5. Operation Manual BB KANGRIM HEAVY INDUSTRIES CO, LTD.Inert Gas Generator KANGRIM Operation Manual KANGRIM INDUSTRIES CO.,LTD.Inert Gas Generator KANGRIM CONTENTS PAGE 1 GENERAL 3 La General 5 12 Explosive Limits 6 13 _ Inert Gas System 7 1.4 Quantity and Rate of Supply of Inert Gas 7 15 Safe Oxygen Levels 8 16 Health Hazard with Inert Gas: 8 2 DESCRIPTION 16 2d The Oil Burner 18, 22 Burner/Serubber Unit 20 23 The Combustion Air System 2 24 Deck Water Seal 23 25 Non Return Valve 23 2.6 Deck isolating Valve 23 27 Press. Vacuum Breaker 23 4. INSTRUMENTATION AND CONTROL SYSTEM 24 31 Indicating /Recording Instruments 26 32 Safety Interlocks 27 33 Instrumentation and Control Panels 28 4 INSTRUCTION FOR PLANT START, OPERATION AND STOP’ 30 41 Short Form, Step by Step, Plant Start and Stop Instructions 32 42 Descriptive instructions for Plant Start and Operation 34 & ADJUSTMENT AND TOLERANCES, MAINTENANCE 36 5.1 Adjustments and Tolerances 38 5.2 Maintenance a 6. SOME POSSIBLE CAUSES TO FAULTS DURING START AND 47 OPERATION 61 If Control Current is not on 49 62 If ignition Does not Take Place 49 63 If Fuel Oil Pressure is too Low 49 64 If Sea Water Pressure is too Low 49 65 If Sea Water Level in Cooling Tower is too High 49 If Inert Gas Temperature is Higher than Approx. 5 ‘C Above 49 Sea Water Inlet Temp. If the Instrument Air Pressure is too Low 49 KANGRIM INDUSTRIES CO., LTD.Inert Gas Generator KANGRIM 7. INSTRUCTION FOR OPERATION OF DECK DISTRIBUTION 50 SYSTEM 7.1 General 2 7.2 Inert Gas Supply Equipment on Deck 2 8. GAS DISTRIBUTION OPERATING INSTRUCTIONS 54 8.1 General 56 82 Shut Down s7 83 Inerting Empty Tanks at Sea 59 84 ig Cargo a 8.5 Loading Passage 65 8.6 Cargo Discharge and Commemcement of Crude Oil Washing 68 8.7 Crude oil washing (Bottom of Tanks) n 88 Purging at sea "4 8.9 — Gas-freeing Using Portable Fans 1 8.10 Gas-freeing Using the IGG Blowers 80 8.11 Inerting to water ballast tanks under Hydro-Carbon Gas Detecing 83 8.12 Ventilation of water ball 86 KANGRIM INDUSTRIES CO., LTD. 2Inert Gas Generator KANGRIM 1. General KANGRIM INDUSTRIES CO.,LTD.1 12 13 14 15 16 1.6.41 1.6.2 1.63 1.6.4 1.6.5 1.66 1.6.7 168 16.9 Inert Gas Generator GENERAL TABLE OF CONTENT General Explosive Limits Inert Gas System Quantity and Rate of Supply of Inert Gas Safe Oxygen Levels Health Hazard with Inert Gas Oxygen Dificiency Toxicity of Hydrocarbon Vapours Inert Gas Toxicity Entering a tank for inspection and Repair Safety on deck Source of Ignition ‘Tank Pressure Electrostatic Hazards Repair of Inert Gas Generating Plant KANGRIM INDUSTRIES CO., LTD.Inert Gas Generator KANGRIM 1 GENERAL 1.1 General ‘The main reason for the installation of an Inert Gas system on board a tankship is to minimize the danger of fire or explosion in cargo tanks This danger always exists, due to the fact that all three elements needed to start a fire or an explosion will be present. These three elements are: 1, combustible element, fuel, represented by hydrocarbon vapours from the cargo. 2 Energy to start the combustion, represented by sparks from various sources. 3 ‘Oxygen to support the combustion, represented by the oxygen in the air, which contains roughly 21 % Oxygen and 79 % Nitrogen, ‘To set off fire or explosion all three elements must be present simultaneously. If any of the three elements can be eliminated, the danger of explosion is also eliminated, and this is the philosophy behind the inert gas system. When looking for the simplest element to remove, one will find that: 1, The fuel part can never be eliminated, due to the nature of the cargo, which in itself is highly inflammable The cargo will always evaporate explosive hydrocarbon vapours, which will fill any void spaces in the tanks, and mix with the air entering the tanks through open hatches, ete. On ballast voyage the empty tank is also filled with a mixture of air, drawn in when unloading and vapours from the cargo remain in the tank. 2. The energy spark to set off an explosion is also very difficult to eliminate completely. Exhaustive studies have been made by maritime bodies worldwide. No exact conclusion has been drawn, but it is a recognized fact that the most dangerous source of ignition is that of static electricity, which may be created in various ways inside the tank. ‘The nature of this static electricity is such that itis impossible to eliminate, ficult to recognize, and therefore almost as The remaining element to support combustion oxygen, is always present, being 21% of the earth’s atmosphere. KANGRIM INDUSTRIES CO., LTD. 512 Inert Gas Generator KaNGRIM The percentage of oxygen inside the cargo tanks can be controlled, by replacing the air with an inert gas, namely, a gas with an oxygen content too low to form an explosive mixture regardless of the amount of petroleum gas in the atmosphere of the tank. Explosive Limits ‘The chemical composition of air is basicly: 21% volume 79% volume Oxygen - 0: Nitrogen - N2 ‘A mixture of hydrocarbon gas and air has two limits of explosivity. the lower explosive limit (LEL), is 2% of gas (98 % of air) the upper explosive limit (UEL), is 10 % of gas (90 % of air) Within these two limits, the mixture is inflammable. Below the lower explosive limn, the mixture is too lean to burn. Above the upper explosive limit, the mixture is too rich to burn Hydrocarbon gas in a hazardous mixture containing oxygen will only burn, if the content of hydrocarbon gas in the mixture lies between the upper and lower of inflammability. ‘These limits which are respectively 10% and 2% in air, vary according to the oxygen content of the mixture. ‘The gap between them narrows progressive-as the oxygen content diminishes. (See diagram). If the oxygen content of the gas mixture is below 11 %, the hydrocarbon gas contained in the mixture CANNOT BURN WHATEVER ITS CONCENTRATION MAY BE. An atmosphere containing less than 11 % of oxygen is considered to be THEORETICALLY INERT. 10%-U.E.L VARIATION OF THE UPPER IN AIR LIMIT OF INFLAMMABILITY PERCENTAGE myer EAREON cas 9 THE varaaton of nu towen|/” LL. 44 anton oF uz rove) a EMIT OF IFENONEIETY | Fr56- WEAK TO BURN Aatiie ot 1 PERCENTAGE OF OXYGEN IN THE mixture 2% (AIR) (ay VOLUME) KANGRIM INDUSTRIES CO., LTD. 613 14 Inert Gas Generator KANGRIM Inert Gas System ‘The method of protecting an oil tanker by means of inert gas consists in completely isolating the ship's tanks from atmosphere. This is achieved by maintaining a slight overpressure in the tanks at all times, and leaving only the tank breathing valves free to open. While discharging cargo (or ballast from cargo tanks), the liquid pumped out of the tanks is replaced by inert gas. At all times, the pressure of the inert gas in the tanks is maintained slightly above atmospheric pressure. From one dry-docking to the next, the ship is constant protected by inert gas, the only exception belong in the case of work having to be done inside one of the tanks . This procedure means a greater all-round safety in the operation of the ship, not only during tank cleaning, loading and discharging operations, but also during voyages. ‘The inert gas used on this ship is produced by operating a controlled air blower that sucks air from the engine room and feeds the air into the Kang-Rim Inert Gas Generator to burn fuel oil at a very low excess air value. The gas is then cooled and cleaned by sea water in a scrubber unit, and subsequently distributed to the tanks through a deck piping system. ‘The produced gas consists mainly of Nitrogen N2 and Carbon Dioxide CO2, Quantity and Rate of Supply of Inert Gas ‘The most critical demand for Inert Gas is during cargo discharge, when the supply ‘must at least equal the cargo discharge rate. Centrifugal cargo pumps have a rated capacity against a nominal head, but on some occasions it is possible to exceed the rated capacity when discharging against a lower head. To cater for such variations in discharge rate, the Inert Gas System capacity has been sized on the nominal pumping rate multiplied by at least 1.25. IF THE CARGO DISCHARGE CAPACITY EVER EXCEEDS INERT GAS CAPACITY THE DISCHARGE RATE SHOULD BE REDUCED IN ORDER TO MAINTAIN A POSITIVE INERT GAS PRESSURE. KANGRIM INDUSTRIES CO., LTD. 7Inert Gas Generator Ls 16 1.6.1 Safe Oxygen Levels During inert gas plant operations, it is of utmost importance to keep the oxygen level as low as possible, in order to have the greatest possible safety margin. Oxygen levels : 11% 02 : MINIMUM OXYGEN LEVEL necessary to support combustion/explosion. ‘This level however is not considered safe, since there is no margin left for measurement error. 8%02 : MAXIMUM OXYGEN LEVEL ALLOWED during inert gas plant operations. However, all necessary steps must be taken to ensure oxygen level below 8 %. 5%02 : SATISFACTORY OXYGEN LEVEL This is considered the normal maximum level that a good operating vessel shall maintain, even with the worst IGG condition. Less than BEST OXYGEN LEVEL for a good operating vessel. The IGG operations in 3% 02 : the following sections refer to this level. ‘Health Hazards with Inert Gas NOTE! ALL PERSONNEL MUST BE MADE AWARE OF THE HAZARDS AND. PRECAUTIONS LISTED IN THE FOLLOWING PARAGRAPHS ‘Oxygen Deficiency All inerted areas, are areas with an atmosphere containing very little oxygen. Exposure to an atmosphere with a low concentration of oxygen does no necessarily produce recognisable symptoms before unconsciousness occurs. The onset of brain damage amd the risk of death can follow within a few minutes. If the oxygen deficiency is not sufficient to cause unconsciousness, the mind is liable to become apathetic and complacent and even if these symptoms are noticed and escape is attempted physical exertion will aggravate the weakness of both the mind and the body. Itis therefore necessary to ventilate thoroughly the space to be entered so that no pockets of oxygen-deficient atmosphere remain. When testing for entry a steady reading of 21% oxygen is required. KANGRIM INDUSTRIES CO., LTD.Inert Gas Generator KaNGRIM 1.6.2 Toxicity of Hydrocarbon Vapours ‘The toxicity of hydrocarbon gas is not affected by pressure of inert gas. Because of possible gas pockets, gas-freeing for entry into a space must continue until a 1% lower flammable limit (LFL) reading is obtained for the entire compartment, on the portable hydrocarbon gas analyser (explosimeter). 1.63 Inert Gas Toxicity ‘The pressence of toxic gases such as sulphur dioxide, carbon monoxide and oxides of nitrogne can only be ascertained by measurement. However provided that the hydrocarbon gas content of an inerted cargo tank exceeds approximately 2% by volume before gas-freeing commences, the dilution if the toxic components of the flue gas during the subsequent gas-freeing operation can be correlated with the readings on the explosimeter. If by ventilating the compartment, a reading of 1% LFL or less is obtained in conjunction with an oxygen content reading of 21% by volume the toxic trace gases will be diluted to concentrations at which the compartment will be safe for entry. Alternatively, and irrespective of the initial hydrocarbon gas cotent, ventilation must be continued until a steady oxygen content reading of 21% by volume is obtained. 1.6.4 Entering a Tank for Inspection and Repair WARNING THE FOLLOWING SAFETY PROCEDURES ARE COMPLEMENTARY TO THE COMPANY'S SAFETY PROCDEURES, BUT IN THE CASE, OF ANY DISCREPANCY THE COMPANY'S SAFETY PROCEDURES, MUST BE COMPLIED WITH INERT GAS IS NON-POISONOUS, BUT IT IS ASPHYXIATING IF INHALED IN LARGE QUANTITIES. INERT GAS CAN ALSO CAUSE PERMANENT BRAIN DAMAGE IF INHALED IN LARGE QUANTITIES FOR A PERIOD OF 8 SECONDS. Reference must be made to the section on oxygen deficiency, and toxicity of hydrocarbon vapours and flue gas. KANGRIM INDUSTRIES CO., LTD. 9Inert Gas Generator KANGRIM Before Entering a Tank Before entering a tank, ensure the safety of personnel by carrying out the following procedures 1. Check with the portable oxygen analyser that the cargo tank atmosphere contains 21% oxygen. Check that the hydrocarbon content is zero as measured on the explosimeter. These checks must be repeated at several openings in the cargo tank at three different levels including the cargo tank bottom. NOTE : Both hydrocarbon gas and inert gas are heavier than air, therefore the sampling line used ‘must be of sufficient length to reach within 1.2m of the cargo tank bottom from the deck. If'it is necessary to join two lengths of samplimg line to achieve this, the coupling should bbe taped or secured in some way to prevent loss of the lower length of sampling line. 2 ‘The cargo tank atmosphere testing must be carried out by a responsible officer, or under his direct supervision. 3. The hydraulic cargo system power pack must be shut down. Power supply to the cargo system control console is to be switched OFF and a warning notice displayed on the console before ~ any entry is made. 4. A communication procedure must be established between the men entering the cargo tank and a person to be stationed at the tank hatch. 5. Itmust be clearly understood by all personnel that no person is allowed to enter a cargo tank without direct permission from the Chief Officer. 6. Self-contained breathing apparatus must be available at the tank hatch together with a lifeline and rescue harness. 7. The branch line isolating valve must be shut to isolate the cargo tank from the inert gas deck main, During Tank Entry ‘The following precautions must be observed during the whole time in which men are working in the cargo tank : 1. A responsible person must be stationed at the tank hatch with clear instructions not to leave that location. 2 During the entire period that personnel are in a cargo tank, fresh air ventilation must be provided The bridge must be informed that men are working in a particular cargo tank, KANGRIM INDUSTRIES CO., LTD. 10Inert Gas Generator KANGRIM 1.6.5 Safety on Deck WARNING IT IS IMPORTANT TO CHECK THAT THE CARGO TANK PRESSURE. IS ZERO BEFORE ATTEMPTING TO OPEN ANY CARGO TANK HATCH COVER. 1 When any cargo tank hatch cover is lifted, personnel must always stand diametrically opposite the hinge and on no account lean over the opening. 2. Whenever purging or gas-freeing is taking place, warning notices are to be placed near tank hatches to warn of dangerous gases. 3. It must be remembered that wind across the deck can cause the cargo tank atmosphere to be drawn from an opening. Personnel should therefore be made aware of the danger of standing downwind of any cargo tank hatch. 4. Personnel must not stand beside a cargo tank opening at any and precautions must be observed. unless absolutely necessary, All company precautions are to be observed at all times regardless of inert gas system. operation. 1.6.6 Source of Ignition Smoking ‘Smoking must be permitted only under controlled conditions at time and in place specified by the Masker. Matches, and especially lighters, must not be carried by personnel while at work on board. Under no circumstances will no smoking rule be lifted. Hot Work No hot work to be carried out in any cargo tank or pumproom at any time without prior permission from Head Office. Metals 1 Aluminium equipment must not be dragged across steel as the resultant smear may cause sparks if struck. 2. No hammering of chipping must be carried out unless the area has been declared gasfree by the Chief Officer. KANGRIM INDUSTRIES CO., LTD. aesInert Gas Generator KANGRIM 3 ‘The use of non-sparking tools is not recommended, as tests have shown that they do not effect a significant reduction in he risk of gas igniticn when compared to the associated with ferrous tools : there are also certain risks inherent in their use. Absorbent Material ‘Some materials, when damp or soaked in oil especially vegetable oil are liable to ignite because of the build-up of heat during oxidation. For this reason, absorbent material MUST NOT be stowed near oil or paint etc. If such materials become damp, they must be dried stowage. If they become soaked with oil, they must be cleaned or destroyed. Pyrophoric Oxidation Inert gas provides a complete protection only if fully operational and properly operated. In case of inert gas system failure, this protection not only ceases, but byproducts of the inert ‘gas (such as pyrophorics and static electricity) may increase the risk of explosion and fire if air is introduced in the tanks without following the proper procedures. ‘Measurements have revealed that cargoes of normally sweet crude are occasionally sufficiently sour to give rise to several percent of hydrogen sulphide gas in the vapour space. Ina oxygenfree atmosphere, where hydrogen sulphide is present, iron oxide (rust) is converted to iron sulphide. When the iron sulphide is subsequently exposed to air, itis oxidized back to iron oxide, free sulphur, and sulphur oxide gas. This oxidation can be accompanied by the generation of considerable heat so that individual particles may become incandescent. Rapid exothermic oxidation with incandescence is termed pyrophoric oxidation. Pyrophoric iron sulphide capable of pyrophorie oxidation in air - can ignite flammable hydrocarbon-air mixture, In refinery operation pyrophoric iron sulphide is well recognized as a potential source of ignition Pyrohoric deposits are apt to accumulate in storage tanks in sour crude service and in process equipment handling sour streams. When such tanks or equipment are taken out of service, itis normal practice to keep all internal surfaces thoroughly wet during ventilation so that there can bbe no pyrophoric reaction before the equipment is made gasfree. Deposits and sluge must be kept wet until removed to a safe area where subsequent ignition will cause no damage. Numerous fires have occurred when deposits have dried out prematurely. While pyrophoric iron sulphide is a widely recognized ignition source in shore-based operation, it has rarely been cited as the cause of a marine ignition. Presumably marine operations have been free of this hazard because cargo tanks (of non-inerted ships) normally contain some ‘oxygen in the vapour space. The presence of oxygen inhibits the conversion of iron oxide toi sulphide by hydrogen sulphide. KANGRIM INDUSTRIES CO., LTD. 12Inert Gas Generator KANGRIM Cargo tanks which are inerted may contain little or no oxygen. Thus there is a possibility that pyrophoric deposits may be formed when sour cargo is carried. In normal operation of inerted tankers the cargo tanks are not allowed to become flammable at any time. Thus the pressence of any pyrophoric deposits in the cargo tank or in the vent and inert gas piping would not result in an ignition. However, if the inert gas plant were to become inoperable, cargo or ballast discharge with air entering the cargo tanks could result in a flammable atmosphere with the risk of ignition if pyrophorie deposits were present. Most foreseeable inert gas system failures are can be avoided by timely maintenance. Furthermore, most breakdowns can be repaired adequately in a few hours. Certain components, notably the blowers, can fail totally without warning and all vessels are advised to keep spares of these components which are a long delivery item. IN THE EVENT THAT THE INERT GAS GENERATOR BECOMES INOPERATIVE BOTH AT SEA AND IN PORT, THE GROUP MANAGER MUST BE ADVISED IMMEDIAT- ELY, NOTIFYING HIM POSSIBLY BY TELEPHONE, OF THE EXISTING SITUATION AND OF MATERIALS / SPARES REQUIRED TO RESTORE THE SYSTEM IN GOOD WORKING ORDER. 1.6.7 Tank Pressure I should be advised of the practical hazards when an inerted cargo tank ‘is maintained pressure. The pressure must be sufficiently relieved before opening any tank lids, usage plugs or tank washing openings. 1.6.8 Electrostatic Hazards ‘An electrostatic charge can occur in the small particulate matter carried in flue gas. Although the charge is normally of a low level, much higher levels have been observed with ‘water mists created by tank washing. Cargo tanks are usually in an inerted condition and electrostatic ignition is not a consideration unless the oxygen content of the tank atmosphere is increased by the entrance of air, or unless it is necessary to inert a tank already containing a flammable atmosphere. 1.6.9 Repair of Inert Gas Generating Plant Inert gas is asphyxiating and extreme caution must be exercised at all times when working on the plant. Being in fresh air during the work is not a safety guarantee, since inert gas possibly leaking from the plant can still cause unconsciousness very quick. The plants should therefore be completely gas free before any equipment is opened up. eee KANGRIM INDUSTRIES CO., LTD. 13