PO-20.

1
SAFETY AND DESIGN OF LNG RECEIVING TERMINALS:
AN INDIAN PERSPECTIVE
SECURITE ET CONCEPTION DES TERMINAUX DE
RECEPTION GNL: UNE PERSPECTIVE INDIENNE
M. V. R. Someswarudu
Senior Manager
Business Development Group
V. S. Sadana
Additional General Manager
O & M Group (Presently with OISD)
Gas Authority of India Limited
16, Bhikaiji Cama Place
New Delhi 110 066 India
ABSTRACT
LNG import is one of the options for meeting the growing demand for natural gas in
India. Therefore, Government of India has given in-principle clearance for various LNG
terminals. In view of emerging scenario, it has become necessary to adopt and develop
standards covering safety and design aspects of the LNG Terminals in India. There are
specific considerations for the Indian LNG Terminal projects such as Seismic conditions,
Port layout and congestion etc., which may differ vis--vis the terminals in Far-Eastern
and European countries.
Indian safety standards already exist and are applicable for other petroleum product
terminals. Keeping in view of the technological advancements, cost reductions and
scaling up of trains; new standards are still being developed in case of LNG.
The proposed paper would cover and address the features of Indian safety standards
on LNG, which were evolved after reviewing the national and international standards, as
given below:
Guidelines for Process blocks and the spacing between tanks and other equipment
Basic design considerations for storage tanks
Safety features in design and operation of LNG vaporizers and piping
Fire protection, Safety and Emergency Systems
Port design and tanker receiving facilities
RESUME
Limportation de GNL est lune des options pour satisfaire la demande croissante de
Gaz Naturel en Inde. En consquence, le Gouvernement Indien a accord une autorisation
de principe pour la construction de plusieurs Terminaux de GNL. Dans le cadre de cette
nouvelle activit, il est devenu ncessaire dadopter et de crer des standards pour dfinir
les critres de scurit et de conception de Terminaux Mthaniers en Inde. Des conditions
spcifiques sont prendre en compte pour les projets de Terminaux en Inde, telles
conditions de sisme, schmas portuaires et congestion du trafic maritime, qui peuvent
diffrer par rapport aux terminaux de lExtrme-Orient et des pays Europens.
PO-20.2
Des standards de scurit indiens existent dj et sont applicables dautres
terminaux de produits ptroliers. Sans perdre de vue les spcificit et les avances
technologiques, les rductions de cots et les accroissements de capacit unitaire des
installations, de nouveaux standards sont encore dvelopper dans le cas du GNL.
La prsentation propose couvrira et expliquera les particularits des standards de
scurit Indiens pour le GNL, qui sont dvelopps en tenant compte des standards
nationaux et internationaux comme mentionn ci-aprs :
Rgles pour les linstallation installations de procd et les espacements entre les
rservoirs et les autres quipements
Rgles pour la conception et lingnierie de base des rservoirs de stockage GNL
Rgles de scurit pour la conception et lexploitation des regazifieurs de GNL et la
tuyauterie
La protection incendie, les systmes de scurit et durgence
Conception des ports et des installation de rception des navires mthaniers
INTRODUCTION
India is one of the largest emerging energy markets in the world and in particular in the
Asian Region. Though India is endowed with large primary energy reserves, greater focus
is now on gas in view of socio-economic, technological and environmental issues. The
demand supply gap of natural gas is rapidly increasing in India, necessitating large
imports of gas. As LNG import is one of the options for meeting the rising demand,
Government of India had given in-principle clearance for a number of LNG import
proposals.
The LNG terminals, which have been given in-principle clearances by the Government
of India, are shown in the map on the following page.
While India is poised to enter the LNG business in a considerable way, it has become
necessary to adopt and develop standards covering safety and design aspects for the LNG
terminals to be set up.
Oil Industry Safety Directorate (OISD) is a technical directorate, under the aegis of the
Ministry of Petroleum and Natural Gas, that formulates and coordinates the
implementation of a series of self regulatory measures and standards aimed at enhancing
the safety in the oil and gas industry in India. The standards cover the entire spectrum of
upstream and down stream activities pertaining to layout, operation, maintenance,
inspection, safety audits, fire fighting etc., which are implemented by public sector oil
companies. The rich experience of Indian industry in handling of similar commodities
under cryogenic conditions has thus helped in development of safety standard for LNG.
In due course these standards, developed by OISD, are likely to be applicable for all
industries in the hydrocarbon sector.
PO-20.3

Proposed LNG Terminals
Existing Gas Pipeline
System (GAIL)
(GAIL)piPROPOSED
India : Proposed LNG Terminals &
the Existing Gas Pipeline network
INDIAN OVERVIEW
The general considerations for the Indian LNG terminal projects, which may differ vis--
vis the terminals in Far-Eastern and European countries, are as follows:
Seismicity conditions
Port layout and congestion etc.
In the context of above, the following aspects have been reviewed while developing the
standard:
Type of Storage tanks: Most parts of the coastal India are lying outside the seismically
active regions as compared to that of Japan. Similarly, in general, the population densities
PO-20.4
in the coastal India are lower compared to that of Japan. Based on these considerations,
the types of storage tanks considered for development of standards cover only the above
ground LNG storage tanks. However, it is not intended to exclude the other storage
concepts and designs which have been proven in service.
Composition of LNG: The LNG trade is under continuous evolvement and it may
witness a sea change in the future as new market, new supply sources and new trade
practices are emerging. At present the exporters and importers are linked through specific
contracts irrespective of their geographical location. Considering the magnitude of
potential savings in the optimization of supply chains, it is quite possible that there could
be swapping and bartering of LNG in future. Consequently, the import terminals may not
only receive the LNG for which the contracts have been entered but also the LNG from
other sources. Thus, the import terminals might receive LNG from different liquefaction
plants. As the variations in the compositions would give rise to rollover, emphasis has
been given to address the rollover problems in the standard.
Port Operations: In view of its long coastline and expansion of trade the port
infrastructure is in the development stage as the existing major ports are congested to
locate LNG import facilities in close proximity. Thus, very few existing ports can
accommodate and handle LNG in addition to the present cargo. The terminals, which are
being developed at beach locations, would need to develop the suitable sea front
facilities and port systems to handle LNG. However, the systems such as vessel traffic
movement and control etc. in the existing ports would need to be properly interfaced with
that of the LNG terminal systems.
Experience of the I ndustry: Indian safety standards already exist and already applicable
for other petroleum products and terminals. The international safety standards, codes and
the practices for design and operation of LNG terminals, have been considered and
reviewed. This review, coupled with the experience of the Indian industry has contributed
in developing the Standard for storage and handling of LNG.
Others: The standard is not intended to be an engineering document but would provide safe
practices in operation and design of the terminals. As India is likely to be an importer of LNG in
the near future, the coverage includes only LNG receiving terminals rather than LNG liquefaction
facilities and the export terminals.
ANALYSIS OF THE EXISTING STANDARDS
There are various existing international standards for design of LNG installations, design
and construction of low pressure, low temperature tanks, storage and handling of LNG
etc. The features of Membrane tanks have also been considered in the latest standards
such as EN 1473 (1997).
While some of these adequately cover about the design aspects of the storage tanks, some
of them cover the safety aspects of the LNG handling. Any specific standard if followed
in full shall be adequate but at the same time, misrepresentation of any standard with
partial recommendations may pose a threat to the safety of installations. As a specific
instance, the hydrostatic test of the storage tanks and the duration of such test specified
differently in various codes. So, it is imperative that any designer would need to follow a
specific code in totality while designing the installations.
While preparing the Indian safety standard, the available standards on LNG handling
have been reviewed and analyzed with a view to adopt various safety aspects. This
PO-20.5
analysis together with discussions with various LNG terminal operators has given inputs
for the Indian safety standard.
INDIAN STANDARDS APPLICABLE FOR PETROLEUM PRODUCTS
The existing standards for other petroleum product installations have been developed
based on the experience of the industry. The adequacy of such standards for LNG
installations has been reviewed and industry experience, in handling cryogenic
hydrocarbons such as ethylene, has been taken into consideration while developing
standard on LNG.
Considering the technological developments in the field of LNG and the techno-
economics in installation of large LNG storage tanks it has become necessary to review
the height restrictions imposed for the other petroleum product storages. Further, it is
imperative that only the import terminals would be set up in India, a net importer of
energy.
SALIENT FEATURES OF THE INDIAN SAFETY STANDARD
The salient features of the standard, which are mandatory in nature only, are brought out
in the following paragraphs.
The Risk Analysis study would need to be carried out for any LNG Terminal to be set up.
The selection of the type of storage tank shall be based on the results of the Risk Analysis
study and the level of risk it is posing on the surroundings.
Guidelines for Process Blocks and the Spacing between Tanks and Other
Equipment:
The site for LNG Terminal must provide ease of access to the personnel, equipment,
materials etc. from offsite locations to reach the site for fire fighting or controlling spill
associated hazards or for the evacuation of the personnel.
The Layout shall consider the classification of Zones i.e. Gas Zone and Non-gas Zone.
Inter distances between blocks and facilities shall be governed by the Indian safety
standard on Layouts for Oil and Gas Installations (OISD 118) or the results of the Risk
Analysis study, whichever are higher. Inter-tank/container spacing shall be governed as
per NFPA 59A. As per the norms laid in the standard, storage or any process equipment
handling LNG, with a capacity more than 50m
3
shall not be located in buildings.
Basic Design Considerations for Storage Tanks:
Leakage: A single containment tank shall be surrounded by a bund wall / dyke to contain
any leakage. Incase of membrane tanks, nitrogen breather system shall be used to monitor
the natural gas concentration in the insulation space.
No bottom nozzles shall be provided to the storage tanks.
Dyke shall be provided for the following:
Single containment tank
Double containment with metallic outer tank
Full containment with metallic outer tank
Membrane tank
PO-20.6
The containment volume of the dyke shall be equivalent to 110 % capacity of the largest
tank within the dyke.
Adequate number of cold detectors for monitoring leakage of LNG at the tank roof shall
be provided. Tanks with an open annular space and not filled with perlite insulation shall
have a pump to remove the liquid.
Pressure/Vacuum Relief: Pressure relief valve shall be entirely separate from the vacuum
relief valve. In order to take care of mal-function of any of the relief valves due to
blockage in the sensor line, one extra relief valve (n+1) shall be installed. Necessary
provision shall be provided to protect the tank from overpressure as well as to take care of
the safe discharge.
Provision shall be made to inject nitrogen or dry chemical powder at the mouth of safety
relief valve discharge.
Rollover Protection: Inlet piping must be designed to avoid stratification of LNG (by
providing top and bottom fill lines). Provision for density measurement on tank shall be
provided for the entire height of the tank. For taking care of over pressurisation due to
roll over, one of the following options shall be provided:
Flare system to be designed
Rupture disc to be provided on the tank with isolation valve (lock open condition)
releasing to atmosphere
Density meters and temperature sensors along the height of the storage tanks shall be
provided.
Overfill Prevention: Two independent type level measuring instruments shall be provided
for the tank. The level instrument shall be equipped to provide remote reading and high-
level alarm signals in the control room. In addition, independent switches for high-level
alarm and high-high-level alarm with cut off shall be provided. The high-high-level
instrument should be hard wired directly to close the liquid inlet valves to the tank.
The design level of the storage tank shall be the maximum liquid level specified by the
designer / manufacturer or 0.5 m below the top of the shell, whichever is lower. The tank
shall not be provided with over flow arrangement.
The instrumentation for storage facilities shall be designed and provided in such a way
that the system attains fail-safe condition in case of power or instrument air failure.
Others: There is no limit on the height of the tank envisaged other than the engineering
considerations. Tanks should be tight enough to prevent any evaporation losses and also
to avoid ingress of air and moisture.
For the storage tanks, water sprays shall be provided on the tank shell including the roof
and the appurtenances on the tank.
For single containment tanks as well as double / full containment tanks having metallic
outer tank, and membrane tank which are having a dyke, high expansion foam systems
shall be provided.
The possibility of an adjacent tank fire must be taken into consideration when designing
insulation for LNG storage tanks.
PO-20.7
If electrical heating system is provided to the tank, it shall consist of a number of
independent parallel circuits so designed that electrical failure of any one circuit does not
affect power supply to the remaining circuits.
Safety Features in Design and Operation of LNG Vaporizers and Piping:
Vaporizers: Vaporizers shall be designed for working pressure at least equal to the
maximum discharge pressure of the LNG pump or pressurized container system
supplying them, whichever is greater.
Manifold vaporizers shall have both inlet and discharge block valves at each vaporizer.
Isolation of an idle manifold vaporizer to prevent leakage of LNG into that vaporizer
shall be accomplished with two inlet valves with safe bleed arrangement in between.
Each heated vaporizer shall be provided with safety interlock to shut off the heat source
from a location at least 15 m distant from the vaporizer. The device shall also be operable
at its installed location.
The shutoff valve installed at the inlet of the vaporizer (at least 15 m away from the
vaporizer) shall be operable either at installed location or from a remote location and the
valve shall be protected from becoming inoperable due to external icing conditions.
Relief Valves on the vaporizers shall be designed in accordance with the type of
vaporizers. The discharges from the relief valves shall be located at a safe height from
adjoining operating platform.
Send-out: Suitable automation shall be provided to prevent the discharge of either LNG
or vaporized gas into a distribution system at a temperature either above or below the
design temperature of the send out system. Such automation shall be independent of all
other flow control systems and shall incorporate shut down valves used only for
contingency purposes.
Unloading Lines: The unloading and transfer lines for LNG should have minimum
number of flange joints. Consideration should be given to provide cold sensors for
flanges of size 200 mm and above as well as where there are clusters of flanges.
Fire Protection, Safety and Emergency Systems:
The receiving terminal shall be provided with Flare system to enhance the plant safety.
Emergency Shutdown (ESD) Systems: The ESD system shall consider process safety as
well as leakage of gas, fire, smoke as well as cold detection and linear detection. They
shall be of failsafe design. It should be installed, located or protected so as it is easily
operable in the event of emergency or failure of the normal control system. If they are not
of failsafe design, they shall have all components that are located within 15 m of the
equipment to be controlled either:
Installed or located where they will not be exposed to a fire or
Be protected against failure due to fire exposure of at least 10 minutes duration.
Emergency Procedures: A detailed emergency procedure manual (to be available in the
plant control room) shall be prepared to cover the potential emergency conditions. Such
procedure shall include but not necessarily be limited to the followings:
PO-20.8
Applicable steps (shut down / isolation) to ensure the escape of gas or liquid is
promptly cut off or reduced as much as possible in case of emergencies
Use of fire protection facilities and First aid
Notification of public authorities and communication procedure in case of
emergency
Duties of personnel
A portable flammable gas indicator shall be readily available in the plant. For installation
of Fire protection facilities, OISD 116 (Fire Protection facilities for Petroleum Refineries
and Oil / Gas processing Plants) shall be followed.
No drain shall be open to atmosphere. Provision should be given to collect the LNG from
the unloading arm to a closed system by way of providing blow down vessel or any other
suitable arrangement.
Others: Buildings or structural enclosures in which LNG, flammable refrigerant and gases
are handled shall be of lightweight, non-combustible construction with non-load bearing
walls.
Port Design and Tanker Receiving Facilities:
Quick Release Hooks: All mooring points should be equipped with quick release hooks.
Multiple hook assemblies should be provided at those points where multiple mooring
lines are deployed so that not more than one mooring line is attached to a single hook.
Unloading Arms: The connection of the arm end to the ship crossover flange shall be
provided with a special automatic Emergency Release Coupler (ERC) device. Each
unloading arm shall be fitted with an Emergency Release System (ERS), able to be inter-
linked to the ships ESD system. This system must operate in two stages to stop LNG
pumping and close block valves in the pipelines and entails automatic activation of the
dry-break coupling at the ERC together with its quick-acting flanking valves.
Cargo Transfer: Prior to cargo transfer, the officers in charge of vessel cargo transfer and
the shore terminal shall inspect their respective facilities to ensure that transfer equipment
is in the proper operating condition. Following this inspection, they shall meet and
determine the transfer procedure, verify that adequate ship-to-shore communications exist
along with the interlocking between ship and terminal control room are established, and
review emergency procedures. During unloading operation, the terminal operator shall
take control of the unloading.
Ship bunkering shall not be permitted during LNG unloading operations. Vehicle traffic
shall be prohibited on the berth within 30 m of the unloading manifold while transfer
operations are in progress. Warning signs or barricades shall be used to indicate that
transfer operations are in progress.
Others: No uncontrolled ignition source should be within a predetermined safe area,
centred on the LNG carriers cargo manifold. The minimum exclusion zone from any
ignition source should be determined from the design considerations and dispersion
studies envisaged in the risk analysis report.
PO-20.9
In addition to the adherence of the instructions and procedures of the Port Regulatory
Authority, the ships should be berthed in such way that in case of emergency the ship can
sail out (head on) immediately.
SUMMATION
The evolution of a safety standard, for the terminals handling LNG, would enable
rationalization and provide guidelines on minimum safety requirements for various
terminal developers in the country. The proper understanding and the experience gained
by the Indian industry in development of such standard have demonstrated that India is
fully geared up to handle LNG in an efficient and safe manner in the years to come.
ACKNOWLEDGEMENT
The authors would like to take the opportunity to thank OISD and Gas Authority of
India Limited (GAIL) for their encouragement in the production of this paper.
REFERENCES
Standard for the Storage and Handling of Liquefied Natural Gas (OISD 194), Oil
Industry Safety Directorate, New Delhi
Standard for Layouts for Oil and Gas Installations (OISD 118), Oil Industry Safety
Directorate, New Delhi
N. J. Fulford and M. D. Slatter Developments in the safe design of LNG Tanks,
Cryogenics 1988 (Vol. 28)
N. Ketchell, R Robinson, P. Genoud Quantification and Comparison of the Risks of
LNG Storage Concepts Membrane and Full Containment, Paper presented in LNG 12
Conference
International Standards on LNG: API 620, NFPA 59A, BS EN 1473, BS 7777