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D2. Protecting LNG processes

The document discusses the importance of pressure relief devices, specifically safety valves and rupture discs, in ensuring the safety of liquefied natural gas (LNG) processes. It highlights the benefits of using combination devices that integrate both safety valves and rupture discs to prevent overpressure and improve operational efficiency. As LNG production is expected to grow significantly, understanding the optimal protection methods for these processes is crucial for industry stakeholders.

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7 views

D2. Protecting LNG processes

The document discusses the importance of pressure relief devices, specifically safety valves and rupture discs, in ensuring the safety of liquefied natural gas (LNG) processes. It highlights the benefits of using combination devices that integrate both safety valves and rupture discs to prevent overpressure and improve operational efficiency. As LNG production is expected to grow significantly, understanding the optimal protection methods for these processes is crucial for industry stakeholders.

Uploaded by

Chemical.Ali
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Protecting LNG processes

6/19/2024
While the liquified natural gas (LNG) industry is a relatively new part of the global
energy market (roughly 50-yr-old), it is one of the fastest growing segments. The LNG
process chain includes several complex and diverse processes, from extraction,
liquefaction and transport to consumption. To ensure the safety of these processes,
pressure relief devices such as safety valves and rupture discs are required throughout
various aspects of the LNG process chain to prevent serious accidents caused by
overpressure.

A safety valve is a spring-loaded pressure relief valve (PRV) actuated by the static
pressure upstream of the valve. A rupture disc is a non-reclosing PRV activated by the
static differential pressure between the device’s inlet and outlet. 1 Safety valves and
rupture discs are possible solutions to overpressure in LNG processes, and each device
has benefits and disadvantages. They are used separately or in combination,
depending on the specific requirements of the process.

Protecting PRVs with rupture discs: Combination device. Safety valves are widely
used within LNG trains for overpressure protection. However, PRVs can quickly reach
their limits, particularly where there are major requirements regarding the medium’s
tightness or if it is viscous, sticky or freezing. In addition, each PRV allows a certain
level of leakage. Seat tightness requirements are defined in American Petroleum
Institute (API) 527—the acceptance criteria allow for a certain number of bubbles,
meaning some leakage is inevitable during normal operation.2 It must be considered
that these leakage rates are established on a brand-new valve in a controlled factory
environment.

A solution involving an upstream rupture disc unites the benefits of both devices. This
arrangement is called a combination device per the International Organization of
Standardization (ISO) 4126-3.3 When combined, PRVs and rupture discs are a
reasonable and economical solution for various applications. The benefits of the
combination include:

 Isolating 100% of process fluids


 Avoiding product loss during normal operation
 Preventing rogue emissions
 Isolating PRVs from corrosive process media, resulting in cost savings on PRV
materials and maintenance
 Preventing PRV blockage
 Pop testing the PRV onsite, with no need for removal (FIG. 1).
FIG. 1. A combination device with a rupture disc for onsite testing of PRVs.

Current codes and standards recommend the technical and economic benefits of
combination devices, which are finding more applications in modern processes. For
example, an application where a rupture disc is commonly found within the LNG
process is in front of safety valves on the vaporizers in regasification plants.

However, as such processes frequently run on a duty, standby and redundancy basis
(three sets)—and there are many on each asset—contractors, engineers and original
equipment manufacturers (OEMs) tend to choose lower technology, cross-scored,
forward-acting rupture discs due to the lower price level. Additionally, the effect of
backpressure on the rupture discs from adjacent relief and flare streams can be
ignored.4 As end users require more and more output, they put higher volumes through
existing assets to the point where the cycling and operating pressures increase, pushing
the installed rupture discs beyond their operating limits. Ultimately, the rupture discs can
fatigue and fail prematurely.

High lifecycle. Rupture discs with a long lifetime are recommended to avoid premature
failure. Proprietary reverse-acting rupture discsa provide longer-term cost benefits. The
author’s company’s rupture disca was manufactured using Euler’s critical load formula to
determine the burst pressure. The disc is nearly immune to damage caused by
improper installation or handling, which maximizes the disc’s lifetime. The rupture
disca also ensures that it can withstand a high level of backpressure without causing any
damage to the disc (FIG. 2).
FIG. 2. A reverse acting rupture disc for absolute leak tightness.

The system is leak-proof and back in operation quicker. Monitoring can also be
used to report when the disc has ruptured. Conventional signaling devices require
cables to be mounted on the rupture disc, which must then be routed through the
holder. The author’s company’s sensorb operates differently. In this case, a signal
indicator is attached to the rupture disc during manufacturing. The sensor is screwed
into a blind tapping in the rupture disc holder, where it monitors the position of the signal
indicator. This means that the wiring only starts outside the rupture disc holder.

After an overpressure event, the outlet part of the rupture disc holder must be removed,
and the rupture disc replaced; the system can then be put back into operation. The
signaling cables no longer need to be rerouted to the respective switching box. 5

The process is leak-tight, and the blind tapping in the holder replaces the tapping, which
is usually required. The absence of cable glands means they cannot become porous,
preventing an escape from the process media (FIG. 3).

FIG. 3. When the rupture disca opens, the sensorb will release information to
the system’s process control unit.
The end user received an engineered solution for maximum vessel and personnel
protection. Choosing the correct disc design and material leads to an increased service
life and eliminates the need for frequent shutdowns for periodic maintenance. The user
can profit from substantially reduced capital expenditure (CAPEX) and associated
installation costs using the rupture discs compared to using any other valve, reducing
the process’ overall emissions balance.

Protecting compressors under challenging circumstances. Protecting compressors


is another application within the LNG process where rupture discs are used rather than
safety valves. Due to their compact, reliable design, centrifugal compressors are often
used for offshore liquefaction.6 Such turbomachinery uses a dry gas seal, which uses
clean gas under pressure on the external side of the seal, so the only leak through the
seal is the buffer gas into the compressor. An important component of a dry gas seal is
the vent system. For the primary vent system, a rupture disc is typically installed in
parallel with the vent line to rupture at a set pressure and prevent excessive pressure
on instruments during a primary seal failure. A signaling system on the primary vent
system is recommended to enable integrity checks while the seal system is still online.

Customers using dry gas seals require rupture discs to be installed to vent excess
pressure in case the primary seal experiences a catastrophic failure. If the pressure
increases beyond its predetermined limit, a higher gas flow or backpressure in the
piping system is present and must be safely vented. A signaling device is also required
to detect a change in the rupture disc status to initiate a shutdown of the process in the
event of overpressure.

A rupture discc with integrated signaling is cost-effective and reverse-acting with an


integrated polyamide signaling device, suitable for the demanding conditions in dry gas
seal applications. The rupture discc uses laser technologyd, ensuring high-quality,
accurate burst control even in the harshest environments. The integrated signaling
device informs operators immediately that the disc has burst and must be replaced. It is
possible to restart the compressor with the damaged rupture disc in place, which is why
it is critical that signaling is used to alert operators to avoid incident.

Takeaway. These are only two examples of how rupture discs are used across the LNG
process, but there are many other uses, such as protecting heat exchangers and
cryogenic storage tanks. As LNG production is expected to double over the next two
decades—with the U.S., Canada, Russia and Australia leading the development of
these global projects—it will become increasingly important for those involved in LNG
contracts to understand the best and safest way to protect their processes.

Notes

a REMBE’s KUB

b REMBE’s NIMU
c REMBE’s IKB

d REMBE’s unique Contour Precision Lasering™

LITERATURE CITED

1API, “API standard 520: Part 1─Sizing, selection and installation of pressure-relieving
devices,” July 2014, online:
https://www.api.org/~/media/files/publications/whats%20new/520pt1_e9%20pa.pdf

2API, “API standard 527: Seat tightness of pressure relief valves,” November 2014,
online: https://www.api.org/~/media/files/publications/whats%20new/527_e4%20pa.pdf

3ISO, “ISO 4126-3:2006: Safety devices for protection against excessive pressure: Part
3: Safety valves and bursting disc safety devices in combination,” March 2006, online:
https://www.iso.org/standard/34203.html

4API, “API standard 521: Pressure-relieving and depressuring systems,” January 2014,
online:
https://www.api.org/~/media/files/publications/whats%20new/521%20e6%20pa.pdf

5The American Society of Mechanical Engineers (ASME), “Boiler and pressure vessel
code, Sec. VIII Div. 1,” 2017, online: https://www.asme.org/getmedia/c041390f-6d23-
4bf9-a953-646127cfbd51/asme-bpvc-brochure-webview.pdf

6Stahley, J., et al., “Dry gas seal system design standards for centrifugal compressor
applications,” Texas A&M University, 2001, online:
https://oaktrust.library.tamu.edu/bitstream/handle/1969.1/163307/t31pg145.pdf;jsessioni
d=F0C003C24086CEC4A4C55D8251A34E6E?sequence=1

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