operations & safety training

TECHNICAL TRAINING

All Rights Preserved By Siddiqui

Contents

Introduction BM Energy (Netherlands –BD) JV Ltd Product Line & Regional Distribution BM Cylinder & Classification Regulator & Classification Burner & Spare Parts Valve & Classification Definition of LPG in Details Plant Operation Distribution Process of Cylinder Refill Sphere & Carousel Evacuation Point Tanker Bay Reason of Accident What is Safety ? Safety Tips


Introduction BM Energy (Netherlands –BD) JV Ltd


Introduction BM Energy (Netherlands –BD) JV Ltd (Continued)

BM Energy (Bd) Limited expertise LPG Import, Storage & bottling facility at Shitakundo,

Chittagong ,Bangladesh.

The Joint Venture consists of Netherlands and Bangladesh and signed an agreement in 31st

January 2012. This acquisition will be the downstream business to distribute LPG under the

“BM LP Gas” brand name. The company operates a world class, LPG import, bottling and

distribution facility with going to developing a strong nationwide cylinder distribution

network. BM Energy will supply auto-gas to service stations and bulk LPG to industry and

commercial users.

Gas Filling Plant 3000 Metric ton Capacity (On process to 9000 M/Ton)

Euro-Asia Standard Maintained (Plant Operation)

Cylinder Quality US DOT 4BA 240

Mig welding & Zink Metal coating


Introduction BM Energy (Netherlands –BD) JV Ltd (Continued)


Cylinder

12 KG Cylinder 22 mm

12 KG Cylinder 20 mm

33 KG Cylinder

45 KG Cylinder

LPG (Liquefied Petroleum Gas)

Auto Gas & Car Conversion

Industrial Installation support

# 12 KG Cylinder Body Thickness : 2.65 MM

# 33 & 45 KG Cylinder Body Thickness : 3 MM

Product Line (BM ENERGY)


Regional Distribution Network Nationwide

Regional Distribution Center

(RDC)

Plant


Product Availability, Distribution& Refill Process at your

Distribution/Storage

No.1 – Refill process from RDC

Factory RDC (Dhaka) Distributor’s Point Dealer

CTG

End User/Commercial/Industrial Clients

No.2- Empty Cylinder sending process to RDC & CTG Plants

End User/Commercial/Industrial Clients Dealer Distributor

Factory CTG RDC (Dhaka)


Cylinder & Classifications


12KG 22mm Cylinder

Identification: Red Color in Cylinder Foot Ring

Identification: Red Color in Cylinder Collar

12 KG 20 mm Cylinder All Rights Preserved By Siddiqui

33 KG Commercial Cylinder

45 KG Commercial/Industrial Cylinders


Regulator

•Works as an external media

•Control Increase & Decrease Volume of pressure

A Regulator automatically cuts off the flow of a gas at a certain

pressure. Regulators are used to allow high / Low pressure fluid supply lines or

tanks to be reduced to safe and/or usable pressures for various applications

Regulator

Domestic Commercial# High Pressure # High Pressure# Low Pressure # Low Pressure


High Pressure Regulator: Generate & Control Volume of Pressure

Domestic High Pressure (12 & 33 kg)

Commercial High Pressure (45 kg)


Low Pressure Regulator: Built in volume of pressure.

Domestic Low pressure (12 & 33 kg)

Commercial Low Pressure (45 kg)


Burner (Domestic & Commercial)

A gas burner is a device to generate a flame to heat up products using

a gaseous fuel such as natural gas or propane / LPG.

# Low Pressure (Domestic Use Only)

•Per Hour Gas Consumption Up to (2 – 5) Kg

•Size 10 Inch – 25 Inch

# High Pressure (Commercial Use Only)

•Per Hour Gas Consumption above 5 Kg

•Size above 25 Inch


Spare Parts

Hose Pipe Hose Clam Hose Nipple

Teflon Tape

Perfect Flame

LPG Cylinder with Gas + Regulator On top Of Valve + Clam + Horse pipe+ Clam + Teflon tape both side of pipe + Burner = Perfect Fire /Heat for Your Cook


Valve & Valve Classifications

Working as an internal media.

Control Media for Vapor &

Liquid Flow


Valve Classifications

Valve

Vapor Valve Liquid Valve

Compact Valve Liquid withdrawal

# Access flow control

POL Valve

# Male Thread

# Female Thread


Compact Valve ( Domestic Use)

Rubber / Gas kit

Oaring

Spindale Guide

Spring

Adjusting Screw

Safety Relief Valve


POL Valve (Commercial / Industrial Use)

Oaring

Thread (if internal means female, if external means male)

Cap

Safety Relief valve

Spring

Adjusting Screw


Liquid Withdrawal Valve

Liquid Withdrawal Valve• MALE THREADED WITH EXTENDED

PIPE

# In the joint of Stick sometime we put excess flow

control valve for stop flowing liquid gas.


LPG & Definitions

WHAT IS LPG?

Liquefied Petroleum Gas (LPG or LP Gas) refers to a mixture of hydrocarbon gases with compounds containing primarily propane (C3 H4) and butane (C4 H8).

LPG means liquefied petroleum gas. It is a mixture of Propane & Butane.

Although these gases are in vapor form, they are compressible to transportable liquid. They can be liquefied through a compression process at ambient temperature, refrigeration at atmospheric pressure, or a combination of both.

The pressure required to liquefy the vapor is relatively low, allowing easy storage of the liquid gas in pressurized vessels at ambient temperature. LPG returns to vapor form when the pressure is released.

LPG is most commonly traded as a mixture of propane and butane. The ratio of the mixture typically varies depending on the climate - the cooler the climate, the higher the propane content. As a precaution, a powerful odorant (Ethyl Mercaptan) is added in small amounts to make gas leaks easily detectable as LPG is highly flammable, odorless and colorless.


LPG & Definitions (Continued)

Vapor is the natural form of LP Gas at atmospheric pressure & temperature

Liquid is the natural form of LP Gas when contained under pressure.

LP Gas vapor is flammable when mixed with Air.

Boiling temperature of propane is -42 degree Centigrade.

Boiling point of butane is -0.5 degree centigrade


LPG is 1.5 times Heavier than Air


Color of LPG & Expansion Rate

LPG is colorless tasteless,

looks like waterVapor expansion Ratio


LPG INSIDE CYLINDER


HOW IS LPG PRODUCED

LPG is extracted both during natural gas production and crude oil refinery processing.

Natural gas may contain up to 10% of propane and/or butane, which is removed for technical, commercial and safety reasons. Crude oil refining typically produces around 2% to 4% of propane and/or butane.Historically, LPG – essentially a by-product – was very often flared. However, the increased value of and demand for LPG, coupled with the undesirable environmental impact of flaring, have justified the significant investment in the storage and distribution of LPG.


ADVANTAGES OF LPG

A clean and efficient fuel, LPG emits 20% less carbon dioxide (CO2) than heating oil and

50% less CO2 than coal. LPG makes cooking, heating and generating electricity in an

environmentally friendly manner possible.

CLEAN

Burns cleanly, producing no soot and very low sculpture emissions

GREEN

When burnt, the amount of CO2 per kWh produced is 81% that of oil and less than 70%

that of coal

EFFICIENT

Has a higher calorific value of 94 MJ/m3 than Liquefied Natural Gas (38 MJ/m3)

CONVENIENT

Can be easily stored and transported in cylinders of various sizes to meet the needs of

different types of consumers


USES OF LPG

LPG has developed into one of the world's most versatile forms of modern energy sources.

It is widely used in the retail and residential sector as a fuel for heating and cooking

appliances.

Applications of LPG can also be found in various sectors including industrial,

commercial, agricultural and transportation. In the chemical industry, LPG is commonly

used as a feedstock and has naphtha as its competitor.

Common Uses

COOKING

Offers chefs greater control over the heat and flame intensity levels

HEATING

Provides an eco-friendly alternative to electricity and heating oil

AUTOGAS

Non-toxic, non-corrosive, clean, and extends the lifespan of vehicles and the environment

POWER GENERATION

Enables highly efficient, decentralized power generation through self-contained generators


Unique Properties of LPG

LPG has unique properties allow it to be used everywhere:

PORTABLE

LPG can be transported, stored, and used virtually anywhere in the world. It does not require a

fixed network and will not deteriorate over time.

CLEAN

LPG is very clean burning and has lower greenhouse gas emissions than any other fossil fuel

when measured on a total fuel cycle. Originating mainly from natural gas production, it is also

non-toxic and will not contaminate soil or aquifers in the event of a leak.

ACCESSIBLE

LPG can be accessible to everyone everywhere today without major infrastructure investment.

Nothing needs to be invented and there are enough reserves to last many decades.

EFFICIENT

LPG is cost-effective, since a high proportion of its energy content is converted into heat. LPG

can be up to five times more efficient than traditional fuels, resulting in less energy wastage and

better use of our planet’s resources.

CONVENIENT

LPG is a multi-purpose energy. There are more than a thousand applications, from cooking,

heating, air conditioning and transportation, to cigarette lighters and even the Olympic torch.


FIRE CONDUCT


Cylinder filling process

LPG comes from abroad

Jetty unloading 2KM Long Pipe Line under deep sea

3000 MT storage (On Process up to 9000 MT)

Digital carousel machine

Cylinder testing Unit

Filtration of the gas

Correct weight

Safe transportation

Fire fighting


SITAKUNDO PLANT

LPG CARRIER SITAKUNDO STORAGE


FILLING PROCESS

CAROUSEL – DOSTIC CYLINDER FLOOR SCALE – 33 & 45KG CYLINDER


Plant Operation

Generator House Electricity Backup for the Plants & HQ

Program Logic Control (PLC Room)

Emergency Shut Down (ESD)

Remote Shut Down (RSD)

Isolator for Cylinder & Truck fill pumps

LPG Compressor Isolator

Carousel panel Sub main

Fire Pump

Fire Pump HouseFire Protection Back up for Plants

High Tension Switch Room Supply Electricity to the Plants & HQ

Water Pump HouseReserve Water & Supply to the Plants & HQ


Spare Area

Carousel

Ramp

Evacuation Point

Tanker Bay

Compressor RoomAir Pressure not more than 8.5 KG

Work ShopMaintenance Works

Spare Parts &Equipment’s


Distribution Process of Cylinder Refill •All the Truck & Lori have to primary check in gate point.

•Truck or Lori driver /helper‘s cell phone & other necessary things must be deposited to the security

guard room (Entrance) for safety purposes. At a time Truck/Lori driver or concern person have to

submit mode of payments to the distribution department.

•Empty Cylinder truck has to go through Weight Bridge for counting the weight of Empty cylinder

with truck.

Weight Bridge


•Truck along with empty cylinder comes in unloading point. Cylinder Transfer Docket = C.T.D

have to submit to the distribution department. From unloading point driver, security & ram

supervisor they all put their signature unloading/loading slip in the particular place. Count all

empty cylinders properly.

•Refill gas 12 kg carousel area and 45 kg from Ramp area.

•Loading all empty cylinders in the truck & counting them with witness of driver, security & Ram

supervisor and sign again in loading slip as before.

•Loaded truck will go to Weight Bridge again for counting the quantity of total amount

gas.(Loaded gas cylinder with truck – Empty cylinder with truck = Total quantity of gas)

• Loaded gas truck will come to the security main guard room, security will count the cylinder with

gas finally, If security found everything is ok then, security gate will allow to pass the gate with

necessary papers which are provide by our distribution department (VAT ,Sales invoice, Gate pass,

C.T.D)


Sphere & Carousel

LPG Sphere All Rights Preserved By Siddiqui

Sphere Area Carousel & Ramp

•Automatic Filling Station for 12 Kg carousel area

•Manually filling station for 33/ 45 Kg in Ramp Area

•Individually Command set for each filling station ( K-Factor System)

•Gas Filling process by conveyor chain ( for 12 Kg)

•Entry / Unload Point one person is responsible for Gasket & Count empty cylinder

•Manually Checking total cylinder weight

•Cylinder lick check point (Manually using soup & shampoo mix water)if cylinder we found lick then

send to the evacuation point.

•Cylinder seal point ( Using Hologram / shrink paper)

•Loading Point have to count the full cylinder & load inside truck

• Supervisor is responsible for this continuing process & report to the distribution department

Automatic refill in conveyor chain


Manually command (K-factor) system

Evacuation Point

•Using Haskell Pump for take back gas from lick cylinder to vessel.

•Two types of lick can be happens

•Cylinder Body lick ( Not repairable)

•Valve Damage (If repairable then has to pay for new one)


Tanker Bay

•LPG line from down & vapor line from upstairs of Sphere makes Tanker bay’s individual

stations.

•This station can refill portable tankers for bulk supply


Reason of Accident

Decanting

Leakage at anywhere

Keeping LPG cylinder beside

oxygen

Hazardous area/Not well

ventilated

Smoking/Naked Light

Moving cylinder unsafely

Making higher layer of

full/empty cylinder

Lack of knowledge on safetyAll Rights Preserved By Siddiqui

Leak Detecting


Hazardous pipe & Poor material


Gasket Leak


REJECTED CYLINDER


UNSAFE CYLINDER


UNSAFE TRUCK FOR LPG CARRYING


UNSAFE STACKING ON TRUCK & COVER VAN


UNSAFE TIE UP BY ROPE


UNSAFE DRIVING


CORRECT STACKING CYLINDER


What is Safety?

S Secure Strategic

A Access Awareness

F For For

E Everyone Everyone


Safety Tips

LPG Basic Tips

Fire Extinguisher


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2010-2012 2013-2015 2016-2018 2019-2022

LPG USES Prospects ahead


Thank YouPrepared By

Md . Abu Bakar SiddiquiH D. Hospitality Management Lincoln University, USA

(Malaysia Campus) & Bachelor of Commerce (NUB)

Asst. Manager – Sales & Marketing , Dhaka Zone

BM Energy BD Ltd

Cell : +8801777740158

Email: [email protected],

[email protected]


operations & safety training

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