6.

LIQUID NATURAL GAS (LNG) TO COMPRESSED NATURAL

GAS (CNG)

COMPONENTS PRESENT IN CONVERSION OF LNG TO CNG ARE:-

 LNG TANKER – Double walled cryogenic tanker containing LNG (-1620 C) from
Gujarat state petronet limited, Dahej (Gujarat) to THINK Gas Bagroda (MP).

 SUBMERSIBLE PUMP - The pumps that transport LNG, such as those that move it
into, around, and out of the storage tanks on LNG tankers, must operate at cryogenic
temperatures. The pumps used must be highly reliable, durable and constructed of
compatible materials For LNG applications, specialised submerged motor-driven
cryogenic pumps are used. Some of the benefits of submerged operation include that,
as a cryogenic fluid, LNG is an excellent electrical insulator, and the motor is
completely isolated from oxygen in the atmosphere, eliminating the risk of fire or
explosion. This design also removes the need for rotating seals, which can be
problematic and introduce a potential point of failure. Submerged LNG pumps are
constructed as a single unit, with the pump mounted on the same shaft as the motor, to
be submerged in the LNG. Some of the cryogenic LNG fluid moves through the gap
between the pump’s rotor and stator to cool the motor. There are three main types
used – fixed, vessel-mounted and retractable – with various adaptations available to
suit the needs of a specific project and application.
 VARIABLE FREQUENCY DRIVE (VFD) - AC motor speed is controlled in two
ways either by controlling the voltage or frequency. Frequency controlling gives
better control due to constant flux density than voltage control. This is where the
working of VFDs comes to play. It is a power conversion device that converts the
 fixed voltage, fixed frequency of the input power to the variable voltage, the variable
frequency output to control AC induction motors.
It consists of power electronic devices (like IGBT, MOSFET), high speed central
controlling unit (such as a microprocessor, DSP), and optional sensing devices
depending on the application used.

 RESISTANCE TIME DETECTOR (RTD) - An RTD (Resistance Temperature

Detector) is a sensor whose resistance changes as its temperature changes. The
resistance increases as the temperature of the sensor increases. The resistance vs
temperature relationship is well known and is repeatable over time. An RTD is a
passive device. It does not produce an output on its own. External electronic devices
are used to measure the resistance of the sensor by passing a small electrical current
through the sensor to generate a voltage. Typically 1 mA or less measuring current, 5
mA maximum without the risk of self-heating.

 SOLENOID VALVE - Solenoid valves are electromechanically driven, quick-acting

safety devices to control gas supply to appliances and pipework while reinforcing an
efficient use of equipment. They are installed in LNG pumping equipment, metering
units, filling systems and gas and tank applications. The valves come with slow
opening and fast closing actuators. Solenoid valves can be configured to be normally
opened or closed.

Fig.4.2 – Solenoid Valve.

 LNG STORAGE TANKS - A liquefied natural gas storage tank or LNG storage tank
is a specialized type of storage tank used for the storage of Liquefied Natural Gas.
LNG storage tanks can be found in ground, above ground or in LNG carriers. The
common characteristic of LNG Storage tanks is the ability to store LNG at the very
low temperature of -162 °C (-260 °F). LNG storage tanks have double containers,
where the inner contains LNG and the outer container contains insulation materials.
Tanks vary greatly in size, depending on usage. In-ground LNG tanks are also used,
these are lined or unlined tanks beneath ground level.[2] The low temperature of the
 LNG freezes the soil and provides effective containment. The tank is sealed with an
aluminium alloy roof at ground level. All piping connected to the LNG tanks, whether
above ground or in-ground, are routed through the top of the vessel. In LNG storage
the pressure and temperature within the tank will continue to rise. LNG is a cryogen,
and is kept in its liquid state at very low temperatures. The temperature within the
tank will remain constant if the pressure is kept constant by allowing the boil off gas
to escape from the tank. This is known as auto-refrigeration. Lng storage tank
capacity is 113 kilolitres and Maximum allowable working pressure is 12 bar.
 Multiple Effect Evaporator – In regasification plant this unit is used to convert
Natural Gas from liquid state to Gaseous State. There are two set of evaporators, one
set is connected between PRS and LNG tank, which is eventually forming PNG at 4
bar. And another set is connected between LNG tank to High Pressure (HP) pump,
which eventually is used to convert LNG to Compressed Natural Gas (CNG).
 High Pressure Pumps (HPP) – High pressure pumps are used to fill the cascades at
high pressure.
 Cascades - CNG Cylinder Cascades for the storage and transportation of the gas from
on-line stations to daughter stations, mobile gensets and variety of applications. These
cascades come with various water capacities and storage pressures to meet specific
customer requirements.

Process Description - Firstly LNG tankers are filled at Gujarat petronet limited, Dahej
(Gujarat) which are double walled cryogenic tanker and LNG IS AT -1620 C and it is then
transporated to THINK Gas CGS station at Bagaroda (M.P.)

LNG is pumped to the LNG storage tanks having double containers, where the inner contains
LNG and the outer container contains insulation materials because LNG is at -1620 C through
a submersible pump. To prevent the pump from getting corroded by LNG at -1620 C, LNG is
recirculated using variable frequency drive by slowly passing the LNG through pump in
incremental time of 45 seconds using solenoid valve. This process increases temperature of
LNG from -1620 C to normal room temperature. LNG is stored in the LNG storage tanks and
then it is sent to evaporator to gasify the LNG and then it is sent to high pressure pumps to
increase the preesure above 200 bar in the CNG cylinder cascades. Then the cascades are sent
to the city CNG station.

Types of CNG Stations - For transportation of natural gas within a city, a pipeline is laid from
the city gate station where natural gas is pushed at a pressure of 15 bars or even lower. In
order to dispense gas to CNG vehicles, there are CNG stations at various locations, where the
gas is compressed up to 250 bars initially and then dispensed to vehicles at a pressure of 200
bars.

The following are the types of CNG stations:

  Online station

Natural gas is transporter from CGS to Online stations via. steel pipelines. At the
online station, natural gas is received at a pressure of 19 bars and then compressed up
to a pressure of 250 bars with the help of a reciprocating compressor

It is used to compress gas directly from the pipeline and the discharge can be used to fill the
CNG vehicles at CNG retail outlet. The capacity of such a compressor is selected based on
the vehicle likely to be filled in that station and with the provision for expected future
expansion. It may be equipped with a 1200 SCMH capacity compressor for compressing the
natural gas from 49 bar to 225 bar. All categories of vehicles are refueled i.e. Bus, Car, LMV,
LCV, and autos. Cascade filling facilities will not be available at the online station as it is in
Mother station. The investment of an online station is midway between daughter station and
mother station.

Typically, a CNG online station consists of the following equipment are CNG compressor ,
CNG dispenser and Storage cascade.

 Mother station

A mother station is similar to an online station. It has the facility to refuel mobile cascades in
addition to the local demand of vehicles. A mother station is connected to natural gas
pipelines & has preferably more than one compressor.The mother station compressor is of
capacity of around 1200 SCMH & it compresses natural gas from a pressure of 15-19 bar to
200-250 bar. The compressor is of high capacity.
The mother CNG station fills mobile cascades for daughter stations and also fills stationary
cascades for dispensing CNG into vehicles. All categories of vehicles can be refueled at a
mother station, i.e. bus, car, light motor vehicle, light commercial vehicle & autos.The
mother station has a facility to feed two to three daughter stations. Mother station are
connected to steel grid, through which gas is transported from CGS to mother station.

Gas from the distribution pipeline is compressed using a multistage compressor into a
cascade storage system. This system is maintained at a pressure higher than that in the
vehicles on-board storage, so that gas flows to the vehicle under differential pressure.
Typically the cascade storage operates in the range of 205 bar to 250 bar, while the vehicles
maximum onboard cylinder pressure is 200 bar. In order to make the utilization of
compressor and buffer storage, more efficient fast fill CNG station usually operates using a
three stage cascade storage system.

From the natural gas tank, gas goes through refueling connector and a non-return valve. After
that it passes through a solenoid valve, pressure regulator, engine management & injection
system & is finally filled to the vehicle.

 Daughter station

Mother stations feed gas to daughter stations . CNG is dispensed using mobile cascades.
Mobile cascades at daughter stations are replaced when pressure falls. The pressure depleted
mobile cascade is refilled at mother station.

In this case the investment is least among all stations. In each successive filling, there is a
decrease in storage pressure. It is to be noted that once storage pressure drops, refueling time
increases and quantity of CNG dispensed to vehicle also decreases.

The sizing of mobile cascades and trucks is decided based on the distance between mother
stations to daughter station. Number of LCV/HCV, to and fro frequency is decided based on
the load. Daughter station has a facility to feed small vehicle alone. It is easy to set up
daughter station and it can be set up at small towns, junctions & villages (where steel pipeline
network does not exist). This facility has proved to be boon for villages, which do not have
direct access to natural gas. This type of station may be converted to booster or online as per
demand.

 Daughter booster station

 CNG is dispensed to vehicles based on the principle of pressure equilibrium. Once the
pressure of a mobile cascade drops below 200 bars at daughter stations, vehicles get less
amount of gas, which is below 200 bars. With each fill thereafter, the amount of gas
dispensed to vehicles starts decreasing and the filling time starts increasing, thereby leaving
the customer dissatisfied.

Daughter booster stations address the issue. These are similar to daughter stations. However,
in order to cater to customers with regard to the amount of gas dispensed as well as filling
time, a booster compressor (hydraulic type with variable suction pressure) is installed in
between the mobile storage and the CNG dispenser. The booster compressor increases the
pressure above 200 bars once the pressure of the mobile cascade falls below 200 bars. Thus,
the maximum amount of gas stored in the mobile cascade is dispensed to the daughter booster
station.