See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/302590217

LPG Storage Tank and Pipe Line Report

Technical Report · May 2016

DOI: 10.13140/RG.2.1.3112.0244

CITATIONS READS

0 4,510

1 author:

Sajjad KHUDHUR ABBAS Al-Amshawee

Universiti Malaysia Pahang
49 PUBLICATIONS   165 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Sustainable Approach Of Recycling Palm Oil Mill Effluent Using Integrated Biofilm - Membrane Filtration System For Internal Plant Usage View project

Spectrum Bacteria Tech (SBT) View project

All content following this page was uploaded by Sajjad KHUDHUR ABBAS Al-Amshawee on 10 May 2016.

The user has requested enhancement of the downloaded file.

 LPG Storage Tank
and Pipe Line Report

This report is submitted on 3 May 2016 , for Safety and loss prevention
workshop (1) , The National University of Malaysia , Faculty of
Engineering and Built Environment.

Prepared by:
SAJJAD KHUDHUR ABBAS P81540
KHADEJA . KHALIFA . D KHALIFA P84863
SAIF TALIB ABDUL SAMAD P84857

Supervised by:
Prof. Ir. Dr. MOHD SOBRI BIN TAKRIFF
LPG Storage and Pipeline Report Safety and Loss Prevention

Table of Contents
1 A-Summary of hazardous properties of LPG................................................................................... 3
2 Hazard system for the storage tank and the pipeline..................................................................... 3
3 Safe use of liquefied petroleum gas (LPG) ...................................................................................... 4
3.1 Siting of the tank ..................................................................................................................... 4
3.2 Ventilation and conditions around the tank ........................................................................... 5
3.3 Tanker access .......................................................................................................................... 6
3.4 Security ................................................................................................................................... 6
3.5 Impact protection ................................................................................................................... 6
3.6 Emergency arrangements ....................................................................................................... 6
3.7 Notes ....................................................................................................................................... 7
4 Main principle of the inherent safety and their applicability to the proposed fuel transportation
and storage system (Figure W1-1) .......................................................................................................... 7
4.1 Minimization ........................................................................................................................... 7
4.2 Substitute (Substitution) ......................................................................................................... 8
4.3 Moderate (Attenuation) ......................................................................................................... 8
4.4 Limitation of effects ................................................................................................................ 9
4.5 Simplification and error tolerance .......................................................................................... 9
5 FMEA ............................................................................................................................................. 10
6 FMEACA......................................................................................................................................... 11
7 HAZARD AND OPERABILITY STUDY REPORT ................................................................................. 12
8 Team Role and Responsibilities .................................................................................................... 14

Page | 1
LPG Storage and Pipeline Report Safety and Loss Prevention

Disclaimer
This information is based on our current knowledge and is intended to describe the product for
the purposes of health, safety and environmental requirements only. It should not therefore be
construed as guaranteeing any specific property of the product.

Page | 2
 LPG Storage and Pipeline Report Safety and Loss Prevention

1 A-Summary of hazardous properties of LPG.

 LPG is approximately twice as heavy as air when in gas form and will tend to sink to the lowest
possible level and may accumulate in cellars, pits, drains etc.
 LPG in liquid form can cause severe cold burns to the skin owing to its rapid vaporisation.
 Vaporisation can cool equipment so that it may be cold enough to cause cold burns.
 LPG forms a flammable mixture with air in concentrations of between 2% and 10%
 It can, therefore, be a fire and explosion hazard if stored or used incorrectly.
 Vapour/air mixtures arising from leakages may be ignited some distance from the point of
escape and the flame can travel back to the source of the leak.
 At very high concentrations when mixed with air, vapour is an anaesthetic and subsequently
an asphyxiate by diluting the available oxygen.
 A vessel that has contained LPG is nominally empty but may still contain LPG vapour and be
potentially dangerous. Therefore, treat all LPG vessels as if they were full.
 Fire, explosion, asphyxiation, environmental harm, toxic, vaporisation can cool equipment and
cause cold burns, empty vessels can still be dangerous as vapours stay within the vessel, they
are stored under great pressure, gas is heavier than air and will need gas detection

2 Hazard system for the storage tank and the pipeline

Table 1 Hazard system for the storage tank and the pipeline

Items Details
Source process vessel may suffer loss of
containment at any level ranging between a
pinhole leak to a catastrophic failure
Receptors Workers
Neighbour Companies
School (2.2 km )
Government complex ( 0.9km)
Commercial area (0.75km)
Two resident area ( 1.5 km )
Transmission Path Fire - thermal
Explosion – overpressure
Toxic gas - dispersion with wind
Barrier ERP (Emergency response protocol)
Control systems
Training

Page | 3
LPG Storage and Pipeline Report Safety and Loss Prevention

Lets assume that explosion will happen by leaking so any ignition source can led to huge
explosion but what is the area that the explosion will cover ? , we can make comparing but our
project and San Juanico disaster , in this disaster the capacity was 11,000 m3 , in our project
its ( 1000*1000ton /553 = 1808 m3 ) the damaged area by the disaster was 1,200 m along , in
our project may be the damage will cover a round 1 km ( max ) , 250m ( min ) . The following
conclusion and recommendation were made based on this study.
 Increase the number of LPG detectors in the unloading area, valves and installation in
vaporiser area etc
 Prevent ignition sources around the LPG storage and associated areas such as explosion
proof electrical equipment’s and installations and flame proof trucks etc.
 The heat intensity at a distance of 550 meter approximately reaches 4 KW /m2 for LPG
tank catastrophic failure sufficient to cause pain to personnel is likely. During LPG
transfer operation restricted number of operational team to be allowed and plan the land
use surrounding to this facility accordingly.
 The shock wave pressure of 0.2 Bar reaches approximately 40 m contour for pipeline
rupture scenario with late ignition. From this serious effects are result from shock wave
in explosion which to be considered during new facility around.
 LPG warning signs to be provided around the storage facility such as highly flammable,
no smoking etc.

3 Safe use of liquefied petroleum gas (LPG)

When the risks are properly identified and managed, LPG can be safely used as a fuel source for
many applications. This information is aimed primarily at users of LPG to provide information
and help to ensure it is used safely.

LPG storage tank ( Safety of your LPG storage tank )

3.1 Siting of the tank

There should be a minimum distance (called the separation distance) between the tank and any
building, boundary line or fixed source of ignition. This should have been checked when the
tank was first installed and the supplier will know what the distance should be if you are unsure.
Modifications to the area may have been made since the tank was installed. These could include
altering walls, building sheds or fences, installing electrical equipment near the tank or planting
trees or shrubs nearby. These should not be any closer to the tank than this minimum distance
and, if they are, then arrangements need to be made to move them.
There should not be any drains or gullies near to the tank unless a water trap is provided to
prevent gas entering the drains. This is because LPG is heavier than air and if a leak were to
develop from the tank or its controls or pipework or when it is being filled then the vapour
could accumulate in an untrapped drain or gully. Ignition of these vapours could then lead to
fire/explosion.
The tank should also not be painted in any colour other than originally supplied as this may
increase the amount of heat it absorbs from the sun.

Page | 4
LPG Storage and Pipeline Report Safety and Loss Prevention

3.2 Ventilation and conditions around the tank

In case of leaks there should be plenty of room around the tanks to ensure good air flow so that
pockets of heavier-than-air LPG vapours cannot build up around them.
It is also very important to keep the area around the tank free of rubbish, particularly if it is
combustible or could reduce the levels of ventilation. For similar reasons keep weeds and grass
cut down around the tank. If you choose to use a weed killer then you should not use something
that is chlorate-based (as this can make the dead plants easier to ignite).

Page | 5
LPG Storage and Pipeline Report Safety and Loss Prevention

3.3 Tanker access

There should be a dedicated flat parking area for the tanker delivering LPG. This parking area
should be clear on a delivery day and people should be kept away from the tank and tanker
while the transfer of LPG is taking place. The supplier of the LPG will need to make sure that
the tanker cannot drive away with the supply hose still connected, that there is no risk of an
electrical spark being generated from static electricity or by other means. The LPG suppliers
should ensure that their drivers are suitably trained and have the correct procedures to follow.

3.4 Security
People are not involved with the installation, for example workers with no responsibility for
the LPG or visitors to the site, should be kept well away from it. No one should smoke, use
electrical equipment or park vehicles near the tank . ‘No smoking’ and other signs should be
clearly displayed and maintained. Ignition sources, eg bonfires and barbecues, should not be
allowed near the tank. Temporary use of grass-cutting equipment within the vicinity of the tank
is permitted.
For larger tanks (ie four tonnes or higher LPG capacity) a security fence is required to keep it
secure. This fence should allow natural air flow (eg made from wire mesh) and should be kept
in good condition. Any gates should be kept locked unless access to the tank is required. For
tanks below four tonnes LPG capacity, there may be certain circumstances where a fence may
not be necessary. This can only be justified where the risk of interference is low, and there is
no uncontrolled public access - for example due to tank location or other accessibility factors.
Tank valve covers should be kept locked whether or not the tank is fenced.
3.5 Impact protection

If possible, the tank (and its associated piping) should not be located in areas where there is
motor traffic. However, where this is not possible, then protection from a motor vehicle hitting
the tank is required such as crash barriers or bollards. A security fence and/or road markings
(eg ‘no-parking’ notices, double yellow lines) are unlikely to provide this protection.

3.6 Emergency arrangements

The LPG tank will have printed on it the supplier’s emergency number that should be called if
there is a leak. If a fire breaks out then the user should have in place an emergency plan which
includes evacuating people from the premises. In general, leave tackling any fire near the tank
to the fire brigade unless it is judged that it can be put out without endangering anyone. In the
event of an emergency, and where it is safe to do so, the shut-off valve on the top of the tank
and the emergency control valve (ECV) should be closed.

Page | 6
LPG Storage and Pipeline Report Safety and Loss Prevention

3.7 Notes

LPG cylinders are stored on construction sites, the area should be at ground level and readily
accessible to facilitate the prompt removal of cylinders in case of emergency. Wherever
possible, storage areas should be in the open air, protected from unauthorised access by a fence
at least 2m high with two means of exit via gates which open outwards and are not self-locking;
there should be sufficient shelter to prevent cylinders from being exposed to extremes of
weather. The floor should be paved or compacted level, and a suitable hard standing provided
for the delivery and dispatch of cylinders.
The area should be kept clear of all flammable material, weeds and rubbish; there should be no
adjacent drains or cellars and permanent notices stating “LPG - Highly Flammable” should be
prominently displayed adjacent to each entry point. Notices prohibiting smoking and naked
lights should also be posted.

4 Main principle of the inherent safety and their applicability to the

proposed fuel transportation and storage system (Figure W1-1)

4.1 Minimization
Table 2 Minimization (inherent safety)

Inherent Safety Objective Approach Limitation/Contradicting

Principle
Minimization/ •Reducing the amount •Process intensification • Economics implication
Intensification of hazardous material
present at any one time •More efficient process • Unproven technology
units
. Minimized • Transferring hazard
consequence of hazard • Chang size of the tank
realization if it is large to change
to small
- For example the
capacity of the LPG
tank 1000 tons to can
do two tanks 500tons
and500tons.

• Centralized storage
facility

Page | 7
LPG Storage and Pipeline Report Safety and Loss Prevention

4.2 Substitute (Substitution)

Table 3 Substitute (inherent safety )

Inherent Objective Approach Limitation/

Safety Contradicti
Principle ng
•Substitution • Replacing one material •Use solvents that are less toxic • Unproven
with another of less hazard technology
•Use less hazardous chemicals such as
solvent, heating and cooling media • Requires
larger
•Use chemicals with higher flash points, inventory
boiling points, and other less hazardous
properties

•Use water as a heat transfer fluid instead of

hot oil

•Use mechanical pump seals vs packing

- Its closure is activated by level switch LSH
- shut-off valve V302 should

•Use mechanical gauge vs mercury

•substance with a less hazardous material or

processing route with one that does not
involve hazardous material

4.3 Moderate (Attenuation)

Table 4 Moderate (inherent safety )

Inherent Safety Objective Approach Limitation/Contradicting

Principle
Moderation/attenuation • Less hazardous • Dissolve hazardous • Unproven technology
operating condition material in safe solvent
• Requires larger inventory
• Less hazardous • Reduce process
forms temperature and
pressure
• Reducing the
strength of an effect • Use vacuum to
reduce boiling point

• Refrigerate storage
vessels

•materials in their least

hazardous forms or
identify processing
options that involve
less severe processing
conditions

Page | 8
LPG Storage and Pipeline Report Safety and Loss Prevention

4.4 Limitation of effects

Table 5 Limitation of effects (inherent safety )

Inherent Safety Objective Approach Limitation/Contradicting

Principles
• limitation of effects • To limit • Large spacing • Economic implication
consequence of between process units • Larger land area
hazard realization • More extensive piping
• Changing process • Unproven technology
•Separate pump design and conditions
rooms from other
rooms • Design that would
To avoid knock-on minimized loss of
effects containment

• Place control rooms

away from operations

4.5 Simplification and error tolerance

Table 6 Simplification and error tolerance (inherent safety )

Inherent Objective Approach Limitation/Contradicting

Safety
Principle
Simplification • To avoid or • Keep piping systems neat and visually • Not optimum process
minimized easy to follow
chances for • Over dependency on
error • Pick equipment that requires less manual control
maintenance/low failure rates
• Eliminating
problems by • Design control panels that are easy to
design rather comprehend
than adding Design plants for easy and safe maintenance
additional
equipment or • Label vessels and controls to enhance
features to understanding/coluor coded pipe
deal with
them
• Separate systems and controls into blocks
that are easy to comprehend and understand

• Simplification Design processes,

processing equipment, and procedures to
eliminate opportunities for errors by
eliminating excessive use of add-on safety
features and protective devices.

Page | 9
LPG Storage and Pipeline Report Safety and Loss Prevention

5 FMEA
Table 7 Storage tank FMEA

Storage tank FMEA

N Component Actions /
Failure Failure Sympto Safe Guards Recommend
o Description mode effect(s ms ation
) •  No
• Valve v301 •  No fuel • earthquake resistant
fuel to • 
Inlet valve failed closed in tank T- next construction Preventiv
1 unit e
v301 301 • relive valve maintena
•  Low • isolator nce
level • extra valves on the inlet and •  Install bypass
alarm
outlet of the tank
trigge
red • concrete wall
•extra detector (temp. sensor )
• vortex breaker

Figure 1 PID Based on the outcomes of the FMEA

Page | 10
LPG Storage and Pipeline Report Safety and Loss Prevention

6 FMEACA
Table 8 Storage tank FMEACA

Storage tank FMEACA

N Component Failure Failure Symptoms Frequen Severi Score

o Description
mode effect(s) cy ty

• Inlet valve • Valve v301 • No fuel in tank •  No fuel to next

1 unit 4
v301 failed closed T-301 2
2 (low)
•  Low level alarm
triggered

Figure 2 PID Based on the outcomes of the FMEACA

Page | 11
 LPG Storage and Pipeline Report Safety and Loss Prevention

7 HAZARD AND OPERABILITY STUDY REPORT

Table 9 HAZARD AND OPERABILITY STUDY REPORT

HAZARD AND OPERABILITY STUDY REPORT

Project Title LPG Transportation and Storage system

Project Number: 001 Date: 25 Oct 2012

Drawing Number: PID – fig 1 Chairman: Mr X

Node: Node No 1 Study Team: team1

Item: inlet valve Parameter: Flow

GUIDE
WORDS DEVIATIONS CAUSES CONSEQUENCES SAFEGUARDS ACTION REQUIRED

•  Valve failed •  Fire in the no fuel in •  Low level Alarm •  maintenance is

storage tank required
No flow into closed
NO v301 •  Install level indicator
tank • earthquake resistant
•  Pipe blocked •  Impurities of residue construction
close the outlet trench

• relive valve

• isolator

• extra valves on the

inlet and outlet of the
tank

• concrete wall

•extra detector ( temp.

sensor )

• vortex breaker

Page | 12
LPG Storage and Pipeline Report Safety and Loss Prevention

Figure 3 Improved PID of storage tanks based on the results of the HAZOP analysis

Page | 13
 LPG Storage and Pipeline Report Safety and Loss Prevention

8 Team Role and Responsibilities

SAJJAD KHUHDUR KHADEJA . KHALIFA SAIF TALIB

Providing : Providing Providing
 MSDS sheet  Main principle of the  FMEA
 Summary of Hazard inherent safety and
 FMEACA
Properties their applicability to
 HAZOP report
 Safe use of liquefied the proposed fuel
petroleum gas (LPG) transportation and  P&ID
 Hazard system for the storage system
storage tank and the
pipeline

Summary and declare, Our Report done by group work. we held many meeting at UKM, NEW LIBRARY. In
our meeting we discussed the tasks and started managing the tasks by giving each team member individual task
so we can manage our time easily. after we finished the tasks, we started to explain to each other what is required
to complete the tasks so we started to discuss until we managed the best work for LPG Storage and Pipe Line
Report. We declare this Report done by Teamwork.

Page | 14

View publication stats