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Simplify BOG recondenser design and operation—Part 1

S. P. B. Lemmers, Vopak LNG Holding BV, Rotterdam, The Netherlands

LNG receiving and regasification terminals connect the intermittent process of LNG carrier
unloading and/or loading with the mostly continuous process of LNG vaporization and gas
transmission into a sendout pipeline system.

In addition to these LNG carrier operations, truck/train loading operations can take place
simultaneously. During all operational modes of the LNG terminal, boiloff gas (BOG) is
produced, which requires processing to avoid flaring or venting (under normal operating
conditions) and to minimize the environmental impact of the facility.

There are several options to choose from for the design of BOG recondensers used in LNG
terminals. Design options and equipment installations are reviewed, with a focus on the
most optimal methods.

BOG recondensation approach

Of the various options for BOG handling, the most common approach is recondensing the
BOG in a BOG recondenser. Discussed are the design, process control and operational
elements of the most common types of BOG recondensers used in LNG terminals
worldwide.

BOG generation and handling. Generation of BOG takes place in any operational mode of
the LNG terminal. BOG is produced mainly because the LNG is stored at cryogenic
conditions in a much warmer ambient environment. The generation of BOG is the result of
several factors:

Steady-state heat leak into the LNG carrier, LNG storage tanks, process equipment
and LNG process piping
Mechanical energy input by process equipment [e.g., low-pressure (LP) in-tank and
high-pressure (HP) sendout pumps]
Displaced vapors from the LNG carrier and LNG storage tanks due to unloading,
loading and sendout flowrates
BOG generation and/or reduction due to creation of BOG/LNG equilibrium in LNG
storage tanks
Elevation difference between LNG from the LNG carrier and LNG from the storage
tanks
Atmospheric pressure changes.
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The amount of BOG generated is a function of the absolute rates of the above phenomena,
and it changes significantly between the various operational modes. The main operational
modes of LNG terminals are the holding mode (with gas sendout, but no LNG carrier
unloading or loading) and the LNG carrier unloading and/or loading mode(s), also with gas
sendout.

Several common options exist for handling BOG generation in an LNG terminal:

LP compression into a fuel gas system—e.g., for LNG vaporization inside the LNG
terminal, for use by nearby industrial consumers or for power generation
HP compression to natural gas pipeline pressures
BOG reliquefaction inside the LNG terminal and return as LNG to the storage tanks
LP compression into a BOG recondenser, in which the BOG is recondensed to LNG.

The last BOG handling option, which focuses on the BOG recondenser, is considered here.

BOG recondensers are commonly applied in LNG terminals where there is continuous
sendout of natural gas via vaporization of LNG. Both HP compression and BOG
reliquefaction have high capital and operating costs, whereas LP compression requires a
substantial nearby consumer of LP fuel gas. However, such a consumer is generally not
available.

Vapor handling system. The vapor handling system option including the BOG recondenser
consists of the BOG desuperheater (required for reducing BOG compressor suction
temperature), the LP BOG compressor(s) and the BOG recondenser (Fig. 1).

Fig. 1. Process flow of a typical LNG receiving and regasification terminal.

In the BOG recondenser, the BOG is brought into contact with subcooled LNG for
recondensation of the BOG. The LNG is subcooled because the BOG recondenser operates
at substantially higher pressures (typically between 5 barg and 10 barg) than the LNG
storage tanks, which are slightly above atmospheric pressure.

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In the holding mode of operation, all BOG from the LNG storage tanks is routed to the LP
BOG compressors, which compress the BOG into the BOG recondenser. During the
unloading mode of operation, most of the BOG is returned to the LNG carrier to
compensate for liquid volume reduction in the LNG carrier, with the balance going to the LP
BOG compressors and the BOG recondenser. The directions of flow are vice versa for the
loading mode of operation.

During these main operational modes, LNG is continuously pressurized and vaporized on
the sendout pipeline system. When there is no gas sendout, the LNG terminal is in zero
sendout mode. In this operational mode, other solutions for BOG handling should be
pursued, as the BOG recondenser cannot be operational without LNG sendout for
recondensation.

Conventional BOG recondenser designs are based on cocurrent downflow direct-contact

packed-bed columns for recondensation, with a holdup section for the downstream HP
pumps. They are installed between the LP pumps and compressors and the HP pumps.
The setup essentially consists of a partly packed column that has two primary functions.
The upper portion houses a packed-bed section in which BOG is contacted with subcooled
LNG to recondense the BOG. The lower portion of the BOG recondenser with the holdup
section serves as a surge drum for the HP pumps, and the skirt height and level provide the
required net positive suction head (NPSH) for the HP pumps.

BOG recondenser design

It is essential to consider practical design elements, such as piping connections, HP pump

vents, minimum flow recycle, pressure safety valves (PSVs), vent/flare options and padding
gas, for two types of BOG recondenser designs.

Designs fundamentals. There are two basic designs for BOG recondensers: The annular
space type and the top packed-bed section type. Both of these designs operate in the
cocurrent downflow regime, which means that both BOG and LNG are introduced at the top
of the BOG recondenser and flow downward. The less common countercurrent and static-
mixing BOG recondenser designs are not considered here.

Annular space type. This first type contacts the LNG and BOG in a packed bed in the
center, surrounded by an annular space. The LNG and BOG are fed to the central packed-
bed section. The liquid level in the BOG recondenser annular space is controlled by
manipulating the inlet LNG flowrate to the packed-bed section, since all of the LNG is
directed to the packed-bed section. The packed-bed liquid level, which is distinct from the
level in the annular space (as is the pressure), is not directly controlled and will vary with
the BOG/LNG flow ratio in the center section. The LNG levels and vapor pressures in the
center section and annular space differ during operation.

Top packed-bed section type. The second type of design has a packed section spanning
the complete vessel diameter of the top section, and it has a bottom LNG inlet for the
holdup sections of the HP pumps. The single level is controlled via the bottom LNG inlet
flow.

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LNG for recondensation, which is part of the LNG flow to the BOG recondenser, is
introduced into the top packed-bed section and brought into contact with the BOG for
recondensation. The pressure in the packed-bed section is identical to the pressure in the
holdup section (except for some pressure drop over the packed bed), and it can be
controlled by the LNG supply to the top packed-bed section of the BOG recondenser. Fig. 2
shows examples of the two basic types of BOG recondensers.

Fig. 2. BOG recondensers: Annular space type (left) and top packed-bed section
type (right).

Mechanical design complexity comparison. From a mechanical design point of view, it is

obvious that design and construction of an annular space type BOG recondenser are more
complex. The annular packed-bed section needs to be supported from the top and should
not vibrate at the bottom.

The top packed-bed section type supports the bed all the way around and, therefore, is
more robust. This design features a dedicated removal nozzle for when the packing
requires replacement of the top packed-bed section, while the annular space type requires
more decommissioning and reinstatement work.

Process piping connections. Although both types of BOG recondenser designs fulfill the
same functions—i.e., to recondense BOG and provide NPSH for the HP pumps—the
process piping connections to HP pumps, vent/flare, padding gas, PSVs, operational and
maintenance bypasses, and control valves can differ from design to design. Designers may
even vary the lineup and controls for the same type of BOG recondenser.

Minimum flow recycle and vent connections. The HP pump, being a high-head, multiple-
stage canned pump, requires minimum flow protection. The HP canned pump motors are
cooled by the LNG. To ensure that the HP pump remains filled with liquid and under
cryogenic conditions at all times, the BOG generated from the surrounding heat leak and
HP pump mechanical energy is vented. Both the minimum flow recycle and vent lines can
be directed either to the BOG recondenser or to the LNG storage tank(s).

Minimum flow recycle to LNG tanks. Directing the recycle back to the LNG storage tanks
provides the advantage of no disturbance to the BOG recondenser operation, such as an
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impact on pressure and level control. It also allows for continued sendout of natural gas
when the BOG recondenser is out of operation for statutory inspection or maintenance.
When the BOG recondenser is out of operation for inspection or maintenance for a
prolonged period of time, the BOG must be vented and/or flared.

However, a 900-pound-pressure-rating, stainless steel head, sized for recycle operation

from all HP pumps, needs to be routed from the HP pump area to the top of the storage
tanks for this design. This requirement impacts the capital expenditure (CAPEX) of the
project, as well as the operational expenditure (OPEX), since the generated BOG from the
HP recycle operation requires another cycle of compression by the LP BOG compressors.

Venting of HP pumps to LNG tanks. When the HP pumps are not located near the BOG
recondenser (for example, when an LNG terminal has been revamped and there is no space
available next to the BOG recondenser), dedicated vent pots are required for the HP pumps
to provide the required NPSH and maintain cryogenic conditions in the HP pump.

The vent pots are provided with reverse-acting level control (wherein vent gas flow from the
pot is manipulated), and the outlet of the vent pot is directed to more than one LNG storage
tank via a dedicated common vent header. This arrangement not only increases CAPEX, but
it also has operational downsides.

If the level control of the vent pots fails, then LNG is spilled into the vent head to the LNG
storage tanks, or it can reach the vent and/or flare knockout drum installed at a low point.
This is problematic because the vent header generally runs from the vent pots on low
elevation over sleepers or a pipe rack to the top of the LNG storage tanks. This setup
inherently forms a “low point” in which LNG can be trapped, blocking the free flow of vent
gas from the HP pumps. This issue can cascade to vent pot control of other HP pumps,
potentially resulting in the warming of the HP pumps. This scenario is depicted in Fig. 3.

Fig. 3. BOG recondenser piping connections.

The introduction of the vent pots with controls also introduces flanges, safety implications
for fire and gas, cold protection zones and additional control complexity and maintenance
requirements.

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Venting of HP pump minimum flow recycle to recondenser. Routing both the minimum
flow recycle and the HP pump vents directly to the BOG recondenser provides a simpler
design solution, with shorter process connections and fewer process controls, provided
that the HP pumps are located in the vicinity of the BOG recondenser. Locating the HP
pumps near the BOG recondenser is normally possible during LNG terminal design.

The individual HP pump vents and common HP pump vent header must be continuously
sloped to the top of the BOG recondenser to enable free vent gas flow (i.e., bubbles created
by excess heat) to the recondenser. No level controls or dedicated vent pots are required,
and the level in the common HP pump vent line is equal to that of the BOG recondenser,
since these levels are communicating.

Fig. 4 shows the two design examples applicable to both BOG recondenser types. The
minimum flow recycle connection from the HP pumps to the BOG recondenser should be
brought into the holdup section of the BOG recondenser, and into the annular section for
an annular type BOG recondenser. A baffle “impingement” plate should be considered to
avoid excess turbulence.

Fig. 4. HP pump vent and minimum flow recycle connections to the BOG
recondenser or tank(s).

However, the alternative of bringing the HP pump minimum flow recycle to the packed
section is not recommended, since this process lineup will disturb the pressure controls in
the top of the BOG recondenser during HP pump recycle operation.

Please note that routing the recycle and vent connections to the BOG recondenser is only
feasible if there is no need for continued LNG terminal sendout operations when prolonged
shutdowns (i.e., statutory periodic inspections) cannot be avoided.

Padding gas connection. Padding gas, taken from downstream of the LNG vaporizers, is
required to maintain a minimum pressure in the BOG recondenser for maintaining required
NPSH and stable HP pump operation. BOG is supplied to the top of the packed section.
Therefore, the most logical location to introduce padding gas is the BOG inlet connection,
and all mechanical support and internals for receiving gas from the top are already
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designed and installed for this purpose. The introduction of padding gas at any other
location (e.g., underneath the packed bed or directly into the annular space) requires an
additional nozzle on the BOG recondenser, as well as additional mechanical internal design
and reinforcements of the packed bed.

Introducing padding gas underneath the packed bed makes sense if the bed can be
blocked by fouling. However, the BOG recondenser service is one of the cleanest in the oil
and gas industry, and blocking of the packed section by fouling is not feasible. Padding gas
can always be safely introduced from the top.

Pressure safety valve connection. The connection to the PSV should be on the top of the
BOG recondenser, preferably from the BOG inlet connection, for similar reasons as the
padding gas supply connection (i.e., the additional nozzle, and no possibility of blocking the
packed bed due to fouling). Connecting the PSV underneath the packed bed is often
proposed; this stems from refinery services where mist mats and packed sections can be
blocked due to fouling.

However, LNG and BOG services are very clean. The PSV comes in a twin configuration to
enable online maintenance, since the BOG recondenser forms a single point of exposure for
LNG terminal availability.

Operational bypass. Some BOG recondenser designs apply an operational bypass, in which
a portion of the LNG from the LP pumps bypasses the BOG recondenser and flows directly
into the HP pump suction cans. This is done to decrease the size of the holdup section (for
any given holdup section residence time) and to reduce vessel costs. Such a bypass is
technically feasible since not all of the LNG is required for BOG recondensation.

However, the introduction of an operational bypass does require additional flow controls
that will open the bypass when the flow through the BOG recondenser increases above the
design flow through the bottom section. Therefore, instrument functions, control valves and
cold-keeping bypasses must be added to the design. In Fig. 5, a flow controller (FC 2),
associated controls and hardware are added to the design when an operational bypass is
installed. Experience shows that the added cost offsets the CAPEX savings from the BOG
recondenser size reduction.

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 Fig. 5. BOG recondenser operational and maintenance bypasses.

Reductions in the BOG holdup section (and, therefore, the BOG recondenser size) are
usually possible without an operational bypass, simply by reducing the holdup time from
traditionally conservative values. Experience has shown that holdup time is not critical;
designs with zero holdup time that pump LNG directly into the HP pump suction are in
operation. Designs where all of the LNG passes through the BOG recondenser require a
higher LNG control valve turndown than do designs with an operational bypass.

Inspection and maintenance bypass. Authorities sometimes impose the statutory

requirement for scheduled internal inspection and BOG recondenser entry, even for a clean
and noncorrosive service like BOG recondensation. To enable vessel entry and inspection
while continuing sendout operation (with inevitable temporary venting/flaring of BOG), a
maintenance bypass for LNG around the BOG recondenser, cold-keeping bypasses and

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positive isolation must be introduced. During this operation, the HP vent and HP pump
minimum flow recycle can only be diverted to the tanks, requiring the installation of an
additional means of venting the HP pumps (i.e., vent pots).

Due to the various disadvantages associated with the installation of a

maintenance/inspection bypass for statutory inspection, many projects ask to be exempt
from the standard requirements for vessel entry and physical inspection. Instead, these
projects propose a reliability-based online inspection. Projects should ask for this
exemption at the start so that the exemption is available during the design stage, and so
that CAPEX for maintenance bypasses and isolation valves can be eliminated.

Platforms and control valves at grade. Some designs use platforms and have control
valves installed at these elevated platforms. The introduction of many platforms at several
levels not only increases the cost, but it also complicates operations and maintenance. It is
recommended to have piping dressed/clipped on the BOG recondenser, and to avoid the
use of concrete/structural steel platforms, as a means of reducing the overall project cost.

In addition, it is beneficial to operations and maintenance to install control valves as often

as possible at grade level. Recently installed control valves have much better turndown
than previous designs, and they eliminate the need for control valves to be in a split-range
configuration. The reduction in the amount of required control valves, brought about by this
improved turndown, reduces the need to introduce more platforms.

Platforms will be congested, complex and more complicated to operate and maintain when
there are many of them, and also when the control valves around the BOG recondenser
form a single point of exposure (requiring the BOG recondenser operation to stop upon
failure) when they are supplied with bypass.

In one industry example, control valves were passing and leaking at a top platform level.
Workers discovered the leaking valves only because they heard noises at grade level.
Therefore, by installing more platforms, significant operational issues may go undetected.

Fig. 6 shows a design with minimal platforms, where the only reason for workers to climb
to the top platform of the BOG recondenser is to conduct PSV inspection and maintenance.

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Fig. 6. BOG recondenser design with minimized platforms and control valves at
grade (left) vs. a traditional platform design (right).

Design takeaway

A few conclusions can be drawn from the preceding discussion of BOG recondenser
design:

From a mechanical design point of view, an annular space type of BOG recondenser
is more complex and, therefore, likely more costly
Minimum flow recycle and vents on HP pumps should be routed to the nearby BOG
recondenser, rather than to the LNG storage tanks, to minimize operational
complexity and CAPEX:
HP pump vent pots (required for venting to LNG storage tanks) introduce
flanges, fire zones and operational difficulties when the level control fails
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 Running the minimum flow recycle for the HP pumps back to the LNG storage
tanks introduces a costly, 900-pound-pressure-rating return line
No separate padding gas connections to the BOG recondenser are required; padding
gas should enter through the BOG inlet connection
The BOG recondenser service is clean, and the packed bed cannot foul up; the
connection to the PSV should, therefore, be installed on the BOG inlet line, which
eliminates the requirement of a dedicated nozzle
It is doubtful if the installation of an operational bypass actually saves costs, as the
bypass comes with control valves, cold-keeping bypasses, and additional process
control complexity, which largely offsets the savings
from a reduced BOG recondenser holdup volume
It is strongly recommended to ask for exemption of statutory BOG recondenser
inspection and entry from authorities; when such an exemption is granted, a costly
maintenance bypass may be eliminated from the project
To reduce costs and complexity, control valves should be installed as often as
possible at grade, minimizing the number of platforms
Piping to the BOG recondenser should be dressed/clipped as much as possible.

Less is more. An overview of the most commonly used design methods for BOG
recondensers reveals the advantages and disadvantages in BOG recondenser design. BOG
recondensers of both types—annular space type and packed-bed type—have been installed
and operated successfully.

As a general recommendation, BOG recondenser designers are advised to consider simple

designs, as discussed in Part 1 of this article. Part 2, to be published in the July/August
2014 issue, will examine the operational aspects of BOG recondensers. GP

Acknowledgment

The author thanks Michiel Baerends from Fluor BV and his colleagues at Vopak LNG
Holding BV (part of Koninklijke Vopak NV), as well as Gate terminal BV for reviewing the
article prior to publication.

Sander P. B. Lemmers has more than 17 years of experience in both the technical and
business facets of the global engineering, procurement and construction industry. His
technical competencies include the engineering and design of LNG production and
regasification facilities, offshore oil and gas production, gas compression platforms,
ethylene cracking complexes, gas purification and NGL recovery processes. His business
competencies include knowledge of management information systems, management
accounting, sales coordination, strategic business planning and business risk
management. He holds a BSc degree and an MSc degree in industrial engineering and
management and an MSc degree in chemical engineering from Twente University for
Technical and Social Sciences in Enschede, The Netherlands.
At present, Mr. Lemmers is involved in the development of LNG and other liquefied gas
terminals in Southeast Asia, Scandinavia, France and The Netherlands.

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