Handouts - Cryogenic Piping systems-LNG Terminals

10/22/2016
Cryogenic Piping systems

LNG terminals
Javier García-Lozano
1 PLANT ENGINEERING WORKSHOP 2016 – WWW.INIPED.COM
1. Introduction. LNG terminals and cryogenic piping systems
When working for the first time in LNG terminals, even the most experienced piping
engineers should take into consideration the special requirements associated to the
cryogenic piping. Once introduced some general considerations, this document will focus
on the main problems and concerns related to the materials, pipe routing, stress analysis
and supports design for these particular systems. Finally, we will review some good
engineering practices to be implemented “before, during and after” the Cool down.
1.1 LNG terminals
The NG (Natural Gas) is considered an interesting and “clean” energy source, less
contaminating than other hydrocarbons. Nevertheless, although huge quantities have
been actually identified, the reservoirs are mainly located in remote areas and the
transportation by gas pipelines is not economically sustainable for long distances due to
the high volume occupied by the Natural Gas at ambient temperature. Then the Natural
Gas is liquefied and transformed in LNG, reducing the volume 600 times and making the
transoceanic transportation by LNG carriers feasible and profitable.
The main function of the LNG regasification plants is to unload the LNG shipped by a LNG
carrier, to store it in a LNG tank and to supply the vaporized LNG to other customers
commonly through the trunk-line (main gas pipeline) and also / alternatively transported
with truck lorry.
The general process description of a LNG terminal may be as follows:

- Once the LNG carrier arrives to the jetty of the terminal, the loading arm dedicated to
the liquid phase and the main unloading line shall be arranged to unload the LNG from
the carrier towards the storage tanks, by means of the unloading pumps on the carrier.
- During LNG unloading, BOG (Boil-Off Gas) is generated due to heat ingress into the
cryogenic systems and physical replacement.
- Part of BOG is returned to the LNG compartment of the carrier through the gas phase
return arm and return line to balance the pressure of the compartment
- The rest of the BOG shall be re-condensed after pressurized by the BOG compressor
and mixed with low pressure LNG.
- The re-condensed BOG and LNG from the storage tank together will be sent through
high-pressure transfer cryogenic pumps.
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- The LNG shall be heated and vaporized to gas phase NG (Natural Gas) by utilizing
open rack or submerged-combustion Vaporizers
- Finally the NG is pressure adjusted and measured in the fiscal metering system before
sent to the pipe network.
- LNG could also be sent (utilizing low-pressure transfer cryogenic pumps) to the truck
lorry for transportation.
Figure 1. LNG carrier
1.2 Cryogenic piping systems
The main fluid in this terminals is LNG, which needs to be stored and transported at
cryogenic temperature, around -160º Celsius, to maintain the liquid phase. Consequently,
not only all the process lines, but also other services (drains, vents) in any LNG terminal,
are cryogenic piping operating at -160º Celsius approximately and with design
temperature around -170º Celsius.

2. Materials
The cryogenic temperature demands special materials piping materials and insulation
2.1 Cryogenic insulation
Insulation is required to reduce the transfer of heat to piping and equipment but also to
avoid condensation and icing on the exterior surface.
Specific and detailed installation drawings are required to define the typical section for
each insulation class but also the contraction joints (both horizontal and vertical), reducers,
tees, etc.
Figure 2. Detail of Vapor stop
Figure 3. Detail of horizontal contraction joint

Figure 4. Typical section for Insulation class C1
Figure 5. Detail of elbow insulated with 2 layers

Figure 6. Detail of tee insulated with 3 layers
Commonly used materials are cellular glass and polyisocyanurate, arranged in one, two or
even three layers, depending on the design temperature and the nominal pipe diameter.
Total
Inner layer Middle layer Outer layer
thickness
90 40 - 50
100 50 - 50
110 60 - 50
120 70 - 50
130 40 40 50
140 40 50 50
150 50 50 50
160 50 60 50
Figure 7. Thickness of individual layers for Insulation class C1

Total
Inner layer Middle layer Outer layer
thickness
60 - - 60
70 - - 70
80 - - 80
90 - - 90
100 50 - 50
110 50 - 60
120 50 - 70
Figure 8. Thickness of individual layers for Insulation class P1
Insulation Classes
NPS
C1 C2 C3 P1
½” 80 100 100 60
¾” 90 110 100 70
1” 90 120 100 70
1 ½” 100 130 110 80
2” 100 130 120 80
3” 110 140 120 90
4” 120 160 130 90
6” 130 160 140 100
8” 130 170 150 100
10” 140 180 150 110
12” 140 190 160 110
14” 140 190 160 110
16” 150 190 - 110
18” 150 200 - 120
20” 150 210 - 120
24” 160 210 - 120
28” 160 210 - -
30” 160 220 - -
32” 160 220 - -
36” 160 220 - -
Figure 9. Insulation classes

2.2 Piping material
Austenitic stainless steels are used for cryogenic service (lines with operating temperature
below -46º Celsius). Common grades are 304 (18% Cr – 8% Ni) and 316 (16% Cr – 12%
Ni – 2% Mo). Also L grades are used; low carbon content, better weldability but worse
mechanical properties. Nowadays dual quality is the preferred option; low carbon content
to improve the weldability but maintaining the standard mechanical properties
3. Pipe routing
Due to the special nature of cryogenic piping, there are some particular design
requirements to be considered:
3.1 Pipe Spacing
Higher insulation thickness for cold conservation compared with “hot lines” in other type of
industrial plants implies increasing the pipe spacing among adjacent pipes.
Figure 10. Pipe spacing

Figure 11. Pipe track with cryogenic piping
3.2 Minimum distances
Insulation erection process in order to prevent thermal loss and ensure that all the layers
(up to three) are sealed requires detailed and accurate installation details. As a
consequence, the different layers are stepped; this particular configuration demands the
installation of a straight pipe spool between two consecutive pipe accessories (e.g. bends,
tees and also pipe supports).
Figure 12. Minimum distances for dirrefent arrangements

Figure 13. Minimum distance between adjacent bends
4. Stress analysis
4.1 Critical lines
In any LNG terminal, all the process lines (including LNG and BOG) but also other
services (drains, vents), are cryogenic piping operating at cryogenic temperature (below -
46º Celsius and at -160º Celsius in case of LNG) and with design temperature around -
170º Celsius.
Consequently, around 40% of the overall lines are cryogenic and therefore critical lines
from stress analysis point of view.
4.2 Thermal contraction
The stress analysis in the majority of the industrial plants evaluates the thermal expansion
of the piping and the associated stresses, loads on supports, structures and transferred to
equipment, etc. In case of cryogenic piping, although it might seem obvious, the piping
“contracts” instead of expanding; therefore the experienced analyst should “change” his
usual reasoning and be aware that the pipe movements are opposite as in the case of “hot
piping”; e.g. in an expansion loop, the bend is moving towards the anchor or fixed point:
Figure 14. Deflected dhape for a cryogenic expansion loop

It should be highlighted that the thermal contraction of the stainless steel used for
cryogenic piping at -160º Celsius is close to 3 mm/m (specifically around 2,6 mm/m).
Then, all the cryogenic systems demand a flexible design with several expansion loops
and changes in direction in order to avoid excessive pipe movements which may cause
overstress, loads on equipment exceeding the allowable values, etc.
On the other hand, being the operating and design temperature equal or very similar for
every LNG line, an experienced analyst could easily anticipate the expected movements
for a particular support from installation to operation just knowing the position of the
adjacent fixed or anchor supports, due to same thermal contraction for all lines
When significant seismic or wind need to be considered, the stress calculations becomes
even more complex and the analyst should balance a flexible system to cope with the
thermal contraction at cryogenic temperature but also with enough restrictions to withstand
these occasional loads.
4.3 Transient analysis (water hammer)
In LNG terminals, different transient scenarios (also called “water hammer”) may occur
and need to be considered. The first step of the analysis is quite complex and requires a
multidisciplinary and close collaboration among different disciplines; process, piping
design, stress analysis, MTO, mechanical, instrumentation, etc. As a result, the
overpressure shall be evaluated and the unbalanced forces considered as an occasional
load to be input in a stress calculation.
Some of the scenarios to be considered are:
- Rapid valve closure (on-off valve) in the LNG unloading line
- LNG carrier pumps trip
- LNG carrier pumps star-up
- Loading arm quick disconnection
All these calculations shall consider the characteristics of the LNG (which differ from
water): density, bulk modulus, “c” or the propagation speed of the wave, etc.
4.4 Sensitive equipment
The stress analyst should pay attention to the maximum allowable loads at the nozzles of
some sensitive equipment where the cryogenic piping is connected: LNG tank, Cryogenic
Pumps, BOG Compressors, Absorber, Loading Arms that connect with the LNG carrier…
Some of these equipment are not commonly found in other industrial plants and the
analyst may not be used to work with some of the reference codes; e.g. OCIM for loading
arms.

Figure 15. Loading arms connected to LNG carrier

Figure 16. LNG tank
4.5 Offshore structures
Every LNG terminal has at least two off-shore structures, commonly piled to the subsea
bed and called:
- Jetty; where the LNG carrier arrives, is fixed and connected by the loading arms
- Trestle; a straight structure including a road and a pipe rack with all the piping required
to unload the LNG, BOG and in general to connect the Jetty with the on-shore area
where the main equipment are located; pumps, compressors, vaporizers…
Figure 16. Trestle and Jetty

The stress analysis should consider the differential displacements among the different
structures and sections (commonly the trestle is splitted in different sections); these
movements to be imposed at the pipe supports could be significant in both longitudinal and
lateral directions.
Figure 17. Effect of differential lateral displacements of the trestle
Figure 18. Effect of differential longitudinal displacements of the trestle
5. Supports Design
5.1 Cryogenic insulation: PUF, vapor barrier, adhesives and sealants
The insulation material that forms the central part of the insulated pipe support assembly is
commonly manufactured using fire-retarding, high density polyurethane foam (HD-PUF).

The HD-PUF is monolithically molded in heavy duty molds under carefully controlled
conditions in respect of temperature and humidity, a process that provides uniform
properties and ensures dimensional stability with no warping.
Figure 19. PUF for cryogenic support
PUF has the task of insulating thermally but also distributing and withstanding the loads.
Different layers (up to three) are arranged to avoid propagation of thermal loss. The
mouldings incorporate carefully sized step joints, both radial and longitudinal, respectively
to prevent a direct heat path from the surface of the insulation through to the surface of the
pipe and to match the layering of the adjoining line insulation.
Radial stepped joints between lower and upper cradles shall have a gap to maintain the
structural integrity of the support during the thermal contraction of the piping system.
These gaps shall be filled with an appropriate insulation flexible material.
Figure 20. Radial stepped joints

In addition to the main insulating material (PUF), other specialized products are required for a
proper installation of the cryogenic supports:
- Temporary protector dealing for all surfaces of the bearing shells exposed to the inclemency
of the weather during the time since the installation of the bearing shells until proceeding
with the line insulation installation. Also a joint sealant should be field applied between the
lower clamp and the protection of the vapor barrier.
Figure 21. Longitudinal stepped joints with temporary protector
- To prevent moisture ingress, a laminated aluminum / polyester foil (with a vapor permeance
of not more than 0.02 perms) is factory bonded to the outermost surface of the outer layer of
the PUF assembly. The protection of this vapor barrier is normally provided by the installation
of a stainless steel (type 316) shield 0.6 mm thick.
- High strength cryogenic adhesives are used for bonding different products (vapor barrier and
its protection) and among layers of PUF.
- Spring washers are normally used to ensure the proper bolt tightening once the piping has
been coolded down.
Figure 20. General arrangement for cryogenic support

5.2 Cryogenic insulation: Densified wood

Nowadays, the densified wood has been replaced by the PUF in the majority of the piping
supports but it is still used in some particular cases such as trunnion supports or clips in
cryogenic equipment.
Figure 21. Clip with densified wood for cryogenic vessel.

Figure 21. Double-trunnion support with densified wood for cryogenic pipe.
5.3 Standard Supports
Drawings for the most typical and commonly used supports are generally called “standard
supports drawings. A collection of these standard supports drawing (or “standard supports
book”) shall be developed for each project in order to ensure an adequate design and
location of the supports. Also specialized manufacturers have developed their own
catalogue for the most commonly used cryogenic supports:
Figure 22. Resting support

Figure 23. Guide for vertical pipe

Figure 24. Guide + Resting support
Figure 25. Hanger support

Figure 24. Axial Stop
5.4 Special Supports

Whenever it is possible a standard support will be used, in order to minimize the number
of special supports. Nevertheless, some special support drawings shall be developed for
each project, generally for main lines, high loads and at particularly difficult locations:
Figure 25. Four-shoes Axial Stop + Guide

Figure 26. Anti-vibrating Support
Figure 27. Support for non-insulated piping at cryogenic temperature

Figure 28. Double-shoe axial stop allowing lateral movement
Figure 28. Finite element model of anchor for vertical pipe

6. Cool Down
During day to day operations of LNG receiving terminals, process pipes are at uniform
cryogenic temperatures (around ‐160° Celsius) and experience relatively low thermal
stresses. However, since such facilities are built at ambient conditions, fast temperature
changes and high local temperature differences will occur during the initial cooldown.
In order to ensure the pipe integrity and to minimize leaks, the stress engineers
collaborate in some activities Before, During and After the cool down.
6.1 Bowing effect
During the cooldown, the pipes are brought from ambient temperatures down to operating
temperatures. In practice, the first introduction of LNG in the pipes creates significant
temperature differentials; the bottom “cold” portion of the pipe that comes in contact with
LNG cools down much faster than the top “warm” portion of the pipe in contact with only
vapor. Large temperature differentials within the pipe cross section form and can lead to
substantial thermal stresses, both tensile and compressive. This effect is called “bowing”.
The stress engineer could calculate the related thermal stress in order to determine the
maximum gradient temperature within the pipe cross section that should be allowed during
the cool down:
Figure 29. Thermal bowing calculation with specialized stress analysis software

6.2 Stress isometrics with supports displacement.
Taking as a basis the result data obtained in the stress calculation, the specialist
engineers elaborate specific isometric drawings to be used during the cool down, showing
the displacements expected in the pipe supports due to thermal contraction:
Figure 30. Isometric for cool down with support thermal displacements
Also some additional stress verifications might be needed for the cool down in case some circuits
are cooled down in a different scenario than the operating cases already analysed during the
engineering phase of the project; e.g. flexible hose that connects suction and discharge headers of
the cryogenic pumps, while the rest of connected lines remain at ambient temperature.

Figure 31. Flexible hose used during cool down
6.3 Site activities before cool down.
Once the specific isometric drawings to be used during the cool down have been
elaborated, the stress engineers work using this documentation to develop the following
activities at site:
- Check potential interferences or clashes during the cool down due to the movements of
the piping system caused by the thermal contraction.
- Mark-up the displacements expected in the pipe supports due to thermal contraction;
both the “erection” position (at ambient temperature) and the “operating” position (at
cryogenic temperature) are marked-up in both the cryogenic pipe support and the
supporting structure.

Figure 31. Longitudinal movement during cool down, marked-up in resting + guide support
Figure 32. Lateral movement during cool down, marked-up in resting support

6.4 Site activities during and after cool down.
During the cool own, the stress engineers continuously monitor the LNG lines in order to
verify that the displacements expected in the pipe supports due to thermal contraction are
correctly achieved. The pipe is used as a “thermometer” while it is being cooled down and
hence the engineers could verify not only the final position of the support at -160º Celsius
but also intermediate displacements while the pipe is gradually decreasing its temperature,
comparing the movements already achieved by the support with the temperature shown in
the field instruments. Also the maximum thermal gradient between the top and the bottom
of the pipe should be monitored to avoid excessive bowing effect.
Once the cool down has finish, it is good engineering practice to perform a detailed survey
of all the piping systems involved, in order to solve any interference or clash and to record
the as built position of the piping and its supports.
7. Mitigation actions to avoid problems at site

Firstly, all the special requirements associated to the cryogenic piping introduced in this
document should be taken into consideration from the beginning of the engineering phase
of the project.
Secondly, due to the special nature of the materials involved, it is strongly recommended
that the manufacturers develop installation manuals at least for the cryogenic insulation
and cryogenic supports. These documents shall be strictly followed at site, with the
supervision of specialized engineers. Safety data sheets and manufacturers
recommendations shall be followed for all the auxiliary materials.
Finally, it is advisable to prepare protocols or check lists to supervise the correct

development of some specialized erection activities. For instance, a good engineering
practice is to install some of the cryogenic shoes (where relevant axial movement due to
thermal contraction is expected) displaced in the opposite direction of the expected
movement and consequently not aligned with the centre of the structure where they are
resting. This practice permits some cost saving associated to the length of the shoes but in
case it is not properly supervised, the incorrect installation of these displaced shoes might
become a critical issue on site.

Figure 33. Displaced installation of Cryogenic shoes
Figure 34. Installation of Cryogenic support

Handouts - Cryogenic Piping systems-LNG Terminals

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Handouts - Cryogenic Piping systems-LNG Terminals

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10/22/2016

Cryogenic Piping systems

1. Introduction. LNG terminals and cryogenic piping systems

1.1 LNG terminals

The general process description of a LNG terminal may be as follows:

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Figure 1. LNG carrier

1.2 Cryogenic piping systems

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2.1 Cryogenic insulation

Figure 2. Detail of Vapor stop

Figure 3. Detail of horizontal contraction joint

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Figure 4. Typical section for Insulation class C1

Figure 5. Detail of elbow insulated with 2 layers

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Figure 6. Detail of tee insulated with 3 layers

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2.2 Piping material

3.1 Pipe Spacing

Figure 10. Pipe spacing

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Figure 11. Pipe track with cryogenic piping

3.2 Minimum distances

Figure 12. Minimum distances for dirrefent arrangements

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Figure 13. Minimum distance between adjacent bends

4.1 Critical lines

4.2 Thermal contraction

Figure 14. Deflected dhape for a cryogenic expansion loop

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4.3 Transient analysis (water hammer)

4.4 Sensitive equipment

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Figure 15. Loading arms connected to LNG carrier

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Figure 16. LNG tank

4.5 Offshore structures

Figure 16. Trestle and Jetty

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Figure 17. Effect of differential lateral displacements of the trestle

Figure 18. Effect of differential longitudinal displacements of the trestle

5.1 Cryogenic insulation: PUF, vapor barrier, adhesives and sealants

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Figure 19. PUF for cryogenic support

Figure 20. Radial stepped joints

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Figure 21. Longitudinal stepped joints with temporary protector

Figure 20. General arrangement for cryogenic support

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5.2 Cryogenic insulation: Densified wood

Figure 21. Clip with densified wood for cryogenic vessel.

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5.3 Standard Supports

Figure 22. Resting support

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Figure 23. Guide for vertical pipe

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Figure 24. Guide + Resting support

Figure 25. Hanger support

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Figure 24. Axial Stop