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Safety in LNG Regasification
SAFETY IN LNG REGASIFICATIONPresented Byy
Man Mohan Ahuja SR. Vice President (Technical), Petronet LNG Limited
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
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E-mail: ahujamm@petronetlng.com
Safety in LNG Regasification
SAFETY & ENVIRONMENT PROTECTION SAFETY & ENVIRONMENT PROTECTION IN OIL & GAS INDUSTRYIN 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 T i l Fi (J i )
I t ti l l ti OMI SIGTTO t N ti l
Storage Terminal Fire (Jaipur)
International regulations: OMI, SIGTTO, etc... National regulations: (like OISD in
India)India)
I
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Oil & Gas companies policiesInsurance
requirements
Safety in LNG Regasification
SAFETY REQUIREMENTS IN LNG INDUSTRYSAFETY REQUIREMENTS IN LNG INDUSTRYSince accident in Cleveland (USA) in 1942 LNG has been considered as
Transport by sea: IMO rules Plants & Storages:
Since accident in Cleveland (USA) in 1942, LNG has been considered as Hazardous product, various regulations have been developped:
Transport by sea: IMO rules, SIGTTO recommendations, OCIMF rules, Classification , Insurances requirements.
gNFPA 59 A (USA)49 CFR part 193 (USA)EN 1473 (Europe)J G A Rules
Companies
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
National regulations, safety and regulatory bodies,Environment protection bodies & Associations.
Policies, Engg. Standards
Safety in LNG Regasification
SAFETY REQUIREMENTS IN LNG INDUSTRYSAFETY REQUIREMENTS IN LNG INDUSTRYSafety and environment protection are considered since preliminary design S e y d e v o e p o ec o e co s de ed s ce p e y des gstudies. Codes and regulations mainly provide:
Design criterias: Seismic designMinimum safety
distances: consideringDesign criterias: Seismic design,impounding systems, etc...
distances: considering accident scenarios and consequences: vapour clouds, fire radiation,clouds, fire radiation, Cold explosion, etc,...
Design & construction rules:Min. safety systems, Min. Hazardous areas classification: fire-proof
eq ipment Electric & instr mentation
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
y y ,protection, Fabrication,construction and control stds.
equipment, Electric & instrumentation equipment classification
Safety in LNG Regasification
SAFETY REQUIREMENTS IN LNG INDUSTRYSAFETY REQUIREMENTS IN LNG INDUSTRYWh tWh t ii LNG ?LNG ?Physical properties
• Liquefied Natural gas:
WhatWhat isis LNG ?LNG ?
• Colourless liquid,• Mainly CH4 (>80%),• Cold: temperature ≈ -160°C,• Density at 1 bar ≈ 450 kg/m3
• V f LNG• Vapour of LNG:• Odourless and colourless,• Density at 1 bar and 20°C ≈ 0 8 kg/m3• Density at 1 bar and 20°C ≈ 0.8 kg/m3• Flamability limits LFL: 5%, UFL:15%
• Vapourization of LNG
LNG in storage tank is violently
boiling liquid
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
• Vapourization of LNG• 1 m3 LNG 600 m3 of gas at 20°C
Safety in LNG Regasification
Properties of LNG
• Properties of LNG that have safety implications include auto-ignition temperature Low temperature heat of vaporizationignition temperature, Low temperature, heat of vaporization,flammability limits, heat transfer rate of boiling liquid andspecific gravity
• The average auto ignition temperature for pure methane at• The average auto-ignition temperature for pure methane atatmospheric pressure is 537oC, which is quite high
• The lower and upper flammability limit of methane in air is 5% &15% b ol me respecti el15% by volume respectively.
• In a closed tank, the percentage of methane is 100%, thus itcannot ignite.
• Methane leaking from a tank in a well – ventilated area is likely torapidly dissipate to less than 5% , thus it is relatively safer ascompared to other fuels
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LNG FILIM
Safety in LNG Regasification
Properties of LNG
• The most of Hazardous properties of LNG are due toextreme low temperatures
• The only danger from skin contact with LNG is freezing;there are no poisonous or toxic effects.Ti d f t ld i i il t d• Tissue damage from extreme cold is similar to damagefrom extreme heat.
• Unlike heat burns a cryogenic burn victim will not feelUnlike heat burns, a cryogenic burn victim will not feelpain 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 theaffected area from cold surface
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affected area from cold surface
Safety in LNG Regasification
PROPERTIES OF LNG – REACTION ON WATER
Un like other liquid petroleum products LNG reactsvigorously with water and vapourizes very fast (leavingnothing behind) posing minimum risk for the marine lifenothing behind) posing minimum risk for the marine life
RPT
However LNG reacts violently with water and may cause
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explosion due to RPT
Safety in LNG Regasification
LNG PROPERTIES• LNG VAPOUR CLOUD DISPERSION
i d di i
Cloud heigth
Continuous release
X
Wind directionSubsidenceBy gravity
Passivedispersion
e ease
LNG CLOUDCloud radius
LNG CLOUD DISPERSION
TEST
Wind direction
Instantaneousrelease
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release
Safety in LNG Regasification
LNG PROPERTIES• HEAVY GAS CLOUD DISPERSION FC TANKS
1.2
atio
n
0 4
0.6
0.8
1
r con
cent
ra
0
0.2
0.4
0 20 40 60 80 100 120Distance (m)
Mol
ar
Calculation tools :
•Integral Model : EVANUM
•3D: MERCURE HEAVY
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3D: MERCURE HEAVY GAS
Safety in LNG Regasification
Example of vapors dispersion
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Safety in LNG Regasification
Example of LNG vaporization
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Safety in LNG Regasification
Example of LNG pool fire
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Safety in LNG Regasification
LNG RECEIVING TERMINAL
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Safety in LNG Regasification
LNG TERMINAL DAHEJMetering
GW PUMP
AIR HEATER
STV
GW PUMP
WATER PUMP
SCV
R
HW PUMPBOG COMP.
RECONDEN
GTGUNLOADING/ VAPORRETURN ARMS
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15SHIPLNG TANK
LPPUMP
HPPUMP
NSOR
Safety in LNG Regasification
DESIGN HELP - SPECIAL CODES & STANDARDS
A SAFE & SMOOTHLY OPERATING FACILITY CAN BE
GENERALLY ENSURED IF THE APPLICABLE CODES &GENERALLY 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 & TerminalOperators):
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Operators):•OISD STDS 116, 118 & 194
Safety in LNG Regasification
ISO ACCREDITATIONCertified by DNV on 21st Jan-05
ISO 9001: 2001 QMS ISO 14001: 1996 EMS OSHAS 18001: 1999
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Safety in LNG Regasification
IDENTIFICATION OF RISKS
• External Origin• Natural Risks (Earthquakes, flooding, wind, typhoons and
lighting)lighting)• Non Natural Risks (from other industry, Marine traffic, Aircraft
crash)• Internal OriginInternal Origin
• Release of LNGo Release from tanker, Spill from un-loading armso Failure of transfer line Inner / outer tank failureo Failure of transfer line, Inner / outer tank failureo Overfilling of storage tanks, Send out pump failure
• Release of NGo 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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Safety in LNG Regasification
Two phase releases
Phenomena in case of LNG releaseFraction of LNG will flash (vapors)A fraction of liquid stays in suspension (aerosol)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)temperature, leak size, release height)
Different types of releasesLow pressure →Liquid releasep qHigh pressure →Gas release
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Safety in LNG Regasification
LNG leaks: main parameters
Release CharacteristicsUpstream ConditionsPressure, flow rateThermodynamic state of LNGPressurePressureTemperatureOverheated or not
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Safety in LNG Regasification
Example of LNG release
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Safety in LNG Regasification
RISK / HAZARD CONTROLRISK / HAZARD CONTROL
• M t id th f l• Measures to avoid the cause of release• 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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Safety in LNG Regasification
FACILITIES : UNLOADING ARMS
Unloading Arms designedfollowing OCIMF guidelines,
i i i i iwhich ensures compatibility withmost of the ships & safe operation
One of the significant feature isOne of the significant feature isinstallation of PERC
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Safety in LNG Regasification
Un-loading Arm – During Testing
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Safety in LNG Regasification
PERC REACTIVATION – DURING TESTING
BACK
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Safety in LNG Regasification
FACILITIES : LNG TANKS
Two nos. – 160,000 m3
capacity
Type: Full Containment
Design codes: BS 7777, APIDesign codes: BS 7777, API 620, EN 1473, NFPA 59A
Dia: 81 m; Height – 55 m; g
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Safety in LNG Regasification
LNG STORAGES TANK-PLLBOG pipe
Roof insulation (glass wool)
Concrete roofBOG pipe
Suspended deck
Insulation (Perlite) Resilient blancket
Bottom insulation (foam glass)Prestressed concrete
outer shellInner Tank 9% Nickel Steel
blancketLNG filling pipes
Full containment above groundLNG Tank Concrete slab
Low pressuresubmerged pump(removable)
Cryogenic Liner
Boil Off rate: 0.08% capacity/day
Piles
Air heating
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Ground level
Safety in LNG Regasification
TANK SAFETY
Containment Type Single Double Full
Remarks
Results of Consequence Modeling
g
At Luvara
Acceptable (0.9 Kw/m2)
Acceptable
( nil )
No affect
outside plant
NFPA 59 A Criteria is 5 KW/m2
Heat flux
due to LNG Fire
At
GCPTCLAcceptable
(1.2 Kw/m2 ) Acceptable (0.1 Kw/m2)
No affect outside plant
Flux causing structural
damage estimate is
25 Kw/m2
25 Kw/m2
5 Kw/m2 distance
700 m
300 m
77 m
3 Kw/m2 1200 m 700 m 88 m
Minimum
distance to property line
3 Kw/m2 distance
1200 m 700 m 88 m
Hazardous
Vapour Cloud
Spread
Unacceptable
(2500 m to 5600 m)
Unacceptable
(1100 m to 1200 m)
Acceptable
(57 m)
LEL not to
spread outside battery limit
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Cloud 5600 m) 1200 m) battery limit
*** PLL has selected fully contained tanks to ensure MAXIMUM SAFETY
Safety in LNG Regasification
LNG Regasificationg
For ORVs Sea water characteristics t t blnot acceptable
For SCVs high operating cost & high exhaust gas mission
Open Rack pVapourizer (ORV)
Submerged Combustion
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Submerged Combustion Vapourizer (SCV)
Safety in LNG Regasification
LNG REGASIFICATIONLNG REGASIFICATION
Air HeaterRLNG
Air Heater
GW Pump
STVWater Collection
Water Pump
Water to different users
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
30Glycol Water Circulation LNG
Water Pump
Safety in LNG Regasification
FACILITIES : AIR HEATERS & STVs
7 STVs / Air Heaters with 1127 STVs / Air Heaters with 112 fans-16.4 MW each
Close loop system with no exhaust
Only ambient air heat
No external firingNo external firing
Most environment friendly system
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STV
Safety in LNG Regasification
SAFETY ISSUES
PROJECT IMPLEMENTATION
Safety studies
HAZIDH d Id tifi ti
Project Technical reviewsHazard Identification
HAZAN
SAFETY CONCEPT
HAZANHazard Analysis:
Potential Hazards & consequences
HAZOPHazard and operability analysis:
Systematic approach to identify hazards and operability problems
QRAQuantitative Risk Assessment
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and operability problems QNumerical calculation of Risk level
Safety in LNG Regasification
SAFETY MEASURESSAFETY MEASURES INCORPORATED IN THE DESIGN
• State-of-the-Art Technology.• Automatic Safety Shutdown System.• System for early detection of leakage / spillage of LNG• System for early detection of leakage / spillage of LNG
or regasified LNG.• Plant Design and Equipment Layout as per
International & Domestic Safety Standards.y• Dedicated team to ensure adherence to safety measures.• Safety Audits & Mock Drills• Regular Safety Trainings (Internal & External)• Regular Safety Trainings (Internal & External)• Incedent Reporting & Analysis
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Safety in LNG Regasification
EQUIPMENT LAYOUTEQUIPMENT LAYOUT
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Safety in LNG Regasification
REGASIFICATION TERMINALREGASIFICATION TERMINAL EQUIPMENT LAYOUT
• EN 1473 & NFPA 59 A provides guideline
• Layout to ensure LNG piping is minimezedLayout to ensure LNG piping is minimezed
• Layout to ensure risk does not extend beyond the plot
• M i C t l t b i h d• Main Control room to be in non-hazardous area.
• Hazardous area classification may be decided based oni i i f i idispersion calculation from possible spills.
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Safety in LNG Regasification
Safety Distance – Dahej LNG Plant
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
The required safety distance form leakage point for HP & LP source are 190m and 168m which could be accommodated within the Allocated plot
Safety in LNG Regasification
Safety Distance – Kochi LNG Plant
The required safe distances from leakage point from HP & LP source
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
are 141 & 105 m, which could not be accommodated within the allotted plot. PLL had to use water curtains to resolve this problem
Safety in LNG Regasification
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 valveso Step 1: - Close the NG / LNG valveso Step 2: - Disconnect the NG / LNG un-loading Arms
• Failure of both the steps only can cause the LNG spill.LNG T f Li• LNG Transfer Lines
• Pipes are protected against corrosion, overpressure, Vehicle crash,equipment fall by design features & mostly being welded pipes
• Inner Tank Failure• Inner Tank Failure• Design Features (e.g. metallurgy, welding procedures, earthquake
factor, low temperature detectors, no nozzle on side or bottom oftank, provision of VRV etc.) make the failure chance almost rare.p
• Outer Tank Failure• Pre-stressed concrete outer tank designed to with stand cold LNG &
external aggression due to LNG leak, earthquake, projectile attack
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etc.
Safety in LNG Regasification
LNG Spill Prevention Methods
• Release From Valve Packing• Extended Bonnet Valves Have been used
Packing leak can be predicted by early accumulation of• Packing leak can be predicted by early accumulation offrost
• Early detection & tightening procedures are developed toprevent liquid escapep q p
• Release from piping flanges, Spool Pieces & Hoses• Use of flanges, spool pieces & Hoses for LNG has been
minimized (practically zero).(p y )• Future connections (or other tapings), where flange
connections are necessary, are properly vented• Leaks In Gas Phase Pipingp g
• Leaks resulting in the release of cold gas can occur in thepiping associated with the vaporization of natural gas.
• This area is provided with extra instrumentation
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• This area is provided with extra instrumentation
Safety in LNG Regasification
HANDLING OF LNG LEAKS & SPILLS
• Elaborate Leak detection systemy• Thermal Sensors• Gas Detectors
• procedures to protect personnel from contract with leaking liquid p p p g qor cold vapor and minimize the chance for vapor contact with potential source of ignition
• Equipment such as barricades, Warning signs and combustible gas q p , g g gindicators are available at the plant
• Elaborate Emergency Shut Down (ESD) system & System isolation• ESD1: - Stop Ship Un-loadingp p g• ESD2: - Stop Send out system• ESD3: - Stop Complete facility
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Safety in LNG Regasification
ACTIVE EMERGENCY / FIRE PROTECTION AS SMEASURES
• Fi W t S t Ri M i H d t T• Fire Water System: Ring Main, Hydrants, Tower Monitors, Remote / manual operated spray system, Water Curtain
• High Expansion Foam System• Clean Agent (Inergen) system
P t bl Fi E ti i h• Potable Fire Extinguisher• Mobile Fire Fighting triple purpose (Water/Foam/DCP)
Tender• Personal Protection Gears & Breathing Apparatus• Oil Spill Handling Equipment
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Safety in LNG Regasification
AN ACTIVE MEANOF PROTECTION :
THE WATER CURTAINTHE WATER CURTAIN
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Safety in LNG Regasification
Mitigation effects of a water curtain
Mechanical Dispersion (heating, dilution) Chemical dilution (absorption)dilution) Chemical dilution (absorption)
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Thermal radiation mitigation
Safety in LNG Regasification
Mitigation effects of a water curtain
Example of nozzles ramps
Nozzles characteristicsNozzles characteristicsDiameterSize of spraysMomentum of sprays
Downward curtain (full cone nozzles)Curtain geometryNumber of nozzles per linear meter of
curtainSpacing between the nozzlesDistance between the nozzles ramps
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
Upward curtain (peacock tail)
Safety in LNG Regasification
Mitigation effects of a water curtain
Field tests (pool fire) –Gaz de France
Significant thermal radiation mitigation, depending on the water curtain characteristics
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p g
Safety in LNG Regasification
REDUCING THE FLAMES :USE OF FOAM
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Safety in LNG Regasification
SAFETY ISSUES: Foam generation system
• Physical foam effects:• Before ignition:• Before ignition:
• Isolate LNG layer from ambiant air• Reduce the vaporization
G• Warm-up LNG vapours• Increase the dispersion
• After ignition: Airg• Reduce heat exchanges between
the LNG layer and the flame • Produce steam which reduce the
fl
Nozzle Pre-mix=
Waterflame• Reduce combustion ratio• Reduce fire radiation
Foam
Water +
Emulsifier≈3% vol
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Foam
Safety in LNG Regasification
Reduction of fire with foam
Evolution of the received flux during the phases of foam discharging and destruction (50 m² circular LNG pool fire)discharging and destruction (50 m circular LNG pool fire)
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Safety in LNG Regasification
SAFETY ISSUES
•FIRE FIGHTING SYSTEMSE ti i hi t• Extinguishing agent:Chemical powder
• Fixed systems: Powder gunsy g• Mobile systems:
Trucks, 100kg powder extinguisherextinguisher
• Hand extinguisher: 9kg• Extensive training of g
Operators • safety teams
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Safety in LNG Regasification
Spreading and vaporization of pools
Spreading of an LNG poolLow pressure LNG spills from a pipeline or a vesselLNG comes into contact with groundLNG gains some heat from groundI f i iIncrease of vaporizationGround is cooled downLNG spreads, forming a poolLNG continues to cool down groundLNG continues to cool down groundTemperature differential between ground and LNG decreases, and thus heat exchange
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Safety in LNG Regasification
SAFETY - DOCUMENTATION• A Comprehensive set of Documentation is in Place for Safe &p
Reliable Operation:• Disaster Management Plan
• Oil Spill Contingency Plani.
• Port Administration
• Port Operations• Port Operations
• Health, Safety and Environment (HSE)
• Maintenance of Tugs and Support Craft & Jettyg pp y
• Training
• Terminal Information & Regulations & Operation Books
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Safety in LNG Regasification
Concluding Remarks• Follow the Codes & Standards leads to safe design &
operation• St di lik HAZOP QRA SIL Ri k A l i t d i• Studies like HAZOP, QRA, SIL, Risk Analysis etc. during
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• Carryout detailed modeling studies to establish compliance with environmental / regulatory requirements in project development process from the very beginning
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Safety in LNG Regasification
REDUCING THE RISKS AT DAHEJ TERMINALREDUCING THE RISKS AT DAHEJ TERMINALDESIGN & CONSTRUCTION E R l C liDESIGN & CONSTRUCTION Emergency Release CouplingFull containment Storage Tanks
Some
examples:
Lay-out: safety distances
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon SectorCold and Gas Detection
Safety in LNG Regasification
LNG IS A MATURE INDUSTRY ENJOYING A VERY HIGH LEVEL SAFETY RECORD
WORLDWIDE
THANK YOU FOR YOUR ATTENTION
12th Aug, 10 Petrofed – Seminar on Safety in Hydrocarbon Sector
182,000 m3 LNG tanks under construction Petronet LNG Ltd LNG Terminal Kochi