SOP (Standard operating procedure) for Filling Liquid

Cylinder with transport tank using pump transfer method

1. Scope:
This document provides guidelines for filling of LNG liquid cylinders using low pressure
transport tank having submersed pump; using these guidelines liquid cylinders can be
filled without venting LNG to atmosphere. The Pump will be powered through on board
Generator.

In addition, it provides guidelines on how to accurately & reliably measure the quantity
of Dispensed LNG using inbuilt flowmeter & printer.

Guidelines for

- Site preparation

- Safe handling & operation

- Emergency response

are specified for reference purpose.

Note: This document provides guidelines for trained operators. It is responsibility of owner,
operator to ensure rules or regulations are complied. Rules & methods take precedence over
this document (Refer reference Section).

2. Reference:

Standard/ Description
Regulation
Standard for the production, storage and handling of
NFPA 59A
liquefied natural gas (LNG)
CGA P-12 Safe handling of cryogenics liquids
GCR 2016 Gas cylinder rules 2016
SMPV 2016 Static & Mobile pressure vessels (Unfired) rules 2016
3. General (Common) guidelines applicable:
3.1 Material Safety Data sheet (MSDS) of LNG should be available

3.1.1 At unloading site & end user location preferably with site operator
or technician.

3.1.2 In truck & vehicle transporting LNG liquid cylinders, preferably

with trained operator or technician.

3.2 All personnel involved in filling, transportation & use should be trained in
handling of Methane (Natural gas) & Cryogenic pressurized liquids.
Should also have under taken training in regards to fire safety & emergency
response associated with Methane gas.

3.3 Records & logs should be maintained at each stage of

3.3.1 LNG transport tank loading

3.3.2 LNG transport tank unloading

3.3.3 Transportation of LNG liquid cylinder

3.3.4 At site of LNG liquid cylinder usage.

Logs should contain at minimum details of time, description of operation,

Name of operators, LNG contents before & after operations.

4. Site preparation for liquid cylinder filling:

LNG liquid cylinder filling operation should be carried in a safe & hazard free site which
is equipped with fire extinguishing systems suitable to handle LNG related fire systems
(Ex : Foam type fire extinguisher).

Safety decals, Operating instructions & Emergency response details should be

specified at multiple easily visible locations.

During the filling the site should be

4.1 Free of any source of heat or ignition.

4.2 Free of any clutter or materials that are easily combustible.

 4.3 Use of mobiles, electronic items other than those approved should be
prohibited.

5. Regulatory requirements for India:

Following requirements are to be satisfied as per Petroleum & Explosive Safety
Organization (PESO)

5.1 Liquid cylinder should be approved by PESO.

5.2 Check & verify periodic inspection documents; Filling should not be done if
criteria established by PESO are not satisfied.

5.3 Ensure safety decals, manufactures instruction & Emergency response

details are clearly legible;

6. Prefilling procedure & checks:

6.1 Inspect LNG liquid cylinder that needs to be filled. Observe to check any
abnormal behaviour, damage or breakage & Leakage.

6.2 Inspect LNG transport tank; Observe to check any abnormal behaviour,
damage or breakage & Leakage.

6.3 Record prefilling level of LNG transport tank.

6.4 Park transport tank in orientation, position; engage parking brake.

6.5 Switch off engine; take keys from driver & keep in a safe box away from
truck.

6.6 Chock wheels;

6.7 Attach grounding able to grounding clit.

6.8 Clean the Filling hose by Air.

6.9 Record level & pressure of LNG transport tank.

6.10 Connect vent valve “1” of liquid cylinder to HC-2 fill/drain connection on
transport tank using a stainless steel braded hose.

6.11 Connect “HC-1” fuelling connector of transport tank to liquid fill valve “2”
of LNG liquid cylinder using a stainless steel braded hose pipe.
 6.12 Open vent valve “1” of liquid cylinder and “HC-2 fill/ drain connection of
transport tank and allow the pressure to equalize.

7. Filling procedure:
7.1 Open liquid fill valve “2" on liquid cylinder;

7.2 Start pump to initiate filling operation by pressing the start button. Valve
“V-2” & “V-17” on transport tank will open automatically.

7.3 No additional pump cooling time is required as pump is submersed type.

7.4 Pump has Safety features built into it. It will not start until all the
predetermined conditions are satisfied. It also has inbuilt pump dry run
protection.

7.5 Keep observing the filling. Actual filling process should be complete within
2 to 3minutes.

7.6 Continue filling until stipulated weight/ level is achieved. System will auto
detect the quantity of LNG filled & automatically shut off the pump. For a
typical 200 litre capacity liquid cylinder weight of LNG should not be more
than 58 kg or 137 litre.

7.5 Close all valves on liquid cylinder.

7.6 Valves ‘V-2” and ‘V-17” on transport tank will close automatically.

7.7 Open hose bleed valves to depressurize hoses.

7.8 Wait for icing to disappear before disconnecting fill & vapour return hose
pipes.

7.9 Disconnect grounding cable.

Note: It is recommended that the filling activity be carried by at least two personnel trained in
cryogenic handling & fire hazards associated with natural gas.

8. Post filling procedure & checks:

8.1 Disconnect the hose safely and stow hose in hose stowage box carefully.
8.2 Print delivery ticket.
Warning:

Following safety precautions are recommended for safety of personnel involved &
surrounding property. Before operating equipment read & follow the recommended
safety precautions & also specified reference publications. Failure to observe safety
precautions may result in property damages, personnel injury or fatality.

Disclaimer:
This document is to familiarize the trained technicians/ operators with features, safety
precautions & operating procedure for the equipment. It is the sole responsibility of
purchaser/ operator of this equipment to warn all associated parties on the hazard &
safety precautions.

9. Hazards associated with LNG:

LNG or Liquefied Natural Gas is predominantly Methane (CH4). It is cooled to very

low temperatures (Approximately -163OC) and stored in specialized equipment as
cryogenic liquid.

Working with LNG & associated equipment’s can expose you to following hazards:

9.1 Flammable gas:

LNG in liquefied form is not flammable. However

gas is flammable in the concentration of 5 to 15%

in air. Small liquid leaks can pose large fire hazard

near the leak. Any process or procedure that

generate sparks, flame or heat should not be used
in the designated filling area.

9.2 Cryogenic temperatures:

LNG is liquefied form is stored in pressurized form at
temperatures of around -163OC. Accidental contact
of cold LNG with eyes or skin can cause injury such
as frost bite or cold burning. Safety equipment’s
(personal protective equipment’s) should be used
during the operations.
 9.3 Asphyxiate –Ventilation required:
LNG is non-toxic; it is an inert gas and can cause
asphyxiation if present in large quantities. Natural
gas being a colourless, odourless & tasteless gas
cannot be detected by human senses. Storage &
operations should be carried out in well ventilated &
designated filling area.

10. Safety precautions & personnel training:

Store the equipment’s in well ventilated areas. This will prevent the build-up/
accumulation of Methane/ Natural gas if leaks are present.

Use proper personnel protective equipment’s when working with LNG systems.

All personnel involved should be trained in hazards associated with pressurized

cryogenic liquids & dealing with fires associated with Natural gas.

Emergency response procedure should be established. Fire extinguishing systems

should be placed in designated areas. Water or CO2 should not be used to douse the
fire associated with Natural gas/ Methane.
 PRV-1 PRV-2 ENQ-KPE-1108

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