• LP MR COMPRESSOR : MFR STD MAT
• MP MR COMPRESSOR : MFR STD MAT
• HP MR COMPRESSOR : MFR STD MAT
• MAIN PROPANE COMPRESSOR : MFR STD MAT
• MAIN PROPANE TRANSFER PUMP : MFR STD MAT
• MR LIQUID EXPANDER : MFR STD MAT
• MAIN PROPANE DRAIN PUMP : MFR STD MAT
Facilities

1. Major Systems
• c 1 – Propane Refrigerant (PR) system provides chilling to about ‐35o C for the Natural Gas
circuit, and the MR system.
• 2 – Mixed Refrigerant (MR) system provides the low temperature refrigeration to produce
the LNG in the MCHE
2. Brief Description
• The gas is first cooled from 30°C to 13.7°C in the HHP Propane Cooler, then is cooled down
again to ‐3.2°C in the HP Propane Cooler, furthermore is cooled to ‐19.5°C in the MP Propane
Cooler and finally to about ‐33°C in the LP Propane Cooler.
• Cold natural gas from propane coolers is then fed to the bottom of the MCHE where it is
liquefied against Mixed Refrigerant (MR).
• The MCHE contains two bundles: the warm bundle at the bottom and cold bundle at the top.
The LNG exits the cold bundle at the top of the MCHE at ‐145°C
Facilities
Cont…
1. Major Systems
2. Brief Description
• Pressure reduction uptp 2 barg in LNG Liquid Expander.

• Final pressure let down of the LNG is performed by a back pressure control valve located
downstream the expander.
• The LNG product is sent to the Helium Recovery Drum, where the LNG Liquid is flashed.
• From the bottom of Helium Recovery Drum, the LNG finally feeds the top of the Nitrogen
Stripping Column which operates at 0.15 barg and about ‐160 °C. The purpose of the
Nitrogen Stripping Column is to reduce Nitrogen content in the produced LNG.
• Lastly, by means of the LNG Product Pump , the LNG flows to the LNG Storage Tanks.
Facilities
C3MR Process
OVERVIEW
• Considerations for the design of an LNG plant.
• Overview of a typical LNG plant.
• Introduce Mechanical refrigeration
• Explain the arrangement of the C3MR process.
Facilities
TYPICAL BLOCK DIAGRAM-LNG LIQUIFACTION:
LPG
FRACTIONATION Product
Feed Gas LPG AND
GASOLINE Gasoline
ACID GAS HIGH LEVEL DEHYDRATIO FRACTIONATIO

REMOVA CHILLING N& CHILLIN N(NGL UNIT)
L MERCURY G
REMOVAL LIQUIFACTION
(MAIN
REFRIGERATION CRYOGENIC
HEAT
EXCHANGER)
Facilities
TYPICAL BLOCK DIAGRAM-LNG LIQUIFACTION:
3.9
From Residue bar(A) –
compressor -33°C -145°C 160°C)
HHP/ MCHE LNG LIQ HELIUM Nitrogen LNG LNG
HP/MP/LP EXPANDE RECOVER Stripping PUMP STORAGE
propane R Y DRUM Column TANK
cooling
Facilities
Fundamentals
Steps:
The natural gas usually enters the
liquefaction process from pretreatment at
about 37C (above point A)
Feed is cooled down to about 15C by either
air or water coolers.
Propane is usually used to cool the NG to
about 4C and this is where most of the water
traces is condensed and knocked out of the
NG by flashing.
Then the NG is cooled down to its dew
point (B) and further to its bubble point (C)
and it is sub-cooled to a certain temperature
(point D) after which it is depressurized to
atmospheric pressure through a valve. The
final temperature is about -160C (point E)..
Facilities
Fundamentals
.
Facilities
Fundamentals
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Facilities
Fundamentals
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Facilities
Fundamentals
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Facilities
Fundamentals
Steps:
One very useful tool in gas liquefaction is the
cooling curve. Such curve is shown for a
capacity of 4.5 mtpa.
Facilities
Fundamentals
Facilities
However, real processes cannot be
Fundamentals built to exactly follow the cooling
curve, and therefore, need to have
temperatures below the curve. Thus,
the closer the refrigeration heating
curve to the LNG cooling curve, the
more efficient the process is.
The area between the LNG cooling curve
(orange line above) and the refrigeration
heating curve (green line) represents the
amount of heat lost during the liquefaction
process. The area above the refrigeration line
represents the amount of work done by the
system and the closer the lines are to each
other the less work the system has to do. The
figure above corresponds to the MR process,
in which a mixed refrigerant is used.
Facilities
Fundamentals
Note:
Pure refrigerant-based Phillips cascade is shown
below.
Facilities
Fundamentals
Overview of liquefaction processes
The APCI (Air Products and Chemicals Inc.) process, also called Propane Pre-cooled Mixed
Refrigerant Process (PPMR) currently holds 88% of the liquefaction plants on the market.
Their technology uses a three stage refrigerant cooling powered by two 85 MW Frame 7
compressors.
Stage -1 :Pre- propane cooling stage

The first stage is a pre- propane cooling stage that cools the mixed refrigerant and inlet treated gas
to around 1.6C.
Stage -2,3 : Mixed refrigerants (MR)

The next two cooling stages, held in a heat exchanger tower, use mixed refrigerants (MR) of about
27% methane, 50% ethane, 20% propane, 2% Butane ,and 1% nitrogen to cool and condense the
natural gas. The flowsheet is shown in the next figure:
Facilities
Fundamentals
.
Facilities
Fundamentals
.
Facilities
Liquefaction & Refrigeration process The overall process
APCI – Process requires around
150000 kw out of the
three Frame 7
compressors and the
heat exchangers in the
tower are Spiral
Wound Heat
Exchangers (SWHE).
Facilities
……
Concern:
While APCI controls the majority of liquefaction plants in operation today, their older designs have
limitations. As stated earlier, APCI uses Frame 7 compressors with a rating of about 85 MW. Being
so large, Frame 7 compressors only have one vendor that makes them (GE).
Additionally, the use of large compressors raises reliability concerns. If one compressor goes down,
production halts until the problem is fixed. Another disadvantage of having a large compressor is
that it is only sufficient for large flow and it can not handle low flow rates (less than 1000 BCFD).
The heat exchanger tower, SWHE are manufactured only by Linde. If any clog or freezing occurs in
one of the heat exchanging streams then the whole process is stopped until the problem is fixed.
Facilities
……
Concern:
Boil of gas (BOG) compressors.
The BOG compressors are usually installed close to the LNG tank, in order to recover gas vapors
that boil off from the LNG tank. The BOG is usually driven by an electric motor, and the compressor
may be a horizontally split machine or an integral compressor design.
The most critical aspects of this compressor are the very low operating temperature (−
120°C/−161°C) and the design aspects associated with it in terms of materials, dry gas seals, inlet
guide vanes and in the case of some integral-type compressors, diffuser guide vanes. In some LNG
processes, the BOG compressor may have to compress the BOG from close to atmospheric
pressure to fuel gas pressure which in the case of some aeroderivatives can range from 40 to 60
bar. In these cases, centrifugal multistage machines may be used and variable IGVs are often used
for flow control.
Facilities
LNG Physical Properties
Facilities
NGL Recovery & Fractionation
Purpose:
• Sufficient quantities of recovered propane are used to satisfy refrigerant make up requirement for
fractionation and recovery Unit.
• Sufficient quantity of recovered Ethane gas is used as fuel gas.
• Recovered propane and butane are used as reinjection at upstream of main cryogenic exchanger.
• NGL Recovery Unit is intended to recover C2+ in the Demethanizer Column from NGL feed for
Base Case.
Facilities
Facilities
1. Major Systems
• NGL Recovery Section
• NGL Fractionation Section
• Auxiliary Propane Refrigeration Section
2. NGL Recovery Section

• XXXXXX
Facilities
1. Major Systems
• NGL Recovery Section
• NGL Fractionation Section
• Auxiliary Propane Refrigeration Section

3. NGL Fractionation Section
• DEETHANIZER COLUMN
• Operates at 12.2°C/32.5 bara at top and 90.2°C/33.3 bara at bottom and is designed to
achieve a high ethane recovery (the minimum C2 purity is 96% molar) from the feed.
• This column is fed by the liquids (NGL) separated in the bottom of the Demethanizer
column.
Facilities

1. Major Systems
• DEPROPANIZER COLUMN
Operates at 48.0 °C/16.7 bara at top and 102.6 °C/17.3 bara at bottom is designed to
propane product from the C4 fraction of the NGL. Moreover, the Depropanizer is designed
to provide on‐spec propane refrigerant necessary for the make‐up of Auxiliary Propane,
Main Propane and MR Circuits.
Facilities

1. Major Systems
• DEPROPANIZER COLUMN
• DEBUTANIZER COLUMN
Designed to produce a mixed butanes overhead product (the minimum C4 fraction purity
is 97.99% molar) and the pentanes/gasoline products from the column side/bottom. If C6
is present in the column feed (rich case only), the C5 is extracted as side stream and the
gasoline is extracted as bottom stream; otherwise no side stream is extracted and C5 is
extracted as bottom stream. For Lean Case composition the Debutanizer Column is OUT
OF SERVICE.
Facilities

1. Major Systems
4. Auxiliary Propane Refrigeration Section
• Besides the main process facilities, dedicated to the recovery and the fractionation of the
NGL, an Auxiliary Propane refrigerant close loop has been provided in order to ensure the
cooling requirements of NGL Recovery & Fractionation.
• The refrigeration is achieved using propane at two different pressure levels:
• medium pressure (MP) at 3.9 bara/‐6.3°C
• low pressure (LP) at 1.4 bara/‐34.8°C.
Facilities
Gas Turbine Power Generators System
Purpose:
• Provides the electric power to the LNG train and its associated utilities and offsites units.
• During normal operation the gas turbines are the sole source of electrical power for the LNG
trains and their offsite and utility facilities.
• They are designed to burn fuel gas normally supplied from LNG Trains.
• They are also designed to burn feed gas during start‐up operation.

1. The electric power is generated by Frame 6 GTGs.
2. xxxx
1. Storage
1. Amine Solvent Storage
2. Hot Oil Storage
3. LNG Storage and Loading System
4. LPG Refrigeration, Storage and Loading Unit
5. Refrigerant Storage System
6. Gasoline system
7. Amine Solvent Storage
8. Hot Oil Storage
2. Utilities
3. Effluent
1. Storage
2. Utilities
1. Hot Oil System
2. Cooling Water System
3. Emergency Diesel Generator System
4. Common Fuel Gas System
5. Instrument and Plant air system
6. Nitrogen storage and vaporization system
7. Potable Water System
8. Demineralised and Service Water System
3. Effluent
1. Storage
2. Utilities
3. Effluent
1. Effluent and Wastewater System
2. Flare system
Flare Syetm
Flares System MOC
• Wet gas flare stack
• Designed to handle saturated HC with water vapor and/or contain free
liquid hydrocarbons and water. The MOC are CS due to a MDMT of -
29°C (-20°F) for stack.
• Dry gas flare stack
• Designed to handle cryogenic hydrocarbons, both vapor and liquid. The
MOC is 304L SS due to a MDMT of -196°C (-320°F) for stack.
• Marine flare
• Designed to handle LNG vapors from the LNG storage tank in the event
of a failure of the Boil-Off Gas Compressors. The MOC is 304L SS due to
a MDMT of -196°C for stack.
• Acid Gas Thermal Oxidizer
• Designed to handle Acid Gas streams that are vented from all Gas Train
processes. The 304L SS cladding is impervious to wet CO2 corrosion.
QA
&
Thank You!
10
3
DISCLAIMER
This presentation has been prepared by a representative of Worley.
The presentation contains the professional and personal opinions of the presenter, which are given in good faith. As such, opinions presented herein may not always necessarily reflect the position of Worley as a whole, its officers or executive.
Any forward-looking statements included in this presentation will involve subjective judgment and analysis and are subject to uncertainties, risks and contingencies—many of which are outside the control of, and may be unknown to, Worley.
Worley and all associated entities and representatives make no representation or warranty as to the accuracy, reliability or completeness of information in this document and do not take responsibility for updating any information or correcting any error or omission that may become apparent after this document has
been issued.
To the extent permitted by law, Worley and its officers, employees, related bodies and agents disclaim all liability—direct, indirect or consequential (and whether or not arising out of the negligence, default or lack of care of Worley and/or any of its agents)—for any loss or damage suffered by a recipient or other
persons arising out of, or in connection with, any use or reliance on this presentation or information.
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Introduction to LNG & Material used in

Trainer : Satyapada Mandal

Some Useful Definition

• Cryogenic Temperature/Service is defined as temperatures below -101°C.

• The presentation focuses on LNG plant process facilities overview in general.

Material Degradation Mechanism for LNG Plant

• Carbonic Acid Corrosion by wet CO2

• Protective Coating and Insulation Selection

Wet CO2 Corrosion

Amine Corrosion and Cracking

• For temperatures warmer than -29°C, carbon steel (CS) is used

Equipment/System Design Considerations:

Equipment/System Design Considerations:

• Feed Gas Compressor

• Compressor Dry Seal Gas System

Equipment/System Design Considerations:

CO2 and H2S removal stage

Equipment/System Design Considerations:

System Design consideration

Refrigerant fluid choice:

Real one stage refrigeration cycle : Dry Cycle:

System Design consideration

• NITROGEN STRIPPING COLUMN : 304L SS (Shell) 304L SS (Internal)

System Design consideration

System Design consideration

Equipment/System Design Considerations:

• Pressure reduction uptp 2 barg in LNG Liquid Expander.

ACID GAS HIGH LEVEL DEHYDRATIO FRACTIONATIO

TYPICAL BLOCK DIAGRAM-LNG LIQUIFACTION:

Stage -1 :Pre- propane cooling stage

Stage -2,3 : Mixed refrigerants (MR)

2. NGL Recovery Section

2. NGL Recovery Section

Equipment/System Design Considerations:

Equipment/System Design Considerations:

Equipment/System Design Considerations:

Equipment/System Design Considerations:

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