EIA STUDY FOR EXPANSION OF Document No.

ENNORE LNG TERMINAL FROM 5 B507-1742-EI-2201

Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL
Page 12 of 155

CHAPTER – 2

PROJECT DESCRIPTION

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 Document No.
EIA STUDY FOR EXPANSION OF B507-1742-EI-2201
ENNORE LNG TERMINAL FROM 5 Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL Page 13 of 155

2.0 INTRODUCTION

This existing terminal receives imported LNG through LNG carriers / ships at a dedicated
LNG Berth already constructed inside Kamarajar Port and stores the same at cryogenic
temperature of (-) 162 Degree Celsius and near atmospheric pressure i.e. 180 mbar in 2
nos of above ground full containment type LNG tanks of 180000 cubic meter capacity each.
Full containment tanks are the safest tanks for LNG storage. LNG stored at (-) 162deg C in
the tank is pumped with the help of In-tank Low Pressure pumps at 10 bar to flood the
suction of High-Pressure pumps, which in turn pressurize LNG to 90 bar. LNG is then
converted into gas in the Shell and Tube type Vaporisers by indirect heating with room
temperature water-glycol mixture. The glycol is mixed with the water so that water should
not freeze and stop circulating through the equipment. The regasified LNG (RLNG) at 90
bar pressure is then sent to the metering & send-out pipeline for transportation to various
customers through a cross country pipeline network. The proposed project envisages
expansion of existing Ennore LNG Terminal from 5 MMTPA to 10 MMTPA.

As part of the expansion work, 2 additional Full Containment type LNG storage tanks of
180,000 cubic meter capacity each, High Pressure LNG Pumps, Vaporizers, Atmospheric
Air Heaters, Captive Power Plant will be installed along with allied piping, civil,
instrumentation and electrical jobs apart from requisite utilities and ancillary facilities. Piping
will be fabricated with fully welded joints avoiding flange connections, thereby reducing the
risk of leakages. Boil-off gas generated in the Terminal will be converted to liquid LNG with
the help of re-condenser and sent back into the system. Safety and integrity of the facilities
is ensured through gas detection and alarm system installed in the Terminal. The expansion
project will be built in line with the international/ Indian codes and standards in terms of
construction and safety. For expansion of the Terminal, no additional land is required since
the additional LNG storage tanks as well as regasification facilities will be located within the
existing premises of the Terminal at Kamarajar Port, Ennore, Tamilnadu.

2.1 OVERVIEW OF PROJECT

The Ennore LNG terminal is currently designed considering the following sendout:

 Normal – 20 MMSCMD
 Minimum – 8 MMSCMD
 Design – 24 MMSCMD (20% overdesign)

The terminal is designed to provide sendout gas at the battery limit at the following
pressures:
 Normal operating pressure: 88 barg
 Minimum operating pressure: 80 barg
 Maximum pressure: 95 barg

The send out temperature at normal operating pressure will be minimum 5oC.

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EIA STUDY FOR EXPANSION OF B507-1742-EI-2201
ENNORE LNG TERMINAL FROM 5 Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL Page 14 of 155

The proposed configuration to augment the capacity of existing Ennore LNG Terminal from
5 MMTPA to 10 MMTPA (20 MMSCMD to 40 MMSCMD) has the following broad scope of
the project facilities:

1. LNG Storage Tanks and associated facilities

2. Regasification facilities including Offsites and Utility Blocks

The expansion project will have the following components:

 Storage system: LNG storage tanks and Low pressure LNG pumps
 High pressure LNG pumps
 Vaporizers
 Metering system and Final Pressure Adjust
 Fuel gas / natural gas system
 Relief and drain system

Tie-ins and plot plan space will be considered to cover the future expansions. In below
sections, detailed descriptions have been provided.

2.2 PROPOSED PROCESS DESCRIPTION

The process description for various process systems provided in following sections.

2.2.1 Storage system: LNG Storage tanks and low pressure LNG Pumps

Two (2) full containment storage tanks of having capacities of 180,000 m3 each have been
considered for the LNG reception and storage. Unloading operation from carriers can be
done to a single tank or simultaneously to both tanks. This section consists of two (2) tanks
and four (4) Low Pressure LNG Pumps per tank. Each storage tank and its group of LP
LNG pumps (considering one as spare) are able to provide the normal / maximum Terminal
send out. The tanks are provided with two filling lines to achieve an optimum mixing
between LNG with different composition. One line sends LNG to the top of the inner tank
and the other line sends LNG to the bottom. The filling mode depends on the quality of the
stored and the unloaded LNG. When unloaded LNG is heavier than stored, the LNG from
carrier is sent to the top of the inner tank. Lighter LNG from carrier is sent to the bottom of
the tank. The top loading will be carried out using a piping connection in to the top of the
tank with a splash plate. The bottom loading will be performed using a standpipe inside the
tank with a down-comer pipe. Tanks will store the LNG, and the space at the tank top shall
hold the vapours generated due to the tank heat leak (Boil off Gas, BOG). LNG from LP
LNG Pumps is collected from both storage tanks in the LP header to send the LNG to the
Recondenser and to the truck loading area. LP LNG pumps are protected from low flow by a
kick backline under flow control. BOG is handled with the existing BOG Compressors to be
returned to the jetty during ship unloading and to be recovered, used as fuel gas and
recondensed with LNG.Tanks normal operating pressure varies from 100 to 250 mbarg,
depending on Terminal operation mode(ship unloading or no ship unloading). Tank
pressure is maintained with BOG compressors. An absolute pressure controller acting over
compressor capacity is included in both tanks to maintain the operating pressure of the
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ENNORE LNG TERMINAL FROM 5 Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL Page 15 of 155

tanks. Two gauge pressure controllers are also included in both tanks to add high pressure
NG in case of low pressure or to send the BOG to the flare in case of high pressure in the
system. For emergency situations pressure relief valves and vacuum breaker valves are
installed on the top of each storage tank to ensure the tank integrity. Alarms and shutdown
devices have been incorporated to provide maximum safety for the tanks.

2.2.2 High Pressure LNG Pumps

LNG from LP pumps, via recondenser and by-pass line, is pumped by the High Pressure
LNG pumps to the vaporizers under flow control. The pressure of this stream is increased
up to the pressure level required for the natural gas transmission system (95 barg max) by
these pumps. Minimum flow protection facilities (kick-back line) have been provided in order
to protect the pumps. Pump suction barrel pressure is floating with the recondenser.

2.2.3 Vaporizers

LNG at adequate pressure is routed from the high pressure pumps to the vaporizers under
flow control according to Terminal send out. The LNG is heated and vaporized from -135ºC
to 7ºC approximately. The vaporization system configuration consists of six (6) Shell and
Tube Vaporizers (STV’s) which use water– ethylene glycol mixture (WEG) as intermediate
fluid in a close loop. Ethylene glycol content is 36 wt. % to avoid freezing inside vaporizer.
The STV’s are vertical type with process fluid (LNG) by the tube side and heating medium
(WEG) by the shell side. To avoid heating medium freezing, the cold end of the exchanger
is in co-current flow and the rest in counter-current flow. There are, therefore, two hot fluid
inlets to the shell and a single outlet. The LNG enters the exchanger at the bottom and NG
exits at the top. The Ambient Air Heaters (AAHs) are forced draft type used for heating
water-ethylene glycol mixture from the vaporizers outlet.

2.2.4 Metering System and Final Pressure Adjust

Natural gas, before sent to the natural gas transmission system, needs to be metered.
Fiscal metering is required using ultrasonic flow meters. The pipeline pressure will vary due
to different changes in demand, therefore, a pressure control valve shall be provided
downstream of the metering station in order to ensure a steady Terminal send out
operation. The range of operating pressure in the grid is from 80 barg to 95 barg. In case of
high pressure, pressure controller can reduce the LNG flow rate to vaporizer in order to limit
the NG sent to the grid.

2.2.5 Fuel Gas/ Natural Gas System

Fuel gas is required for minor consumptions such as flare header purging, flare pilot
lightning, etc. Compressed BOG is used as fuel gas and NG from vaporizers is used as
back-up. Additionally, natural gas is required to be supplied as fuel for the Captive Power
Plant located within the LNG Terminal. This natural gas is provided from the send out
header upstream of the metering system.

2.2.6 Relief and Drain System

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ENNORE LNG TERMINAL FROM 5 Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL Page 16 of 155

Relief philosophy is based on sending the warm relieves (gas) to the BOG header (tank
vapour space).Warm relieves coming from recondenser and compressors pressure safety
valves are directed to the BOG header. Due to the large volume of the system, no
pressurization is expected and the vapour relief would not discharge to flare. A flare system
within the Terminal is considered as final destination in case of overpressure of the BOG
system. The flare stack is the final disposal element that uses combustion to do it in a safe
way. The flare system receives mainly controlled discharges from tanks and other
equipments and depressurization of the plant for maintenance and for fire emergency
protection. Relief from safety valves of major equipments such as tanks and vaporizers will
be sent to atmosphere at safe location.

A dedicated LNG drain system is provided. In general, major and minor systems and
thermal relief valves discharge to this system. LNG drain system consists in a drain header
that collects different drainages and thermal expansion liquid relieves. Drainages from high
pressure equipment are provided with restriction orifice to limit the flow rates and protect
drain system piping from high pressures. Drain header discharges to an underground
horizontal vessel with boot. This drain drum is balanced with the BOG header. It is emptied
pumping out the liquid to the storage tanks using a vertical motor-driven submersible- type
centrifugal pump mounted inside the boot of the drain vessel. Some systems are not
drained to the dedicated drain system. The unloading arms and the jetty head are drained to
the storage tanks through the unloading lines using the jetty knockout drum. The
compressor suction knockout drum is drained directly to the storage tanks using the
compressor drain vessel. Finally, some systems, such as LP pumps wells, individual LP
pumps discharge lines and truck loading area, are drained directly to the storage tanks.

2.2.7 Recirculation Lines

When large LNG lines are not in operation, ambient heat leak into these LNG filled lines
may produce vaporization. Therefore, it is a good practice to circulate LNG through all this
lines to keep them at a constant temperature. No vaporization is allowed. Unloading lines
during no ship unloading and between LNG ship arrivals, the cooling operation is performed
by the recirculation of LNG from the LP send out header through one of the unloading lines
up to the unloading arms isolation valves. The recirculation flow is returned back to the
Terminal through the other unloading line and this LNG is sent to the recondenser during
normal operation. Part of the recirculation flow returns to the two storage tanks to keep all
tank fill lines cold. In case of the Terminal is in zero send outmode, the LNG from
recirculation lines is sent to the tanks and the BOG generated is sent to the flare. LP LNG
pumps discharge lines: the discharge line of each LP pump that is not in service is kept cold
by circulating LNG from the LP send out header up to pump well through a small by-pass
around block valves and check valves. The cool down return lines, which are located as
close as possible to vaporizers inlet flange, send the LNG from each vaporizer to the tanks
via the recirculation lines. Trucks loading lines: using LNG from the LP pumps the truck
loading lines are kept cold. The LNG is sent back to the tanks.

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EIA STUDY FOR EXPANSION OF B507-1742-EI-2201
ENNORE LNG TERMINAL FROM 5 Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL Page 17 of 155

Figure 2.1: PFD of the proposed process facilities

2.3 Utilities and Ancillary Facilities

Nitrogen
Nitrogen is required at the terminal for equipment purging and maintenance purposes.
Adequate on site nitrogen generation and storage for liquid nitrogen will be provided at the
terminal. The nitrogen generation is based on normal purging and maintenance
requirements. For start-up and/or LNG tank purging, additional nitrogen will be made
available on site by providing liquid nitrogen tanks from supply vehicles.

Air
Instrument and utility air for use within the terminal are produced on site. Three air
compressors will provide necessary air for instrument, plant air and Nitrogen. Regenerative
instrument air drying system, separate instrument and utility receivers, and piping headers
are provided.

Power
Total power requirement for the proposed project is 12 MW. The additional power
requirement will be met from own Captive Power Plant. A battery supplied UPS
(Uninterrupted Power Supply) system powers the Emergency Shutdown (ESD) and gas and

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EIA STUDY FOR EXPANSION OF B507-1742-EI-2201
ENNORE LNG TERMINAL FROM 5 Rev 0
MMPTA TO 10 MMTPA OF M/S IOLPL Page 18 of 155

fire systems to ensure the operation of critical systems in the unlikely event of a complete
failure of the power.

Raw Water system

For proposed project treated water requirement is 10 m3/hr. The water will be used mainly
for service water, fire water make up, horticulture and drinking water. Water will be
generated in-house from atmosphere.

Waste and Wastewater Treatment

In LNG vaporization scheme normally no liquid, gaseous and solid waste is generated. Only
domestic sewage is generated, which is collected and handled through soak-pit/ septic
tanks.

Gas Detection, Alarm, Firefighting and ESD Systems

A centralized spill, fire and combustible gas alarm and control system will provide input to
an information management system. Automatic detection devices, manual alarms and
audible and visual signaling devices will be strategically located throughout the terminal.
Automatic detection devices will include flame, fire and heat, smoke, low temperature and
combustible gas detectors. CCTV monitors will be installed to allow visual surveillance of
critical facilities from the central control room. An emergency shutdown system (ESD) will
be incorporated in the design of the terminal and provide the operators with the capability of
remotely shutting down the entire or selective portions of the terminal.

Communications
The terminal will be outfitted with up-to-date communications equipment capable of
maintaining contact with the LNG carriers scheduled to offload at the terminal and with the
standby tugs.

Buildings
Switchgear/MCC Building - will house switchgear, motor control centers, panel boards,
UPS, batteries and battery charges, lighting transformers, PLC panels for switchgears,
MCCs, generator control panels and other equipment. Additional buildings based on
requirements would be provided.

2.4 Land Requirement

For this proposed project, no additional land is required. All the proposed project facilities
are coming up within the existing LNG Terminal complex area. Total area of Ennore LNG
terminal is 128 acres. Existing green belt area of terminal is 42.24 acres. The plot plan of
proposed plant is attached as Figure 2.2 and Annexure-IV.

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 EIA STUDY FOR EXPANSION OF Document No.
ENNORE LNG TERMINAL FROM 5 B507-1742-EI-2201
MMPTA TO 10 MMTPA OF M/S IOLPL Rev 0
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Figure 2.2: The Plot Plan of the Expansion project at Ennore LNG terminal

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