LNG storage tanks

Following an initial project carried out by its subsidiary Terre Armée in Qatar in 1982, Campenon Bernard SGE (the future VINCI Group) made a return to this country with the awarding on October 17, 1995 of a design-build contract for three 140,000-m3 liquefied natural gas (LNG) storage tanks. These tanks consist of a reinforced prestressed concrete shell encasing and protecting a self-supporting steel and nickel inner chamber designed to store LNG. The outer concrete casing can confine the liquefied gas in the event of a leak in the inner chamber. Each shell consists of a reinforced concrete foundation resting on piles driven into the bedrock and supports a circular prestressed concrete skirt. A spherical dome in reinforced concrete seals the structure at the top.

BACKGROUND

Eighty kilometres from the capital of Qatar lies one of the world’s largest gas deposits: the North Field gas field. Following the field’s discovery by Shell in the 1970s, initial production was earmarked for domestic energy needs. Later, Qatar negotiated long-term contracts with consuming countries. Two state companies were created to manage export; today, these companies are developing their own facilities on the same site, Ras Laffan, located 80 kilometres north of Doha, the capital city. In December 2010, Qatar became the world’s leading exporter of liquefied natural gas with an annual production of 77 million tonnes.

TECHNICAL OVERVIEW

The inner chambers consist of 409 reinforced concrete piles one metre in diameter and 10 metres long driven into the bedrock 7 metres deep on backfilled land reclaimed from the sea. On these piles rests a reinforced concrete foundation slab that supports the inner steel-and-nickel chamber. To prevent ground-freezing and the appearance of ice pockets that would damage the structure of the storage tanks, the foundation slab is isolated from the chamber by a double layer of foamed glass insulation and a perlite concrete ring that acts as a support structure for the skirt of the inner chamber. The foundation slab supports a prestressed concrete skirt whose carbon steel inner lining seals in methane vapour.
The one-metre gap between the shell and metal chamber is filled with perlite, a heat-insulation material. The bottom 5 metres of the skirt and the tank are protected by a second insulating barrier designed, in the event of a leak in the inner chamber, to prevent LNG from reaching the junction of the lining and the foundation slab. The steel lining in the skirt, which is in contact with LNG, consists of nickel-enhanced cryogenic steel designed to retain its ductility even in the event of a gas leak and a dramatic temperature drop.
The shell is designed to ensure airtightness and withstand the effects of inner overpressure and decompression. The storage tanks are located on the seashore in a hot, humid, and saline environment that is particularly harsh. To ensure a long useful life in such an environment, the concrete used in this project contains silica fume, which reduces its porosity. The foundation piles, which are partly embedded below the water table, are shielded against corrosion by a cathodic protection system. A plastic film was installed below the foundation slab to protect the tank from rising saltwater. Finally, the walls and roof were covered in acrylic paint to protect them from atmospheric humidity.

Calculations and the choice of materials were made with potential accidents in mind. As a result, the outer shell is designed to withstand a five-hour outdoor blaze, an impact from a 110-kg object travelling at 160 km/hr, an earthquake, gales of up to 150 km/hr, and a leak of the inner chamber.

IMPACT

With roughly 15% of the world’s natural gas reserves, Qatar ranks third in this regard behind Russia and Iran. Qatar’s massive early investment in the natural gas sector and its very favorable geographical position on Gulf trade routes have enabled the country to become the world’s leading supplier of this resource in 2010.
Today, the Ras Laffan site produces 77 million tonnes of LNG a year, that is, 300,000 barrels a day, which is twice the output of the world’s second-largest producer, Indonesia. The site is home to the largest gas liquefaction facility in the world, producing a quarter of the LNG needed worldwide. Its main export market is the United States, but it also sells this resource to countries in Asia and Europe.

Project participants

Client
Ras Laffan Liquefied Natural Gas Company Limited

Project management
Jgc Corporation / The M.W. Kellog Company Joint Venture (Epc Contractor)

Key figures

Implementation dates
October 1995 to March 2000

Concrete
39,707 m3

Formwork
60,214 m2

Reinforcement
4,659 t