World's Largest PC LNG Storage Tank Development and Construction/Research&Develo...

Page 1 of 3

Outline

Aiming to make more efficient use of available land at LNG terminals and to reduce construction costs through economy of scale, Osaka

Gas has exerted efforts in developing large-capacity PC(Prestressed Concrete) tanks as a new type of LNG storage tank with excellent

safety and reliability features.

3
In 1993, Osaka Gas successfully completed construction of the 140,000 m PC LNG storage tank at Senboku LNG Terminal II as the first
3 3
of its kind in Japan. The second 140,000 m tank was completed in 1996, followed by the 180,000 m PC tank in 2000 as the world's
largest aboveground LNG storage tank.

Based on accumulated experiences of the construction of large-capacity storage tanks with the latest design and construction technique to
3
reduce both construction cost and construction period, the newest 180,000 m PC LNG storage tank was completed at our Himeji LNG
Terminal in August 2003.

This report focuses on the development of heavy thickness inner tank material and radiographic inspection technique which made the
3
construction of 180,000 m tank possible, as well as the very latest various techniques for reducing construction cost and shortening
construction period.

Technologies for increasing capacity

Thick inner tank material

9% nickel steel is used for the inner tank because it has superior strength and toughness even at temperatures as low as -160℃.
Since the inner tank wall is thicker at larger tank capacity, we had to produce 9% Ni steel plates that were thicker than anything we
3
had used before. In contrast to the 30 mm thick plates that were used for 80,000 m class tanks, we had to use 40 mm thick plates
3 3
for the 140,000 m tanks and 50 mm thick plates for the 180,000 m tanks. The strength and toughness were enhanced for the
thick 9% Ni steel by introducing the latest technologies in steel production that helped to improve the heat treatment process and

reduce impurities. In the process of commercializing thick 9% Ni steel, a number of strength and toughness tests were performed,
including the low-temperature fracture tests, in order to ensure the material's safety for use in a large-capacity tank.

High-performance radiographic inspection technology for thick wall welds

Radiographic inspection was performed for 9% Ni steel welded joints (50 mm thick) by the most powerful X-ray apparatus with 470
kVp maximum tube voltage. Research was conducted to obtain the best quality image for 50 mm thickness by using this X-ray

equipment. This technology shortened inspection time and improved the quality of inspection.

http://www.osakagas.co.jp/rd/sheet/003e.html 3/3/2009
World's Largest PC LNG Storage Tank Development and Construction/Research&Develo... Page 2 of 3

Technologies for reduction in construction cost and period

High-strength, self-compacting concrete

2
High-strength concrete as 60 N/mm , 1.5 times stronger than conventional concrete was adopted for the prestressed concrete outer
tank wall material, which helped to reduce wall thickness by about 30%. The high powder content of the concrete enables to employ

self-compacting concrete. Accordingly reduction of concrete placing times by means of heightening of concrete placing lot derived

shortening work period. And labor saving conducted elimination of workers for compacting concrete. Design requirements for PC
outer tank concrete include self-compactibility, as well as high-strength and liquid tightness after hardening, and life-long durability.

Accordingly, materials and admixtures were developed along with production, quality control and installation technologies for

concrete placement.

Enlarged shell plates

Expanding width of each inner shell plate from 3.2 meter to 4.3 meter and thus reducing shell plate courses from 11 courses to 8

courses have achieved the decrease in welding work on the inner tank. In employing large size 9% Ni steel plates, it was confirmed

that the uniformity was maintained throughout the plate in the material performance and dimensional accuracy.
Self-elevator scaffold
The outer tank is divided into circular segments and constructed stage by stage in a vertical direction. The conventional construction

method needs large crawler cranes to elevate the large scaffold and formwork divided into 36 segments. In the new construction

method, adoption of hydraulic jacks for the elevation can elevate the entire scaffold and formwork simultaneously. This method
enables to shorten the construction period.
Quality control and assurance system for concrete using Information Technology

Monitoring of manufacturing data such as records of individual material weight, surface water ratio of aggregates and mixer load
value is indispensable because self-compactability of the concrete depends on the during mixing condition. This system enables to

collect the manufacturing information in real time by using internet, self-compactability of the concrete can be adjusted surely and
promptly.

New method for self filling Poly-urethane foam with a simultaneous mesh lining
New method for self filling PUF with a simultaneous mesh lining is adopted for construction of cold resistance relief inside PC outer
tank. In conventional method, after the sprayed PUF was shaved and formed, mesh lining was pasted up. In this method, the

construction of PUF and mesh lining are conducted simultaneously by winding off the rolled mesh lining from bottom of the LNG tank
and injecting PUF between mesh lining and outer tank. In addition to cutting cost and shortening the work period, reduction of
hazardous job on the gondolas in the high and narrow space such as height of 40 m and width of 1.1 m. And improvement of

execrable working condition in the airborne dust, and reduction of most waste are achieved.

Roof structures constructed to the blocks

By the completing the knuckle-plates or roof frames and plates, which were conventionally carried in with the single article, to the

blocks at shop, large shortening of the on-site process has been acquired.

Conclusion

Osaka Gas has conducted a number of studies over the years that eventually led to the development of a safe and reliable world-record
3
capacity 180,000 m PC LNG storage tank. In addition to the advantage of the scale brought about by increasing the tank capacity,
construction costs were significantly reduced by aggressively introducing various new technologies that reduced construction cost and
3 3
period. In terms of the land use, the 180,000 m PC LNG storage tank can be installed in the same space used for a 75,000 m double-
walled metal tank, which is an improvement in land use efficiency of 2.5 times.

Latest technologies for PC LNG tank

http://www.osakagas.co.jp/rd/sheet/003e.html 3/3/2009
World's Largest PC LNG Storage Tank Development and Construction/Research&Develo... Page 3 of 3

Conventional results

PC LNG storage tank proposed by Osaka Gas has been recognized as the tank which achieves High safety, Efficient land use and
Economical construction. 30 units of our PC tanks (including under contemplation) have been adopted inside and outside Japan (as of April
2008). In addition, our PC tank has received the JPCEA* Award for Outstanding Structures and JHPI** Technical Award for our

Development technologies or Capacity-enlargement technologies.

*JPCEA : Japan Prestressed Concrete Engineering Association
**JHPI : High Pressure Institute of Japan

http://www.osakagas.co.jp/rd/sheet/003e.html 3/3/2009