BULK HANDLE LPG SAFELY

By

NARAYANA PILLAI.P.N
EX: General Manager FEDO-FACT -KOCHI

1
Oil Refining & Fractional
Distillation

2
 Crude Distillation Unit

Crude is Heated With Emulsifying

Agents And Condensed Naphtha
Goes To LPG Recovery Unit.

Raw Naphtha is heated to separate

out Kerosene , Diesel etc . in stages
 LPG Recovery Unit
• The overheated gases are cooled to
condense LPG

• Naphtha Splitter Unit : Separate out

different Types of Naphtha
CHEMICAL ACCIDENTS
CAN CAUSE

• FIRE

• EXPLOSION

• TOXIC RELEASE

5
 LPG FIRE NCIDENTS
• IOC WEST DELHI LPG BOTTLING
MAY16,1983

• HPCL VIZAG SEPT 14 ,1997

• PEMEX MEXICO NOV 19,1984

6
HPC -VIZAG

7
SOME PICTURES

8
RUNNING FOR LIFE

9
GREEN BELT AREA
ON SITE

GREEN BELT
(500 MTS)

10
Pemex Before BLEVEs

11
Pemex After

12
F-4 Failure

13
Bullet Tank Area

14
Maximum Missile

15
WHAT IS LPG ?
• Petroleum gases in
liquid form and major
elements are:-
• Propane C3H8
• Propylene C3H6
• N-butane C4H10
• Iso-butane C4H10
• Butylene C4H8

16
WHAT IS LPG ? cont--
• Small quantities of one or
more of the following are
also present :-

• Ethane C2 H6

• Ethylene C2H4

• Pentane C5H12

• Pentene C5H10
17
 TYPES OF LPG

• Commercial Butane

• Commercial Butane –
Propane

• Commercial propane

MOUNDED BULLETS
18
LPG FILLING

An automated carousel for filling

of LPG Cylinders 19
PROPERTIES OF LPG
• LPG is a liquid under pressure but a
gas at ambient conditions.
• Vapour LPG is twice as heavy as
Air.
• Liquid LPG is half as heavy as
water.
• LPG is colourless liqud
• LPG has a low boiling point of
-180C.

20
PROPERTIES OF LPG cont--
• LPG has a narrow
flammability range between
1.8 to 9.5% in air.
• Flash point of LPG is -24.50
C
• The approximate minimum
ignition temperature of LPG
is in the range 4100C to
5800C.
• LPG is odourless.
21
PROPERTIES OF LPG cont--
• Ethyl Mercaptan(C2H6S) is
added as an odourant to detect
LPG in case of leaks.

• LPG is non-toxic.

• It is lightly anaesthetic and

can cause suffocation, if
present in sufficiently high
concentrations.

22
ETHYL MERCAPTAN- C2H6S
• F.P - 48C
• LEL 2.8% V
• UEL 18% V
• VP 1.14kg/cm2 AT 37.8C
• DEENSITY 2.1(AIR1.0)
• TOXICITY:-
• Oral LD50 682mg/kg
• Inhalation LC50 > 2.52mg/L
• Dermal LD50 >2000mg/kg
• TLV 0.5PPM

23
PROPERTIES OF LPG
• Liquid LPG can cause
severe cold burns to
the skin owing to
rapid vapourisation
and the consequent
lowering of
temperature

24
ADVANTAGES OF LPG
• Clean Burning
• No soot, burners have
a longer life - so
maintenance is low
• No spillage as it
vaporises at
atmospheric
temperature and
pressure.
25
ADVANTAGES OF LPG cont--
• Effects of corrosion are greatly
reduced
• Instantly controllable flame
temperature
• Avoids Scaling and
decarborising of parts
• Environmentally friendly fuel,
with minimal sulphur content
and sulphur- free emissions
26
ADVANTAGES OF LPG cont--

• Very high efficiency

with direct firing
system Instant heat for
faster warm-up and
cool-down

• Can be used for a

variety of applications

27
 USED AS REFRIGERANT
• Dry propane (refrigerant designator R-290)
and isobutane (R-600a) the blend "R-290a" has
negligible ozone depletion potential and very
low global warming potential
• Can serve as a functional replacement for R12,
 R-22, R-134a and other chloro fluoro carbon
or hydrofluorocarbon refrigerants in
conventional stationary refrigeration and air
conditioning systems.
28
Typical LPG Specification
IS 4576 -1999 VP AT 40C
IS 10.G Kg/Cm2

29
30
31
 G/L RATIO

•Propane-based LPG is compressed into 274 times less

space than its gases would normally occupy, forcing it to
turn into a liquid.

•Butane-based LPG is compressed slightly less into about

32
233 times less space
 COMPARISON WITH NG
• LPG is composed primarily of propane
(C3H8)and butane,(C4H10) while Natural
Gas is composed of the lighter Methane
gas(CH4) and Ethane(C2H6)

• LPG, vapourised and at atmospheric

pressure, has a higher calorific value
(10,800Kcal/Kg) than natural gas (methane)
(8,000 – 9,480 kcal/Kg)
33
 STORAGE CONDITIONS
• The storage temperature of LNG is –162°C
and is described as cryogenic conditions.
• The liquid occupies 600 times less space
than natural gas in its gaseous state, making
it practical to ship by ocean tanker.
• And it's stable and safe, because even
though compressed in volume,
• The liquid remains at normal atmospheric
pressure

34
LNG STORAGE TANK

35
IS CODES

• Physical properties
IS:4576

• Test method IS:1448

36
BULK STORAGE
• SPHERES

• BULLETS

• MOUNDED BULLETS

• AT AMBIENT TEMP

• AT AMBIENT PR
(REFRIGERATED)
37
BULK TRANSPORT

• BY RAIL WAGONS

• BY ROAD TANKERS

38
LOADING & UNLOADING

• COMPRESSOR

• PUMPS

• GANTRIES

• INTERCONNECTING
PIPINGS
39
40
41
42
LPG HAZARDS

• FIRE
• EXPLOSION
• LEL 1.9 %
• UEL 9.5 %
• BLEVE
• UCVCE
• VAPOUR CLOUD
CAN TRAVEL
TO 1500 Mts

43
BLEVE

44
RAIL TANKER FIRE

45
OTHER HAZARDS
• If 0.1% con air
inhaled for 5 min
person feels giddy

• 0.5% inhaled for 4

min exhibits
symptoms of
alcoholic

46
SAFETY GUIDE LINES

• EMPLOY GOOD
ENGINEERING
PRACTICES IN DESIGN

&

• CONSTRUCTION

47
48
49
DESIGN & CONSTRUCTION
CODE

• STORAGE VESSELS
ASME Sect VIII Div-1

• BS 1500

50
 MINIMUM DISTANCE

Volume(water capacity) Min separating distance

CUBIC METRES METRES
UP TO 9 7.5
10 TO 135 15.0
136 TO 350 22.5
351 TO 560 30.0
ABOVE 560 45.0
FROM NAVIGABLE WATER 15.0
BETWEEN TWO LPG STORAGES 15.0
51
 FIRE PROTECTION STANDARDS
• NFPA 58-Storage and handling LPG
• NFPA 59- LP Gas at utility gas plants
• API 2510 –Design and construction of LP-
gas installation at marine and pipeline
terminals, Natural gas processing plants and
Tank farms
• OISD 144 FOR LPG BOTTLING PLANTS

• Rules of the Fire Office Committee - London

52
 METHODS OF PROTECTION
• When exposed to fire:-
• 25 mm thk steel plate will reach 6900 c in 16 min
• 13mm ,, 8 min

• At 6900c a typical pressure vessel would rupture

in 2.5 min (BS:1501-151 Grade-B)

53
PROTECTION AGAINST FIRE
• Slopping the ground

• Insulation

• Water drenching

• Depressurising
54
 SLOPPING THE GROUND
• To prevent accumulation of spillage

• Slope 1 in 40

• Provide spillage collection at a distance

55
 INSULATION
• ICI LPG code stipulate tank
insulation
• Other codes stipulate fire proofing of
supports only
• Insulation slows down the rate of heat
rise
• Treated as an additional facility to
water drenching
56
• LP Gas storage sphere collapsed while being filled for a
hydrostatic pressure test killing a worker underneath.
• Support legs had corroded due to water trapped between
Insulation and support column.

57
 WATER DRENCHING
(Medium velocity spray system)
 Widely used to prevent over pressure

 Take care to prevent thermal shock

 Rate of water spray is 10 Lpm/m2

 Apply water as quickly as possible

58
59
60
61
62
63
 DE PRESSURISING
 REDUCE PRESSURE TO REDUCE METAL
STRESS

 BY RELIEF VALVES SUITABLY SIZED

 API RECOMMENDS TO REDUCE PRESSURE

TO 8 BAR OR TO 50% OF DESIGN PRESSURE
WHICH EVER IS LOWER IN 15 MINUTES

64
INSTRUMENT
• ROV IN LIQID OUTLET

• LEVEL GAUGE WITH

REMOTE INDICATION
AND INLET CUT OFF
FACILITY

• Continues Gas Detection

Monitors

65
 GAS MONITORING
• HYDROCARBON DETECTORS

• ELECTRO CATALYTIC TYPE

• MOLICULAR DIFFUSION TYPE

√ FOR LPG MOLICULAR DIFFUSION IS USED

• DETECTOR HEADS,POWER
UNIT,AMPLIFIER,ALARM,GRAPHIC
PANEL,LEL METER etc are elements
66
67
TRANSPORT BY ROAD

• MAJOR FORM OF
TRANSPORT IS BY
ROAD
• THIS POSES A LOT OF
HAZARDS
• MOTOR VEHICLE RULES
129 TO 137 IS FRAMED
TO PREVENT
ACCIDENTS

68
LPG ISO Container

69
LP Gas Vehicle parking and
protection against movement

70
SALIENT FEATURES ARE
• Display a distinct mark of
the class label appropriate
to the goods

• Every package shall

display class label

• Size,mode of display,
position ,colour—etc
prescribed

71
Salient Features
• Emergency
information panel
• Correct technical
name
• Class label
• Name &Tel no
ofconsigner
• HAZCHEM code
72
 Salient Features
• Consigner to give safety information to
transporter

• Transporter shall ensure that all details are made

available

• Owner should ensure that the driver has

sufficient understanding of the hazard
73
 Salient Features
• Driver shall observe all precautions at
all times
• In case of accident driver to report to
the nearest police station
• Table II gives indicative criteria
&Table III lists chemicals with hazard
classification

74
EMERGENCY PANEL
LOCATIONS

75
 Chemical Safety
Wear Correct Recognize Chemical Symbols
Personal Protective
Equipment (PPE)

76
EXAMPLE –EMERGENCY
PANEL

77
 HAZCHEM code
NFPA Classification
• USES NUMERALS 1to 4
• Eg:Chemical-Ethylene
• HAZCHEM CODE -2WE
• 2- Indicates that water fog,
foam or dry agent can be
used but not water jet
• W- indicates violent
chemical
• E- means evacuation of
people 78
TREM CARD
• Transport Emergency Card
• chemical identity
• Nature of hazard
• Protective device
• Emergency action
• Spillage
• Fire
• First aid
79
80
Transport Emergency Plan
• Objectives are:-

• Localize the emergency

• To minimize the effect of

the accident on people
&property

81
IDENTIFICATION&ASSESMENT
OF HAZARD
• Chemicals transported
• Quantities
• Transport route
• Enroute accident prone
points
• Past accident records
• Chemicals usually involved
• Condition of roads --etc
82
 Above assessment will help

• Diversion of hazardous goods transport

• Improvement of roads

• Change in statute ---etc

83
 Elements of planning for
Transport Emergencies
• Notification
• Command &communication
• Fire response
• Fire & spill control
• Vapour control
• Decontamination
• Level of protection
• personnel protection equipments
84
THANK YOU

• FOR

• YOUR ATTENTION

85