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Lecture 12 From: Dr. Ahmed E.

Abdelfattah Helmi

Liquefied Natural Gas Transportation & Storage


LNG Transportation

Ships
Typical ships are shown in the next two figures 45&46. The concept of membranes is based on the idea that the forces exerted by the LNG cargo are transmitted by a metallic membrane to the ships inner hull (these are double hull ships). The Norwegian company Moss Rosenberg introduced the concept of spherical tanks. The capacity of these ships is between 100,000 to 140,000 m3. The ships are powered with a medium speed 4-stroke diesel engine, which is capable of providing fuel efficiency and operates on burning low pressure gas. It consumes 0.15% of the cargo through what vaporizes of the LNG and that adds up to consuming 2 % of adds up to consuming 2 % of the LNG produces over the life of the project.

Figure 45 Schematic and photo of LNG carrier with GAZ Transport Membrane

Figure 46 Schematic and photo of LNG carrier with Moss Rosenberg self-supporting tanks

LNG Storage
All field erected LNG storage tanks have a primary and a secondary containment system. The primary container is for normal operation and the secondary containment is for the highly unlikely event of a leak in the primary container. World wide a variety of storage tank types have been developed and constructed over the years. Those that have been successful can be categorized into the following types: 1. Single containment types have a cylindrical metal primary tank and an earthen dike wall secondary containment. Single containment tanks were the first type developed and are now used mainly in remote locations. 2. Double containment types have a cylindrical metal primary tank and an independent metal or reinforced concrete, open top secondary containment outer tank. This type was developed for small sites; however few have been built because the full containment type, below, was soon developed. 3. Full containment type tanks have a cylindrical metal inner primary tank and metal or pre-stressed concrete outer secondary containment tank structurally independent but combined into one structure. Today full containment tanks are the most common type used. 4. Full containment membrane type has a cylindrical thin metal membrane primary container structurally supported by an outer pre-stressed concrete cylindrical tank. The outer concrete tank also serves as the secondary leak containment. Applications of membrane tanks have been far less than the other types of tanks except in Japan and Korea. 5. Even though all of the above listed structures can be built in-ground, only membrane tanks, type 4, have been regularly built below grade. The outer wall of an in-ground tank is not pre-stressed. The outer wall is held in compression by soil pressure which in turn also supports the LNGs hydrostatic load.

The approximate number of field erected LNG tanks operating worldwide is summarized in the following list1: Single Containment Type 320 Double Containment Type 15 Full Containment Type 110 Membrane Containment Type 30 Membrane In-ground Containment Type 50

6.2.1 Full Containment Tanks A liquefied Modern LNG storage tanks are typically full containment type, which has a pre-stressed concrete outer wall and a high-nickel steel inner tank, with extremely efficient insulation between the walls. The common characteristic of LNG Storage tanks is the ability to store LNG at the very low temperature of -162 Large tanks are of low aspect ratio (height to width) and cylindrical in C. design with a domed steel or concrete roof. LNG storage tanks can be found in ground, above ground or in LNG carriers. Storage pressure in these tanks is very low, less than 10 kPa (1.45 psig). Sometimes more expensive underground tanks are used for storage. Smaller quantities (700 m and less), may be stored in horizontal or vertical, vacuum-jacketed, pressure vessels. These tanks may be at pressures anywhere from less than 50 kPa to over 1,700 kPa (7 psig to 250 psig). LNG must be kept cold to remain a liquid, independent of pressure. Despite efficient insulation, there will inevitably be some heat leakage into the LNG, resulting in vaporization of the LNG. This boil-off gas acts to keep the LNG cold. The boil-off gas is typically compressed and exported as natural gas, or is re-liquefied and returned to storage. Figure 47 illustrates the full containment cryogenic tank internals.

Figure 47 Full Containment Tank Internals.

6.2.2 COMPARISON OF FULL CONTAINMENT AND IN-GROUND TANKS Economics


The capital cost of constructing an in-ground LNG tank is over twice that of a full containment tank. In-ground tanks consume more electrical energy for increased boil-off compression, soil and foundation heating and ground water pumping. The extra power consumption is approximately a constant 1,500 kW load.

Design and Safety


When LNG tanks are located in areas of possible aircraft impact; full containment tanks have a higher chance of impact than in-ground tanks. Structures that are built into the ground generally have reduced acceleration loads generated from seismic events. This is because motions of in-ground storage system follow the seismic ground shaking and are not amplified through the structure of the tank as is the case for an above ground storage system. In addition, sloshing responses of LNG tanks resulting from seismic activity are lower for underground tanks. This however does not mean that an in-ground tank is safer than an above ground tank. It means that an aboveground tank is designed to higher seismic loads than an in-ground tank. In all cases LNG tanks are designed to maximum seismic activity for each tank type and its location.

Ground water can be very problematic for in-ground LNG tanks. The density of LNG is less than one-half that of water. If for some reason ground water was to rise around an in-ground tank or leak into it, buoyant forces could lift the tank or displace LNG over the tank wall. However such an event is considered highly unlikely.

Operation and Maintenance


The soil heating cables on an in-ground tank are located such that they are almost impossible to repair. Redundant heating cables will be installed to lessen the possibility of failure. Since most equipment and piping is located on the roof of an LNG tank, access to this equipment is generally easier for in-ground tanks. Above-ground LNG tanks do not require the operation and maintenance of dewatering pumps. Because much on an in-ground is covered with soil, tank inspection and monitoring is difficult and possible problems may go unnoticed. When problems do occur, it is much harder to repair them. For example, the in-ground tanks in Yung-An (Taiwan) have been leaking for years, but due to the difficulty in pinpointing the leak location and accessibility, have elected not to try to repair the leak. Figure 48 shows a variety of design in installation of LNG storage tanks.

Figure 48 LNG Tank designs

6.2.3 Case Study: KOGAS LNG STORAGE TANK


In 2005, Korea Gas Corporation (KOGAS) developed the largest above-ground full containment LNG storage tank in the world which has a gross capacity of 200,000m3. The main objective of the development of the large capacity LNG storage tank is to reduce the construction cost and to use the construction site more effectively.

According to BS 7777 specifications, LNG tanks are classified in three different types. Single containment tank is either a single tank or a tank comprising an inner tank and outer container designed and constructed so that only the inner tank is required to meet the low temperature ductility requirements for storage of the product. A double containment tank is a tank designed and constructed so that both the inner tank and the outer tank are capable of independently containing the refrigerated liquid stored. And full containment tank in figure 49 is described as a double tank designed and constructed so that both the inner tank and the outer tank are capable of independently containing the refrigerated liquid stored. The difference between the double containment and full containment is that the outer tank of a full containment tank is intended to be capable of both containing the refrigerated liquid and of controlled venting of the vapour resulting from product leakage after a credible event. Among these three types of LNG tanks, the full containment type is regarded as the most advanced type. The tanks are also classified by the elevations from the ground level: above-ground type, inground type and under-ground type. The large tank developed by KOGAS is an above-ground, full containment type which consists of inner and outer tank. The inner tank is manufactured with 9% nickel steel and the outer tank is composed of reinforced concrete and pre-stressed concrete. The 9% nickel steel is widely used as a material for the inner tank since it has the strength and toughness enough for the cryogenic uses. The inner tank also has a function of preventing the LNG from leakage. Meanwhile, the concrete outer tank is designed to resist all the external loads including seismic load. Insulating materials are placed between the inner and outer tank to preserve the stored LNG. Specifications of the 200,000 m LNG storage tank The technical specifications of the tank were determined on the basis of the KOGAS ITB (invitation to bid) as follows: - type of tank : above-ground, full containment - inner tank : 9% nickel steel - outer tank : pre-stressed concrete - roof : concrete dome with suspended ceiling deck - secondary barrier : 9% nickel steel corner protection system up to 5m high from the tank bottom then polyurethane foam(PUF) coating - type of base : brine heating system(BHS) - seismic requirements : SSE 0.2g, OBE 0.1g - gross capacity : 200,000 m3 - design pressure : 29 kPa - design boil-off rate : 0.05 vol%/day The tank is of an above-ground, 9% nickel steel full containment type with a pre-stressed concrete outer tank and a corner protection system of 9% nickel steel as a secondary barrier. The base of the tank has a bottom heating system (BHS) using ethylene glycol as brine fluid. The roof has a suspended ceiling deck and a steel lined concrete dome.
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First of all, different hydraulic calculations and process simulations from ship to tanks were carried out for determining the maximum elevation of the tank top. With the results of the calculations and simulations and the technical requirements above, the size of the tank to be developed was determined. Figure 49 shows the sectional view of the LNG storage tank of 200,000m3. - diameter of inner tank : 84.0 m - design liquid level : 36.22 m - maximum operating level : 35.92 m - height of inner tank : 37.61 m - thickness of shell insulation : 1200 mm - diameter of outer tank : 86.4 m - height of outer tank : 52.4 m

Figure 49 Sectional View of the Full Containment LNG Tank

The LNG is stored in the 9% nickel steel inner tank. The steel liner installed on the inside surface of the outer concrete tank provides the gas tightness. The boil-off rate is determined by the insulation system. In case of an LNG leakage, liquid may impact on the outer tank. Accordingly, the liquid tightness must be guaranteed by the corner protection system as well as the polyurethane foam coating installed on the inside surface of the concrete wall. The concrete outer tank protects the inner tank in case of emergency come from the outside. The bottom heating system is installed in order to avoid frost heave. The roof liner consisting of a 5mm thick steel membrane stiffened with rafters in radial and tangential directions acts as formwork for the concrete sphere. The steel structure is fabricated on the bottom slab and lifted by air pressure to its final position. Rafters and roof liner plates are connected with a steel compression ring anchored in the concrete roof ring-beam by welding.

6..2.3.2 DESIGN OF INNER TANK


The principal design codes applied to the design of the inner tank are API 620 and NFPA 59A. The basic design data applied in the design are as follows: Basic Design Data - type of tank : 9% nickel steel full containment - gross capacity : 200,000 m3 - design pressure : 29 kPa - design temperature : -170oC - specific gravity of LNG : 0.48 - design boil-off rate : 0.05 vol%/day - design vacuum : -0.5 kPa - diameter of inner tank : 84.0 m - height of inner tank : 37.61 m - maximum liquid feed rate : 11,000 m3/hr - number of shell courses : 10 - seismic loads: horizontal SSE : 0.2 g horizontal OBE : 0.1 g vertical seismic response : 2/3 of horizontal values

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