FULL SCALE QUALIFICATION TRIALS AND CERTIFICATION OF THE AMPLITUDE-LNG LOADING SYSTEM

Transcription

1 23rd Wrld Gas Cnference, Amsterdam 2006 FULL SCALE QUALIFICATION TRIALS AND CERTIFICATION OF THE AMPLITUDE-LNG LOADING SYSTEM Main Authr Phillip Cx Technip France C - Authr Guillaume Rmbaut Gaz de France

2 1. ABSTRACT The Amplitude-LNG Lading System (ALLS) has been cnceived and develped thrugh a series f phased develpments by a cnsrtium f cmpanies, cnsisting f Technip, Eurdim, KSB and Gaz de France. All develpment phases, frm 1999 t 2006, have been spnsred thrugh JIPs invlving majr Oil & Gas cmpanies, LNG peratrs and engineering cmpanies, and the ALLS cnsrtium. The aim is t prvide the LNG Industry with a family f cmpliant methds f transferring LNG, which can be used in nearshre and ffshre envirnments. By separating the mring and transfer peratins, and using nn-dedicated LNG carriers whenever pssible, system architectures are kept simple and light, and the perability f the whle LNG chain is ptimized. The use f crygenic flexibles and their integratin int a harmnised system will reduce weather dwn time t an abslute minimum whilst cnsiderably imprving safety aspects f marine peratins. The methds used are based n the well prven principles f R&D develpment thrugh small scale and full scale testing, fllwed at all stages by recgnised certificatin authrities. LNG Industry standards such as OCIMF and EN1474 have been used as the basis f develpment fr the cnnectin assembly, which cmprises f a hydraulic QCDC, ERS and guidance system fr all cnnectin, discnnectin and emergency situatins. The paper examines in detail the full scpe f the trials, which are taking place in the Gaz de France Mntir LNG imprt terminal n the French west cast in The trials are split int 2 parts. The first part is t install a cmplete ALLS including a 50m lng, 16" ID crygenic flexible n a dynamic test bench, 70m verall length and 23m high, with a dynamic arm t simulate a significant wave height f 5.5m, and acceleratin f 4m/s². When all cmpnents have been verified, "live" LNG frm the terminal will be circulated thrugh the cmplete system and all peratins as fr LNG carrier transfer peratins will be tested. The ALLS will then be installed n the LNG terminal jetty, and fflading frm an LNG carrier, thrugh the ALLS with the crygenic flexible will take place. All f these peratins have been previusly validated by a full FEED study, and DNV has carried ut Hazid and Risk Assessments and issued a Statement f Feasibility. Thrugh DNV, wh is an active partner in this develpment, this equipment will be certified using their RP-A203 "Qualificatin Prcedures fr new Technlgy" with the final aim f issuing a Statement f Fitness fr Service. This will finally qualify the ALLS fr bth ship-t-ship (side-by-side and tandem cnfiguratins) and ship-t-shre architectures. By using cmpliant transfer systems the safety aspect f LNG transfer peratins can be imprved by increasing the distance between the LNG carrier and the LNG facilities, whether they are fixed r flating, liquefactin r regasificatin.

3 TABLE OF CONTENTS 1. Abstract 2. Intrductin 3. Design basis 3.1 Operating Cnditins 3.2 Additinal Design Features 4. Cmpnent Design and Testing 4.1 Crygenic flexible 4.2 Multi-functin Cnnectin system 5. Preparatin f a full-scale Operatinal System test F.E.E.D. 6. Mntir Operatinal Pilt Unit 6.1 Definitin 6.2 Trials Prgramme 6.3 Equipment Package 6.4 Qualificatin and Certificatin Prcess 7. Results 8. Cnclusins

4 2. INTRODUCTION The transfer f LNG has traditinally been carried ut using rigid lading arms with the LNG carriers (LNG-C) mred alngside well-sheltered berths with very little influence frm wind r wave induced mtins. Indeed any psitinal variatin has cme frm the tidal effects with dynamic mvement being limited t a few centimeters in mst cases. With the advent f ffshre LNG and the requirement t ensure maximum availability f the transfer facilities in full marine envirnments, new systems are being evlved and the need fr crygenic flexibles t integrate int a large number f architectures has becme prevalent. The LNG industry has always been, and cntinues t be, a safety cnscius industry, and this has prven t be the nly path t fllw t maintain an excellent track recrd and reduce risk t an abslute minimum. This therefre means that any new systems r equipment must be fully develped, tested, qualified and certified befre being ffered t the Industry as a whle. This paper will present the lng and methdical perid f develpment f the Amplitude-LNG Lading System (ALLS) and its qualificatin and certificatin prcess. These develpments and trials were partly funded thrugh a series f Jint Industry Prjects (JIPs) invlving a grup f majr Operatrs, LNG shipping cmpanies and engineering cmpanies.

5 3. DESIGN BASIS A mdern LNG transfer statin has traditinally been cmpsed f the fllwing main cmpnents: 3 x 16 internal diameter rigid lading arms fr liquid gas 1 x 16 internal diameter rigid lading arm fr gas return 1 x 16 internal diameter rigid lading arm as a spare line Each lading arm is equipped with a cmplete safety system, cmprising an Emergency Release System (ERS) and a Quick Cnnect Discnnect Cupler. In additin a psitin mnitring system is required t cnstantly mnitr the psitin f each lading arm extremity. All f this equipment is cmpleted by a cmplex cntrl system incrprating all electrical, hydraulic and electrnic functins. The design basis f the ALLS was therefre t reprduce the same peratinal functins but t replace the rigid arms with crygenic flexibles. 3.1 Operating Cnditins Each liquid gas crygenic flexible shuld be designed fr: 10,000 cubic meters per hur flw rate f liquid natural gas Design pressure f 10 bars Nrmal transfer pressure f 3 t 5 bars Operating temperature range frm plus 40 C dwn t minus 163 C Design temperature frm plus 40 C dwn t minus 193 C. Each gas return crygenic flexible shuld be designed fr: 30,000 cubic meters per hur flw rate f gas Design pressure f 0.5 bars Nrmal transfer pressure f 0.15 bars Operating temperature range frm plus 40 C dwn t minus 140 C Design temperature frm plus 40 C dwn t minus 163 C. Hwever all flexibles are identical and therefre interchangeable. 3.2 Additinal design features Additinal design features fr the ALLS were defined as being: 50 thermal cycles per year Minimum service life f 5 years N ice frmatin allwable n the exterir f the flexible itself Flexible gd fr aerial service, but able t withstand temprary immersin in seawater. All materials used t be cmpatible with LNG Cmpliance with existing OCIMF and EN 1474 regulatins when applicable 4. COMPONENT DESIGN AND TESTING Prir t planning a full system test and qualificatin, the majr cmpnents were built, tested and certified separately. 4.1 Crygenic flexible Due t the temperature and inner diameter cnstraints, the use f standard plastics in a nnbnded flexible structure is nt acceptable. The flexible structure is therefre cmpsed f (starting frm the inner layer): A stainless steel bellws t ensure leakprfness, fluid cmpatibility and flexibility

6 Plyester armurs and spiral layer t sustain any axial lading and prvide an initial thermal barrier Thermal insulatin tapes t keep the LNG at crygenic temperature and prevent ice build-up n the utside surface f the flexible Intermediate leakprf sheath t cntain any internal fluid leak External leakprf sheath t prevent any water r humidity ingress and prvide mechanical prtectin fr the inner layers. The cnstructin f a prttype, 16 ID and 17m lng, was cmpleted in 2000, and was subjected t a cmprehensive test prgramme thrughut 2000 and This included extensive fatigue testing at crygenic and ambient temperatures (up t 2 millin cycles) and a burst test. In additin small scale testing (8 ) was carried ut n the internal bellws, as well as tensile tests n the armurs als at crygenic temperature. Bureau Veritas witnessed this series f tests, and a full reprt issued t them. This test prgramme culminated in the issuance f a B.V. Cncept Apprval Certificate in 2003, reference E&P/10591A Full Type Apprval certificatin is t be issued upn cmpletin f full manufacturing prcedure dcumentatin and results f a full manufacturing prcess using a dedicated bench. 4.2 Multi functin cnnectin system This cmprises a cmplete Emergency Release System (ERS) and a Quick Cnnect Discnnect Cupler (QCDC). In additin, due t the requirement fr cnnectin and discnnectin in dynamic mde, a mechanical guidance system was als built, integrated and tested. This assembly, knwn as Cnnectis, and develped by KSB and Eurdim, is the secnd key cmpnent f the ALLS. The main elements are as fllws: Quick Cnnect Discnnect Cupler t ensure ease f cnnectin and discnnectin t the LNG-C maniflds, with 6 duble lcking hydraulic clamps Emergency Release System t allw emergency release under safe cnditins. This incrprates duble Danaïs ffset butterfly valves and actuatrs, and an emergency release cllar. Guiding and Alignment Device (funnel, pin, guide frk, cable, winch) All f these elements (except the Guiding device) were tested separately and assembled, at ambient and crygenic temperatures, using OCIMF and EN1474 specificatins. Bureau Veritas als witnessed these tests and a B.V. Type Apprval Certificate was issued in 2004, reference 13031/A0 BV. The full-scale Guiding system was als tested, whilst subjected t heavy vertical and hrizntal lads, n a test bench simulating dynamic mvement f the LNG carrier manifld. 5. PREPARATION OF A FULL SCALE OPERATIONAL SYSTEM TEST F.E.E.D. The requirement t carry ut full-scale dynamic testing, with circulatin f LNG, was deemed necessary by the ALLS team as well as the grup f spnsrs. Hwever as n ffshre LNG plants exist it was decided, thanks t a prpsal by Gaz de France, t study the pssibility f carrying ut a full-scale test prgramme in the Gaz de France LNG imprt and regasificatin terminal in Mntir, n the West cast f France. Due t the sensitive nature f all such terminals, a cmplete FEED had t be carried ut prir t any final g-ahead being given. During the executin f this FEED the fllwing bjectives fr the full-scale test prgramme were defined: T demnstrate the viability f the ALLS thrugh the qualificatin f all f the perating prcedures and functinalities relative t bth sheltered and harsh envirnment facilities T check and cnfirm the behaviur and perfrmances f the system n real crygenic fluid transfer cnditins (thermal, hydraulic, vibratin etc)

7 T demnstrate in real fflading cnditins the perfrmance and cmpliance f an integrated LNG transfer facility (including a Psitin Mnitring System) using the ALLS as an alternative t the rigid arms system T prve that the ALLS cmplies with the needs and requirements f all relevant Authrities and actrs invlved in traditinal terminals T engage Det Nrske Veritas (DNV) t manage the qualificatin f the ALLS, thrugh t issuance f a Fitness fr Service Statement, using the DNV RP A-203: Certificatin f New Technlgy. The FEED deliverables were further defined as being: a) General: Prject Executin Plan (fr the Operatinal trials phase) Full test prgramme Planning fr Operatinal phase Cst Estimate b) Qualificatin: Qualificatin Basis Technlgy qualificatin Plan DNV Statement f Endrsement c) Test Benches Design & General Arrangements Flexible pipe cnfiguratins Prcedures and equipment lists d) LNG carrier General arrangement fr fflading Scantling f lads e) Lading system Crygenic flexible pipe specificatins General arrangements (flexible, cnnecting system, hydraulics, instrumentatin, cntrl, psitin mnitring system) f) Prcess and Instrumentatin Prcess Flw diagrams Piping & Instrumentatin Diagrams Prcess descriptin g) Risk Assessment HAZOP study HAZID study Safety Study The cnclusins f the FEED were that the full-scale trials (knwn as the Mntir Operatinal Pilt Unit Mntir OPU) were feasible, in spite f the added difficulties f wrking in an peratinal terminal, in an ATEX (Explsive Atmsphere) envirnment, and the need fr lcal gvernmental apprval and authrisatin. In additin DNV issued a Statement f Endrsement, which stated that the ALLS technlgy can be prven Fit fr Service by successfully carrying ut the remaining planned qualificatin activities, certificate reference SOE 2004/001.

8 6. MONTOIR OPERATIONAL PILOT UNIT 6.1 Definitin The Mntir Operatinal Pilt Unit (OPU) cnsists f a full Engineering, Prcurement, Fabricatin, Cnstructin, Installatin, Cmmissining, Testing and Operatin f a cmplete Amplitude- LNG Lading System. T carry ut the prject, a full Prject Executin Plan (PEP) has been elabrated. There are a large number f interfaces at different levels f interactin t be cnsidered in rder t prperly rganise the OPU. The PEP had therefre t initially take the fllwing int accunt: Results frm the FEED Phase Baseline management, Studies and Functinal Analysis Validatin f the FEED prir t OPU realisatin phase start-up Definitin f test prgramme and authrisatins Manufacturing f ALLS equipment (FATs, Certificatin, delivery) Installatin n-site and hk-up Operatin f test prgramme Decmmissining Certificatin and final Statement f System Operability The verall missin statement was defined as being: T cmplete the Validatin and Qualificatin f the Amplitude-LNG Lading system by giving factual terms f reference fr this new slutin f LNG transfer, in terms f Overall perfrmance Safety Efficiency and user friendliness Investment, cst Cnstructin time Operatin / maintenance csts Cmpliance t applicable standards System adaptability and specifically fr Mntir, Administrative and LNG Terminal requirements. 6.2 Trials prgramme The OPU trials prgramme was split int 2 distinct parts. The first part was t perfrm dynamic trials n a test bench, simulating ship-t-ship perating cnditins in pen sea. By qualifying t the mre extreme tandem, r bw t stern, fflading cnditins with aerial flexibles, mre benign cnfiguratins such as side-by-side cnfiguratins, were als qualified. The specificities f each cnfiguratin were fully examined and treated by DNV. In additin these dynamic trials were t be cnducted with flw f LNG, either frm the adjacent LNG strage tanks, r frm an LNG carrier during discharging mde. This flexibility allwed varying flw rates t be used and measured.

9 The secnd part was t install the ALLS, in its supprts n the LNG berth, and t fflad live LNG frm a carrier, in parallel with the existing rigid fflading arms, by cnnecting t ne f the midships manifld flanges. The dynamic trials were t fully demnstrate the SYSTEM OPERABILITY fr all required peratins in wrking mde, i.e. at ambient temperature Handling, cnnectin, discnnectin, emergency discnnectin & strage.. and then in full peratinal mde: Handling Cnnectin Cl-dwn Transfer f LNG End f LNG transfer Purge Discnnectin Strage This sequence f trials was t be repeated with LNG flw, bth in static and dynamic cnditins. In additin an emergency discnnectin under cld cnditins will be carried ut. The LNG berth fflading als included a cmplete set f peratinal prcedures prir t LNG transfer. This final phase f the OPU was t fully demnstrate in real LNG fflading cnditins, the perfrmance f an LNG transfer using the ALLS, and t prve that this new system cmplies with the needs and requirements f all relevant actrs and Authrities, including LNG terminal supervisr and LNG carrier captain. 6.3 Equipment package The ALLS cnsists f 4 distinct packages, these being the crygenic flexible, the Cnnectis assembly, the supprt architecture and the Cntrl package. Prir t the OPU, bth the flexible and the Cnnectis have undergne extensive full-scale prttype testing, bth at crygenic and ambient temperatures. This led t Bureau Veritas certificatin fr bth cmpnents, with Type Apprval fr the Cnnectis (QCDC / ERS) based n cmpliance t OCIMF & EN1474 standards, and Cncept Apprval fr the flexible. Full Type Apprval fr the flexible will be issued by B.V. upn cmpletin f the manufacturing prcess fr the OPU flexible (50m f 16 I.D. structure) and presentatin f the full dssier. The supprt architecture, as it will be specific t each prject, and is in any case part f the dynamic test bench fr the OPU, cannt individually certified. Hwever it s design and acceptance will be required t match the relevant certifying authrities requirements n each prject. The Cntrl package cnsists f all electrical, hydraulic, instrumentatin, cntrl panels, Psitining Management System and infrmatin transfer material. This equipment must meet OCIMF and EN 1474 requirements as a minimum. In additin fr the OPU package all f the instrumentatin sensrs required fr the trials results must be included. These include sensrs fr measurement f temperature, flw rate, vibratin, pressure drp, angular mvement, gas detectrs, vide cameras, strain gauges, hydraulic pressure etc, etc. In all an impressive 251 measurements will be cntrlled fr the OPU trials. 6.4 Qualificatin and Certificatin Prcess The reference dcument fr the ALLS trials at Mntir is DNV RP - A203: Qualificatin Prcedures fr New Technlgy. This dcument has the bjective f prviding a systematic apprach t the qualificatin f new technlgy, ensuring that the technlgy functins reliably within specified limits. Its scpe is

10 applicable fr cmpnents, equipment and assemblies, which can be defined as new technlgy within the hydrcarbn ffshre arena. During the FEED phase a cmplete 4-day HAZID wrkshp was carried ut n the ALLS, with the identificatin f 52 activities, 13 f which were cnsidered High Risk, linked t 7 failure mdes, n the Risk Classificatin matrix. The end f the OPU prgramme will clse all f these activities, mstly by presentatin f cmpleted reprts and dcumentatin, f which 39 will issue frm the OPU results themselves. These failure mdes were identified as being: 1. Shut dwn valves n lnger perable 2. Failure f Psitin Management System 3. Inability t perfrm purge and drainage 4. LNG Carrier drift / drive ff 5. LNG release (emergency discnnectin) 6. Pull-in winch fails t cnnect 7. Mechanical damage t end cnnectr. It can be readily seen that these 7 failure mdes, whilst needing t be fully addressed and reslved, are applicable t any LNG transfer system. By issuance f the Statement f Endrsement, DNV has fund that the ALLS technlgy can be prven fit fr service, thrugh the remaining planned qualificatin activities. In ther wrds, t crrectly execute the Mntir Operatinal Pilt Unit trials. The awarding f Type Apprval, by B.V., fr the crygenic flexible, requires that all manufacturing prcesses are fully dcumented and cntrlled. This is in cnfrmity with standard flexible manufacturing prcedures, which B.V. has been carrying ut since 1990 thrugh a Guidance Nte N1364. This details the qualificatin and certificatin prcess frm issuance f Type Apprval, thrugh Independent Design Review and Certificate f Cnfrmity. This prcedure, thrugh crrelatin with prttype wrk, als includes all manufacturing prcesses, raw material supply and factry acceptance tests, and ensures that, fr each type f flexible, repeatability and cnfrmity fr repeated rders can be btained, cntrlled and guaranteed. 7. RESULTS Whilst the full results f the trials will nt be available until later in 2006, it is wrthwhile cnsidering all f the preliminary and preparatry wrk that has been carried ut. This wrk, which nevertheless cnsist f many intermediate results, is significant in that n shw stppers have been identified, thus prving that ur develpment perid and previus test prgrammes are leading us t a technically acceptable system, which can be perated in a cnsistent, repeatable and reliable manner. These intermediate results include: Elabratin f full peratinal prcedures Lad and cnfiguratin analysis f the system in up t 6.5m significant wave height Dynamic simulatin Definitin f Cntrl & Hydraulic systems Manufacturing f the wrlds first single length 50m x 16 crygenic flexible Elabratin f architectures and cnnectin / discnnectin equipment & prcedures Design and manufacturing f LNG carrier spl piece Definitin f extra lading n LNG carrier midships manifld area LNG carrier deck supprts Qualificatin and Certificatin 8. CONCLUSIONS The aim f this lng and detailed develpment perid, which started in 1999, has always been t prvide the nascent ffshre LNG Industry with a range f cmpliant transfer systems, which can be used

11 in a safe and efficient manner in all nearshre and marine cnfiguratins. By cmplying with existing standards such as OCIMF and EN1474, especially in the cntext f peratinal practices, including emergency prcedures, it has been pssible t extend the wrking envelpe f LNG transfer systems in dynamic mdes. Side-by-side and tandem LNG transfer systems, in marine dynamic envirnments are nw fully available, and the Industry can be assured that they are based n slid qualificatin methds. Ease f cnnectin and repeatability f marine peratins is a must fr all LNG carrier Captains and crew, and by including all architectural design and installatin as part f the verall package, all prject specific issues are taken int accunt. By designing and qualifying new equipment, rather than attempting t mdify existing land-based systems, all essential criteria have been analysed and included. The use f crygenic flexibles enables custm-built slutins that allw the LNG carriers t remain at safe distances frm the LNG facilities, whether these are fixed r flating, and liquefactin r regasificatin. Hwever the ALLS develpments cntinue and detail design wrk is already in prgress fr Marine LNG terminals, incrprating flating flexibles and a fixed r flating single pint mring system. This indeed will be the mirrr image f Crude Oil marine terminals and have a majr impact n the reductin f envirnmental impact n castlines. The LNG Industry will dubtless cntinue an expnential expansin thrughut the cming decades as natural gas prgressively replaces crude il. By pening up a family f new slutins fr safe LNG transfer in marine cnditins, this wrldwide requirement fr mre and mre LNG terminals can be met in the mst effective manner pssible.