LNG Production
in Stavanger
2
Contents.
3 Introduction
6 The basics
10 Plant features
Overall process
Natural gas treatment
Natural gas liquefaction
LNG storage and loading system
Coil-wound heat exchanger
17 Project execution
23 Closing remarks
24 Contact
3
Introduction.
With a LNG production capacity of 900 TPD or 0.3 MTPA the plant
represents a new category of LNG plant types. This category
of Small to Mid-Scale LNG plants shows the same reliability,
robustness and safety features as world-scale LNG plants, while
integration in existing sites is much less complex with moderate
CAPEX and shorter project execution time.
The plant is operated in base load mode and em- ing terminal in Sweden. There it is regasified in markets and provides a great improvement
ploys intermediate storage of the LNG product submerged combustion vaporizers and directly to the energy supply situation in Sweden. This
in an insulated tank before it is loaded to road routed to a nearby refinery. A smaller quantity of paper describes the Stavanger LNG facilities
tankers or LNG carrier ships. The trucks carry the the LNG received in this terminal is loaded into from gas treatment, liquefaction with a single
LNG over long distances to satellite stations in road trucks for transport to remote locations in mixed refrigerant cycle in a coil-wound heat
various cities of Norway. After revaporization Sweden. exchanger, through storage, to unloading and
of the LNG the natural gas is finally distributed distribution of the LNG to various consumers in
to a variety of industrial and private consum- As LNG is considered the most environmentally Norway and Sweden.
ers. Another part of the LNG is transported by friendly hydrocarbon fuel, it is expected that this
LNG carrier ship to the Nynäshamn LNG receiv- domestic natural gas initiative creates new gas
4
and work camps are moderate in comparison and Project execution schedule
in many cases a significant part of the work force Prior to commencement of any significant plant Based on a high-quality basis of design there are
recruits are from the region.In summary, plot ar- engineering activities, item s such as exploration contractors available to quote a firm price for en-
ea, work force and camp size as well as explo- on a world-scale LNG plant, appraisal and envi- gineering, procurement and erection (EPC) of a
sion loads and building heights are lower for ronmental approval activities as well as the de- mid-scale LNG plant. All in all it may take around
mid-scale LNG plants. These factors, especially velopment of field infrastructure may take many fifteen months to properly prepare for final in-
at the lower end of the capacity range, allow the years. Plant engineering activities prior to a final vestment decision from commencement of plant
LNG plant to be located in industrial zones and investment decision (FID) in world-scale LNG, in engineering activities. Construction activities of
thereby also benefit from existing infrastructure. most cases, involve a pre-FEED and a FEED study. mid-scale LNG projects will take in the order of
Some sites which are typically considered as a one and a half years less than construction activi-
mid-scale LNG location such as refinery sites, The latter already includes a significant level of ties of world-scale LNG projects. Mid-scale LNG
iron ore, bauxite or container terminals may detail engineering activities, including a 30% projects from commencement of first plant engi-
even offer wharf and jetty infrastructure. All the plant model as a basis for a reasonably precise neering activities can be expected to produce first
above can reduce overall mid-scale LNG project cost estimate. This need for detailed engineer- LNG at l east two years earlier than a world-scale
costs significantly. ing is to a large extent driven by the sheer size LNG plant. Taking into account the entire project
and complexity of world-scale LNG projects. It development phase mid-scale LNG projects, in
Modularization typically takes two years to complete pre-FEED many cases, will produce first LNG four to five
Module sizes and weights are considerably small- and FEED activities prior to any final investment years earlier than world-scale LNG projects.
er for mid-scale LNG plants where even the tall- decision.
est modules would not exceed a footprint of
20 m x 20 m and weights would not exceed Mid-scale LNG projects, compared to world-scale
1,000 metric tons. Such sizes and weights can LNG projects, are fast track projects. Securing
be easily lifted without being limited to only a off-take rights from existing natural gas pipeline
few available special cranes, as would be the systems prior to starting serious plant engineer-
case for bigger modules being applied for world ing activities takes comparatively little time.
-scale LNG plants. Furthermore, sites are more Mid-scale LNG projects in most cases can be ten-
accessible with smaller modules and it is likely dered without upfront pre-FEED and FEED.
that modules can be hauled in without dedicat-
ed new port investment in the case of mid–scale
LNG plant modules. Last, but not least, a larger
pool of potential module yards is available around
the world for moderately sized modules. Some
of the more complex and heavier modules of
world –scale LNG plant s can only be built by a
handful of yards.
The Basics.
Basic data process design Feed gas composition Utilities
The design of the plant is based on state-of- Composition (mole %): Instrument air, nitrogen and demineralized water
the-art natural gas liquefaction technology. – Nitrogen 0.65 are produced within the LNG plant. Electric pow-
– Methane 88.22 er, potable water and fire water are supplied from
Design basis – Ethane 8.43 outside Battery Limit.
The Stavanger LNG plant consists of natural gas – Propane 0.55
treatment, gas liquefaction, LNG tank and load- – Butanes 0.05 The tank return gas as well as vapour return from
ing facilities as well as utilities. The liquefaction – Pentanes 0.00 LNG loading is utilized as fuel gas. The fuel gas is
process is based on a most efficient single mixed used for flare pilots and fired heater of the hot
refrigerant cycle. In addition, CO2 as well as traces of H2S and oil unit. Not used fuel gas is sent as tail gas to the
sulfur are present in the feed gas. The feed local gas grid at Battery Limit.
The LNG production capacity of the plant is 900 gas operating pressure is 120 bar g.
tpd with an expected on-stream time of 330 days The hot oil system provides the process heat for
per year. Design hourly liquefaction capacity is LNG specification the plant at two temperature levels. Two cycles
37 t/h with a storage capacity of 30,000 m³ of Composition (mole %): are introduced, a medium temperature cycle for
LNG, which is the equivalent of approx. 12 days – Nitrogen max 1.0 regeneration of the amine and a high tempera-
production. The capacity of the LNG send-out ture cycle for heating of regeneration gas for the
and distribution system meets the requirement Ambient site conditions driers.
of loading 25 - 100 m³/h by truck and 150 - The average ambient temperature ranges from
1.000 m³/h by ship (dependent on ship size). 30°C in the warmest to -15°C in the coldest month.
The design temperature for air-cooling is 13.2°C.
Process features
The main process and utility units are illustrated
in the block diagram in Fig 1. The mixed refriger-
ant cycle liquefaction process requires the com-
ponents nitrogen, ethylene, propane, butane,
and a portion of the compressed tank return gas
(Linde patent). Refrigerant nitrogen and purge
nitrogen are identical and both generated in a
nitrogen package.
Fuel gas
Liqu. refr.
Vap. refr.
Purified Dry
feed gas feed gas LNG
Waste water
LNG truck
loading station
(loading bay)
Waste water
LOW EMISSIONS
Plant features.
Overall process Natural gas liquefaction
The plant consists of natural gas treatment and After CO2 and H2O removal, the natural gas is
liquefaction, LNG storage tank, one LNG ship routed to the cold part of the process, which
loading and one truck filling station. The natural features three coil-wound heat exchanger bun-
gas is cooled, liquefied and subcooled in a coil- dles integrated in one shell (“rocket”), as well
wound heat exchanger by a most efficient single as several separation vessels. The natural gas
mixed refrigerant cycle. This cycle provides cold is first cooled in the feed gas precooler. The
temperatures by Joule-Thomson expansion and purified gas is condensed in a feed gas liquefier
liquid vaporization of the mixed refrigerant with- and subcooled in a feed gas subcooler (fig. 2).
in the shell of the CWHE. The refrigerant cycle is
recompressed in an electric motor driven inte-
grally geared turbo compressor.
LNG
MR1
NG
11
The coil-wound heat exchanger (CWHE) can be accommodate several process streams in one used most efficiently. The proprietary suspen-
considered as the heart of the LNG plant. Its pur- exchanger. Each CWHE is specifically tailor made sion system allows the Linde CWHE to cope with
pose is to liquefy the dried and cleaned natural for the thermal & hydraulic performance require- large temperature differences and changes as
gas (NG). This is realized by pre-cooling, liquefy- ments. Heating surfaces up to 40,000 square well as sharp pressure drops during operation.
ing and sub-cooling natural gas in a three stage metres can be installed in heat exchangers bun- In particular during start-ups, shut downs and
heat exchanger. The Linde proprietary coil-wound dles with diameters up to 5.5 metres and a total operational upset conditions Linde CWHE are
heat exchanger technology perfectly fulfils the weight of 250 tons in the Linde own fabrication well known as a very robust equipment without
requirements for such equipment. facility. Larger units are feasible and are assem- any kind of bundle sagging. Temperature ele-
bled in yards close to the coast. ments as well as laser-optic measurement de-
With its history going back as far as to the time vices installed during bundle winding provide
when Carl von Linde for the first time success- In general a CWHE comprises multiple layers of the relevant data for optimum process control.
fully liquefied air on an industrial scale, Linde is tubes particularly selected for the anticipated
now looking back on more than thousand coil- service, which are wound helically around a cen- After assembly with the pre-fabricated pressure
wound heat exchangers successfully manufac- tre pipe. For the reason of perfect tightness, the vessel shell, the complete CWHE is not only
tured and brought to operation. CWHE’s are bundle tubes are welded to the tube sheet and subject to pressure testing, but also extensive
robust, compact and reliable and serve a wide for highest process efficiency the bundle is cov- tightness testing with pure helium to ensure
field of applications with a large range of tem- ered by an additional inner shell, the so called highest quality. Linde coil-wound heat exchang-
perature, pressure and can be designed and shroud. A highly developed distribution system ers are 100% self-draining which reduces pos-
fabricated in various materials. They are suitable above the bundle makes sure that for falling film sible corrosion defects, accumulation of process
for single as well as two phase streams and can evaporation, the installed heating surface is impurities and defrost time.
With the Stavanger project, for the first time a Further, the transition joints from aluminium to The Stavanger CWHE is fully made of stainless
stainless steel MCHE for LNG liquefaction service steel piping becomes obsolete. External loads steel, including all its internals. With a total
was put into operation. Based on historical and imposed from structural attachments such as weight of 120 metric tons and a heating area
market reasons, aluminium was the state of the platforms or pipe racks can be accommodated of about the size of a football field and tubes as
art material for the application of a CWHE in easily. Inspections on the heat exchanger and long as the distance from Berlin to Copenhagen
natural gas business. maintenance on the surrounding installation can the MCHE ranges in the medium scale of world
be executed by local staff without special alu- class MCHEs in LNG business. However, due to its
Even though aluminium is the state of the art minium know-how. unique material selection it can be considered as
material, stainless steel can provide some ben- one of a kind.
efits. Among those benefits are factors such as
higher design pressures and temperatures, high-
er material strength values and less or no tube
leakage. Especially for off-shore and marine
service stainless steel is by far better in fatigue
resistance. As per Linde´s experience it is not
recommendable to use aluminium in any part
of a heat exchanger for such applications.
Temperature is probably the quantity that is The Stavanger CWHE has been equipped with a
measured most in LNG plants. Thermocouples or new approach to measure temperature, which is
thermistors are mainly applied to piping, vessels based on optical fibers. The fiber optic distrib-
and machinery. When looking at the main heat uted temperature sensing (DTS) technique is an
exchanger, special knowledge for installation of innovative way to obtain thousands of tempera-
temperature measurements has been developed ture measurements with comparatively low
in the past. The aim was to gain insight into effort. A single optical fiber can replace many
temperature distribution and thus liquid distribu- point sensors because temperature is measured
tion inside the bundles of the coil wound heat along the fiber with a local resolution of down to
exchanger (CWHE). However, more detailed half a meter. By co-installation of the fiber with
information is coupled to number of measure- the tubes during fabrication of the CWHE a huge
ment points and thus to installation effort. amount of single measurement points is acces-
sible from inside the bundle of the CWHE.
16
Briefly, the measurement principle is based on In the figure, the shell-side temperature distri-
the Raman-effect as a result of laser-light trans- bution in the liquefier bundle during cool-down
mitted through the fiber and scattering of spec- is shown in form of a longitudinal section. Since
tral components in backward direction. This full 3D temperature data is available, also cross
components travel to the starting point of the sections or iso-surfaces of temperature can be
fiber where they are filtered and detected. The generated to visualize radial or axial distribution,
intensities of these spectral components are pinch points or other effects.
related to the temperature at the origin of this
scattering process. Because the velocity of light This is truly a step change in process measure-
propagation in the optical fiber is well known, ment. The wealth of information from this inno-
the location can be determined from the time- vative measurement technique not only sup-
of-flight of the returning backscattered light. ports R&D and engineering for improvement of
CWHEs but will also support our customers with
The DTS system enables more than 4000 single valuable real-time data for optimizing energy
measurement points from the bundles of the efficiency or detecting critical states, e.g. in
Stavanger CWHE, which is a huge number com- LNG-FPSO.
pared to the few single point measurements
used previously. During start-up of the LNG
plant, the system has already proven its useful-
ness and successfully demonstrated its capabili-
ties even at the low temperatures of natural gas
liquefaction.
Project execution.
Linde Engineering successfully delivered to the The client provided the atmospheric LNG tank This ahead of time completion was a result of
client a fully operational base load LNG plant. with a total capacity of 30,000 m³ and the LNG the early definition of handover systems and
The overall scope of work was to realize through jetty as an open berth structure with concrete pressure/electrical/instrumentation test packs
all phases of project execution the implemen- beams and slabs and a loading platform area of during the engineering phase, which allowed a
tation of a LNG production plant in Risavika near 40 m x 20 m. Linde’s scope covered the whole prioritised pre-manufacturing of piping, sequen-
Stavanger in Norway, according to Norwegian/ process equipment for the LNG tank including tial piping installation and pressure testing,
European Standard NS EN 1473. The LNG plant the removable electric motor driven LNG Load- followed by a staggered mechanical completion
was built on a 300 m x 100 m plot, which was ing Pumps and the marine loading arm for the of subsystems .
partly reclaimed from sea. The scope of work jetty with a capacity up to 10,000 m³/h (typical
consisted of the complete LNG plant started-up ship tank volume). The construction phase was supported by the
for commercial production with all tests passed “integrated completion management system
successfully. The plant achieved the status “commissioning (ICM)”, a newly developed and for the Stavanger
completed and in all respect ready for LNG pro- project customized software package which al-
duction” in August 2010, 1 month ahead of lowed the detailed follow up and exact progress
schedule. measuring of all relevant construction activities.
18
A part of the Stavanger LNG product is trans- LNG receiving terminal in Nynäshamn/
ported by vessel to the Nynäshamn LNG receiv- Sweden
ing terminal in Sweden. It is partly regasified in Linde’s subsidiary, Cryo AB from Gothenburg, CRYO AB has designed and manufactured more
submerged combustion vaporizers and routed has built this mid-scale LNG terminal in Sweden than 60 flat bottom tanks for cryogenic service,
to a nearby refinery. A smaller quantity of the with a 20,000 m3 full containment LNG storage mostly for air gases, in Europe and South Ameri-
LNG received in this terminal is loaded into LNG tank, which is the first terminal in the country. ca. In addition, cryogenic equipment for natural
trucks for road transport to remote locations in Linde’s sister company AGA Sweden is the own- gas has been delivered to a number of projects.
Sweden. er and operator of this terminal. AGA is engaged
in the value chain of small-scale LNG, by ship-
ping it from the LNG plant at Stavanger to the
terminal, before distributing it by truck to the
end clients.
LNG receiving terminal main operations Ship unloading station (jetty) LNG storage tank
Fig. 4 shows a sketch of the LNG receiving termi- The terminal receives LNG from LNG carriers on a The LNG Storage Tank at the Terminal has a work-
nal. Its purpose is to perform the following tasks: regularly basis. The LNG is unloaded by means of ing capacity of 20,000 m3 and is a “full contain-
– Receive, Liquefied Natural Gas LNG pumps on board of the carrier. LNG is pumped ment tank” with operating pressures slightly
from ships to a loading arm at the Jetty station and further above atmospheric pressure. Two LNG pumps
– LNG storage to the LNG storage tank through an insulated are submerged in the liquid. LNG is pumped
– Handle BOG (Boil Off Gas) pipe. The normal loading of the LNG ship loading either to the re-condenser, to LNG trailers and/
– Supply pressurized and gasified NG (GNG) pump is 1000 m³/h. Only one of two pumps is in or to the booster pumps for refinery gas supply.
to Nynäs refinery operation, the other is in stand-by. Internal pump recirculation and continuous cool-
– Discharge LNG to trailers ing of external piping are also important tasks
From the LNG storage tank vapor is routed back for the LNG pumps.
to the carrier via another insulated pipe and a
separate loading (gas return) arm. The vapor On top of the LNG storage capacity, the storage
return line relieves displacement gas in the tank, by its vapor space, also accommodates a
storage tank caused by the “piston effect” from great gas buffering capacity. This gas buffering
the raising liquid level. The vapor is transferred capacity is used to collect and even out pressure
to the carrier where it counteracts the (vacuum) swings in the entire “uncompressed” gas volume
“piston” effect from the sinking liquid level. of the terminal. This includes discharge gas from
safety, and thermal relief valves. All such gas
sources are connected to the storage tank vapor
space via a main blow-off line.
Steam
Vaporizer
Gas cooler
Re-condenser GNG
to Nynäshamn
Buffer tank
Booster
BOG compressor
pumps
GNG
to Nynäshamn
Plant overall operational philosophy Environmental aspects have been considered All steel structures, piping systems and other
The terminal is designed for unmanned opera- when designing the terminal including design metal parts and equipment are connected to a
tion. Control and supervision may well be per- of process control. Emissions of NG to the envi- common equipotent bounding system. A zone
formed from a remote control room. Alarms will ronment are almost totally eliminated and emis- classification will prevent the existence of igni-
be transferred to operators on duty, directly via sions of combustion gases (flaring) will only tion sources at the terminal.
SMS or from the remote control room. All safety take place at rare occasions and only as a meas-
functions will be controlled by the PLC at the ure to avoid release of unburned combustible Additional precautions during ship unloading
terminal. The functions in the remote control gas. If any problems occur during ship unloading,
room will also be available at the local control pumping will cease immediately and valves to
room in the service building. Terminal layout and safety considerations isolate the transfer pipeline will close in a pre-
The terminal will be divided into four separate determined sequence. This sequence follows
The trailer filling process will be operated by the areas; jetty area, tank area, process area and recommendations by SIGTTO, Society of Interna-
truck driver. The trailer filling procedure has tank filling area. This layout, based on the con- tional Gas Tanker and Terminal Operation. It is
automatic functions for fast and reliable service. dition of the surroundings, provides increased controlled by equipment on the tanker and on
At ship unloading, the jetty has to be attended security since a potentially hazardous event in shore. The emergency shut down, ESD, proce-
by at least two operators. The operator will be one of the areas is not likely to affect the other dure can be initiated either from the ship or from
in contact with the ship and the remote control areas. the shore.
room during the whole unloading process. Be-
fore unloading from the ship, the operator will
have to inspect the equipment involved in the
operation lines, valves and instruments.
Closing remarks.
Small and mid-scale LNG technology will en- With the introduction of such LNG plants, com- Mid-scale LNG plants are an economically inter-
able industrial users, such as refineries and bined with the respective transport and regasi- esting alternative to world-scale LNG plants.
power plants, in stranded markets to switch to fication infrastructure, natural gas markets can While export schemes appear to require plant
cost efficient and environmental friendly gas. be dynamically developed. It is evident that natu- capacities above 500.000 tpa, merchant LNG
The demand for natural gas in Norway and ral gas, as a cleaner fuel, will play an increasingly schemes appear economically attractive already
Sweden is projected to increase in the near important role in the primary energy mix. at smaller capacities. Mid-scale LNG plants, by
future. The Stavanger LNG plant in connection virtue of their moderate size and complexity,
with the Nynäshamn LNG receiving terminal With the LNG from Stavanger plant, a high de- have the potential to be located in industrialized
will open a new era in meeting the increasing gree of flexibility in the energy supply will be areas which allows investment in infrastructure
demand in this area. made available to the benefit of all natural gas to be kept at reasonable levels. Capital require-
consumers with fluctuating or peak demand ments and execution risks are significantly lower
profiles. than in world-scale LNG projects. Moderate size
and complexity allows companies lacking the
The Stavanger LNG plant provides a means to resources of an international oil & gas major to
commercialize indigenous natural gas resources. develop and even fully control an LNG project
This, in return, supports the local economy and while enjoying an equal amount of off-take,
provides additional labor. level of safety, quality, reliability and a compara-
ble efficiency as in a minority shareholding of a
Furthermore the Stavanger LNG plant provides world-scale LNG project. Moreover, mid-scale
a “rubber tire pipeline” to small natural gas con- LNG offers a unique opportunity to monetize
sumers in Norway and Sweden. The transport of local or regional gas surpluses of moderate size
LNG via tanker trucks makes the distribution of in a fast track fashion.
natural gas to intermediate-sized consumers
also possible.
Linde’s Engineering Division is a leading player in the international plant engineering business. Across the globe, we have
delivered more than 4,000 plants and cover every step in the design, project management and construction of turnkey
industrial facilities. Our proven process and technology know-how plays an indispensable role in the success of our customers
across multiple industries – from crude oil, natural gas extraction and refining to chemical and metal processing.
At Linde, we value trusted, lasting business relationships with our customers. We listen carefully and collaborate closely with
you to meet your needs. This connection inspires us to develop innovative process technologies and equipment at our high-
tech R&D centres, labs and pilot plants – designed in close collaboration with our strategic partners and delivered with passion
by our employees working in more than 100 countries worldwide.
From the desert to the Arctic, from small- to world-scale, from standardised to customised builds, our specialists develop plant
solutions that operate reliably and cost-effectively under all conditions.
You can always rely on us to deliver the solutions and services that best fit your needs – anywhere in the world.