PREFABRICATED PANEL AND WATERTIGHT AND THERMALLY INSULATED TANK

Abstract

A prefabricated panel (1) for the manufacture of a watertight and thermally insulating wall, in which the base plate, the first layer of thermal insulation and the watertight coating have a first rectangular contour while the second layer of thermal insulation has a second rectangular contour of smaller dimensions than the first rectangular contour, so that the second layer of thermal insulation does not cover an edge area (28) of the watertight coating along the four edges of the first rectangular contour, in which the first layer of thermal insulation has two secondary blocks (22), the two secondary blocks being juxtaposed in a width direction of the first rectangular contour and separated by a spacer piece (36),a first composite sheet (23) bonded to the first secondary block having an overhanging portion (15) which extends beyond the first secondary block in the width direction to span the spacer piece and is bonded to a second composite sheet (23) bonded to the second secondary block. Figure to be published: 1,

Description

Title of the invention: PREFABRICATED PANEL AND WATERPROOF AND THERMALLY INSULATED TANK technical field

[0001] The invention relates to the field of leak-proof and thermally insulated membrane tanks. In particular, the invention relates to the field of leak-proof and thermally insulated tanks for the storage and / or transport of liquefied gases at low temperatures, such as tanks for transporting Liquefied Petroleum Gas (also called LPG) at temperatures ranging, for example, from -50°C to 0°C, or for transporting Liquefied Natural Gas (LNG) at approximately -162°C at atmospheric pressure. These tanks can be installed on land or on a floating structure. In the case of a floating structure, the tank can be used for transporting liquefied gas or for receiving liquefied gas to serve as fuel for the propulsion of the floating structure. Technological background

[0002] A generally flat prefabricated panel for manufacturing a watertight and thermally insulating wall is known, notably from document WO2015197638. The prefabricated panel comprises successively a rigid base plate, a first layer of thermal insulation supported by the base plate and forming, with the base plate, a secondary insulating barrier element, a watertight coating that completely covers the first layer of thermal insulation by being bonded to the first layer of thermal insulation and forming a secondary watertight membrane element, a second layer of thermal insulation that covers a central area of ​​the first layer of thermal insulation and the watertight coating, and a cover plate covering the second layer of thermal insulation and forming, with the second layer of thermal insulation, a primary insulating barrier element, wherein the base plate,The first layer of thermal insulation and the waterproof coating of the prefabricated panel have a first rectangular outline, while the second layer of thermal insulation and the cover plate have a second rectangular outline smaller than the first rectangular outline, so that the second layer of thermal insulation and the cover plate do not overlap the edge area of ​​the waterproof coating along all four edges of the first rectangular outline. The thermal insulation layers can be made of glass fiber reinforced polyurethane foam.

[0003] With such prefabricated panels, it is possible to manufacture leak-proof and thermally insulated tanks for the storage and / or transport of liquefied gas at low temperature. For a large volume tank, this requires covering considerable flat surfaces with juxtaposed prefabricated panels.

[0004] The quantity of supply and handling operations required to manufacture such a tank therefore depends on the wall surface area covered by each prefabricated panel. It is thus advantageous to enlarge the prefabricated panel as much as possible to increase the efficiency of the manufacturing operations for a watertight and thermally insulated tank. Summary of the invention

[0005] Certain aspects of the invention stem from the observation that modifying the manufacturing tools for polymer foam blocks is difficult and costly. A key idea of ​​the invention is to provide a large-surface prefabricated panel that can be made with commercially available polymer foam blocks or, at least, whose manufacture does not require significant investment in tooling.

[0006] For this purpose, according to one embodiment, the invention provides a prefabricated panel of the aforementioned in which the first layer of thermal insulation comprises at least two secondary blocks of polymer foam, the at least two secondary blocks being juxtaposed in a width direction of the first rectangular contour and separated by a spacer piece, and in which the waterproof coating comprises a first composite layer bonded to a first of the secondary blocks and a second composite layer bonded to a second of the secondary blocks, the first composite layer having an overhanging portion which extends beyond the first secondary block in the width direction to span the spacer piece and is bonded to the second composite layer.

[0007] Thanks to these characteristics, it is possible to obtain a generally flat prefabricated panel, that is to say, one suitable for covering a flat load-bearing wall, the width of which can reach at least twice the width of a secondary polymer foam block. This panel can be entirely prefabricated in the workshop for installation in a single piece in its final position in order to create a watertight and thermally insulating tank.

[0008] Another advantage of this prefabricated panel is to limit the number of bonding operations carried out directly in the sealed and thermally insulated tank during its construction.

[0009] According to embodiments, such a prefabricated panel may include one or more of the following characteristics.

[0010] According to one embodiment, the spacer piece comprises a fibrous or cellular material compressed between lateral end surfaces of at least two secondary blocks, the lateral end surfaces extending in a length direction from the first rectangular contour.

[0011] According to one embodiment, the spacer piece comprises a strip of glass wool.

[0012] According to one embodiment, the base plate comprises a first base plate element bonded under a first of said secondary blocks, a second base plate element bonded under a second of said secondary blocks and a third base plate element fixed straddling under the first base plate element and under the second base plate element and spanning the spacer piece.

[0013] The third base plate element can be made in different ways.

[0014] According to one embodiment, the third base plate element comprises a rigid plate fixed in a counterbore bordering the first base plate element and the second base plate element.

[0015] According to one embodiment, the third base plate element comprises a composite sheet bonded astride the underside of the first base plate element and the second base plate element

[0016] According to one embodiment, the length and width of the first rectangular contour are greater than or equal to 2 m ± 20 mm. According to another embodiment, the length of the first rectangular contour is greater than or equal to 3 m ± 30 mm. "±" here indicates a dimensional tolerance range. 2 m ± 20 mm therefore defines a range between 1980 mm and 2020 mm.

[0017] According to one embodiment, the first rectangular contour and / or the second rectangular contour is a square.

[0018] The second layer of thermal insulation can be formed of one or more elements.

[0019] According to one embodiment, the second layer of thermal insulation comprises at at least three primary polymer foam blocks, the at least three primary blocks being juxtaposed in the width direction of the first rectangular contour and comprising a first primary block bonded to the first composite layer opposite the first secondary block, a second primary block bonded to the second composite layer and a third primary block fixed to the first composite layer straddling the first secondary block and the second secondary block by crossing the spacer piece, the cover plate comprising cover plate elements fixed respectively to each of said at least three primary blocks.

[0020] According to another embodiment, the second layer of thermal insulation comprises at least two primary polymer foam blocks, the at least two primary blocks being juxtaposed in the width direction of the first rectangular contour and comprising a first primary block bonded to the first composite layer at the level of the first secondary block and on the overhanging portion of the first composite layer, and a second primary block bonded to the second composite layer, the cover plate comprising cover plate elements fixed respectively to each of said at least two primary blocks.

[0021] According to one embodiment, the second layer of thermal insulation comprises a filling piece arranged on the second composite layer between the first primary block and the second primary block.

[0022] Such a filling piece can be made of insulating, fibrous or cellular material, for example glass wool or polymer foam.

[0023] Preferably, each of the first and second primary blocks has relation slots extending in a thickness direction of the second layer of thermal insulation and opening onto a top surface of the second layer of thermal insulation, the cover plate elements fixed on each of the first and second primary blocks having edges aligned with said relaxation slots.

[0024] According to one embodiment, a connecting piece links cover plate elements fixed to the first primary block and cover plate elements fixed to the second primary block to prevent separation between the first and second primary blocks. The connecting piece also ensures the flatness of the cover plate elements of the primary blocks during assembly.

[0025] Such a connecting piece can be made in various ways, for example from metal, wood, or plastic, for example in the form of a bar or a plate. In one embodiment, the connecting piece is temporarily attached during the manufacture of the prefabricated panel and is intended to be removed from the prefabricated panel before its use in a tank wall. In another embodiment, the connecting piece has fixing holes for temporarily attaching the connecting piece to the first and second primary blocks by means of studs or threaded rods. In yet another embodiment, the connecting piece is permanently attached during the manufacture of the prefabricated panel and is intended to remain on the prefabricated panel when it is used in a tank wall.According to one embodiment, the permanently fixed connecting piece is made of plywood or composite material and is housed in a counterbore in the cover plate of the primary blocks.

[0026] According to one embodiment, the base plate is made of plywood or composite material.

[0027] According to one embodiment, the cover plate is made of plywood or composite material.

[0028] According to one embodiment, the polymer foam is a polyurethane foam reinforced with fibers, for example glass fibers.

[0029] According to one embodiment, the cover plate carries metal strips for welding a primary waterproof membrane.

[0030] According to one embodiment, the invention also provides a manufacturing method for manufacturing a generally flat prefabricated panel, the method comprising: providing two prefabricated sub-assemblies, each prefabricated sub-assembly successively comprising a rigid base plate element, a secondary polymer foam block bonded to the base plate, a composite sheet that completely covers the secondary block by being bonded to the secondary block, a primary polymer foam block that covers a central area of ​​the secondary block and the composite sheet and is fixed to the composite sheet, and a cover plate element that covers the primary block and is fixed to the primary block,the base plate element and the secondary block of the prefabricated sub-assembly having a third rectangular contour, while the primary block and the lid plate element have a fourth rectangular contour smaller than the third rectangular contour, such that the primary block and the lid plate element do not cover an edge area of ​​the composite sheet along the four edges of the third rectangular contour, the composite sheet of a first of the prefabricated sub-assemblies having an overhanging portion that extends beyond the secondary block in a width direction of the third rectangular contour, juxtapose the two prefabricated sub-assemblies parallel to each other in the width direction of the third rectangular contour, interposing a spacer piece between the secondary blocks of the two prefabricated sub-assemblies,so that the overhanging portion of the composite sheet of the first prefabricated sub-assembly spans the spacer piece and covers the composite sheet of a second prefabricated sub-assembly, glue the overhanging portion of the composite sheet onto the composite sheet of the second prefabricated sub-assembly, fix a third primary block onto the overhanging portion of the composite sheet between the primary blocks of the two prefabricated sub-assemblies, and fix a third base plate element straddling the base plate elements of the two prefabricated sub-assemblies, the third base plate element spanning the spacer piece.

[0031] The invention also provides a watertight and thermally insulating tank comprising a tank wall fixed to a flat load-bearing wall, the tank wall comprising the aforementioned prefabricated panels juxtaposed parallel to each other, such that the edge area of ​​the watertight lining of a first of the The prefabricated panels are adjacent to the edge zone of the waterproof coating of a second set of prefabricated panels. the tank wall further comprising a sealing strip arranged straddling the edge areas adjacent to the waterproof coatings of the first and second prefabricated panels and bonded in a watertight manner to the waterproof coatings of the first and second prefabricated panels to complete the secondary waterproof membrane between the first and second prefabricated panels, the tank wall further comprising insulating blocks arranged on the sealing strip, an insulating block being placed each time between the second layers of thermal insulation of the first and second prefabricated panels, so as to complete the primary insulating barrier between the first and second prefabricated panels, the insulating block comprising a layer of thermal insulation covered with a rigid plate, so that the rigid plates of the insulating blocks and the cover plates of the first and second prefabricated panels constitute a substantially continuous support surface suitable for supporting a primary waterproof membrane.

[0032] Thanks to prefabricated panels that can have increased dimensions, it is possible to limit handling and gluing operations in the tank and thus increase the efficiency and productivity of the manufacturing operations of such a tank.

[0033] The techniques described above for manufacturing a prefabricated panel or a sealed and thermally insulated tank can be used to manufacture a tank for the storage and / or transport of liquefied gas at low temperature. Such a tank can be part of an onshore storage facility, for example for storing LNG, or be installed in a floating structure, coastal or in deep water, including an LNG carrier, a ship powered by a combustible liquefied gas, a floating storage and regasification unit (FSRU), a floating production and remote storage unit (FPSO), and others.

[0034] According to one embodiment, a ship for the transport of a cold liquid product comprises a double hull and the aforementioned tank disposed in the double hull.

[0035] According to one embodiment, a transfer system for a cold liquid product comprises the aforementioned vessel, insulated pipes arranged to connect the vessel's tank to a floating or land-based storage facility, and a pump to drive a flow of cold liquid product through the insulated pipes from or to the floating or land-based storage facility to or from the vessel's tank.

[0036] According to one embodiment, the invention also provides a method for loading or unloading a ship mentioned above, in which a cold liquid product is conveyed through insulated pipes from or to a floating or land-based storage facility to or from the ship's tank. Brief description of the figures

[0037] The invention will be better understood, and other objects, details, features and advantages thereof will become more apparent from the following description of several particular embodiments of the invention, given solely by way of illustration and not limitation, with reference to the accompanying drawings.

[0038] Fig. 1 represents an exploded plan view of a prefabricated panel according to a first embodiment.

[0039] [Fig.2] is an enlarged view of area II of [Fig.1] in a variant.

[0040] Fig. 3 is a top view of the prefabricated panel of Fig. 1.

[0041] Figure 4 is a partial perspective view of the prefabricated panel of Figure 1. from above, during a step of gluing a joining block.

[0042] Fig. 5 is a view analogous to Fig. 3, further showing a handling tool assembled to the prefabricated panel.

[0043] The [Fig.6] is a cross-sectional view along line VLVI of the [Fig.5].

[0044] Figure 7 is a view analogous to Figure 1, showing a second mode of production of the prefabricated panel.

[0045] Fig. 8 is a schematic cutaway representation of a methane tanker comprising a ship tank and a terminal for loading / unloading this tank. Description of the implementation methods

[0046] With reference to figures 1 to 7, we will now describe a prefabricated panel 1 or 101 which can be manufactured in large dimensions and which can be used in a sealed and thermally insulating tank wall.

[0047] With reference to Figures 1 to 4, the prefabricated panel 1 is substantially rectangular in shape and comprises a base plate 3, for example made of 9 to 15 mm thick plywood, surmounted by a first layer of thermal insulation 4, itself surmounted by a waterproof coating 6 made of composite material. The waterproof coating 6 is bonded to the first layer of thermal insulation 4.

[0048] A second layer of thermal insulation 7 is bonded to the waterproof coating 6 and itself supports a cover plate 8, for example, made of 12 to 15 mm thick plywood. Subassembly 3-4 constitutes the secondary insulating barrier element. Subassembly 7-8 constitutes the primary insulating barrier element and, as shown in [Fig. 3], has a rectangular shape with sides parallel to those of the secondary insulating barrier element. In plan view, the two insulating barrier elements are rectangular with the same center. The primary insulating barrier element leaves a peripheral edge surface exposed. 28 of the waterproof coating 6 all around the primary insulating barrier element. The waterproof coating 6 constitutes the secondary waterproof membrane element.

[0049] The first layer of thermal insulation 4 is here formed of two secondary blocks 22, having the shape of rectangular parallelepipeds, which are juxtaposed in the width direction by interposing a spacer piece 36 between their lateral surfaces 27.

[0050] The base plate 3 is here formed in three parts: two base plate elements 21 extend respectively under the two secondary blocks 22 from the lateral end surfaces of the prefabricated panel 1 towards the center and stop at a distance from the lateral surfaces 27 ([Fig. 1]) or extend to the lateral surfaces 27 ([Fig. 2]), each having a counterbore 35 at the end adjacent to the lateral surface 27. A connecting plate 5 is placed under the two secondary blocks 22 between the two base plate elements 21 ([Fig. 1]) or in the counterbores 35 ([Fig. 2]) and spans the lateral surfaces 27 and the spacer piece 36. The counterbores 35 extend in the width direction to a dimension adapted to receive the connecting plate 5. The depth of the counterbores 35 is like the thickness of the plate The connection length 5 is, for example, 5 mm.

[0051] The waterproof coating 6 is here formed in two parts: two rigid composite sheets 23 cover respectively the two secondary blocks 22. One of the two rigid composite sheets 23 (on the left in [Fig.1]) has an overhanging portion 15 which is glued overlapping onto the other rigid composite sheet 23 and spans the lateral surfaces 27 and the spacer piece 36.

[0052] The second layer of thermal insulation 7 is here formed in three parts: two primary blocks 24 respectively cover a central area of ​​the two secondary blocks 22 and of the two rigid composite sheets 23, while leaving the peripheral edge surface 28 exposed. A primary connecting block 17, of the same thickness as the two primary blocks 24, is placed on the rigid composite sheet 23 which has the overhanging portion 15 and fills the space between the two primary blocks 24. Relaxation slots 26 are formed in the primary blocks 24 and optionally in the primary connecting block 17, and pass through all or part of the thickness of the second layer of thermal insulation 7.

[0053] The cover plate 8 is formed of a multitude of cover plate elements 25 arranged on the two primary blocks 24 and of one or more cover plate elements 18 arranged on the primary connecting block 17. The contours of the cover plate elements 25 follow the relaxation slots 26.

[0054] As seen in [Fig.3], metal strips 29 are fixed to the cover plate elements 18 and 25 at locations that correspond to the contours of the metal plates (not shown) to form a primary sealing membrane.

[0055] Fig. 1 is a plan view which does not imply the dimensions of the elements in the length direction of the prefabricated panel 1. In the length direction, visible in Fig. 3, each of the secondary blocks 22 preferably extends in a single piece along the entire length of the prefabricated panel 1, in order to promote its rigidity. Similarly, the rigid composite sheets 23 preferably extend in a single piece along the entire length of the prefabricated panel 1, in order to promote sealing.

[0056] However, in one variant, particularly to increase the length of the prefabricated panel 1, several secondary blocks 22 can be arranged end to end also in the lengthwise direction, in addition to the divisions made in the widthwise direction. The same applies to other elements described above: base plate elements 21, connecting plate 5, primary blocks 24, primary connecting block 17, spacer piece 36.

[0057] To ensure the fixing of the prefabricated panel 1 on a supporting structure (not shown), wells 30 are provided, regularly distributed on the two longitudinal edges of the prefabricated panel 1, to receive dowels fixed on the supporting structure according to the known technique.

[0058] The prefabricated panel 1, which has just been described, can be prefabricated to form an assembly whose various components are bonded together in the arrangement indicated above. The thermal insulation layers 4 and 7 can be made of a cellular plastic material such as polyurethane foam. Preferably, glass fibers are embedded in the polyurethane foam to reinforce it. The density of the polyurethane foam is, for example, between 50 and 250 kg / m³, preferably between 90 and 170 kg / m³.

[0059] A particularly effective technique for manufacturing the prefabricated panel Method 1 consists of manufacturing two subassemblies, 2 and 12, and then assembling them with the interposition of the spacer piece 36. More specifically, each of the two subassemblies, 2 and 12, comprises a secondary block 22, a base plate element 21, a rigid composite sheet 23, a primary block 24, and cover plate elements 25. It will be noted that subassembly 2 or 12 is very similar to a prefabricated panel of the prior art and can therefore be manufactured efficiently using proven methods. However, subassembly 2 or 12 differs from the prefabricated panel of the prior art in the following ways: - the absence of wells 30 along the lateral surfaces 27, intended to be located in the middle of the prefabricated panel 1, - and the interruption of the base plate elements 21 at a distance from the lateral surfaces 27 ([Fig.1]) or the presence of the counterbores 35 ([Fig.2]).

[0060] Furthermore, subassembly 12 differs from subassembly 2 in that the rigid composite sheet 23 has the overhanging portion 15 which protrudes from the secondary block 22 on the side intended to be in the middle of the prefabricated panel 1.

[0061] The assembly of the two sub-assemblies 2 and 12 can be carried out by the following steps: - juxtaposition of the two secondary blocks 22 with interposition of the spacer piece 36 between the lateral surfaces 27, - fixing the connecting plate 5 under the two secondary blocks 22, for example by stapling, screwing and / or gluing, - bonding of the overlapping portion 15 onto the other rigid composite sheet 23, - bonding of a joining block 10 onto the rigid composite sheet 23 and its overhanging portion 15, the joining block 10 including the primary connecting block 17 and the cover plate elements 18.

[0062] The connecting plate 5 prevents the two subassemblies 2 and 12 from separating during the bonding steps and during the handling of the prefabricated panel. It can be retained at least until the adhesive used has completely dried or polymerized, after which it can be removed, but it is preferably retained for the entire service life of the prefabricated panel.

[0063] Certain steps can be carried out in a different order. For example, the installation of the connecting plate 5 can take place after the overhanging portion 15 has been glued.

[0064] As shown in [Fig. 4], connecting bars 40 or other similar connecting elements can be used to temporarily or permanently join the two subassemblies 2 and 12 from above during the bonding steps. The connecting bars 40 have two ends attached respectively to cover plate elements 25 of the two subassemblies 2 and 12, spanning the gap between the primary blocks 24. The connecting bars 40 have holes for attaching them to the two subassemblies 2 and 12. This attachment can be achieved using studs or threaded rods with nuts.

[0065] For gluing the overhanging portion 15, a pneumatic press (not shown) can be housed under the connecting bars 40 as described for example in KR20050015840A.

[0066] Fig. 4 represents the bonding of the joining blocks 10 in the space between the primary blocks 24. The connecting bars 40 prevent mutual separation of the two sub-assemblies 2 and 12 during this step and can be kept until complete drying or complete polymerization of the glue used, after which they can be removed.

[0067] In an alternative (not shown) variant, the connecting bars 40 are replaced by connecting plates housed in counterbores of the cover plate elements 25 to avoid any added thickness. Such connecting plates can remain permanently in the prefabricated panel 1. These connecting plates can have the same characteristics as the connecting plate 5.

[0068] The prefabricated panel 1 can be manufactured in large dimensions, for example 2m wide by 2m long or 2m wide by 3m long. To mount the prefabricated panel 1 in the tank's supporting structure, it is preferable to use a rigid mounting tool.

[0069] A suitable mounting tool, assembled to a load-bearing wall 31, is shown in Figures 5 and 6. The mounting tool is, for example, made of steel or wood. It comprises an upper structure 33 forming a lattice resting on the cover plate 8 and fixing rods 32, fixed to studs 39 fixed to the load-bearing wall 31 and engaged in the wells 30 and in holes provided in the upper structure 33. The fixing rods 32 allow the prefabricated panel 1 to be clamped between the load-bearing wall 31 and the upper structure 33, for example by means of nuts not shown, in order to allow the compression of sealant strips interposed between the bottom plate 21 and the wall of the tank 31, without subjecting the prefabricated panel 1 to bending stresses.

[0070] In [Fig. 5], the upper grid 33 has three bars extending lengthwise and four bars extending widthwise. Other geometries are of course possible.

[0071] To handle the prefabricated panel 1 without damaging it through excessive bending, it is also preferable to use a rigid handling tool. The lattice-shaped upper structure 33 can provide a suitable handling tool. For this purpose, the upper structure 33 is fixed to the cover plate 8 by means of studs or threaded rods with nuts. These threaded rods can, in particular, cooperate with oblong holes provided in the upper structure 33 and with threaded inserts 38 provided for this purpose on the cover plate elements 25.

[0072] Fig. 7 shows a prefabricated panel 101 according to a second embodiment, in which the geometry of one of the two primary blocks is modified, in that the primary block 124 extends towards the middle of the prefabricated panel 101, covering entirely or partially the overhanging portion 115 of the rigid composite sheet 23.

[0073] Like the prefabricated panel 1, the prefabricated panel 101 can be manufactured by assembling two subassemblies 2 and 112 having respectively the primary block 24 and the primary block 124. The assembly steps are unchanged, except for the presence of the primary block 124 above the overhanging portion 115, and the fact that the block of connection 10 has a reduced dimension and is glued only on the rigid composite sheet 23 next to the overhanging portion 115.

[0074] In an unrepresented variant, the block 124 above the overhanging portion 115 extends to the primary block 24 of the subset 2, i.e. it is not necessary to provide the connecting block 10.

[0075] To manufacture a watertight and thermally insulating tank wall, the prefabricated panel 1 or 101 can be used in the same way as the prefabricated panels of the prior art. See, for example, WO2015197638. Thanks to the increased dimensions of the prefabricated panel 1 or 101, a tank can be manufactured with fewer panels than in the prior art, for the same capacity.

[0076] Preferably, the width of the prefabricated panel 1 or 101 is chosen to be equal to the combined width of two prior art prefabricated panels and the gap usually left between the two prior art prefabricated panels. Thanks to this choice, the prefabricated panel 1 or 101 can occupy, in the watertight and thermally insulated tank wall, exactly the space that was previously occupied by two prior art prefabricated panels. This choice considerably reduces the need to modify the design of the other elements of the tank wall. In particular, it will not be necessary to change the position of the studs on the load-bearing wall, but only to remove every other row.

[0077] A simple way to obtain the above dimensioning is to choose a spacer piece 36 whose width is equal to the width of the usual gap, and to keep the known width for the secondary blocks 22. The spacer piece 36 can be made of glass wool, polymer foam or have the structure of an inter-panel joint, for example described in WO2019155157.

[0078] The dimensioning described above with a multiple of 2 can also be achieved with a larger integer multiple, for example 3 or 4. In other words, the prefabricated panel 1 or 101 could occupy, in the sealed and thermally insulated tank wall, exactly the space previously occupied by three or four prefabricated panels of the prior art. However, enlarging the prefabricated panel increases its weight and may therefore generate new requirements for handling equipment. The multiple 2 thus offers an attractive compromise between increased efficiency on the one hand and compatibility with available handling equipment on the other.

[0079] In an unshown variant, the secondary block 22 and the rigid composite sheet 23 which receive the overhanging portion 15 or 115 can be extended towards the middle of the prefabricated panel 1 or 101, to provide a larger surface area bonding to the overhanging portion 15 or 115. This widening can be compensated by a corresponding thinning of the spacer piece 36.

[0080] The primary waterproof membrane is shown only in [Fig. 8]. It can be made with corrugated metal sheets or by any other known technique. Preferably, the prefabricated panel 1 or 101 is designed, particularly in its dimensions and the positioning of the metal strips 69, so that it allows the use of corrugated metal sheets of the prior art. Thus, the manufacturing and installation operations of the primary waterproof membrane are virtually unchanged.

[0081] Dimensional example 1 below refers to [Fig. 1]. Dimensional example 2 below refers to [Fig. 7].

[0082] Dimensional example 1 (in mm)

[0083] Width of prefabricated panel 1: 2010

[0084] Length of prefabricated panel 1: 2010

[0085] Width of secondary block 22: 990

[0086] Width of the spacer piece 36: 30

[0087] Width of primary block 24: 680

[0088] Width of the connecting block 10: 340

[0089] Length of primary block 24 and connecting block 10: 1700

[0090] Dimensional example _ 2 (in mm)

[0091] Width of primary block 124: 920-1020

[0092] Width of the joining block 10: 0 - 100

[0093] The following dimensional tolerances can be applied: for values ​​less than 1200 mm the tolerance is ± 10 mm, for values ​​close to 2000 mm the tolerance is ± 20 mm and for values ​​close to 3000 mm the tolerance is ± 30 mm.

[0094] With reference to [Fig.8], a cutaway view of a vessel 70, which is here a methane tanker, shows a sealed and thermally insulating tank 71 of generally prismatic shape mounted in the double hull 72 of the vessel 70. The wall of the tank 71 comprises a primary sealed membrane intended to be in contact with the LNG contained in the tank, a secondary sealed membrane arranged between the primary sealed membrane and the double hull 72 of the vessel 70, and two thermally insulating barriers arranged respectively between the primary sealed membrane and the secondary sealed membrane and between the secondary sealed membrane and the double hull 72.

[0095] In a manner known per se, loading / unloading pipelines 73 arranged on the upper deck of the ship can be connected, by means of suitable connectors, to a marine or port terminal to transfer a cargo of LNG from or to the tank 71.

[0096] Figure 8 shows an example of a marine terminal comprising a loading and unloading berth 75, a subsea pipeline 76, and an onshore installation 77. The loading and unloading berth 75 is a fixed offshore installation comprising a movable arm 74 and a tower 78 that supports the movable arm 74. The movable arm 74 carries a bundle of insulated flexible pipes 79 that can be connected to the loading / unloading pipelines 73. The steerable movable arm 74 adapts to all LNG carrier sizes. An unshown connecting pipeline extends inside tower 78. The loading and unloading station 75 allows the ship 70 to be loaded and unloaded from or to the onshore facility 77. This facility includes liquefied gas storage tanks 80 and connecting pipelines 81 linked by the subsea pipeline 76 to the loading or unloading station 75.The subsea pipeline 76 allows the transfer of liquefied gas between the loading or unloading station 75 and the onshore installation 77 over a long distance, for example 5 km, which allows the ship 70 to be kept a long distance from the coast during loading and unloading operations.

[0097] To generate the pressure necessary for the transfer of the liquefied gas, pumps on board the ship 70 and / or pumps equipping the land installation 77 and / or pumps equipping the loading and unloading station 75 are used.

[0098] Although the invention has been described in connection with several particular embodiments, it is clearly evident that it is by no means limited to them and that it includes all technical equivalents of the means described as well as their combinations if these fall within the scope of the invention.

[0099] The use of the verb "comprise", "comprendre" or "include" and its conjugated forms does not exclude the presence of other elements or other steps than those stated in a claim.

[0100] In claims, any reference sign in parentheses shall not be interpreted as a limitation of the claim.

Claims

1.

2. Demands Prefabricated panel (1, 101) for the manufacture of a watertight and thermally insulating wall, the prefabricated panel being generally flat and comprising successively a rigid base plate, a first layer of thermal insulation supported by the base plate and constituting with the base plate a secondary insulating barrier element, a watertight coating which completely covers the first layer of thermal insulation by being bonded to the first layer of thermal insulation and which forms a secondary watertight membrane element, a second layer of thermal insulation which covers a central area of ​​the first layer of thermal insulation and the watertight coating, and a cover plate covering the second layer of thermal insulation and constituting with the second layer of thermal insulation a primary insulating barrier element, in which the base plate,the first layer of thermal insulation and the waterproof coating of the prefabricated panel have a first rectangular contour while the second layer of thermal insulation and the cover plate have a second rectangular contour of smaller dimensions than the first rectangular contour, so that the second layer of thermal insulation and the cover plate do not cover an edge area (28) of the waterproof coating along the four edges of the first rectangular contour, in which the first layer of thermal insulation has at least two secondary blocks (22) of polymer foam, the at least two secondary blocks being juxtaposed in a width direction of the first rectangular contour and separated by a spacer piece (36),and wherein the waterproof coating comprises a first composite layer (23) bonded to a first of the secondary blocks (22) and a second composite layer (23) bonded to a second of the secondary blocks (22), the first composite layer (23) having an overhanging portion (15, 115) which extends beyond the first secondary block in the width direction to span the spacer piece and is bonded to the second composite layer (23). Prefabricated panel according to claim 1, wherein the spacer piece (36) comprises a fibrous or cellular material, compressed between lateral end surfaces (27) of at least two secondary blocks, the lateral end surfaces extending in a length direction of the first rectangular contour.

3. Prefabricated panel according to claim 2, wherein the spacer piece (36) comprises a glass wool strip.

4. Prefabricated panel according to any one of claims 1 to 3, wherein the base plate comprises a first base plate element (21) bonded under a first of said secondary blocks (22), a second base plate element (21) bonded under a second of said secondary blocks (22) and a third base plate element (5) fixed straddling under the first base plate element and under the second base plate element and spanning the spacer piece.

5. Prefabricated panel according to claim 4, wherein the third base plate element (5) comprises a rigid plate fixed in a counterbore (35) bordering the first base plate element and the second base plate element.

6. Prefabricated panel according to claim 4, wherein the third base plate element (5) has a composite sheet glued astride the first base plate element and the second base plate element.

7. Prefabricated panel according to any one of claims 1 to 6, wherein the second layer of thermal insulation comprises at least three primary polymer foam blocks, the at least three primary blocks being juxtaposed in the width direction of the first rectangular contour and comprising a first primary block (24) bonded to the first composite layer opposite the first secondary block (22), a second primary block (24) bonded to the second composite layer and a third primary block (10) fixed to the first composite layer straddling the first secondary block and the second secondary block by crossing the spacer piece (36), the cover plate comprising cover plate elements (25) fixed respectively to each of said at least three primary blocks.

8. A prefabricated panel according to any one of claims 1 to 6, wherein the second layer of thermal insulation comprises at least two primary polymer foam blocks, the at least two primary blocks being juxtaposed in the width direction of the first rectangular contour and comprising a first primary block (124) glued to the first composite layer at the right of the first secondary block (22) and on the overhanging portion (115) of the first composite layer, and a second primary block (24) glued to the second composite layer, the cover plate comprising cover plate elements (25) fixed respectively on each of said at least two primary blocks.

9. Prefabricated panel according to claim 8, wherein the second layer of thermal insulation comprises a filler piece (10) arranged on the second composite layer between the first primary block (124) and the second primary block (24).

10. Prefabricated panel according to any one of claims 7 to 9, wherein each of the first and second primary blocks (24, 124) has relation slots (26) extending in a thickness direction of the second layer of thermal insulation and opening onto an upper surface of the second layer of thermal insulation, the cover plate elements (25) fixed on each of the first and second primary blocks having edges aligned with said relaxation slots (26).

11. Prefabricated panel according to any one of claims 7 to 10, wherein a connecting piece (40) links cover plate elements (25) fixed to the first primary block (24) and cover plate elements (25) fixed to the second primary block (24) to prevent a separation movement between the first primary block (24) and the second primary block (24).

12. A watertight and thermally insulating tank (71) comprising a tank wall fixed to a flat load-bearing wall, the tank wall comprising prefabricated panels (1, 101) according to any one of claims 1 to 11 juxtaposed parallel to each other, such that the edge area of ​​the watertight coating of a first of the prefabricated panels is adjacent to the edge area of ​​the watertight coating of a second of the prefabricated panels, the tank wall further comprising a sealing strip arranged straddling the adjacent edge areas of the watertight coatings of the first and second prefabricated panels and bonded in a watertight manner to the watertight coatings of the first and second prefabricated panels to complete the secondary watertight membrane between the first and second prefabricated panels, the tank wall further comprising insulating blocks arranged on the sealing strip, an insulating block being placed each time between the second layers of thermal insulation of the first and second prefabricated panels, so as to complete the primary insulating barrier between the first and second prefabricated panels, the insulating block comprising a layer of thermal insulation covered with a rigid plate, so that the rigid plates of the insulating blocks and the cover plates of the first and second prefabricated panels constitute a substantially continuous support surface suitable for supporting a primary waterproof membrane.

13. Vessel (70) for the transport of a cold liquid product, the vessel comprising a double hull (72) and a tank (71) according to claim 12 disposed in the double hull.

14. Transfer system for a cold liquid product, the system comprising a vessel (70) according to claim 13, insulated pipes (73, 79, 76, 81) arranged to connect the vessel's tank (71) to a floating or land-based storage facility (77) and a pump to drive a flow of cold liquid product through the insulated pipes from or to the floating or land-based storage facility to or from the vessel's tank.

15. A method of loading or unloading a ship (70) according to claim 13, wherein a cold liquid product is conveyed through insulated pipes (73, 79, 76, 81) from or to a floating or land-based storage facility (77) to or from the ship's tank (71).

16. A manufacturing method for producing a generally flat prefabricated panel, the method comprising: providing two prefabricated subassemblies (2, 12), each prefabricated subassembly successively comprising a rigid base plate element (21), a secondary block (22) of polymer foam bonded to the base plate, a composite sheet (23) that completely covers the secondary block by being bonded to the secondary block, a primary block (24) of polymer foam that covers a central area of ​​the secondary block and the composite sheet and is fixed to the composite sheet, and a cover plate element (25) that covers the primary block and is fixed to the primary block, the base plate element (21), and the secondary block (22) of the prefabricated sub-assembly having a third rectangular contour while the primary block (24) and the cover plate element (25) have a fourth rectangular contour of smaller dimensions than the third rectangular contour, so that the primary block and the cover plate element do not cover an edge area (28) of the composite sheet along the four edges of the third rectangular contour, the composite sheet (23) of a first of the prefabricated sub-assemblies having an overhanging portion (15) which overhangs the secondary block in a width direction of the third rectangular contour, juxtapose the two prefabricated sub-assemblies (2, 12) parallel to each other in the width direction of the third rectangular contour, interposing a spacer piece (36) between the secondary blocks (22) of the two prefabricated sub-assemblies, so that the overhanging portion (15) of the composite sheet of the first prefabricated sub-assembly (12) spans the spacer piece and covers the composite sheet (23) of a second of the prefabricated sub-assemblies, glue the overhanging portion (15) of the composite sheet onto the composite sheet (23) of the second prefabricated sub-assembly (2), fix a third primary block (10) onto the overhanging portion (15) of the composite sheet between the primary blocks (24) of the two prefabricated sub-assemblies, and fix a third base plate element (5) straddling under the base plate elements of the two prefabricated subassemblies (2, 12), the third base plate element spanning the spacer piece (36).

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