LNG Regasification Safety

Safety in LNG Regasification
SAFETY IN LNG REGASIFICATION

Presented By y
Man Mohan Ahuja

SR. Vice President (Technical), Petronet LNG Limited E-mail: ahujamm@petronetlng.com
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12th Aug, 10
Petrofed Seminar on Safety in Hydrocarbon Sector
SAFETY & ENVIRONMENT PROTECTION IN OIL & GAS INDUSTRY

A strong concern since the beginning as Oil&gas are considered as hazardous products. Nevertheless major accidents have occured: Mexico (LPG), Lyon (France, Raffinery), Sea pollution after various Oil Tankers accidents, IOC St Storage T Terminal i l Fire Fi (Jaipur) (J i )
I t International ti l regulations: l ti OMI OMI, SIGTTO SIGTTO, etc... t
National N ti l regulations: (like OISD in India)
Oil & Gas companies policies

12th Aug, 10
Insurance I requirements
SAFETY REQUIREMENTS IN LNG INDUSTRY

Since accident in Cleveland (USA) in 1942, 1942 LNG has been considered as Hazardous product, various regulations have been developped: Transport by sea: IMO rules, rules SIGTTO recommendations, OCIMF rules, Classification , Insurances requirements. Plants & Storages: g NFPA 59 A (USA) 49 CFR part 193 (USA) EN 1473 (Europe) J G A Rules
National regulations, safety and regulatory bodies, Environment protection bodies & Associations.
12th Aug, 10
Companies Policies, Engg. Standards
SAFETY REQUIREMENTS IN LNG INDUSTRY

S e y and Safety de environment v o e protection p o ec o are e considered co s de ed since s ce preliminary p e y design des g studies. Codes and regulations mainly provide: Design criterias: Seismic design design, impounding systems, etc... Minimum safety distances: considering accident scenarios and consequences: vapour clouds, fire radiation, Cold explosion, etc,...
Hazardous areas classification: fire-proof eq ipment Electric & instrumentation equipment, instr mentation equipment classification
12th Aug, 10
Design & construction rules: y systems, y , Min. Min. safety protection, Fabrication, construction and control stds.
SAFETY REQUIREMENTS IN LNG INDUSTRY Physical properties Liquefied Natural gas: Colourless liquid, Mainly CH4 (>80%), Cold: temperature -160C, Density at 1 bar 450 kg/m3 Vapour V of f LNG LNG: Odourless and colourless, Density at 1 bar and 20C 0.8 0 8 kg/m3 Flamability limits LFL: 5%, UFL:15% Vapourization of LNG 1 m3 LNG 600 m3 of gas at 20C
12th Aug, 10
Wh t is What i LNG ?
LNG in storage tank is violently boiling liquid
Properties of LNG
Properties of LNG that have safety implications include autoignition temperature, temperature Low temperature, temperature heat of vaporization, vaporization flammability limits, heat transfer rate of boiling liquid and specific gravity
The average auto-ignition auto ignition temperature for pure methane at

atmospheric pressure is 537oC, which is quite high
The lower and upper flammability limit of methane in air is 5% &

15% by b volume ol me respectively. respecti el
In a closed tank, the percentage of methane is 100%, thus it

cannot ignite.
Methane leaking from a tank in a well ventilated area is likely to

rapidly dissipate to less than 5% , thus it is relatively safer as compared to other fuels
LNG FILIM
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12th Aug, 10
Properties of LNG
The most of Hazardous properties of LNG are due to
extreme low temperatures
The only danger from skin contact with LNG is freezing;

there are no poisonous or toxic effects.
Tissue Ti d damage f from extreme t cold ld is i similar i il to t damage d

from extreme heat.
Unlike heat burns, burns a cryogenic burn victim will not feel
pain until the injured part has begun to thaw.
If the skin has surface moisture on it, , contact with cold objects will result in freezing of the skin to the objects. Flesh will be torn when the victim tries to remove the affected area from cold surface
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12th Aug, 10
PROPERTIES OF LNG REACTION ON WATER

Un like other liquid petroleum products LNG reacts vigorously with water and vapourizes very fast (leaving nothing behind) posing minimum risk for the marine life
RPT
However LNG reacts violently with water and may cause explosion due to RPT
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12th Aug, 10
LNG PROPERTIES
LNG VAPOUR CLOUD DISPERSION
Cloud heigth
Continuous release e ease

Subsidence Passive By gravity dispersion
Wind i d direction di i
X
LNG CLOUD DISPERSION TEST
Cloud radius
Wind direction
Instantaneous release
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12th Aug, 10
LNG PROPERTIES
HEAVY GAS CLOUD DISPERSION FC TANKS
Molar r concentra ation
1.2 1 0.8 0.6 04 0.4
0.2 0 0 20 40
Distance (m)
60
80
100
120
Calculation tools : Integral Model : EVANUM 3D: MERCURE HEAVY 3D: GAS
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12th Aug, 10
Example of vapors dispersion
12th Aug, 10
Example of LNG vaporization
12th Aug, 10
Example of LNG pool fire
12th Aug, 10
LNG RECEIVING TERMINAL
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12th Aug, 10
LNG TERMINAL DAHEJ

AIR HEATER Metering
GW PUMP STV
WATER PUMP
SCV
BOG COMP.
HW PUMP
UNLOADING/ VAPOR RETURN ARMS
SHIP
12th Aug, 10
LP PUMP LNG TANK
R E C O N D E N S O R
GTG
HP PUMP
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DESIGN HELP - SPECIAL CODES & STANDARDS A SAFE & SMOOTHLY OPERATING FACILITY CAN BE GENERALLY ENSURED, ENSURED IF THE APPLICABLE CODES & STANDARDS ARE FOLLOWED IN TRUE SENSE. Some of the special codes followed for LNG terminals are National Fire Protection Association ( NFPA-59 A ) British Standard ( BS 7777 ) European Committee for Standardization ( EN 1473 ) : OCIMF (Oil Companies International Marine Forum): SIGTTO (Society International Gas Tanker & Terminal Operators): OISD STDS 116, 118 & 194
12th Aug, 10
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ISO ACCREDITATION
Certified by DNV on 21st Jan-05
ISO 9001: 2001 QMS ISO 14001: 1996 EMS OSHAS 18001: 1999
12th Aug, 10
IDENTIFICATION OF RISKS
External Origin
Natural Risks (Earthquakes, flooding, wind, typhoons and lighting) Non Natural Risks (from other industry, Marine traffic, Aircraft crash)
Internal Origin
Release of LNG
o Release from tanker, Spill from un-loading arms o Failure of transfer line, line Inner / outer tank failure o Overfilling of storage tanks, Send out pump failure
Release of NG
o Tank safety valves, Vapouriser safety valves, Flare stack

Process upsets like equipment failure, utility failure, roll over are not included as these are covered under ESD system
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12th Aug, 10
Two phase releases

Phenomena in case of LNG release Fraction of LNG will flash (vapors) A fraction of liquid stays in suspension (aerosol) The other part of liquid falls on the ground(rainout) Proportions depend of jet characteristics (pressure, temperature, leak size, release height) Different types of releases Low p pressure Liquid q release High pressure Gas release
12th Aug, 10
LNG leaks: main parameters

Release Characteristics Upstream Conditions Pressure, flow rate Thermodynamic state of LNG Pressure Temperature Overheated or not
12th Aug, 10
Example of LNG release
12th Aug, 10
RISK / HAZARD CONTROL

M Measures to t avoid id the th cause of f release l Measures to reduce the consequence of a release. LNG Spill Action Plan
Prevent spill Detect spill, if it happens Keep the spill volume minimum Control the Vapours Detect the fire quickly, if it happens Control the fire immediately, if it is detected Protect the other facilities Extinguish the fire
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12th Aug, 10
FACILITIES : UNLOADING ARMS

Unloading Arms designed following OCIMF guidelines, which i ensures compatibility i i i with i most of the ships & safe operation One of the significant feature is installation of PERC
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12th Aug, 10
Un-loading Arm During Testing
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12th Aug, 10
PERC REACTIVATION DURING TESTING
BACK
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12th Aug, 10
FACILITIES : LNG TANKS
Two nos. 160,000 m3 capacity Type: Full Containment Design codes: BS 7777, API 620, EN 1473, NFPA 59A Dia: 81 m; ; Height g 55 m
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12th Aug, 10
LNG STORAGES TANK-PLL

BOG pipe Concrete roof
Roof insulation (glass wool) Suspended deck
Insulation (Perlite)
LNG filling pipes Prestressed concrete outer shell Inner Tank 9% Nickel Steel Low pressure submerged pump (removable)
Resilient blancket Bottom insulation (foam glass) Cryogenic Liner Concrete slab Air heating
Full containment above ground LNG Tank Boil Off rate: 0.08% capacity/day
Piles
Ground level 27
12th Aug, 10
TANK SAFETY
Results of Consequence Modeling
Single g Heat flux due to LNG Fire At Luvara At GCPTCL Acceptable (0.9 Kw/m2) Acceptable (1.2 Kw/m2 ) Containment Type Double Acceptable ( nil ) Acceptable (0.1 Kw/m2) Remarks Full NFPA 59 A Criteria is 5 KW/m2 Flux causing structural damage estimate is 25 Kw/m2 Minimum distance to property line No affect outside plant No affect outside plant
5 Kw/m2 distance 3 Kw/m2 distance Hazardous Vapour Cloud Spread
700 m 1200 m
300 m 700 m
77 m 88 m Acceptable (57 m)
Unacceptable Unacceptable (2500 m to (1100 m to 5600 m) 1200 m)
LEL not to spread outside battery limit
*** PLL has selected fully contained tanks to ensure MAXIMUM SAFETY
12th Aug, 10
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LNG Regasification g
For ORVs Sea water characteristics not t acceptable t bl For SCVs high operating cost & high exhaust gas mission
Open p Rack Vapourizer (ORV)
Submerged Combustion Vapourizer (SCV)

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12th Aug, 10
LNG REGASIFICATION
RLNG Air Heater
GW Pump
Water Collection
STV
Water to different users Water Pump
Glycol Water Circulation

12th Aug, 10
LNG 30
FACILITIES : AIR HEATERS & STVs
7 STVs / Air Heaters with 112 fans-16.4 MW each Close loop system with no exhaust Only ambient air heat No external firing Most environment friendly system
STV
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12th Aug, 10
SAFETY ISSUES
PROJECT IMPLEMENTATION
Safety studies HAZID H Hazard d Identification Id tifi ti
Project Technical reviews
HAZAN Hazard Analysis: Potential Hazards & consequences
SAFETY CONCEPT
HAZOP Hazard and operability analysis: Systematic approach to identify hazards and operability problems
QRA Quantitative Risk Assessment Q Numerical calculation of Risk level

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12th Aug, 10
SAFETY MEASURES INCORPORATED IN THE DESIGN

State-of-the-Art Technology. Automatic Safety Shutdown System. System for early detection of leakage / spillage of LNG
or regasified LNG. Plant Design and Equipment Layout as per International & Domestic Safety y Standards. Dedicated team to ensure adherence to safety measures. Safety Audits & Mock Drills Regular Safety Trainings (Internal & External) Incedent Reporting & Analysis
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12th Aug, 10
EQUIPMENT LAYOUT
12th Aug, 10
REGASIFICATION TERMINAL EQUIPMENT LAYOUT

EN 1473 & NFPA 59 A provides guideline Layout to ensure LNG piping is minimezed Layout to ensure risk does not extend beyond the plot Main M i Control C t l room to t be b in i non-hazardous h d area. Hazardous area classification may be decided based on
dispersion i i calculation i from f possible i spills. i
12th Aug, 10
Safety Distance Dahej LNG Plant
The required safety distance form leakage point for HP & LP source are 190m and 168m which could be accommodated within the Allocated plot
12th Aug, 10
Safety Distance Kochi LNG Plant
The required safe distances from leakage point from HP & LP source are 141 & 105 m, which could not be accommodated within the allotted plot. PLL had to use water curtains to resolve this problem
12th Aug, 10
LNG Spill Prevention Methods

Release From Un-loading Arms
Powered Emergency Release Coupling with two step ESD System o Step 1: - Close the NG / LNG valves o Step 2: - Disconnect the NG / LNG un-loading Arms Failure of both the steps only can cause the LNG spill. Pipes are protected against corrosion, overpressure, Vehicle crash, equipment fall by design features & mostly being welded pipes Design Features (e.g. metallurgy, welding procedures, earthquake factor, low temperature detectors, no nozzle on side or bottom of tank, p provision of VRV etc.) make the failure chance almost rare. Pre-stressed concrete outer tank designed to with stand cold LNG & external aggression due to LNG leak, earthquake, projectile attack etc.
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12th Aug, 10
LNG Transfer T f Lines Li Inner Tank Failure
Outer Tank Failure
LNG Spill Prevention Methods
Release From Valve Packing

Extended Bonnet Valves Have been used Packing leak can be predicted by early accumulation of frost Early detection & tightening procedures are developed to prevent liquid p q escape p Use of flanges, spool pieces & Hoses for LNG has been (practically y zero). ) minimized (p Future connections (or other tapings), where flange connections are necessary, are properly vented Leaks resulting in the release of cold gas can occur in the piping associated with the vaporization of natural gas. This area is provided with extra instrumentation
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12th Aug, 10
Release from piping flanges, Spool Pieces & Hoses

Leaks In Gas Phase Piping p g

HANDLING OF LNG LEAKS & SPILLS

Elaborate Leak detection system y
Thermal Sensors Gas Detectors
p procedures to protect p personnel p from contract with leaking g liquid q

or cold vapor and minimize the chance for vapor contact with potential source of ignition
Equipment q p such as barricades, , Warning g signs g and combustible gas g

indicators are available at the plant
Elaborate Emergency Shut Down (ESD) system & System isolation

ESD1: - Stop p Ship p Un-loading g ESD2: - Stop Send out system ESD3: - Stop Complete facility
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12th Aug, 10
ACTIVE EMERGENCY / FIRE PROTECTION MEASURES AS S
Fire Fi Water W t System: S t Ring Ri Main, M i Hydrants, H d t Tower T

12th Aug, 10
Monitors, Remote / manual operated spray system, Water Curtain High Expansion Foam System Clean Agent (Inergen) system P t bl Fire Potable Fi Extinguisher E ti i h Mobile Fire Fighting triple purpose (Water/Foam/DCP) Tender Personal Protection Gears & Breathing Apparatus Oil Spill Handling Equipment
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AN ACTIVE MEAN OF PROTECTION : THE WATER CURTAIN
12th Aug, 10
Mitigation effects of a water curtain
Mechanical Dispersion (heating, dilution) Chemical dilution (absorption)
Thermal radiation mitigation

12th Aug, 10

Example of nozzles ramps
Nozzles characteristics Diameter Size of sprays Momentum of sprays Curtain geometry Number of nozzles per linear meter of curtain Spacing between the nozzles Distance between the nozzles ramps
Downward curtain (full cone nozzles)
Upward curtain (peacock tail)

12th Aug, 10
Field tests (pool fire) Gaz de France
Significant thermal radiation mitigation, p g on the water curtain characteristics depending
12th Aug, 10
REDUCING THE FLAMES : USE OF FOAM
12th Aug, 10
SAFETY ISSUES: Foam generation system
Physical foam effects: Before ignition:

Isolate LNG layer from ambiant air
Reduce the vaporization

Warm-up LNG G vapours
Increase the dispersion

Air
Nozzle
After ignition: g
Reduce heat exchanges between the LNG layer and the flame Produce steam which reduce the fl flame Reduce combustion ratio Reduce fire radiation Foam
Pre-mix = Water + Emulsifier 3% vol

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12th Aug, 10
Reduction of fire with foam

Evolution of the received flux during the phases of foam discharging and destruction (50 m m circular LNG pool fire)
12th Aug, 10
SAFETY ISSUES
FIRE FIGHTING SYSTEMS

E Extinguishing ti i hi agent: t Chemical powder Fixed systems: y Powder g guns Mobile systems: Trucks, 100kg powder extinguisher Hand extinguisher: 9kg Extensive training g of Operators safety teams
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12th Aug, 10
Spreading and vaporization of pools
Spreading of an LNG pool Low pressure LNG spills from a pipeline or a vessel LNG comes into contact with ground LNG gains some heat from ground Increase I of f vaporization i i Ground is cooled down LNG spreads, forming a pool LNG continues to cool down ground Temperature differential between ground and LNG decreases, and thus heat exchange
12th Aug, 10
SAFETY - DOCUMENTATION
A Comprehensive p set of Documentation is in Place for Safe &
Reliable Operation:
Disaster Management Plan Oil Spill Contingency Plani. Port Administration Port Operations Health, Safety and Environment (HSE) Maintenance of Tugs g and Support pp Craft & Jetty y Training Terminal Information & Regulations & Operation Books
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12th Aug, 10
Concluding Remarks
Follow the Codes & Standards leads to safe design &
operation
Studies St di like lik HAZOP, HAZOP QRA, QRA SIL, SIL Risk Ri k Analysis A l i etc. t during d i
the design phase help in ensuring the safety during construction & operation. For Key to Success remember
Engineering is easy Environmental issues, public safety & public perception are difficult Carryout detailed modeling studies to establish compliance with environmental / regulatory requirements in project development process from the very beginning
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12th Aug, 10
REDUCING THE RISKS AT DAHEJ TERMINAL

DESIGN & CONSTRUCTION Full containment Storage Tanks Some examples E Emergency Release R l Coupling C li
Lay-out: safety distances
12th Aug, 10
Cold and Gas Detection
LNG IS A MATURE INDUSTRY ENJOYING A VERY HIGH LEVEL SAFETY RECORD WORLDWIDE
THANK YOU FOR YOUR ATTENTION

182,000 m3 LNG tanks under construction Petronet LNG Ltd LNG Terminal Kochi
12th Aug, 10

LNG Regasification Safety

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Safety in LNG Regasification

SAFETY IN LNG REGASIFICATION

Man Mohan Ahuja

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

SAFETY & ENVIRONMENT PROTECTION IN OIL & GAS INDUSTRY

I t International ti l regulations: l ti OMI OMI, SIGTTO SIGTTO, etc... t

National N ti l regulations: (like OISD in India)

Oil & Gas companies policies

Safety in LNG Regasification

SAFETY REQUIREMENTS IN LNG INDUSTRY

Companies Policies, Engg. Standards

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

SAFETY REQUIREMENTS IN LNG INDUSTRY

Safety in LNG Regasification

LNG in storage tank is violently boiling liquid

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

The average auto-ignition auto ignition temperature for pure methane at

The lower and upper flammability limit of methane in air is 5% &

In a closed tank, the percentage of methane is 100%, thus it

Methane leaking from a tank in a well ventilated area is likely to

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

The only danger from skin contact with LNG is freezing;

Tissue Ti d damage f from extreme t cold ld is i similar i il to t damage d

Safety in LNG Regasification

PROPERTIES OF LNG REACTION ON WATER

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Continuous release e ease

LNG CLOUD DISPERSION TEST

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Example of vapors dispersion

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Example of LNG vaporization

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Example of LNG pool fire

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

LNG RECEIVING TERMINAL

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

LNG TERMINAL DAHEJ

UNLOADING/ VAPOR RETURN ARMS

LP PUMP LNG TANK

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Safety in LNG Regasification

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

o Tank safety valves, Vapouriser safety valves, Flare stack

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

Two phase releases

Petrofed Seminar on Safety in Hydrocarbon Sector

Safety in LNG Regasification

LNG leaks: main parameters