LNG Reference Projects. February 2013

Transcription

1 LNG Reference Projects February 2013

2 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) -2-

3 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 -3-

4 Cryogel-Over-PIR Improved Spacing, Schedule & Fire Resistance -4-

5 Elbow Design -5-

6 Installation in St. John, NB -6-

7 Cutting Area Within the Unit -7-

8 This Is What 200 Cryogel Z Elbows Looks Like In Storage -8-

9 Valves and Flanges on Offshore LNG Import Terminal Scope: 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 -9-

10 Shrink an LNG Import Terminal to 300 x

11 and Mechanical Clashes Spring Up -11-

12 Everywhere -12-

13 A Spec Was Created For Tying Cryogel Into Adjacent Insulation Cellular glass Void fill Cryogel -13-

14 Particular Attention Was Paid to the Tie-Ins -14-

15 Void Spaces Were Stuffed With Fiber -15-

16 Cryogel Layers Were Then Applied And Held With Tape Cryogel Z Void Fill -16-

17 Each Layer Was Marked for Inspection -17-

18 SS Bands Used to Secure the Cryogel Over the Foamglas -18-

19 Cryogel Joints Were Sealed with Foil-Faced Butyl Tape -19-

20 Valves Were Finished With a Butyl Membrane & UV-Cure GRP -20-

21 Insulating Double-Gimbaled Cryogenic Flex Joints

22 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 -22-

23 As-Delivered Flex Joints Prior to Insulation -23-

24 Void-Filling with Fibrous Blanket Material -24-

25 Installing Cryogel Layers -25-

26 Insulation Complete w/ External Expansion-Contraction Joint -26-

27 Finished Article Ready for Transport -27-

28 Lifting Gimbal Joint -28-

29 Positioning Beneath Riser Pipe -29-

30 Both Gimbal Joints Installed on Liquid and Vapor Return Lines -30-

31 LNG Tank Risers

32 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 -32-

33 Steel Clamp Rings Used to Protect Insulation & Support Jacket Ring 5 Ring 4 Ring 3 1¼ SS bands Pipe guide Pipe wall Heavy-gage stainless steel clamp rings at each tank ring pulled double duty: Ring 2 Ring 1 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 Anchor 1 insulation support ring -33-

34 Material Was Pre-Cut on the Ground to the Right Circumference -34-

35 During Installation, Cryogel Was Held In Place with Tape -35-

36 Foster Vapor Stops Being Painted -36-

37 Minimal Clearance Between Insulation, Tank Stiffener Rings -37-

38 Stainless Steel Clamp Ring Held on with Bands -38-

39 Pipe Guides Constructed to Allow Minimal Rattle Space -39-

40 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 -40-

41 All Joints Taped to Provide Continuous Vapor Barrier -41-

42 Standoffs Support Jacket While Bands Harness Bottom Head -42-

43 Jacketing Near the Sphere s Apex, Before Painting -43-

44 The Finished Article -44-

45 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-

46 10 x 60 Vessel As-Delivered from Fabrication Yard -46-

47 On a 34-Layer System, Keeping an Accurate Count is Important -47-

48 Patterns Created In-Place By Simply Removing Excess Material -48-

49 Bands and Bridles Installed Every Fourth Layer for Support -49-

50 Final Layer Installed, Banded and Sealed with Tape -50-

51 Fiber Blankets Protect the Vapor Barrier from Screw Punctures -51-

52 Finished Article Awaiting 250-Mile Transport by Truck -52-

53 Rigging and Installation On Site -53-

54 Heat Exchanger Modules Location: Northern Alberta Scope: Three pre-insulated heat exchanger modules Date: Mar, 2007 Process Temp.: 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 -54-

55 Heat Exchanger Insulation Survives Transport and Handling -55-

56 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 -56-

57 Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment -57-

58 Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment -58-

59 Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment -59-

60 Pyrogel Enables Pre-Insulation, Transport of Pipe & Equipment -60-

61 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 -61-

62 Thank You