WO2023139436A2 - Modular mid-scale liquefied natural gas production system and method - Google Patents

Modular mid-scale liquefied natural gas production system and method Download PDF

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Publication number
WO2023139436A2
WO2023139436A2 PCT/IB2023/000040 IB2023000040W WO2023139436A2 WO 2023139436 A2 WO2023139436 A2 WO 2023139436A2 IB 2023000040 W IB2023000040 W IB 2023000040W WO 2023139436 A2 WO2023139436 A2 WO 2023139436A2
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WO
WIPO (PCT)
Prior art keywords
natural gas
liquefied natural
train
modularized
gas production
Prior art date
Application number
PCT/IB2023/000040
Other languages
French (fr)
Other versions
WO2023139436A3 (en
Inventor
Rajeev Nanda
Terence Ashley SMITHIES
Jichuan Hu
Jagdish J. PIPARIA
Xun JIN
Partha Ghosal
Original Assignee
Technip Energies France
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Application filed by Technip Energies France filed Critical Technip Energies France
Publication of WO2023139436A2 publication Critical patent/WO2023139436A2/en
Publication of WO2023139436A3 publication Critical patent/WO2023139436A3/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0257Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0259Modularity and arrangement of parts of the liquefaction unit and in particular of the cold box, e.g. pre-fabrication, assembling and erection, dimensions, horizontal layout "plot"
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/0002Processes or apparatus for liquefying or solidifying gases or gaseous mixtures characterised by the fluid to be liquefied
    • F25J1/0022Hydrocarbons, e.g. natural gas
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H5/00Buildings or groups of buildings for industrial or agricultural purposes
    • E04H5/02Buildings or groups of buildings for industrial purposes, e.g. for power-plants or factories
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0257Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0258Construction and layout of liquefaction equipments, e.g. valves, machines vertical layout of the equipments within in the cold box
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0257Construction and layout of liquefaction equipments, e.g. valves, machines
    • F25J1/0269Arrangement of liquefaction units or equipments fulfilling the same process step, e.g. multiple "trains" concept
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F25J1/0283Gas turbine as the prime mechanical driver
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0281Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc. characterised by the type of prime driver, e.g. hot gas expander
    • F25J1/0284Electrical motor as the prime mechanical driver
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J1/00Processes or apparatus for liquefying or solidifying gases or gaseous mixtures
    • F25J1/02Processes or apparatus for liquefying or solidifying gases or gaseous mixtures requiring the use of refrigeration, e.g. of helium or hydrogen ; Details and kind of the refrigeration system used; Integration with other units or processes; Controlling aspects of the process
    • F25J1/0243Start-up or control of the process; Details of the apparatus used; Details of the refrigerant compression system used
    • F25J1/0279Compression of refrigerant or internal recycle fluid, e.g. kind of compressor, accumulator, suction drum etc.
    • F25J1/0296Removal of the heat of compression, e.g. within an inter- or afterstage-cooler against an ambient heat sink
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2210/00Processes characterised by the type or other details of the feed stream
    • F25J2210/62Liquefied natural gas [LNG]; Natural gas liquids [NGL]; Liquefied petroleum gas [LPG]
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2290/00Other details not covered by groups F25J2200/00 - F25J2280/00
    • F25J2290/40Vertical layout or arrangement of cold equipments within in the cold box, e.g. columns, condensers, heat exchangers etc.
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25JLIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2290/00Other details not covered by groups F25J2200/00 - F25J2280/00
    • F25J2290/42Modularity, pre-fabrication of modules, assembling and erection, horizontal layout, i.e. plot plan, and vertical arrangement of parts of the cryogenic unit, e.g. of the cold box

Definitions

  • the disclosure generally relates to hydrocarbon production facilities. More specifically, the disclosure relates to modular and compact production facilities of hydrocarbons such as liquefied natural gas.
  • Liquefied Natural Gas A large portion of natural gas traded internationally is in the form of Liquefied Natural Gas (“LNG”). Liquefaction plants/terminals constitute a key link in natural gas value chain, producing LNG from natural gas via a cryogenic process, store the product in large storage tanks, and then load the LNG into LNG carriers bound for export destinations.
  • LNG Liquefied Natural Gas
  • Liquefaction plants are traditionally arranged in trains.
  • a train is a collection of process systems necessary to perform complete function of processing gaseous feed gas and converting it into liquid LNG product.
  • a liquefaction train can vary in size from small- scale to mid-scale to large-scale with distinct selections of technologies and equipment.
  • the capacity of a mid-scale train is generally in the range of 1 to 3.5 million tons per annum (“MTPA”) LNG production.
  • An onshore base load liquefaction plant often consists of multiple identical trains, sometime constructed at different times.
  • the trains are served by other common facilities located outside battery limits (OSBL), including utilities, LNG storage, LNG loading, marine systems, and so forth.
  • OSBL outside battery limits
  • onshore LNG plants are mostly ‘‘stick built”, which is built on site with individual components as a traditional method of construction. The construction process takes thousands of onsite construction workers at a time and could last years to finish. Stick built LNG plants usually occupy massive real estate.
  • the present disclosure provides a system and method of efficiently designing a compact and modularized midscale liquefied natural gas (“LNG”) production train.
  • the train includes Natural Gas Pretreatment and Natural Gas Liquefaction sections designed in a unique way that reduces footprint, capital and operating cost, and overall project schedule.
  • the modularized train can contain substantially complete process systems required for natural gas pretreatment (including inlet gas reception, mercury removal, acid gas removal, dehydration, heavies removal) and liquefaction (including pre-cooling, condensing, subcooling, and refrigerant circuits). Necessary hardware including mechanical and electrical equipment, piping and instrumentation are all included.
  • the train is configured into a framed compact multi-level structure with air coolers on the top level and process equipment underneath, which results in significant reduction in footprint compared to conventional stick-built design and significant reduction in footprint compared to conventional modularized design.
  • the inventive modularized midscale liquefied natural gas production train results in about 30% reduction in footprint compared to conventional stick-built design and about 10% reduction in footprint compared to conventional modularized design.
  • the LNG liquefier and rundown line and associated piping are located in a way to minimize cryogenic liquid lines and concentrating the lines and equipment with cryogenic service in small area at the end of module;
  • the air coolers with high duty are arranged on one side for minimizing air recirculation
  • the compressor drivers are located at the ends of module for ease of installation and maintenance;
  • the air coolers located close to gas turbines are provided with high air flow fans to increase the air flow from the air coolers to prevent hot air recirculation to the gas turbine air intake;
  • the disclosure provides a modularized liquefied natural gas production train, comprising: a framed multi-level structure comprising natural gas liquefaction process systems required for natural gas pretreatment, liquefaction, and refrigerant compression and related hardware including mechanical and electrical equipment, piping and instrumentation; wherein air coolers are installed on a top level of the structure with other process equipment located on multiple levels underneath the air coolers; wherein the structure has a central pipe rack the runs a longitudinal length of the structure with equipment located on both sides of the central pipe rack; and wherein one more refrigerant compressors and related power drivers are located at an end of the structure.
  • Figure 1 is a representation of a footprint comparison between a stick built facility, conventional modularized (semi-modular) built facility, and the inventive modular built facility having similar function and production.
  • Figure 2A is a schematic side view of an inventive embodiment of the modularized fully framed multi-level structure.
  • Figure 2B is a schematic isometric view of the modularized fully framed multi-level structure of Figure 2A.
  • Figure 3 is a schematic top view of an illustrative layout of various equipment of each side of the central corridor that distributes weight and shape symmetry of a module.
  • Figure 4A is a schematic enlarged end view of the modularized fully framed multilevel structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
  • Figure 4B is a schematic enlarged side view of the modularized fully framed multilevel structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
  • Figure 5 is a schematic diagram of divisional flexibility of modules for the modularized fully framed multi-level structure of Figures 2A-2B.
  • Figure 6A is schematic top view of an illustrative location for refrigerant compressors drivers, such as motors.
  • Figure 6B is schematic top view of an illustrative location for refrigerant compressors drivers, such as gas turbines.
  • Figure 7 is schematic top view of an illustrative routing for cryogenic service lines, such as a rundown line.
  • Figure 8 is schematic top view of an illustrative routing for cryogenic equipment and piping, including a rundown line routing.
  • Figure 9 is schematic top view of an illustrative location for pumps.
  • Figure 10 is schematic top view of an illustrative location for a stationary hydraulic lift and laydown area.
  • Figure 11 is schematic top view of an illustrative location for built-in drain drums.
  • references to at least one item may include one or more items. Also, various aspects of the embodiments could be used in conjunction with each other to accomplish the understood goals of the disclosure. Unless the context requires otherwise, the term “comprise” or variations such as “comprises” or “comprising,” should be understood to imply the inclusion of at least the stated element or step or group of elements or steps or equivalents thereof, and not the exclusion of a greater numerical quantity or any other element or step or group of elements or steps or equivalents thereof.
  • the terms “top”, “up”, “upward”, “bottom”, “down”, “downwardly”, and like directional terms are used to indicate the direction relative to the figures and their illustrated orientation and are not absolute relative to a fixed datum such as the earth in commercial use.
  • inner refers to a direction facing toward a center portion of an assembly, component or system, such as longitudinal centerline of the assembly, component or system
  • outer refers to a direction facing away from the center portion of an assembly, component, or system.
  • Coupled means any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, operably, directly or indirectly with intermediate elements, one or more pieces of members together and may further include without limitation integrally forming one functional member with another in a unitary fashion.
  • the coupling may occur in any direction, including rotationally.
  • the order of steps can occur in a variety of sequences unless otherwise specifically limited.
  • the various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps.
  • Element numbers with suffix letters are to designate different elements within a group of like elements having a similar structure or function, and corresponding element numbers without the suffix letters are to generally refer to one or more of the like elements.
  • Any element numbers in the claims that correspond to elements disclosed in the application are illustrative and not exclusive, as several embodiments may be disclosed that use various element numbers for like elements.
  • the present disclosure provides a system and method of efficiently designing a compact and modularized midscale liquefied natural gas production train.
  • the train includes Natural Gas Pretreatment and Natural Gas Liquefaction sections designed in a unique way that reduces footprint, capital and operating cost, and overall project schedule.
  • the train is configured into a framed compact multi-level structure with air coolers on the top level and process equipment underneath, which results in significant reduction in footprint compared to conventional stick-built design and significant reduction in footprint compared to conventional modularized design.
  • Figure 1 is a representation of a footprint comparison between a stick built facility, conventional modularized (semi-modular) built facility, and the inventive modular built facility having similar function and production.
  • the present invention train design 2 (shown in Figures 2A and 2B) is configured into a framed and compact multi-level structure with air coolers on the top level and process equipment underneath, which results in about 30% reduction in footprint compared to conventional stick-built design 4 and about 10% reduction in footprint compared to conventional modularized design 6.
  • the compactness is important for at least two reasons. For instance, a train with 2.0 MTPA nominal capacity using the present invention measures about 800 feet (245 meters) long, 128 feet (40 meters) wide.
  • modules are often shipped to location and moved from the ship with motorized transports. The footprint is limited by the ship. Compaction allows more equipment and potentially more production from the same footprint. The invention accomplishes the increased compaction over even current modularization designs.
  • Figure 2A is a schematic side view of an inventive embodiment of the modularized fully framed multi-level structure.
  • Figure 2B is a schematic isometric view of the modularized fully framed multi-level structure of Figure 2A.
  • Figure 3 is a schematic top view of an illustrative layout of various equipment of each side of the central corridor that distributes weight and shape symmetry of a module.
  • Figure 4A is a schematic enlarged end view of the modularized fully framed multi-level structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
  • Figure 4B is a schematic enlarged side view of the modularized fully framed multi-level structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
  • the present invention can configure an entire LNG train 10 into a fully framed multi-level structure.
  • a structure not only provides space to contain all components within the train, but also is supported adequately for marine and road transportation either as one or multiple modules.
  • the first level 12 (also referred to as a bottom deck herein) is a structural base and is elevated from the ground or other supporting surface to allow roll-on roll-off transportation on ship and shore with self-propelled module transporters (“SPMT”) 14.
  • SPMT self-propelled module transporters
  • Air coolers 16 are installed on a top level 18 of the structure and other process equipment are located in levels underneath the top level with the air coolers. Tubes coupled with the air coolers can include at least portions of high flux tubes.
  • the air coolers can be installed so that air coolers that collectively form a majority heat load of the train and air flow are installed on one portion of the top level to reduce hot air recirculation and reduce a size of at least a portion of the air coolers.
  • an air cooler located in proximity to a gas turbine can include a high air flow fan to reduce hot air recirculation to an intake of the gas turbine.
  • Compression equipment such as a booster compressor 76
  • a pre-treatment section such as pretreatment module 66
  • process towers 68 can be located on an opposite side of the pipe rack 24 of the central corridor 26.
  • At least some of the compression equipment can be located at an edge, such as a corner, of the train for easy replacement and maintenance access.
  • large compressors requiring large motor drivers and variable frequency drives are generally located on the edges of the modules. This location allows high tension cables to be outside the train and not in close proximity of other ISBL equipment, which enhances the safety of the plant.
  • the train 10 structure has a built-in central pipe rack 24, shown particularly in Figure 4A, along the train length in the longitudinal direction. Equipment are placed on both sides of the pipe rack.
  • This central pipe rack 24 provides easy and organized connectivity for piping and cables.
  • a central corridor 26 is consequently formed within the train structure that combines the vacant space required for safety distance (such as reduced overpressure in case of explosion) and maintenance access, and hence achieved superior compactness over conventional designs.
  • a pre-cooling heat exchanger 82 can be located on one side of the central corridor 26 in a liquefaction section (such as liquefaction module 54) and a liquefier 50 can be located on an opposite side of the central corridor. In this way, superior weight distribution and shape symmetry of the module is achieved.
  • Local electrical rooms and/or substations 84 can be located at outside edges 86 of the train and distal from liquefied natural gas rundown lines and a cryogenic area, described above, to have clean air intake access. Also, instrument junction boxes 88 can be located along the central corridor 26, distal from liquefied natural gas rundown lines and a cryogenic area.
  • FIG. 5 is a schematic diagram of divisional flexibility of modules for the modularized fully framed multi-level structure of Figures 2A-2B. Consistently designed and framed and supported throughout, the elongated train structure can be further divided into multiple modules, when justified by specific needs of a project. Great flexibility exists in dividing the train into multiple modules along the latitudinal direction, without altering overall train structure design and equipment layout. A single module is possible for the entire train of small capacity. A mid-scale train would generally have three modules. When arriving at the site, individual modules are installed back-to-back along the train longitudinal direction with aligned central pipe rack and leveled decks. As examples, various different ways of module division include but are not limited to:
  • the train structure 30 can be one single module
  • the train structure 32 can be divided into a process module and a refrigerant compressor(s) module;
  • the train structure 34 can be divided into a pretreatment module, a liquefaction module, and a refrigerant compressor(s) module.
  • the train structure 36 can be divided into a pretreatment module and a liquefaction/refrigerant compressor(s) module.
  • Figure 6A is schematic top view of an illustrative location for refrigerant compressors drivers, such as motors.
  • Figure 6B is schematic top view of an illustrative location for refrigerant compressors drivers, such as gas turbines.
  • Figures 6A and 6B illustrates two alternatives with electric gas motors and turbines, respectively.
  • LNG liquefaction is achieved by exchanging heat with circulating refrigerant, hence the duty required to cool and/or condense refrigerant is very significant.
  • the heat is rejected via a very large number of air coolers into the atmosphere as a heat sink.
  • air coolers in prior art are often placed on top of the pipe rack.
  • a large open top level 18 is formed and is made available for air cooler 16 installation.
  • at least two air cooler banks 38A and 38B are arranged side-by-side fully occupying the top level width.
  • the air coolers can be installed on the top level independent of any cantilever extensions extending laterally from the train. As a result, no additional footprint structure is required for air coolers.
  • refrigerant compressor(s) 40 and refrigerant compressor power driver(s) 42 are strategically located at an end 44 of the elongated train 10 structure, such as the end of a compression module 46, allowing easy access for maintenance.
  • the compressor(s) and driver(s) can be aligned such that their shafts are in parallel with the longitudinal length of the train, including parallel with the length of the pipe rack 24, described above.
  • the power driver 42 is interchangeable between gas turbine driver and electric motor driver.
  • Such a location also provides flexibility to accommodate compressor design variability (such as barrel vs. horizontal split casing, single vs. multiple bodies, and so forth), causing little if any impact on overall train structure design and equipment layout.
  • FIG. 7 is schematic top view of an illustrative routing for cryogenic service lines, such as a rundown line.
  • cryogenic service lines such as a rundown line.
  • a gas turbine When a gas turbine is used, its air intake 48 is oriented away from process equipment located inside the train structure. This improves safety by reducing possible entrained flammable hydrocarbons in the air entering the gas turbine. It also reduces potential hot air recirculation from air coolers.
  • One or two Liquefiers for LNG precooling, condensing, and subcooling may be required depending on liquefaction processes.
  • the present invention differs in that the liquefier(s) 50 can be installed at a reserved location within the train 10 and supported by the train structure.
  • This enclosed liquefier design shortens the inter-connecting piping between the liquefier 50 and connecting equipment, and hence reduces contained hydrocarbon liquid inventory such as LNG or refrigerant. It allows the train 10 structure to provide support for the liquefier and avoid a dedicated support structure often required to support this tall exchanger and its associated piping and valves. In the case of multi-train layout, the spacing between the two adjacent trains in parallel can be reduced without the liquefier(s) sticking out.
  • vacuum insulated pipes 58 can be used. By using vacuum insulated pipes 58, LNG troughs are not needed for spill containment. The design helps achieve superior safety and cost effective pre-fabricated design.
  • Figure 8 is schematic top view of an illustrative routing for cryogenic equipment and piping, including a rundown line routing.
  • the LNG liquefier 50 and rundown line 56, shown in Figure 7, and associated piping are located in a way to minimize cryogenic liquid lines and concentrating the lines and equipment with cryogenic service in a small cryogenic area 60 at the end 52 of liquefaction module 54 in this embodiment.
  • the design achieves high compactness and enhanced safety.
  • Figure 9 is schematic top view of an illustrative location for pumps. Pumps 62 can be located on the first level 12 along sides 64 of the central corridor under the pipe rack for easy maintenance access. Also, all the pumps in the liquefaction module 54 and pretreatment module 66 (shown in Figure 8) can be localized in a small area which allows for collection of potentially contaminated rainfall water from directly underneath the pumps and thus permitting a significant capital cost savings for a reduced water treatment system capacity.
  • Figure 10 is schematic top view of an illustrative location for a stationary hydraulic lift and laydown area.
  • the central corridor 26 is designed to safely accommodate any removed item from within the train that requires maintenance and transfer to a lift system 70 on a first level 12 that can be installed at an end 72 of a module.
  • the lift system 70 can be hydraulic.
  • Upper levels can have drop zone openings 74 to the first level 12 within the central corridor 26.
  • the drop zone openings 74 allow for superior ergonomics, a further safety escape system, and a well-ventilated area for maintenance.
  • Figure 11 is schematic top view of an illustrative location for a built-in drain system. Oily water and chemical drain systems 78 are pre-installed within the module frames beneath the bottom deck and distal from the LNG rundown lines and cryogenic area described above.
  • the modularized liquefied natural gas production train has been described above with some specificity, the train is not limited to such a configuration.
  • the number of levels and modules, height of the bottom deck above grade, location of various sections in modules, and other features can vary.
  • the train could be stick built with the same layout concept to achieve compactness and cost reduction.
  • Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the disclosed invention as defined in the claims.
  • some of the components could be arranged in different locations, and other variations that are limited only by the scope of the claims.

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Abstract

The present disclosure provides a system and method of efficiently designing a compact and modularized midscale liquefied natural gas production train. The train includes Natural Gas Pretreatment and Natural Gas Liquefaction sections designed in a unique way that reduces footprint, capital and operating cost, and overall project schedule. The train is configured into a framed compact multi-level structure with air coolers on the top level and process equipment underneath, which results in significant reduction in footprint compared to conventional stick-built design and significant reduction in footprint compared to conventional modularized design.

Description

TITLE OF THE INVENTION
[0001] Modular mid-scale liquefied natural gas production system and method
CROSS REFERENCE TO RELATED APPLICATIONS
[0002] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not applicable.
REFERENCE TO APPENDIX
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] Field of the Invention.
[0006] The disclosure generally relates to hydrocarbon production facilities. More specifically, the disclosure relates to modular and compact production facilities of hydrocarbons such as liquefied natural gas.
[0007] Description of the Related Art.
[0008] A large portion of natural gas traded internationally is in the form of Liquefied Natural Gas (“LNG”). Liquefaction plants/terminals constitute a key link in natural gas value chain, producing LNG from natural gas via a cryogenic process, store the product in large storage tanks, and then load the LNG into LNG carriers bound for export destinations.
[0009] Liquefaction plants are traditionally arranged in trains. A train is a collection of process systems necessary to perform complete function of processing gaseous feed gas and converting it into liquid LNG product. A liquefaction train can vary in size from small- scale to mid-scale to large-scale with distinct selections of technologies and equipment. The capacity of a mid-scale train is generally in the range of 1 to 3.5 million tons per annum (“MTPA”) LNG production. An onshore base load liquefaction plant often consists of multiple identical trains, sometime constructed at different times. The trains are served by other common facilities located outside battery limits (OSBL), including utilities, LNG storage, LNG loading, marine systems, and so forth.
[0010] In the past, onshore LNG plants are mostly ‘‘stick built”, which is built on site with individual components as a traditional method of construction. The construction process takes thousands of onsite construction workers at a time and could last years to finish. Stick built LNG plants usually occupy massive real estate.
[0011] During recent years, modular construction has been increasingly applied in LNG project execution, which in many cases shortens project schedule and reduces risks, at the same time saving cost. However, the extent of modularization and its specific implementation varies a great deal from project to project. The following observations are made in literature of modular LNG train design.
[0012] First, modularization remains a construction method rather than a design philosophy. Consequently, a train has the same or similar configuration and layout as a conventional stick built one, only to be sliced up into smaller sections when it comes to construction execution. One consequence is a very large train footprint due to most process equipment being located on the base level, even though the equipment may have been included in different modules.
[0013] Second, only parts of the train are modularized, leaving the remaining sections still to be stick built. This is prevalent in most of the current “modular” trains. Non-modular sections of the train often involve components that are challenging to be modularized, for example tall and heavy columns, liquefier, large rotating equipment, pipe rack, electrical/instrumental equipment, and others. The US Patent 10,539,361 , for instance, has much equipment located in unframed sections or even outside modules. As a result, the train footprint remains significant and a substantial amount of field work is still required.
[0014] Third, a large number of modules is often required to construct a complete LNG train, which increases exponentially with train size. The number and size of modules rely on many practical constraints in module fabrication, marine shipping, road transportation, and other factors. A train, especially a large-scale one, is sometimes divided into dozens of modules, which leads to a large number of interfaces/golden welds to be connected in the field. It also adds complexity and uncertainties to construction execution, as all these modules could be built and shipped from different yards around the globe, that need to be managed and coordinated. From this perspective, less number of modules are desirable for which midscale trains offer better prospects.
[0015] Given these shortcomings in prior art, alternate and better designs are much needed to realize full benefits from LNG train modularization.
BRIEF SUMMARY OF THE INVENTION [0016] The present disclosure provides a system and method of efficiently designing a compact and modularized midscale liquefied natural gas (“LNG”) production train. The train includes Natural Gas Pretreatment and Natural Gas Liquefaction sections designed in a unique way that reduces footprint, capital and operating cost, and overall project schedule. The modularized train can contain substantially complete process systems required for natural gas pretreatment (including inlet gas reception, mercury removal, acid gas removal, dehydration, heavies removal) and liquefaction (including pre-cooling, condensing, subcooling, and refrigerant circuits). Necessary hardware including mechanical and electrical equipment, piping and instrumentation are all included. The train is configured into a framed compact multi-level structure with air coolers on the top level and process equipment underneath, which results in significant reduction in footprint compared to conventional stick-built design and significant reduction in footprint compared to conventional modularized design. In at least one illustrative comparison, the inventive modularized midscale liquefied natural gas production train results in about 30% reduction in footprint compared to conventional stick-built design and about 10% reduction in footprint compared to conventional modularized design.
[0017] The inefficiencies of prior art are removed in the new method described in this invention. The efficiency of compactness is further improved by arranging process equipment/ systems in a strategic and unique way in at least one or more of the following:
• By combining vacant spaces required for multiple purpose, such as maintenance access, safety distance, and process technology reasons;
• The LNG liquefier and rundown line and associated piping are located in a way to minimize cryogenic liquid lines and concentrating the lines and equipment with cryogenic service in small area at the end of module;
• The air coolers with high duty are arranged on one side for minimizing air recirculation;
• The compressor drivers are located at the ends of module for ease of installation and maintenance;
• The large compressors requiring large motor drivers and variable frequency drives are located on the extremities of the modules; this allows the high tension cables to be outside the modules and not in close proximity of other “inside battery limits” (“ISBL") equipment, which enhances the safety of the plant; • Due to short length of LNG run down line, the vacuum insulated pipes are used which avoids LNG troughs for spill containment and this achieves superior safety and cost effective pre-fabricated design;
• The air coolers located close to gas turbines are provided with high air flow fans to increase the air flow from the air coolers to prevent hot air recirculation to the gas turbine air intake; and
• The local electrical rooms and/or substations on the module located at outside edges of the module away from LNG rundown lines and cryogenic area.
[0018] This strategic placement of the equipment also leads to low hydrocarbon inventory of LNG and other cryogenic fluids which leads further to compactness without compromising the process safety. Furthermore, the strategic design of module(s) provides flexibility to add options with no impact to overall module design and equipment layout.
[0019] The disclosure provides a modularized liquefied natural gas production train, comprising: a framed multi-level structure comprising natural gas liquefaction process systems required for natural gas pretreatment, liquefaction, and refrigerant compression and related hardware including mechanical and electrical equipment, piping and instrumentation; wherein air coolers are installed on a top level of the structure with other process equipment located on multiple levels underneath the air coolers; wherein the structure has a central pipe rack the runs a longitudinal length of the structure with equipment located on both sides of the central pipe rack; and wherein one more refrigerant compressors and related power drivers are located at an end of the structure.
[0020] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0022] Figure 1 is a representation of a footprint comparison between a stick built facility, conventional modularized (semi-modular) built facility, and the inventive modular built facility having similar function and production.
[0023] Figure 2A is a schematic side view of an inventive embodiment of the modularized fully framed multi-level structure.
[0024] Figure 2B is a schematic isometric view of the modularized fully framed multi-level structure of Figure 2A.
[0025] Figure 3 is a schematic top view of an illustrative layout of various equipment of each side of the central corridor that distributes weight and shape symmetry of a module.
[0026] Figure 4A is a schematic enlarged end view of the modularized fully framed multilevel structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
[0027] Figure 4B is a schematic enlarged side view of the modularized fully framed multilevel structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
[0028] Figure 5 is a schematic diagram of divisional flexibility of modules for the modularized fully framed multi-level structure of Figures 2A-2B.
[0029] Figure 6A is schematic top view of an illustrative location for refrigerant compressors drivers, such as motors.
[0030] Figure 6B is schematic top view of an illustrative location for refrigerant compressors drivers, such as gas turbines.
[0031] Figure 7 is schematic top view of an illustrative routing for cryogenic service lines, such as a rundown line.
[0032] Figure 8 is schematic top view of an illustrative routing for cryogenic equipment and piping, including a rundown line routing.
[0033] Figure 9 is schematic top view of an illustrative location for pumps.
[0034] Figure 10 is schematic top view of an illustrative location for a stationary hydraulic lift and laydown area.
[0035] Figure 11 is schematic top view of an illustrative location for built-in drain drums.
DETAILED DESCRIPTION
[0036] The Figures described above and the written description of specific structures and functions below are not presented to limit the scope of what Applicant has invented or the scope of the appended claims. Rather, the Figures and written description are provided to teach any person skilled in the art how to make and use the inventions for which patent protection is sought. Those skilled in the art will appreciate that not all features of a commercial embodiment of the inventions are described or shown for the sake of clarity and understanding. Persons of skill in this art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present disclosure will require numerous implementation-specific decisions to achieve the developer’s ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, and likely are not limited to, compliance with system-related, business-related, government-related, and other constraints, which may vary by specific implementation, location, or with time. While a developer’s efforts might be complex and time-consuming in an absolute sense, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill in this art having benefit of this disclosure. It must be understood that the inventions disclosed and taught herein are susceptible to numerous and various modifications and alternative forms. The use of a singular term, such as, but not limited to, “a,” is not intended as limiting of the number of items. Further, the various methods and embodiments of the system can be included in combination with each other to produce variations of the disclosed methods and embodiments. Discussion of singular elements can include plural elements and vice-versa. References to at least one item may include one or more items. Also, various aspects of the embodiments could be used in conjunction with each other to accomplish the understood goals of the disclosure. Unless the context requires otherwise, the term "comprise" or variations such as "comprises" or "comprising,” should be understood to imply the inclusion of at least the stated element or step or group of elements or steps or equivalents thereof, and not the exclusion of a greater numerical quantity or any other element or step or group of elements or steps or equivalents thereof. The terms “top”, “up”, “upward”, “bottom”, “down”, “downwardly”, and like directional terms are used to indicate the direction relative to the figures and their illustrated orientation and are not absolute relative to a fixed datum such as the earth in commercial use. The term “inner,” “inward,” “internal” or like terms refers to a direction facing toward a center portion of an assembly, component or system, such as longitudinal centerline of the assembly, component or system, and the term “outer,” “outward,” “external” or like terms refers to a direction facing away from the center portion of an assembly, component, or system. The term “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and may include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, operably, directly or indirectly with intermediate elements, one or more pieces of members together and may further include without limitation integrally forming one functional member with another in a unitary fashion. The coupling may occur in any direction, including rotationally. The order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Similarly, elements have been described functionally and can be embodied as separate components or can be combined into components having multiple functions. Some elements are nominated by a device name for simplicity and would be understood to include a system of related components that are known to those with ordinary skill in the art and may not be specifically described. Various examples are provided in the description and figures that perform various functions and are non-limiting in shape, size, description, but serve as illustrative structures that can be varied as would be known to one with ordinary skill in the art given the teachings contained herein. As such, the use of the term “exemplary” is the adjective form of the noun “example" and likewise refers to an illustrative structure, and not necessarily a preferred embodiment. Element numbers with suffix letters, such as “A”, “B”, and so forth, are to designate different elements within a group of like elements having a similar structure or function, and corresponding element numbers without the suffix letters are to generally refer to one or more of the like elements. Any element numbers in the claims that correspond to elements disclosed in the application are illustrative and not exclusive, as several embodiments may be disclosed that use various element numbers for like elements.
[0037] The present disclosure provides a system and method of efficiently designing a compact and modularized midscale liquefied natural gas production train. The train includes Natural Gas Pretreatment and Natural Gas Liquefaction sections designed in a unique way that reduces footprint, capital and operating cost, and overall project schedule. The train is configured into a framed compact multi-level structure with air coolers on the top level and process equipment underneath, which results in significant reduction in footprint compared to conventional stick-built design and significant reduction in footprint compared to conventional modularized design.
[0038] Figure 1 is a representation of a footprint comparison between a stick built facility, conventional modularized (semi-modular) built facility, and the inventive modular built facility having similar function and production. The present invention train design 2 (shown in Figures 2A and 2B) is configured into a framed and compact multi-level structure with air coolers on the top level and process equipment underneath, which results in about 30% reduction in footprint compared to conventional stick-built design 4 and about 10% reduction in footprint compared to conventional modularized design 6. The compactness is important for at least two reasons. For instance, a train with 2.0 MTPA nominal capacity using the present invention measures about 800 feet (245 meters) long, 128 feet (40 meters) wide. Secondly, modules are often shipped to location and moved from the ship with motorized transports. The footprint is limited by the ship. Compaction allows more equipment and potentially more production from the same footprint. The invention accomplishes the increased compaction over even current modularization designs.
[0039] Figure 2A is a schematic side view of an inventive embodiment of the modularized fully framed multi-level structure. Figure 2B is a schematic isometric view of the modularized fully framed multi-level structure of Figure 2A. Figure 3 is a schematic top view of an illustrative layout of various equipment of each side of the central corridor that distributes weight and shape symmetry of a module. Figure 4A is a schematic enlarged end view of the modularized fully framed multi-level structure of Figures 2A-2B, illustrating a central corridor and central pipe rack. Figure 4B is a schematic enlarged side view of the modularized fully framed multi-level structure of Figures 2A-2B, illustrating a central corridor and central pipe rack.
[0040] Contrasting to prior art, the present invention can configure an entire LNG train 10 into a fully framed multi-level structure. Such a structure not only provides space to contain all components within the train, but also is supported adequately for marine and road transportation either as one or multiple modules. The first level 12 (also referred to as a bottom deck herein) is a structural base and is elevated from the ground or other supporting surface to allow roll-on roll-off transportation on ship and shore with self-propelled module transporters (“SPMT") 14. Air coolers 16 are installed on a top level 18 of the structure and other process equipment are located in levels underneath the top level with the air coolers. Tubes coupled with the air coolers can include at least portions of high flux tubes. The air coolers can be installed so that air coolers that collectively form a majority heat load of the train and air flow are installed on one portion of the top level to reduce hot air recirculation and reduce a size of at least a portion of the air coolers. Further, an air cooler located in proximity to a gas turbine can include a high air flow fan to reduce hot air recirculation to an intake of the gas turbine.
[0041] Compression equipment, such as a booster compressor 76, can be located on one side of the central corridor 26 in a pre-treatment section (such as pretreatment module 66) and process towers 68 can be located on an opposite side of the pipe rack 24 of the central corridor 26. At least some of the compression equipment can be located at an edge, such as a corner, of the train for easy replacement and maintenance access. Also, large compressors requiring large motor drivers and variable frequency drives are generally located on the edges of the modules. This location allows high tension cables to be outside the train and not in close proximity of other ISBL equipment, which enhances the safety of the plant.
[0042] Multiple levels 20 allow vertical offset among equipment and enables more compact layout. As a result, the train footprint is significantly smaller compared with other designs with the same capacity as described in Figure 1 above.
[0043] The train 10 structure has a built-in central pipe rack 24, shown particularly in Figure 4A, along the train length in the longitudinal direction. Equipment are placed on both sides of the pipe rack. This central pipe rack 24 provides easy and organized connectivity for piping and cables. A central corridor 26 is consequently formed within the train structure that combines the vacant space required for safety distance (such as reduced overpressure in case of explosion) and maintenance access, and hence achieved superior compactness over conventional designs.
[0044] A pre-cooling heat exchanger 82 can be located on one side of the central corridor 26 in a liquefaction section (such as liquefaction module 54) and a liquefier 50 can be located on an opposite side of the central corridor. In this way, superior weight distribution and shape symmetry of the module is achieved.
[0045] Local electrical rooms and/or substations 84 can be located at outside edges 86 of the train and distal from liquefied natural gas rundown lines and a cryogenic area, described above, to have clean air intake access. Also, instrument junction boxes 88 can be located along the central corridor 26, distal from liquefied natural gas rundown lines and a cryogenic area.
[0046] Figure 5 is a schematic diagram of divisional flexibility of modules for the modularized fully framed multi-level structure of Figures 2A-2B. Consistently designed and framed and supported throughout, the elongated train structure can be further divided into multiple modules, when justified by specific needs of a project. Great flexibility exists in dividing the train into multiple modules along the latitudinal direction, without altering overall train structure design and equipment layout. A single module is possible for the entire train of small capacity. A mid-scale train would generally have three modules. When arriving at the site, individual modules are installed back-to-back along the train longitudinal direction with aligned central pipe rack and leveled decks. As examples, various different ways of module division include but are not limited to:
• In one embodiment, the train structure 30 can be one single module;
• In one embodiment, the train structure 32 can be divided into a process module and a refrigerant compressor(s) module;
In one embodiment, the train structure 34 can be divided into a pretreatment module, a liquefaction module, and a refrigerant compressor(s) module.
• In one embodiment, the train structure 36 can be divided into a pretreatment module and a liquefaction/refrigerant compressor(s) module.
[0047] Figure 6A is schematic top view of an illustrative location for refrigerant compressors drivers, such as motors. Figure 6B is schematic top view of an illustrative location for refrigerant compressors drivers, such as gas turbines. Figures 6A and 6B illustrates two alternatives with electric gas motors and turbines, respectively. LNG liquefaction is achieved by exchanging heat with circulating refrigerant, hence the duty required to cool and/or condense refrigerant is very significant. In an air-cooled liquefaction train, the heat is rejected via a very large number of air coolers into the atmosphere as a heat sink. To avoid taking additional plot space, air coolers in prior art are often placed on top of the pipe rack. Such solutions however are constrained by the available width of the pipe rack. It is not uncommon for a liquefaction train to extend extra distance in length (that is, longitudinal) direction just to accommodate air coolers. There are also designs to build structures dedicated for air coolers or use self-standing air coolers, which in either case would require large additional plot.
[0048] With a fully framed train 10 structure of the present invention, a large open top level 18 is formed and is made available for air cooler 16 installation. There is a lot more space in width (i.e. latitudinal) direction compared to only the pipe rack as in prior art. With the geometry of air coolers carefully selected, at least two air cooler banks 38A and 38B are arranged side-by-side fully occupying the top level width. The air coolers can be installed on the top level independent of any cantilever extensions extending laterally from the train. As a result, no additional footprint structure is required for air coolers.
[0049] In the present invention, refrigerant compressor(s) 40 and refrigerant compressor power driver(s) 42 are strategically located at an end 44 of the elongated train 10 structure, such as the end of a compression module 46, allowing easy access for maintenance. In addition, the compressor(s) and driver(s) can be aligned such that their shafts are in parallel with the longitudinal length of the train, including parallel with the length of the pipe rack 24, described above. With being located at the end 44 of the train 10, the power driver 42 is interchangeable between gas turbine driver and electric motor driver. Such a location also provides flexibility to accommodate compressor design variability (such as barrel vs. horizontal split casing, single vs. multiple bodies, and so forth), causing little if any impact on overall train structure design and equipment layout. [0050] Figure 7 is schematic top view of an illustrative routing for cryogenic service lines, such as a rundown line. When a gas turbine is used, its air intake 48 is oriented away from process equipment located inside the train structure. This improves safety by reducing possible entrained flammable hydrocarbons in the air entering the gas turbine. It also reduces potential hot air recirculation from air coolers.
[0051] One or two Liquefiers for LNG precooling, condensing, and subcooling may be required depending on liquefaction processes. The present invention differs in that the liquefier(s) 50 can be installed at a reserved location within the train 10 and supported by the train structure. This enclosed liquefier design shortens the inter-connecting piping between the liquefier 50 and connecting equipment, and hence reduces contained hydrocarbon liquid inventory such as LNG or refrigerant. It allows the train 10 structure to provide support for the liquefier and avoid a dedicated support structure often required to support this tall exchanger and its associated piping and valves. In the case of multi-train layout, the spacing between the two adjacent trains in parallel can be reduced without the liquefier(s) sticking out.
[0052] The liquefier 50 located at an end 52 of a liquefaction section 54, the LNG rundown line 56 can be routed outside of the structure boundary from the same end and away from the train resulting in minimum length of LNG rundown line 56 within the train 10 leading to minimum inventory of LNG within the train and thus enhanced safety. Due to short length of LNG run down line 56, vacuum insulated pipes 58 can be used. By using vacuum insulated pipes 58, LNG troughs are not needed for spill containment. The design helps achieve superior safety and cost effective pre-fabricated design.
[0053] Figure 8 is schematic top view of an illustrative routing for cryogenic equipment and piping, including a rundown line routing. The LNG liquefier 50 and rundown line 56, shown in Figure 7, and associated piping are located in a way to minimize cryogenic liquid lines and concentrating the lines and equipment with cryogenic service in a small cryogenic area 60 at the end 52 of liquefaction module 54 in this embodiment. Thus, the design achieves high compactness and enhanced safety.
[0054] Figure 9 is schematic top view of an illustrative location for pumps. Pumps 62 can be located on the first level 12 along sides 64 of the central corridor under the pipe rack for easy maintenance access. Also, all the pumps in the liquefaction module 54 and pretreatment module 66 (shown in Figure 8) can be localized in a small area which allows for collection of potentially contaminated rainfall water from directly underneath the pumps and thus permitting a significant capital cost savings for a reduced water treatment system capacity.
[0055] Figure 10 is schematic top view of an illustrative location for a stationary hydraulic lift and laydown area. The central corridor 26 is designed to safely accommodate any removed item from within the train that requires maintenance and transfer to a lift system 70 on a first level 12 that can be installed at an end 72 of a module. The lift system 70 can be hydraulic. Upper levels can have drop zone openings 74 to the first level 12 within the central corridor 26. The drop zone openings 74 allow for superior ergonomics, a further safety escape system, and a well-ventilated area for maintenance.
[0056] Figure 11 is schematic top view of an illustrative location for a built-in drain system. Oily water and chemical drain systems 78 are pre-installed within the module frames beneath the bottom deck and distal from the LNG rundown lines and cryogenic area described above.
[0057] While the modularized liquefied natural gas production train has been described above with some specificity, the train is not limited to such a configuration. For example, the number of levels and modules, height of the bottom deck above grade, location of various sections in modules, and other features can vary. In some cases when module transportation becomes a constraint, the train could be stick built with the same layout concept to achieve compactness and cost reduction. Other and further embodiments utilizing one or more aspects of the inventions described above can be devised without departing from the disclosed invention as defined in the claims. For example, some of the components could be arranged in different locations, and other variations that are limited only by the scope of the claims.
[0058] The invention has been described in the context of preferred and other embodiments, and not every embodiment of the invention has been described. Obvious modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicant, but rather, in conformity with the patent laws, Applicant intends to protect fully all such modifications and improvements that come within the scope of the following claims.

Claims

WHAT IS CLAIMED IS:
1 . A modularized liquefied natural gas production train, comprising: a framed multi-level structure comprising natural gas liquefaction process systems required for natural gas pretreatment, liquefaction, and refrigerant compression and related hardware including mechanical and electrical equipment, piping and instrumentation; wherein air coolers are installed on a top level of the structure with other process equipment located on multiple levels underneath the air coolers; wherein the structure has a central pipe rack the runs a longitudinal length of the structure with equipment located on both sides of the central pipe rack; and wherein one or more refrigerant compressors and related power drivers are located at an end of the structure
2. The modularized liquefied natural gas production train of claim 1 , wherein the refrigerant compressors and related power drivers are longitudinally aligned with the longitudinal axis of the train.
3. The modularized liquefied natural gas production train of claim 1 , wherein the framed multi-level structure comprises one single module.
4. The modularized liquefied natural gas production train of claim 1 , wherein the framed multi-level structure comprises multiple modules along a longitude of the structure direction without impacting a layout of the structure and equipment.
5. The modularized liquefied natural gas production train of claim 1 , wherein the multiple modules comprise at least one of a process module and a refrigerant compressor module; a pretreatment module, a liquefaction module, and a refrigerant compressor module; and a pretreatment module and a liquefaction/refrigerant compressor module.
6. The modularized liquefied natural gas production train of claim 1 , wherein the air coolers are installed on a top level of the structure independent of an existence of one or more cantilever extensions extending laterally from the multi-level structure.
7. The modularized liquefied natural gas production train of claim 6, wherein the air coolers that are installed on the top level occupy no more than the width of the top level.
8. The modularized liquefied natural gas production train of claim 6, wherein tubing coupled with the air coolers comprise at least portions of high flux tubes.
9. The modularized liquefied natural gas production train of claim 1 , wherein the air coolers installed on a top level of the structure are installed so that air coolers that collectively form a majority heat load of the train and air flow are installed on one portion of the top level to reduce hot air recirculation and reduce a size of at least a portion of the air coolers.
10. The modularized liquefied natural gas production train of claim 1 , wherein an air cooler located in proximity to a gas turbine comprises a high air flow fan to reduce hot air recirculation to an intake of the gas turbine.
11 . The modularized liquefied natural gas production train of claim 10, further comprising vacant space created underneath the central pipe rack is configured to mitigate overpressure damage in the event of explosion and provide a safe distance between equipment and a maintenance space for equipment in a central location.
12. The modularized liquefied natural gas production train of claim 1 , wherein the one more refrigerant compressors and related power drivers located at an end of the structure are configured for interchangeable replacement between a gas turbine driver and an electric motor driver.
13. The modularized liquefied natural gas production train of claim 1 , wherein a liquefied natural gas liquefier is installed in a module and supported by structure of the module in proximity to a refrigerant compressor and configured to reduce hydrocarbon inventory in the train for safety.
14. The modularized liquefied natural gas production train of claim 13, wherein the liquefier is located at one end of a liquefaction module and a liquefied natural gas rundown line is routed outside of the liquefaction module boundary from the same end and away from the liquefaction module to reduce presence of the liquefied natural gas rundown line within the module and inventory of liquefied natural gas within the module for enhanced safety.
15. The modularized liquefied natural gas production train of claim 13, further comprising configuring locations of the liquefied natural gas liquefier and rundown line and associated piping to concentrate cryogenic lines and equipment with cryogenic service in an cryogenic area in proximity to an end of the module.
16. The modularized and complete liquefied natural gas production train of claim 13, wherein at least a portion of the liquefied natural gas rundown line comprises vacuum insulated pipes to at least reduce requirements of liquefied natural gas troughs for spill containment.
17. The modularized liquefied natural gas production train of claim 1 , wherein a plurality of pumps are located on a bottom deck of the train along sides of the central corridor for maintenance access.
18. The modularized liquefied natural gas production train of claim 17, wherein pumps in the liquefied natural gas liquefier and pre-treatment portions of the train are located in an area configured for collection of the potentially contaminated rainfall water underneath the pumps and reduction in capacity requirements of a water treatment system.
19. The modularized liquefied natural gas production train of claim 1 , wherein at least one large compressor and variable frequency drive is located at an edge of a module of the train for maintenance and safety.
20. The modularized liquefied natural gas production train of claim 1 , further comprising a lift system installed at an end of a module of the train and configured to move items between an elevation on the train and a lower elevation, wherein the central corridor space is configured to allow removal of equipment from within the module and transfer to the hydraulic lift system.
21 . The modularized liquefied natural gas production train of claim 20, wherein levels higher than a first level with the central corridor are configured with drop zone openings in the levels to the first level.
22. The modularized liquefied natural gas production train of claim 1 , wherein compression equipment is located on one side of the central corridor in a pre-treatment section and process towers are located on an opposite side of the pipe rack in the central corridor.
23. The modularized liquefied natural gas production train of claim 1 , wherein a pre-cooling heat exchanger is located on one side of the central corridor in a liquefaction section and a liquefier is located on an opposite side of the central corridor.
24. The modularized and complete liquefied natural gas production train of claim 1 , further comprising local electrical rooms and/or substations located at outside edges of the train and distal from liquefied natural gas rundown lines and a cryogenic area to have clean air intake access.
25. The modularized and complete liquefied natural gas production train of claim 1 , further comprising local instrument rooms and junction boxes located on an outside edge of a module of the train distal from liquefied natural gas rundown lines and a cryogenic area.
26. The modularized complete liquefied natural gas production train of claim 1 , further comprising oily water and amine drain systems pre-installed within at least one module frame beneath a basement floor distal from liquefied natural gas rundown lines and a cryogenic area.
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