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Grasping the potential

Kjell Ove Ulstein and Per Helge Madsen, Wärtsilä Gas Solutions, AS,
Norway, review the latest trends occurring in the LNG regasification
sector and some of the new regasification technologies and
supporting systems currently available and in development for FSRU
conversations.

07 Nov 2020 · 5 min Gas solutions

Kjell Ove Ulstein and Per Helge Madsen, Wärtsilä Gas Solutions,
AS, Norway, review the latest trends occurring in the LNG
regasification sector and some of the new regasification
technologies and supporting systems currently available and in
development for FSRU conversations.

The global demand for LNG is increasing at a fairly rapid rate. According to Shell’s latest
LNG Outlook, demand rose by 12.5% to 359 million t in 2019, while consulting giant
McKinsey expects average annual growth of 3.6% per year through 2035. This rise in
demand places a strain on conventional shore-based regasification, which involves
transferring the LNG to terminals for storage in tanks before it is regasified and
pressurised with vaporising equipment, prior to it being delivered to the distribution
networks.

During the past 15 years, alternative solutions have been developed that are faster and
which, by extension, are also less expensive. Among these are Wärtsilä’s regasification
modules designed for use onboard FSRUs, as well as shuttle and regasification vessels
(SRVs).

Having the regasification (regas) equipment onboard the vessel allows high-pressure gas
to be delivered to land-based networks, either via a floating buoy and submerged
pipeline system from an offshore location or via loading arms on a jetty. Both FSRUs and
SRVs provide greater flexibility than conventional land-based regas facilities, and the time
from investment decision to start-up is relatively short.

By offering a fast-track means for opening energy markets, supply diversity is increased,
costs are reduced, and environmental benefits are enhanced. A further advantage of
utilising an FSRU, rather than a fixed land-based regas facility, is that it can be moved to a
new offshore location should the business environment change.

SRVs, which transport LNG in large quantities while also using the onboard regas
equipment to vaporise the LNG before sending it to a land-based network, typically work
in pairs using separate mooring buoys. The brief overlap between one shuttle arriving
and the other departing allows a continuous flow of high-pressure natural gas to be
supplied.

A seawater heated regas system

Since 2006 up until mid-2020, Wärtsilä has developed and delivered 21 regas systems
for FSRUs and SRVs, as well as one for an offshore jetty. The first two systems were
steam heated using a water-glycol mix as the intermediate medium, but subsequently,
11 deliveries were made using seawater as the heating medium with propane utilised as
the intermediate medium. These systems were delivered as complete modules for easy
integration into LNG vessels, both for new-build vessels and for conversion projects to
existing ships. The system depicted in Figure 1 has an intermediate loop of propane,
where propane evaporates against the seawater in the plate heaters (PHEs). The
propane condensates towards the LNG in printed circuit heat exchangers (PCHEs). By
using the latent heat in the propane, only small amounts of it need to be circulated,
while its low freezing point allows the use of printed circuit heat exchangers that are very
compact and efficient. As a result, the entire system is rather compact and suitable for
installation onboard ships with limited availability of space.

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Figure 1. A seawater heated system with propane used as the intermediate medium

Figure 2. A seawater heated system with water glycol used as the intermediate
medium.

LNGBooster NGVent
Multicable
Pump to/fromcabinet
(PSV/BDV) WÄRTSILÄ
6*6.6KVCable 12"SS150

BOGInlet SWInlets WGOutlets LNGDrain LPNGreturn

8"SS150 3x30"CS10K 3*30"CS10K 2"SS150 8"SS150

LNGInlet
14"SS150 RegasificationModule NGOutlet
16"SS900

WG
Deluge NitrogenSupply InstrumentAir OverboardDrain
8"CS150 1"SS150 2"SS150 8"SS150 filling/draining
2"SS150

Figure 3. Typical interconnection points for a 3 × 250 million ft³/d Wärtsilä regas
module.

Switching to water glycol

Subsequent to these deliveries, Wärtsilä developed seawater heated systems using
water glycol instead of propane as the intermediate medium. Propane is a very suitable
fluid for this application, since it will not freeze and has good
thermodynamic properties. However, the use of hydrocarbons in the deck area is
restricted by some of the industry’s major operators.

With water glycol, the heat exchangers need to be larger but the use of hydrocarbons as
the intermediate fluid is eliminated. Since 2017, Wärtsilä has produced and delivered
nine systems of this type. As shown in Figure 2, the system has an intermediate closed
circulating loop of water glycol, which heats the LNG in two stages. The initial heating
stage is in a shell and tube heat exchanger taking the LNG to a minimum heat of -15˚C,
and the second stage is in a printed circuit heater, taking the temperature up to
approximately 10˚C below that of the seawater.

The water glycol is circulated at a constant speed regardless of the LNG capacity, making
control of the system very simple. The system can be arranged in such a way that the
water glycol is channelled down to sea level, with the seawater/water glycol heater
located there. This eliminates much of the power needed to lift the seawater to deck
level.

Furthermore, since the water glycol loop is operated at a higher delta temperature (dT)
than the seawater temperature in and out, the flow typically contains one-third of
seawater. This means that the piping required to bring the water glycol up and down is
much less than it would be for piping the seawater up and down.

The major benefits

Wärtsilä regas systems are delivered as complete modules, with all the engineering,
component procurement, and construction of the module carried out entirely by the
company’s execution team, making integration of the modules very easy. All the
interconnection work and intercommunication activities with the parties executing the
required utility systems is similarly very simple and straightforward.

In addition to those already mentioned, other benefits of Wärtsilä’s systems include: a

fast delivery time of approximately 16 months; the compactness and flexibility of the
plant configuration; the ease of operation and maintenance; and the fact that all
equipment can be repaired or replaced on board a vessel.

Case study
Wärtsilä has been commissioned to build and deliver a large power plant to El Salvador,
which will eventually supply approximately 30% of the country’s energy needs. The plant
will operate on LNG.

In order to deliver LNG to the facility, a 290 m long Moss type LNG carrier, built-in 2002,
is being converted by Wärtsilä into an FSRU. This is a major project that is being carried
out on a tight schedule of just 14 months; having started in October 2019 with an
expected completion date of the end of 2020. In order to be successful, the project
requires close co-operation between all the parties involved.

The vessel is being fitted with a regas module, a compressor module, and a power
module, all integrated as a single common package. The heat source will be seawater
with water glycol as the intermediate medium. Wärtsilä’s experience and integration
capabilities are considered an an essential element in meeting the various requirements
of the project.

The regas module comprises four trains each of 70 million ft³ and has a total weight of
approximately 450 t. It includes 300 lb of piping systems and has a length of 14.87 m, a
width of 13.25 m, and a height of 18.18 m. The compressor module has two trains with
noncryogenic
screw compressors and an approximate weight (including the skid) of approximately 200
t. It measures 22.46 m long, 8.11 m wide, and 7.49 m high.

The power module features three Wärtsilä 34DF dual-fuel engines capable of running on
either LNG or conventional marine diesel fuels. The total weight of the module, including
the crane, is approximately 750 - 850 t. It is 19.7 m long, 16.24 m wide, and has a height
of 14.9 m. If the exhaust casing is included, the height is increased to 31.95 m. The three
modules comprise the equipment required for an FSRU conversion. Supplied in this
form, as complete modules, the conversion work and the interfacing with the yard are
simplified. At the same time, the engineering, component procurement, and the
production of the modules are carried out more efficiently, since Wärtsilä handles
everything using the same project group and production yard.

It is hard to overstate the complexity of such a project, and the skills needed to bring it
to a successful conclusion. When the conversion from LNG carrier to FSRU is completed,
it will feature energy efficiency, robustness, and operational flexibility comparable to
Wärtsilä’s other FSRU projects.

Figure 4. The layout of the former LNG carrier after conversion to an FSRU.

Figure 5. A Wärtsilä water glycol regas module ready for shipment. All connection co-
ordinates are clearly marked.

Figure 6. The Wärtsilä Compact Reliq can be installed on existing vessels without
extensive modification requirements.

Fulfilling gas chain

supply requirements
Wärtsilä has products and complete systems serving the entire gas value chain. Among
its offering is the capability to develop and deliver other products that may be required
for the conversion of LNG carriers to FSRUs. One example is reliquefaction systems to
handle the problem of boil-off gas (BOG).

The regas system itself has the capability to recondense BOG, but only while the system
is being operated. Furthermore, when the regas system is operating on limited send-out
capacity, the BOG recondensing capability is limited. In these situations, an additional
system for handling the BOG is usually required. Gas combustion units (GCUs) are a
common solution.

A GCU is a burner which combusts the BOG in a controlled manner without the risk of
releasing unburned natural gas into the atmosphere. Although a possible solution for
BOG handling, no useful energy can be recovered from a GCU, which is why it should
primarily be recovered by other means.

Wärtsilä’s BOG reliquefaction process is based on reversed nitrogen Brayton cycle

refrigeration technology. This means that the process is a closed nitrogen cycle for
extracting heat from the BOG. Typically, the reliquefaction system is used to control the
cargo tank pressure by liquefying BOG. The system has the capability to handle all BOG
(100% capacity) or only excessive BOG not burned in the engines (partial liquefaction).

Adding onboard reliquefaction

flexibility.
Another recent introduction to this field is Wärtsilä’s Compact Reliq reliquefaction plant.
The system is compact in design, enabling it to be installed on existing gas carriers and
LNG bunker vessels without extensive modification work.

The system is designed to reliquefy BOG, while also keeping the cargo cool under all
operational conditions. The Brayton technology allows a portion of the BOG to be
utilised as fuel for the vessel, while the excess can be liquefied and sold with the LNG
cargo. Liquefying the BOG instead of burning it in a GCU also has a positive
environmental effect, as no gases are released into the atmosphere.

Conclusion
Increasing demand around the world for LNG is disrupting the conventional means of its
regasification in land-based facilities. Greater flexibility enabling faster and less costly
means for regasification is clearly called for, which has, in turn, led to a fairly rapid
increase in the use of floating alternatives. The technology is well established and the
solutions are proven. One can assume that growth in this market will continue to gain
pace.

Written by

Wärtsilä

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