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Specialized Training For Oil Tankers CH 9 INERT GAS SYSTEM PDF
Specialized Training For Oil Tankers CH 9 INERT GAS SYSTEM PDF
Learning objectives
- which oil tanker must be provided with an inert gas system
- the inert gas system
- the inert gas plant
- the scrubber
- the inert gas blowers
- the inert gas pressure regulating valve
- the non-return devices
- the inert gas distribution and venting
- gas-analysing, recording and indicating equipment
- operations
- meters, indicators and alarms
- emergency procedures
- maintenance and testing
9.1 GENERAL
Fire and explosion are among the greatest threats to the mariner; a tank ship carrying
crude oil, refined petroleum, or chemicals is an even greater threat. Fortunately, a
properly designed, installed, operating, and maintained inert gas system (IGS) will
completely prevent fire and explosion in an intact ship tank. Combustion is impossible
without oxygen; if there is some way to keep the oxygen below about 8 percent, the
ship will be free of danger from explosions in intact tanks. Typically, this is done by
adding to the tank atmosphere a gas that has less oxygen (often 5 percent or less) than
air, which has an oxygen concentration of 21 percent. Of course, when a tank is opened,
as in a collision, oxygen can enter the tank regardless of the IGS. In the 1920's and
1930's, one American petroleum company suffered several tank ship fires and decided
to inert the cargo tanks of its ships. Reportedly, its vessels have not had any intact cargo
tank fires since that time.
In the mid1970' s, a series of tank ship accidents led to the International Conference on
Tanker Safety and Pollution Prevention (TSPP) of 1978 and the passage of the Port and
Tanker Safety Act of 1978 (PTSA). International rules are contained in Chapter II-2,
Regulation 62 (Inert Gas Systems) of the International Convention for the Safety of
Life at Sea (SOLAS), 1974. The first set of amendments to SOLAS 74 were adopted
and came into force on 1 September 1984; under them, a ship must satisfy applicable
requirements to receive a SOLAS Safety Certificate. The second set of amendments to
SOLAS 74 come into effect on 1 July 1986; they have only a minor effect on the IGS
requirements.
9.2.2 Quality
A final oxygen level of 8% or less will be more easily achieved if the oxygen content of
the inert gas in the inert gas main is considerably less than 8%. Ideally the inert gas
should not contain oxygen but this is not possible in practice.
When using flue gas from a main or auxiliary boiler, an oxygen level of less than 5%
can generally be obtained, depending on the quality of combustion control and the load
on the boiler.
When an independent inert gas generator or a gas turbine plant with afterburner is
fitted, the oxygen content can be automatically controlled within finer limits, usually
within the range 1.5% to 2.5% by volume and not normally exceeding 5%.
Whatever the source, the gas must be cooled and scrubbed with water to remove soot
and sulphur acids before being supplied to the cargo tanks.
The International Convention for the Safety of Life at Sea (SOLAS 1974), as amended,
requires that inert gas systems be capable of delivering inert gas with an oxygen content
in the inert gas main of not more than 5% by volume at any required rate of flow; and
of maintaining a positive pressure in the cargo tanks at all times with an atmosphere
having an oxygen content of not more than 8% by volume except when it is necessary
for the tank to be gas free. Existing systems are only required to be capable of
producing inert gas with an oxygen content not normally exceeding 5% by volume, and
of maintaining the tank inerted at all times except when it is necessary for the tank to be
gas free.
Usually located on the main deck, the deck water seal is the primary safeguard to
automatically prevent a reverse flow of cargo gas from a tank to the boilers, the
engines, or the IGG. The deck water seal offers a positive break in the system by means
of a water trap. This permits inert gas to be delivered to the main deck while preventing
gas backflow, even when the IGS is shut down. The regulations require two
independent water supplies for the deck water seal. When the IGS is operating, the
scrubber pump supply is used; the second supply, normally the salt-water service pump,
is used when the IGS is not operating. Each pump must be capable of operation at all
times. The deck water seal is provided with a heater to prevent the water from freezing
and an automatic control system that prevents overheating of the seal. Although not
required, a demister is usually fitted to remove entrained water. There is always a water
layer through which the inert gas bubbles
There are three general types of deck water seals: wet, dry, and semidry.
(1) The wet seal is described in Figure 9.1.
It is deemed the most reliable and is the only type generally approved for use on most
vessels.
Figure 9.1
(2) The semidry seal operates dry after the IG flow displaces the water. Venturi action
returns the water when a gas block is needed as described in Figure 9.2.
This type of seal as been approved for U.S. vessels on a case-by-case basis, if the unit is
quick acting, has no moving parts, and has no sensors that are subject to failure.
Figure 9.2
(3) The dry seal operates normally dry and is filled with water when the IG plant is shut
down or when tank pressure exceeds the IG pressure. This system requires more
operating parts, reacts slower and is not deemed as reliable as the wet type. Dry seals
are not approved for use on U.S. vessels. See Figure 9.3 for a more complete
description.
In the dry type seal, the water is drained from the seal when the IG plant is in operation
(gas flowing to the tanks), and filled with water when the IG plant is either shut down,
or the tank pressure exceeds the IG blower discharge pressure. Filling and drainage are
performed by automatically operated valves controlled by the levels in the water seal
and the drop tank, and by the operating state of the blowers. Vessels must be equipped
with seals that are completely passive in operation, so that failure of sensors, control
systems, or moving parts cannot cause failure to establish a seal. Active seals, such as
the dry seal shown above, are not acceptable.
Figure 9.3
9.8 INERT GAS DISTRIBUTION AND VENTING
9.8.1 General
The inert gas main may be divided into two or more branches forward of the non-return
devices. The inert gas supply main shall be fitted with branch piping leading to each
cargo tank. Branch piping for inert gas shall be fitted with either stop valves or
equivalent means of control for isolating each tank. Where stop valves are fitted, they
shall be provided with locking arrangements, which shall be under the control of a
responsible ship's officer. The control system operated shall provide positive indication
of the operational status of such valves.
Oxygen analyser
9.10 OPERATION
9.10.1 Introduction
The purpose of an IG system is to keep the oxygen content of the vapour space below
the level needed for combustion. For crude carriers, the oxygen content of the inert gas
delivered to the cargo tanks should be no more than 5 percent, to ensure that there is not
enough oxygen in the tank to support combustion.
On board oil tankers required to have an inert gas system the cargo tanks should
preferably at all times be inerted and have a tank atmosphere with an oxygen content
not exceeding 8% by volume except when the tanks need to be gas-free.
This means that during normal operation of oil tankers the following operational modes
frequently take place:
Inerting of empty tanks
Inerting during loading and simultaneous discharge of ballast
Inerting during loaded sea voyage
Inerting during discharging and ballasting
Inerting during tank cleaning
Purging prior to gas freeing and use of the IGS during gas freeing.
The vessel used as an example in this paper is fitted with so-called “purge pipes” for
ventilation and purging. (see Fig. 1 on page 19 of this chapter)
On board vessels without purge pipes but with stand-pipes (i.e. vent pipes from deck
level and about 2500 mm up vertically from deck level), these pipes are to be opened
instead of the purge pipes mentioned in this paper.
The vessel is not fitted with SBT (Segregated Ballast Tank) capacity according to
MARPOL 73/78, and ballast water has to be carried in cargo oil tanks on ballast
voyages.
IG operation panel
When all tanks are satisfactorily inerted, the tanks should be put under a slight
overpressure, normally 300-600 mm W.G., and the plant closed down according to
instructions and the tank isolating valves closed.
Fig. 1 indicates the plant in operation
The vessel is supposed to arrive at the loading port with all cargo tanks inerted.
If the ship is fitted with a central gas vent outlet, all tanks to be loaded are connected to
the vent system.
In case only local P/V valves are fitted, the valves are checked and adjusted for
evacuation of gas through the high-speed valves.
It should be checked that all tank hatches are closed and possible float level indicators
are operable.
9.10.4 Discharge of ballast
Discharge of ballast can be done either before or during the loading. During discharge
of ballast, before loading is commenced, the inerting procedure is the same as during
discharge of cargo. See below.
The inert gas system can be operated if required, but will normally not be required to
deliver any gas to the deck lines.
If by chance the ballast discharge rate is higher than the loading rate, the inert gas
system must be in operation and the deck pressure adjusted sufficiently high to give a
positive outflow of inert gas through the ventilation mast (or the individual P/V valves
on the tanks). This is to avoid air being sucked into the tank system by a possible under
pressure in the ballast tanks.
In order to start the loaded voyage with positive pressure in the tanks, the IGS has to be
started and tanks purged to a pressure of 300-600 mm W.G.
When the pumping (discharge) starts, the pressure in the usage volume will drop. Now
the control valve (7) will start operating and will open, for inert gas to compensate the
pressure drop and keep a constant pre-selected pressure in the tanks. After some time
the required pressure is established. At this moment the volume delivered from the
inert gas system is equal to the delivery by the cargo pump. This condition is illustrated
in Fig. 5.
If, for any reasons, access to the cargo tanks is necessary during discharge, the
following procedure should be followed:
Reduce the inert gas pressure by adjusting the set point of the pressure
control valve.
When the tanks' inert gas pressure is reduced to near atmospheric pressure,
a suitable ullage hatch has to be opened carefully.
When reading is finished, the hatch may be closed and the pressure raised,
if desired.
When discharge and stripping are finished, the tanks should be put under the desired
positive pressure.
The tank pressure and oxygen concentration should be monitored during the voyage
and new purging or 'topping up' should be done when necessary.
9.10.11 Gas-freeing
When access to the cargo tanks is necessary for inspection, repair, etc., the inert gas or
inert gas/hydrocarbon gas mixture has to be replaced with fresh air. This replacement
is called “gas-freeing”.
The gas freeing is normally carried out by one or more of the following three methods:
1. By portable tank ventilators
2. By permanently installed tank ventilators blowing air into tanks through the
cargo oil piping system
3. By using the fans of the inert gas system with suction from fresh air instead of
from the scrubber.
Whatever method is being used for gas freeing, the following steps should be taken:
1. Hydrocarbon gas concentration to be measured in each tank to be gas-freed.
2. If the concentration of hydrocarbon gas is 2.5% by volume or less, ventilation
with fresh air may start immediately.
3. If the concentration of hydrocarbon gas is above 2.5% by volume, the tanks
should be purged with inert gas until the concentration is 2.5% by volume or less
before ventilation with fresh air starts.
4. Ventilation should continue until the concentration of hydrocarbon gas is 5%
LEL or less and the oxygen level is 21% by volume before the tank is certified
gas-free.
Gas freeing can take place either by a dilution method or by a displacement method, as
indicated on Figs. 8 and 9.
Using the dilution or mixing method, the fresh air is blown, at high pressure, into the
tank at deck level, forced down to the bottom of the tank and vented out at deck level.
See Fig. 8.
By the displacement method the air is blown in slowly at deck level and is forced out of
the tank near the bottom, through the purge pipe. See Fig. 9.
Although a turbulent mixing flow is wanted if using the dilution method, the opposite is
wanted if using the displacement method. Consequently, the different methods require
different air inlet nozzle arrangements where the fresh air enters the tank.
.1 In the case of tankers built on or after 1 September 1984, the venting system is
checked to ensure that approved devices to prevent the passage of flame into
cargo tanks are fitted and that these devices are in a satisfactory condition.
.2 In the case of tankers built before 1 September 1984 the flame screens are
checked to ensure that they are in a satisfactory condition.
In the case of product carriers if it is essential to clean tanks following a failure of the
inert gas system and inerted conditions as defined in SOLAS Regulation 62.2.2 cannot
be maintained, tank cleaning should be carried out with an external supply of inert gas
connected to the system. Alternatively, if an external supply of inert gas is not
connected to the ship, the following precautions should be taken:
.2 The tank should be isolated from other tanks and from any common venting
system or the inert gas main and maximum ventilation output should be
concentrated on that tank both before and during the washing process.
Ventilation should provide as far as possible a free flow of air from one end of
the tank to the other.
.3 The tank bottom should be flushed with water and stripped. The piping system
including cargo pumps, crossovers and discharge lines should also be flushed
with water.
.4 Washing should not commence until tests have been made at various levels to
establish that the vapour content in any part of the tank is below 10% of the
lower flammable limit.
.5 Testing the tank atmosphere should continue during the washing process. If the
vapour level rises to within 50% of the lower flammable limit, washing should
be discontinued until the vapour level has fallen to 20% of the lower flammable
limit or less.
.7 The tank should be kept drained during washing. If build-up of wash water
occurs, washing should be stopped until the water has been cleared.
.8 Only clean, cold seawater should be used. Recirculating systems should not be
used.
.10 All deck openings, except those necessary for washing and designed venting
arrangements, should be kept closed during the washing process.
During cargo operations in port, more stringent regulations of the port Authorities shall
take precedence over any of the foregoing emergency procedures.
The attention of the ship's master should be drawn to Regulation 11 (c) of Chapter 1 of
the 1978 SOLAS Protocol in the event of the inert gas system having become
inoperative."
9.12.2 Scrubber
Where feasible, all access plates and internal components such as demister pads and
scrubber trays shall be removed. Soot and scale deposits shall be removed prior to the
inspection. The following areas and internal components should be given close
attention:
(1) Internal coatings should be completely intact. Check for signs of chipping or
cracking, particularly around internal fastenings.
(2) Inspect gas inlet pipe in the scrubber water seal for corrosion and holes or leaking
flanges, especially above the water level, that would allow gas to bypass the seal
and render it ineffective.
(3) Closely inspect the internal area at the bottom of the scrubber for corrosion,
especially in way of the effluent discharge line. Check the discharge line for
clogging.
(4) Inspect float switches, temperature sensors, Venturi slots, impingement plates,
packed trays, and demisters (as applicable) for damage, wastage, and corrosion.
(5) Ensure that the water heater (used to prevent water freezing) and its control system
are in good condition.
(6) Inspect fresh and saltwater inlet piping for corrosion or wastage, and especially for
holes or leaking flanges. Check spray nozzles for clogging and intact condition.
9.12.3 Valves
Boiler uptake (or IGG) valves, blower inlet and discharge valves, recirculating valves,
pressure regulating valves, deck mechanical non-return valves, deck isolating valves,
and IGS isolating valves shall be disassembled for inspection.
Valve internals shall be inspected for cleanliness, and for signs of corrosion or erosion.
Careful attention should be given to "butterfly" mechanisms to ensure free, smooth
operation and proper seating. Check non-return valve seals. If accessible, either through
inspection ports or disassembled components, the internal areas of the inert gas main
and branch lines shall be checked for excessive scale buildup or soot deposits, which
could result in a critical gas pressure drop between the IGS blowers and the cargo
tanks.
9.12.5 Blowers
The inspection ports and access plates on all blowers shall be opened. Blower
impellers, bearings, and casings shall be checked for corrosion or excessive buildup of
deposits that may cause blade failure. If accessible, fresh water flushing spray nozzles
shall be checked for intactness or clogging; the blower drain piping, for corrosion or
clogging.