000 CG VT 0001

157883-000-CG-VT-0001
E&C Cryogenics Standard Plants

Nitrogen Generation Unit (APSA L1)
Training documentation
Peru LNG
E&C Cryogenics Standard Plants
- 4, rue des fusills 94781 Vitry Sur Seine France Tel: + 33 (1) 45 73 66 66 - Fax : + 33 (1) 46 80 44 40
Author : ALSPE/CoH Revision: 0- 02-2009
Taining - PERU LNG

Nitrogen Generation Unit
Generic part
1 Day Welcoming introduction Process introduction Summary and training program philosophy Nitrogen Generation Unit systemic presentation PFD & PID Compression module Purification module 2 Day Heat Exchange module Distillation module Cold Production module Mass balance Safety : CnHm risks, safely operation
sd st
Operation training
3rd Day Process control overview Start-up and shutdowns Deriming / Drying & exceptional regeneration Main control loops Alarms and trips Operating manual R01/R02 timing Supervision in steady conditions Trouble shooting quiz Operators questions and answers Training evaluation by participants Conclusions
CGG 09_018 dt 10th of april 2009
PRESENTATION
PERU LNG 2009
1. Generalities
1.1. Nitrogen On-Site Supply System

N2 purity
100%
APSA
Bulk Supply 99.9%
Small Cryo. Cryo.
APSA L APSA LE
Large Cryo. Cryo. High Purity LIN
SPI
Small Membranes
AMSA
Large Membranes
95% 10 100 1000 10000
N2 Production (Nm3/h)
PERU LNG 2009
1. Generalities
1.2. APSA L /LE : Process and Markets
APSAAPSA-L
Classic 7-10 barA N2
Chemicals Refineries Glass
APSAAPSA-LC
Claude Cycle 2-3 barA N2
Glass
APSAAPSA-LE
Booster Re-cycle Ultra High Purity
Electronics
PERU LNG 2009
1. Generalities
1.3. Air Separation Unit (ASU) Inlet & Outlet
SOURCE : Atmospheric Air
Air Separation Unit
PRODUCTS: O2, N2, Ar

(gas or liquid)
WASTE NITROGEN
PERU LNG 2009
1. Generalities
1.4. Raw material composition ELEMENTS SYMBOL O2 N2 Ar He Ne Kr Xe H2 H 2O CO2 CH4 C 2+ COMPOSITION IN VOLUME 20,9 78,1 0,93 5,24 18,18 1,139 0,086 0,5 % % % ppm ppm ppm ppm ppm
Principal
OXYGEN NITROGEN ARGON HELIUM NEON KRYPTON XENON HYDROGEN STEAM CARBON DIOXIDE HYDROCARBONS
Rare gas
variable 300 700 ppm 3 5 ppm < 0.5 ppm
Impurities
PERU LNG 2009
1. Generalities
1.5. Cryogenic production stages ?
COLD PRODUCTION HEAT EXCHANGE
PURIFICATION
COMPRESSION
DISTILLATION
PERU LNG 2009
1. Generalities
1.6. Cryogenic production modular approach

GASEOUS PRODUCTS Residual Gas HEAT EXCHANGE
COLD PRODUCTION
Air PURIFICATION
COMPRESSION
DISTILLATION LIQUID PRODUCTS
PERU LNG 2009
1. Generalities
1.7. Plants Modules Overview

DISTILLATION PURIFICATION
COMPRESSION
HEAT EXCHANGE
COLD PRODUCTION
PERU LNG 2009
1. Generalities
1.8. APSA L : Global Scheme
Residual Gas
AIR
APSA L LIN GAN
Nitrogen recovery 40%
PERU LNG 2009
1. Generalities
1.9. APSA L : Process Cycle

Residual Enriched Gas (>35% O2) Gaseous N2 to customer Liquid N2 to backup
R01
R02
D01
Air inlet C01
K01
Compression Purification
Power Cooling Water
Cold Production
Civil Works
Heat Exchange
Distillation
PERU LNG 2009
10
AIR PURIFICATION
PERU LNG - 2009
Air Purification
OBJECTIVES OBJECTIVES
TO TO REMOVE REMOVE THE THE VARIOUS VARIOUS AIR AIR CONTAMINANTS CONTAMINANTS IN IN ORDER ORDER TO TO PREVENT PREVENT TROUBLES TROUBLES IN IN APSA APSA UNITS: UNITS:
TEMPERATURE ~ -180C
WATER WATER(air (airmoisture) moisture) Carbon CarbonDioxide DioxideCO2 CO2 Hydrocarbons HydrocarbonsCnHm CnHm Nitrous Nitrousoxide oxide(N2O) (N2O)
PERU LNG - 2009
Air Purification
Purification Purification requirements requirements
WATER CO2 CnHm N2O
- unit unit corrosion corrosion - plugging plugging (pipes, (pipes, exchangers, exchangers, column) column) by by solidification solidification due due to to cryogenic cryogenic temperature temperature (0C (0C // ice) ice)
- plugging plugging (pipes, (pipes, exchangers, exchangers, column) column) by by solidification solidification due due to to cryogenic cryogenic temperature temperature (-130C (-130C // solid solid CO2) CO2)
- explosion explosion risk risk in in the the vaporizers vaporizers with with oxygen oxygen enriched enriched
atmosphere atmosphere (Rich (Rich Liquid, Liquid, Oxygen) Oxygen)
- explosion explosion risk risk with with CnHm CnHm
PERU LNG - 2009
Air Purification
Air Air Composition Composition // Air Air Contaminants Contaminants
Air Composition Inlet Comp. Normal 78.11 % 20.96 % 0.93 % saturation 350 450 ppm < 0.1 ppm 18 ppm 5.2 ppm 1 6 ppm 1.139 ppm 0.5 ppm 0.086 ppm Inlet Comp. Peak Purif. Outlet Max allowab
N2 O2 Ar H2 O CO2 CnHm Ne He CH4 Kr H2 Xe
Nitrogen Oxygen Argon Water Carbon Dioxide Hydrocarbons Neon Helium Methane Krypton Hydrogen Xenon
600 ppm 0.5 ppm
0.1 ppm
15 ppm
8 ppm
+ other natural or industrial impurities : hydrocarbons,CO, H2S, NO2 .....

PERU LNG - 2009 4
Air Purification
Process Process presentation presentation
Contaminant-free Air OBJECTIVES: OBJECTIVES: ELIMINATION ELIMINATION OF OF WATER WATER IN IN VAPOUR VAPOUR FORM FORM ELIMINATION ELIMINATION OF OF CARBON CARBON DIOXIDE DIOXIDE CO2 CO2
MOLECULAR SIEVE: CO2, CnHm
ELIMINATION ELIMINATION OF OF HYDROCARBONS HYDROCARBONS EXCEPT EXCEPT
METHANE METHANE CH4 CH4 and and some some other other CnHm CnHm
ALUMINA: WATER
Air Airpasses passesthrough throughupward upwardaavessel vessel equipped with two specific materials: equipped with two specific materials: - -ALUMINA : :to ALUMINA totrap trapwater watermolecules molecules Air with contaminants: H2O, CO2, CnHm - -MOLECULAR : :to MOLECULARSIEVE SIEVE totrap trapCO2 CO2and and Hydrocarbon molecules Hydrocarbon molecules
PERU LNG - 2009
Air Purification
Adsorption Adsorption Process Process
ATTRACTION Molecules
ALUMINA ALUMINA and and MOLECULAR MOLECULAR SIEVE SIEVE are are solid solid materials materials in in the the form form of of porous porous particles particles of of 2 2 to to 5 5 mm mm diameter: diameter: they they are are called called ADSORBENTS ADSORBENTS..
Pores DIFFUSION/ FIXATION
The The ADSORPTION ADSORPTION process process occurs occurs in in 2 2 steps: steps: - first, first, an an attraction attraction of of the the molecules molecules to to the the adsorbent adsorbent - then, then, a a diffusion diffusion of of the the molecules molecules into into the the pores pores where where they they are are fixed fixed (or (or trapped). trapped).
Adsorbent
PERU LNG - 2009
Air Purification
Adsorption Adsorption Process Process
Reversible Process : Adsorption & Desorption

Adsorption Adsorption increases increases (the (the amount amount of of adsorbed adsorbed molecules molecules increases) increases) when: when: the the pressure pressure increases increases the the temperature temperature decreases decreases Gaseous phase
Adsorbed phase
Solid
ADSORPTION ADSORPTION IS IS A A REVERSIBLE REVERSIBLE PROCESS: PROCESS: if if the the pressure pressure decreases decreases or or if if the the temperature temperature increases increases,, the the adsorbed adsorbed molecules molecules will will be be able able to to leave leave the the pores pores of of the the adsorbent adsorbent particles: particles: this this is is the the Desorption Desorption of of the the adsorbent adsorbent.. (also Regeneration)) (also called called Regeneration Thus, a fixed fixed adsorbent adsorbent quantity, quantity, we we design design a a cyclic cyclic process process Thus, for for a with with alternating alternating phases: phases: adsorption/desorption. adsorption/desorption. we we can can play play with with the the temperature: temperature: TSA TSA cycle cycle (Temperature (Temperature Swing Swing Adsorption) Adsorption) we we can can play play with with the the pressure pressure: : PSA PSA cycle cycle (Pressure (Pressure Swing Swing Adsorption). Adsorption).
PERU LNG - 2009 7
Air Purification
Adsorbent Adsorbent characteristics characteristics
The name of Adsorbents designates porous solid materials. Their main characteristic is a maximum surface (active zone for the adsorption process) in a small volume: we define the specific area. Adsorbents come in different forms: - spherical balls - cylindrical pellets - irregular crushed particles
Each gram of product particle has a surface equivalent to a tennis court

Chimical formula Specific area m2/g 800 to 1500 300 to 350 900 Pore diameter Angstrm (10-10 m) 40 to 5000 10 to 40 3 to 10
ACTIVATED CARBON ALUMINA MOLECULAR SIEVE: Type A, Type X
C AL2O3 SiO2, Na2O CaO, K2O
PERU LNG - 2009
Air Purification
Selectivity Selectivity of of the the process process
Affinity (Adsorbent / Molecule) depends on :

The The type type of of adsorbent: adsorbent: presence presence of of attraction attraction field field diameter diameter of of the the pores pores The The type type of of molecule: molecule: their their physical physical and and chemical chemical characteristics characteristics determine determine the the intensity intensity of of the the adsorbent adsorbent attraction: attraction: so, so, we we designate designate molecules molecules strongly strongly attracted attracted (with (with electrical electrical moment) moment) and and molecules molecules weakly weakly attracted attracted (neutral (neutral molecules) molecules) the the size size of of the the molecules molecules must must be be smaller smaller than than the the diameter diameter of of the the pores: pores: thus, thus, nitrogen nitrogen molecule molecule is is able able to to pass pass into into a a4 4 pore, pore, but but not not into into a a3 3 pore. pore.
Adsorbed molecules ACTIVATED CARBON ALUMINA MOLECULAR SIEVE Oil vapour: Hydrocarbons C2 and C3 types H2O C2H2, NO2, CO2, H20
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10
Air Purification
Choice Choice of of adsorbents adsorbents
The function of the adsorption process for an APSA unit is to trap in vapour form the air contaminants such as water, carbon dioxide CO2 and hydrocarbons, before feeding the cold box. To trap water, knowing that air is always saturated after compression process, the choice indifferently could be molecular sieve or alumina. We prefer alumina for the following reasons: - alumina is less sensitive to the possible presence of liquid water particles - the temperature of regeneration process for alumina is colder: around 40C for alumina, 250C for molecular sieve
ALUMINA ALUMINA
H O 22 H O
To trap CO2, the only choice is molecular sieve. The same for hydrocarbons, mainly made up of acetylene C2H2: it is not possible to trap methane CH4 by the adsorption process.
MOLECULAR MOLECULAR SIEVE SIEVE

CO 2, ,C 2 H2 CO 2 C2 H2
PERU LNG - 2009 11
Air Purification
Adsorption: Adsorption: Water Water analogy analogy
Saturated Gas
ADSORPTION
Dry gas
Saturated zone
front
Clean zone
DESORPTION (REGENERATION)
Saturated Gas Dry gas
END OF DESORPTION (REGENERATION)
PERU LNG - 2009
12
Air Purification
Installation Installation design design
The The design design of of the the installation installation is is a a combination combination with with two two types types of of adsorbents: adsorbents: first, first, compressed compressed air air passes passes through through a a bed bed of of alumina alumina in in order order to to trap trap water water then, then, compressed compressed air air passes passes through through a a bed bed of of molecular molecular sieve sieve intended intended to to trap trap CO and Hydrocarbons CO2 2 and Hydrocarbons Thus, Thus, we we keep keep molecular molecular sieve sieve free free of of moisture moisture contamination. contamination.
MOLECULAR SIEVE
CO2, C2H2
MOLECULAR SIEVE
Adsorber V-6701 A/B
ALUMINA
H 2O
ALUMINA
AIR
AIR
PERU LNG - 2009 13
Air Purification Adsorption Adsorption // Regeneration Regeneration Cycle Cycle

Using Using a a fixed fixed amount amount of of adsorbent, adsorbent, we we know know that that the the duration duration of of adsorption adsorption process process will will be be limited: limited: after after a a certain certain duration duration of of air air circulation, circulation, the the pores pores of of the the adsorbent adsorbent become become saturated: saturated: -- with with water water molecules molecules for for alumina alumina and Hydrocarbon molecules for molecular sieve -- with with CO CO2 2 and Hydrocarbon molecules for molecular sieve
We We obtain obtain the the saturation saturation of of the the adsorbents: adsorbents: the the adsorption adsorption process process is is over. over.
Contaminant-free air
Air with contaminants

ADSORPTION
To To achieve achieve a a continuous continuous air air purification purification compatible compatible with with the the non-stop non-stop distillation distillation process process of of APSA APSA unit, unit, we we need need an an operating operating cycle cycle with with two two adsorbers. adsorbers.
REGENERATION
An An arrangement arrangement with with two two adsorbers adsorbers in in parallel parallel allows allows to to purify purify compressed compressed air air with with one one adsorber adsorber ((ADSORPTION phase ), while the second ADSORPTION phase), while the second one one is is in in desorption process ( REGENERATION phase ). desorption process (REGENERATION phase). When When the the first first adsorber adsorber is is close close to to the the limit limit of of adsorption adsorption capacity, capacity, we we perform perform a a reverse reverse operation operation in in order order to to feed feed with with compressed compressed air air the the second adsorber, which is contaminant-free thanks second adsorber, which is contaminant-free thanks to to the the previous previous regeneration regeneration process. process.
PERU LNG - 2009 14
Air Purification
Adsorption Adsorption front front in in the the bed bed
Contaminant-free air
t = 100 min
Bed Height
0 200 100 0 0
Adsorbed quantity
t = 20 min
500
400
300
CO2 (ppm)
Air with contaminants
Adsorbed quantity
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15
Air Purification Regeneration Regeneration front front in in the the bed bed
Regeneration fluid : Vaporized Rich Liquid (VRL)
Vaporized Rich Liquid
Bed Height
0 500 400 300 200 100 0 0
Desorbed quantity
CO2 (ppm)
Desorbed quantity
Saturated Vaporized Rich Liquid

PERU LNG - 2009 16
Air Purification Adsorption Adsorption // Regeneration Regeneration Cycle Cycle

Influence of pressure and temperature
Adsorbed quantity
T1
1 Pressure effect (depressurization) 2 Temperature effect (heating) 3
T2 > T1
Partial pressure
PERU LNG - 2009
17
Air Purification
Air
Technology Technology
Regeneration Regeneration fluid fluid : : Vaporized Vaporized Rich Rich Liquid Liquid (VRL) (VRL)

Horizontal Horizontal beds beds
Mole Sieve bed Alumina bed
Adsorption Adsorption phase phase : : Cycle Cycle time time :: 150 150 min min Air Air pressure pressure :: 8.1 8.1 bar bar g g Air Air temperature temperature :: 40C 40C Regeneration Regeneration phase phase : : Regeneration Regeneration temperature temperature :: 90C 90C (heater (heater outlet) outlet) Air Air pressure pressure :: 0.1 0.1 bar bar g g Heating Heating duration duration :: ~20 ~20 min min Cooling Cooling duration duration :: ~100 ~100 min min
Air
PERU LNG - 2009
18
Air Purification
V01 V01 // V02 V02 Installation Installation

Electric heater EH-6701
VRL
CVWO009A
Air to Cold Box

CVWO009B
CVAG06A
CVAG06B
KV 530
Regeneration Phase
V-6701 A
KV 515 KV 516 KV 510
Event VRL
V-6701 Adsorption Phase B

KV 525 KV 526 KV 520
Air
PERU LNG - 2009 19
Air Purification
Purification Purification cycle cycle

Purification steps
Air
HP Isolation Depressurization Blow-Off

Bottle in Regeneration phase
VRL
VRL
Bottle in Adsorption phase
Heating Cooling LP Isolation Pressurization Parallel position Adsorption
Air
PERU LNG - 2009
20
Air Purification
Pressure Pressure cycle cycle
Air Bottle 1
pressure Adsorption Regeneration
Heating Cooling
Bottle in Regeneration phase
VRL
VRL
Bottle in Adsorption phase
time
Bottle 2
Regeneration
Heating Cooling
Adsorption
pressure
time
Air
PERU LNG - 2009
21
Air Purification
Automatic Automatic sequence sequence
VRL
Cold Box
VRL
Cold Box
V6701 A
Event
V6701 B
V6701 A
Event
V6701 B
Air
Air
On line V6701 B HP Isolation V6701 A
Depressurization V6701 A
PERU LNG - 2009
22
Air Purification
VRL
Cold Box
VRL
Cold Box
V6701 A
Event
V6701 B
V6701 A
Event
V6701 B
Air
Air
Blow-Off V6701 A
Heating V6701 A
PERU LNG - 2009
23
Air Purification
VRL
Cold Box
VRL
Cold Box
V6701 A
Event
V6701 B
V6701 A
Event
V6701 B
Air
Air
Cooling V6701 A
LP Isolation V6701 A
PERU LNG - 2009
24
Air Purification
VRL
Cold Box
VRL
Cold Box
V6701 A
Event
V6701 B
V6701 A
Event
V6701 B
Air
Air
Pressurization V6701 A
Parallel Position
PERU LNG - 2009
25
Air Purification
Temperature Temperature profile profile
Temperature
Inlet temperature
Heating temperature
Good Regeneration indicator
Outlet temperature
Cold Desorption Hot Desorption
Heat Peak VRL temperature at cold box outlet
Heating
Cooling
Time
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26
Air Purification
What does the purification process look like ?
PERU LNG - 2009
27
Air Purification
What does the purification process look like ?
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28
EXCHANGERS
PERU LNG - 2009
4. Heat Exchange
4.1. Why exchange the heat ?

Residual Enriched Gas (>35% O2) Gaseous N2 to customer Liquid N2 to backup
R01
R02
D01
Air inlet C01
K01
Compression Purification
Cold Production
Heat Exchange
Distillation
NON-CRYOGENIC
CRYOGENIC
PERU LNG - 2009 2
4. Heat Exchange
4.2. Principles of Heat Exchange

GOAL
To get air at good conditions for the distillation To warm up gaseous product from the cryogenic temperature to the ambient one
PRINCIPLES
Heat flux from the Hot fluid to cold fluid Driving force = temperature difference Counter flow arrangement Heat exchange in an aluminium brazed Heat Exchanger
PERU LNG - 2009
4. Heat Exchange
4.3. Heat exchange formula
H = K . S . Ln(T)
where
H = Duty or Heat exchanged (kcal/h) K = Heat exchange coeff = f(fluids, material, flow) (kcal/h.m2.C) S = Surface (m2) T = Average temperature difference between hot and cold fluids (C)
PERU LNG - 2009
4. Heat Exchange
4.4. Heat exchange formula
H = Q . Cp . T
where
H = Duty or Heat exchanged (kcal/h) Q = Flowrate (Nm3/h) Cp = Specific heat (kcal/Nm3/C) T = Temperature difference for the same fluid (C)
PERU LNG - 2009
4. Heat Exchange
4.5.Three types of heat exchanger
Counter-current
Co-current
Cross current
PERU LNG - 2009
4. Heat Exchange
4.6. Co-current exchanger

Insulation
Cold Nitrogen Hot Nitrogen Cold Nitrogen
-100C 0C -100C
-50C -50C -50C
Same number of hot passages and cold passages Temperature of Hot Nitrogen at the end of the exchanger ?
PERU LNG - 2009 7
4. Heat Exchange
4.7. Counter-current exchanger
-5C Hot Nitrogen 0C -5C
-10C -5C -10C
-100C -95C -100C
Cold Nitrogen
Cold Nitrogen
Same number of hot passages and cold passages Temperature of Hot Nitrogen at the end of the exchanger ?
PERU LNG - 2009 8
4. Heat Exchange
4.8. T Warm End definition

Air WN2 GAN
T warm end
Brazed aluminium HX T cold = 0C T warm end ~ 2C
T cold
Loss of cold capacity to be produced by the turbine
PERU LNG - 2009
4. Heat Exchange
4.9. Basis about heat exchange diagram
-5C Air
Exchanged heat (kcal/h)
-50C -45C -50C
-100C -95C -100C
N2
0C -5C
N2
Ho t
ld o C
-100
co m
m o c
po
po
si te
te i s
T Warm End ?
-95
-5
Temperature (C)
PERU LNG - 2009 10
4. Heat Exchange
4.10. Real heat balance diagram for APSA L

H Heat flow (kcal/h)
1400000
1200000
Hot composite
1000000
Cold composite
800000 600000
400000
200000
0 -200 -150 -100 -50 0 50
Temperature (C)
PERU LNG - 2009 11
4. Heat Exchange
4.11. Heat balance

QC T4 T1 T4 T1
Warm end
Cold end
T3
QF
T2
T3
T2
H = Q . Cp . T
H = HC = QC . CpC . ( T2 T1 ) = - HF = - QF . CpF . ( T4 T3 )
PERU LNG - 2009 12
Heat Balance :
4. Heat Exchange
4.12. Heat exchange exercise

Warm end 8 Nm3/h 20C 25C We
consider a counter flow exchanger
We
want to warm up 5 Nm3/h of N2 from - 100 to 20C at 1 bar abs 8 Nm3/h flowrate of Air is available at 25C and 5 bar abs = 0.31 kcal/Nm3/C
NITROGEN
A AIR
Cp(Air) Cp(N2)
= 0.31 kcal/Nm3/C
-100C 5 Nm3/h Cold end
T=?
Air temperature at cold end ?
PERU LNG - 2009
13
4. Heat Exchange
4.13. Heat exchange exercise result

Warm end 8 Nm3/h 20C 25C
Heat exchanged by Nitrogen HN = 5x0.31x[20-(-100)] = 186 kcal/h

2
NITROGEN AIR
Heat exchanged by air HAIR = 8x0.31x[T-25] But HN = - HAIR = 186 kcal/h

2

Then 8x0.31x[T-25] = -186 kcal/h Finally T = -186/(8x0.31)+25 = -50C
-100C 5 Nm3/h Cold end
T= -50C
PERU LNG - 2009
14
4. Heat Exchange
4.14. Influence of flowrate on heat exchange
Flow evolution
T warm end
T cold end
Hot fluid
Cold fluid
PERU LNG - 2009
15
4. Heat Exchange
4.15. Influence of temperature on heat exchange
Temperature
T warm end
T cold end
Hot fluid
Cold fluid
PERU LNG - 2009
16
4. Heat Exchange
4.16. Counter flow arrangement
Perforated fins
Heringbone fins
Spacer bar Parting sheet
Exchange fin
Serrated fins
Spacer bar
Flowrate Parting sheet

PERU LNG - 2009 17
4. Heat Exchange
4.17. Different flow arrangements
PERU LNG - 2009
18
4. Heat Exchange
4.18. Different type of distributors
PERU LNG - 2009
19
4. Heat Exchange
4.19. Different type of fins
Straight fins
Serrated fins
Perforated fins
Heringbone fins
PERU LNG - 2009 20
4. Heat Exchange
4.20. General view of the heat exchanger
1 4 3 5 2 7
8 6 9
10 11 12 14 1 3 15
1 2 3 4 5
- Assembly - Outlet fluid - Core - Header - Nozzle
6 7 8 9
- Width - Stack - Length - Passes
10 11 12 13 14 15
- Side plate - Parting sheet - Heat transfer fins - Distributor fins - Spacer bar - End bar
PERU LNG - 2009 21
4. Heat Exchange
4.21. General view of the heat exchanger
PERU LNG - 2009
22
4. Heat Exchange
4.22. Warm end Embrittlement hazard
Nitrogen piping at warm end of the Heat Exchanger is not designed for cryogenic temperature Occasionally, there can be cold fluid ingress at the warm end :
During process deviation During stop of the plant
Precautions must be taken to prevent cold embrittlement
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23
COLD PRODUCTION
PERU LNG 2009
6. Cold Production
6.1. Energy balance principle
heat (inlet ) = heat (outlet )
Heat inlet or Cold losses
APSA-L
Heat losses or Cold inlet
PERU LNG 2009
6. Energy Balance & Cold Production

6.2. Cold balance application

0.1 bar g 35C
Warm end T
7 bar g -171C
GAN LIN
Liquid production
R01
R02
D01
Air inlet C01
Insulation losses
K01
Turbine work
8 bar g 40C
PERU LNG 2009 3
6. Cold Production
6.3. Energy balance

Cold losses or heat inlets
Heat exchanger warm end temperature difference Liquid production Heat entrance due to non perfect insulation
Cold inlets or heat losses
Turbine work Isotherm expansion of products Liquid assist
PERU LNG 2009
6. Cold Production
6.4. Cold balance comparison
Small units
GAS LIQUID
Large plants
GAS LIQUID
Insulation Warm end T Liquid production
70% 30% 0%
7% 2% 91%
20% 80% 0%
1% 3% 96%
PERU LNG 2009
6. Cold Production
6.5. Why a Cold Production is required ?

AIM
START-UP: COOL DOWN To ensure a decrease of the temperature in the cold box NORMAL RUN: ENERGY BALANCE To maintain the cold balance of the plant
HOW
By withdrawing some heat out of the cryogenic system By expansion of air
PERU LNG 2009
6. Cold Production
6.6. Turbine principle

Symmetric Symmetricwork workto tothe theone oneof ofa acentrifugal centrifugalcompressor compressor
Compresseur
Turbine
PERU LNG 2009
6. Cold Production
6.7. Turbine thermo-dynamical Principle
Theorem of Bernoulli :
P V + E = cste 2
Dynamic pressure
Turbine
Static pressure
Compressor / Pump
PERU LNG 2009
6. Cold Production
6.8. Turbine thermodynamical Principle
Increase in the gas speed without energy extraction in the inlet vanes (1) static pressure diminishes Decrease in the gas speed with energy extraction in the relaxation wheel (2) dynamic pressure diminishes Decrease in the gas speed without energy extraction in the diffuser (3) dynamic pressure is transformed into static pressure
PERU LNG 2009 9
2 1
6. Cold Production
6.9. Turbine overview
Entrance gas process
Outing g as
process
Turbine body
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10
6. Cold Production
6.10. Turbine wheels

Gas outing
Gas entrance
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11
6. Cold Production
6.11. Turbine wheels
Wheel of the turbine
Discharge
Adjustable diffuser (IGV)
Arrival of the fluid by the volute
PERU LNG 2009
12
6. Cold Production
6.11. Speed triangle

Fixed part : Distributor
0
r U1
r r U r V2 2 W2
2
r W1
r V1
1 2 3
Mobile guide vanes Wheel
PERU LNG 2009
13
6. Cold Production
6.12. How braking cryogenic turbines ?

Production of mechanical energy with the expansion wheel
Energetic stability Consumption of this energy
Braking of the turbine
Electrical generator
Oil spin-dry pump
Oil brake
Air brake
Booster brake
PERU LNG 2009
14
6. Cold Production
6.13. APSA-L Oil brake turbine principle
Oiled contact surface
Turbine wheel
- Figure of an oil brake PERU LNG 2009 15
6. Cold Production
6.14. APSA-L cold production equipment
Air Water Air
Oil Tank
PERU LNG 2009
16
6. Cold Production
6.15. APSA-L PERU LNG : LIN Production Case
F = 1650 Nm3/h P = 4.3 bar g T = -148C
LRV Turbine
-19 kW 19 kW
F = 1650 Nm3/h P = 0.2 bar g T = -184C
S = 43000 rpm
PERU LNG 2009 17
6. Cold Production
6.16. Cryostar ECO turbine
Oil tank
Oil brake valve

PERU LNG 2009 18
6. Cold Production
6.17. Cryostar ECO turbine

Oil pump
Oil tank
Oil cooler
PERU LNG 2009
19
6. Cold Production
6.18. Turbine elements
Expander stage
Oil brake sleeve in bearing housing

PERU LNG 2009 20
6. Cold Production
6.19. Expansion turbine behaviour

2 choices to increase the cold production of the plant: increase the turbine inlet pressure of 100 mbar decrease the turbine outlet pressure of 100 mbar What is the best choice ?
EXPANSION POWER VARIATION VS P VARIATION EITHER ON MP SIDE OR BP SIDE
16.1
Conclusion
Be careful with
the pressure on the BP side of the turbine. Quick loss of cold production
Power (kW)
16 15.9 15.8 15.7 15.6 15.5 15.4 15.3 15.2 15.1 15 0 10 20 30 40 50 DP (mbar) 60 70 80 90 100
GAIN BP
POWER BP VAR (KW) POWER MP VAR (kW)
GAIN MP
PERU LNG 2009
21
6. Cold Production
6.20. P&ID : Expansion turbine
PERU LNG 2009
22
AIR DISTILLATION PRINCIPLE
PERU LNG -2009
Distillation
Goal and principle
GOAL
To separate Nitrogen and Oxygen from atmospheric Air

PRINCIPLE
Separation by Distillation : Content difference between liquid and vapour phases

KEY PARAMETERS
Boiling Point Liquid vapour equilibrium Fractional distillation Reflux
PERU LNG -2009
Distillation
PRINCIPLE PRINCIPLE
WATER + ALCOHOL MIXTURE:

ALCOHOL: most volatil component WATER: least volatil component
VAPOUR: enriched in most volatil component:
ALCOHOL
LIQUID Mixture Two components:
LIQUID: enriched in least volatil component:
WATER + ALCOHOL
BOILING
APSA03/Distill1/VA#1
WATER
PERU LNG -2009 3
Distillation
PRINCIPLE PRINCIPLE
AIR = MIXTURE NITROGEN (79 %) + OXYGEN (21 %)

most volatil component : NITROGEN least volatil component : OXYGEN
VAPOUR: enriched in most volatil component:
NITROGEN
LIQUID AIR -200C, 1 b abs
LIQUID: enriched in least volatil component:
BOILING
OXYGEN
PERU LNG -2009 4
Distillation
Boiling finition Boiling Point Point d dfinition
At Atthe theboilling boillingpoint, point,there thereare aretwo twophases: phases: --a aboiling boilingLIQUID LIQUID --a arelease releaseof ofVAPOUR VAPOUR A Aboiling boilingpoint pointis isdefined definedwith: with: --a aTEMPERATURE TEMPERATURE T T --a aPRESSURE PRESSURE P P
VAPOUR
Thus Thuswe wedefine defineaa LIQUID-VAPOUR LIQUID-VAPOUREQUILIBRIUM EQUILIBRIUM
P, T
LIQUID
PERU LNG -2009
Distillation
Boiling Boiling Points Points

Boiling point values and volatility scale
Name
Symbol
Molecular Weight (g)
Boiling Temperature @ 1,013 bar abs.
Helium Hydrogen Neon Nitrogen Air Argon Oxygen Kripton Xenon
He H2 Ne N2 Air Ar O2 Kr Xe
2 2 20 28 29 40 32 84 131
-269 C -253C -246C -196C -191C -186C -183C -153C -108C
PERU LNG -2009
Distillation
At the boiling point, if one parameter changes (Pressure or Temperature), the other parameter has to change too:
NITROGEN
VAPOUR
OXYGEN
VAPOUR LIQUID
LIQUID
1 b abs - 196 C
1 b abs - 183 C
VAPOUR LIQUID
3.6 b abs - 183 C
VAPOUR LIQUID
3.6 b abs - 168 C
VAPOUR LIQUID
11 b abs - 168 C
VAPOUR
LIQUID
11 b abs - 152 C
PERU LNG -2009 7
Distillation
Boiling Boiling Points Points Curves Curves
PRESSURE AND TEMPERATURE RELATIONSHIP: If the Pressure increases, the Temperature has to increase too OR If the Temperature increases, the Pressure has to increase too AND inversely.
Do les courbes des points dbullition: Consequence: the boiling point curves
4
Pressure = f (Temperature)
Temperature = f (Pressure)
Liquid State
Gaseous State
Gaseous State
Liquid State
Curves: Liquid state and Gaseous state separation

PERU LNG -2009
Distillation

Nitrogen versus Oxygen
4.5 b abs
VAPOUR
1.3 b abs
VAPOUR
- 183 C
LIQUID LIQUID
- 196 C
NITROGEN NITROGEN NITROGEN OXYGEN OXYGEN OXYGEN
- 180 C ISOTHERMAL ISOTHERMAL

Nitrogen Nitrogen is is more more volatil volatil than than Oxygen Oxygen:
1 b abs ISOBARIC ISOBARIC
-NITROGEN NITROGEN = = most volatile component -OXYGEN OXYGEN = = least volatile component
PERU LNG -2009 9
Distillation
Nitrogen Nitrogen - Oxygen Oxygen mixture mixture
For Foran anOXYGEN-NITROGEN OXYGEN-NITROGENMIXTURE MIXTUREat atthe theLIQUID-VAPOUR LIQUID-VAPOUR EQUILIBRIUM, EQUILIBRIUM,
NITROGEN NITROGENbeing beingthe themost mostvolatile volatilecomponent: component:
--the thevapour vapourphase phaseBECOMES BECOMESENRICHED ENRICHED

IN INNITROGEN NITROGEN
- -the theliquid liquidphase phaseBECOMES BECOMESLESS LESS CONCENTRATED IN NITROGEN: CONCENTRATED IN NITROGEN: CONSEQUENTLY, CONSEQUENTLY,IT ITBECOMES BECOMES ENRICHED IN OXYGEN ENRICHED IN OXYGEN
P, T
O2+N2
O2+N2
(the )) (theVapour Vapourphase phaseand andthe theLiquid Liquidphase phaseare arecalled calledCONCOMITANT CONCOMITANTPHASES PHASES
PERU LNG -2009 10
Distillation
Fractional Fractional Distillation Distillation

VAPOUR even more enriched in NITROGEN
CONDENSER
VAPOUR: enriched in NITROGEN
2d BOILING LIQUID: enriched in OXYGEN
1st BOILING
Liquefaction: Liquid enriched in NITROGEN
PERU LNG -2009
11
Distillation

VAPOUR: "PURE" NITROGEN
Successive Boilings and Liquefactions
UR O P VA
R MO
OR M ND A E
ITR N N DI E ICH R N EE
EN G O
LIQUID: "PURE" OXYGEN
LIQ
EN G XY O IN D HE ty) C I vi R a N r E E by g R MO own D N sd A w RE id flo O M iqu D l I ( U
PERU LNG -2009
12
Distillation
ISOBARIC ISOBARIC SYSTEM: SYSTEM: pressure pressure is is the the same same in in each each vessel vessel e.g.: e.g.: 1 1b b abs abs
- 196 C
"PURE" NITROGEN
CONSEQUENCE: CONSEQUENCE: TEMPERATURE TEMPERATURE GRADIENT GRADIENT
- 183 C
"PURE" OXYGEN
PERU LNG -2009
13
Distillation
Vapour: HOTTER
LIQUID LIQUID VAPOUR VAPOUR CONTACT CONTACT
SUPPRESSION OF THE BOILERS AND CONDENSERS

For that, we achieve a LIQUID-VAPOUR CONTACT: the Vapour passes through the Liquid in the vessel - the vapour HOTTER, makes the liquid boiling - the liquid COLDER, condenses the vapour
Liquid: COLDER
Boiling of the LIQUID = VAPOUR
LIQUID (colder)
LIQUID-VAPOUR Contact
Heat Transfer (calories)
LIQUID-VAPOUR CONTACT
VAPOUR (hotter) Liquefaction of the VAPOUR = LIQUID
PERU LNG -2009
14
Distillation
LIQUID LIQUID VAPOUR VAPOUR CONTACT CONTACT
SUPPRESSION OF THE BOILERS AND CONDENSERS
We We only only need: need: One One boiler boiler at at the the bottom bottom One One condenser condenser at at the the top top
CONDENSER
TE
T: N IE D RA r G e RE hott er U AT ur is cold R E apo d is P i V M

u Liq
BOILER
PERU LNG -2009 15
Distillation Fractional Fractional Distillation Distillation : : Columns Columns

CONDENSER
MOST VOLATILE COMPONENT
VAPOUR BECOMES RICHER IN MOST VOLATILE COMPONENT
LIQUID BECOMES RICHER IN LEAST OLATILE COMPONENT
DISTILLATION DISTILLATION COLUMNS: COLUMNS: TRAYS TRAYS PACKING PACKING
LABORATORY LABORATORY Device Device
LEAST VOLATILE COMPONENT
BOILER: Vaporizer
PERU LNG -2009 16
LIQUID-VAPOUR CONTACT CONTACT LIQUID-VAPOUR
Distillation
CONDENSER
Regular Regular Column Column

Condenser
LIN DRAW-OFF
GAN DRAW-OFF
GAN LIN
AIR FEED VAPOUR LIQUID = REFLUX
PACKING SECTIONS
AIR
GOX DRAW-OFF
GOX
LOX DRAW-OFF
VAPORIZER
Vaporizer LOX
PERU LNG -2009 17
Distillation
Volatility scale
Air Air Components Components breakdown breakdown
NITROGEN
HELIUM HYDROGEN NEON
He H2 Ne N2 Ar O2 Kr Xe CnHm
AIR :
NITROGEN OXYGEN ARGON HELIUM KRYPTON NEON XENON HYDROGEN CnHm
OXYGEN
ARGON KRYPTON XENON CnHm
PERU LNG -2009
18
Distillation
From From the the regular regular column column to to the the APSA APSA
FOR A GAS NITROGEN PRODUCTION, ONLY THE UPPER SECTION OF THE COLUMN IS NECESSARY: we do not need the lower section
CONDENSER
GAN DRAW-OFF
LIN DRAW-OFF
CONDENSER
VAPOUR
AIR FEED
GAN DRAW-OFF
LIN DRAW-OFF
GOX DRAW-OFF LOX DRAW-OFF
VAPORIZER
LIQUID
AIR FEED
PERU LNG -2009
19
Distillation
From From the the regular regular column column to to the the APSA APSA
CONDENSER EQUIPMENTS NEEDED:
- PACKING SECTION - CONDENSER AT THE TOP - AIR FEED IN GASEOUS STATE
GAN DRAW-OFF
PACKING SECTION
- GAN DRAW-OFF - LIQUID WASTE OUTLET
AIR FEED
Air feed must be in gaseous state,
so that, the vaporizer is no longer necessary

PERU LNG -2009 20
in order to build-up the up-coming vapour:
LIQUID WASTE OUTLET
Distillation
Material Material Balance Balance
INCOMING INCOMING MATERIAL MATERIAL QUANTITY= QUANTITY= OUTGOING OUTGOING MATERIAL MATERIAL QUANTITY QUANTITY
400 Nm3/h
THE THELIQUID LIQUIDWASTE WASTEIS ISTHE THE CONSEQUENCE OF THE MATERIAL CONSEQUENCE OF THE MATERIAL BALANCE: BALANCE: Flowrate, Flowrate,O2 O2content content ITS ITSO2 O2CONTENT CONTENTIS ISALWAYS ALWAYSHIGHER HIGHER THAN THE ONE OF AIR; THAN THE ONE OF AIR; For Forthat, that,this thisliquid liquidis iscalled: called:
1000 Nm3/h O2 = 21 %
RICH RICHLIQUID LIQUID
Flowrate = 1000 - 400 = 600 Nm3/h 1000 x 21 % O2 = = 35 % 600
PERU LNG -2009
21
Distillation VAPORIZATION VAPORIZATION vs vs LIQUEFACTION LIQUEFACTION

VAPORIZATION
1 kg Liquid 1 kg Vapour
heat quantity SUPPLY
LIQUEFACTION
1 kg Vapour
1 kg Liquid
heat quantity DRAW-OFF
PERU LNG -2009
22
Distillation LATENT LATENT HEAT HEAT OF OF VAPORIZATION VAPORIZATION

DEFINITION: Heat quantity necessary to vaporize totally 1 kg of liquid
1 kg Liquid
1 kg Vapour
Heat quantity: kcal
OXYGEN: OXYGEN: 51 51kcal kcal(-183 (-183C, C,11b babs) abs) NITROGEN: NITROGEN: 47.6 47.6kcal kcal(-196 (-196C, C,11b babs) abs)
PERU LNG -2009
23
Distillation
OBJECTIVES:
Vaporizer Vaporizer -- Condenser Condenser system system

CONDENSER LIN
To liquefy gas nitrogen at the top of the column in order to achieve the Reflux.
GAN
PRINCIPLE: We need a specific device to draw-off the connecting heat quantity from gas nitrogen.
Heat quantity DRAWN-OFF
GAN
LIN
PERU LNG -2009 24
Distillation
PRINCIPLE:
In In an an EXCHANGER, EXCHANGER, we we achieve achieve an an HEAT HEAT TRANSFER TRANSFER (CALORIES) (CALORIES) between between GAS GAS NITROGEN NITROGEN and and RICH RICH LIQUID LIQUID CONSEQUENCES: CONSEQUENCES: - Gas Gas Nitrogen Nitrogen becomes becomes liquefied liquefied (heat (heat quantity quantity draw-off) draw-off) - Rich Rich Liquid Liquid becomes becomes vaporized vaporized (heat (heat quantity quantity supply) supply)
Vaporized
RL
RL
Heat TRANSFER
GAN
LIN
PERU LNG -2009
25
Distillation
Vaporized

Upper part
RL
RL
Heat TRANSFER
Vaporized RICH LIQUID
GAN
LIN
AN EXCHANGER IS LOCATED AT THE TOP OF THE COLUMN IN ORDER TO ACHIEVE THE HEAT TRANSFER BETWEEN RICH LIQUID AND GAN
EXCHANGER
RICH LIQUID bath GAN
LIN
APSA column
PERU LNG -2009 26
Distillation
APSA APSA column column :: final final construction construction

RICH LIQUID VALVE VAPORIZER - CONDENSER E02 RICH LIQUID BATH
VAPORIZED RICH LIQUID
GAN DRAW-OFF
K01
RICH LIQUID PIPE
GASEOUS AIR BOTTOM RICH LIQUID
PERU LNG -2009
27
Distillation
Reflux Reflux Ratio Ratio R R :: definition definition
GAN
L R= V
Where: V = Vapor Flowrate (Nm3/h) L = Liquid Flowrate (Nm3/h)
AIR RL
PERU LNG -2009
28
Distillation
Reflux Reflux Ratio Ratio R R :: definition definition
GAN
GAN
L R= V
Where:
V
AIR
L = V GAN
and
V = Air
Consequently, R = f (GAN & Air flow rates) : AIR LR
R=
Air GAN Air

PERU LNG -2009 29
Distillation
Incomming N2 amount
Air GAN
Reflux Reflux Ratio Ratio R R variation variation

Outgoing N2 amount
RL Total
L/V
1000x79% = 400x100% = 400 790 1000x79% = 450x100% = 450 790
600x65% = 390 390
790 840
390/790= 0.49 340/790= 0.43
GAN
The column becomes less concentrated in Nitrogen : Consequently, the column becomes enriched in Oxygen
AIR The GAN purity decreases (O2 content increase)

PERU LNG -2009
LR
30
Distillation
Conclusion Conclusion :: Reflux Reflux Ratio Ratio impact impact
GAN
GAN R = L/V
% N2 GAN
(GAN Purity)
AIR RL
PERU LNG -2009
31
Distillation
TECHNOLOGY TECHNOLOGY :: Packing Packing element element
AST (Advanced Sieve Trays)
Benefits :
Very efficient liquid vapour contact Low pressure drop (liquid film distribution) High operating flexibility (minimal / maximal gas load) High capacity (maximal gas load) Low inertia
PERU LNG -2009 32
Distillation
Structure: assembly of corrugated metallic sheets (aluminium).
PERU LNG -2009
33
Distillation
The Liquid-Vapour contact is obtained by the division of the liquid on the corrugated-crossed sheets: the liquid film is drawn downwards by gravity while the gas (vapour) flows upwards through the perforations and the void spaces between the sheets.
Corrugatedcrossed aluminium sheets
Perforations
PERU LNG -2009
34
Distillation
Vaporizer Vaporizer Vaporizer Vaporizer -- Condenser Condenser
GOAL to condense gas at the top of the distillation column in order to ensure a liquid reflux in the column to vaporise Rich liquid fluid at a lower pressure in order to feed the turbine (APSA L/LE) or the booster (APSA LE)
GAN
PRINCIPLES Heat exchange in an aluminium brazed Heat Exchanger Counter flow arrangement Heat flux from the Hot fluid to cold fluid Driving force = temperature difference
AIR
LR
PERU LNG -2009
35
Distillation
Vaporizer Vaporizer
TECHNOLOGY : Bath type vaporiser KEY COMPONENT FOR THE PRESSURE MAP AND FOR THE COLD PRODUCTION SAFETY : in all cases the vaporiser must
E02 Vaporizer Vaporized RICH LIQUID -172C 4.8b
be completely submerged
EXCHANGER T= 2C RL + VRL
RICH LIQUID bath
GAN
Incondensable gases
GAN
GAN
-170C 9.7b LIN LIN RL

PERU LNG -2009 36
LIN
APSA column
Distillation
Vaporizer Vaporizer deconcentration deconcentration purge purge
AIR downstream the Air Purification still Contents some contaminants:
HYDROCARBONS N2O
A PART OF THESE COMPONENTS ARE STOPPED IN THE PURIFICATION UNIT THE OTHER PART ENTER IN THE COLD BOX
The light components go up (ex: H2,) The heavy component go within the vaporiser bath (RL)
PERU LNG -2009
37
Distillation
Vaporizer Vaporizer deconcentration deconcentration purge purge
AMONG THESE HEAVY COMPONENTS, SOME ARE NOT VAPORISED CONCLUSION : WITHOUT ANY PURGE IT COULD HAPPEN AN ACCUMULATION OF HYDROCARBONS WHICH CAN FORM EXPLOSIVE COMPLEXES WITH RICH LIQUID BATH TO AVOID ACCUMULATION, THE BATH MUST BE PURGED PERMANENTLY DECONCENTRATION PURGE :
DIRECTLY LINKED TO THE SAFETY OF THE PLANT
PERU LNG -2009
38
MASS BALANCE
PERU LNG 2009
7. Mass balance
7.1. Mass balance formula
(inlet ) = (outlet )
Residual Gas
GLOBAL
AIR
APSA L
inlet flowrate = outlet flowrate inlet flowrate,i = outlet flowrate,i inlet N flowrate = outlet N flowrate
2 2
PERU LNG 2009 2
MASS BALANCE
PARTIAL
MASS BALANCE
GAN
7. Mass balance
7.2. Mass balance application
Residual Gas
GLOBAL
MASS BALANCE
QAir = QRes + QGAN

PARTIAL
MASS BALANCE
AIR
APSA L
QN2,Air = QN2,Res + QN2,GAN xAir.QAir = xRes.QRes + xGAN.QGAN
GAN
where
QAir = inlet air flowrate xAir = inlet air Nitrogen composition

PERU LNG 2009 3
7. Mass balance
7.3. Mass balance exercise

A
customer want to produce N2 at a purity of 1ppm O2.
Residual Gas
He
wants to use his air network producing 4000 Nm3/h.
A
AIR
APSA L
classical O2 content in the Residual gas is 30 % for such a plant. is not considered in the calculation composition : 78.11 % N2, 0.93% Ar, 20.96% O2
Argon
GAN
Air
How
much Nitrogen he will produce in these conditions ?

PERU LNG 2009 4
OVERVIEW OF APSA L CONTROL
PERU LNG 2009
9. Process Flow Diagram : Warm Skid
PERU LNG 2009
9. Process Flow Diagram : Cold Box
PERU LNG 2009
9. Process Flow Diagram : LIN Storage
PERU LNG 2009
GENERAL SAFETY
PERU LNG - 2009
Safety issues on APSA-L
General Safety Issues

General hazards in industrial environment Hazards specific to ASU
CnHm related hazards

Identification Prevention
PERU LNG - 2009
General Safety Rules

What kind of risks ?

Running machines Electricity Pressure Noise Under-oxygenation (Anoxia) Over-oxygenation Cryogenic temperatures High temperatures Burning
PERU LNG - 2009
Example: Pressure hazard

THE DANGER FROM PRESSURISED EQUIPMENT IS DUE TO THE QUANTITY OF ENERGY STORED IN THE DEVICE TO COMPRESS THE FLUIDS IT CONTAINS.
THIS ENE
RGY CAN BE CONSIDERABLE!
IN CASE OF RUPTURE: THIS ENERGY CAUSES ABRUPT EXPANSION OF THE FLUID.
LEAK AND BURSTING

31
EXPLOSION
PERU LNG - 2009 4
Example: Pressure hazard (continued)

PIPING AND CONTAINERS COMPLIANT WITH CURRENT REGULATIONS ALWAYS MAKE SURE THERE IS ZERO PRESSURE BEFORE SERVICE OPERATIONS
-> Design codes -> Scheduled inspections -> Tests SAFETY DEVICES
SAFETY MEASURES
OBSERVE SERVICE OPERATION PROCEDURES
REPORT ANY DEFECT OBSERVED ON A DEVICE, A PIPE OR SAFETY PART IMMEDIATELY

PERU LNG - 2009 5
32
Usual Hazardous works :

Work at high levels Digging work Hoisting and handling equipments Traffic Electricity Machines Work on piping or vessel Welding Sources of radioactivity
PERU LNG - 2009

Safety Management
Defining clearly responsibilities Approvals and qualifications

Qualified and trained workers Qualified subcontractors

Procedures
Work permit Electrical / Mechanical isolation
Equipments
PPE Certified tools / machinery
EIS Management?
PERU LNG - 2009
Usual Personal Safety equipment

Helmet Safety glasses and adequate face shields for specific hazards (chipping, acid work, welding, molten metals ) Ear plugs and noise-proof head sets Safety shoes Clean and Fire-proof clothing Safety mittens or gloves Protective masks with suitable filter Safety belt or harness if necessary
PERU LNG - 2009
ASU Related Safety

Gas Hazards
Processed gases of ASU involve 2 main specific hazards 1) Inflammation or explosion 2) Anoxia
Inflammation or explosion
Causes
Presence of flammable gas in air Oxygen enriched atmosphere (more than 21% oxygen) liquid oxygen filling station oxygen expansion valve station oxygen metering station liquid or gaseous oxygen vent
PERU LNG - 2009 9
Concerned zones
O2 gas hazard
PROPERTIES
GAS ENABLES AND MAINTAINS COMBUSTION. .
SAFETY MEASURES
No leaks
DETECTION O 2%
After analysis if O 2 = 21%
WITH AIR
COLOUR
NAME
IDENTIFICATION of pipes and storage locations.
Purge venting to the outside
PERU LNG - 2009
10
O2 gas hazard (continued)

OXYGEN O 2
PERCEPTION DENSITY/AIR
Colourless, odourless, tasteless. d = 1.1

AIR
SPECIAL PRECAUTIONS
21%
Detection with alarm if % O2 in air exceeds 25%. No grease, no oil.
NORMAL PROPORTION IN AIR EFFECT OF OXYGEN ENRICHMENT ON COMBUSTION Fuels ignite more easily. Flames much hotter and spread more quickly
% O2 in air Effect on combustion FASTER COMBUSTION QUICK COMBUSTION
INSTANTANEOUS COMBUSTION EXPLOSION
No particles. Clean clothing made from fire resistant textiles Controlled speed with slow manoeuvres. Floors clean and made from non combustible materials.
25% 30% 50%
PERU LNG - 2009
11
ASU Related Safety

Gas Hazards
Anoxia
2 types
Sudden : less than 6% O2, victim falls down immediately Slow : different steps, deeper breath, heart beats, no attention, thinking wrong, no fell pain .
Causes
Gas containing not enough oxygen under an assimilable form by the human body Inner cold box & Outer cold box Confined area or insufficiently ventilated Analysers rooms, or cabinets, control room Trenches or low points (sewer, pits) When using cryogenic liquids (nitrogen, argon ) In vessels of the purification unit (desorption of beds)
PERU LNG - 2009 12
Concerned zones

N2 gas hazard
Normal breathing
PROPERTIES
GAS DOES NOT SUPPORT LIFE. WHEN THESE GASES ARE PRESENT: THE QUANTITY OF O 2 DECREASES, ATMOSPHERE UNDER OXYGENATED, ASPHYXIA.
21% O2 18% O 2
Vertigo, headaches Asphyxia
SAFETY MEASURES
DETECTION
Alarm if O <18%
2
0% O 2
After analysis if O 2= 21%
or
If O2 < 18%
No leaks
COLOUR
NAME
WITH AIR
IDENTIFICATION of pipes and storage locations.
Purge venting to the outside
PERU LNG - 2009
13
ASU Related Safety

Cold Hazards General

Liquefied gas concentrates in a small volume big amount of matter

Effects
Every touch with liquefied gas causes frostbite similar to burn Skin and lungs can be damaged by cold atmosphere Lower the temperature, longer the touch, more serious effects are Hypothermia can cause death
Safety rules
Do not touch cold material Do not stay in a cold atmosphere Do not walk in a zone where cryogenic liquid has flown Do not purge voluntarily cryogenic liquids on the ground Take care of wet clothes
PERU LNG - 2009 14
ASU Related Safety

Operating in Heat Insulated Area

Perlite Insulation (cold box, exchanger box)

Perlite : hydrated silicate pre-submitted to an expansion Highly irritant material to be handled with gloves, glasses and mask Extremely light and fluid (a fall in perlite lead to death)
Rock-wool insulation (cold tank, exchanger box)

Highly itching material Work in a tunnel highly dangerous (risk of collapsing)
Nearly all heat insulated area are considered CONFINED SPACE specific entry rules apply
PERU LNG - 2009
15
HYDROCARBONS SAFETY
PERU LNG 2009
Hydrocarbons Safety
1.
CnHm Hazards: Explanations
1. Risks related to the impurities in the bath type vaporizers 2. Right/wrong operation of the E02 vaporizer 3. Right/wrong operation of the front end purification (FEP)
2.
Hazards Controls:
The 8 Golden Rules
PERU LNG 2009
Hydrocarbons Safety
Some characteristics of the main impurities present in the atmosphere

Impurity Formula Normal content in air in ppm Solubility Limit in LOX at - 181C in ppm no second phase
128 000-250 000 13 000-30 000
Inflamability Equilibrium limit in O2 in ppm 54000 30000 27000 25000 21000 21000 18000 coefficient K in LOX at - 181C 0.3 5,2 E-5 2,0 E-3 3,4 E-2 5,0 E-7 5,0 E-6 1,3 E-10 3,3 E-3 7,0 E-4
Methane Ethane Ethylene Acetylene Propane Propylene n Butane Carbon dioxide Nitrous oxide Ozone
CH4 C2H6 C2H4 C2H2 C3H8 C3H6 nC4H10 CO2 N2O O3
<5 < 0,5 < 0,5 < 0,5 <1 <1 <1 < 400 < 0,6 < 0,1
4-6 9 800 3 600 - 6 700 700 4-5 140 - 160 no second phase
PERU LNG 2009
Hydrocarbons Safety
Bath type vaporizer operation (APSA-L)
Internal type (main vaporiser E02)

LRV
LP
Important RECIRCULATION of liquid (thermosiphon effect): - around 1 Nm3 vaporised *

Rare gases purge Ne, He, H2
- for 50 Nm3 of non-vaporised LR *
LR Purge
GAN & LIN Prod.
HP
* figures corresponding to an exchanger completely immersed

PERU LNG 2009 4
Hydrocarbons Safety
Proper and Wrong operation of a bath type vaporizer

Normal operation
Gas = 100 Nm3/h + Liq = 5000 Nm3/h N20 = 41 ppm
Reduced feed
Liq = 25 Nm3/h N2O = 160 ppm Gas = 100 Nm3/h N20 =100 ppb
DEPOSIT N2O
Heat to vaporise 100
Heat to vaporise 100
Liq = 5100 Nm3/h N20 = 40 ppm
Liq = 125 Nm3/h N20 = 40 ppm *

* considering CO2 in that case, only 1 ppm in the feed would lead to deposit
PERU LNG 2009 5
Hydrocarbons Safety

CORRECT VAPORISATION DRY VAPORISATION
GAS LIFT STOPPED
TOO LOW LEVEL

Gas lift in normal operation. Recycling = up to 50 times the vaporised flowrate Solubility limit is reached. Deposits of CnHm, CO2 or N2O are building up Concentration is increasing
PERU LNG 2009
Hydrocarbons Safety

DISTILLATION after pluging of a channel in the vaporiser
Pluging by solid : - suspended solids (aerosol of oil - dust of adsorbent) - dissolved impurities CO2, N2O after reaching the solubility limit. Then concentration in liquid impurities (CH4 - C3H8 - C2H6)
PERU LNG 2009
Hydrocarbons Safety

Normal Operation: Excess liquid flowing out No concentration Normal level Dry Boiling: No liquid out Concentration build up Deposit starts if liquid gets saturated and Contaminants cannot be eliminated with the gas phase
Low level
Low level
PERU LNG 2009
Hydrocarbons Safety
Application: APSA-L E02 Vaporizer
CnHm enter
LRV
VAPO E02
CnHm exit
LRV QLRV LR QLR
IN QIN
PI
4.2 barg
LR
QAIR QAIR LR = AIR AIR K QLRV + QLR QLR

Purge PurgeRate Rate= =0.2% 0.2%of ofAIR AIRFLOW FLOW Concentration Concentrationfactor factor= =500 500
Air Aircontent content CH 5 ppm 4 = CH 4 = 5 ppm C 2H 6 = 0.2 ppm C 2H6 = 0.2 ppm C 2H 2 = C H = 0.5 0.5ppm ppm
2 2
LOX LOXcontent content CH 2500 4 = CH 2500ppm ppm 4 = C H = 100 ppm 2 H 6 C 100 ppm 2 6 = C H = 250 2 H 2 = C 250 ppm ppm
2 2
PERU LNG 2009 9
Hydrocarbons Safety
Adsorption Principles
The Front End Purification (FEP) is designed to stop completely :

H2O CO2
H2O and CO2 free air
But other impurities from the air pass through the adsorber before CO2 :
CH4 C2H6 C3H8 N2O C2H4 Methane Ethane Propane Nitrous Oxide Ethylene
Air with all contaminants

ADSORPTIO N
REACTIVATION
And Andmay mayenter enterinto intothe theCold ColdBox Box

PERU LNG 2009 10
Hydrocarbons Safety
Adsorption capacity of Front End Purification

total Front end purificaton
H2O, CO2, nC4H10, C2H2, O3.
partial
C3H8, NO H2, CO, CH4, C2H6
N2O, NO2, C2H4
none
ADSORPTION LEVELS
PERU LNG 2009
11
Hydrocarbons Safety
Contaminants dangerous for the purification
Some CONTAMINANTS can badly damage the molecular sieves

They are mainly: - the acid gases : CI2, SO2, H2S etc., NH3 - miscellaneous organic molecules
PERU LNG 2009
12
Hydrocarbons Safety
Potential hazards in the Front End Purification

Abrasion of a part of the adsorbent (velocity too high)

Risk of channeling = by pass flow Risk of lower adsorption capacity Risk of introducing adsorbent dust in the cold box

Internal bypass of the beds, by leakage Liquid water carry-over (separation problem) :
CO2 adsorption capacity is reduced if water vapor reaches the molecular sieve A part of the adsorbent can be destroyed

Presence of some aerosols which go through the FEP Presence of dangerous contaminants in the mole sieve Too long adsorption phase :
break-trough of CO2 or H2O
Example of CO2 entering an APSA L4 : -10 ppb of CO2 entering continuously : 2 kg per year -2 ppm of CO2 during 15 minutes : 15 grams of deposit
PERU LNG 2009 13
Hydrocarbons Safety
Triangle of FIRE applied to E02 Vaporizer
FU EL
CnHm deposits CnHm dissolved Aluminium
Velocity of gaz / liquid? Ozone decomposition ? Static Electricity ?
OXYGEN
LR Purity Liquid state
ER EN
GY
PERU LNG 2009 14
Hydrocarbons Safety
Event sequence to explosion

Spontaneous ignition of reactive material on Aluminum platefin main vaporizer in cold box
Explosive rupture of cryogenic distillation column
Combustion of accumulated hydrocarbon contaminants on Aluminum vaporizer cores
Flash vaporization of cryogenic liquid
Presence of airborne fuel - aerosols light hydrocarbons concentration/accumulation in LOX & on Aluminum surfaces with N2O or CO2 ice & dry-boiling
Massive runaway combustion of Aluminum exchangers in oxygen (exothermic reaction)
Uncontrolled escalation to explosion
PERU LNG 2009
15
Hydrocarbons Safety
Risks related to the impurities in the vaporizers
During the operation of the ASU, the concentration of impurities in the bath of the vaporiser may lead to strong explosions : - Hydrocarbons, such as Ethane, Propane, Ethylene, Acetylene, or aerosols, can concentrate and/or deposit. The Lower Inflamability Limit is reached in LOX - Ozone is a strong ignition agent These explosion hazards exist when there is a lack of LOX (LR) feed into the passages, caused by : - Too low level of the bath of the vaporiser - Plugging of passages by solid deposits: CO2* , N2O*, dust... * Risk of accidental deposit of CO2 or N2O, due to their low solubility in LOX, 5 ppm and 160 ppm respectively.
PERU LNG 2009
16
Hydrocarbons Safety
Possible Damage Overview
PERU LNG 2009
17
Hydrocarbons Safety
How to control the CnHm hazards
The 8 GOLDEN RULES

1. Environmental Survey 2. Operation of FEP 3. Operation of Vaporizer 4. Deconcentration purge 5. Periodical Deriming 6. Control of the transient phases 7. Control of other sources of pollution 8. EIS management
PERU LNG 2009
18
Hydrocarbons Safety
1. Environmental Survey
1. Surrounding industries and distances 2. Atmospheric conditions 3. Air analysis 4. Communication with surrounding industries The plant operator shall maintain an environment file including following information : Nearby industries liable to release gases Distances between those potentials sources and the air intake of the ASU (+ height of sources) Presence of haze (organic aerosols)
Polluted site or Not ?
PERU LNG 2009
19
Hydrocarbons Safety
2. Operation of FEP Complete retention of CO2 in FEP is of vital importance for the unit (low solubility in RL : 5 ppm at 181C) Air conditions evolutions have an impact on :
Mass Flow Rate Pressure Temperature Duration of the adsorption Air Cleanliness
Regeneration conditions act on :

Regeneration gas flow rate Duration of heating Heating temperature
PERU LNG 2009
20
Hydrocarbons Safety
2. Operation of FEP
FEP performance control : CO2 content analysis at outlet

1 ppm 3 ppm Alarm Shutdown of the unit after 15 minutes
Control of the desorption effectiveness : temperature peak

Alarm in case of no heat peak
Recommended REGEX operation after CO2 breakthrough test (3 years)
PERU LNG 2009
21
Hydrocarbons Safety
3. Control of the level of bath vaporizer

Upper level tap (100%of the transmitter scale) Level sample 100% immersion (Level Set Point) 90% immersion (Low Level Threshold) 80% immersion (Very Low Level Threshold) Height, m 70% Lower tap of LT2 LT2
LT1 2nd transmitter = improvement
0% immersion Lower level tap for LT1 (0% of LT1)
Plant Shutdown after 1 hour

Transmitters:
Calibration using the heights and the density of the liquid Check with level sample gauge
PERU LNG 2009
22
Hydrocarbons Safety
4. Deconcentration Purge Deconcentration line: 1/2.LR.04 Deconcentration type: intermittent purge (but permanently in service) Deconcentration volume: at least 0.2% of the air flow Deconcentration control: sequence linked to the level of vaporizer E02
Time of purge is constant Level drop is monitored Alarm is raised in case of low level drop
PERU LNG 2009
23
Hydrocarbons Safety
5. Periodical Deriming
The objective is to vaporize any contaminants which may have entered in the equipment of the cold box
Every 3 years Applied to cold box equipment only (compressor and FEP are running independently) Deriming operation
Low pressure High flow
Deriming mean
Dry air Usually ambient temperature Exceptionally hot temperature (65C is the limit for the aluminum heat exchanger)
Refer to PFD
PERU LNG 2009 24
Hydrocarbons Safety
6. Transient Phases
Start-up
As much liquid production as possible Minimum air input Liquid assist after first liquid production (LIN only)
Shut-down
Drain ALL liquid after 48h shut-down Drain if E02 level is below 80% immersion

Change of run-type
Maintain vaporizers level
Normal run
Control of frosted pipes and dead-ends
PERU LNG 2009
25
Hydrocarbons Safety
7. Other sources of pollution

Machine: Turbine
Lubricated machine Seal gas pressure
Instrument air
Usually: dry air Back-up ?
Air intake
Car parking, Truck unloading Hot works, fires... Exchanger water leak...
PERU LNG 2009
26
Hydrocarbons Safety
8. E.I.S Management
E.I.S = Element Important for Safety

Safety Protection Loops Alarm and Shutdowns parameters
Set-points Delay Hysteresis
Qualified personnel
Management of Change
PERU LNG 2009
27
Hydrocarbons Safety
Conclusions Hazard Hazardis isa acombination combinationof of A Apolluted pollutedatmosphere atmosphere A Anot notproper properoperation operationof ofthe thevaporizer vaporizer
Can Can lead lead to to severe severe accidents accidents

THE THEGOLDEN GOLDENRULES RULES
1. 1.Environmental EnvironmentalSurvey Survey 2. 2.Operation Operationof ofFEP FEP 3. 3.Operation Operationof ofVaporizer Vaporizer 4. 4.Deconcentration Deconcentrationpurge purge 5. 5.Periodical PeriodicalDeriming Deriming 6. 6.Control Controlof ofthe thetransient transientphases phases 7. 7.Control Controlof ofother othersources sourcesof ofpollution pollution 8. 8.EIS EISmanagement management
PERU LNG 2009 28
DERIMING AND EXCEPTIONAL REGENERATION
PERU LNG 2009
1. Deriming Procedure
Deriming and Drying Procedure

Purpose Remove contaminants in every locations they are subject to accumulate Accelerate to warm up of the plant after a shutdown Main recommendations All liquids should be completely purged before starting deriming Start deriming with all valves closed 6 phases in order to defrost progressively the plant Proceed from a clean circuit towards a dirty circuit Use the lowest pressure possible Keep the deriming outlets wide open Control the deriming flow rate in order to avoid high velocities
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PERU LNG 2009
PERU LNG 2009
2. Exceptional Regeneration
Purpose Remove impurities not desorbed during regular reactivation Exceptional procedure to avoid any damage Carry out : At initial start-up
To clean from contaminants accumulated during transportation To control adsorption capacity respect to design capacity
After an pollution accident

Late reversal Liquid water from R02 Unusual temperature at the inlet of the dryers
After repetitive CO2 break-through
PERU LNG 2009
Highlights Passing dry gas at low pressure and increased temperature Long period of time through the bottle (24 hours at least) Temperature in the bottles may range from 230 to 290C Temperature increase : two steps to avoid damage of adsorbents
Temperature
290C
Outlet electrical heater Bottle bottom

~ 240C
145C ~120C
Effective Effectivepart partof of exceptional regeneration exceptional regeneration
Phase 1
Phase 2
Phase 3
Phase 4
Time
PERU LNG 2009
Q(WN = 121 Nm3/h 2) ) Q(WN 2 = 121 Nm3/h PP (V-6701 A) == 1.033 bar abs (V-6701 A) 1.033 bar abs TI 513 outlet = 240C TI 513 outlet = 240C
ATM
EH-6701 PV 561 From Exchangers

TI 580
Instrument Air Deriming Air To Exchangers
KV 540 V-6701 A
ATM
V-6701 B
KV 515
TI 513
ATM
AIR C01
Inlet Water Outlet Water

PERU LNG 2009 7
PERU LNG NITROGEN GENERATOR SYSTEM TRAINING
PERU LNG 2009
NITROGEN GENERATOR TRAINING

1. Process description APSA L 2. Air Purification Unit 2. 1 Exceptional Regeneration 3. Turbine Expanders 4. Cold box warm standstill 5. Production 6. Trip and shutdown 7. Start up cold standstill 8. Control loop description 9. Stutdown
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1. Process description APSA L
Compression
Purification
Heat exchange
Cold production
Distillation
PERU LNG 2009
2. Air Purification Unit

To start it we should do a Initialization; for this the inlet valve should be close and the inlet pressure PT_502 at 0 bar. You choose the bottle which be in regeneration and press initialization button. The Bottles will place in HP isolation step. You open inlet valve FV_580 to pressurize the bottle on line and the HP cold box Open it to have enough flow for regeneration. You should open the KV_540 to send air in regeneration bottle and put the PV_561 in auto mode with SP at 160 mbar. When flow from cold box is enough you close KV_540. When the timer step is done and you have all condition, a indication Next step appear you can move manually the sequence by Next step button If you need to move all the sequence you have a Bypass button to bypass the heating and cooling timer. But this dont bypass other step. If all is correct you should put the sequence in auto mode in order to avoid CO2 breakthrough. You can open air production valve FV561 and put in auto SP 750 AIR Nm3/h In case of problem you must put the sequence in manual mode and check the problem.
PERU LNG 2009 4

1. High Pressure Isolation Isolation of the bottle in adsorption Timer step 360s 2. Depressurization The bottle is slowly depressurized in opposite direction to the adsorption flow. Drop pressure of bottle should be done during step timer else we have Depressurization to long and stop the sequence. Timer step 300s
Cold Box N2 heater
Cold Box N2 heater
KV_540
cold box
KV_540
cold box
KV_530
KV_530
V-6701A
Hp isolation
V-6701B
In service
V-6701A
Hp isolation
V-6701B
In service
venting
venting
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
Air
Air
PERU LNG 2009

3.Blow-off Start to send flow thought the bottle. We should have minimum 8 mbar of DP on heater else Alarm EH-6701 Heater low flow. Timer step 60s
Cold Box N2 heater
4.Heating The heater starts to increase temperature at around 150C In case of the outlet temperature is always < 135c after 15 min Alarm Heater start fault Timer step 45mn
Cold Box N2 heater
KV_540
cold box
KV_540
cold box
KV_530
KV_530
V-6701A
Blow Off
V-6701B
In service
V-6701A
Heating
V-6701B
In service
venting
venting
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
Air
Air
PERU LNG 2009

5. Cooling The heater is turned off and we keep the waste nitrogen Flow to cold down the adsorbent. If the outlet heater temperature is not drop less 50c in 10min: Alarm Stop heater fault Timer step 75min
Cold Box N2 heater
6. Low Pressure Isolation Isolation of the bottle regenerate Timer step 120s
KV_540
cold box
Cold Box N2 heater
KV_540
cold box
KV_530
KV_530
V-6701A
Cooling
V-6701B
In service
V-6701A
LP isolation
V-6701B
In service
venting
venting
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
Air
Air
PERU LNG 2009

7. Pressurization The bottle is pressurized with purified air from the outlet of the other bottle. If the pressure dont increase 2 Alarms Pressurization to long and Bottles DP to high Timer step 1332 s
Cold Box N2 heater
8. Parallel The purpose of this step is to reduce the temperature of the purified gas entering the exchangers: Timer step 60s
KV_540
cold box
Cold Box N2 heater
KV_540
cold box
KV_530
KV_530
V-6701A
Pressurization
V-6701B
In service
V-6701A
Parallel
V-6701B
In service
venting
venting
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
KV_515 KV_516 KV_510
KV_525 KV_526 KV_520
Air
Air
PERU LNG 2009

Temperature
Heater temperature
Inlet temperature
Outlet temperature
Cold Desorption
Hot Desorption heater pick
Blow off temperature
Heating
Cooling
Time
Total Time on line 160 min; Heating Temperature 150C In case of trip you should note the bottle in regeneration and the bottle on line with the time of both in order to restart on same position.
PERU LNG 2009 9
2. 1 Exceptional Regeneration
The exceptional regeneration is done only on firth start up and after stop maintenance each 2 years. Or if you make a C02 breakthrough. You should do it in manual mode and activate the Regex button.
290C
150C
120C
PHASE 1
PHASE 2
PHASE 33
PHASE 4
PERU LNG 2009 10
2.1 Exceptional Regeneration

Phase 1 The first heating step is equal to a normal regeneration. Start flow to EH-6701 and Temperature at 150C When outlet temperature reach 120C start phase 2 Depending of the amount of water adsorbed on the alumina, the duration of phase 1 is expected to be 2h to 4h.
Phase 2 The temperature should reach 290C, adjust the regeneration flow to this. When outlet temperature is at 230C start phase 3. The expected time of this phase is about 2 h to 3h.
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11
2.1 Exceptional Regeneration

Phase 3 Depending on the heat loss, a final temperature of approximately 230C is reached at the outlet of the vessel for exceptional regeneration. The gas at the outlet of the heater is still at 290C. Hold the temperature for 6 to 9 hours.
Phase 4 Turn off the heater (cooling step of the normal sequence) and wait until the temperature at the outlet of the bottle indicates 25C. The expected time of this step is about 4 h to 6 h
PERU LNG 2009
12
3. Turbine Expanders
RTS No low oil tank level and oil temperature > 24C Pressure seal gas > 1.5 bar Request Button to start the oil pump Oil pressure > 6,5 HP Column level not high Inlet valve close Nozzle valve close.
PERU LNG 2009
13
4. Start up Cold Box warm standstill

The cold box must be start only after drying, in order to remove totally the water. Some dew point should be done at different point and we should have around - 60C. The derimming procedure can be use to be sure all lines are dry. - Cooling down: When the compressor running the HP column is pressurized. You start to make flow by opening the FV_565B and put it in Auto mode witch SP at 60% of nominal flow ~2700Nm3/h. You open the HV_502 at 60% to make flow through the E-6702. Open the LV_564 fully to start flow on LP column and send gas to the turbine and put the PV_590 in auto mode with SP at 4 bar.
PERU LNG 2009
14
4. Cold box warm standstill

The oil pump turbine was started and you have the RTS. Open the isolation valve HV_562, the turbine will run at low speed. Open slowly the Nozzle valve by the LIC_552 in manual mode to increase the speed more than 7000 Nm3/h in 2min else you trip. Increase the nozzle opening to close the PV_590 but take care at pressure of LP column and speed of turbine maximum 35 000 rpm Monitoring the outlet temperature TI_558 to dont reach -180C This cold will cold the main exchanger E-6701 and decrease the air temperature monitoring on TI552A. Be careful the TI_582 and TI_565 outlet exchanger should be stay warm. The cooling of E-6702 and LP column is monitoring on TI84A and TI556.
PERU LNG 2009 15
4. Cold box warm standstill

With the temperature drop the flow will increase Put the FIC_580 in Auto mode to control inlet flow, the SP would be adjusting in order to have a homogeny cooling and not so fast around -1c by hour to avoid any stress on columns and pipes The first liquid appear in HP column, at around 30% open purge to evacuate it, and after the liquid in LP column. When the liquid are rebuild, close the HV_502 at 50%. Adjust the turbine load and put the LIC_552A in auto mode SP at 45% Put the LV_564 in auto mode SP at 100%
PERU LNG 2009
16
5. Production
Gan Production: When the cold box is stable and the purity AIT_568 is < 50 PPM Put FIC_580 in Cascade mode and insert the flow request on HIC565 Activate the Gan Production Button. This will put in auto mode the flow controller FIC_565A with SP the HIC565 and adjust the FIC77B SP at 5% less in order to send gas to customer; If consummation is enough the FV_565B valve will be totally close and in case of flow degrease or stop the valve will adjust the flow out of cold box. In case of purity come > 200 ppm the valve FV_565A will close and when the purity came back the valve will open automatically.
PERU LNG 2009
17
5. Production
Lin Production: The Lin production can be activate only if the turbine run, if we have enough liquid in HP column and a good purity. If the pressure PI606/PI626 < 9.8 bar and LI605/LI625 < 90%. This activation will increase the air inlet flow of 6%.
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18
6. Trip
To avoid unit trip directly the faults are separated but after some delays if no action are take the unit will trip.
-
Dryer sequence stop. I20T

Air to V-6701A delta pressure is too high during pressurisation of V-6701A (PI_502 PI_512) (UA502A) Air to V-6701B delta pressure is too high during pressurisation of V-6701B (PI_502 PI_522) (UA502B) V-6701A depressurization step is too long (UAn52A) V-6701A pressurization step is too long (UAn52B) V-6701B depressurization step is too long (UAn55A) V-6701B pressurization step is too long (UAn55B) Electrical heater EH-6701 heating start failure (UAn57A) Electrical heater EH-6701 heating stop failure (UAn57B) Heater flow end tempo alarm PDALL_534 (PDALL_534) Outlet C02 analyse alarm too high (AAHH542)
If this condition appear the cycle is stop and a timer of 15 min start. If the problem is not resolve you activate next trip.
PERU LNG 2009
19
6. Trip
Turbine TRIP
Emergency stop (HS584) Outlet turbine temperature alarm too low (TALL558) Turbine seal gas too low pressure (PALL570) Turbine oil too low pressure (PALL572) or (PSLL575B) Turbine speed alarm low (575Turbine speed alarm too high (SAHH575) or (SSHH575) Turbine vibration alarm too high (VAHH575) Turbine oil pumps off (ES_586A&B) Turbine oil return temperature alarm too high (TAHH571) Unit Shut Down The trip of the turbine dont trip the cold box but after some time you will lose the liquid level.
PERU LNG 2009
20
6. Trip
Cold Box TRIP

Condenser E-6702 level alarm too high (LAHH551) HP column C-6701 level alarm too high (LAHH552) Condenser E-6702 level alarm too low (LALL551) + Gan prod Condenser E-6702 not submerged alarm (LALL564) + Gan prod Emergency button (HSn53) Gaseous Nitrogen temperature alarm too low (TALL565) Waste oxygen temperature alarm too low (TALL582) Condenser E-6702 level alarm low (LAL551) + Gan prod + Turbine off Instrumentation air pressure too low (PAL550) Unit Trip Instrumentation open loop ESD
Close Lin Production and Gan Production FV_565A the valve B will open. Open LP column purge when level come high.
PERU LNG 2009
21
6. Trip
Unit
TRIP
ESD Inlet air pressure too low (PALL502) Air Purification Shut Down > 15 min Emergency switch HS n53 Inlet Air temperature alarm too high (TAHH 502) 30sec delay. Waste Oxygen pressure alarm too high (PAHH 571) 30sec delay. Cold box trip CnHm purge trip 24hr delay CnHm alarm too high (AAHH_584) 24hr delay Cold box inlet air temperature alarm too high (TAHH_580) Instrument air header pressure low ( PALL 550) Operator stop Reduce N2 Production request at 2250 Nm3/H Trip APU; Cold Box; Turbine Action more: Inlet air valveFV_580at 15%.
PERU LNG 2009
22
7. Star up Cold standstill

To start we should not be in level high alarm in Hp column and LP column, purge liquid if you need. Start the oil turbine system When compressor and Apu have started and in auto mode. Put the LV_564 in auto with Sp at 100% in order to keep level in LP column Start flow with the FV_565B SP 2700Nm3/h. When turbine is RTS start it in manual mode, increase speed higher than minimal at this moment the level in the vaporizer will start to increase and decrease according to the pressure fluctuation until the PIC590 stabilizes the pressure. When all is stable put the LIC_552A in auto. Be careful the temperature decrease faster than Warm standstill. Also the flow increase so put the FIC_580 in auto mode. When the purity come back start the production
PERU LNG 2009 23
8. Control loop description

PIC 561 Waste gas pressure outlet turbine control Functions: 1. ensure that enough residual gas is going through the heater (PV_561 closed) for regeneration of the adsorption bottles 2. maintain the turbine discharge pressure stable
If the pressure PI561 then the valve PV_561 Action direct This controller must remain in automatic mode Typical set point = 160 mbar NB: forced jump at every bottle change-over (+/- 20%)
PX 561 PT 561
COLD BOX
PIC 561
Silencer
E-6701
PV_561
Atm
V-6701B V-6701A
PERU LNG 2009
24

PIC 590 E-6702 Condenser pressure AND D01 inlet pressure Functions: 1. Maintain E-6702 condenser pressure stable in order to keep a column pressure stable 2. AND keep the turbine delta P constant If the pressure PI590 then the valve PV_590 Action direct This controller must remain in automatic mode Typical set point = 4,2 bar

PIC 590 PT 590
PV_590
E-6702
D01 D01
To V6701A/V6701B
PERU LNG 2009 25

FIC 565A
Gaseous nitrogen to customer

Function: Limit the nitrogen flow to the network at the requested flow available from the cold box. If the flow FI565 then the valve FV565 Action reverse The set point: SP565A = HIC565 (In Cascade mode) (HIC565 => GAN request by the operator on the DCS)
FX 565
PT 565 FT 565 TE 565
FIC 565A
FY 565A
<
PT 556
PIC 556
C-6701
GAN
E-6701
FV615A
To GAN Network
PERU LNG 2009 26

FIC 565B Gaseous nitrogen to the vent Function: Maintain a (nearly) constant flow out of the cold box if the flow to the network is lower than the requested flow. If the flow FI565 then the valve FV_565B Action reverse In cascade mode the set point: SP565B = SP565A -5% (Calculated by the PLC)
FX 565
PT 565 FT 565 TE 565
S04t
Silencer
FIC 565B
C-6701
GAN
E-6701
FV_565B
ATM
PERU LNG 2009
27

FIC_580 Control the air flow at the inlet of the cold box Function: Maintain a constant air flow to the Cold Box If the flow FXI580 then the valve FV_580 Action reverse In cascade mode the set point is calculated according to the nitrogen requirement RSP580 = (A * HIC565) + HIC502BG +- AIC565 (A is the extraction ratio adjusted during start-up) HIC565 GAN request by operator HIC502BG Bias request by operator AIC565 Can be increase or decrease SP value 500 Nm3/h
FX 580
V-6701A V-6701B
HIC 565BG
BIAS Request
FIC FIC
SP
FIC FIC
HIC 565
GAN Request
C01 C01
FV_580
PT 580
FT 580
TE 580
AIC 565
+- 500 Nm3/h AIR TO COLD BOX PERU LNG 2009 28

LIC_552A
Column C-6701 Level

Function: Keep a sufficient cold production when the plant is running in Gas mode. The output of this controller is acting on the turbine nozzles If the level LI552 then the valve HV_573 Action reverse Typical set point = 45 %
D01 D01
C-6701
LT 552
LIC 552A
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29

LIC_552B Column C-6701 Level Function: Control the column level while the plant is running in liquid production mode . The output of this controller is acting on the LV552B If the level LI552 then the valve LV552B Action direct Typical set point = 45 % (same as LIC_552A)
LV552B
LIN STORAGE
C-6701
LT 552 LIC 552B
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30

LIC564 Condenser E-6702 Level Function: Maintain always the E-6702 condenser level above the top of the condenser by liquid transfer from C-6701 to E-6702. If the level LI564 then the valve LV_564 Action reverse The set point = 100 % immersion. For safety reason (to avoid dry vaporization and then hydrocarbon concentration), it must be respected. Automatic mode.
LIC 564
E-6702
LV_564
LT 564
C-6701
PERU LNG 2009 31

SIC575 Turbine speed controller Function: Maintain the speed to the nominal value by acting on the Inlet Guide Vanes (IGVs) If the speed SI575 then the IGVs HV_573 Action reverse This controller is generally not used because the IGVs are normally controlled by LIC_552A
HV_573
D01 D01
ST 575
SIC 575
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32

Oil Brake valve Turbine oil flow adjustment Function: This is not a controller, it just allows you to act manually on the oil brake and by this mean, adjust the frigorific capabilities of the turbine. It is adjusted manually to change between LIN and GAN runs If the valve is , the speed and the power Action reverse This valve must never be totally closed in order to avoid any over speed or any damage in the cartridge by over heating of the oil. The oil temperature should never exceed 100C
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33
9. Shutdown
Shutdown Before stop the plant to be sure Nitrogen backup work properly and the air instrumentation backup is available. To shut Down the plant you can put the Operator stop button this is equal at unit trip or unload each part and stop it. The check valve CVW011 will close to avoid liquid purge go back to waste line. It is better to stop Air Purification Unit after a complete regeneration of bottles in order to restart on this. If the plant is stop less than 48 hours we can keep the liquid inside monitoring by hydrocarbon analyzer. To be sure valve PV_590 and PVn89 are in auto mode and the HV_502 is fully open to control pressure. If it is more than 2 days the liquids must be drain to avoid concentration of hydrocarbon and if it is for maintenance the plant should be warm up.
PERU LNG 2009 34

000 CG VT 0001

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E&C Cryogenics Standard Plants

E&C Cryogenics Standard Plants

Author : ALSPE/CoH Revision: 0- 02-2009

Taining - PERU LNG

CGG 09_018 dt 10th of april 2009

PERU LNG 2009

1.1. Nitrogen On-Site Supply System

95% 10 100 1000 10000

PERU LNG 2009

1.2. APSA L /LE : Process and Markets

Classic 7-10 barA N2

Chemicals Refineries Glass

Claude Cycle 2-3 barA N2

Booster Re-cycle Ultra High Purity

PERU LNG 2009

1.3. Air Separation Unit (ASU) Inlet & Outlet

SOURCE : Atmospheric Air

Air Separation Unit

PRODUCTS: O2, N2, Ar

PERU LNG 2009

variable 300 700 ppm 3 5 ppm < 0.5 ppm

PERU LNG 2009

1.5. Cryogenic production stages ?

COLD PRODUCTION HEAT EXCHANGE

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1.6. Cryogenic production modular approach

DISTILLATION LIQUID PRODUCTS

PERU LNG 2009

1.7. Plants Modules Overview

PERU LNG 2009

1.8. APSA L : Global Scheme

APSA L LIN GAN

Nitrogen recovery 40%

PERU LNG 2009

1.9. APSA L : Process Cycle

Air inlet C01

PERU LNG 2009

PERU LNG - 2009

PERU LNG - 2009

Purification Purification requirements requirements

WATER CO2 CnHm N2O

- explosion explosion risk risk with with CnHm CnHm

PERU LNG - 2009

N2 O2 Ar H2 O CO2 CnHm Ne He CH4 Kr H2 Xe

600 ppm 0.5 ppm

+ other natural or industrial impurities : hydrocarbons,CO, H2S, NO2 .....

Process Process presentation presentation

ELIMINATION ELIMINATION OF OF HYDROCARBONS HYDROCARBONS EXCEPT EXCEPT

PERU LNG - 2009

Adsorption Adsorption Process Process

Pores DIFFUSION/ FIXATION

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Adsorption Adsorption Process Process

Reversible Process : Adsorption & Desorption

Adsorbent Adsorbent characteristics characteristics

Each gram of product particle has a surface equivalent to a tennis court

ACTIVATED CARBON ALUMINA MOLECULAR SIEVE: Type A, Type X

C AL2O3 SiO2, Na2O CaO, K2O

PERU LNG - 2009

Selectivity Selectivity of of the the process process

Affinity (Adsorbent / Molecule) depends on :