BASED ON EXPERIENCE - TGE Gas · PDF filebased on experience. tge gas engineering. evolution...

www.tge-gas.com Page 109/11/2016
BASED ON EXPERIENCETGE GAS ENGINEERING
EVOLUTION OF SAFETY DESIGN FOR CRYOGENIC TANKS REVAMP VS. NEW BUILT

Overview on the services and experience of TGE Gas Engineering GmbH
Examples of revamp projects
Some spotlights on overall requirements for the design of cryogenic tank farms
Conclusion
CONTENT

TGE Gas Engineering GmbH (TGE) is one of the worlds leading contractors for projects involving the storage and handling of liquefied gases in the energy and petrochemical/chemical industries.
TGE has over 30 years of experience in this field, providing full range of services from concept /feasibility studies through to Lump Sum Turn-Key Project execution.
Our target is to provide to customers the added value based on our experience and Know-How in delivering millions of m of Liquefied Gas Storages and Handling Facilities.
TGE is a technology focused company that is active worldwide with main operating units throughout Europe and Asia.
0
1.000.000
2.000.000
3.000.000
4.000.000
5.000.000
6.000.000
Overallcapacity
LNG Ethylene /Ethane
Propylene,LPG, etc.
LIQUEFIED GAS STORAGE CAPACITY PERFORMED (m)
Status Sep. 2016
COMPANY PROFILE

Storages and Terminals for LNG
Small-Mid Scale Natural Gas LNG Liquefaction Plants
Storage and Terminals for Petrochemical/Chemical Gas
Other Package Plants for gas
treatment or elements of storage product lines
LNG as Fuel
Storage Tank Design Services
PRODUCT LINES

17 Projects in Total (EPC & EP+CS)
Import Terminals: 9
Export Terminals: 7
Import/Export Terminal: 1
72 LNG Truck/Container Loading Stations
Total Regasification Capacity > 13 mio t/a
Total Production Capacity Small-Mid Scale LNG > 3 mio t/a
Reference for all relevant International Design Codes:
Tanks: EN 14620, EUROCODE API 625, API 620, ACI 376
Facilities: EN 1473, NFPA 59a,
STORAGE TANKS
Storage Tanks installed 30,000 - 160,000 m
Storage Tanks designed 5,000 - 260,000 m
Storage Tanks installed in Europe 940,000 m
Storage Tanks installed in Asia 1,908,000 m
STORAGES AND TERMINALS FOR LNG
INSTALLED CAPACITY
21 Full Containment Tanks 2,838,000 m
5 Single Containment Tanks 170,000 m
TOTAL INSTALLED CAPACITY 3,008,000 m
FACTS & FIGURES

36 Projects in Total (EPC & EP+CS) for Petrochemical Products: Ethylene, Ethane, Propylene, Butane, LPG, Ammonia.
STORAGE TANKS
Tanks installed with capacities from up to 3,000 - 120,000 m
Facilities installed in Europe 327,000 m
Facilities installed in Asia 1,684,000 m
STORAGES AND TERMINALS FOR PETROCHEMICAL GASES
INSTALLED CAPACITY
20 Full Containment Tanks with installed capacity 1,205,000 m
22 Single Containment Tanks with installed capacity 560,000 m
TOTAL INSTALLED CAPACITY 1,765,000 m
FACTS & FIGURES
LARGEST INSTALLED CAPACITY
LPG 120,000 m Full Containment
Ethylene 80,000 m Full Containment
Ethane 120,000 m Full Containment
Propylene 80,000 m Full Containment
Ammonia 25,000 ton Full Containment

Consultancy
Technical and Commercial Feasibility Studies
Site Selection
Conceptual Design
Environmental Impact Assessment (EIA) and HAZOP Studies
Capital Cost (CAPEX) and Operating Cost (OPEX) Estimation
Business Plan for Capital Investments and Operations
Basic Engineering and Front End Engineering Design (FEED)
Detailed Engineering
Procurement/Procurement Services
Construction/Construction Services
Supervision Services
Pre-Commissioning and Commissioning Services
Start-Up/Shut Down Services
Selection and Training of Operators
Operation and Maintenance Services
Life-Cycle Engineering Studies and Plant Life-Cycle Optimisation
SCOPE OF SERVICES

Ammonia - Toxic, Hazardous to Waters
No Flare connected, low tech instrumentation
Single wall
Overfill protection directly to sewage
Various shell penetrations (instruments, manhole)
PSV to atmosphere, design pressure 2 psi g
Zip-weld -> uncontrolled evaporation
Tank insulation: exposed to atmosphere
Considered loads:
dead weight hydrostatic pressure, internal gas pressure, wind
15,000 TON AMMONIA TANK BUILT AROUND 1970 (OUTSIDE EU)
REVAMP PROJECTS - EXAMPLE 1

External insulation deterioated, structure corroded, undetected icing
Ship unloading with hoses
BOG system outdated
15,000 TON AMMONIA TANK BUILT AROUND 1970

FC Steel / Steel with bottom outlet acc. to API 620
Design Pressure 290 mbarg
State of the Art Instrumentation, DCS, Fail safe SCS
New BOG Handling Systems, Unloading Systems, Send out Pumps, etc.
25,000 TON AMMONIA TANK NEW BUILT 2013

Old tank completely inspected, refurbished
Updated instrumentation, valves, safety installations, etc.
Back in service together with new tank
Sharing process installation as BOG system, send out systems, DCS, etc.
Updated to State of the Art Instrumentation
Connected to new BOG Handling Systems, Send out Pumps, etc.
BUT
still an old tank
with single wall
zip weld
lower design pressure
bottom outlet instead of submerged in-tank pumps
with the related trade off on operation, safety, etc.
NEW BUILT AMMONIA TANK 2013 + OLD TANK REFURBISHED

Tank was originally designed as Single Containment forEthylene Service located in a petrochemical complex
Inner tank 9% Ni, outer tank CS, Perlite
Upgraded several times over its lifetime
First out of service inpection in 1990
Concrete bund wall added in 90s to upgrade to Double Containment
Changed to Propylene service
Inspected and modified again in 2015 in order to allowEthane service
13,000 M ETHYLENE TANK COMMISSIONED 1967 (INSIDE EU)

Refurbishment: Best option for operator to satisfydemand on relatively short notice
Safety Concept is still acceptable to authorities
New Installations for BOG handling, send out, updated Tank Instrumentation, Tank SafetyValves, etc.
Certain constraints with regard to the OLD tank had to be solved or compromises are accepted
13,000 M ETHYLENE TANK COMMISSIONED 1967 (INSIDE EU)

Load Cases past dead weight hydrostatic pressure, internal gas pressure, wind live loads
Load Cases actual as before plus seismic ( OBE and SSE) fire blast spill
Verification of ULS and SLS for metallic components concrete components
LOAD CASES OF THE PAST VERSUS ACTUAL APPROACH TO STRUCTURAL DESIGN
SAFETY CONCEPTS / DESIGN CRITERIA
Verification of allowable stresses metallic components

Individual / mandatory regulations are subject to revision
SEVESO III (Directive 2012/18/EU)
PURPLE BOOK
EN 1473, NFPA59A
Strfallverordnung
NEW REQUIREMENTS MAY ENDANGER PERMIT FOR CONTINUED OPERATION OF OLD TANK
REQUIREMENTS TODAY HSE DESIGN & PERMITTING
SAFETY CONCEPTS / DESIGN CRITERIA

Classification of establishment is based on Qualifying Quantities
More than 200 ton of total storage of ammonia and liquefied flammable gases incl. LPG and natural gas
upper-tier establishment (Seveso II, Seveso III)
Safety report (Article 10)
(c) demonstrating that adequate safety and reliability have been taken into account in the design, construction, operation and maintenance of any installation, storage facility, equipment and infrastructure connected with its operation which are linked to major-accident hazards inside the establishment;
5. Without prejudice to Article 11, the operator shall periodically review and where necessary update the safety report at least every five years. The operator shall also review and where necessary update the safety report following a major accident at its establishment, and at any other time at the initiative of the operator or at the request of the competent authority, where justified by new facts or by new technological knowledge about safety matters, including knowledge arising from analysis of accidents or, as far as possible, near misses, and by developments in knowledge concerning the assessment of hazards.
ESTABLISHMENTS ACC. ART.10 (SEVESOIII)QUALIFYING QUANTITIES

Evaluation on a case-by-case study
Evaluation of demands of owners and authorities
Design life time of 30 years often already exceeded fatigue corrosion
Due to its construction, inspection of steel bottom not possible corrosio

BASED ON EXPERIENCE - TGE Gas · PDF filebased on experience. tge gas engineering. evolution...

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