LNG罐箱操作的指导手册（英文版）

    Categories: 罐箱运营
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    关于课程

    本课程包含如下内容，算是有史以来最全的LNG罐箱系统操作手册，强烈建议大家学习：

    第一节：摘要

    第二节：安全指示

    第三节：设备规格

    第四节：装载和卸载LNG

    第五节：阀门操作图

    第六节：关于装卸LNG罐式集装箱的注意事项

    第七节：LNG罐式集装箱操作注意事项（参考）

    第八节：运输过程中出现异常情况的应对措施（参考）

    第九节：LNG罐式集装箱的维护和修理（参考）

    第十节：LNG罐式集装箱的监管（参考）

    第十一节：LNG罐式集装箱的日常检查（参考）

    第十二节：集装箱维护和检查（参考）

    第13节：定期自愿检查（参考）

    第14节：记录（参考）

     

    What Will You Learn?

    • 了解LNG罐箱（T75)的设备构造
    • 了解LNG罐箱的装卸货流程
    • 了解LNG罐箱的风险控制体系
    • 了解LNG罐箱日常检查内容等

    Course Content

    Safety Considerations
    In this User’s Manual, in order to use the equipment safely and correctly, and to prevent any damage to the operator or equipment before it occurs, we will call your attention with signs such as are displayed as follows: DANGER! This indicates that imminent danger of death or severe injury may result if this sign is ignored and handled incorrectly. WARNING! This indicates that danger of death or severe injury is conceivable if this sign is ignored and handled incorrectly. CAUTION! This indicates that danger of injury and property damage is possible if this sign is ignored and handled incorrectly

    Section 1: Summary
    This LNG tank container is manufactured for use in trans-shipment as well as land trailer and train transportation as a 40 ft tank container; the ISO 40ft dimension tank container frame loads a cryogenic container as well as pertaining valves and measuring instruments, and shall be used for container transport of liquefied natural gas. The cryogenic container consists of a stainless steel inner vessel and carbon steel outer vessel, and the insulation layer consists of vacuum composite insulation, so that natural evaporation of the liquefied natural gas is kept to an absolute minimum and able to provide safe transportation. Also, the necessary valves and measuring instruments for the operation are compactly installed inside the rear operating cabinet. In times of unloading etc., the pressurizing evaporator will use the local ground facilities, and a pressure build coil is not installed. Each instrument of this LNG tank container is manufactured according to UN Portable Tank T75, and specifications are respectively regulated by those related laws and rules, making operational safety etc. a requirement. When using these facilities, please fully understand the function of the apparatusfor correct operations, in order to safely and efficiently use the stored gas.

    Section 2: Safety Directions

    Section 3: Apparatus Specification

    Section 4: Loading and Unloading LNG

    Section 5: Valve Operation Chart

    Section 6: Caution Regarding Unloading LNG Tank Container
    In transhipping a tank container to a ship, trailer, or train, please do work with extreme care, after sufficiently understanding the cautionary notes below. If handled incorrectly, it is possible to cause tank container frame deformation, or physical loss or damage to the trailer chassis, etc. There are 4 corner fittings on both the upper and lower corners of this container for transhipping. When transhipping to a trailer chassis, a ship, or a train, use the upper 4 corner fittings to transfer by hoisting vertically, and lowering vertically. When transhipping the tank from a ship etc., generally a gantry crane is used, and tranship it to a trailer chassis. The twist lock serves as a junction in the trailer chassis. After loading the tank container, please check that the twist lock is fixed securely, so that it will not come off during transportation. The fixation of the tank container to the ship is the responsibility of the ship side. 1)Caution for temporarily placing a tank container When you tranship a tank container, you may have to place it temporarily. When you place it temporarily, you have to select a flat place where there is enough space for a large-sized heavy machine, like a top lifter etc., to move back and forth, that has fire extinguisher installed, has no fire-hazardous objects around, and is off-limits to the public. 2)Precaution to load on a ship When loading a tank container on a ship, check the internal pressure of the vessel in advance; if the pressure is high, discharge in a safe location to lower it, and please act very carefully so that the safety valves etc., will not operate during shipping. Lock the doors of the operation cabinet etc., and please thoroughly check the doors, etc., so that they will not open during shipping. When loading on a ship, according to Ship Safety Act, the tank container will be put on the ship deck. Additionally, please be warned that the movable load on the upper part of said container is limited to one container-load (less than 30,480kg).

    Section 7: Caution Regarding LNG Tank Container Operation (Reference)
    7.1 In operating the LNG Tank Container, the utmost attention is required for vehicle safety and accident prevention. Especially in road traffic, please do not jump start, suddenly stop, suddenly accelerate, turn sharply, etc. 7.2 Please try to ensure that the crew gets enough rest both mind and body, and to maintain their physical condition in order for safe and secure operation and monitoring. 7.3 When traveling by trailer etc., a transportation plan must be carried, and the predetermined roads must always be travelled. 7.4 The movement monitor individual should constantly check the internal pressure of the vessel during vehicle travel, and please be careful that it does not go above 0.39MPa. Additionally, please record the pressure inside the vessel on a regular basis. 7.5 Except for during emergencies, please do not discharge LNG on public roads. 7.6 If there is a rise in the pressure inside the vessel, and it is considered necessary to discharge LNG, please do so at the nearest designated place. 7.7 While traveling, the crew should refrain from smoking except in allowed places. 7.8 When traveling inside of a factory yard for receiving, discharging of LNG, or gas discharge, please travel safely following the guidance of an attendant. 7.9 The crew records driving daily reports for every operation, and please submit these to the supervisor. Additionally, any special notes must be reported. 7.10 When operating a vehicle, such as a trailer etc., for a long period of time, poor road conditions were encountered, or a large shock was received, stop at a safe spot on the way, and please perform inspection to confirm that there is no gas leakage, no abnormal rise in the internal pressure of the vessel, or no frost. 7.11 If stopped while traveling, please select a safe place with little traffic and that is more than 15m from any sources of fire. Please set the side brakes and set chocks to the wheels. 7.12 If the crew parks while traveling, please do not leave the LNG Tank Container vicinity. If leaving is a necessity, please stay within range where constant monitoring is possible. 7.13 When you move the LNG Tank Container at the quay, please note the following points: • The hoses are detached. • The ground wire is detached. • Primary Safety Valve Master Valve is open. • Rear control cabinet door is completely closed. • The chock is detached. • There is no fear of ignition sources for any gas leakage from the cargo handling facilities etc. • Confirm with the supervisor that all the handling is completed.

    Section 8: Counter-measures for Abnormalities during Transportation (Reference)
    8.1 After taking emergency measures for any abnormal situations during travel, such as leaks, fire, abnormal internal pressure of the vessel, traffic or train accidents, etc., please call the predetermined emergency contact, and obtain instructions for the safety maintenance thereafter. 8.2 If you are unable to stop the liquid gas leak even after emergency measures, secure a safety perimeter around the vehicle, and please report to the nearest police, fire department, and communitybased disaster management office for assistance. 8.3 If the leaked gas catches fire, attempt preliminary measures to extinguish the fire, and report to the fire department and police. If it is possible to move to a large safe location, please move it to a safe place. Please try to ensure a safe perimeter until the emergency support, police, or the fire department arrives. 8.4 If a sudden rise in the internal pressure of the vessel is confirmed, move immediately to a safe location, and please lower the pressure by discharging via the Gas Drain Valve. Afterwards, please move to the nearest predetermined factory to repair and take appropriate measures. 8.5 Please take the following measures if a traffic accident, such as a collision etc, occurs: • If there is an injured person, please put first priority on their rescue. • Please secure the safety in the vicinity by using red flags, a smoke candle, etc., to draw the attention of anyone nearby. • Please check for abnormalities of both the tank container and vehicle, and if a leak is present, after implementing emergency measures, report to the nearest police and fire department. • Please try to prevent any secondary disaster. 8.6 Measures when the vehicle breaks down and cannot move on a railway crossing: • If there is time, please ask the help from other cars to move and escape. • If there is not enough time to move, please run as fast as possible in the direction that the train will come from, stand more than 50 m on the outside of the railway crossing and stay in a place where the train is recognizable from 800 m away while considering the terrain, and signal the train using a red flag and smoke candle. When the train safely stops, explain the situation, and please obtain the help necessary to move outs of the railway crossing. 8.7 Take the following measures an abnormality is recognized in the environment of the operation route: • If there is a fire in the vicinity of the operation route, please change the route, make a large detour, and take a safe route. If there is no safe route available, please take refuge in a place as safe as possible, and try to monitor for safety. If it is difficult to move the vehicle because of traffic conditions, please maintain maximum distance from other vehicles. To protect against any fires in close proximity, please contact the fire department and police for help to prepare water for sprinkling. • For other weather conditions including thunderstorms, storms, snowfall, etc., please consider the principle of safety first respective to the condition, act cautiously, and do not engage in reckless travel to hurry. 8.8 On the ship, please check the pressure inside of the vessel on a regular basis, and if an abnormal rise in pressure is confirmed and it is anticipated that the Safety Valve will be activated, discharge the gas from the Gas Drain Valve to lower the pressure to an appropriate pressure for the Inner Vessel. • When releasing gas, please confirm the safety of the surroundings, and ensure that there are no sources of fire, etc. • When releasing gas, please report to the captain in advance, and ask for consent for the operation.

    Section 9: Maintenance and Repair of LNG Tank Container (Reference)
    9.1 As a basic principle, repair of vessels, piping, valves, instruments, PBC, and others shall be outsourced to manufacturers. 9.2 Simple repairs – such as backlash or damage of bolts, nuts, and gaskets – shall be done by the individual(s) in charge of tank inspection and maintenance. 9.3 If fittings or other instruments of piping are removed or loosened for maintenance or repair, a nitrogen leak test is required once the equipment is restored. Nitrogen purging is required before loosening or removing fittings or other instruments. 9.4 In case of using fire for maintenance, gas inside the vessel and piping must be completely purged by nitrogen to secure the safety of the site and surroundings before any commencement of work.

    Section 10: Supervision of the LNG Tank Container (Reference)
    10.1 The owner of the LNG Tank Container must assign a supervisor or equivalent (hereby referred to as “Supervisor” in the following section) to handle the matters concerning ensuring the safety of the tank container and the travelling vehicle. 10.2 The Supervisor must constantly be aware of the condition of the tank container, the vehicle, and the crew, and must take the necessary measures for the safe travel of the tank container and vehicle. 10.3 The Supervisor must educate and train the crew on every occasion regarding the basic properties of LNG and its gas, information concerning cryogenic temperature as well as the structure and the treatment of the Tank Container, and prevention of disaster and procedures and counter measures to take in the event of abnormalities. 10.4 When the tank container and vehicle are parked under traveling conditions in a parking lot for a prolonged period of time because of holidays or some other reason, or left in a container storage location for an extended period of time, the Supervisor should be able to monitor the pressure inside of the vessel and conditions conducive to the safe release of gas. 10.5 When suspending travel of the tank container and vehicle for maintenance, repair, or inspection, etc., and parking at another office or in a factory yard for an extended period of time, or parking at the tank container storage location for a long time, the Supervisor should make safety management measures of the tank container and the vehicle clear. 10.6 The owner of the tank container and vehicle should establish a system to be able to organize an emergency dispatch and the ability to deal with the incident safely. Additionally, please provide an evacuation factory along the travel route for inspections, gas discharge, rest, etc. 10.7 The Supervisor must inspect the daily running report of the tank container and vehicle on every occasion of travel, instruct the crew thoroughly on instruction matters, and confirm matters reported by the crew. The instruction matters are as follows: • the weather condition(s) of the day • the construction site(s) on the designated traveling route or on closely adjacent road(s), traffic restriction hour(s), and detour route(s) • predicted congestion intervals • places for rest and temporary inspections along the route • emergency contact(s) • special notification matter(s) from the police, etc. regarding road traffic26 • the address, map, and route of the factory designated for evacuation • other matters necessary for safe traveling Reported matters are as follows: • record of the pressure inside the vessel during travel • actual situations and their treatment respective to the instructions • abnormalities in the tank container and vehicle at the time of travel • record of work and facilities along the transportation route • other matters deemed necessary to report 10.8 The Supervisor should organize and keep the records concerning travel. 10.9 Please confirm that the parking area and the container storage location provides good ventilation, is safe from fire, and there is no fear of occurrence of disaster, and please have a leak detector and fire extinguisher available.

    Section 11: Daily Inspection of the LNG Tank Container (Reference)
    Vehicle inspection is done according to vehicle inspection standards established in the Road and Transportation Vehicle Law, and tank container inspection will be conducted as follows: 11.1 Tank users shall visually check vessels to confirm that there is no abnormal frosting, etc. 11.2 Tank users shall check to confirm whether or not there are any cracks or defects in vessel attachments and container frames. 11.3 Tank users shall check that when the tank is filled, it is not overfilled. 11.4 Tank users shall check for abnormal pressure inside the vessel. 11.5 Tank users shall check whether or not each valve is properly switched (opened or closed). 11.6 Tank users shall check for leaks, damage, and abnormalities in the pneumatic piping which controls the emergency shut-off valve. 11.7 Tank users shall check whether or not impurity is pooled inside the flame arresters. 11.8 Tank users shall check the condition of ground wires and clips. 11.9 Tank users shall check whether or not the rear operation room is kept tidy. 11.10 Tank users shall check if the operation room door is opened or closed. 11.11 Tank users shall check the availability of vehicle equipment, portable equipment, and spare parts. The crew will conduct tank container and vehicle inspection daily, and any imperfections must be immediately reported to the supervisor, and maintenance conducted in order to keep the tank container and vehicle in best condition. The supervisor must confirm that the tank container and vehicle are always kept maintained in best condition.

    Section 12: Container Maintenance and Inspection (Reference)
    12.1 Container maintenance methods and plan approval UN Portable Tank T75 inspection and maintenance methods and plan etc. require Maritime Authority approval. If maintenance is outsourced, the consignee must apply to and gain the approval of the Department of Transportation with jurisdiction. 12.2 Regular inspection Following initial inspection at time of manufacture, regular inspection is conducted at a frequency not exceeding 5 years. Inspection details are as follows: • Visual check and structural check of both inner and outer regions • Airtight test • Actuation check of attached equipment • Capacity check and alignment examination of pressure safety equipment • Vacuum level check 12.3 Interim inspection 2.5 years after the initial inspection but before the regular inspection, an interim inspection will be conducted according to the following: • Visual check and structural check of both inner and outer regions • Airtight test • Actuation check of attached equipment • Capacity check and alignment examination of pressure safety equipment • Vacuum level check 12.4 Special inspection Conducted in the case that damage, corrosion, or leakage is obvious, or any defects of the vessel are found. The range of the special inspection will depend on the vessel damage or deterioration, and inspection details will be chosen from the initial inspection program. 12.5 Maintenance and inspection record At least 2 consecutive preceding regular maintenance inspection records must be appropriately saved. Additionally, special inspection records must be saved until the next regular inspection. Documents related to tank structure and strength etc. necessary for maintenance and inspection must always be managed and saved.

    Section 13: Regular Voluntary Inspection (Reference)
    There is no legal obligation, but conduct inspection to comply with the LNG semi trailer. 13.1 External visual inspection A visual inspection is conducted once per day before the commencement of work, after completing work, and during parked conditions. • Pressure gauge, Level gauge display and actuation check • Valve switch and display check (whether or not each valve properly switches) • Pipes, fittings, gaskets, O-ring etc. check for any damage or cracks • Abnormal frost and condensation • Delamination, cracking, or corrosion etc. of paint • Fire extinguisher attachment condition • Regular disaster prevention tools content check • Documents and records check • Other overall visual appearance 13.2 Leak inspection To be conducted for every liquid filling and discharge operation. Leak detector and soap are used (bubble leak test). • Inspect for leaks on pipes, valves, fittings, and other instruments. 13.3 Airtight test To be conducted at least once a year. • The test is to be conducted at 1.1 times higher than the maximum filling pressure of the vessel, pipes, valves, and fittings. 13.4 Safety valve actuation inspection To be conducted at least once a year. • Remove the safety valve, and use the safety valve actuation test device to conduct test. 30 13.5 Pressure gauge inspection To be conducted at least once a year. • The pressure gauges must be removed and tested with a standard pressure tester. 13.6 Differential pressure gauge inspection To be conducted at least once a year. • The gauges must be compared with a standard differential pressure gauge (U-shaped tube, etc). 13.7 Valve inspection To be conducted at least once a year. • Operation condition, external appearance, and seat leakage must be checked.

    Section 14: Records (Reference)
    14.1 Create records for all the inspection items, and keep these records. 14.2 Please create records of all the maintenance and repairs, and keep these records. 14.3 Please create records about the cargo work and keep these records. 14.4 Please create records about the travels and keep these records. 14.5 Please create records concerning other necessary matters and keep these records.

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