LNG Reference Projects

LNG Reference Projects
February 2013
LNG Reference Projects
Existing Installations
• Everett LNG (USA)
• Freeport LNG (USA)
• Bay State Gas (USA)
• Sabine Pass LNG (USA)
• National Grid / Haverhill (USA)
• Golden Pass LNG (USA)
• Canaport LNG (Canada)
• Manzanillo LNG (Mexico)
• Altamira LNG (Mexico)
• Mejillones LNG (Chile)
• Peru LNG
• Gate LNG (The Netherlands)
• Adriatic LNG (Italy)
• Egyptian LNG
• Qatar LNG
• RasGas (Qatar)
• Yemen LNG
• Hazira LNG (India)
Specified But Not Yet Installed
• Kittimat LNG (Canada)
• Dunquerke LNG (France)
• Yamal LNG (Russia)
• Zeebrugge LNG (Belgium)
• Bahia Blanca LNG (Argentina)
• Gorgon LNG (Australia)
• Pluto LNG (Australia)
• Gladstone LNG (Australia)
• Dighi LNG (India)
• Petronet LNG (India)
• Skikda LNG (Algeria)
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LNG Import Terminal In St. John, New Brunswick
• Scope: >5000 m of
cryogenic and utility piping
• Date: August 2008
• Process Temps.: -260°F (-162°C)
to ambient
• Design Goal: Condensation
control; flash-freeze protection of
fire-water lines in LNG spills
• Insulation: 2 layers (20 mm)
Cryogel-Z over PIR
• Results:
– Material was specified because of the reduced labor force, faster installation
schedule, and fire protection
– Contractor stated that wished he could have done 100% Cryogel, as it “would
have gone on five times faster”
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Cryogel-Over-PIR Improved Spacing, Schedule & Fire Resistance
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Elbow Design
-5-
Installation in St. John, NB
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Cutting Area Within the Unit
-7-
This Is What 200 Cryogel Z Elbows Looks Like In Storage
-8-
Valves and Flanges on Offshore LNG Import Terminal
• Scope:
– 1500+ valves & flanges >2”
• Location:
– Southeast of Venice, Italy
• Process Temp.:
– -260°F (-162°C)
• Other Factors:
– Clashes and supply / logistical issues
with baseline material
• Insulation:
– 7-11 layers Cryogel Z
• Results:
– All material air-freighted to job site
within 4-weeks ARO
– 700 insulators trained on Cryogel
– All clashes resolved ahead of schedule
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Shrink an LNG Import Terminal to 300’ x 600’…
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…and Mechanical Clashes Spring Up…
-11-
…Everywhere
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A Spec Was Created For Tying Cryogel Into Adjacent Insulation
Cellular glass
Void fill
Cryogel
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Particular Attention Was Paid to the Tie-Ins
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Void Spaces Were Stuffed With Fiber
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Cryogel Layers Were Then Applied And Held With Tape
Cryogel Z
Void Fill
-16-
Each Layer Was Marked for Inspection
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SS Bands Used to Secure the Cryogel Over the Foamglas
-18-
Cryogel Joints Were Sealed with Foil-Faced Butyl Tape
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Valves Were Finished With a Butyl Membrane & UV-Cure GRP
-20-
Insulating Double-Gimbaled
Cryogenic Flex Joints
Insulating Cryogenic Flex Joints
• Scope:
– 36” LNG flex joints
• Location:
– Mexico
• Temperature:
– -260°F (-162°C)
• Design Goals:
– Condensation control on a
doubly-gimbaled flex joint
for large bore pipe
• Insulation:
– 4-5” (11-13 layers) Cryogel Z
to match 8-9” of PIR
• Results:
– Insulated in Houston and trucked to Mexico
– Worked with EPC, joint manufacturer and contractor on the overall design
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As-Delivered Flex Joints Prior to Insulation
-23-
Void-Filling with Fibrous Blanket Material
-24-
Installing Cryogel Layers
-25-
Insulation Complete w/ External Expansion-Contraction Joint
-26-
Finished Article Ready for Transport
-27-
Lifting Gimbal Joint
-28-
Positioning Beneath Riser Pipe
-29-
Both Gimbal Joints Installed on Liquid and Vapor Return Lines
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LNG Tank Risers
Insulating LNG Tank Risers
• Scope: 150’ of 24” and 12” pipe
• Process Temp.: -260°F (-162°C)
• Insulation:
– 2.8” (70 mm) Cryogel Z
• Other Factors:
– Frequent thermal cycling
– Only 3” of clearance between pipe
surface and tank stiffening rings
– All work done between LNG deliveries
– Insulated pipes pass through hoop
guides designed to limit sideways
deflection due to wind loads. Insulation
had to withstand compressive-, shear-,
and impact-loading
• Results:
– Lines are in-service; Tank 2 this year
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Steel Clamp Rings Used to Protect Insulation & Support Jacket
1¼” SS bands
Pipe wall
Ring 5
Ring 4
Ring 3
Heavy-gage stainless
steel clamp rings at
each tank ring pulled
double duty:
Pipe guide
Ring 2
Fabricated
SS clamp ring
LNG
1.They acted as a
bumper between the
insulation and the
pipe guide, and
2.Periodically
supporting the 150’
of SS jacket
Ring 1
Anchor
1” insulation
support ring
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Material Was Pre-Cut on the Ground to the Right Circumference
-34-
During Installation, Cryogel Was Held In Place with Tape
-35-
Foster 90-66 Vapor Stops Being Painted
-36-
Minimal Clearance Between Insulation, Tank Stiffener Rings
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Stainless Steel Clamp Ring Held on with Bands
-38-
Pipe Guides Constructed to Allow Minimal Rattle Space
-39-
Liquid Ethylene Sphere in Brazil
• Scope:
– 60’ ethylene sphere
• Location:
– Southern Brazil
• Temperature:
– -30°F (-34°C)
• Design Goals:
– Condensation control
– 90-min fire protection
• Insulation:
– 50 mm Cryogel Z +
10 mm Pyrogel XT +
galvanized steel jacket
• Results:
– Reduced thickness by 67%
– 20% faster installation than with spray foam
– Sproule Mfg. designed cut patterns, resulting in a 98.5% material yield
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All Joints Taped to Provide Continuous Vapor Barrier
-41-
Standoffs Support Jacket While Bands Harness Bottom Head
-42-
Jacketing Near the Sphere’s Apex, Before Painting
-43-
The Finished Article
-44-
Super-Insulated Liquid Ethylene Vessel
• Scope: 10’ x 60’ ethylene bullet
• Location: Southampton, UK
• Design Goals:
– Maintain liquid during 6-week T/A without refill or refrigeration (BOG <5 kg/day)
– Passive fire protection
• Insulation Design:
– 13.4” (340 mm) of Cryogel,
jacketed with SS
• Results:
– Vessel was pre-insulated in
Manchester, then trucked
250 miles to Southampton
– Unit successfully installed
and operated during T/A
– Now in-service as just a
very well-insulated
ethylene storage vessel
-45-
10’ x 60’ Vessel As-Delivered from Fabrication Yard
-46-
On a 34-Layer System, Keeping an Accurate Count is Important
-47-
Patterns Created In-Place By Simply Removing Excess Material
-48-
Bands and Bridles Installed Every Fourth Layer for Support
-49-
Final Layer Installed, Banded and Sealed with Tape
-50-
Fiber Blankets Protect the Vapor Barrier from Screw Punctures
-51-
Finished Article Awaiting 250-Mile Transport by Truck
-52-
Rigging and Installation On Site
-53-
Heat Exchanger Modules
• Location: Northern Alberta
• Scope: Three pre-insulated
heat exchanger modules
• Date: Mar, 2007
• Process Temp.: 250-400°F
• Design Goal: Heat conservation
• Insulation: 2” mineral wool ¾” Pyrogel
• Other Factors: Modules insulated in Kansas City; transported to Alberta
• Results:
– Insulation survives the abuse of long-distance road transport
– Thinner profile reduced interference near inlets, outlets, and structural supports
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Heat Exchanger Insulation Survives Transport and Handling
-55-
SAGD Operation, Ft. McMurray, AB
• Scope: 3 km of 24” pipe
• Date: Summer 2009
• Process Temp.: 300°C (570°F)
• Design Goal: Heat conservation
• Other Factors: All piping
was pre-insulated in Edmonton
and trucked 6 hours to remote
work site
• Results:
– Eliminated need for an on-site man camp
– Reduced effective labor rate from $200/hr to $45/hr
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Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
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Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
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Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
-59-
Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment
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Summary and Conclusions
• Efficiency
– Most efficient insulation materials in the world
– Saves energy
– Reduces touch temperatures
• Productivity
– Flexible blanket form for increased productivity
– Streamlined planning, supply chain, and logistics
– Better space efficiency
– Enables pre-insulation of piping and equipment
• Durability
– Resistance to damage by water, heat, and mechanical abuse
– Will not promote corrosion under insulation
– Exceptional fire protection
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Thank
You