B&V Mini LNG Plant

April 2013
LESSONS LEARNT OF CHINA LNG PROJECTS & LNG BUSINESS MODEL

Presented for: Lessons Learnt Session BKK PII
Habibie Razak, P. Eng., ASEAN Eng.
Project Manager, Indonesia Black & Veatch Energy, OIL & GAS
AGENDA
INTRODUCTION TO B&V PRICO TECHNOLOGY PROCESS OVERVIEW
Process Flow Overview
Inlet Pressure Control
CO2 Removal Dehydration Liquefaction Refrigeration Boil-off Gas Regeneration Gas
Equipment Arrangement
Utilities Description
AGENDA (cont.)
OPERATING SYSTEM
Shutdown
Restart
EPC PROJECT EXECUTION STRATEGY
CHINA LNG BUSINESS DISTRIBUTED MODEL

LNG BUSINESS IN THE WORLD, OVERVIEW LESSONS LEARNT CLOSING REMARKS AND QUESTIONS
INTRODUCTION TO B&V PRICO TECHNOLOGY
April 2013
BLACK & VEATCH SERVICE AREAS

ENERGY
Lessons Learnt Session, BKK PII, April 2013
WATER
TELECOMMUNICATIONS
MANAGEMENT CONSULTING
FEDERAL
ENVIRONMENTAL

50 YEARS OF LNG LEADERSHIP
B&V
April 2013
23 Plants in operation Experienced with SMR, Expander, Cascade, N2 Process 140 MM Tons LNG Focus in PRICO SMR process 18 Plants in Operation 14 new Plants in Engineering/Construction Broad range of sizes (3 to 150 MMSCFD) Covered by 3 US international patents/new filings New developments internationally and in US

SMR PROCESS CHARACTERISTICS
Single refrigeration system Lower equipment count (low cost) Simplified process operation Compression can be parallel/series Flexible with changing feed-stocks Easy to start-up, shutdown and restart Systems hold refrigerant when idle Applied over a broad range of capacities
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Versus N2 or Expander Processes 30 40 % more efficient Much less steel components and piping Only one compressor, no expander Composition flexibility Versus C3/MR, DMR or Cascade No series system Can be parallel configuration Much simpler, easy to operate No loss of refrigerant on shutdown
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April 2013
ADVANTAGE OF MODERN SMR PROCESS

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April 2013
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PRICO MAIN EXCHANGER (COLD BOX)
Aluminum plate fin exchangers (cores) in parallel Strictly use external connections No valves or equipment in cold box Plate fins are highly efficient and reliable More than 30+ years of service (no repairs) More than 100 cores in operation
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April 2013
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April 2013
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PROCESS OVERVIEW
PROCESS OVERVIEW
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April 2013
DESIGN BASIS One of small scale LNG Plant in China is designed to process 960,000 Nm3/day of feed gas to produce a guaranteed 692.86 tons/day of LNG. Production of LNG involves removal of CO2, water and mercury from the natural gas stream, cooling it sufficiently to totally condense the gas, hydrogen flash removal, and then directing the LNG to the storage tanks.
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PROCESS OVERVIEW
DESIGN BASIS
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April 2013
Treated gas enters the cold box at about 40C LNG, leaves the cold box condensed at -156C and flashes down to -164C in the storage tanks.
The resulting high-nitrogen flash gas as well as other boiloff gas is recovered with the BOG compressor and sent back to the cold box for re-liquefaction and nitrogen removal. Re-liquefied BOG is returned to the tank as LNG product while the purged N2 stream is blended into the plant fuel system.
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April 2013
PROCESS OVERVIEW
Design Feed Gas Composition
21C & 7.0 Mpag
Component Design mol %
The PRICO Refrigerant system is specifically tailored to the design gas composition. Some components in the gas will freeze at LNG temperatures and must be removed during liquefaction to prevent this. Nitrogen and Hydrogen must be specially handled to prevent excess accumulation in the system.
Methane (C1) Ethane (C2) Propane (C3) i-C4 n-C4 i-C5 n-C5 C6 C7 C8 C9 C10 C11 Nitrogen1 Hydrogen2 CO23 He H2S,mg/Nm3 , mg/Nm3 Benzene Cyclohexane Mcyclohexane Toluene O2 Mercury4, g/Nm3
92.94 3.97 0.69 0.12 0.12 0.05 0.03 0.09 0.63 (1.2 max) 0.01 (0.8 max) 1.31 (3.0 max) 2.8 0.0034 0.0061 0.0027 0.0011 0.000 <100
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PROCESS OVERVIEW
Regen Compression PRICO Refrigeration Heavies FEED Gas
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April 2013
To FG
To Storage
H2-Rich to FG
Amine CO2 Removal Mole Sieve Dehydration
Liquefaction
H2 Removal
LNG Regen Gas
N2-Rich to FG
N2 Removal
BOG
BOG Compression LNG LNG Storage Tank

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April 2013

Inlet Gas Pressure Control Feed gas arrives at about 7.0 Mpag and is pressure controlled at approximately this pressure. Less refrigeration is required to liquefy a given amount of gas at higher pressures, so in general the higher pressure the better.
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April 2013

CO2 Removal Gas must be treated to <50ppmv CO2 to prevent freezing during liquefaction with Proprietary MDEA Amine-based solvent Absorbs Acid Gases (CO2, H2S, etc) as the feed is contacted within a tray tower Absorption is reversed by hot stripping vapors in a regenerator tower Vapors generated via a steam-heated re-boiler
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Process Flow Overview CO2 Removal
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April 2013
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April 2013

Mole Sieve Dehydration
Gas must be treated to <0.1 ppmv H2O to prevent freezing during liquefaction
Molecular Sieve Adsorbs water at moderate temperatures and releases it at high temperatures Regeneration via heated dry feed gas slipstream; regen gas is then cooled, separated, compressed and recycled.
Dust is removed via after filters Mercury can attack the aluminum in the liquefaction process so is removed via a bed of sulfur-impregnated carbon.
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Mole Sieve Dehydration
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April 2013
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Refrigeration Refrigeration process uses a single mixed refrigerant loop compressed by a 2-section centrifugal compressor Refrigerant is compressed, partially condensed and sent to the main refrigerant exchanger via vapor pressure and refrigerant pumps
Chilling occurs when the high pressure refrigerant is let down to low pressure (Joule-Thompson Effect)
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April 2013
Process Flow Overview, Refrigeration
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April 2013

Liquefaction
Heavies are condensed from the feed gas at about -60 and removed to ensure that the LNG equipment will not plug or foul at LNG temperatures. Gas is chilled to -156 for full liquefaction at the end of the Refrigerant Exchanger. H2 is preferentially removed in the Hydrogen Flash via product flash to 0.7Mpag. LNG taken from the Hydrogen Flash Drum bottom is routed to the storage tank. The compressed boil-off gas from the tank is re-liquefied in the Refrigerant Exchanger. N2 contained in the BOG is removed in the Nitrogen Flash Drum. LNG from the drum is returned to the tank and the N2-rich gas is blended into plant fuel. H2-rich gas and N2-rich gas are both warmed by dry treated gas before being blended into the fuel system. The startup exchanger is needed during initial startup in order to condense and remove heavies that could otherwise freeze in the colder bottom section of the Refrigerant Exchanger.
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Process Flow Overview, Liquefaction
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April 2013
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April 2013

Heavies Handling Heavies are warmed and partially vaporized in 3 steps using a stream of warm refrigerant liquid from the refrigerant loop. (E305 HP Heavies Exchanger, E304 LP Heavies Exchanger & E311 Condensate Exchanger.
The vapor produced in the first vaporization step at V-310 HP Heavies Flash Drum is mixed with the used mole sieve regeneration gas and recycled into the feed using the regeneration gas compressor. Liquid goes on to the next vaporization step (V-311 LP Heavies Flash Drum). Vapors from the 2nd and 3rd vaporization steps (from V311 LP Heavies Flash Drum & V-312 Condensate Drum) are blended into the plant fuel system. Any remaining heavies liquids are sent to the condensate drum for storage and eventual removal via truck.
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Process Flow Overview Heavies Handling
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April 2013
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April 2013

Refrigerant Storage The PRICO refrigerant is a mixture of nitrogen and hydrocarbons that is optimized for a given feed gas composition. It is therefore important to store these separate components on-site to make composition adjustments to the loop as needed. Liquid refrigerants (ethylene V402, propane V403, isopentane V404) are stored in vessels on-site
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April 2013

Refrigerant Storage Storage is also provided for any excess refrigerant mixture in the loop; this can be saved for later use. Refrigerant is introduced via a small slipstream of hot refrigerant from the compressor discharge. For methane makeup, feed gas may generally be used if the hydrogen content is low. If the feed H2 content is high, LNG may be used to limit accumulation of H2 in the loop.
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April 2013

Refrigerant Storage
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Boil-Off Gas Handling Boil-off and flash gas from the tank and loading truck loading system is combined and compressed BOG compressor is an oil-flooded screw compressor for high turndown capabilities
The BOG cross exchanger is used to ensure non-cryogenic operation of the compressor. The compressed BOG is returned back to the Refrigerant Exchanger to be re-liquefied to LNG and purged of excess nitrogen
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PFD Review BOG Compression

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Process Flow Overview LNG Storage
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Equipment Arrangement
Project Plot Plan
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April 2013
LNG Storage
Process Facility
Flare
LNG Loadout
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April 2013
Liquefaction Area Equipment Layout

Refrigerant Storage
Amine System
Dehydration
Refrigeration /Liquefaction
BOG/Regen Compressors
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Process Area Equipment Elevation
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Utilities Description
Fuel Gas Flare
Nitrogen
Instrument Air Water
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April 2013
Fuel Gas
Fuel Gas is supplied from a variety of sources. H2-Rich Vapor from V-308 Hydrogen Flash Drum/E-309 Hydrogen Flash Heater N2-Rich Vapor from V-309 Nitrogen Flash Drum/E-310 Nitrogen Flash Heater Heavies Flash Vapor from V-311 Heavies Flash Drum Heavies Flash Vapor from V-312 Condensate Drum Inlet feed gas may be used as a makeup supply to the fuel gas header Fuel gas is used in the following places; Steam Boiler Regeneration Gas Heater Flare tip & Flare header sweep Pad gas or sweep gas to various vessels.
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Flare
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April 2013
Both a Cold Flare Header and Warm Flare Header are provided in the plant. Relief valves and manual drains in refrigerant and cryogenic services discharge to the cold flare header. Relief valves and manual drains of amine system, dehydration and regeneration gas system discharge to the warm flare header. The outlet of DCS controlled depressuring valve downstream of the F202 A/B dust filters are connected to the cold flare header. This is used if the feed-gas is not meeting CO2 & H2O level before going to the cold-box. The outlet of DCS controlled depressuring valve on the V-301 refrigerant suction drum overhead are connected to the cold flare header. This is used if the suction pressure of the refrigerant compressor is higher than design pressure. Flare headers are provided with purges (fuel gas) to keep air from infiltrating into the flare headers and potentially resulting in a flammable mixture of hydrocarbons and air within the piping system.
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April 2013
Flare
The cold/warm flare knockout drums, are located in the flare headers to trap liquids.
The headers should be sloped so that the flare knockout drums are the low point in the system and everything else free drains to the drums. The drums keep liquids from accumulating in the flare headers resulting in liquids being entrained up the flare stack during a high flow case, potential high backpressure in the flare system, and/or entrained liquids raining to grade around the stack. An electric heater is located in the cold KO drum to weather off the liquids to the flare.
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Nitrogen
Nitrogen is supplied at 0.6 Mpag. There are two sources for nitrogen: Plant PSA nitrogen system for general utility use Vaporized liquid nitrogen for refrigerant makeup and other dry services The nitrogen headers supply nitrogen for Refrigerant makeup Compressor seal purges Refrigerant Exchanger insulation space purge Other miscellaneous purging services Utility Stations Start-Up purging and drying
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18 April 2012
Instrument Air
Instrument air is provided at 0.6 Mpag IA is compressed air that has been dried to a -40C dewpoint for use in moisture sensitive services The instrument air system supplies dry air to: Control actuators Utility stations in the plant Flare system
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April 2013
Demineralized Water
Usually treated on site via filtration and reverse osmosis and stored in a plastic, FRP or SS tank Used where the natural mineral content of local water can lead to poor performance or corrosion Demineralized water is used for water make-up in: Steam boiler to help maintain proper chemical concentrations Lean amine surge drum to replace water lost in saturated treated feed gas Amine storage tank to dilute neat amine to a manageable consistency
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OPERATION SYSTEM
Shutdown
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April 2013
Shutdowns
Utilities Support Systems (Flare and Fuel Gas)
CO2 Removal (Amine System)

Dehydration (Mol Sieve) Liquefaction Refrigerant
Plant Isolation
Unplanned Shutdowns
Emergency Shutdowns
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18 April 2012
Shutdowns
Cause and Effect Diagram
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April 2013
Shutdowns
EXTENDED REFRIGERANT LOOP SHUTDOWN For shutdowns, unless maintenance is planned or the system will require opening, the refrigerant can remain in the system and may be allowed to warm to ambient temperature, as the system design pressures will accommodate this condition.
However, if maintenance requires access to the refrigeration loop, it is desirable to de-inventory to V-401 Refrigerant Make-up Tank and save as much refrigerant as possible prior to opening the system. If only working on a single piece of equipment, isolate and drain that equipment and associated piping only, and keep refrigerant in the rest of the system.
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Shutdowns UNPLANNED
Unplanned shutdown may be initiated by:
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April 2013
In the control room or in the field, operators may initiate an emergency shutdown (SIS trip) from switches in the control room or in the field in the event of a catastrophic fire, explosion or uncontrolled release of hazardous materials to atmosphere An emergency shutdown will be activated automatically on plant power failure, instrument air failure, or one of several abnormal process conditions listed in the Cause and Effect Diagram. For unplanned shutdown responses of the systems, refer to the plant Cause and Effect Diagram.
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April 2013
Shutdowns UNPLANNED
If any equipment in the unit shuts down, operators should attend to the following items:
Discontinue NG feed if necessary to prevent untreated NG from entering downstream equipment. Verify that all levels and pressures have been properly maintained, all valves are in their proper positions, alarms and shutdowns have cleared, and no personnel are in an area that might be a hazard to themselves or the equipment.
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Restart
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April 2013
Restart
General Amine System Utility System Dehydration Refrigeration Liquefaction
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EPC PROJECT EXECUTION STRATEGY
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PROJECT EXECUTION STRATEGY
April 2013
B&V
Black & Veatch provide total Engineering, Procurement, Construction (EPC) for all projects. We work with local contractors to execute the construction led by construction management team including to provide all pre-commissioning, commissioning, start-up services to hand over a complete operating facility. Engineering Stage B & V provide engineering services starting with Front-End Engineering Design (FEED) to Detailed Engineering Design (DED) for whole packages with: Process Engineering Civil & Structural Engineering Rotating Equipment & Piping Engineering Instrument & Control Engineering Scheduling & Cost Estimates
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April 2013
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Procurement Stage Typical LNG Plant, major equipment and materials are procured from and contracted to several vendors/contractor/suppliers managed by project manager of Black & Veatch Brazed Aluminum Heat Exchanger (BAHE) or Cold-box supplied by multiple qualified vendors The refrigerant compressor complete with gear-box and driver supplied as one package by qualified vendors having experiences in handling refrigerant components. Their scope is to include technical assistance and commissioning. BOG compressor, regeneration gas compressor and/or recycle gas compressor sourced from qualified vendors. Dehydration, amine treating package supplied by packagers delivering with or without pre-assembled skids including technical assistance during installation until commissioning
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April 2013
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Procurement Stage (Continued) Carbon steel & stainless steel for pressure vessels, heat exchangers, condensers, and any associated drums supplied and fabricated by respective vendors. Preferred to go with local fabricators subject to vendor surveillance program conducted by construction and procurement team. Piping bulk materials including carbon and stainless steel pipe including fittings supplied by certified manufacturers as per the international standards and codes such as ASME, ANSI, etc. Valves and special cryogenic materials supplied by trusted manufacturers as per the international standards. All utility system comprised demineralization package, nitrogen packages, flare system, emergency power, consumable storage, instrument air, office, DCS, fire protection system supplied by different reputable vendors. LNG tank materials & loading system supplied by reputable vendors.
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April 2013
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Construction Stage Construction manager & team provided construction work breakdown structure along with the schedule development to run the project on site. There are several main scope of works can be decomposed to work breakdown structure (WBS) for LNG Plant Project 1. Inlet gas compression
2. Amine treating package 3. Dehydration system 4. Liquefaction system 5. Refrigerant make-up 6. Boil off gas compression 7. Regeneration gas compression 8. Flare system 9. Utility system 10.LNG tank 11.Buildings 12.Transfer System
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EXMAR PROJECT, AN EPC PROJECT
April 2013
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EXMAR PROJECT, AN EPC PROJECT
April 2013
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April 2013
EXMAR LNG Barge
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EXMAR FLSRU PROJECT
April 2013
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Black & Veatch has been a pioneer in the LNG industry since 1960s and provide EPC for topsides liquefaction equipment & packages using its patented PRICO LNG technology. Black & Veatch also provide on site commissioning and start-up Once the EXPORTTM has been built, it will be towed from China to Colombia where it will be owned and operated by EXMAR for Pacific Rubiales Corporation. The project is on progress for fabrication and expected to finish on 4th quarter of 2014. The fabrication is located in Zhang Jia Gang, 2 hours by land from Shanghai Wison offshore & Marine Ltd is delivering overall EPCI to EXMAR. Headquartered in Shanghai, Wison is constructing the facility through its wholly owned fabrication facility in Nantong, China A global Black & Veatch team working from offices in several countries supporting Wison on this project
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Project Organization Chart
Project Owner/Client
April 2013
B&V
Project Manager Procurement Construction
Engineering & Project Support
Process Engineer Civil/Structural Engineer Rotating/Piping Mechanical Eng
Procurement Services Purchase Orders Vendor Qualification
Site Management QA/QC National/Local Contractor Scheduler Local Procurement Commissioning & Start-up
Electrical Engineer
Instrument & Control Engineer Project Control & Scheduler
Traffic & Logistics

Expediting
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April 2013
B&V
EPC Project Responsibilities B & V manages the entire scope of works as the EPC contractor to coordinate the design, procurement & construction performed by B&V and partners including all contractors and suppliers who are working for project. A typical project would include the following: Perform engineering design internally within B&V engineers comprised multidiscipline of engineering to meet the standard and specification. Review the design package from each vendor and identify the interfaces and interconnections among them. Project Manager to ensure there are no missed items. Manage and coordinate with B & V construction. management team during construction, commissioning and start-up stage. Management of subcontractors and suppliers to ensure that all works are completed to the specifications and meeting B & V EHS policy and regulation.
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April 2013
B&V
EPC Project Responsibilities (Continued) B & V manages the entire scope of works as the EPC contractor to coordinate the design, procurement & construction performed by B&V and partners including all contractors and suppliers who are working for project. A typical project would include the following: Project management to meet planned schedules and within the agreed financial budgets. Ensure financial controls are in place and provide reporting via project controls officer that reflects the status of each cost center under project managers control. Complete reviews of projects to ensure engineering, risk management, QA/QC are all being attained and kept to the minimum standard. Procure major equipment to ensure all these equipment are complying with standard and specification.
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CHINA LNG DISTRIBUTED MODEL
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April 2013 B&V
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April 2013 B&V
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LNG BUSINESS IN THE WORLD; OVERVIEW
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LNG BUSINESS IN THE WORLD, OVERVIEW
April 2013
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LNG BUSINESS IN THE WORLD, OVERVIEW
April 2013
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LNG BUSINESS IN THE WORLD, APPLICATION OF LNG
Diesel substitution UP to 65%
V16 engine 4500 HP Multiple point injection Method .

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Diesel substitution Up to 65% . 6 cylinders in line / 210 Hp . Fumigation Method .
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TO CONVERT THE LARGEST DIESEL ENGINES THAT WILL REMAIN UNDER OPERATION .
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1. 2. Dump Truck Tug Boat
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WHAT IS DUAL FUEL
DUAL FUEL MEANS :
A mixture of two fuels at the same time. Natural Gas fuel is introduced into the diesel engine combustion chambers and becomes the main fuel .
A portion of diesel is required for the ignition and lubrication process .

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Investment depends on
Engine Size & number of cylinders Method : Fumigation or multiple points injection Level of required protection and monitoring Amount of LNG to be carried onboard
Savings depends on
Diesel oil price . LNG price . Operation cycles .
Diesel per MMBTU @ +/- 28 US$ LNG per MMBTU FOB PT Badak NGL for example @ +/- 12US$
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LESSONS LEARNT
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April 2013
B&V
LESSONS LEARNT
SMR PRICO offer modular concept with more flexibility. SMR technology fits well across a broad range, offshore & onshore. In term of EPC work, PRICO LNG technology is easy to build since the equipment layout is consistent therefore the project can be done properly and on timely manner. LNG is becoming competitively to substitute diesel (USD 12 14/MMBTU versus USD 28 30/MMBTU) Non-traditional uses for LNG: Distributed LNG Vehicle fuels LNG in China is used for domestic need, NO EXPORTS. B & V experienced and capable to undertake lump sump EPC projects with proven track records.
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B&V
April 2013
QUESTIONS?
1. 2. 3.
Quo Vadis Indonesia in term of Energy Policy Strategy? Can we get more VALUE ADDED? Where are we (PII)?
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B&V Mini LNG Plant

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April 2013

LESSONS LEARNT OF CHINA LNG PROJECTS & LNG BUSINESS MODEL

EPC PROJECT EXECUTION STRATEGY

CHINA LNG BUSINESS DISTRIBUTED MODEL

INTRODUCTION TO B&V PRICO TECHNOLOGY

BLACK & VEATCH SERVICE AREAS

INTRODUCTION TO B&V PRICO TECHNOLOGY

INTRODUCTION TO B&V PRICO TECHNOLOGY

INTRODUCTION TO B&V PRICO TECHNOLOGY

Lessons Learnt Session, BKK PII, April 2013

INTRODUCTION TO B&V PRICO TECHNOLOGY

ADVANTAGE OF MODERN SMR PROCESS

INTRODUCTION TO B&V PRICO TECHNOLOGY

INTRODUCTION TO B&V PRICO TECHNOLOGY

INTRODUCTION TO B&V PRICO TECHNOLOGY

INTRODUCTION TO B&V PRICO TECHNOLOGY

INTRODUCTION TO B&V PRICO TECHNOLOGY

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013

LNG Regen Gas

BOG Compression LNG LNG Storage Tank

Process Flow Overview

Process Flow Overview

Process Flow Overview

Process Flow Overview CO2 Removal

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Process Flow Overview

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Process Flow Overview, Refrigeration

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Process Flow Overview, Liquefaction

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview Heavies Handling

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Lessons Learnt Session, BKK PII, April 2013

Process Flow Overview

Lessons Learnt Session, BKK PII, April 2013

PFD Review BOG Compression

Process Flow Overview LNG Storage

Lessons Learnt Session, BKK PII, April 2013

Project Plot Plan

Lessons Learnt Session, BKK PII, April 2013

Liquefaction Area Equipment Layout

Process Area Equipment Elevation

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013

CO2 Removal (Amine System)

Lessons Learnt Session, BKK PII, April 2013

Lessons Learnt Session, BKK PII, April 2013