Full-scale Lng Trials of a New Lng Transfer System

7/27/2019 Full-scale Lng Trials of a New Lng Transfer System

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FULL-SCALE LNG TRIALS OF A NEW TRANSFER SYSTEMON THE GAZ DE FRANCE MONTOIR LNG TERMINAL

Guillaume RombautProject Manager

Gaz de France SASaint-Denis La Plaine, 93211, [email protected]

Phillip CoxBusiness Development Manager

Technip FranceParis La Dfense, 92973, France

Bernard DupontDirector

Eurodim SARueil Malmaison, 92566, France

Pascal VinzioValve Technical Director

KSB SASGradignan, 33173, France

ABSTRACT

Future development of LNG projects, whether for export or import facilities, in

sheltered or harsh environments (in term of marine and meteorological conditions) rely

on the ability of the LNG Industry actors to bring innovative technical solutions to tackle

the problem of LNG transfer in open sea.

Since there is a spectrum of offshore LNG transfer solutions in development,

cryogenic flexible hose based LNG transfer systems appear to answer the LNG Industry

requirements in term of performances.

The full-scale LNG trials to be performed at the Gaz de France Montoir-de-Bretagne

LNG receiving terminal are the last stage of a complete and serious development of such

solution.

These industrial trials are part of a whole qualification process managed by a

certification organism through a recognised procedure for the qualification of newtechnology.

The Amplitude-LNG Loading System (ALLS) has been under development for the

past six years and is now at the edge to demonstrate its performances for LNG transfer in

dynamic conditions with significant wave height up to 5.5 m.


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INTRODUCTION

This paper will focus on the last qualification stage of the Amplitude-LNG Loading

System (ALLS) based on cryogenic flexible hose technology at the Gaz de France

Montoir-de-Bretagne LNG receiving terminal.

This new technology has been developed as an integrated solution for LNG transfer in

ship-to-shore and ship-to-ship configurations and from sheltered to harsh environments.

Indeed, the offshore installations represent a vehicle for progress consistent with the

LNG market growth and it opens new perspectives and new challenges for the whole

LNG Industry. In order to ensure that these new LNG chains operate correctly and at an

optimum rate, the development of an efficient and safe LNG transfer system is a key link

on which progress is still challenging the actors involved in this field.

Whilst the transfer of LNG in real offshore conditions is a recent requirement, and

several systems are under development, there is no actual system in operation, which isable to withstand the marine and meteorological conditions required by the offshore LNG

chains to guarantee their availability.

Based on these assessments, any LNG transfer system has to comply with the

following criteria:

Fundamental safety;

Existing standards and specifications, as far as they can be applied in an offshore

context;

Project specifications and requirements;

Marine classification regulations;

Marine and meteorological conditions even severe;

Ensure offloading from different LNG carrier sizes, without adversely affecting

the carriers themselves.

In addition, the transfer system must propose procedures for operational connection,

disconnection, emergency disconnection, storage and replacement, with full safety and

repeatability.

To achieve these requirements, the development of a new LNG transfer systemshould be governed by close partnerships between LNG operators, engineerings and

equipment manufacturers.

Furthermore, certification organisms have to be involved to guarantee that the

innovative solution meets the LNG industry standards.

The ALLS development has followed these basic principles, the full-scale LNG trials

program through a Joint Industry Project (JIP) being the last stage in order to obtain a full

qualification of the system.


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QUALIFICATION PROCESS

Technology qualification is the process of providing the evidence that a new

technology will operate reliably within specific limits by applying a structured approach

to ensure a traceable and transparent qualification process.

The reference document for the ALLS qualification process managed by DNV is

DNV-RP-A203: Qualification Procedures for New Technology.

This qualification work process ensures that all aspects of new technology are

adequately addressed and the technology is proven to comply with stated functional

requirements and reliability targets. The process starts off by defining the qualification

basis, with functional requirements and reliability targets, which the technology is to

meet. Then the system is divided into manageable parts, and classified with respect to

novelty (technology assessment). Following this, a thorough risk-ranking process

identifies all potential failure modes of concern. Qualification activities are thus defined

to address those failure modes. The activities of the qualification plan are then assessedwith respect to the likelihood of these being successfully completed within the available

time. Depending on the probability of success of the project, a Statement of

Endorsement can be issued. Finally the activities of the technology qualification plan are

executed to derive all the information needed to reduce the uncertainties to an acceptable

level in order to obtain a Statement of Fitness for Service.

This methodology has been applied to ALLS and the full-scale LNG trials at the Gaz

de France Montoir-de-Bretagne LNG receiving terminal are part of the whole

qualification process. The main functional requirements related to the use of ALLS as

LNG transfer system are:

Table 1: ALLS typical functional requirements related to the qualification.

LNG line LNG vapour return line

Diameter 8 to 24 8 to 24

Design pressure (barg) 10 0.5

Design temperature - 163 C - 163 C

Typical flow rate10,000 m3/h

(with three 16 flexible hoses)30,000 (n)m3/h

Note: LNG and vapour return lines are technically identical and fully interchangeable if necessary.

MONTOIR OPERATIONAL PILOT UNIT (OPU)

The Montoir OPU JIP is sponsored by Gaz de France, BP Exploration, Chevron

Energy, Conoco Shipping Company, Hogh LNG and Total and involved the ALLS

consortium.

This JIP led by Technip France involved Det Norske Veritas for the qualification

process.


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LNG full-scale trials requirements

The requirement to carry out full-scale dynamic testing, with circulation of LNG, was

deemed necessary by the ALLS consortium as well as the group of sponsors constituted

of future LNG operators. However as no offshore LNG plants exist it was decided, thanks

to a proposal by Gaz de France, to study the possibility of carrying out a full-scale testprogram in the Gaz de France Montoir-de-Bretagne LNG receiving terminal on the West

coast of France. Due to the sensitive nature of all such terminals, a complete FEED (Front

End Engineering Design) and process compatibility study had to be carried out prior to

any final go-ahead being given.

FEED phase

During the execution of this FEED the following objectives for the full-scale test

program were defined:

To demonstrate the viability of the ALLS through the qualification of all of theoperating procedures and functionalities from sheltered to harsh environments;

To check and confirm the behaviour and performances of the system on real

cryogenic fluid transfer conditions;

To prove that the ALLS complies with the needs and requirements of all relevant

Authorities and actors involved in traditional terminals;

The conclusions of the FEED were that the full-scale trials were feasible, in spite of

the added difficulties of working in an operating terminal, in an ATEX (EXplosive

ATmosphere) environment, and the need for local governmental approval and

authorisation. In addition, DNV issued a Statement of Endorsement (certificatereference SOE 2004/001), which stated that the ALLS technology could be proven Fit for

Service by successfully carrying out the remaining planned qualification activities.

Qualification activities

Ship-to-shore and ship-to-ship (tandem) configurations. During the FEED phase a

complete qualification work process led by DNV was carried out on the ALLS, with the

identification of 16 high-risk activities linked to 7 potential failure modes, which are:

Shut down valves no longer operable

Failure of Position Management System

Inability to perform purge and drainage

LNG Carrier drift / drive off

LNG release (emergency disconnection)

Pull-in winch fails to connect

Mechanical damage to end connector.

Ship-to-ship (side-by-side) configuration and control command. The qualification

work process has been updated during the Montoir OPU phase leading to 6 new potential


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failure modes (3 for the side-by-side configuration and 3 for the control command)

corresponding to few high-risk activities. These failure modes are:

Side-by-side configuration:

o Collision with outboard equipment during LNG transfer;

o Flexible hose catenary in contact with sea during LNG transfer;

o ESD1 failure resulting in damage of the offloading system;

Control command:

o QCDC open unintentionally during LNG transfer;

o ERC fails to open through the PLC (Programmable Logic Controller);

o ERC fails to open manually.

It can be readily seen that all these failure modes, whilst needing to be fully addressed

and resolved, are applicable to any LNG transfer system.

HAZID study

During the FEED phase a complete HAZID (Hazard Identification) workshop led by

DNV was carried out on the Operational Pilot Unit (OPU means the test bench and all its

equipments). This HAZID has been updated during the Montoir OPU phase.

HAZOP study

A full HAZOP study was conducted during the FEED phase to identify any items that

could result in unsafe operating conditions or unexpected operational difficulties. TheHAZOP has been also updated during the Montoir OPU phase to take into account all the

functionalities of the test bench and the procedures developed.

Safety study

General approach. The particular safety study carried out by Gaz de France can be

distinguished from a classical one because it does not concern functionality related to

terminal operation and is limited to few types of equipment. Furthermore, the innovative

nature of ALLS and the temporary use of the dynamic test bench required adapting the

classical safety study methodology.

After the systematic analysis of the hazards and the assessment of the seriousness of

the scenarios, the effects caused by all of the scenarios appear to be inflated by a worst-

case scenario. Furthermore, the measures adopted to prevent this scenario or to lessen its

effects encompass all of the measures that must be implemented for other less serious

scenarios.

Dimensioning scenario. The worst-case scenario concerns an LNG test at full flow

with a guillotine rupture of the flexible hose at the test bench (4000 m3/hr for 30s

followed by a valve emergency shut down) while the crane is in a low position and with

unfavourable meteorological conditions (stable atmosphere and weak wind).


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This extreme scenario has two main consequences to be taken into account: i) the

delayed ignition of the cold natural gas cloud caused by such a spillage, ii) the thermal

effects of the LNG pool fire.

The simulations have been performed with dedicated tools for LNG, which had been

developed in the past by Gaz de France and qualified by tests campaigns and third partyexpertises when used for safety studies. The results show that the test bench does not

contribute an extra critical hazard to the current installations and terminal environment

but this leads to restrictions for the dynamic test bench design and construction.

Permitting

Gaz de France has submitted to the local governmental representative (Prefect) the

project to get the necessary authorisation to operate the dynamic test bench described

below in the context of an LNG operating terminal classified as a SEVESO II industrial

site under the European regulation.

The local governmental representative considered the dynamic test bench as an

extension of the Montoir-de-Bretagne terminal existing installations. Thus, the

authorisation process had to follow the same steps than for a terminal.

Following this administrative procedure, a prefectorial by-law has been obtained for a

six months period with the possibility to renew it once. This by-law confirmed the

conclusions of the safety study carried out by Gaz de France and detailed the design,

construction, operation and safety aspects that must be taken into account by the project.

MONTOIR OPU DYNAMIC TRIALS

Dynamic tests objectives

The dynamic test bench (see figure 6) has been designed to reproduce extreme severe

offshore dynamic motion conditions. The objectives of the tests, which will be carried out

on this dynamic test bench, are:

To demonstrate the viability of the ALLS through the qualification of all the

operating procedures and functionalities from sheltered areas to harsh

environments. Therefore, three LNG transfer base cases have been selected:

o Ship-to-shore / shore-to-ship LNG transfer in sheltered areas (seefigure 2);

o Ship-to-ship LNG transfer in side-by-side configuration in benign

offshore environmental conditions (see figure 3);

o Ship-to-ship LNG transfer in tandem configuration in harsh

environmental conditions (see figure 4).

To check the behaviour and the performances (thermal, hydraulic, mechanical)

of the system in real LNG transfer conditions.


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Figure 2: Ship-to-shore configuration for sheltered areas (Gerris architecture).

Figure 3: Ship-to-ship LNG transfer in side-by-side configuration.

Figure 4: Ship-to-ship LNG transfer in tandem configuration (Light Reel

architecture).

Dynamic test bench principles

Dynamic motions. The dynamic test bench has been designed to simulate the most

significant motions, which can occur at the LNG carrier connection point during the

ALLS operations:

Eurodim patent pending

Eurodim patent pending


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Mdiathque Gaz De France Yves Blond

test benchlocal control

room

bench

Gaz de France Montoir-de-Bretagne LNG terminal

dedicatedtest area

Mdiathque Gaz De France Yves Blond

test benchlocal control

room

bench

Gaz de France Montoir-de-Bretagne LNG terminal

dedicatedtest area

Heave acceleration = 4m/s max;

Heave amplitude = 6.5 m max;

Period = 8s.

These motions correspond to the ALLS base case, stern to bow LNG transfer betweentwo ships tandem moored in harsh environment i.e. a significant wave height of 5.5m.

Vertical offset. To reproduce the vertical LNG carrier draught variations as well as

tide variations, different positions of the mobile arm will be used to execute the tests in

static conditions.

Torsion. The maximum allowable torsion deflection of the flexible hose in static

conditions is 0.6/m and 0.3 /m in dynamic conditions, configurations which can occur

in an emergency situation. To reproduce these conditions for the trials on the dynamic

test bench, torsion will be applied to the flexible hose by rotation of one end fitting.

Dynamic test bench location

According to the safety study conclusions and by considering that the major scenario

consequences should not lead to domino effects on the terminal installations, the test

bench has been localised inside the dedicated test area. This leads to the following layout

scheme for the whole installations of the dynamic test bench.

Figure 5: Top view of the Gaz de France Montoir-de-Bretagne LNG receivingterminal and dynamic test bench location.


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TD3 TS2 TS1

- 6.5 m

+ 6.5 m

TD3 TS2 TS1

- 6.5 m

+ 6.5 m

Dynamic test bench description

Supporting structures. The dynamic test bench is constituted of three supporting

structures of 25 meters height, which are:

Fixed end supporting structure (TS1): This structure allows the fixed connectionof the LNG pipe to the flexible hose. A platform supports the handling equipment

and allows access to the instrumentation;

Handling and storage supporting structure (TS2): This structure allows storing the

flexible hose in catenarys configuration and supports the storage and handling

equipments (hydraulic winch). This structure has platforms to access the

connecting system instrumentation or for maintenance work;

Mobile end supporting structure (TD3): This structure is constituted of a mobile

arm and the supporting structure itself. A hydraulic jack applies static and

dynamic motions to the mobile arm thanks to a hydraulic power unit located at the

15 meters intermediate platform. The mobile arm supports a pull-in winch toallow connection and disconnection of the ERS mounted at the flexible hose end

to the QCDC installed at the mobile arm extremity.

Figure 6: Dynamic test bench structures scheme.

Cryogenic flexible hose. The main technical characteristics of the flexible hose to be

tested are:

Design Pressure: 10 barg;

Length: 50 m

Internal diameter: 16

Weight: 120 kg/m (empty) 186 kg/m (full of LNG)

Minimum bending radius: 4.5 m (storage)

Piping. The main characteristics of the pipes of the dynamic test bench are given

below:


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LNG lines: The test bench has eighteen inches main LNG lines connected to the

thirty-two inches LNG offloading header of the tank N2 through specific 32-

18 flanges shown on figure 7.

Purge lines: The purge line collector has a four inches diameter and is connected

to the general purge network of the terminal;

Utilities: The dynamic test bench is also connected to fuel gas, nitrogen and

instrument air networks of the terminal.

Figure 7: 32-18 LNG flange connections.

Power systems, equipment and instrumentation.

Independent power supply;

Hydraulic power units;

Hydraulic winches;

Flow-meter;

Surface temperature probes;

Pressure transmitters;

CCTVs (Closed circuit TeleVision);

Gas and fire detection;

Moreover, numerous sensors have been installed on the test bench in order to collect

all the necessary measurements for the qualification.

Control room. To operate the test bench, collect the data and ensure a perfect

coordination with the terminal, a dedicated local control room has been built for the test

bench operators.

Dynamic test bench construction

The main objective during test bench construction was to minimize the impact on the

terminal operations. It has so been decided to declare the whole area dedicated to the test

bench as a closed and independent construction site with access through the terminal

roads. This leads to a different regulation for the construction site, independent from the

safety policy of the terminal and allow handling all the safety and health aspects withoutimpact on the terminal.


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The photos here below (figure 8) show different steps of dynamic test bench

structures construction.

Figure 8: Dynamic test bench structures assembly (from top left to down right).

Figure 9: Dynamic test bench overview during construction.

Dynamic test bench process

The test bench can accept LNG flow in both directions related to two different LNG

circulation modes as described below:

Local control room and power supply

ALLS

Main LNG pipes

LNG purge network

Mobile armLocal control room and power supply

ALLS

Main LNG pipes

LNG purge network

Mobile arm


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UNLOADING SYSTEM

TANK

RV 2

TANK

RV 1

TANK

RV 3

FT1VB59

1VB60

LP DISCHARGE SYSTEM

1VB92

1VP461VB331

PT

PT

TT

TT

TT

TT

ESD1ESD1

ESD2

14"

18"

16"

14"

18"

18"x16"

18"

18"

TO SEND-OUT

SYSTEM

UPSTREAM

BERTH

DOWNSTREAM

BERTH

UNLOADING SYSTEM

TANK

RV 2

TANK

RV 1

TANK

RV 3

FT1VB59

1VB60

LP DISCHARGE SYSTEM

1VB92

1VP461VB331

PT

PT

TT

TT

TT

TT

ESD1ESD1

ESD2

14"

18"

16"

14"

18"

16"

18"

18"

LNG CARRIER

UPSTREAM

BERTH

DOWNSTREAM

BERTH

TO SEND-OUT

SYSTEM

Recirculation mode: The purpose of the recirculation mode is to keep the test

bench in cold condition, in order to allow testing the connection, disconnection

(including ESD and ERS sequences) and purge operations.

Offloading mode: The purpose of the offloading mode is to test the transfer

system with high LNG rates in order to measure pressure drops and flow induced

vibrations. Pressure measurements will allow validating theoretical calculations or

alternatively tuning the parameters used in theoretical calculations.

The process flow diagrams (PFD) corresponding to the circulation modes principle

are given below:

Figure 10: Recirculation mode (top) and offloading mode (down).

According to the test program and operations to be carried out on the dynamic test

bench, specific procedures related to the test bench process and ALLS operability have

been developed. These procedures deal with all the necessary phases to operate ALLS

and are split as detailed here below:

Storage;

Connection;

Cooling down and filling with LNG;

Stand-by in cold conditions;

Purge and disconnection to storage position;


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Emergency disconnection;

Access and handling.

As the qualification activities include some items related to ALLS operability (see

Qualification process HAZID), the procedures should demonstrate their reliability to

operate the system in safe and repeatable conditions.

Dynamic test bench operating condit ions

A dedicated Gaz de France team will operate the test bench from the local control

room in close coordination with the terminal operators to ensure that any tests or actions

do not conduct to an unsafe state for the test bench or the terminal process.

Moreover, both ALLS LNG operators and terminal LNG operators have been trained

on the other team respective installations to guarantee a sufficient knowledge of all the

actors involved during the trials.

Dynamic tests program

The test program has been elaborated according to:

Qualification activities to be performed and witnessed by DNV representative;

Dynamic test objectives;

LNG operators requirements;

LNG standards requirements (OCIMF and EN1474)

The resulting full-scale trials have then been detailed in order to fulfil all the

objectives associated with the test program. The main phases are described here below:

Ambient temperature tests:

o Objectives: demonstrate the ALLS operability for:

Connection/disconnection;

Handling;

Guiding and alignment;

o Test conditions: Static (ship-to-shore base case);

Dynamic (side-by-side and tandem configurations)

With and without torsions

LNG tests;

o Objectives: validate the process operations;

Connection;

Cooling down;

Purge;


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Disconnection;

Storage;

Emergency disconnection;

o Test conditions identical than for ambient temperature tests;

o Specific measurements:

Pressure drops;

Longitudinal and radial thermal gradients;

Vibrations.

Planning

At the time this article is written, the installations described above are at the

commissioning stage, which should end at the early beginning of 2007 and followed by

the test program as given above. A full qualification of ALLS is thus expected in 2007.

DYNAMIC TESTS KEY POINTS

The main operating aspects to be checked during the dynamic qualification trials

regarding the ALLS functional requirements for a future use in operation are:

Overall performances;

Safety;

Operability in term of user-friendliness during handling, connection, purge and

disconnection phases;

Reliability (notably for emergency disconnection in dynamic conditions);

Repeatability of the procedures whatever the conditions (static or dynamic);

Maintenance.

The dynamic tests should answer all the questions and get the LNG industry confident

with the use of ALLS, which intend to be used as well for ship-to-shore or ship-to-ship

LNG transfer (side-by-side and tandem mooring configurations) up to a significant wave

height of 5.5 m. Here below, we will focus on three important aspects: i) purge, ii)

emergency disconnection, iii) maintenance.

Purge

Purging and drainage of the flexible hose before disconnection has been identified as

a failure mode of the transfer system during FEED phase. Therefore, the procedure has to

demonstrate its efficiency according to the basic principles given above.

As the flexible hose is in catenary configuration, gravity will not help to purge the

system. Starting with the assessment and the fact that it will not be possible to guarantee

full purging and inerting due to flexible hose bellows structures a specific procedure has

been developed.


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This particular procedure will be tested few times in static and dynamic conditions

according to the trial program. Its efficiency being a key point for the ALLS qualification,

the test results will be fully analysed by DNV, which will witness the test on site.

Emergency disconnection

The connecting system has been designed for safe and reliable emergency

disconnection with very minimal spillage (less than 2 litres for a 16 transfer system)

thanks to the eccentric tandem butterfly valves geometry of the ERS.

Even if the LNG spillage is a key point for operator safety and to avoid damage to the

carrier, the whole system behaviour during emergency disconnection in dynamic

conditions has to be checked in accordance with the following points:

No mechanical stress appears at the end fittings of the system;

No clash is observed between the structures and the flexible hose;

Speed limiter located on the ERS slows the flexible hose lowering (speed of fall

of 0.5 m/s) until the load is taken back by the handling cable;

No dynamic oscillations appear;

Flexible hose stays in catenary configuration.

Maintenance

Another important aspect for operators is the ability of the system to be easily

inspected or repaired on site without involving huge means, which can be problematic in

offshore conditions.

As the purge procedure philosophy described above does not intend to fully purge and

inert the flexible hose in normal operating conditions, another specific procedure for

maintenance has been developed. Its basic principle is to lay down on the ground (or on a

platform) the end part of the flexible hose with the connecting system and to sweep the

system thanks to dedicated connections linked with the purge network to put the system

in a safe state for inspection, maintenance or connecting system re-assembly after an

emergency disconnection.

Figure 11: Flexible hose end with connecting system on the ground for inspection

(left), flexible hose lift test with cranes (right).


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CONCLUSION

The development of innovative LNG transfer solutions, able to meet the needs for

future coastal weather exposed onshore plants or real offshore installations, is necessary

to support the LNG Industry growth.

The LNG full-scale trials to be performed at the Gaz de France Montoir-de-Bretagne

LNG receiving terminal on the Amplitude-LNG Loading System (ALLS) are the ultimate

stage of this technology qualification. These trials correspond to operating conditions as

close as possible from the ones the system has been designed for in term of performances

and operability.

The results should lead to a full qualification of ALLS and a Statement of Fitness for

Service issued by DNV is expected according to the DNV-RP-A-203 recognized

qualification procedure.

In a more general overview, the ALLS has been designed to have operation thresholdsfor LNG transfer (up to 5.5 m in tandem configuration) always above mooring thresholds,

this offloading system never being thus the limiting factor for the offshore LNG chains.

It has to be said that the developments, certifications and qualification obtained on the

ALLS have been made possible thanks to close partnerships between all the actors

involved all along the LNG chains.

This world first should bring the LNG Industry to be confident with the use of

cryogenic flexible hose based transfer system for the next generation of LNG plants.

REFERENCES CITED

[1]. Key Cryogenic Components for Dynamic Marine LNG Transfer at Sea:

Development and Tests Completed B. Dupont (Eurodim), P. Cox (Technip

France), J.-C Garrigues (KSB-Amri) OTC 15227

[2] Cryogenic Flexible for Offshore LNG Transfer P. Cox (Technip France), J.-M

Gerez (Technip France), J.-P Biaggi (Technip France Genesis) OTC 15400

[3] Innovative Architectures for Transfer at Sea Studied B. Lanquetin (Total), P.-

L Lanteri-Minet (Gaz de France), B. Dupont (Eurodim) OTC 15229

[4] Full Scale Qualification Trials and Certification of the Amplitude-LNG Loading

System P. Cox (Technip France), G. Rombaut (Gaz de France) 23rdWGC

Full-scale Lng Trials of a New Lng Transfer System

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