Engineers India Limited

Mounded LPG Bullets Safety in Design, Construction,

Inspection and Operation

National Seminar on Safety in Hydrocarbon Sector : Drilling to Dispensing

Thursday, September 27th, 2012

L.K. Vijh, Executive Director (Plant Operations & Safety Division), Engineers India Limited

Presentation Plan
Introduction to LPG Storage and Transfer
BLEVE
What is Mounded Bullet !!!!!!!?
Design Codes Applicable
Facility Sitting

Design Parameters
Instrumentation and fittings on vessel
Fire and Gas Detection
Operation, Maintenance and Inspection

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Slide No.-2

Introduction
LPG is a mixture of propane and Butane with an explosive range of 1.8%
to 9.5% in air

LPG is colorless with an thermal expansion coefficient of 0.00237 per C

LPG due to its inherent properties is susceptible to fire and explosion

hazards

The conventional method of storage of LPG in India is in a pressurized

vessel installed aboveground. For large volumes cryogenic storage option
can be used

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Slide No.-3

BLEVE
Boiling Liquid Expanding Vapor Explosion (BLEVE)

Caused by external flame impinging on the shell of a vessel above the

liquid level, weakening the container leading to shell rupture
Causes a sudden release of a large mass of pressurized superheated
liquid

Superheated liquids flash typically increasing the volume over 200 times.

Results in heavy damage due to fire ball, pressure wave and impact by
vessel fragments.

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Slide No.-4

BLEVE Incident
San Juanico Disaster PEMEX, Mexico, 1984

BEFORE

AFTER

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Slide No.-5

San Juanico Disaster, PEMEX, Mexico, November 19,1984

8 Pipe rupture occurred near the sphere
The Control Room operator tried to identify the cause of pressure fall but without success.
The release of LPG occurred for more than 5-10 minute
The gas cloud grew to cover a large area and ignited from a ignition by ground flare.
The VCE severely damaged the tank farm and resulted in LPG leak from other damaged tanks
Just 4 minutes later first tank underwent BLEVE.

Over the next hour, 12 separate BLEVE explosions were recorded.

The two largest BLEVEs(from 2400 m3 spherical tanks) registered 5.0 seismic reading on R.S
The explosions destroyed the local town of San Juan Ixhuatepec.
Approximately 500-600 people killed and 5000-7000 others suffering severe burns.

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Slide No.-6

Lessons Learned - San Juanico Disaster

Sitting of Major Hazard Installation

The high death toll occurred because the housing was too near to the plant.
At the time the plant was constructed the area was underdeveloped, but over
the years the built-up area had gradually crept up to the site.

Layout and Protection of large LPG Storages

The total destruction of the facility occurred because there was a failure of
the overall system of protection, which includes layout, emergency isolation
and water spray systems.

Gas Detection and Emergency Isolation

One feature which might have averted the disaster is more effective gas
detection and emergency isolation. The plant had no gas detector system and
probably as a consequence, emergency isolation was too late.

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Slide No.-7

Mounded LPG Storage

A storage vessel sited above ground and completely

covered by a mound of earth or similar inert material except
for nozzles, manhole covers

Mounded Storage of LPG has proved to be safer compared

to above ground storage

Eliminates the possibility of fire engulfment and radiation

from a fire in close proximity.

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Slide No.-8

Mounded LPG Storage

Mounded bullets have a sand cover around that can take

impact of external projectiles/ flying object

Area of Land required to locate mounded bullet is minimal

compared to conventional storage

Mounded storage is designed considering maximum

working temperature as 55 deg C

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Slide No.-9

Mounded Storage

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Slide No.-10

Mound - Fabrication
Mounded vessel(s) shall be placed on a firm foundation & installed so as to prevent movement or floatation.

The preferred type of foundation is a continuous sand bed, supporting the vessel over its full length.

The foundation shall be constructed with a slope of at least 1:200 to facilitate draining of the vessel.

The sand beneath the vessel shall be adequate elevation not less that 0.76 m to facilitate drainage.

Mound shall be earth, sand or non-combustible (vermiculate or perlite) for atleast 700 mm thickness.

The mound shall protect the vessel from radiation and robust against jet fire impingement.

The surrounding of bottom nozzle should be filled with such material that can absorb settlement.

Provision for monitoring settlement of the vessel at minimum 3 reference points shall be provided.
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Slide No.-11

Mounded Storage Construction Methodology

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Slide No.-12

Mounded Bullet

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Slide No.-13

Mounded Bullet

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Slide No.-14

Engineers India Limited

Design ,Operation, maintenance of LPG Mounded Bullet

26th September 2012
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Slide No.-15

Inherent Safety Aspects

Cover

of Mounded Bullet protects the vessel from Fire engulfment and

radiation from a fire in close proximity
Intrinsically passive and safe environment eliminates possibility of
Boiling Liquid Expanding vapour cloud explosion(BLEVE)
No Domino Effect
Reduced Fire case PSV loads as compared to Spheres
Reduced firewater requirement for fire fighting.
Difficult for external agencies to identify the mound as a storage facility

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Slide No.-16

Facility Sitting/ Layout Considerations

S.No

Description

Separation
Distances* (m)

Between mounded storage and boundary, property line, group

of buildings not associated with LPG Plant.

15

Between mounded storage and any other (other than pump/

compressor) facility associated with LPG plant.

15

Between mounded storage and fire water pump house and/ or

fire water tank

30

Road of minimum 3.5 m width shall be provided around the mound for movement of earth
moving/ fire fighting equipment

Accessibility to Fire tender at least two sides.

Location of Fire hydrants and monitors at Safe distance.
Locate LPG storage far away from Main Units in downwind direction
Bullet dished ends not to face vital installation
2 m of Minimum inter-distance between the edge of the vessel(s) in a mound is maintained
for bullets having diameter 2m and above to facilitate safe installation, testing,
maintenance and removal of vessels.
* Reference from OISD-150
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Slide No.-17

Storage Principles

LPG is commercial Butane and commercial Propane.

LPG may be liquefied by moderately increasing the pressure or
reducing temperature
Refrigerated storage is used by suppliers to store large volume of LPG
The main form of LPG storage is LPG Bullets
Normally 85% of capacity is filled with liquid and the remaining space
being taken up with vapor.
As LPG is drawn from the Bullet ,vapor pressure in the Bullet drops and
eventually the liquid boils and producing more vapor and restoring the
pressure.
When liquid temperature rises for instance in summer the vapor
pressure increases .
When liquid temperature drops, the vapor pressure drops.
Typical Bullet size3500m3 of size 8000 MM ID X 80,000 MM (T/T)
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Slide No.-18

Design Codes
Standards

OISD-STD-150 (Design and Safety Requirements For LPG Mounded Storage Facility
OISD-STD-144 (LPG Installations)
OISD-STD-169 (Guidelines for small LPG Plants)
OISD-STD-116 (Fire Protection facilities for Petroleum Refineries and Oil/Gas Processing)
OISD-STD-118 (Layouts for Oil and Gas Installations)
OISD-STD-152 (Safety instrumentation for process system in HC industry)
OISD-STD-164 (Fire Proofing in Oil & Gas Industry)

PD:5500, Specification of Unfired Fusion Welded Pressure Vessels, 2009 Edition

The Static and Mobile Pressure Vessels (Unfired) Rules, 1981, (with latest amendments)

Approval Given by Chief Controller of Explosives (CCOE ) as per SMPV

Rules

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Slide No.-19

Design Parameters
Description

Values*

Design Code

ASME SEC VIII or PD 5500 or equivalent duly approved by CCE

MOC (no H2S)

ASTM A 516 Gr. 70 (IT) or SA 537 C II (IT) or PD : 5500 or equiv

MOC (with H2S)

ASTM A 516 Gr. 60 or Equiv

Design Temperature

-27 C to + 55 C

Design Pressure

14.5 kg/cm2.g at top of the vessel

Corrosion Allowance

Minimum 1.5 mm (Internal)

Corrosion Protection

Cathodic Protection System Provided

External surface of vessel are surface coated for protection from corrosion

Radiography

Full

Stress Relieving

100% irrespective of thickness

* Reference from OISD-150

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Slide No.-20

Fittings and Instrumentation on Vessel

Emergency Isolation
Fire Safe ROV shall be provided on first flange on liquid line (s), vapour outlet and re-circulation
lines from the vessel either from bottom or. No other flanges is provided up to ROVs.
In case of liquid line from the bottom of the vessel, the minimum distance of 3 m from the vessel
to ROV is maintained
The ROV is provided with volume bottle arrangement for two operation of ROV during
instrumentation air failure

Safety Relief Valves

Each vessel shall be provided with at-least two safety relief valves whose capacity shall be
minimum 30% of the capacity required for an equivalent size of above ground vessel.
All vents and drains are routed to closed Flare system where Flare is available. Otherwise vented
vertically upwards to atmosphere ensuring effective dispersion of hydrocarbons

Level Indication
Minimum two different types of level indicators and one independent high level switch shall be
provided. One transmitter shall be of Servo type and other Radar type.
Radar type level instrument shall have facility to measure RVP and temperature.
Min two number of manholes on the top of vessel is provided

Pressure and Temperature Indication

One pressure and temperature measuring instrument shall be provided.
PG shall be provided with two isolation valves and an excess flow check valve.
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Slide No.-21

Mounded Lpg Storage

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Slide No.-22

Bottom Oulet Nozzle

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Slide No.-23

LPG - Water Drain System

Problem of ice formation preventing valve closure.

ANTIFREEZE GLOBE VALVE provided.

DEAD MAN HANDLE VALVE provided in series to ensure operator

presence during the entire draining operation.

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Slide No.-24

Gas Detection System

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Slide No.-25

Fire Detection System

Fire Detectors
Automatic fire detectors based on heat detection through thermal fuses/
quartz bulbs/ EP detectors shall be used

Sensor Location
Minimum one detector on each exposed portion of vessel. If nozzles are
covered in dome, each group shall have at least two detectors.
At least one detector near ROV on all liquid line.

General Scheme for Quartzoid Bulb Detection

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Slide No.-26

Actions on Fire Detection

Audiovisual alarm at the local/ main control panel and fire water station,
indicating the fire

All ROVs on the affected vessel shall close

LPG Pumps and Compressors in LPG Storage area shall trip.

Sprinklers if provided shall operate

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Slide No.-27

Fire Water System & Fire Proofing

Active Fire Protection
Hydrants and monitors are considered for adequate coverage of
unprotected portions exposed to thermal radiation including the top of
the mound and product pipelines
Hydrants and monitors are located at a safe place and shall not be
installed within 15 meters from the exposed portion facilities/equipment
Auto actuated WaterSprinkler arrangement for top exposed domes,
structures and pumps
Passive Fire Protection
The fire proofing ( 2 Hours rating) of all exposed portion of the vessel is
done including piping up to the first ROVs, appurtenances etc

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Slide No.-28

Mounded Bullet

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Slide No.-29

Mounded Bullet

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Slide No.-30

Operation, Maintenance and Inspection

Vessel shall be hydro-tested once every 10 years or at every welding whichever is earlier.

Vessel shall be tested every 5 years internally using visual and NDT Testing. Wall thickness shall be
measured ultrasonically.

Safety relief valves shall be tested and calibrated every year.

Settlement of the vessel shall be monitored at least on half yearly basis.

Sprinkler spray density, flow rate and response time for every facility shall be verified once in every 6
months
Cathodic protection System
CP system given for the bullet is to provide protection against soil side corrosion.
Protective potential readings to be monitored at fortnightly and quarterly intervals.
Insulating joints shall be inspected once in a year.

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Slide No.-31

Operation, Maintenance and Inspection

Maintenance & Testing stipulation given in the code aims to ensure
integrity for continued operation.

LPG Vessels are known to suffer deterioration and failures.

Tests at 5 years intervals are extremely critical as the vessel is taken out of
service and offers rare opportunity to inspect it from inside.
Operators must engage specialist over and above NDT agency to get full
benefit.

Other special NDT tests to be carried out are

Magnetic Particle Inspection
Ultrasonic Flaw Detection
Dye Penetrant Test
Hardness Measurement
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Slide No.-32

Operation, Maintenance and Inspection

It has been experienced that mounded bullets have suffered deterioration
which was revealed during internal inspection.

In one such instance the defect was serious enough to call for derating of
the vessel.

EILs specialist group was approached by the owner to avoid derating.

After thorough study, a rectification scheme was given which met the
statutory approval and the bullet was brought back to sound health for
normal operation.

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Slide No.-33

Operation

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Slide No.-34

Commissioning
Commissioning of bullets are carried out as per following steps:
Cleaning and flushing /blowing of system
Tightness test with water/air/Nitrogen with maximum possible pressure
app 10-12 kg/cm2 g
Simulated check of all controls and interlock
Check of all Security System

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Slide No.-35

Commissioning

Inertise with Nitrogen or completely fill up with water to displace air.

In case of water,
displace slowly water with LPG vapors by slowly draining water
When pressure in bullet is equivalent to vapor pressure , pump in liquid
LPG
In case of Nitrogen ,
Nitrogen is to be purged with LPG vapor and also vent out to remove
residual Nitrogen
When pressure in bullet is equivalent to vapor pressure , pump in liquid
LPG

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Slide No.-36

Operation
Receiving

LPG product from Unit

Unloading LPG and receiving in bullet for initial requirement
Loading of LPG to Railway wagon
Loading of LPG to Road tanker
Transfer of LPG to Pipelines to Pump to other storage
Pump out of LPG received off-spec for reprocessing
Unloading of sick wagon or sick Tanker
Pump out for LPG vaporizer for Refinery scenario

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Slide No.-37

Operation - Receiving
Receiving

LPG product from Unit

Normally all the vapor lines of Bullets are kept open
Outlet and recirculation line valves are closed
Inlet valve is opened and receiving line is lined up
in the inlet manifold.

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Slide No.-38

Operation-pump Out
Pump

out for Reprocessing/Pump out for

vaporizer/Transfer of LPG to Pipelines to Pump to
other storage
Outlet valve of Bullet is opened and lined up to
Reprocessing Pump /Sale Pump/Vaporizer Feed
Pump
Inlet valve of Bullet is opened and MCF line is
lined up to the Inlet manifold
Pump is started with MCF lined up

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Slide No.-39

Operation - Loading
Loading

of LPG to Railway wagon/Loading of LPG

to Road tanker
Outlet valve of Bullet is opened and lined up to
Loading Pump
Recirculation line valves are opened and lined up
to the same bullet
Vapor space of the Wagon tanker /Road tanker is
line up to vapor line to displace vapor while loading
Pump is started with MCF lined up

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Slide No.-40

Operation Unloading Sick Tanker

Unloading LPG and receiving in bullet for initial requirement/Unloading of
sick tanker
Vapor line valve of Bullets are kept open an
Inlet opened and liquid line from tanker line is lined up to Inlet Header
Unloading compressor shall take vapor from vapor line and compress
and route to tankers .
Tanker liquid is displaced with vapor
Liquid is routed to Bullet through Recirculation line
After complete unloading of liquid compressor is used to draw residual
vapor from tanker and route to vapor phase of bullet through vapor line

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Slide No.-41

Operation Unloading Sick Tanker

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Slide No.-42

THANK YOU

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Slide No.-43