KSC S.No,1431 MUSASHI GLORIA LPG Reliquefaction plant Refrigeration capacity test procedure (For Commercial Propane) Date : April 21, 2010 Place : Off Singapore NISSIN GAS ENGINEERING LTD.Contents 1. Outline of the plant. 2. Refrigeration theory... 3. Test procedure. 4. Mode of test (example) .. 5. Confirmation of the designed refrigeration capacity from the test result. NOTE : The capacity checked with this test is a theoretical estimation based upon data collected uring actual gas test. Since the piping system on board is not designed to measure necessary data, such as suction mass flow, real ethane content in re-liquefied cargo in a receiver, etc, with accurate instruments, the calculation result may vary from real value with deviation of plus/minus five percent.‘This document is applied for a reftigeration capacity test of LPG reliquefaction plant, handling Commercial Propane. 1, Outline of the plant The plant consists of four(4) identical units and each unt is equipped with a knockout drum, a cargo compressor, an intercooler, a cargo condenser, a cargo receiver and level control valves as shown on Fig. 1. Boil off gas from the cargo tanks is compressed at Ist stage of the compressor and Subsequently cooled in the intereooler by means of partial expansion of liquefied cargo. Then cargo gas is compressed again in 2nd stage of the compressor up to condensing pressure Highly pressurized cargo gas is cooled and condensed in the condenser with sea water as cooling medium. The cargo receiver installed under the condenser collects the liquefied cargo, Before being retuned to the cargo tanks, the reliquefied cargo is sub-cooled in the cooling coil of the intercooler. The automatic level control valves are equipped to control the liquid level in the intercooler and the cargo receiver. weseceeny HS, Tague ebette ale SHORES) 2Refrigeration theory Refer to the flow diagram on Fig. | and the p-i diagram on Fig. , mass flow of boi-off gas at the point “A” multiplied by enthalpy difference “A-G” is refrigeration capacity Q=Mx Ai M=Vir M: — Mass flow (kg/h) Ai: Enthalpy difference (ki/kg) Q: Refrigeration capacity (MJ/a) Vv: Suction volume of the compressor Ist stage (m*/h) ve Specific volume (m°/kg) Note: The enthalpy difference "A-G" is used to make the "GROSS refrigeration capacity" and "A’-G" is used to make the "NET refrigeration capacity." Test procedure 1 we can measure V, v, and Ai in the preceding clause, the reftigeration capacity can be calculated. Specific volume, v, on the point "A" can be found out on p-i diagram with the Suction pressure and temperature, Ai can also be found on p-i diagram as enthalpy difference of “A-G”, with data found as liquid temperature between level control valve and receiver, as the point "G", and with suction gas temperature, as point “A”. See Fig, 2 Unfortunately, suction volume of the compressor "V" cannot be measured directly, because ‘measuring device is not assembled on the suction line. In order to find out the mass flow, the internal piping must be simplified, temporarily jection to the intercooler is to be closed, which is the flow from "F" to "D" on Fig, 2. Now, the diagram is roughly simplified as provisional pei diagram on Fig. 3. Then the liquefied cargo accumulated inside the receiver on a level gauge is to be measured, as mass flow. The measured cargo is the mass flow “M” and the suction volume measured on the provisional p-i diagram is shown larger volume than the regular normal operation "with intercooler" process. Therefore the measured result should be adjusted with FigS "ESTIMATED PERFORMANCE CHART for 2K160-2F Compressor". i diagramThe way of measuring the reliquefied volume, increasing speed of liquefied cargo level accumulated in the receiver is to be measured. Inner diameter of the receiver is 439.2 mm as shown on Fig. 4. When the time for the liquid level to be increased 250 mm in the receiver is counted, the mass flow “M" can be calculated as follows; 4392X x 3600 ———" X 250K —— x gx 106 t t Measured time (second) &: Density of requefied cargo (kg/liter) Table 1 Density (kg/liter) of reliquefied Commercial Propane in the receiver measured at "F" A Ethane content in liquid phase, mol% in cargo tank B Ethane content in vapor phase, mol% at inlet of the plant Hauer | io Tas | 20 | 25 | 30 | 35 | 40 2.5 mol% 16 mol% 2.0 mol% 14 mol% 1.5 mol% 12 mol% 1.0 mol% 10 mol% 0.5 mol% Smol% 0.0 mal% 0.0 mol% 0.5083 | 0.5015 | 0.4945 | 0.4875 | 0.4793 | 0.4699 | 0.4587 0.5089 | 0.5023 | 0.4953 | 0.4884 | 0.4804 | 0.4715 | 0.4610 0.5096 | 0.5030 | 0.4961 | 0.4892 | 0.4815 | 0.4730 | 0.4634 0.5103 | 0.5037 | 0.4969 | 0.4901 | 0.4826 | 0.4746 | 0.4657 | 0.5115 | 0.5051 | 0.4985 | 0.4917 | 0.4847 | 0.4775 | 0.4701 0.5116 | 0.5052 | 0.4985 | 0.4918 | 0.4848 | 0.4777 | 0.4704 >i >|w >| le >| >Peat F (T_ | High icvel 10 =94392 Measuring range (250mm). In case of inquiring Ai, the following table 2 and 3 are convenient. Table 2 Enthalpy of the vapor at the inlet of plant and "A" 5 0 +5 | +10 | +15 | +420 | 425 Vaportemp. © | -10 Enthalpy k/kg | 788.4 | 797.2 | 799.7 | 805.5 | 810.6 | 815.7 | $20.8 | 825.9 Table 3 Enthalpy of the liquid at the outlet of intercooler "G" Liquid temp.°C | -10 | -5 0 5 10 15 20 Enthalpy kihke | 393.5 | 406.1 | 4187 | 4312 | 4438] 4585/4731‘Mode of test (example) Trial 1 2 3 Average | Cargo liquid temp. co | 44 Gas inlet press. ae f 4 | Gas inlet temp. ie 1s | Gas outlet press. oe 1.30 Liq. temp. inteceiver | 20.0 Reliquefied speed See. i 21.0 Liquid temp after LC. | oo | ‘Sea water temp. c 15.0 Cargo composition C-Propane with 2.5 mol Ethane in liquid phase After measuring the temperature at "A" and "G", the valve of liquid inlet into the intercooler is to be closed, then increasing speed of the liquid level in the receiver, 250mm, is to be ‘counted. See Fig. 4. 439.2 a aut 250 sea X gX 10° (A-G)X MYM Refrigeration capacity kJ/h Reliquefied speed Sec. Density of liquid kgflitter Enthalpy of inlet gas k/kg Enthalpy of liquid kT/kg, '/M = Capacity Ratio of with/without intercooler won w Q t g A G M For example, it is assumed that increasing speed of the liquid level, t, was 27 see. Density of liquid can be found on Table 1, in accordance with liquid temperature in receiver, 20°C, and ethane content in liquid phase, 2.Smol%, ie. g = 0.4945 kp/itter, Enthalpy of inlet gas and liquid can be found on Table 2 and 3, in accordance with ges inlet temperature, -15°C, and Liquid temperature after intercooler, OC, ie. A= 781.3 kJ/kg and G=418.7 kikg, Capacity ratio with/without intercooler can be found on Fig. 5, and in this éase 0.92. 439.2% 3.14 4 = 833,058 kJ/h (= 833 MJ/h) 3600 %250X ——~ X 0.4945 106 X (781.3-418.7)X 0.92Confirmation of the designed refrigeration capacity from the test result ‘The designed refrigeration capacity is planned under the following conditions, 1) Composition in liquid phase Ethane 2.5 mol% Propane 97.5 mol% 2) Suction gas temperature +20 °C 3) Suction gas pressure 10 kPaG 4) Cooling sea water temperature 320 5) Reftigeration capacity About 740 Mish {tis difficult to make correspondence with the design conditions at test field. Then in order to Gonfirm the designed refrigeration capacity from the test results, itis necessary to modify for the following items. © Modification for ditference of the suction temperature and the suction pressure. ® Modification for difference of the cooling sea water temperature. ® Modification for difference of the ethane content in the cargo For the purpose of the above modifications, Fig. 6 "Refrigeration Capacity Correction Chart” should be used. In this case, the chart says that correction factor of the model test condition is LOL. Finally the refrigeration capacity under the design conditions is calculated as follows. Qd: Refrigeration capacity at design condition Qt: Refrigeration capacity at mode! test condition Qd = Qt/1.01 = 833 1. 01 = 825 My/4-2-2. No.2 Unit - Refrigeration capacity correction chart =10 10 Suction Gas Temperature (t) LL 1.0 Refrigeration Capacity Eereeiaa ace 0.9 085. Estimated performance chart for 2K160-2F (Fig.5) Handling Cango: Comercial Propane, Compressor speed : 580 rpm Rev. 21 ithout Intercooler} 230) 220} 210} g 3 B 3 Rated power (kW) 170} 160 150} 140) 130 1000 1060 1100 11501200 1250~=—S«1300.~=—=—«1350 Actual suction volume (m3/h) Handling Cargo : Comereial Propane, Compressor speed : 580 rpm th Intercooler] Rev. 21 240) 230} 220} 8 BR & 5 Rated power (k¥) 8 180) 170 160} 900 950 10001050 1100 1150 1200 «1250 Actual suction volume (m3/h) 14