Welcome

Webinar on Safety Practices in CGD Industry

conducted by Natural Gas Society

GAIL (India) Limited, Bhubaneswar

 Discussion Topic
Safe Loading &
Unloading of LNG
Truck / Lorry

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 Content of Presentation
➢ About GAIL CGD, Bhubaneswar
➢ About LCNG satellite station
➢ Process flow diagram
➢ Understanding properties of LCNG
➢ Unloading procedure
➢ Safety during unloading
➢ Safe handling of LNG
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CITY GAS DISTRIBUTION IN BHUBANESWAR
CITY GAS DISTRIBUTION PROJECT

About GAIL CGD, Bhubaneswar

➢ Pradhan Mantri Urja Ganga Natural
Gas pipe line namely Jagdishpur-
Haldia- Bokaro- Dhamra Pipe line
project..
➢ Grant of Authorization by PNGRB for
CGD Bhubaneswar & Cuttack in
Odisha.
 Concept of LCNG satellite station

➢Jagdishpur- Haldia- Bokaro- Dhamra pipe line is

under construction.
➢Non-availability of gas through pipe line
➢CNG & PNG demand
➢Initially gas sourcing was done through CNG
mobile cascade. (from M/s BGL- Kakinada)
➢To fulfill the increasing demand of gas- Planned
for installation of LNG satellite station 5
LNG SATELLITE STATION BHUBANESWAR

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 BENEFIT OF LCNG SATELLITE STATION

CNG Dispensing CNG Cascade Filling

FOR DBS/ DS

LNG Dispensing LLCNG

Domestic PNG
LNG Cylinder Filling
Customers

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 PRS
SKID

HIGH PRESSURE
VAPORISER
PROCESS FLOW DIAGRAM
 PROPERTIES OF LNG
1 Chemical Liquefied Natural Gas
CHEMICAL IDENTITY Name
2 Composition Methane (97 %), ethane & propane (3%)

1 Liquid at (-) 162 °C

2 Boiling Point (-)161.5 °C
3 Specific Gravity 0.45 (water = 1)
4 Auto-ignition 540 °C (Gas Phase)
Temperature
5 Density (g/ml) 0.45 at boiling point

PHYSICAL & CHEMICAL PROPERTIES 6 Vapor Pressure 466,000 mm Hg @ 25°C

7 Physical State Liquid
8 Color Colorless
9 Odor Odorless
10 Solubility in water (20°C) 24.4 parts per million (wt)
11 Vapor Density >1 @-112 degrees C (Air= 1)
12 Lower Explosion Limit 5% (by volume, gas phase)
13 Upper Explosion Limit 15% (by volume, gas phase)
14 Percent Volatile (by 99%
volume)
15 Expansion ratio 1:600

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 PROPERTIES OF LNG

FIRE & EXPLOSION HAZARDS OF LNG

➢ LNG vapors are extremely flammable and can be ignited by heat, sparks,
flames, static electricity, and other sources of ignition.
➢ LNG is stored under pressure and temperature controlled conditions.
Containers of LNG exposed to excessive heat or flame may rupture violently
➢ Vapors may travel considerable distances to a source of ignition where they can
ignite, flash back, or explode
➢ Vapours are initially heavier than air and may travel short distances to a
point of ignition or flashback.
➢ Liquid releases of flammable vapours at well below ambient temperatures
readily form a flammable mixture with air.
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 PROPERTIES OF LNG

FIRE & EXPLOSION HAZARDS OF LNG

➢ Direct water at the source of the leak, pooled LNG, or safety devices; the
indiscriminate use of water on surfaces of cryogenic containers and
piping can lead to heavy icing, causing excessive loads on structures and
the failure of valves, instrumentation, and other control devices.
➢ Application of water to pools of LNG will cause the LNG to vaporize more
rapidly, generating more gas to feed a fire or create a larger vapor cloud.

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 LNG UN-LOADING SKID
Minimum Cooling Temp:- (-) 90 dC
SS Braided flexible hose

Unloading Pump Skid- Up to 350 LPM

 SAFE UNLOADING PROCEDURE

PRE-STARTING PROCEDURE
➢ Joint inspection of LNG tanker
➢ Proper placement of the LNG tanker in the unloading bay in drive out position
➢ Placement of stoppers/ wheel chokes in front & rear wheel
➢ Ensure the engine as well as the master switch is off/complete disconnection
from the battery. Remove the ignition keys.
➢ Ensure that the pressure in the air tank of the vehicle is 5 - 7 kg/cm². (for
operation of air operated valves.)
➢ Connect the earthling cable bonded to the fixed installation to the outer vessel of
TT. Ensure that the earthling cable is plugged on a bare metal of the outer vessel
and not on a painted surface.

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 SAFE UNLOADING PROCEDURE

PRE-STARTING PROCEDURE

➢ Measure the Earthing value after connecting the earthing strip with the TT to ensure the
functioning of the earthing system. (resistance below 1 ohm)
➢ Ensure all fittings /valves etc. of TT are in proper position.
➢ Before commencing the unloading operation a visual check of the surrounding shall be carried
out for any unusual or dangerous situation.
➢ Warning notice Tag stating “LNG unloading is in progress” should be placed at the front and rear
of the TT.
➢ Connect Filling hose FH-51 of Pump Skid to tanker unloading point (Valve No: M1), and Vapour
return hose FH-52 to tanker (Valve No: M2). To avoid the sagging, provide proper support to the
hose.
➢ Ensure the PSV of the TT is in line. Open the M3 (PBU inlet) and M5 (PBU outlet) of the Pressure
Built-up Unit (PBU) of TT and build the tanker pressure to 6.0 kg/cm2.

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 SAFE UNLOADING PROCEDURE

UNLOADING LNG FROM LNG TANKER (TT):

➢ Open the Valve M-101(inlet of Unloading Pump, P-101) and M-102 (sump return/circulation of
P-101) of pump skid and valve M2 of TT for checking the leakage of hose connection.
➢ Ensure all the interlocks are in line.
➢ Open ESDP-1(LNG outlet of TT) and ESDP-2 (BOG inlet of TT) of transport tank.
➢ Now LNG from tanker is filled in the hose pipeline circuit.
➢ Check leak tightness of the total skid along with the connecting hoses by applying soap
solution.
➢ On confirmation of no leak crack open the valve M1 (TT manual valve of LNG) of Transport
Tank.
➢ Start the cooling cycle from TT to unloading pump skid to TT. Observe the temperature (TE
101), Pump o/l to TT. Select the unloading system to Storage Tanks T-101A/B.

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 SAFE UNLOADING PROCEDURE

UNLOADING LNG FROM LNG TANKER (TT):

➢ Ensure opening of ESD02A/B. Line up M1A/B and M3A/B valves of storage tank for bottom
filling and M2A/B and M5A/B for top filling of storage tanks A & B respectively. Top filling is
preferable over bottom filling as it leads to reduction of tank pressure during unloading of LNG.
➢ Ensure cooling at least for 30 minutes for proper cooling. Ensure the pump P-101 cool down by
circulation of LNG and wait for getting the pre- cooling temp. (value - 90°C of TE-101). Slowly
open the M1 valve on TT, more if required. (Do not open the valve fully). If pre-cooling of the
pump is not achieved even after one hour of starting the cooling down, open B3 on (TT)
transport tank for achieving cool down.
➢ Start the pump, P-101 and then slowly open M103 and close M102 of Pump skid. Open the
M1 valve of TT fully. LNG filling to storage tank will start as per the tank selection done.
➢ Constantly monitor the differential pressure across the pump, P-101 (DPT-101) & the pressure
of storage tank (PT-1A/B). Top filling of the storage tank will ensure reduction in tank pressure.

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 SAFE UNLOADING PROCEDURE

UNLOADING LNG FROM LNG TANKER (TT):

➢ Monitor the pressure of TT also. If required open the pressure build valve M3 (PBU inlet) and
M5 (PBU outlet) to keep the pressure at 6.0 kg/cm2.
➢ During the LNG transfer operation, the level in Storage tank should be monitored continuously
through LG (In local) and LT (On DCS). The automatic valve in fill line of storage tank shall shut
off when the Max fill level is reached as safety feature.
➢ The maximum allowable liquid levels inside the Storage tanks are 83 to 85% only. When the
liquid level of Storage tank reaches to 83 to 85%, the pump should stop to avoid over-filling of
the storage tanks.
➢ The unloading pump, P-101 will stop once the Differential pressure (DPT-101) across the pump
P-101, falls below 4 kg/cm2.

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 SAFE UNLOADING PROCEDURE

SHUT DOWN OF LNG UNLOADING SYSTEM

➢ Note down the level of liquid left in TT. The level should not be more than 50
MMWC to ensure complete decantation of the TT. Close M1 and M2 of
Transport tank. Wait for 5- 10 minutes and then close M101 and open B101 to
empty out the hose.(Start DG set before emptying out the tankers to avoid
incomplete decantation due to power failure)
➢ Empty out can be ensured by vanishing of ice cover on hose.
➢ Disconnect the hoses from transport tanker. Isolate M1A/B, M3 A/B and
M2A/B, M5A/B of the storage tanks. Ensure closing of ESDs 02A/B.

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 SAFE UNLOADING PROCEDURE

SHUT DOWN OF LNG UNLOADING SYSTEM

➢ Remove the warning notice Tag from the rear and front of the vehicle.
➢ Keep the tanker connected till the disappearance of icing from
➢ Put the master switch ON. Release the hand break and move out from the
transfer area.
➢ Prepare the final unloading slip as per format. Release the tanker after entry
in out register.
➢ The LNG TT weighment slip to be prepared in triplicate and signed by the
driver of the TT, representative of Transporter and customer and each party
shall retain copy of the slip.

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 SAFE UNLOADING PROCEDURE

EMERGENCY SHUT DOWN OF UNLOADING SYSTEM:

➢ Emergency shutdown can be taken by actuating the ESD button from field
or DCS. In case of leakage ESD to be actuated.
➢ Actuation of ESD will lead to stoppage of P-101, closing the storage tank
ESD’s 02A/B.
➢ Close M1 & M2 I/V’s of TT.
➢ Take action as per laid down procedure for handling the emergency.

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 SAFE UNLOADING PROCEDURE

SPECIAL PRECAUTION

➢ Ensure proper earthing of the tank during unloading

➢ Ensure use of wheel stopper
➢ Operators & fire man to be present at the time of unloading
➢ Fire extinguishers to be kept ready during unloading
➢ Use of special PPE like thermal insulating gloves etc. To be used
➢ Use of non sparking tools

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 SAFE UNLOADING PROCEDURE

ACCIDENTAL RELEASE MEASURE

➢ In case of an accidental release, activate your facility’s spill contingency plan,

if available.
➢ Evacuate non‐essential personnel and secure all ignition sources.
➢ Do not allow road flares, smoking, cell phones, or other sources of ignition in
the hazardous area.
➢ Internal combustion engines generate sparks that would serve to ignite LNG
vapors, so do not drive vehicles through the vapor dispersion area, and do
not attempt to start vehicles that are within the vapor dispersion area.
➢ Do not touch spilled liquid (frostbite/freeze burn hazard!), and avoid contact
with any surface cooled by LNG vapor or liquid.
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 SAFE UNLOADING PROCEDURE

ACCIDENTAL RELEASE MEASURE

➢ Evaluate wind direction and speed to determine the direction of

product travel. The vapor cloud may be white, but the color will dissipate as
the cloud disperses; however, the fire and explosion hazard is still present!
Stay upwind and uphill, if possible, and avoid low lying areas.
➢ Test the area for hazardous atmospheres before re‐entering.
➢ Stop the source of the release, if safe to do so.
➢ Do not flush the product down the sewer or drainage systems as it may
create an explosion hazard in these confined spaces. LNG will not
contaminate soil if spilled as it readily evaporates.

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 SAFE UNLOADING PROCEDURE

ACCIDENTAL RELEASE MEASURE

➢ Ventilate confined areas and check for hazardous atmospheres before

entering.
➢ Notify relevant authorities in accordance with all applicable requirements.

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 SAFE UNLOADING PROCEDURE

RECOMMENDED PPE
➢ Skin/Hand Protection: Wear thermal insulating gloves and a face shield
➢ Eye/Face Protection: The use of eye protection (such as splash goggles) is
recommended
➢ Ensure that the protective equipment is rated for the temperature of the
material to be handled. Flame retardant clothing is recommended in any
situation where LNG vapors may ignite accidentally.
➢ Respiratory Protection: Approved, self‐contained breathing apparatus
(SCBA) or equivalent.
➢ Cryogenic suit full body protection.

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 SAFETY ARRANGEMENTS
FIRE PREVENTION SYSTEMS
➢ Hydrocarbon detectors installed near LNG tanks and other strategic
locations to detect the leakage of hydrocarbon i.e. LNG at an early stage
so that immediate action can be taken to stop the leakage. (15% Alarm
25% LEL initiate shutdown)
➢ 5 Nos. at sump area, LNG Tanks, Filling Area, High pressure & low
pressure Vaporizer)
➢ Provision of interlocking systems for immediate closure of valves during
any leakage of LNG to stop further leakage from the system.
➢ Provision of 05 Nos. Emergency shutdown switches as follows for
immediate stoppage of operation during any emergency,

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 INTER DISTANCE BETWEEN FACILITIES
Category: Water Capacity Of LNG storage Vessel >7.6 But<56.8(20 KL)

PARAMETER UNIT SPECIFICATION MEASUREMENT

Distance from Impounding wall to property wall(SMPV) M 8 11
Minimum distance between Vessel & Dyke wall(SMPV) M 1.5 4
Minimum Distance between Dyke wall to Centre of truck M 4 4.5
unloading platform(SMPV)
Distance from Cascade filling point to Boundary M 9 9.6
wall(SMPV)
Installation of Odorizer, CNG Cascade & Compressor Outside the Dyke Outside the Dyke area
area
Installation of Vaporizer(Low & High) Inside the Dyke area Inside the Dyke area

Control Room M 8 32
Minimum distance around cylinder storage(GCR) M 5 6

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 FIRE PROTECTION SYSTEM
➢ 8 Nos. of single headed Hydrant
➢ 4 Nos. of water Cum Foam monitor around the dyke area
➢ 4 Nos. water monitor around the dyke area
➢ 8 Nos. of Hose Box with Hose pipe.
➢ 2 Nos. 45 Ltrs mechanical foam cartridge type fire extinguishers
➢ 2 Nos. 25 kg DCP powder Cartridge type fire extinguishers
➢ 4 Nos. 9 Kg ABC powder pressure type fire extinguishers
➢ 4 Nos. 4.5 kg CO2 gas type fire extinguishers
➢ 2 sets fire buckets (4 nos.) with stand
➢ 02 Nos. fire water storage tanks of 5KL each
➢ Dedicated fire water pumps (02 nos. Jockey pumps of 10 m3/Hr each & 02 nos.
Main pumps of 15 m3/Hr capacity)
➢ 02 Nos. Hose reels near unloading & loading point.
➢ 01 No. Fire service inlet at Entry gate
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FIRE FIGHTING EQUIPMENT
 APPROVALS & LICENSES TAKEN
CLEARANCES FROM LOCAL AUTHORITY

NOC FROM BDA, NOC FROM SPCB, NOC FRRM COMISSIONER OF POLICE, NOC FROM FIRE, NOC FROM ELECTRICAL DEPARTMENT
BASED OF DM NOC LICENCE FROM PESO

1. LICENCE NO: S/HO/OR/03/295 (S92283) UNDER SMPV(U),2016 TO STORE COMPRESSED GAS IN PRESSURE VESSELS
2. LICENCE NO: G/HO/OR/05/133(G50352) UNDER GAS CYLINDER RULES,2016 TO FILL COMPRESSED GAS IN CYLINDERS
3. LICENCE NO: G/HO/OR/06/124(G50352) UNDER GAS CYLINDER RULES,2016 TO STORE COMPRESSED GAS IN CYLINDERS

REGISTRATION FROM DIRECTORATE OF FACTORIES & BOILERS, GOVT OF ODISHA

FACTORY LICENCE- KD-888 (06591)

FIRE CERTIFICATE FROM LOCAL FIRE BRIGADE

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Thank You !!