Gravity-Based LNG Complex Assembly for Arctic Ice Conditions
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Solution Overview
Problem
Current methods for constructing hydrocarbon processing plants, such as LNG plants, face challenges in remote and permafrost areas due to lengthy infrastructure development, high costs, and limitations in ice conditions, with existing methods either being costly and time-consuming for pile foundations or restricted by size and weight limitations for floating structures.
Innovation Solution
The method involves fabricating an integrated production complex on a gravity-based structure (GBS) that can withstand ice conditions, allowing for construction at a specialized site with dry docks, using stages of module fabrication, transportation, and integration on a GBS that can float during transport and installation, eliminating the need for special bridges and enhancing maneuverability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pile foundations are used for constructing LNG plants in remote areas, then the plants can be built onshore with stable support, but the infrastructure development period becomes excessively long and costs increase significantly
Solution Approach 1:
The GBS is pre-assembled and prepared at a shipyard before being transported to the installation site. This preliminary construction phase allows the foundation structure to be ready in advance, eliminating the need for on-site infrastructure development and significantly reducing the overall project timeline while maintaining structural reliability
Solution Approach 2:
The GBS serves as an intermediary structure that combines the functions of both onshore stability and offshore deployment. It acts as a pre-fabricated platform that can be transported to remote locations and installed without requiring extensive local infrastructure, thus resolving the contradiction between structural reliability and construction time
2Ease of manufacture
If floating substructures are used for offshore LNG plants, then construction can be done at shipyards with full infrastructure, but the structures cannot operate in locations with heavy ice conditions due to drifting
Solution Approach 1:
The GBS changes its physical state from floating during transport to fixed on the seabed during operation. This parameter change allows the structure to be easily manufactured at shipyards while maintaining positioning stability in ice conditions through gravitational anchoring on the seabed
Solution Approach 2:
The structure transitions dynamically between two states: a floating state during transportation that enables easy manufacturing and deployment, and a fixed state during operation that provides stability in ice conditions. This dynamic adaptability resolves the contradiction between ease of manufacture and operational reliability
3Productivity
If steel floating substructures are used, then the full construction cycle can be completed at shipyards, but construction costs become excessively high
Solution Approach 1:
The GBS uses reinforced concrete as the primary material instead of steel, creating a composite structure that maintains the productivity benefits of shipyard construction while significantly reducing material costs. The concrete structure achieves the required strength and stability without the high costs associated with steel fabrication and installation
4Adaptability or versatility
If remote construction sites are used for LNG plants, then the plants can be located near hydrocarbon sources, but the delivery of construction materials and equipment becomes costly and difficult
Solution Approach 1:
The GBS and associated equipment are pre-assembled at a shipyard with full infrastructure before being transported to the remote installation site. This preliminary preparation eliminates the need for on-site material delivery and infrastructure development, resolving the contradiction between location flexibility and material delivery cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient construction of hydrocarbon processing complexes in Arctic conditions, reducing infrastructure preparation time and costs, and allowing for ice-resistant installations, while improving the mobility and integration of modules without the need for extensive support structures.
Implementation Method 1
a gravity-based structure (GBS) which is able to stay afloat during water transportation to the site of the integrated production complex
Implementation Method 2
a gravity-based structure (GBS) which is able to stay afloat during water transportation to the site of the integrated production complex
Data Source
AI summary
Topside modules are fabricated at a production site using as a foundation for installation a gravity-based structure (GBS), which can stay afloat during water transportation. Modules fabrication includes: Stage I, fabrication of components; Stage II, fabrication of nodes from the components; Stage III, fabrication of sub-assemblies from the nodes; Stage IV, shotblasting and painting of assemblies; and Stage V, assembling modules from the assemblies. Then modules transportation, movement to their seats on the GBS and their integration include: Stage VI, moving the modules to an area near the dock using self-propelled vehicles. Stage VII, moving each module onto guides of a lifting system installed in a dry dock. Stage VIII, lifting each module until lifting system guides are connected with GBS top slab guides. Stage IX, moving each module to its seat on the GBS, installed on the GBS and integrated with other modules and the GBS.