SHIPBOARD

RELIQUEFACTION BURCKHARDT AND

PLANT
MYCOM PLANTS

OPERATIONS
 LEARNING OBJECTIVES

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 RELIQUEFACTION PLANTS ON LNG/LPG TANKERS

In the case of LPG/LNG and Chemical gas tankers, some form of reliquefaction plant is fitted ( Direct: Single stage, 2-3
stages or Cascade systems); this plant is specifically designed to perform the following functions:

1)To cool down the cargo tanks and associated pipe work before loading

2)To reliquefy the cargo vapour generated by flash evaporation, liquid displacement and boil-off during
loading when there is no vapour return line to shore.

3)To maintain or reduce cargo temperature and pressure within the prescribed design limits of the cargo
system on passage.

The cascade cycle is used for fully refrigerated cargoes where a special refrigerant such as R22* (R 404 or others) is used to obtain the lower carriage
temperatures. Furthermore in these systems, refrigeration plant capacities are not so affected by sea water temperature changes compared with other
reliquefaction cycles. For the carriage of ethylene this type of equipment is essential. We will discuss this plant as same can utilize both make of
compressors.
 BASIC PRINCIPLE
CASCADE DIRECT CYCLE

The cascade system uses a refrigerant such as R404/R407 to condense cargo vapours; simplified diagram for this system is as below. The single-stage
compression of cargo vapour is identical to the single-stage direct cycle, but the cargo condenser is cooled using R22/R404/R407 instead of sea water. The
cargo, in condensing, evaporates the liquid R22 and the R22 vapour is then taken through a conventional R22 closed refrigeration cycle, condensing
against sea water — hence the term Cascade.
RELIQUEFACTION PLANTS ONBOARD
 COMMON MARINE COMPRESSOR TYPES

CARGO COMPRESSORS

• The compressor is the heart of the reliquefaction plant. Two main type of compressors are used, reciprocating or screw.

Reciprocating compressors

• Two types may be found namely conventional compressors and oil-free compressors. They are mainly used in reliquefaction plant for compression of refrigerant
gases or cargo vapour. If used with refrigerants the considerations for normal refrigeration plant apply if used with cargo vapour, special precautions may be
necessary, depending on the cargo. Ex:- Burckhardt Labyrinth compressors

Screw compressor

• Screw compressor for use with liquefied gas cargoes can be either dry oil-free or oil flooded machinery. In the dry machines the screw rotors do no make physical
contact but are held in mesh dryers by external gearing. Due to the leakage effects through the clearances between the rotors, high speeds are necessary to
maintain good efficiency (typically 1200 rpm). The lobes intermesh and gas is compressed in turn. The compressor casing carries suction and discharge ports.
Ex:- Mycom
BURCKHARDT LABY TYPE K
Specification Value
Key word Norgas WZL 0601
Compressor type 2K158-2D_1
Serial no. 100822/100823
Weight of compressor (without flywheel) 4700 kg
Year of manufacture 2007
Process gas LNG/NH3/VCM
Mass flow *
Standard volume *
Suction volume *
Suction temperature *
Suction pressure *
Discharge pressure *
Rotation speed 595 rpm
Maximum power requirement * kW
Electric motor rating 340 kW

The gas is compressed by the labyrinth piston which operates oil-free.

The labyrinth principle developed by Burckhardt Compression AG allows
a contact-free seal between piston and the cylinder wall.
Valves are located in the cylinders, positioned by lanterns and valve
covers. The suction and discharge valves ensure the gas supply to the
individual stages.
Suction valves can be equipped with valve unloaders to control the
capacity.
 LPG BOG LABY®
COMPRESSOR 2K160-2A
LPG carriers fitted with vertically aligned labyrinth
compressors for boil-off gas handling on semi- refrigerated
and fully-refrigerated ships, have long been the preferred
specification for many ship owners and operators. Although
relatively moderate discharge pressure in the range up to 18
– 35 bar g are required for re-liquefaction, the compression
duty is surprisingly very demanding. A wide range of
alternative liquid petroleum cargos, ranging from heavy
liquid VCM, butadiene, through LPG and propane to toxic
ammonia, ethane and ethylene must be managed, with boil-
off gas temperatures ranging from +30 to –104 °C.

Laby® Compressor system installed on an LPG carrier

 BASICS OF THE SCREW COMPRESSOR

The screw compressor is categorized as a positive displacement rotary compressor. As shown above, the refrigerant (gas) is continuously compressed by the 3-
dimensional spaces that are formed by a pair of male and female screw rotors (with different sectional profiles) and the casing, as the spaces change
continuously. The rotor having 4 protruding lobe profiles is called a male or M rotor, and the rotor having 6 concave lobe profiles is called a female or F rotor.
The compressor is driven by the motor connected to the shaft of the M rotor.
 OVERVIEW OF THE MYCOM 2016**C

Items 2016

Product mass kg 1180 1140 1100 1090 1050 1000

Low-stage swept volume m3/h 1460/1210 1460/1210 1460/1210 1220/1020 1220/1020 975/810
@3550 min-1 /2950 min-1
High-stage swept volume m3/h 749/622 624/519 499/415 624/519 499/415 499/415
@3550 min-1 /2950 min-1
Refrigerant - Ammonia, Hydrofluorocarbon, etc.
Design pressure MPa 2.6
Capacity control (Actual load) % 10 to 100

Maximum discharge pressure MPa 1.96

Minimum suction pressure MPa −0.080
Maximum intermediate pressure MPa 0.588
Minimum intermediate pressure - > Suction pressure
Oil supply pressure

· Maximum journal lubrication pressure MPa Discharge pressure + 0.39

· Minimum journal lubrication pressure MPa Discharge pressure +0.049 and Suction
pressure +0.49
· Minimum oil injection lubrication pressure MPa Suction pressure +0.49
A Mycom installed on a Gas carrier Maximum Suction temperature °C 85
The 2016**C model, a compound 2-stage compressor, consists of two
compressors, (i) a low-stage compressor which suctions gas, working fluid, Minimum suction temperature °C −60
from the refrigerating unit and compresses (pressure-raises) the gas and (ii) an Maximum low-stage discharge temperature °C 90
high-stage compressor which furthermore compresses the gas that has been
pressure-raised by the low-stage compressor and sends the resulting gas to the Maximum high-stage discharge temperature °C 100
refrigerating system side.
 RELIQ PLANT: OPERATION MODES
The plant may be arranged with three or four cargo compressors and two or three or four refrigeration systems. The following
combinations are available depending upon cargo quantity, cooling requirement and loading/discharging or cargo change ops:

• One cargo compressor / one refrigeration system, similar to

• Two cargo compressors / two refrigeration systems
• Two cargo compressors / one refrigeration system
• Three cargo compressors / two or three refrigeration
• Four cargo compressors / three or four refrigeration

Basis , types of cargo carried, below is shown a list of typical cargoes carried by gas carriers with description of cycles which may be used in the
reliquefaction plant:

• Ammonia: single stage, 2 stage NIC, 2 stage LSC;

• isoButane: single stage, 2 stage NIC;
• Butadiene: single stage, 2 stage NIC (included);
• Butylene: single stage NIC, 2 stage NIC (included);
• n-Butane: single stage (included), 2 stage NIC (included);
• Propane: single stage, 2 stage NIC, 2 stage LSC;
• Commercial Propane (2.5 mole% ethane): single stage, 2 stage NIC, 2 stage LSC;
• Propylene: single stage, 2 stage NIC, 2 stage LSC;
• Vinyl Chloride Monomer – single stage, 2 stage NIC; where:

• NIC = No Inter-Cooling
Also available at two-stage compression.
• LSC = Liquid Sub-Cooling
Available at two-stage compression. Intercooler in operation for suction gas cooling to
saturated condition at 2nd-stage inlet and for sub-cooling of condensate through the
intercooler coil.
• LSC Flash
Same as LSC, however superheated vapour at 2nd-stage inlet.
 NIC-NO INTERCOOLING
Single Expansion

A
1 2

3 2
0

01
3
h
A B
1 2 3

4 3
0

LK_XX_0005a_01
2
01
4
h
Fig. 3-5 NIC, single or multistage compression without intercooling

•A=1st stage
•B=2nd stage
H=Enthalpy
P=Pressure

NIC = No Intercooling A simple refrigeration cycle consists of an evaporator or a boil-off tank, a compressor, a condenser and an expansion valve. Such a
cycle with a 1- or 2-stage compression is used for applications where either the total pres- sure ratio is low or the suction temperature remains constant at a low level.
This process is normally used for pure gases such as butane, butadiene, VCM, etc.
 DH-DEHEATING
A B

LK_XX_0006a_0 1
A B C
1 2 3 4 5 6

7 6
5 4 0

3 2
7
01
h

Fig. 3-6 DH, multistage compression with intercooling by liquid

injection in be- tween stages

•A=1st stage
•B=2nd stage
•C=3rd stage
H=Enthalpy
P=Pressure

DH = Deheating This cycle includes a multistage compressor. In order to keep the gas temperature of the 2nd and/or 3rd compression stage under the gas
temperature limit, liquid received from the condenser is injected between the stages. Such multistage cycles are used for pure gases. A typical application is Ammonia.
 DH-DEHEATING, DEX
Double Expansion

A B

LK_XX_0007a_0 1
h
Fig. 3-7 DEX, multistage compression

•A=1st stage
•B=2nd stage
H=Enthalpy
P=Pressure

DEX = Double Expansion This refrigeration cycle includes beside the multistage compressor an inter- stage vessel and a second expansion valve. The
cooling of the 1st stage discharge gas takes place in the interstage vessel. The hot gas of the 1st stage is mixed with the liquid and flash received from the condenser.
These multistage cycles are used for pure gases such as Ammonia, Ethylene, etc.
 DH-DEHEATING, FLASH DEX

Double Expansion

A B

LK _ X X _ 0 0 0 9 a _ 0 1
h

Fig. 3-8 Flash DEX, multistage compression

•A=1st stage
•B=2nd stage
H=Enthalpy
P=Pressure

FLASH DEX = Flash Double Expansion

This cycle is similar to DEX cycle. The difference is, that the interstage vessel is only indirectly connected with the 1st and 2nd compressor stage. The 1st stage
discharge gas is therefore only cooled by means of flash gas received from the interstage vessel. This process is also used for pure gases only.
 LSC-LIQUID SUB-COOLING
A B

Fig. 3-9 LSC, multistage compression with subcooling of liquid in interstage bottle

•A=1st stage
•B=2nd stage
H=Enthalpy
P=Pressure

LSC = Liquid Subcooling This refrigeration cycle includes beside the multistage compressor also an interstage vessel and two expansion valves. The 1st
stage discharge gas is cooled down in the interstage vessel with liquid and flash received from the condenser. The main liquid stream leaving the condenser is
subcooled in the interstage vessel and afterwards expanded to the evaporator resp. boil-off tank. These multistage cycles are used for gas mixtures such as commercial
propane.
 FLASH LSC
Single Expansion

A B

5 °C
h

Fig. 3-10 Flash LSC, multistage compression with subcooling of liquid in inter- stage bottle with flash take-

•A=1st stage
•B=2nd stage
H=Enthalpy
P=Pressure

FLASH LSC = Flash Liquid Subcooling - This cycle is similar to LSC cycle. Also here, the only difference is that the interstage vessel is indirectly
connected with the two compression stages. This process is also used for gas mixtures.
 PRECAUTIONS TO BE OBSERVED
BEFORE STARTING THE PLANT.
• The flexible couplings on the drive shaft in the motor room and L.P.G. room must have been greased. The
grease hardens after a time and the grease should be completely changed periodically (about once a month).
• The bulkhead seal cooler must be seen to be full of liquid and there must be no blockage in the system.
• That the compressor is turned manually by inserting a bar into the flywheel and rotating it to ensure that the
compressor is free to run
• That the oil in the compressor crankcase is at the correct level and temperature.
• That water is running through the condenser, and is available for the oil cooler.
• That, the oil return valves on the return lines leading from the oil separator traps on both the L.P. and H.P.
stages to the compressor crankcase are shut.
• That the discharge valves on -the L.P. and H.P. stages of the compressor are open
• That the compressor H.P. suction valve is open and the L.P. suction valve is shut, but free to move
• That there is no liquid in either the heat exchanger or the interstage cooler.
 PRECAUTIONS TO BE OBSERVED JUST AFTER STARTING THE
PLANT.

• The compressor may then be started. As the L.P. suction pressure falls, the suction valve
should be opened slowly, and the rise in oil and vapour discharge pressures carefully
watched. The suction valve must be shut and the compressor stopped immediately should
the vapour discharge pressure rise abnormally. As liquid forms in the condenser, & must be
watched to ensure that the float controlled outlet valve is functioning correctly. (Liquid
should only show in the bottom of the condenser gauge glass.) The condensate return
pressure is checked to ensure that no sprays or filters are impeding the flow back to the tank.
In this connection, the filter traps on the condensate line should be cleaned out and filled
with methanol prior to loading. After the compressor has been running some time and the
bottoms of the oil separator traps are warm, the return valves on the lines leading from the
traps to the compressor crankcase are opened, and the oil heater in the crankcase isolated
and the lubricating oil cooler used.
 PRECAUTIONS TO BE OBSERVED WHILST THE PLANT IS
RUNNING.

• A record should be kept of the plant, covering mainly seawater temperature, condenser pressure, and
compressor L.P. and H.P. suction & discharge temperatures and pressures, oil pressure, condensate
return pressure, etc. Trends are as important as the actual readings.
• The state of the compressor cylinder heads should always be under observation.
• If a cylinder head is unduly cold, this indicates a wet suction; it means that liquid droplets are entering'
-the compressor and vaporizing during compression, the latent heat of vaporization re moving the heat
which would otherwise be gained in the adiabatic process and is a warning of an excessive quantity of
liquid having collected in either the heat exchanger or inter-stage cooler. The compressor must be
stopped, the excess liquid drained away and the float cut-out switch checked for malfunction.
• If a cylinder head is unduly hot, this indicates a faulty suction valve plate or discharge valve plate the
compressor should be stopped and the valve plates, checked. The compressor is stopped by shutting the
L.P. suction valve, thus taking the compressor off load, and then stopping the compressor.
 PRECAUTION’S TO BE OBSERVED AFTER PLANT IS STOPPED.

• The compressor is stopped by shutting the L.P. suction valve, thus taking the compressor off load,
and then stopping the compressor.
• As soon as the compressor is stopped, the isolating valves to the interstage cooler and the heat
exchanger cooler should be shut to exclude the possibility of these filling with liquid from the
condenser during the stoppage.
• Also the condenser should not be emptied of liquid if refrigeration is suspended, in order that
liquid will be readily available when refrigeration is resumed.
• The lubricating oil heater should be placed in service so that the compressor is ready to start when
next required.
• During a prolonged stoppage of the compressor, it should be turned daily by hand to distribute the
wear on the motor bearings (the steady vibration of the ship causes wear on the ball bearings if
kept stationary)
• Maintenance Guidelines • Carry out adjustments, preventive and corrective maintenance in
due-
• date time.
• Regularly check plant components like pressure vessels, coolers, dampers, separators etc. for deposits and
corrosion.
• Recondition loose contacts and damaged cables immediately.
• Protect all plant components such as main motor, oil and coolant system pumps, pneumatic or hydraulic control
systems etc. against un- intended start-up.
• before beginning any inspection or repair, turn the current off at the switch box and padlock the switch in the
OFF position.
• Always adhere to local and company safety regulations (e.g. warning sign “Machine under maintenance or
overhaul”, put up safe work plat- forms, setting spectacle flange etc.).
• Depressurize and purge the compressor plant
 REFRIGERATION PLANT
• Low pressure cut-out, refrigeration compressor IRREGULARITIES
• The compressors suction pressure will depend on cargo conditions, the compressors capacity load and sea-water temperature. Normally a low pressure cut-out is rather unlikely. If the
cargo compressor has stopped, then the R404A-compressor will suck down the pressure and cut out at 0.0 bara. Another reason for cut-out may be a closed valve in the R404A circuit.
 
• High pressure cut-out, refrigeration compressor
• The compressor’s discharge pressure will depend on the seawater temperature, cargo conditions and the compressor capacity. This pressure will normally have a pressure corresponding to
a saturation temperature 5–10◦C above the seawater temperature. Poor seawater cooling will cause a build-up of the discharge pressure and at 20 barg we will have a cut-out. Insufficient
water supply may be due to a fault in the cooling water pump, restricted or closed shut-off valve, a choked seawater strainer etc. Starting the compressor against shut discharge valve will
also result in cut-out on the high-pressure switch.
 
• Low pressure cut-out, oil system refrigerant-side
• When the pressure diff. between compressor discharge line and oil manifold decreases to 1.5 bar and the compressor will cut-out. This may be caused by choked oil filter, stop of oil
pump, defect pressure relief valve or diluted oil.
 
• Moisture in refrigeration system
• The solubility of water in refrigerant is rather small. This may cause water to freeze in the expansion valves and filters in systems that work with an evaporating temperature below 0 ◦C
and the result is unnecessary interruption.
 
• Water in the system is always improper. Besides, the risk of freezing, which is present already by small concentration of water, the risk of corrosion is present at larger water
concentration. There will be no risk of corrosion at evaporation temperature below 0 ◦C, as the water must be removed if the system is going to work satisfactorily. Corrosion is most
pronounced at the warm high pressure side.
 
• The risk is present if refrigerant or oil is filled in to the system and if the filter/drier is not kept in good condition.
 MAINTENANCE
Importance of Preventive Maintenance
By doing preventive maintenance at regular intervals, these improvements arises:
• increased life time
• prevention of breakdowns and damages
• increased safety for man and machine

 Prerequisites for Maintenance

•  

Contamination of process gas!

When performing overhauls or exchanging spare parts, make sure that all significant surfaces have been cleaned according to the cleaning specification
prior to assembling or installation. If in doubt about cleanliness, repeat cleaning procedure.
 
Maintenance Guidelines
Carry out adjustments, preventive and corrective maintenance in due date time.
• Regularly check plant components like pressure vessels, coolers, dampers, separators etc. for deposits and corrosion.
• Recondition loose contacts and damaged cables immediately.
• Protect all plant components such as main motor, oil and coolant system pumps, pneumatic or hydraulic control systems etc. against un- intended start-up.
• before beginning any inspection or repair, turn the current off at the switch box and padlock the switch in the OFF position.
• Always adhere to local and company safety regulations (e.g. warning sign “Machine under maintenance or overhaul”, put up safe work plat- forms, setting spectacle flange etc.).
• Depressurize and purge the compressor plant.
 PREVENT MOISTURE INTO THE REFRIGERANT SYSTEM

• Control that the system has got no leakages, so that a minimum of – R404A and oil must
be refilled.
• Use only R404A and oil of a proper quality.
• Avoid unnecessary opening of any part of the system.
• If the system is opened, see that the pressure inside is a little higher – than the atmospheric
pressure.
• Parts that are opened should be kept warmer than the surroundings. – Otherwise, there will
be a risk of condensation on the colder surfaces.
• Inspection Items
• Inspection Contents
• Check Points and Actions
• Compressor
• Operating hours
• hr
• Total operating hours
• Judgment of periodic maintenance timing
• Suction pressure
• MPa
• Note 1
• Difference from the set value of evaporation temperature equivalent pressure
• Contamination on the cooling pipe surface
• Temperature, flow rate, etc. of the object to be cooled
• Intermediate pressure
• MPa
• Pressure difference from rated operation (normal value)
• If it is too high， check high- stage. If it is too low, check low-stage.
• Discharge pressure
• Mpa
• Difference from cooling water temperature equivalent condensing pressure
• Contamination on condenser cooling pipes
• Non-condensable gases mixed into the system
• Quantity, temperature, etc. of cooling water
• Oil supply pressure
• MPa
• Difference from discharge pressure
• Whether differential pressure is decreasing
• Operation with liquid flow-back
• Whether compressor parts are worn
• Oil filter pressure loss
• MPa
• Pressure difference between oil filter inlet and outlet
• Contamination of lubricating oil
• Clogging of oil filter element
• Suction temperature
• °C
• Whether within upper and lower limits
• Temperature, flow rate, etc. of the object to be cooled
• Degree of superheat for suction
• °C
• Whether degree of superheat is proper
• Adjust expansion valve
• Insufficient refrigerant flow
• Intermediate temperature
• °C
• Whether within upper and lower limits
• Adjust intermediate expansion valve
• Discharge temperature
• °C
• Whether within upper limit
• Non-condensable gases mixed into the system
• Oil supply temperature, insufficient oil supply
• Compressor failure
• Inspection Items
• Inspection Contents
• Check Points and Actions
• Compressor
• Oil supply temperature
• °C
• Whether within upper and lower limits
• Contamination on cooling pipes of oil cooler
• Capacity control Indicated load
• %
• Whether operation is normal
• Damage to solenoid valve coil
• Improper adjustment of manual control valve of electromagnetic assembly
• Leak from mechanical seal
• ml
• Leak per hour
• Mechanical seal failure
• Noise and vibration
•  
• Abnormal noise/vibration
• Compressor failure
• Others
• Motor current
• A
• Whether it is higher than the current at test run
• Compressor/Motor failure
• Oil level of oil separator
• -
• Oil level
• Oil loss
• Replenish oil
• Fluid level in the receiver
• -
• Fluid level
• Replenish refrigerant
• Check for refrigerant leak
• -
• leak or not
• Inside the machine room and in the facility on the load side
• Item
• Inspection interval and Content
• Remarks
• Pressure gauges/ pressure sensors
• Yearly inspection
•  
• Thermometers/ temperature sensors
• Yearly inspection
•  
• Protection devices and safety valves
• Yearly inspection
•  
• Suction strainer
• Inspect after 500 hours from the start of operation.
• If the differential pressure between the front and back of the suction strainer increases, check and clean the suction strainer.
• Yearly inspection and cleaning
• Lubricating oil
• Analyze lubricating oil after 500 hours from the start of operation.
• Replace the oil if the analysis result does not satisfy the control criteria given in Section 4.1.5 "Lubricating oil Management Criteria".
• Analyze oil every 6 months.
• Oil filter element
• Yearly replacement
• Replace the filter element if the differential pressure between the inlet and outlet ports of the oil filter exceeds 0.1 MPa.
• Cooling water side of oil cooler
• Yearly inspection
• Clean if excessively contaminated.
• Cooling water side of condenser
• Yearly inspection
• Clean if excessively contaminated.
• Mechanical seal
• Inspection every year or every 8000 hours of operation Note*
• To be replaced if any abnormality is found
• If it is difficult to stop equipment except for scheduled inspections, replace the part at each inspection.
• Coupling
• Inspection every year or every 8000 hours of operation Note*
•  
 BEST EFFICIENCY
• 4. Conclusions
• 1. In order to achieve the highest efficiency of reliquefaction plant it is important to operate with
• the optimal cycle. In this case taking into account all parameters of loading the one stage cycle
• is 15% more efficient than two stage (300 kW to 260kW).
• 2. Condensing pressure 4.8 bar abs instead of theoretical 3.0 bar is caused by presence of
• incondensable gases from previous CC4 grade in cargo tanks. Higher Butane condensing
• pressure decreases approx. 37% refrigeration capacity from 300kW to 190 kW. In this case,
• carefully removing incondensable gases before loading a new cargo grade is essential in order
• to get the highest efficiency of the reliquefaction plant.
• 3. Real achieved loading rate 80 t/h shows that without influence of incondensable gases which
• reduced refrigeration capacity of reliquefaction plant approx. 37%, the gas plant manufacturer
• diagram [7], for Butane cargo loading rate approx. 90 tons per hour is real.