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PS6-4.1
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
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