Simplify BOG recondenser design and operation

Part 1
S. P. B. Lemmers, Vopak LNG Holding BV, Rotterdam, The Netherlands
LNG receiving and regasification terminals connect the intermittent process of LNG carrier unloading and/or
loading with the mostly continuous process of LNG vaporization and gas transmission into a sendout pipeline
system.
In addition to these LNG carrier operations, truck/train loading operations can take place simultaneously. During
all operational modes of the LNG terminal, boiloff gas (BOG) is produced, which requires processing to avoid
flaring or venting (under normal operating conditions) and to minimize the environmental impact of the facility.
There are several options to choose from for the design of BOG recondensers used in LNG terminals. Design
options and equipment installations are reviewed, with a focus on the most optimal methods.
BOG recondensation approach
Of the various options for BOG handling, the most common approach is recondensing the BOG in a BOG
recondenser. Discussed are the design, process control and operational elements of the most common types of
BOG recondensers used in LNG terminals worldwide.
BOG generation and handling. Generation of BOG takes place in any operational mode of the LNG terminal.
BOG is produced mainly because the LNG is stored at cryogenic conditions in a much warmer ambient
environment. The generation of BOG is the result of several factors:

Steady-state heat leak into the LNG carrier, LNG storage tanks, process equipment and LNG process
piping

Mechanical energy input by process equipment [e.g., low-pressure (LP) in-tank and high-pressure (HP)
sendout pumps]

Displaced vapors from the LNG carrier and LNG storage tanks due to unloading, loading and sendout
flowrates

BOG generation and/or reduction due to creation of BOG/LNG equilibrium in LNG storage tanks

Elevation difference between LNG from the LNG carrier and LNG from the storage tanks

Atmospheric pressure changes.

The amount of BOG generated is a function of the absolute rates of the above phenomena, and it changes
significantly between the various operational modes. The main operational modes of LNG terminals are the
holding mode (with gas sendout, but no LNG carrier unloading or loading) and the LNG carrier unloading and/or
loading mode(s), also with gas sendout.
Several common options exist for handling BOG generation in an LNG terminal:

LP compression into a fuel gas systeme.g., for LNG vaporization inside the LNG terminal, for use by
nearby industrial consumers or for power generation

HP compression to natural gas pipeline pressures

BOG reliquefaction inside the LNG terminal and return as LNG to the storage tanks

LP compression into a BOG recondenser, in which the BOG is recondensed to LNG.

The last BOG handling option, which focuses on the BOG recondenser, is considered here.
BOG recondensers are commonly applied in LNG terminals where there is continuous sendout of natural gas via
vaporization of LNG. Both HP compression and BOG reliquefaction have high capital and operating costs,
whereas LP compression requires a substantial nearby consumer of LP fuel gas. However, such a consumer is
generally not available.
Vapor handling system. The vapor handling system option including the BOG recondenser consists of the BOG
desuperheater (required for reducing BOG compressor suction temperature), the LP BOG compressor(s) and the
BOG recondenser (Fig. 1).

Fig. 1. Process flow of a typical LNG receiving and regasification terminal.

In the BOG recondenser, the BOG is brought into contact with subcooled LNG for recondensation of the BOG.
The LNG is subcooled because the BOG recondenser operates at substantially higher pressures (typically
between 5 barg and 10 barg) than the LNG storage tanks, which are slightly above atmospheric pressure.
In the holding mode of operation, all BOG from the LNG storage tanks is routed to the LP BOG compressors,
which compress the BOG into the BOG recondenser. During the unloading mode of operation, most of the BOG
is returned to the LNG carrier to compensate for liquid volume reduction in the LNG carrier, with the balance
going to the LP BOG compressors and the BOG recondenser. The directions of flow are vice versa for the
loading mode of operation.
During these main operational modes, LNG is continuously pressurized and vaporized on the sendout pipeline
system. When there is no gas sendout, the LNG terminal is in zero sendout mode. In this operational mode, other
solutions for BOG handling should be pursued, as the BOG recondenser cannot be operational without LNG
sendout for recondensation.
Conventional BOG recondenser designs are based on cocurrent downflow direct-contact packed-bed columns
for recondensation, with a holdup section for the downstream HP pumps. They are installed between the LP
pumps and compressors and the HP pumps. The setup essentially consists of a partly packed column that has
two primary functions. The upper portion houses a packed-bed section in which BOG is contacted with subcooled
LNG to recondense the BOG. The lower portion of the BOG recondenser with the holdup section serves as a
surge drum for the HP pumps, and the skirt height and level provide the required net positive suction head
(NPSH) for the HP pumps.

BOG recondenser design

It is essential to consider practical design elements, such as piping connections, HP pump vents, minimum flow
recycle, pressure safety valves (PSVs), vent/flare options and padding gas, for two types of BOG recondenser
designs.
Designs fundamentals. There are two basic designs for BOG recondensers: The annular space type and the
top packed-bed section type. Both of these designs operate in the cocurrent downflow regime, which means that
both BOG and LNG are introduced at the top of the BOG recondenser and flow downward. The less common
countercurrent and static-mixing BOG recondenser designs are not considered here.
Annular space type. This first type contacts the LNG and BOG in a packed bed in the center, surrounded by an
annular space. The LNG and BOG are fed to the central packed-bed section. The liquid level in the BOG
recondenser annular space is controlled by manipulating the inlet LNG flowrate to the packed-bed section, since
all of the LNG is directed to the packed-bed section. The packed-bed liquid level, which is distinct from the level
in the annular space (as is the pressure), is not directly controlled and will vary with the BOG/LNG flow ratio in
the center section. The LNG levels and vapor pressures in the center section and annular space differ during
operation.
Top packed-bed section type. The second type of design has a packed section spanning the complete vessel
diameter of the top section, and it has a bottom LNG inlet for the holdup sections of the HP pumps. The single
level is controlled via the bottom LNG inlet flow.
LNG for recondensation, which is part of the LNG flow to the BOG recondenser, is introduced into the top
packed-bed section and brought into contact with the BOG for recondensation. The pressure in the packed-bed
section is identical to the pressure in the holdup section (except for some pressure drop over the packed bed),
and it can be controlled by the LNG supply to the top packed-bed section of the BOG recondenser. Fig. 2 shows
examples of the two basic types of BOG recondensers.

Fig. 2. BOG recondensers: Annular space type (left) and top packed-bed section
type (right).

Mechanical design complexity comparison. From a mechanical design point of view, it is obvious that design
and construction of an annular space type BOG recondenser are more complex. The annular packed-bed section
needs to be supported from the top and should not vibrate at the bottom.
The top packed-bed section type supports the bed all the way around and, therefore, is more robust. This design
features a dedicated removal nozzle for when the packing requires replacement of the top packed-bed section,
while the annular space type requires more decommissioning and reinstatement work.
Process piping connections. Although both types of BOG recondenser designs fulfill the same functionsi.e.,
to recondense BOG and provide NPSH for the HP pumpsthe process piping connections to HP pumps,

vent/flare, padding gas, PSVs, operational and maintenance bypasses, and control valves can differ from design
to design. Designers may even vary the lineup and controls for the same type of BOG recondenser.
Minimum flow recycle and vent connections. The HP pump, being a high-head, multiple-stage canned pump,
requires minimum flow protection. The HP canned pump motors are cooled by the LNG. To ensure that the HP
pump remains filled with liquid and under cryogenic conditions at all times, the BOG generated from the
surrounding heat leak and HP pump mechanical energy is vented. Both the minimum flow recycle and vent lines
can be directed either to the BOG recondenser or to the LNG storage tank(s).
Minimum flow recycle to LNG tanks. Directing the recycle back to the LNG storage tanks provides the
advantage of no disturbance to the BOG recondenser operation, such as an impact on pressure and level
control. It also allows for continued sendout of natural gas when the BOG recondenser is out of operation for
statutory inspection or maintenance. When the BOG recondenser is out of operation for inspection or
maintenance for a prolonged period of time, the BOG must be vented and/or flared.
However, a 900-pound-pressure-rating, stainless steel head, sized for recycle operation from all HP pumps,
needs to be routed from the HP pump area to the top of the storage tanks for this design. This requirement
impacts the capital expenditure (CAPEX) of the project, as well as the operational expenditure (OPEX), since the
generated BOG from the HP recycle operation requires another cycle of compression by the LP BOG
compressors.
Venting of HP pumps to LNG tanks. When the HP pumps are not located near the BOG recondenser (for
example, when an LNG terminal has been revamped and there is no space available next to the BOG
recondenser), dedicated vent pots are required for the HP pumps to provide the required NPSH and maintain
cryogenic conditions in the HP pump.
The vent pots are provided with reverse-acting level control (wherein vent gas flow from the pot is manipulated),
and the outlet of the vent pot is directed to more than one LNG storage tank via a dedicated common vent
header. This arrangement not only increases CAPEX, but it also has operational downsides.
If the level control of the vent pots fails, then LNG is spilled into the vent head to the LNG storage tanks, or it can
reach the vent and/or flare knockout drum installed at a low point. This is problematic because the vent header
generally runs from the vent pots on low elevation over sleepers or a pipe rack to the top of the LNG storage
tanks. This setup inherently forms a low point in which LNG can be trapped, blocking the free flow of vent gas
from the HP pumps. This issue can cascade to vent pot control of other HP pumps, potentially resulting in the
warming of the HP pumps. This scenario is depicted in Fig. 3.

Fig. 3. BOG recondenser piping connections.

The introduction of the vent pots with controls also introduces flanges, safety implications for fire and gas, cold
protection zones and additional control complexity and maintenance requirements.

Venting of HP pump minimum flow recycle to recondenser. Routing both the minimum flow recycle and the
HP pump vents directly to the BOG recondenser provides a simpler design solution, with shorter process
connections and fewer process controls, provided that the HP pumps are located in the vicinity of the BOG
recondenser. Locating the HP pumps near the BOG recondenser is normally possible during LNG terminal
design.
The individual HP pump vents and common HP pump vent header must be continuously sloped to the top of the
BOG recondenser to enable free vent gas flow (i.e., bubbles created by excess heat) to the recondenser. No
level controls or dedicated vent pots are required, and the level in the common HP pump vent line is equal to that
of the BOG recondenser, since these levels are communicating.
Fig. 4 shows the two design examples applicable to both BOG recondenser types. The minimum flow recycle
connection from the HP pumps to the BOG recondenser should be brought into the holdup section of the BOG
recondenser, and into the annular section for an annular type BOG recondenser. A baffle impingement plate
should be considered to avoid excess turbulence.

Fig. 4. HP pump vent and minimum flow recycle connections to the BOG
recondenser or tank(s).

However, the alternative of bringing the HP pump minimum flow recycle to the packed section is not
recommended, since this process lineup will disturb the pressure controls in the top of the BOG recondenser
during HP pump recycle operation.
Please note that routing the recycle and vent connections to the BOG recondenser is only feasible if there is no
need for continued LNG terminal sendout operations when prolonged shutdowns (i.e., statutory periodic
inspections) cannot be avoided.
Padding gas connection. Padding gas, taken from downstream of the LNG vaporizers, is required to maintain a
minimum pressure in the BOG recondenser for maintaining required NPSH and stable HP pump operation. BOG
is supplied to the top of the packed section. Therefore, the most logical location to introduce padding gas is the
BOG inlet connection, and all mechanical support and internals for receiving gas from the top are already
designed and installed for this purpose. The introduction of padding gas at any other location (e.g., underneath
the packed bed or directly into the annular space) requires an additional nozzle on the BOG recondenser, as well
as additional mechanical internal design and reinforcements of the packed bed.
Introducing padding gas underneath the packed bed makes sense if the bed can be blocked by fouling. However,
the BOG recondenser service is one of the cleanest in the oil and gas industry, and blocking of the packed
section by fouling is not feasible. Padding gas can always be safely introduced from the top.
Pressure safety valve connection. The connection to the PSV should be on the top of the BOG recondenser,
preferably from the BOG inlet connection, for similar reasons as the padding gas supply connection (i.e., the
additional nozzle, and no possibility of blocking the packed bed due to fouling). Connecting the PSV underneath

the packed bed is often proposed; this stems from refinery services where mist mats and packed sections can be
blocked due to fouling.
However, LNG and BOG services are very clean. The PSV comes in a twin configuration to enable online
maintenance, since the BOG recondenser forms a single point of exposure for LNG terminal availability.
Operational bypass. Some BOG recondenser designs apply an operational bypass, in which a portion of the
LNG from the LP pumps bypasses the BOG recondenser and flows directly into the HP pump suction cans. This
is done to decrease the size of the holdup section (for any given holdup section residence time) and to reduce
vessel costs. Such a bypass is technically feasible since not all of the LNG is required for BOG recondensation.
However, the introduction of an operational bypass does require additional flow controls that will open the bypass
when the flow through the BOG recondenser increases above the design flow through the bottom section.
Therefore, instrument functions, control valves and cold-keeping bypasses must be added to the design. In Fig.
5, a flow controller (FC2), associated controls and hardware are added to the design when an operational bypass
is installed. Experience shows that the added cost offsets the CAPEX savings from the BOG recondenser size
reduction.

Fig. 5. BOG recondenser operational and maintenance bypasses.

Reductions in the BOG holdup section (and, therefore, the BOG recondenser size) are usually possible without
an operational bypass, simply by reducing the holdup time from traditionally conservative values. Experience has
shown that holdup time is not critical; designs with zero holdup time that pump LNG directly into the HP pump
suction are in operation. Designs where all of the LNG passes through the BOG recondenser require a higher
LNG control valve turndown than do designs with an operational bypass.
Inspection and maintenance bypass. Authorities sometimes impose the statutory requirement for scheduled
internal inspection and BOG recondenser entry, even for a clean and noncorrosive service like BOG
recondensation. To enable vessel entry and inspection while continuing sendout operation (with inevitable
temporary venting/flaring of BOG), a maintenance bypass for LNG around the BOG recondenser, cold-keeping
bypasses and positive isolation must be introduced. During this operation, the HP vent and HP pump minimum
flow recycle can only be diverted to the tanks, requiring the installation of an additional means of venting the HP
pumps (i.e., vent pots).

Due to the various disadvantages associated with the installation of a maintenance/inspection bypass for
statutory inspection, many projects ask to be exempt from the standard requirements for vessel entry and
physical inspection. Instead, these projects propose a reliability-based online inspection. Projects should ask for
this exemption at the start so that the exemption is available during the design stage, and so that CAPEX for
maintenance bypasses and isolation valves can be eliminated.
Platforms and control valves at grade. Some designs use platforms and have control valves installed at these
elevated platforms. The introduction of many platforms at several levels not only increases the cost, but it also
complicates operations and maintenance. It is recommended to have piping dressed/clipped on the BOG
recondenser, and to avoid the use of concrete/structural steel platforms, as a means of reducing the overall
project cost.
In addition, it is beneficial to operations and maintenance to install control valves as often as possible at grade
level. Recently installed control valves have much better turndown than previous designs, and they eliminate the
need for control valves to be in a split-range configuration. The reduction in the amount of required control
valves, brought about by this improved turndown, reduces the need to introduce more platforms.
Platforms will be congested, complex and more complicated to operate and maintain when there are many of
them, and also when the control valves around the BOG recondenser form a single point of exposure (requiring
the BOG recondenser operation to stop upon failure) when they are supplied with bypass.
In one industry example, control valves were passing and leaking at a top platform level. Workers discovered the
leaking valves only because they heard noises at grade level. Therefore, by installing more platforms, significant
operational issues may go undetected.
Fig. 6 shows a design with minimal platforms, where the only reason for workers to climb to the top platform of
the BOG recondenser is to conduct PSV inspection and maintenance.

Fig. 6. BOG recondenser design with minimized platforms and control valves
at grade (left) vs. a traditional platform design (right).

Design takeaway
A few conclusions can be drawn from the preceding discussion of BOG recondenser design:

From a mechanical design point of view, an annular space type of BOG recondenser is more complex
and, therefore, likely more costly

Minimum flow recycle and vents on HP pumps should be routed to the nearby BOG recondenser, rather
than to the LNG storage tanks, to minimize operational complexity and CAPEX:
o

HP pump vent pots (required for venting to LNG storage tanks) introduce flanges, fire
zones and operational difficulties when the level control fails

Running the minimum flow recycle for the HP pumps back to the LNG storage tanks introduces
a costly, 900-pound-pressure-rating return line

No separate padding gas connections to the BOG recondenser are required; padding gas should enter
through the BOG inlet connection

The BOG recondenser service is clean, and the packed bed cannot foul up; the connection to the PSV
should, therefore, be installed on the BOG inlet line, which eliminates the requirement of a dedicated
nozzle

It is doubtful if the installation of an operational bypass actually saves costs, as the bypass comes with
control valves, cold-keeping bypasses, and additional process control complexity, which largely offsets
the savings

from a reduced BOG recondenser holdup volume

It is strongly recommended to ask for exemption of statutory BOG recondenser inspection and entry
from authorities; when such an exemption is granted, a costly maintenance bypass may be eliminated
from the project

To reduce costs and complexity, control valves should be installed as often as possible at grade,
minimizing the number of platforms

Piping to the BOG recondenser should be dressed/clipped as much as possible.

Less is more. An overview of the most commonly used design methods for BOG recondensers reveals the
advantages and disadvantages in BOG recondenser design. BOG recondensers of both typesannular space
type and packed-bed typehave been installed and operated successfully.
As a general recommendation, BOG recondenser designers are advised to consider simple designs, as
discussed in Part 1 of this article. Part 2, to be published in the July/August 2014 issue, will examine the
operational aspects of BOG recondensers. GP

Simplify BOG recondenser design and operation

Part 2
S. P. B. Lemmers, Vopak LNG Holding BV, Rotterdam, The Netherlands
An LNG receiving and regasification terminal connects the intermittent process of LNG carrier unloading and/or
loading with the mostly continuous process of LNG vaporization and gas transmission into a sendout pipeline
system.
In addition to these LNG carrier operations, truck/train loading operations can take place simultaneously. During
all operational modes of the LNG terminal, boil-off gas (BOG) is produced, which requires processing to avoid
flaring or venting (under normal operating conditions) and to minimize the environmental impact of the facility.

Part 1 of this article discussed optimal designs for BOG recondensers used in LNG terminals. Here, operational
aspects of BOG recondensers, based on the designs selected, are examined.
For the two BOG recondenser designs commonly used in the industry, there are several operational and process
control elements to consider with respect to pressure and level control.
Annular space type
In Fig. 1, an annular space type of BOG recondenser is shown. This type is used in many LNG terminals, both
older and newer. There are a number of advantages and disadvantages to this design.

Fig. 1. Operation of an annular space BOG recondenser.

The LNG and BOG enter the packed section. This type of BOG recondenser works by adjusting the amount of
packed-section area available for condensing, by means of partial flooding of the packed bed. To achieve partial
flooding while ensuring a constant level and net positive section head (NPSH) for the high-pressure (HP) pumps,
a physical separation between the two packed sections and the annular space is required.
The level and pressure in the annular section are kept constant. The level and pressure in the packed section
can be distinct from those in the annular section. Both the pressure and level in the packed section self-adjust in
response to varying BOG/LNG ratios.
At high BOG/LNG ratios, the liquid level in the packed-bed section decreases automatically, through pushing of
liquid to the annular space, as the pressure in this section increases. This process exposes more of the packed
bed, increasing the heat transfer/condensation area to create equilibrium conditionscommonly referred to as
the auto-regulating effect.
Likewise, a lower BOG/LNG ratio tends to reduce pressure in the packed section, which then results in a level
increase in the packed section. In other words, this type of recondenser tends to adjust itself. Both the level and
pressure in the two sections are different.
Pressure control. For stable operation of the BOG recondenser, the BOG compressor discharge pressure and
annulus pressure must be controlled. Also, the annulus level and the BOG recondenser outlet temperature must

be guarded to ensure sufficient NPSH for the HP pumps. The following examples of pressure control have been
proven in the industry.
Example 1. The BOG compressors compress the BOG into the BOG recondenser. The BOG entering at the top
of the BOG recondenser is condensed by contacting the BOG with subcooled LNG from the discharge of the lowpressure (LP) pumps over a packed bed in the BOG recondenser.
The pressure (and, therefore, the level) in the packed bed of the BOG recondenser varies with the ratio of LNG
vs. supplied BOG. When the BOG/LNG ratio increases, the pressure in the packed section will rise, and the level
in this section (which differs from the level in the annular section, as does the pressure) will decrease. This
results in an increase of the available area for recondensation, thereby establishing a new equilibrium where all
incoming BOG is fully recondensed.
The discharge pressure of the BOG compressors is controlled via pressure controller PC1, and the pressure in
the annulus is controlled via pressure controller PC2:

PC1 is a split-range controller that maintains the pressure in the discharge of the BOG compressors via
the control valve, which regulates the flow of BOG to the packed-bed section. If the BOG compressors
discharge pressure becomes too low to guarantee sufficient NPSHrequired for the HP pumps, then PC1 will
introduce padding gas from the HP natural gas system or fuel gas system.

PC2 is a split-range controller that maintains the pressure in the annulus of the BOG recondenser. Even
in the annular space, there will be some recondensation of BOG into the LNG at the interface.
Therefore, to maintain pressure, some BOG must be fed into the annular space. On the other hand,
ambient heat in-leak generates BOG, counteracting the above process. There is a need for split-range
pressure control (i.e., bringing in BOG or venting to the BOG compressor suction head, as required).
When the pressure rises, this controller will first close the control valve on the incoming BOG that
bypasses the packed bed. Then, when the pressure rises further, PC2 will open the control valve to the
LP BOG head upstream of the BOG compressors.

The control characteristics of both pressure controllers are depicted in Fig. 2.

Fig. 2. Pressure control characteristics.

Example 2. To maintain both the correct pressure control (Fig. 3) of the annulus pressure and the NPSHrequired for
the HP pumps, transmitters connected to the annular space provide an input to three pressure controllers to deal
with low (PC1), medium (PC2) and high (PC3) pressure conditions:

Under normal conditions, the pressure in the annulus will be maintained by gas from the BOG
compressors by means of the PC2 pressure controller, which controls BOG flow into the annular space.

If there is less BOG available, then the pressure in the annulus will tend to fall, and the pressure
controller will introduce padding gas. Under normal conditions, the padding gas control valve will be
closed.

If the pressure in the annulus becomes too high, then the PC3 pressure controller will allow BOG to pass
through the vent to the LP BOG head upstream of the BOG compressors. Similar to the padding gas
control valve, this control valve will be closed under normal conditions.

A differential pressure control valve will be provided in the line from the BOG compressors downstream
of the split to the recondenser annulus and center section, to maintain positive BOG pressure upstream
of the BOG recondenser.

Fig. 3. BOG recondenser pressure control.

Level and total volume control. To ensure constant HP pump conditions, the LNG level in the annular space of
the BOG recondenser is controlled via manipulating the LNG inlet valve to the packed-bed section of the BOG
recondenser. The level controller must be tuned so that moderate fluctuations in the BOG recondenser level are
allowed to prevent unacceptable disturbances to the LP pump operation. The control valve should have a high
turndown ratio and high resolution.
As discussed previously, the level in the packed-bed section is not directly regulated; it will vary as a result of the
BOG/LNG ratio. The higher the BOG/LNG injection ratio, the less contacting area is required for recondensation,
and the higher the level will reach. When there is less contacting area, the pressure will rise and the level will
decrease due to the increased pressure.
Conversely, when the BOG/LNG ratio is high, the pressure in the packed section will rise and the level will drop.
This results in an increase of the available area for recondensation; the pressure will fall, and the level will rise
again.
A practical result of this floating packed-section level is the following inverse-response phenomenon. If the
BOG/LNG ratio increases, then the level in the packed bed will decrease, and the level in the annulus will initially
increase because the pressure in the central section increases (pushing LNG from the packed section into the
annular space), which forces the level controller (LC) to close the LNG inlet valve. This reduces the level in the
packed-bed section even further.
To avoid this inverse response of the level control system, an LNG total volume control, based on both the level
in the packed section and the level in the annulus, has been developed and implemented. This response, which
is potentially caused by uncontrolled introduction of padding gas, may displace liquid from the packed-bed

section to the annulus and vice versa, making the simple annulus level an unstable parameter for controlling the
flow of LNG into the recondenser.
For total volume control, liquid levels in both the BOG recondenser annulus and the BOG recondenser packed
bed will be measured and used for calculation of total LNG volume in the BOG recondenser. The calculated total
LNG volume, rather than the level in the annular space, is controlled by regulating the flow of LNG to the packed
bed. By using total volume control, any transient conditions are ignored and the inverse response is eliminated.
The total volume of LNG in the BOG recondenser is calculated as shown in Eq. 1:
LNG volume = Vf Rb2 Lb + ( Rv2 Rb2) La(1)
where:
Vf=Volume of fractional voids
La=Annulus level
Lb=Core section level
Rb=Packed-bed radius
Rv=Vessel radius.
Application of total volume control is depicted in Fig. 4.

Fig. 4. Total volume control applied to the BOG recondenser.

Bottom level and ratio control. All process control examples described so far include LNG flow through the
BOG recondenser packed section. At high LNG terminal sendout rates, this can result in a continuous recycle of
padding gas from downstream of the LNG vaporizers to maintain pressure in the BOG recondenser, since the
LNG sendout rate is significantly higher than that required to recondense all generated BOG.

This operation is not energy efficient; therefore, some annular space type designs have introduced an LNG inlet
into the holdup section. This reduces the BOG/LNG ratio in the packed-bed section and minimizes the
requirement for padding gas. The downside is that it influences the effectiveness of the auto-regulating effect
(when level is maintained predominantly below the packed bed), compared to a BOG recondenser without a
bottom inlet.
Some of these annular space BOG recondenser designs have introduced ratio control for the ratio of LNG to the
packed bed and BOG. The balance of the LNG goes directly into the holdup section of the BOG recondenser.
Since BOG and LNG compositions and temperatures can change, the pressure in the BOG recondenser packed
section is a result of the setpoint of the BOG/LNG ratio controller.
Fig. 5 shows the described level and ratio control scheme. The installation of a bottom LNG inlet that is controlled
by level can influence the effectiveness of the auto-regulating effect, which is the main feature of the annular
space type design. The selection of an annular space BOG recondenser should, therefore, be reconsidered.

Fig. 5. Introduction of level bottom inlet and BOG/LNG ratio control.

Ratio control and pressure override. When the BOG/LNG ratio controller is not programmed and/or configured
correctly, there is a possibility that either padding gas will need to be introduced by PC1(when the LNG-to-packed
bed/BOG ratio is too high), or BOG will need to be directed to the BOG suction head by PC3 (when the ratio is too
low). Either scenario results in a loss of operational energy efficiency.
To resolve this issue, overrides from PC2 can be configured to control the BOG recondenser pressure when the
bypass valve around the pressure differential controller (i.e., the bypass of BOG to the annular space) is already
closed. This scenario is depicted in Fig. 6.

Fig. 6. Level bottom inlet control with pressure override.

Top packed-bed section type

A typical top packed-bed section type of the BOG recondenser is depicted in Figs. 7 and 10. The pressure and
level control for this type are depicted in Figs. 2 and 5 of Part 1. Similar to the annular space type, this BOG
recondenser receives BOG from the BOG compressors for recondensation, and it also provides holdup and
NPSHrequired for the HP pumps.
For the top packed-bed section BOG recondensers, the liquid level is normally below the bottom of the packed
bed. As such, the heat transfer area constantly allows for a simple and proven pressure control scheme. To
control the BOG recondenser pressure, only some of the LNG is routed to the packed bed, with the balance of
the incoming LNG being routed directly to the bottom holdup section. This type of BOG recondenser requires two
LNG inlets.
Pressure control. The main objective of the pressure control is achieved by the flowrate of the subcooled LNG
from the bottom LNG inlet line to the packed section, to keep the BOG recondenser at a pre-set operational
pressure. This control enables stable HP pump and BOG compressor operation. Output from the pressure
controller is cascaded as setpoint to the LNG quench (LNG to packed bed) flow controller.
If the pressure increases, then more LNG is routed to the packed bed, reducing the pressure and preventing the
opening of the connection to the BOG compressor suction head. If the pressure decreases, then the pressure
controller will increase the LNG flowrate via the quench flow controller, to prevent the opening of the padding gas
supply. With this type of BOG recondenser, it is easy to adjust the operating pressure of the BOG recondenser
(typically between 6 barg and 10 barg) in LNG operations.
When no quench flow controller or flow measurement is provided, the pressure controller can directly act on the
quench flow valve. A cascade configuration provides more stability with respect to change in flow, which will be
picked up directly by the flow controller before it affects BOG recondenser pressure.
Level control. The LNG liquid level in the BOG recondenser is controlled by manipulating the bottom LNG inlet
valve to the BOG recondenser. The level controller can be loosely controlled, since neither operation nor the
process requires tight level control in the BOG recondenser.

Process control examples and lessons learned

Process control scenarios can be applied to both types of BOG recondensers, showing control schemes that
work, as well as schemes that have failed to work, in practice.
Ratio control with pressure prediction. For both BOG recondenser designs, the BOG/LNG ratio control
between the LNG quench flow to the packed bed and the incoming BOG has been applied.Fig. 7 depicts this
control scheme for a top packed-bed section type.

Fig. 7. BOG/LNG ratio control with the objective to predict operating pressure.

The objective of this control scheme is to establish a pressure setpoint that is converted into a flow setpoint to the
quench flow controller. The scheme in Fig. 7 is a simplification; an implemented control scheme uses a ratio of
mass-flow of LNG to BOG, corrected for BOG and LNG quench temperature and BOG recondenser operating
pressure. The final volumetric quench flow setpoint is based on actual LNG quench flow density calculations,
shown in Eqs. 24:
LNGtoBOGmassratio = UncorrectedRatio
BOGTCorrection LNGTCorrection(2)
ActualVolLNGtoBOGmassratio =
LNGtoBOGmassratio / LNG(3)
ActualVolFlowLNG = ActualVolLNGtoBOG
massratio BOGmassflow(4)
The control schemes objective is to predict the pressure in the BOG recondenser on the basis of Eqs. 24.
However, multi-process variable control resulted in an offset between the desired pressure in the BOG
recondenser and the actual pressure. This result proved that, even by creating a rigorous mathematical model of
the involved thermodynamics, the pressure in the BOG recondenser could not be predicted.
LNG operations then changed the input to the model (i.e., the desired pressure in the BOG recondenser) so that
the desired pressure was reached. This resulted in manual feedback control by the operator. For instance, if 6
barg was the desired pressure, the operator keyed 6.32 barg into the distributed control system. However, when

the composition changed, the resulting value was 6.65 barg. LNG operations used trial-and-error to achieve the
desired setpoint pressure.
Pressure override on ratio control. Some designs for both types of BOG recondensers have a pressure
override controller on the BOG/LNG ratio control. When the pressure reaches the HP setting, this pressure
controller will take over from the BOG/LNG ratio controller.
As an alternative to this pressure override controller, a pressure controller with a gap could be considered; this
controller acts only on the quench on HP to avoid opening the control valve to the suction of the LP compressors.
On LP, it acts on the quench to avoid the unnecessary supply of padding gas.
Some fundamental questions to ask are, If the pressure must be controlled, can a pressure controller be
installed on the quench? and What are the real advantages and benefits of BOG/LNG ratio control and a
floating pressure? This argument is especially true for the top packed-bed type of BOG recondenser.
Furthermore, the original annular space type without a bottom LNG inlet requires a floating pressure for the autoregulating effect.
By installing the override from PC2, it has become obvious that BOG recondenser control based on ratio control is
not essential. Also, the main pressure control is better located on the bypass, and the quench LNG flow should
be located at the top (Fig. 8).

Fig. 8. Pressure override and padding gas stability.

Padding gas stability. For stable padding gas control of the BOG recondenser pressure, the padding gas
control valves should be installed at a certain distance to the BOG recondenser to provide adequate control time
for the control loop to stabilize. Typically, a few seconds are required for the padding gas control loop to stabilize.
An unstable padding gas control loop results in violent opening and closing of the valve. In one example, LNG
operations decoupled the padding gas control loop due to valve issues.
Full operational bypass without pumps holdup. A BOG recondenser with full operational bypass directly to
the HP pump suction is depicted in Fig. 9. In this configuration, the majority of the LNG completely bypasses the
BOG recondenser and is fed directly into the suction of the HP pumps, while the balance of the LNG is fed to the
packed bed, as required to control the pressure in the BOG recondenser.

Fig. 9. Full operational bypass without holdup for HP pumps with operational bypass.

Successful application of this system has demonstrated that there is no need for substantial liquid holdup in the
BOG recondenser. The one potential operational disadvantage of this control scheme is that the LNG in the BOG
recondenser can be at bubble-point conditions (rather than subcooled, as is the pumped LNG from the LP
pumps), and a sudden inflow of warm LNG (resulting from the interruption of colder LNG flowing directly from the
LP pumps) can upset HP pump operations. This upset would happen at a high level in the aforementioned
example, where the valve supplying subcooled LNG from the LP pumps is closed, and only relatively warm LNG
from the BOG recondenser is fed into the HP pump suction cans.
Control of recondenser bottom pressure. One design that uses bottom pressure control in an attempt to
maintain stable suction conditions to the HP pumps is shown in Fig. 10. At a fixed BOG recondenser pressure,
the HP pump suction pressure is a direct function of the LNG level, so the PC4effectively replaces the normal
level controller, manipulating the control valve to the holdup section. However, this pressure control scheme is
not advised, since 0.5 bar of pressure in the suction needs to be compensated with approximately 10 meters of
LNG, which will result in unstable level and pressure control of the BOG recondenser.

Fig. 10. Control of BOG recondenser bottom pressure.

Compressor type and pressure control. The type of compressor chosencentrifugal or reciprocatingsets
requirements on the BOG recondenser pressure control. The more commonly used reciprocal compressors are
reasonably insensitive to fluctuations in BOG recondenser discharge pressure.
Conversely, the less commonly used centrifugal compressors can easily move between the surge area (at high
BOG recondenser pressure) to the stonewall area (at low BOG recondenser pressure) as a result of discharge
pressure fluctuations (Fig. 11). Therefore, when using centrifugal BOG compressors, the BOG recondenser
pressure must be tightly controlled.

Fig. 11. Typical variable centrifugal BOG compressor curves (either by inlet guide
vanes or speed).

Operation and process control takeaway

Several conclusions can be drawn with respect to the information presented on operation and process control of
both types of BOG recondensers. For the annular space type of BOG recondenser:

Various pressure control schemes have been successfully implemented in the industry, and are
functional

An annular space design having an LNG inlet only to the top packed-bed section can suffer from an
inverse response when configured to operate on level control only; therefore, total volume control is
required for stable operation

The aforementioned type can also introduce the requirement of continuous recycle of padding gas from
the gas sendout system (in the case of high BOG/LNG ratio), at the expense of overall energy efficiency

To avoid continuous recycle of padding gas to the BOG recondenser, an LNG bottom inlet controlled by
level can be introduced at the cost of reducing the effectiveness of the auto-regulating effect

Selecting a top packed-bed type of BOG recondenser should be considered when a bottom LNG inlet is
installed in combination with an annular space type of BOG recondenser, since its main feature, the
auto-regulating effect, will not work when the level remains predominantly controlled below the packed
bed.

For the top packed-bed section type:

Trying to predict the resulting operating pressure on the basis of BOG/LNG ratio has proven not to be
feasible in practice

When the operating pressure must be controlled, a simple pressure control loop (see Figs. 2and 5, Part
1) has proven its effectiveness

BOG/LNG ratio control is feasible, but pressure remains a fluctuating process variable

Controlling the BOG recondenser bottom LNG outlet pressure by controlling level has proven to be
unstable in practice, since a small change in pressure results in a large change in BOG recondenser
level.

For both types:

For BOG recondenser types with a bottom LNG inlet, BOG/LNG ratio control can be used when a
fluctuating pressure in the BOG recondenser is acceptable

When installing BOG/LNG ratio control and pressure overrides, the designer should consider installing
pressure control with a gap, or just a simple pressure control

For stable padding gas control, the padding gas control valves should be installed at a certain distance
to the BOG recondenser to provide adequate time for the control loop to stabilize

In top packed-bed section type BOG recondensers that have operational bypass directly into the HP
pump suction cans, a sudden inflow of warm LNG from the BOG recondenser can disturb HP pump
operations

When a centrifugal BOG compressor is applied, stable pressure control is required to ensure stable
BOG compressor operation. The top packed-bed section type with pressure control on the LNG quench
is more suitable for this process than is the annular space type.

Less is more. An overview of the most commonly used process control and operational tactics of BOG
recondensers reveals the advantages and disadvantages in BOG recondenser operation. BOG recondensers of
both typesannular space type and packed-bed typehave been installed and operated successfully.
As a general recommendation, BOG recondenser designers are advised to consider simple designs and
operational process control mechanisms.
End of series. Part 1, May/June 2014. GP