Cryostar S.A.S.

LNG Cargo Handling Equipment

System and Operational Training Course

for Cryostar Cargo Handling Equipment
for LNG Carriers

Date: 31st July 2006, at DSME Yard, Korea

 This document is CONFIDENTIAL INFORMATION
>>> to Teekay LNG Crews ONLY

Copyright : CRYOSTAR SAS, 2006

1
>>>
Bulkhead

Motor Bulkhead Seal

Gearbox

Local Panel

Compressor
housing

LO Cooler

Steam
Heater
Skid
2
>>>

3
>>>

Lube oil
equipment &
instrumentation

4
>>>

ƒ The lube oil pressure is

initially supplied by the
electrical oil pump.
ƒ The gearbox oil pump takes Oil Supply to
over during start up and Filter gearbox
assures oil pressure.
ƒ Since the surge valve opens
upon a trip, the unloaded
compressor can run down
safely on the residual
pressure, even if the elec. oil
pump fails.
TI 8
ƒ The filter elements are st.steel
and need only be cleaned (not
replaced). PCV 8
ƒ The PCV is adjusted by TE 8
Cryostar. The LD can run at ½ Supply to
speed. The oil pressure is Bulkhead seal
adjusted for this speed.

5
>>>

Auxiliary
Pump

Oil Cooler

Bulkhead
seal oil
collector
6
 >>>

ƒ AUXILIARY LUBE OIL PUMP :

ƒ This 3-screw pump with flexible coupling is flange mounted on the
motor.
ƒ Maintenance is light and piping stress should be checked if any shaft
leaks occur. (Bulkhead welding can induce piping

ƒ This pump is used for :

• the start of the compressor (and then the main oil
pump takes over)
• In case of pressure loss
• For a limited time after compressor stop in order to
reduce cold creep to the gearbox bearings.

7
 >>>

ƒ MAIN LUBE OIL PUMP :

• Designation : three rotor screw pump
• Pump size : 70 or 100 l/min at 6 bar
• Medium/viscosity : Oil ISO VG 22-46
• Maintenance period is 20000 hours

Main
Main pump
pump
ƒ The pumped fluid lubricates the internal parts of
the pump and the roller bearings are greased for
the lifetime of the pumps.
ƒ This pump runs at the same time as the
compressor. It’s driven by the gearbox. It is used
to maintain the lubrication of the lube oil system
during the functioning of the compressor

Lube
Lube oil
oil line
line

Suction
Suction line
line from
from tank
tank
8
 >>>

ƒ OIL TANK :
ƒ The oil spec. is important for good bearing life Use Ashless Oils
ƒ Characteristics
(zinc free)
• Capacity of oil reservoir : 400 l
• ISO viscosity grade VG46
• Specific gravity at 15°C 875 kg/m3
• Viscosity at 40°C 46 cSt
• Viscosity at 100°C 7.0 cSt
• Viscosity index 108
• Pour point -33°C
• Flash point 236°C
• Aniline point 107°C
• Demulsibility (15mn) 40/40/0ml
• Foaming Sequence 0/0ml/ml

Integrated
Integratedlube
lubeoil
oiltank
tank

9
 >>>

ƒ STEAM HEATER ASSY :

ƒ The steam heater is an enclosed envelope with a separate oil volume.
ƒ 70 litres of high flash point oil are required for the 4 compressors.
ƒ It does not usually need maintenance.
ƒ The regulation is by the thermostatic control of the steam inlet valve.
ƒ Deposits should be cleaned from this valve when required.
ƒ The thermostat adjusting scale should be protected from humidity

10
>>>

11
>>> Heat Barrier

Seal Gas

Shaft Seal

Oil Trap

12
 >>>

ƒ The seal gas system is a barrier to gas behind

the compressor wheel.
ƒ It also impedes humidity from the entering
the compressor when stopped (cause of
damage upon start up)
ƒ The seal gas pressure is constant.
ƒ Since cold gas expands upon warming up,
when the compressor is stopped the suction
valve should be left open.
ƒ Seal gas entering the gearbox from shaft seals
is returned to the lube oil sump, separated
from the oil and vented to atmosphere.
ƒ In case of heavy seas, a high tank pressure
wave may temporarily rise above seal gas
pressure.

13
>>>

14
 >>>
ƒ The compressor is of

ƒ axial inflow and Impeller

ƒ radial outflow type.

ƒ Inlet Guide Vanes allow to
control the machine.

IGV

15
>>>

16
>>>

ƒ Allows penetration of gearbox shaft

through the bulkhead into Motor Room Oil OUT

ƒ Oil-filled cartridge type tandem carbon Gearbox

Oil IN
seal on the gearbox low speed shaft.
ƒ It’s oil flow also dissipates shaft heat.
Coupling
ƒ It accepts the shaft movement of
gearbox bearings.
ƒ But can be damaged by inappropriate
dismantling.
ƒ Oil supply from the main lube-oil stream
ƒ Residual oil is normal and is collected in
the oil collector on the motor side.
ƒ The carbon rings are exchanged every 2nd Seal Cartridge
dry dock

17
>>>

ƒ It compensates for the

bulkhead wall deformation
after integration (welding).

18
>>>
Compressor
Compressor
Gearbox
Gearbox Motor
Motor
ƒ Function :
Speed-increasing two-shaft parallel gear

ƒ H/D Compressor :
Compressor shaft speed : 11200 rpm
E-motor shaft speed : 3550 rpm (60 Hz)
Ratio : 3.155
=> 3550 x 3.155 = 11200 rpm

ƒ L/D Compressor :
Compressor shaft speed : 24000 rpm
E-motor shaft speed : 3550 rpm (60 Hz)
Ratio : 6.76
=> 3550 x 6.76 = 24000 rpm

19
>>>

Thrust
Thrust bearing
bearing Mech.
Mech. LO
LO Pump
Pump

ƒ Both HD & LD gearboxes are

similar design but have
different shaft diameters
ƒ The maintenance life of the Low
Low Speed
Speed Shaft
Shaft
high speed shaft bearings is
between 20-25000 hours.
ƒ LD bearings are therefore
exchanged between 7-10
years navigation on average;
ƒ Low speed shaft bearings Radial
Radial bearings
bearings
are expected to last a very
long time indeed…. Compressor
Compressor High
High
Speed Shaft
Speed Shaft
Thrust
Thrust Collar
Collar

20
 >>>

ƒ Assembled between the motor and the

gearbox hub, the coupling alignment is used
to detect main piping stress on the
compressor casing.
ƒ If piping stress is too high, alignment shall
change after bellows are tightened.
ƒ For overhauls the coupling hub must be
heated and extracted
ƒ …..without damaging the bulkhead seal.

Coupling
Coupling
protection
protection

Copper
Copper
Non
Non sparking
sparking

21
>>>

ƒ The actuator is controlled from the CCR or locally via the HIC and IP convertor

Limit Switch ZSL

IP convertor
for remote
Pneumatic control via
Positionner and CCR
Pneumatic feedback card
Actuator

22
>>>

ƒ The HIC :
ƒ Pneumatic station (HIC/ZS/HS3)

• The HIC allows Local control of the IGV

• There is a LOCAL/REMOTE setting for local or CCR control of the IGV
• As well as a PCV for manual operation
• And an output pressure gauge controlling the pneumatic pressure to the IGV actuator.
• The operator can locally control the IGV setting by adjusting PCV knob.

23
>>>
Bulkhead

Motor Bulkhead Seal

Gearbox

Local Panel

Compressor
LO Cooler

Skid
24
>>>

© Cryostar 2006

25
>>>

1
>>>

Shaft alignment is always made afloat and with a full oil tank

Bellows tightening can change alignment

So alignment is made in two steps

1. With bellows loose, oil tank full, vessel afloat
2. With bellows tightened, oil tank full, vessel
afloat
(preferably at the same temperature and sea
conditions)

2
>>>
Allowable Nozzle Forces and
Moments
ƒ Forces and moments must be limited
to avoid deformation and resulting
damage
ƒ Forces and moments on compressor
nozzles due to thermal expansion shall
not exceed following results, in
accordance with NEMA-SM23 :

Inlet Outlet
Force Moment Force Moment

N Nm N Nm
Low Duty Compressor 10” / 8” 8 300 4 600 7 100 3 950

12” / 10” 8 860 4 940 8 300 4 600

High Duty Compressor 20” / 18” 11 250 6 250 10 630 5 920

24” / 20” 12 440 6 910 11 250 6 250
Nozzles designed to withstand min. 2.2 times the values required by NEMA SM-23
3
>>>

Mark 4 fix points on two axes at 90° on the hub on the motor side :

Mount the dial gauges on the special tool as shown :

Turn each time ¼ of turn and write measured values of coaxility and parallelism.
Move the motor with pads on the skid and by shims in order to obtain the value in the table.

4
>>>

Mark 4 fix points on two axes at 90° on the hub on the motor side :

Mount the dial gauges on the special tool as shown :

Low duty compressor High duty compressor

Radial alignment between Maximal 0.1 mm Maximal 0.1 mm
motor and gearbox hub (in
diameter)
Axial alignment between Maximal 0.1 mm Maximal 0.1 mm
motor and gearbox hub

Turn each time ¼ of turn and write measured values of coaxility and parallelism.
Move the motor with pads on the skid and by shims in order to obtain the value in the table.

5
>>>

© Cryostar 2006

6
>>>

1
 >>>

ƒ Surge definition : oscillations of pressure and flow, including a flow reversal. The surge flow
reversal is the only point of the curve when pressure and flow drop simultaneously.
ƒ The surge phenomena :
ƒ Rapid flow oscillations
ƒ Thrust reversals
ƒ Potential damage
ƒ Rapid pressure oscillations with process instability
ƒ Rising temperatures inside compressor

ƒ Some surge consequences : B to C in 20 to 50 mSec

ƒ Unstable flow and pressure

ƒ Damage in sequence with increasing severity to seals, bearings, impellers, shaft.
ƒ Increased seal clearances and leakage
ƒ Reduced compressor life

2
 >>>

ƒ Principle :
ƒ Compressor surge is characterised by erratic compressor inlet and discharge pressure and (usually
audible) flow pulsation.

ƒ It is caused by flow instability in the compressor. Severe compressor surge causes shaft vibration to
increase and may result in severe damage to the compressor.

ƒ An automatic surge control system has to be provided to protect the machines from inadvertently
operating in surge.

ƒ The compressor is equipped with an automatic surge control system; using bypass valve responding to
a low flow controller. The inlet guide vanes on both compressors suction lines are controlled by a
process loop. Speed and inlet guide vanes control the flow and avoid surge.

3
 >>>

ƒ Factors leading to onset of surge : ƒ The approach to surge is fast :

ƒ Start-up ƒ Performance curve is rather flat near surge
ƒ Shutdown
ƒ Operation at reduced throughput
∆
ƒ Operation at heavy throughput with :
• Trips
• Operators errors
• Load changes
• Cooler problems
∆
• Driver problems
• Power loss
• Process Upsets
• Gas composition changes
• Filter or strainer problems
ƒ Surge is not limited to times of reduced
throughput. Surge can occur at full
operation.

4
 >>>

ƒ Anti-surge control valve :

ƒ Criteria for valve sizing are based on experience in design and operating compressor systems. These
criteria reflect the following necessary conditions :
• Valve must be sized to provide adequate anti-surge protection in all operating regimes, including regimes with low operating pressure.
• Valve must be sized to provide flow peaks greater than what is normally required to operate on the surge control line. Valve must not
be oversized in order to avoid choke zone.
• Valve must have speed of response adequate for anti-surge protection for fastest disturbances.
ƒ Information for valve sizing typically may be given by operating point. This one is shown on the
maximum performance curve (shown during the compressor test).

5
 >>>

ƒ Anti-surge system : It is fully automatic and it is

composed of :
ƒ Heavy duty automatic throttling control valve : The concept of this valve is based on an eccentrically
rotating spherical plug, contain in a free flow design body. The plug seating surface is joined by flexible arms to a
hub which slides onto a rotating shaft.

7
 >>>

ƒ The orifice plate permits to know the gas flow at the inlet of process gas.
ƒ The orifice plate is connected to a differential pressure transmitter (flow
transmitter).
ƒ The information is reported via a 4-20 mA signal to the surge control.

Item Name Normal (Instr. Range) Level Type Set point Signal
Operation Setting range
Condition
T : Trip
Process gas flow FT1 35000 m3/h ((0-62 kPa(g)) 4-20 mA A : Alarm
I1 : Start-up interlock L.O. pump
0-6.1 kPa(g) I2 : Start-up interlock machine

8
>>>

1
>>>

Saturated Steam in Gas out

Process
Steam Side Side

Gas/LNG in
Condensate out

2
>>>

ƒ General view of heaters & vaporizers

3
>>>

ƒ View for Dismantling :

4
>>>

The body gasket is of

one piece.

The tube bundle is fully

extracted for gasket
replacement

Retighten the head bolts

after some period in use

5
>>>

The U-tube design allows

ƒ free contraction of the tubes
ƒ free expansion of the shell

Sliding support Fixed support

6
>>>

TE

TC

7
>>>

Split Range Control Diagram

1
Inlet Valve

Valve Opening

0.5

Bypass Valve
0
0 0.5 1
Temperature Correction Signal

8
>>>

© Cryostar 2006

9
>>>

1
 “Drain Trap” Several names for
“Steam Trap”
>>> “Condensate Trap”
the same thing !

Steam Supply

Bypass
valve

Drain
Trap

Note: Bypass valve at the

same level as Steam Trap!
Bypass valve

Drain Trap Condensate

Drain

Isolating valves

2
>>>
Steam Supply Condensate Recovery
ƒ The Drain Trap is the barrier between the
steam supply (~8 bar) and the boiler
feed system (~1 bar).
ƒ In case of a vaporizer with a steam
consumption of ~6’500 kg/h the Drain
Trap handles about 2 litres of condensate
per second.
ƒ The Drain Trap is typically sized for twice
the nominal flow.
ƒ The floater-type Drain Trap is
self-regulating (normally Yard supply).
The level difference H is the 8 bar 1 bar
result of the pressure drop in
piping and isolating valve. H
Condensate
In normal operation, the sight Drain
glass should be even empty !

For hot condensate, the pressure drop in piping and isolating valve results in flash steam.
3
>>>
Log P,h Diagram for Water Multi-Flash 3.2.69 GTCDATA 11.9
1000
110 °C

130 °C

150 °C

170 °C

190 °C

210 °C

230 °C

250 °C

270 °C

290 °C

310 °C

330 °C

350 °C

370 °C

390 °C

410 °C

430 °C

450 °C

470 °C
90 °C

Used Model: Csm

100

10
Condensation
Pressure [bar(a)]

1
-2200 -1700 -1200 -700 -200 300 800

Enthalpy [kJ/kg]

4
>>>

250 °C
Log P,h Diagram for Water Multi-Flash 3.2.69 GTCDATA 11.9

270
290
310
330
350
370
390
410
10

Condensation

Steam flashing starts Pressure drop in

pipe and valves
Pressure [bar(a)]

Expansion in
Drain Trap
13% Flash Steam !
Therefore, increase
Used Model:Csm

1
-2200 -1800
discharge pipe size to
Enthalpy [kJ/kg] consider the flash steam !

5
>>>
Steam Supply

ƒ Bypass Valve installed to allow removal of

Drain Trap for maintenance.
ƒ Globe valve to be used as bypass regulating
valve.
ƒ In normal operation the bypass valve is
closed to avoid disturbance of the Drain
Trap!
Increase pipe size to
A high level H indicates consider the flash steam !
excessive pressure drop
in piping and isolating H
valve !
Piping arrangement to Condensate
Drain
consider pressure drop for
keeping the condensate
level sufficiently low. ~ 13% Flash Steam
Gate valves with low pressure drop to be used.
6
>>>
Steam Supply

Note:
The condensate collector is
just a conduit. H

It is not a buffer with a level

control function! Condensate
Drain

The condensate flow is limited by the Drain

Trap and valves, NOT by the collector !
7
>>>

Proper Arrangement
(seen from above)

Turbulence !

Bypass Line Main Line

Main Line Bypass Line

Turbulence means Pressure Drop

resulting in Flash Steam
Bend Æ good flow guidance
Not recommended !

8
>>>

Note:

Our above guidelines are in fully in line

with the recommendations of SARCO,
a reputed manufacturer of Steam
Traps and other related equipment.

© Cryostar 2005

9
>>>

© Cryostar 2005

10
>>>

1
>>>
Bulkhead
seal
Motor extracted
overhauled by
others Gearbox
cover
opened

Flexible coupling
extracted
Compressor
casing
Bulkhead dismantled
Bellows
dismantled
Actuator
dismounted 2
>>>
Dry Dock Scope

General machine inspection

Extraction and inspection of compressor high speed shaft and bearings.

Inspection and check of bulkhead seal and main gas seal carbon rings.

Replacement of all parts as per the defined Dry Dock Kit.

Re-assembly of gearbox parts and casing cover.

Re-assembly of bulkhead seal

Re-assembly of compressor insulating plates, seal, wheel and casing.

Re-assembly of pipes, expansion bellows by shipyard personnel.

Witness of Motor and coupling re-alignment (alignment only once vessel is floating).

Air running test

General inspection of other compressors

3
 Dry Dock logistics for Preventive Maintenance
>>>

Unforeseen
event

Capital Spares kept

in Warehouse

Using Cryostar Warehouses for Dry Dock

Capital and Dry Dock Spares Kit from
Dry Dock Work Cryostar

4
>>> Contents of the Cryostar Service Agreement

The general philosophy is :

o Stock Warehousing and management by Cryostar
o At Singapore, France, China, USA, etc.

o Cryostar shall ship a Dry Dock Kit at each Dry Dock

o More Kits shall always be available at Cryostar
o No shelf life issues (old o-rings, old parts)

o If other parts are required, the Cryostar technician shall inform the
Owner
o Cryostar shall ship these parts to the vessel and invoice them upon shipment.