CLASSIFICATION NOTES

No. 61.2

LNG BOIL-OFF RE-LIQUEFACTION PLANTS AND GAS COMBUSTION UNITS

MAY 2006

DET NORSKE VERITAS

Veritasveien 1, NO-1322 Hvik, Norway Tel.: +47 67 57 99 00 Fax: +47 67 57 99 11

FOREWORD
DET NORSKE VERITAS (DNV) is an autonomous and independent foundation with the objectives of safeguarding life, property and the environment, at sea and onshore. DNV undertakes classification, certification, and other verification and consultancy services relating to quality of ships, offshore units and installations, and onshore industries worldwide, and carries out research in relation to these functions. Classification Notes Classification Notes are publications that give practical information on classification of ships and other objects. Examples of design solutions, calculation methods, specifications of test procedures, as well as acceptable repair methods for some components are given as interpretations of the more general rule requirements. A list of Classification Notes is found in the latest edition of Pt.0 Ch.1 of the Rules for Classification of Ships and the Rules for Classification of High Speed, Light Craft and Naval Surface Craft. The list of Classification Notes is also included in the current Classification Services Publications issued by the Society, which is available on request. All publications may be ordered from the Societys Web site http://exchange.dnv.com.

Motives New propulsion systems for the latest generation of LNG Carriers introduce reliquefaction plants and gas combustion units for handling the boil-off. This is as an alternative to the traditional arrangements where the boil-off is burned as fuel in boilers. Several LNG carriers now on order will be fitted with re-liquefaction and gas combustion units (incineration). DNV has felt a need to establish guidance for these installations in the form of a new Classification Note (No 61.2). In the not too distant future introducing requirements for these installations in the Rules for Classification of Ships will be considered, but only after having gained more experience with such installations. Thus, in the meantime applicable DNV expectations on new ships to re-liquefaction plants and gas combustion units for handling of LNG "boil-off" are outlined in the Classification Note 61.2.

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Classification Notes - No. 61.2 May 2006

CONTENTS
1. 1.1 1.2 2. 2.1 2.2 3. 3.1 GENERAL................................................................. 4 Introduction................................................................4 Scope ...........................................................................4 ARRANGEMENT .................................................... 4 Re-liquefaction systems .............................................4 Gas combustion unit ..................................................5 MATERIALS, MANUFACTURE, INSPECTION AND TESTING......................................................... 6 Materials.....................................................................6 3.2 3.3 3.4 4. 4.1 4.2 4.3 Piping design and manufacture ............................... 6 Certification of components ..................................... 7 Strength testing.......................................................... 7 MONITORING AND CONTROL ......................... 7 General ....................................................................... 7 Extent of monitoring of re-liquefaction plants ....... 7 Monitoring of GCU ................................................... 7

DET NORSKE VERITAS

Classification Notes - No. 61.2 May 2006

1. General
1.1 Introduction
An alternative to using LNG boil-off gas as fuel in steam boilers, gas turbines or combustion engines is to re-liquefy the vapour and return the LNG to the cargo tanks. The IGC Code requires two means for disposal of the boil-off gas and in the case of re-liquefaction is the primary means the secondary means is typically a Gas Combustion Unit (Thermal Oxidizer) where the boil-off gas is burned and the combustion gas cooled and exhausted to atmosphere.

2. Arrangement
2.1 Re-liquefaction systems
Fig.2-1 and Fig.2-2 show two examples of re-liquefaction systems. The system in Fig.2-1 (Moss Maritime / Hamworthy) uses a nitrogen refrigerant cycle. The nitrogen is compressed in three stages with inter-cooling, then pre-cooled in the cold box and expanded through a rotary expander from about 57 bar pressure to 14 bar. By this expansion the temperature of the nitrogen falls to 163C (Joule-Thompson effect). The cold nitrogen is lead to the cold box where it cools the boil-off gas which has been compressed to about 4.5 bar of pressure in the low duty compressor. The condensed boil-off gas is lead to a liquid receiver where the LNG is collected and the non-condensable gases, mainly nitrogen, is vented. The vented gases are either returned to the vapour main or directed to the gas combustion unit (GCU) for incineration. Venting to the atmosphere is normally not permitted since the contents of methane gas in the vented gas is 20-25% at 4.5 bar of pressure in the liquid receiver.

1.2 Scope
This class note outlines requirements for classification of reliquefaction installations and gas combustion units. Since the installations may differ in arrangements and equipment the requirements outlined may be subject to adjustments to suit the particular installations.

Figure 2-1 Re-liquefaction system (Moss Maritime / Hamworthy)

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Classification Notes - No. 61.2 May 2006

Boil - Off Gas

CW

Vent

BOG Compressor Skid

Cold Box
Flash pot LNG

Load heat exchanger

N2 heat exchanger

CW

N2 rejection column

CCNR Skid

Nitrogen (make - up)

Figure 2-2 Re-liquefaction system (Air Products) process flowsheet

The system in Fig.2-2 (Air Products) is also utilizing a nitrogen refrigerant cycle. The main difference is that while the system in Fig.2-1 achieves the temperature reduction through expansion of the nitrogen alone, the system in Fig.2-2 utilizes the J-T effect both by expansion of the nitrogen and by expansion of the boiloff gas. For this reason the boil-off gas has to be compressed to about 40 bar. After cooling in the cold box (load heat exchanger) the gas is expanded into the N2 rejection column at a pressure of 20 bar.

In the N2 rejection column, cooling of the gas mixture in the packed bed by liquefied gas brings the methane content in the vented gas down to about 5%. With this low methane content the gas may be vented to atmosphere.

2.2 Gas combustion unit

Disposal of boil-off gas may be done by incinerating the gas in a gas combustion unit (GCU). Examples of GCUs for marine use are shown in Fig.2-3 and Fig.2-4.

Mixing device

Funnel Full metallic Air cooled combustion chamber

Self checking Flame detection system

UV

Gas burner Spark igniters (2) Man Hole BOG Diaphragm Air room Combined combustiondilution air fans (3 or +) Constant flow Block & Bleed Valves Control Valve

Figure 2-3 Gas combustion unit - (Snecma Moteurs)

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Classification Notes - No. 61.2 May 2006

Examples
AIR JETS FOR MIXING

Propulsion Primary Diesel Re-liquefaction Diesel Re-liquefaction

Secondary Re-liquefaction GCU

DILUTION AIR FAN

DILUTION AIR FAN

100% STAINLESS STEEL, TWIN SHELL CONSTRUCTION

Diesel

GCU

GCU

REGISTER BURNER WITH DUAL SWIRLER TECHNOLOGY Vent

COMBUSTION AIR FAN (2)

BOG
Double Block & Vent Valves Control Valve

Dual fuel diesel electric

GCU

GCU

Hamworthy Combustion AMOxsafe GCU

International Patent Number PCT / GB 2005 / 004362 pending

Figure 2-4 Gas combustion unit - (Hamworthy Combustion)

The unit consists of an outer and an inner steel cylinder. The inner cylinder is the combustion chamber with gas burners and igniters. Some designs may use pilot burners for ignition while others, as in the example, use direct spark ignition. The combustion chamber has no refractory but is cooled by air flowing in the space between the inner and the outer cylinder. The supply of air for cooling and combustion may be by combined fans, or by separate fans for combustion air and cooling and dilution air. The bulk average exit temperature of the combustion gas must be kept well below 500C in order not to ignite any possible leakages of methane gas and also to avoid excessive heat radiation to surrounding installations. Localised maximum peak temperatures must not exceed 535C. The reduction of gas temperature is achieved by diluting the gas by air before exiting the funnel. A GCU may be accepted to meet the IGC Code requirement for both primary and secondary means for disposal of boil-off gas on condition that redundancy is arranged for fans (combustion and dilution), burners, igniters, gas flow control valve(s) and control system. A GCU control system includes both combustion control and burner management. A redundant GCU control system is a system with dual processors and single I/O or a single processor with an independent manual/remote control system.

Capacity and redundancy 2 x 100% design boil-off gas capacity re-liquefaction units. Common cold box may be accepted. 1 x 100% design boil-off gas capacity re-liquefaction unit. 1 x 100% design boil-off gas capacity GCU. 1 x 100% design boil-off gas capacity GCU with redundant fans, igniters, burners, gas flow control valves and combustion control systems; or 2 x 100% design boil-off gas capacity independent GCUs; or 3 x 50% design boil-off gas capacity independent GCUs 1 x 100% design boil-off gas capacity GCU with redundant fans, igniters, burners, gas flow control valve and combustion control system; or 2 x 100% design boil-off gas capacity independent GCUs; or 3 x 50% design boil-off gas capacity independent GCUs

The design boil-off capacity is normally the maximum boil-off rate. The amount of boil-off gas consumed by the dual fuel engines during harbour operations is defined as the base load (hotel load). This base load may be subtracted from the maximum design boil-off rate to establish the design boil-off capacity of the gas combustion units.

3. Materials, Manufacture, Inspection and Testing

3.1 Materials
Materials for the refrigerant piping and cargo vapour piping are to be suitable for low temperature service. In general material should be selected for a temperature of 165C. Material selection for warmer temperatures in parts of the system may be considered. Requirements for materials, documentation and testing, see Rules Pt.5 Ch.5 Sec.2 D and E. Materials for the steel cylinders of the GCU are to be suitable for the high temperatures. Material quality is to be documented by Works Certificates.

3.2 Piping design and manufacture

Piping shall be joined by butt welding. The number of flanges shall be kept to a minimum. Valves should preferably be of weld-in type. Requirements for design, welding and testing, see Rules Pt.5 Ch.5 Sec.6 C500-C800. For gas combustion units located in enclosed spaces the gas piping within the space shall be of double walled type or fully enclosed in a ventilated duct with arrangements complying with Rules Pt.5 Ch.5 Sec.16 B100 and 200.

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Classification Notes - No. 61.2 May 2006

3.3 Certification of components

Certification DN 75 mm, DNV DN < 75 mm, W Pressure vessels DNV Heat exchangers DNV Compressors DNV Pumps DNV Gas combustion unit W W = Works (makers) certificate Component Valves Rule reference Pt.5 Ch.5 Sec.6 H Pt.4 Ch.7 Pt.4 Ch.5 Sec.4 Pt.5 Ch.5 Sec.6 G

Item/Parameter N2 compressor/expander, vibrations N2 compressor/expander lube oil press N2 compressor, bearings

Alarm H L H

Shut down Comment HH LL HH For shaft power above 1 500 kW Outside normal range

N2 high press/low press differential Cold box enclosure, gas concentration methane oxygen Cooling water press. Cooling water outlet temp. N2 compressor room, O2 concentration N2 compressor room, loss of ventilation N2 rejection column, level N2 rejection column, pressure BOG compressor room O2 concentration BOG compressor room HC gas concentration BOG compressor room fire detection BOG compressor room, loss of ventilation ESD activated Cargo tanks overfill danger

3.4 Strength testing

Piping and heat exchangers shall be hydrostatically tested to 1.5 times the design pressure. Testing by using gas instead of liquid may be accepted on special considerations of safety implications.

H L L H L X H H/L L H X X X HH X X X SD may be time delayed Blow down of gas pressure

4. Monitoring and Control

4.1 General
Monitoring and control systems shall in general comply with the requirements of Rules Pt.4 Ch.9.

4.2 Extent of monitoring of re-liquefaction plants

Item/Parameter BOG compressor, gas outlet temp. BOG compressor, gas outlet pressure BOG compressor, gas inlet pressure BOG compressor, gas inlet/outlet temp. diff. BOG compressor, gas inlet temp. BOG compressor, vibrations BOG compressor, lube oil press BOG compressor, bearings Alarm H H H/L H H H L H HH HH LL HH For shaft power above 1 500 kW Shut down Comment HH HH

H X L

Activate at levels above existing

Loss of power supply to control and monitoring system Instrument air, pressure

4.3 Monitoring of GCU

Item/Parameter Flame failure Loss of combustion air supply Loss of cooling air/dilution air supply BOG inlet temperature Combustion gas exit temperature Methane gas concentration in gas pipe duct Loss of ventilation in gas pipe duct, Alternatively loss of N2 pressure Fire detection in GCU space Alarm X X X L H H X Shut down Comment X X X LL HH HH X

BOG pre-cooler level Vapour header pressure LNG separator level LNG separator, pressure N2 compressor gas inlet pressure N2 compressor gas inlet temp. N2 compressor 2.stage gas inlet temp N2 compressor 2.stage gas outlet pressure N2 compressor 3.stage gas inlet temp N2 compressor 3.stage gas outlet temp. after cooler

H H/L H/L H/L L H H H H H

LL

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