Bulk - Segment

Bulk Cluster
Bulk supply

FILLING PLANT

LPG STORAGE

BULK
DELIVERY

CONSUMER
 Role of Engineering Department

• To adhere the international / global standards while developing

any working within the market.
• Arranging regular joint calls with the sales team in order to understand
the customer needs.
• Setting regular inter-departmental meetings between Sales &
Engineering departments to further understand the working strategy
and develop synergy.
• Understand the tank installations / and assure safety guidelines.
• Regular trainings for Engineering & Sales personnel to keep
abreast with the latest techniques followed internationally.
• Technical assistance to sales department
• Emergency Response
• Complaints Handling
• After Sales Services
• Maintaining the Company Assets
LPG Tanks
BULK TANK CONTROLS
 Our products
• 1 MT tank
• 1MT tank
• 1.75 MT tank
• 2 MT tank
• 2.38 MT tank
• 5 Mt tank
• 200 kg
• 18 kg
• 18 kg
• 11.8 kg
• 45.4 kg
• Vaporizers……………….
• Pump
Pre-Requisites of proper size of tank
depend upon the following factors:

• Consumption of gas or the present fuel consumption.

• Off take of gas.
• Bowser access.
• Gas regulation

For timely replenishment of the tank (s) the tanks should be sized to
provide at least one month of gas
 Customer engineering process
flow- New Development

• ESVR & Technical Assistance

• Explosive License & NOC
• Installation
• Commissioning
ESVR & Technical Assistance
Sales
ESVR raised
Stop

CED
Sales N SVR review/ Review & Completion of SVR Technically by CED
Not assessment
compatible

Y
Sales CED
Short N Site visit Site/ESVR evaluation on location against the SVR and
comings
requisite standards (Technical and safety assessment)
Y

Sales Y Sales
Rectified Proposal/ Financial stability of the project
Contract ensured/verified, Proposal/ contact submitted
Approval from SMM

Contract approved / Cancel

ESVR Format
Site Visit for Technical Assessment
Burner Data Collection
Data collect from burner data plate/Existing fuel used on Burner/Burner orifice
size.

 Site Assessment
◦ The site area should be clean, with respect to combustible material.
◦ The site should be installed at a location with minimum human activity.
◦ The Bulk site should have safety area as per the below table:
 Burner Types
Burner type Application Process Comments
temp 0 C

Atmospheric Domestic/Commercial 50-90 Simple low cost, Limited

heaters/Hot water cookers turn down
Pre-Mix Oven/Dryer 200-400 Good control, use with
multiple nozzles
Nozzle Mix Furnace / Kilns 500-1200 Wide range of flame
pattern
Packaged Boilers / Oven / Dryer 50-500 Low cost , Easy to install,
Limited turn down
Recuperative Metal re-heating furnace, 200-1450 Fuel saving 3-40 %
Aluminum melting
furnace, ceramic kilns
Air duct burner Factory/ Space heating 100-800 Design for high air flow
/Spray dryers/ Paint ovens heaters
 Burner

• Atmospheric burner

• Pre- Mix burner

• Nozzle mix burner

• Packaged type
 Conversions
• Energy:
• 1 kw = 3412 Btu/hr
• 1 Kcal = 3.96 Btu/hr
• 1MJ = 94782 Btu
• 1Therm = 100000Btu
• 1 HP = 42.41 Btu/min
• 1 HP = 746 watts
• 1 HM³= 3600 Cft
• Volume:
• 1 Lit/hr = 0.03532 ft³/hr
• 1 Lit = 0.03532 ft³
• 1m³ = 1000Lit
• 1m³ = 35.31ft³
• Pressure:
• 1 Bar= 14.5 Psi
• 1 in water column = 0.0361 psi
• 1kg/cm² = 14.22 psi
• 1 psi = 27.67 wc
 Fuel Calculations

Fuel = HSD
HSD used in a Hour = 100Lit
Specific Gravity = 0.82
GCV Of HSD = 44738
GCV Of LPG = 47000
KG of LPG = ?
(HSD Lit X Sp. Gr X CV Of HSD)/ CV
Of LPG
( 100 X .82 X 44738) /
= 47000
= 78 Kg
 Fuel Calculations

Fuel = HFO
HSD used in a Hour = 100Lit
Specific Gravity = 0.93

GCV Of HSD = 40,000

GCV Of LPG = 47,000

KG of LPG = ?
(HFO Lit X Sp. Gr X CV Of HFO)/ CV Of
LPG
( 100 X .93 X 40000) /
= 47000
= 79 Kg
 Fuel Calculations

Fuel = NG
NG used in a Hour = 36MMBtu

GCV Of NG/ Cu Ft = 1,000

GCV Of LPG = 47,000

KG of LPG = ?
(NG MMbtu X 10 ^ 6)/ CV
Of LPG
= ( 36 X 1,000,000) / 47000
= 765 Kg
 Tank Off take
Tank capacity Off take (kg/hr)

1 MT 10

1.75 MT 18

2 MT 18

5 MT 35

200 KG 4

These are approximate volume of gas that a respective tank provides at 35C
Vaporizer
 Vaporizers
LPG (Propane, Butane, or Propane/Butane Mixture) at ambient pressure (above its
boiling point temperature) is a gas that is stored in pressurized containers (tanks) in liquid
form. The space in the tank that is not filled with liquid is occupied by vapor. As this vapor
is being used as fuel for connected equipment (burners, heaters, etc.), liquid LPG must
vaporize (change its state from liquid to gas) to occupy the space above the liquid. Any
time a change of state occurs energy is required. If the ambient temperature is above the
boiling point of the LPG (Propane -44°F / -42°C; Butane 32°F / 0°C at ambient pressure),
this energy is transferred in the form of heat from the ambient air through the steel walls
of the storage tank, into LPG. As the heat is transferred from the ambient air to the
vaporization process, the ambient air "looses" this energy and cools down. The amount of
heat that is transferred into the LPG determines the rate of vaporization. As the ambient
air cools down, the rate of vaporization slows down, and stops completely when the
ambient air is at the same temperature as the boiling point of the LPG. Therefore,
naturally occurring vaporization cannot be used for large gas loads, or in low ambient
temperatures. A vaporizer is designed to receive the liquid LPG and raise its temperature
(heat the liquid) well above the boiling point at the delivery pressure. In other words, a
vaporizer generates the (heat) energy that is required to maintain the gaseous state of
the LPG.
Vaporizer
Cont.
 Vaporizer- Electrical Req..
Vaporizer Capacity Heater Current Current Water Anti Capacity of
Model (Kg/hr) Capacity Inlet Outlet Capacity freeze Electrical wire

ETV-30B 30 5 KW 20 A 20 A 58 lit 17 lit 5.5 mm² x 3C

ETV-100B 100 15 KW 20 A 25 A 73 lit 22 lit 8 mm² x 3C

ETV-200B 200 30 KW 20 A 25 A 160 lit 48 lit 22 mm² x 3C

ETV-300B 300 45 KW 20 A 25 A 185 lit 55 lit 38 mm² x 3C

Vaporizers should be weekly checked for water level (by customer) and annually
anti-freeze should be used. Customer site must have a three phase connection
for vaporizer & pump connection.
 Super Gas Bulk Tank Installation.
• Using a pump:
• Pump is mainly utilized in filling of Fork lift truck (FLT) cylinders or any other
vehicle storage tanks.
• Operation:
• Switch on the mains, with liquid inlet vales on tank open, switch on the
pump with the delivery hose connected to the cylinder, open the ball valve
at the end of the hose to allow liquid LPG to travel in the cylinder.
Regulator Operation
 Regulators
• Regulators are installed to reduce inlet (tank) pressure with a corresponding volume
flow rate to requisite line/application pressure. Below are the generally used
regulators with specifications:

Regulator Kg/hr BTU/hr Delivery Pr. (Psi)

4403 TR4 5 ~ 53 250000 ~ 2500000 5 ~ 10

2302 TR4 2.6 ~ 10 25000 ~ 150000 0.3 ~ 0.46

5503 B8 5 ~ 50 250000 ~ 2300000 0.3 ~ 0.46

15BB ML 26.6 ~ 170 1250000 ~ 12000000 25 ~ 50

15BB MN 26.6 ~ 171 1250000 ~ 11000000 0 ~30

002217BX 2.1 ~ 21 100000 ~ 1100000 15 ~45

 Super Gas System
• Now we have……..
– Off take required by application
– Off take of tank
– Requirement of vaporizer
– Requirement of regulator
Customer side regulation
 Gas train

Tank Regulator Ball valve

Secondary piping

Safety shut off

Ball valve Filter Regulator
system valve

Flow & ratio

Burner
control
Air
 Site Selection
• The site area should be clean, with
respect to combustible material.
• The site should be installed at a location
with minimum human activity.
• The Bulk site should have safety
distances as per the below table
 Code & standards
• NFPA 58
• Code of Practice (COP) 1
• HEALTH AND SAFETY GUIDE 34 (HSG 34)
• Mineral gas safety rules 2010 (GOP Rules)
 Safety distance

Min. separation distances (ft)

Vessel Above ground vessels (source of Between Max. No. in a
ignition/boundary etc) containers group

1 MT 10 3 3
1.75 MT 25 3 6
2 MT 25 3 6
2.38 MT 25 3 5
5 MT 25 3 3
200 kg *10 (from openings, drain=5) 4
LOT/VOT *10 (from openings, drain=5)
*For all types of manifolds safety distance from source of ignition, boundary,
line of adjoining property should be 10 ft. The safety distance from windows,
doors & drains should be at least 5 ft.
 Tank Dimensions

Tank

Vessel Dimensions Length Diameter

1MT 11'-7" 3'-2"

Inch

1MT Fr 10'-5" 3'-3"

Inch

1.75 MT Fr 12'-6" 3'-11"

Inch

2 MT 13'-3" 4'
Inch

5 MT 17'-5" 5'-5"
Inch
Site Visit for Technical Assessment
• Safety Distances- Req for Bulk Tank Installation:
Tank size
Number of
tanks 1MT & 1 MT Fr 1.75 MT & 2 MT 2.38 MT 5 MT

width (ft) length (ft) width (ft) length (ft) width (ft) length (ft) width (ft) length (ft)

1.0 24 32 55 64 55 66 56 68
2.0 33 32 65 64 62 66 67 68
3.0 39 32 76 64 72 66 79 68
4.0 52 32 87 64 83 66 116 68
5.0 57 32 105 64 94 66 128 68
6.0 68 32 116 64 130 66 140 68
7.0 136 64 141 66
8.0 147 64 152 66
9.0 158 64 163 66
10.0 169 64 174 66
11.0 180 64
12.0 192 64
 Plinth dimensions
Plinth
Plinth-
Plinth Plinth- Plinth Plinth SW
Dimensio Plinth-SL width Plinth length height dis.
Vessel ns. dis. (A) (B) (C (D) (E) (F)
1MT Foot / Inch 12' 2" 1' 2" 5' 3' 3" 1' 10'
1MT Fr Foot / Inch 12' 8" 8" 3'-11" 3' 3" 1' 10'
1.75 MT Fr Foot / Inch 27'-5" 1'-2" 5'-6" 4' 1' 25'
2 MT Foot / Inch 27'-3" 1'-2" 6'-5" 4' 1' 25'
5 MT Foot / Inch 28'-2" 1'-4" 8'-7.5" 5'-5" 3'-3" 25'

F
D

Source of
C A
Ignition/
B E property
 Tank Foundation
Tank Plinth
Surface
Lengt Area
Vessel Dim. h Dia Plinth-SL dis. Plinth width Plinth-Plinth Plinth length Plinth height Plinth-SW dis. sq ft
Inch 12' 2" 1' 2" 5' 3' 3" 1' 10' 125
1MT
Mm 3532 965 3700 350 1528 1000 300 3048
Inch 12' 8" 8" 3'-11" 3' 3" 1' 10' 118
1MT Fr
Mm 3184 1000 3840 200 1200 1000 300 3048
Inch 27'-5" 1'-2" 5'-6" 4' 1' 25' 169
1.75 MT Fr
Mm 3810 1200.5 8340 350 1670 1220 300 7620
Inch 27'-3" 1'-2" 6'-5" 4' 1' 25' 184
2 MT
Mm 4040 1232 8305 350 1970 1200 300 7620
Inch 27'-3" 1' 4" 6'1" 4' 1' 25' 207
2.38MT
Mm 4756 1200 8305 350 1200 300 7620
Inch 28'-2" 1'-4" 8'-7.5" 5'-5" 3'-3" 25' 324
5 MT
Mm 5318 1650 8566 400 2626 1650 1000 7620
 Super Gas Bulk Tank Installation.
Fixed Liquid Level
Gauge
Gas Service
Connection
Double Check Filler Pressure Relief
Valve Valve

Dial / Float Gauge

Maximum Liquid Level

inside the tank
(Normally sets @ 85%)

Manhole

Liquid withdrawal
Tank Saddle Drain Valve
Civil Earthing Lug valve
Foundation
 Electric Cables
– It is measured as the longitudinal distance from the cables to the
tank)
• 25ft min from Electric cables/ line/ transformers
• Tanks should not be sited directly under/besides power cables
• Similarly the bulk site should be 25ft (min) away from a drain, to
avoid vapor travel over it

– The bulk site should be separated from any other fuel/gas

storage for exact distances contact CED.
– Vaporizers/pump are to be located at least 6 ft from the tank in
the transverse direction (i.e. on the shell side, should not be on
the dish end side), in line of the excess flow valve located at the
center of the tank (bottom).
 Bowser Access
Bowzer accessibilities Recommend
ation
Hazard (electrical cables, transformers etc) 15 ft/ 25 ft
height/ distance
Minimum road width 12 ft
Road turning radius (min. road curvature) 15 ft
Factory /site entrance gate width/ height 12 ft/ 15 ft
Road condition Gravel
carpeting
Turning radius 30 ft
Hose length (working) 95 ft

• Site is to be selected such that during filling the

bowser driver can easily access the bowser and
tank with out any hindrance in-between. There
should not be any wall, door between the
bowser and the tank.
• There must be ample of space for the bowser to
turn back and leave with out having to reverse
the vehicle
 MATERIALS
• Piping
– Pipe can be wrought iron, steel (black or galvanized), brass, copper, polyamide
or polyethene. Following Piping material is used in PPG:
• Steel pipe: carbon steel ASTM A-106 sch.40, seamless.

• Flanges
– Flanges shall have a minimum melting temperature of 1500°F (816°C) and
shall be resistant to action of LPG. The following material should not be used:
• Gray cast iron
• Non-metallic materials.
– Following are the specifications of flanges used at PPG:
• Flanges: Carbon steel ASTM A-105, slip-on or socket-welded, class 150.

• GASKETS
– Gaskets shall be made of metal or other material confined in metal having a
melting point of over 1500°F (816°C) or should be protected against fire
exposure.
 Installation
Sales/CCD/ CED
CED Civil
Short works Dimensioning/ inspection of Plinths by CED
comings Insp Dimensioning visit for Civil Drawing

CCD/ CED
Customer Tank
Rectified shifting Tanks shifted to site from resp. Plants.

CED
Log Data
CED
In-House or Decision on fabrication
Sublet

CED
CED
FabricatioInstallation / fabrication to be inspected/ supervised
Contractor
n/
Bill
Installatio
as per requisite international /SHV fabrication &
n safety standards by CED team

CED/CCD
Finance Customer
scope Verify customer scope completion Piping/fencing etc
 Super Gas Bulk Tank Installation.
• A typical Super Gas bulk installation consists of
the following:
– LPG Vessel(s) sited on civil foundations.
– Vaporizer (optional)
– Pump (optional)
– LPG Piping; primary till the High-pressure regulator
and secondary till the appliance including the
secondary stage regulator(s).
– Filling line (optional)
– Vapor line
– Vapor/liquid return line (optional), used in
conjunction with the vaporizer/pump.
– Vaporizer/pump liquid inlet-line (optional), used in
conjunction with the vaporizer/pump.
– High pressure regulator (near to the vessel)
P& ID of Bulk Site
 Fence
All bulk sites are to be fenced with industrial
type fence of 6 ft height, and must have
two diagonal opening.

The fence is to be made all around the tank

.area at least 5ft from the equipment installed
 Safety:

• No tempering with installation

• No over filling
• No unauthorized entry to LPG area
• No smoking/source of ignition in LPG area
• No parking in side the LPG area
• Sound concrete foundations as per specs provided
• 12 kg x 2 DCP fire extinguisher
• Electrical connections to be fire/explosion proof
Secondary Scope- Pipe Size Selection

 1. Determine the total gas demand for the system by adding up the BTU/hr input from the appliance
nameplates and adding demand as appropriate for future appliances.

 2. For second stage or integral twin stage piping: A. Measure length of piping required from outlet of
regulator to the appliance
 furthest away. No other length is necessary to do the sizing.
 B. Make a simple sketch of the piping, as shown.
 C. Determine the capacity to be handled by each section of piping. For example, the capacity of
the line between a and b must handle the total demand of appliances A, B, and C; the capacity of the line
from c to d must handle only appliance B, etc.
 D. Using Table 3 select proper size of tubing or pipe for each section of piping, using values in BTU/hr
for the length determined from step #2-A. If exact length is not on chart, use next longer length. Do not
use any other length for this purpose! Simply select the size that shows at least as much capacity as
needed for each piping section.
 3. For piping between first and second stage regulators
 A. For a simple system with only one second stage regulator, merely measure length of piping required
between outlet of first stage regulator and inlet of second stage regulator. Select piping or tubing required
from Table 1.
 B. For systems with multiple second stage regulators, measure length of piping required to reach the
second stage regulator that is furthest away. Make a simple sketch, and size each leg of piping using
Table 1, 2, or 3 using values shown in column corresponding to the length as measured above, same as
when handling second stage piping.
Pipe Size Selection
 Pipe Size Selection
Example 1
 Pipe Size Selection
Example 2
Selection Chart
Explosive License & NOC

Contract approved

CED
Print/
Sales
handover
NOC & EL Noc & explosive documents from client

CED
Layout

Sales/ CEDCivilworks/plinths as per CED recommendations

Civil works
suggested to client
CED
CED
Drawings
Site visit Visit to mark and explain
 Explosive License & NOC
• Foundation Drawing
Explosive License & NOC
 Commissioning
Check list
Site inspection
CED
Final (Installation check list completed)
inspection

Sales/ CCD FF raised by SM, form signed by CED Exc.+SVR

First fill raised NOC submitted to NOM via CCD

CED/Fleet
FF
FF request forwarded to OPS

CED/Sales
FF
CED FF request forwarded to OPS
FF accomplished
postponed

CED
Commissioning
Commissioning of system after confirmation from CCD
Formats
 Super Gas Bulk Tank Installation.
COMMISSIONING / DE-COMMISSIONING OF A BULK TANK

– Installation and commissioning of the bulk tank should only be

undertaken by company’s servicemen and authorized contractors.
– Before any bulk tank is sited, the area should be surveyed for any
possible hazards by company’s qualified engineers e.g. overhead power
cables and to the condition of the ground, ensuring stability for delivery
vehicles.
– All combustible material including grass, weeds etc. should be cleared
before the initial fill of LPG and the site should be maintained
accordingly.
– The bulk tank which is to be de-commissioned and purged free of LPG
should be isolated from any process, plant or vessels containing LPG.
De-commissioning of bulk tank should only be done by a qualified
personnel or company’s personnel.
 Super Gas Bulk Tank Installation.
• OPERATION OF TANK
– Open vapor outlet valve (on the multi valve, connected on the yellow vapor line).
If multiple tanks are connected open all the valves.
– Open the high-pressure regulator. The function of this regulator is to set the line
pressure to a desired limit. By turning the knob of the regulator clock wise,
pressure settings can be increased and by rotating it anti-clock wise the pressure
may be reduced.
– Verify the set pressure from the pressure gauge installed after the high-pressure
regulator (generally on the bypass line).The high-pressure regulator is suggested
to be limited to maximum 15 psig.
– Open the shut off vale after the high-pressure regulator to enable the gas to
travel to the secondary piping. The secondary piping must consist of a non-return
valve; flash back arrester on individual application, low-pressure regulator (a
medium stage regulator where required/suggested especially on boiler
applications), filter, pressure indicator and isolation valves.
– When a vaporizer or pump is connected to assist vaporization or liquid supply
respectively, the liquid with-drawl valve (on bottom of tank (s)) is opened to allow
liquid to go into the vaporizer or pump, the vapor/liquid from vaporizer/pump is
returned to tank. Note: all necessary breakers etc should be installed in
electrical lines.
– For operation on vaporizer and pump; which are optional, are as follows:
 Super Gas Bulk Tank Installation.
• Using a vaporizer:
• Main components:
• Vaporizers mainly consist of coil, a water tank, a thermostat, a temperature
gauge and a pressure gauge, safety valve.
• Operation:
• Switch on the mains. When the temperature of the water reaches 70ºC
solenoid valve will get opened. Open the liquid outlet valve of the tank (open
the isolation valve provided on the liquid line i.e. if provided). Liquid will get
converted into vapor in the vaporizer. The maximum setting of temperature
is 80ºC, in case the temperature goes beyond it the thermostat will close
automatically. The solenoid valve will operate again at 70ºC. There is a
pressure relief valve also provided, in case of over pressurization the
pressure relief valve will dispense the excess pressure.
 General Safety Instruction:-
• The premises shall not be used for any other purposes other than storage and
transfer of LPG.
• LPG shall be stored only in vessels/tanks as per capacity and position shown in the
approved plan.
• Every tank shall be outside any building and shall be supported on sound designed
foundations.
• The tank(s) shall at all times maintain from any other facility, building, boundary,
fencing or protected works the distance specified in NFPA 58.
• No alteration of the position of the tank and no placement of tank shall be effected
except with the permission of licensing authority.
• No person shall cause to repair by use of fire, welding, hot riveting or brazing any
tank used for the storage of LPG unless it is thoroughly cleaned and gas freed of
otherwise prepared for safely carrying out such authorized work. Further no line is to
be vented in vicinity of any heat/ignition source.
• No artificial light capable of igniting flammable vapor shall at any time be present
within 25 feet of the LPG transfer and tank area, no person engaged in such activity
shall smoke.
• All electrical equipment such as motors, switches, pumps etc shall be fire proof.
• Fire extinguishers – at least two dry chemical powder of 9-12 kg capacity each shall
be installed at the access points (on fence) to the storage area.
It doesn’t end here……..
 Customer services
• Customer account Management
• Order Management
• Complaint management
 Logistics
• 9 tankers
• Three regions
• Supplying over 2500MT / month
• Telemetry services
 Advantages of telemetry?
• Customer satisfaction
– Gas run outs
– Providing customers with a complete service
– Better billing
– Increased security (leak & fraud detection)
• For company
– logistic savings (decrease of level before filling, increase of mean drop,
decrease of number of fillings per month)
– Increased operational efficiency
– Replenishment forecasting
– Route optimization (reduction of number of deliveries and no delivery)
– Better stock management
– Fraud detection
• General benefit
– Reduced CO2 emissions
Complaint Handling Process

Customer/CCD/
CED Complaint raised, via mail/ telephone
Complaint circulated by CCD

CED Intensity of complaint checked

Scrutinize

CED
Team moved
Leakage, fire, spill - termed as emergency

CED Repair/ rectification as per situation

Rectification

CED
Customer satisfaction note- Time sheet
Record

Stop

CCD/CED
Via email
Complaint Closed
 Super Gas Bulk Tank Installation.
• Never search for leaks with naked lights; only
soapy water should be used to detect the leaks.
In the event that leakage is detected, customer
should immediately contact at
EMERGENCY NUMBER

0800 00050
Bulk Tank Maintenance Process
CED
data Available stock of equipments checked.
Stop
Compilation Bulk stocks verified by CED, Other by Ops

CED
Available in CED Review against requirements/
stock/ No Review Data projections/ forecast
requirement

Inquiries raised (local/ foreign) and

CED subsequent approvals sought
Inquiries / R1/C1

Ops
GRN
CED/ Ops Goods received
Receival of
Equipment

Ops
Log Data CED
Review Data
Review requirement of maintenance
Sorting of equipment to be
repaired/ re-qualified
Check scheduled maintenance record
CED
CED Inquires raised - vendors/ contractors/
Contractor Bill
Inquiries / PO Inspector PO issued by Admin.
To selected vendor/contractor

Finance
Bulk Tank Maintenance Process…… Cont.

CED / Plant
Re-qualification Re-qualification activities conducted at Plants
activities by third party contractors/ inspectors

Vendor All "ok" equipment cleared for use, "failed" equipment

Report Issuance to be marked/discard/ eliminated from inventory

CED
Data review of bulk on site tank re-qual. Requirement

CED/ CCD
Information to Letter to customer for repair/ re-qual. Downtime
Customer Site dismantling etc

CED
Site dismantling
Dismantling of existing tanks/equipment

CED
Tank/ Equipment Already Re-qualified tanks shifting to site
shifting
Replacing with old and shifting these to plants

CED
Site Installation Cont: Bulk Inst. -CED decision - in-house or sublet
 SNG - Definition
• In composition, SNG is a blend of liquefied petroleum gas (LPG) and air to a
specific ratio. The precise and controlled mixing of LPG and air allows it to
be used as an alternative fuel to natural gas for "back-up", 'peak shaving',
and in regions where naturalSNG
gas is not yet available.
NG No orifice changes,
pressure changes or any other changes are required to the natural gas
consuming equipment.
 SNG to NG INTERCHANGEABILTY
SNG “acts like” Natural Gas…

Wobbe Index:
CalorificValue
SG
a measure of the ENERGY
being provided to a combustion
process.
Natural Gas: Synthetic Natural
• Calorific Value = 1000
BTU/SCF Gas:
• Specific Gravity = 0.585 SG • Calorific Value = 1500 BTU/SCF
• Specific Gravity = 1.31 SG

1000 1500
 1310
0.585 1.31
•No pressure changes
•No orifice changes
•Seamless fuel
swapping
Typical SNG System
In-Service Inspection
Re-Qualification
&
CIE Certification
 What is Re-Qualification…?

Re-Qualification of equipment is assurance of

“technically and physically fit”
as per local regulation compliance, inspection and construction
code i.e. CIE 3rd Party Certified, NFPA 58, ASME Sec VIII & API 510
 Vessel Identification (Due Inspection)

Pre-Inspection Activities

In-Service Inspection

Re-Qualification

CIE Certification
Vessel Data Customer Data
Records Records

Vessels to be
Re-Qualified Capacity
As Per Quantity On Site
Manuf. Year & Location Inventory
API 510

Design Data
& In-House
Drawing Inventory Customer

Final List Sr. Nos.

Verification
• Vessel those needs to be re-qualified or due for inspection, identified
against procurement regime and manufacturing year from excel based data.
• After extraction of data from database, we verified all data against vessel
capacity, manufacturing year and location including previous history
(inspection record).
 Vessel
Inspection Plan

In-House On Site
Inspection Inspection

Visit & Meeting

Visit & Marking With Data Verification
Of Vessels Customer Of Vessels

Finalize
Inspection Plan
 Inspection Plan
 A strategy defining how and when a pressure vessel or pressure-relieving
device will be inspected, repaired, and/or maintained.
• Verify year of manufacturing and/or last
inspection on data plate.
• ASME code stamping or mark of code of
construction on data plate.
• Serial number and materials of
construction
• Records of wall and head thickness if
mentioned on data plate.
• In-Service Inspection
– All inspection activities associated with a pressure vessel once it has
been placed in service.
• API 510
– Code covers the in-service inspection, repair, alteration and rerating
activities for pressure vessels and the pressure relieving devices
protecting these vessels.
• External Inspection
– A visual inspection performed from the outside of a pressure vessel to
find conditions that could impact the vessel's ability to maintain pressure
integrity or conditions that compromise the integrity of the supporting
structures, e.g. ladders, platforms. This inspection may be done either
while the vessel is operating or while the vessel is out-of-service.
• Fitness-for-Service Evaluation
– A methodology whereby flaws and conditions contained within an
equipment item are assessed in order to determine the integrity of the
equipment for continued service.
• General Corrosion
– Corrosion that is distributed more or less uniformly over the surface of
the metal.
– Clean vessel sufficiently to allow for visual inspection of internal and
external surfaces if required.
• Thickness Measurements
– Thickness measurement are taken to verify the thickness of vessel
components. This data is used to determine the cor­rosion rates and
remaining life of the vessel.
• Condition Monitoring Locations (CMLs)
• Designated areas on pressure vessels where periodic examinations are
conducted. Previously, they were normally referred to as "thickness
monitoring locations (TMLs)".
• Corrosion Rate
– The rate of metal loss due to the reaction(s) with its environment.
• Defect
– An imperfection, whose type or size, exceeds the applicable
acceptance criteria.
• Design Temperature
– The temperature used in the design of the pressure vessel as per the
applicable construction code.
• Hold Point
– A point in the repair or alteration process beyond which work may not
proceed until the required inspection has been performed.

• Localized Corrosion
– Corrosion that is confined to a limited area of the metal surface.
• Maximum Allowable Working Pressure (MAWP)
– The maximum gauge pressure permitted at the top of a pressure vessel
in its operating position for a designated temperature. This pressure is
based on calculations using the minimum (or average pitted) thickness
for all critical vessel elements, (exclusive of thickness designated for
corrosion) and adjusted for applicable static head pressure and non-
pressure loads, e.g. wind, earthquake, etc.
• Minimum Design Metal temperature (MDMT)
– The lowest temperature at which a significant load can be applied to a
pressure vessel as defined in the applicable construction code (e.g.
ASME Code, Section VIII: Division I, Paragraph UG-20(b)).
• Pressure Vessel
– A container designed to withstand internal or external pressure. This
pressure may be imposed by an external source, by the application of
heat from a direct or indirect source, or by any combination thereof. This
definition includes heat exchangers, air-coolers, unfired steam
generators and other vapor generating vessels which use heat from the
operation of a processing system or other indirect heat source.
• Procedures
– A document that specifies or describes how an activity is to be
performed. It may include methods to be employed, equipment or
materials to be used, qualifications of personnel involved and sequence
of work.
• Repair
– The work necessary to restore a vessel to a condition suitable for safe
operation at the design conditions. If any of the restorative work results
in a change to the design temperature, MDMT, or MA WP, the work
shall be considered an alteration and the requirements for rerating shall
be satisfied. Any welding, cutting or grinding operation on a pressure-
containing compo­nent not specifically considered an alteration is
considered a repair.
• Required Thickness
– The minimum thickness without corrosion allowance for each element of
a pressure vessel based on the appropriate design code calculations
and code allowable stress that consider pressure, mechanical and
structural loadings.
• Rerating
– A change in either the design temperature rating, the MDMT or the
MAWP rating of a vessel. The design temperature and maximum
allowable working pressure of a vessel may be increased or decreased
because of a rerating. De-rating below original design conditions is a
permissible way to provide for additional corrosion allowance.
• Risk-Based Inspection (RBI)
– A risk assessment and management process that is focused on
inspection planning for loss of containment of pressurized equipment in
processing facilities, due to material deterioration. These risks are
managed primarily through inspection in order to influence the
probability of failure.
• Testing
– Testing generally refers to either pressure testing whether performed
hydrostatically, pneumatically or a combination hydrostatic/pneumatic,
or mechanical testing to determine such data as material hardness,
strength and notch toughness. Testing, however, does not refer to NDE
using techniques such as PT, MT, etc.
• Corrosion Rate Determination
– Corrosion rate for thinning damage mechanisms is determined by the
difference between two thickness readings divided by the time interval
between the readings. The determination of corrosion rate may include
thickness data collected at more than two different times.

– Corrosion rate(CR) = T.initial - T.actual/ (T) time between (T.initial &

T.actual) (years)
– CR= T(in) 7mm – T(ac) 6mm / 10 Year = 0.1mm

• Remaining Life Calculations

– The remaining life of the vessel (in years) shall be calculated from the
following formula:
– Remaining Life = Thickness (ac) – Thickness (req.) / Corrosion Rate
(CR)

– Remaining Life (Years) = T (ac) 6mm – T (req.) 5.8 / (CR) 0.1mm = 2

Years
 Vessel
Inspection Plan

In-House On Site
Inspection Inspection

Marked
Tank Report
For
Thickness Generated
[Replacement/
Visual Inspection [NOT OK] [Record]
Repair]

Marked
[UT] Tank For
Marking of Thickness
Thickness Re-Qualification
[CMLs/TMLs] [OK]
Gauging PRV Replacement
• Inspection Plan
– All inspection activities are made as per recommended periodic time
frame as per NFPA 58.
• In-House Inspections
– Inspections of in-house inventory of tanks available at plants.
• Onsite Inspection
– Inspections of installed tanks on customer sites.
• Visual Inspection
– To check the flaws i.e. defects, paint, pitting , corrosion on (shell,
manhole, nozzles & studs) and conditions contained within an
equipment item are assessed in order to determine the integrity of the
equipment for continued service.
– Before inspection clean vessel sufficiently to allow for visual inspection
of internal and external surfaces if required.
– Inspection under the damage paint.
– Marking and cleaning of pitted areas to check depth and area of the pits.
– Visual inspection of thread profiles of studs.
– Visual inspection of LS and CS for defects and corrosion.
• Marking of Condition Monitoring / Thickness Measurement Locations
(CMLs/TMLs)
– Preparation of vessel through markings "thickness monitoring locations
(TMLs)"on shell and dish ends for thickness.

• Thickness Measurements
– After marking of (TMLs), the vessel gauged with a calibrated ultrasonic
meter for thickness to verify the vessel and components.
– If the measured data (taken thickness) is according to design thickness
of the equipment then prepared for re-qualification (PRV replacement)
and generate a report of (fitness-for-service).
– If the measured data (taken thickness) is not according to design
thickness of the equipment then recommendation made for replacement
(with re-qualified tank) and generate a report of (not fit-for-service)
repair required.
 In-Service
Inspections

Certificate
of
De-Valving Hydro Test Re-Valving
Compliance

Internal Clean/Tapping
Pneumatic Sandblast
& External Threaded
[Leak Test] Primer/Paint
Cleaning Couplings

YES Marked Report

Inspection For Generated
Threaded [Repair] [Record]
Couplings [Maintenance]

NO
• De-Valving
– Valve removing is first activity during re-qualification of vessel to
inspection of the couplings and internal assessment.

• Internal & External Cleaning

– To verify and visual assessment of vessel, satisfactory cleaning is
required internal and externally.

• Inspection of Threaded Couplings

– Inspection of threaded couplings is necessary before fit-up of new
fittings. When these couplings found in good condition, can proceed for
new fittings, incase of any damage these refer to maintenance or
replacement with new couplings.
• Hydro Test
– Pressure tests are not normally conducted as part of routine inspection.
A pressure test is normally required after an alteration. After repairs are
completed, a pressure test shall be applied if the inspector believes that
one is necessary. (API5.8.1.1)
– Test Pressure in psi (MPa) = 1.5 MAWP X (S test temp / S design
temp), prior to 1999 addendum
– Test Pressure in psi (MPa) = 1.3 MAWP x (S test temp / S design
temp), 1999 addendum and later
• where
– S test temp = allowable stress at test temperature in ksi (MPa)
– S design temp = allowable stress at design temperature in ksi (MPa)

• Leak (Pneumatic) Test

– After fit-up of new fittings, it is necessary to check and ensure the
leakage from any part. Therefore pneumatic test is made at 7 bar to
verify any leakage from threaded and flange gaskets.
• CIE Certification
– The Final report is issued from CIE approved 3rd Party with challan, on
the basis of this report DOE will issue NOC of installation for customer
site.
 Emergency Response
• Accidents involving company owned assets i.e. Filling Plants, Gas
Centers, Tankers / Trailers, Cylinders at distributor outlets and bulk
industrial sites etc.
• Any external occurrence involving deliberate sabotage of company
owned assets and harm to employees.
• A country wide civilian unrest that may harm company’s employees
or assets.
• Any firing or explosion incident within the close vicinity of filling
plants, retail outlets that has likelihood of affecting company’s
employees or assets.
• Any act of terrorism at Head Office or company operated locations.
 Emergency Response- Emergency Measures
• The management recognizes that all sorts of
emergencies require a high level of vigilance and action
plan thereof to prevent or minimize loss to its employees
and assets.
• The emergency measures have thus been divided into
two major groups:
– Preventive Measures
– Reactive Measures
 Emergency Response- Emergency Measures

Preventive Measures:
• These measures highlight preparedness by the company management in
the likelihood of any possible threat or emergency which include:
• Arrangement of adequate Security at all company’s sites
• Includes availability of closed circuit cameras at sensitive installations like
plants and office entrance.
• Maintaining Visitors log at all company locations and reporting.
• Training of all the people working at company’s premises while defining
individual roles and line of authority.
• Develop a communication action plan for emergencies.
• Provision of emergency medical treatment and first aid services.
• Provision of necessary PPEs and emergency equipment.
 Emergency Response- Emergency Measures

• Preventive Action Plan

• Training of all company’s employees including drivers and security staff at
all sites over product knowledge, handling of safety equipment, first aid
treatment and evacuation plan etc.
• Visitors In / Out register to be maintained actively and shall be signed by
Location Managers or his authorized persons at all company locations on
daily basis. The record at Head office shall be reviewed and controlled by
Security Manager.
• Visitors intending to go to plant operational area will require written
permission from competent authority which is Plant Manager or person
authorized in his absence.
• No visitor or customer shall be allowed to enter into cylinder storage area at
gas depots unless under special arrangements or written permission by
location manager.
 Emergency Response- Emergency Measures

• Preventive Action Plan: Cont…

• All company locations including Mobile Assets and bulk sites shall display
Emergency Response Toll Free Number 0800-00050 for reporting any
untoward incident along with contact numbers of Regional and Head Office
Support Teams. The Toll Free Number shall be carried among the ERM
Team members on thirty days rotation.
• All company operated sites shall be required to display numbers for local
fire brigades, police stations and nearby hospitals for dealing with such
emergencies.
• All bulk customers shall be trained about the product safety and emergency
communication by displaying all necessary contact numbers at such sites.
• The plant managers shall ensure that routine joint visits or drills with civil
defense, local fire brigades and police teams are organized in their area to
meet any subsequent eventuality.
 Emergency Response- Emergency Measures

Preventive Action Plan: Cont…

• Roles of personnel in line with their authority is of utmost importance and
has been defined below to address situations arise out of emergencies
covered under this procedure:
• Head Corporate Affairs
• He is the company’s authorized spokesman directly responsible for
interaction with media and Government bodies during emergency situation.
• Emergency Response Manager
• He is a person who will provide all the technical guidance to Regional
Emergency Teams where necessary and will coordinate for communicating
on ground information within the senior management.
 Emergency Response- Emergency Measures

Preventive Action Plan: Cont…

• Emergency Team Leader
• He is the core member who shall actually lead the response operation within
the region by mobilizing all internal and external resources at the site of
emergency.
• Emergency Team Member
• The job of team executive is to provide assistance to Emergency Team
Leader and will be responsible to manage all emergencies in his absence.
 Emergency Response- Emergency Measures
• Reactive Measures
• Such measures cover response plan in the event of occurrence of internal
or external threat that includes:
• Emergency alerting and response.
• Site Evacuation Plan, security and control
• Coordination within and outside the company
• Emergency Medical Treatment and First Aid
• Incident reporting and investigation
• Remedial actions
 Emergency Response- Emergency Measures
• Procedure:
• All Emergencies shall immediately be communicated to Emergency Toll
Free Number 0800-00050 and the respective Team Leaders of Regional
Emergency Response Teams. If the said numbers are not responding call
immediately to Emergency Team Executive or Group Leader directly for
guidance.
• Regional Emergency Team will immediately mobilize all the required
resources to overcome the threats and shall be authorized to an emergency
expense up to Rs.50,000 under his control. Any expense beyond Rs.50,000
and up to Rs.100,000 shall require authorization by the ERM.
• The ERM shall be responsible to communicate such emergencies to the
Chief Executive Officer of the company and Head Corporate Affairs for his
role on handling the media and government functionaries.
 Emergency Response- Emergency Measures
• Any emergency at Bulk Customer sites or with Mobile Fleet shall be dealt
with immediately after receipt of information at given contact numbers.
However, Regional Emergency Response Team Leader will decide upon
actions required to handle such incidents which may not necessarily require
involvement of Fire Brigade or Police etc.
• Emergency Response Team Leader will be responsible to ensure:
– That immediate medical treatment and first aid services are provided to
the people suffered in the incidents.
– Site security is beefed up adequately and action plan is taken in line
with Standard Operating Procedures developed for various categories of
incidents at plants, Mobile Fleet, Retail Outlets, Bulk sites and Office
• The ERM shall carry out all investigations under supervision of HSE
Manager and submit the final report within 7 days to Advisor(LPG)
accordingly.
 Emergency Response- Emergency Measures

• Emergency Plan Review

• All incidents shall be reviewed and evaluated in terms of
the severity and site/response capabilities and
appropriate steps shall be taken to overcome any gaps
in the system.
• The Emergency Procedure shall also be reviewed
periodically and as necessary, be amended to keep it
current with new or changing site conditions and
requirement.