Alarm & Trip Setting List (4)
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Doc. No.
TANGGUH LNG BPMIGAS
BP Berau Ltd.
63-IOM-PS-1201
Rev.
Author’s Org.
6B
Project
TLNG
KJP
KJP Doc. No.
S-063-1283-001
Date
20 Oct, 06
KJP Job Code
J-3400-20-0000
Sheet
1 of 38
3.8 MTPA TRAIN CAPACITY Operation Manual for Fuel Gas System U-063
X
Rev.
Core
Non-core
For Information
For Review
Date
Page
Description
5A 24 Feb’06
All
For Approval
6A 10 May‘06
All
For Release
6B
20 Oct.06
5, 13, 14,15
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Updated as Marked
Lifecycle Code For Approval
X
Released
As-Built
Prep’d
Chk’d
App’d
T.Kanamaru
Y.Kakutani
Y.Kakutani
Winanto
Y. Kakutani
Y. Kakutani
T.Kanamaru
Y.Kakutani
Y.Kakutani
PT. Brown & Root Indonesia
A
BP App’d
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 2 of 38
CONTENTS 1.
INTRODUCTION.......................................................................................................................4
2. 2.1 2.2 2.2.1 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.4 2.4.1 2.4.2 2.4.3 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.6 2.6.1 2.6.2 2.7 2.7.1 2.7.2 2.8 2.8.1 2.8.2
BASIS OF DESIGN ....................................................................................................................4 General.........................................................................................................................................4 HP Fuel Gas Consumers Firing Load .......................................................................................5 Compressor Gas Turbines Firing Load...................................................................................... 5 LP Fuel Gas Consumers Firing Load........................................................................................5 Boiler Firing Load ..................................................................................................................... 5 Fired Heater Firing Load ........................................................................................................... 5 Incinerator Firing Load .............................................................................................................. 5 Miscellaneous Firing Load ........................................................................................................ 5 HP FG Suppliers Load ...............................................................................................................6 Boil Off Gas (BOG) Supply ...................................................................................................... 6 Dry Sweet Gas Supply ............................................................................................................... 6 AGRU Inlet Gas Supply ............................................................................................................ 6 LP FG Suppliers Load................................................................................................................6 HP Flash Gas Supply ................................................................................................................. 6 Condensate Stabilizer OVHD Gas Supply................................................................................. 6 HP Fuel Gas letdown Supply..................................................................................................... 6 Wet Feed Gas Supply (Black Startup Only) .............................................................................. 6 Fuel Gas Properties.....................................................................................................................7 HP Fuel Gas Properties.............................................................................................................. 7 LP Fuel Gas Properties .............................................................................................................. 8 Special Equipment ......................................................................................................................9 HP Fuel Gas Mixing Drum (051/052-D-1201).......................................................................... 9 Fuel Gas Start-up Heater (063-E-1002) ..................................................................................... 9 Process Description .....................................................................................................................9 HP Fuel Gas System .................................................................................................................. 9 LP Fuel Gas System................................................................................................................. 10
3. 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.3.1 3.3.2 3.3.3
OPERATION VARIABLES AND PROCESS CONTROLS................................................13 External Variables ....................................................................................................................13 Fuel Gas Composition Change ................................................................................................ 13 Electrical Load Change for STG.............................................................................................. 13 Trip of Fuel Users and Fuel Suppliers ..................................................................................... 13 Internal Variables .....................................................................................................................15 2 Train Holding Mode ............................................................................................................. 16 2 Train Loading Mode ............................................................................................................. 16 1 Train Holding Mode ............................................................................................................. 16 1 Train Loading Mode ............................................................................................................. 16 2 Train Loading Mode (Max Fuel Gas) ................................................................................... 16 Process Control .........................................................................................................................16 Pressure Control on Compressed BOG.................................................................................... 16 Pressure Control on HP Fuel Gas System................................................................................ 17 Pressure Control on LP Fuel Gas System ................................................................................ 18
4.
PREPARATION FOR INITIAL START-UP ........................................................................18
5. NORMAL START-UP PROCEDURE ...................................................................................18 5.1 Start-up Procedure after a Scheduled Shutdown...................................................................18 5.1.1 Flare Ignition for Initial Start-up.............................................................................................. 19 5.1.2 LP Fuel Gas System Start-up................................................................................................... 21 5.1.3 Establishment of LP Fuel Gas System for 2 Trains operation ................................................. 21 5.1.4 HP Fuel Gas System Start-up without BOG............................................................................ 22 5.1.5 Establishment of HP Fuel Gas System using Compressed BOG............................................. 23 5.2 Re-start Procedure after Emergency Shutdown ....................................................................23 5.2.1 Re-startup after Total Emergency Shutdown (Black Startup) ................................................. 24 5.2.2 Re-startup after Partial Emergency Shutdown......................................................................... 24
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 3 of 38
6. 6.1 6.2 6.2.1 6.2.2 6.3
NORMAL OPERATION .........................................................................................................25 General.......................................................................................................................................25 Pressure Set Point Adjustment ................................................................................................25 Supply Pressure Adjustment of AGRU Inlet Gas .................................................................... 25 Over Pressure Control for HP Fuel Gas................................................................................... 25 Switch-over to Spare LP Fuel Gas KO Drum ........................................................................25
7. 7.1 7.2 7.3
NORMAL SHUTDOWN PROCEDURE ...............................................................................26 General.......................................................................................................................................26 HP Fuel Gas System Normal Shutdown (One Train Shutdown)..........................................26 LP Fuel Gas System Normal Shutdown (Both Trains Shutdown) .......................................27
8. 8.1 8.2 8.2.1 8.2.2 8.2.3 8.3
EMERGENCY SHUTDOWN PROCEDURE .......................................................................28 General.......................................................................................................................................28 Partial Shutdown by Interlock Logic ......................................................................................28 Shutdown by Train-1(Train-2) Total Shutdown 091(092)-US-2000....................................... 28 Shutdown by Unit 021/031(022/032) Isolation 031(032)-US-2000A ..................................... 29 Shutdown by Unit 041/051(042/052) Isolation 051(052)-US-2400A ..................................... 29 Total Shutdown by Interlock Logic.........................................................................................29
9. 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.9.1 9.9.2 9.9.3
SAFETY PROCEDURE...........................................................................................................30 General.......................................................................................................................................30 Emergency Fire Plan ................................................................................................................31 Fire Fighting and Protective Equipment ................................................................................31 Maintenance of Equipment and Housekeeping......................................................................31 Repair Work..............................................................................................................................31 Withdrawal of Samples ............................................................................................................32 Safe Handling of Volatile and Toxic Materials ......................................................................32 Respiratory Protection .............................................................................................................32 Breathing Apparatus (B. A.) ....................................................................................................33 Nitrogen ................................................................................................................................... 33 Corrosive Materials.................................................................................................................. 33 Chemicals ................................................................................................................................ 33
10. ISOLATION PROCEDURE FOR MAINTENANCE...........................................................34 10.1 General ......................................................................................................................................34 10.2 Basic Procedures.......................................................................................................................34 10.2.1 Train Isolation ......................................................................................................................... 34 10.2.2 Individual Equipment / System Isolation ................................................................................ 34 10.2.2.1 Horizontal and Vertical Pressure Vessels ........................................................................... 34 10.2.2.2 Shell and Tube Heat Exchangers .................................................................................. 35 11. MAINTENANCE PROCEDURE............................................................................................36 11.1 General ......................................................................................................................................36 11.1.1 Routine/First line/ Maintenance .............................................................................................. 36 11.1.2 Breakdown Maintenance ......................................................................................................... 36 11.1.3 Planned Preventive Maintenance............................................................................................. 36 11.1.4 Predictive/Condition Based Monitoring .................................................................................. 36 11.1.5 Turnaround /Inspection Maintenance ...................................................................................... 36 11.2 Precautions prior to Maintenance...........................................................................................36 11.3 Preparation for Maintenance ..................................................................................................37 11.3.1 Installation of blank flanges or spades..................................................................................... 37 11.4 Typical isolation method ..........................................................................................................37 11.4.1 Vessels/Drums......................................................................................................................... 37 11.4.2 Shell and Tube Type Heat Exchangers.................................................................................... 37 11.4.3 Close out.................................................................................................................................. 38 12.
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ATTACHMENT LIST .............................................................................................................38
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
1.
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 4 of 38
INTRODUCTION The Fuel Gas System (Unit-051/052 and 063) is designed to collect, separate liquids, mix and distribute fuel gas required in the Tangguh LNG plant. The system is also designed to minimize sudden variances in the fuel gas stream composition and conditions arising from various plant operating conditions and upsets. Another function of the system is to stabilize the fuel Wobbe index (a function of heating value, gas temperature, and specific gravity) for the gas turbine by heating and mixing the fuel gas properly. The fuel gas is utilized as the main fuel for the gas turbine drivers for the refrigerant compressors, acid gas incinerator, regeneration gas fired heaters and package boilers. A small amount of fuel gas is also used for flare purge & pilot gas, and non-hazardous solid waste treatment incinerator. Based on the requirement of operating pressure, the fuel gas system is divided into two pressure levels, high-pressure fuel gas (HP) and low-pressure fuel gas (LP). The HP fuel gas is utilized for the gas turbine drivers for the refrigerant compressors and the LP fuel gas is utilized for package boilers, regeneration gas heaters, acid gas incinerator and other miscellaneous users. The sources of the HP fuel gas are; -
Boil-off Gas (BOG) leaving the LNG storage and Loading Unit (Unit-071)
-
Spent Regeneration Gas from the regeneration gas system (Unit-031/032)
-
Sour Natural Gas from Feed Gas KO Drum in the AGRU (Unit-021/022)
The sources of the LP fuel gas are; -
Flash Gas from the stabilizer overhead (Unit-011)
-
HP Flash Gas from amine HP flash drum overhead in the AGRU (Unit-021/022)
-
HP Fuel Gas let-down gas from HP Fuel Gas System (Unit-051/052)
-
Feed gas from the Pipeline and downstream of Onshore Receiving Facilities (ORF) Unit (Initial Black Start only)
2.
BASIS OF DESIGN
2.1
General The HP fuel gas system (Unit-051/052) and the LP fuel gas system (Unit-063) are designed to supply HP/LP fuel gas to the plant at any operation mode at either 1 or 2 train operation. Operation modes considered are as follows; Holding Mode:
LNG production being rundown to LNG tank LNG is stored in LNG tank and no product loading operation is being done.
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Loading Mode:
LNG production being rundown to LNG tank
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 5 of 38
LNG is stored in LNG tank and LNG loading operation to a tanker is being done. It is taken into account that the fuel system can operate at any single failure of fuel gas supplier. Refer to section 3.1.3 to show the relationship between process control reaction and response to be taken by operators for process controller reactions and operator responses atin each single failure of HP/LP fuel gas supplier. The simplified HP/LP fuel gas configurations are shown in Figure 2-8-1 and 2-8-2 respectively.
2.2
HP Fuel Gas Consumers Firing Load
2.2.1
Compressor Gas Turbines Firing Load The unique HP fuel consumers are Frame 7 gas turbines for 051-CG-1001/1002 (052-CG-1001/1002). They consume a total firing duty of 457 MW per one LNG train.
2.3
LP Fuel Gas Consumers Firing Load
2.3.1
Boiler Firing Load Three Package Boilers (062-F-1001A/B/C) are required to generate HP steam as below for each operating mode:
2.3.2
Operating Mode
Electric Load [MW]
Steam Load [ton/hr]
Firing Duty [MW]
2 Trains Holding Mode
57.0
98.6 x 3
256.1
2 Trains Loading Mode
60.0
95.7 x 3
248.6
1 Train Holding Mode
43.0
78.4 x 3
203.7
1 Train Loading Mode
46.0
79.6 x 3
206.8
Fired Heater Firing Load The regeneration gas heater (031/032-F-1001) consumes a firing duty of 1.13 - 8.80 MW per one LNG train.
2.3.3
Incinerator Firing Load The incinerator (021/022-F-1010) consumes a firing duty of 23.2 MW per one LNG train.
2.3.4
Miscellaneous Firing Load A small amount of fuel gas is consumed by flare purge & pilot gas (086-FL-1001/1002/1003), and the non-hazardous solid waste treatment incinerator (089-F-1001).
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
2.4
HP FG Suppliers Load
2.4.1
Boil Off Gas (BOG) Supply
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 6 of 38
Components of BOG are methane (C1) and nitrogen (N2). Design flow rate of compressed BOG discharged from U-071 is 75.0 ton/hr at 2 Train Loading Mode, 39.4 ton/hr at 1 Train Loading Mode. The compressed BOG is distributed to both Train-1 and Train-2 in which constant flow rate of the compressed BOG is delivered through the regeneration gas system and excess compressed BOG is delivered bypassing the regeneration gas system. 2.4.2
Dry Sweet Gas Supply Dry sweet gas is supplied through 031/032-PV-1214 on outlet of the dehydration and mercury removal unit as a make-up regeneration gas. It is designed to supply 35.2 ton/hr (2100 kg-mol/h) of the dry sweet gas in case of unavailability of compressed BOG.
2.4.3
AGRU Inlet Gas Supply AGRU inlet gas is supplied through 021/022-PV-1271 downstream of the feed gas KO drum (021/022-D-1001) overhead as a backup fuel in each train. It is designed to supply 46.1 ton/hr of the warm feed gas in case of black startup operation for two gas turbines.
2.5
LP FG Suppliers Load
2.5.1
HP Flash Gas Supply HP flash gas is supplied through 021/022-PV-1205 on overhead of the amine HP flash drum (021/022-D-1001) as a primarily LP fuel gas source in each train. The design flow is 4.4 ton/hr per train.
2.5.2
Condensate Stabilizer OVHD Gas Supply Sour natural gas is supplied through 011-PV-1201/1221 on overhead of the condensate stabilizer (011-T-1001A/B) as a primarily LP fuel gas source. The design flow is 2.3 ton/hr.
2.5.3
HP Fuel Gas letdown Supply HP fuel gas is supplied through pressure let-down valve 091/092-PV-1032 as a supplementary LP fuel gas source. The design flow is 28.2 ton/hr per train to cover 200% of normal flow in case loss of one of two pressure let-down valves.
2.5.4
Wet Feed Gas Supply (Black Startup Only) Wet feed gas from the Pipeline and/or downstream of ORF Unit is supplied through 063-PV-1201 downstream of the fuel gas start-up heater (063-E-1201). The design flow is 14.6 ton/hr based on the requirement of fuel gas for one package boiler operating at rated capacity. This supplier is used only for initial black start-up.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
2.6
Fuel Gas Properties
2.6.1
HP Fuel Gas Properties
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 7 of 38
HP fuel gas properties are following conditions at the inlet of the fuel gas scrubber for the gas turbines. Table 2-6-1 Operating Mode Pressure, kg/cm2G Temperature, ºC
AGRU Inlet Gas
2 Train Holding Mode
HP Fuel Gas Properties 2 Train Loading Mode
1 Train Holding Mode
1 Train Dry Sweet Gas Loading Mode (BOG trip)
24.5
24.5
24.5
24.5
24.5
24.5
70
70
70
70
70
70
Composition, mol% 0.030
0.433
0.249
0.418
0.059
0.030
0.148
0.483
0.476
0.458
0.480
0.501
CO2
12.503
0.728
0.510
0.000
0.328
0.005
N2
0.751
7.942
9.307
8.002
8.306
0.858
C1
84.057
90.248
89.338
91.107
90.648
95.779
C2
1.749
0.102
0.071
0.000
0.143
1.989
C3
0.373
0.022
0.015
0.000
0.010
0.425
iC4
0.059
0.003
0.002
0.000
0.002
0.069
nC4
0.069
0.004
0.003
0.000
0.002
0.078
iC5
0.034
0.002
0.001
0.000
0.001
0.038
nC5
0.024
0.001
0.001
0.000
0.001
0.028
C6s
0.026
0.002
0.001
0.000
0.001
0.025
C7s
0.037
0.003
0.002
0.000
0.001
0.033
C8s
0.023
0.002
0.001
0.000
0.001
0.022
C9+
0.024
0.004
0.003
0.000
0.002
0.020
Aromatics
0.091
0.007
0.005
0.000
0.003
0.084
Sulfur
0.003
0.015
0.014
0.014
0.014
0.016
Molecular Weight
20.23
17.20
17.31
16.97
17.17
16.81
LHV, kJ/kg
35646
42291
41544
43110
42543
48778
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He H2O
LHV, btu/scf
817
824
815
829
828
929
Wobbe Index
39.3
43.0
42.4
43.6
43.2
49.0
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
2.6.2
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 8 of 38
LP Fuel Gas Properties LP fuel gas properties are following conditions at the LP fuel gas header. Table 2-6-2 Operating Mode
Black Start-up
LP Fuel Gas Properties
2 Train Holding Mode
2 Train Loading Mode
1 Train Holding Mode
1 Train Loading Mode
Pressure, kg/cm2G
3.5
3.5
3.5
3.5
3.5
Temperature, ºC
41.3
27.7
27.8
24.7
23.2
Composition, mol%
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He
0.030
0.024
0.024
0.053
0.026
H2O
0.059
0.810
0.817
0.679
0.618
CO2
12.493
18.682
18.758
15.931
16.698
N2
0.751
0.628
0.627
1.162
0.667
C1
84.056
76.731
76.659
79.388
79.044
C2
1.748
1.891
1.885
1.727
1.840
C3
0.373
0.527
0.523
0.454
0.474
iC4
0.059
0.099
0.098
0.083
0.085
nC4
0.069
0.103
0.103
0.088
0.092
iC5
0.034
0.042
0.041
0.037
0.039
nC5
0.024
0.029
0.029
0.026
0.028
C6s
0.028
0.032
0.032
0.029
0.030
C7s
0.044
0.052
0.052
0.046
0.049
C8s
0.038
0.043
0.043
0.038
0.041
C9+
0.075
0.081
0.081
0.071
0.075
Aromatics
0.115
0.219
0.220
0.180
0.186
Sulfur
0.003
0.008
0.008
0.007
0.006
Molecular Weight
20.33
22.26
22.28
21.43
21.63 32083
LHV, kJ/kg
35730
30545
30485
32364
LHV, btu/scf
823
770
769
786
786
Wobbe Index
41.3
37.7
37.7
39.4
39.4
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
2.7
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 9 of 38
Special Equipment Refer to each equipment data sheet for details (Attachment 3).
2.7.1
HP Fuel Gas Mixing Drum (051/052-D-1201) The purpose of the mixing drum is to limit the change rate of Wobbe Index of the fuel gas to the gas turbines. The drum is designed to prevent any liquid carry over and maintain the change rate of the Wobbe Index within a range of +/- 0.3% per second as required by the gas turbine manufacturer. There are ten segments in the drum. A central internal pipe distributes fuel gas into the drum through three holes in each segment. Pipe is closed at bottom and extends to the required segment length. The holes in each segment face the down-flowing gas.
2.7.2
Number of drums:
One (1) / unit
Swing capacity:
46,118 kg/hr (AGRU inlet gas as min. Wobbe Index) ÅÆ 33,537 kg/hr (Dry sweet gas as max. Wobbe Index)
Operating pressure:
26.13 kg/cm2A
Allowable ∆P:
0.3 kg/cm2
Fuel Gas Start-up Heater (063-E-1002) The purpose of the start-up heater is to heat up the LP fuel gas for starting flare ignitions and operating one package boiler to prevent hydrate formation by the pressure let-down. The heater is designed to be capable of heating the amount of required LP fuel gas to operate one package boiler at rated capacity. The electric source for the heater is generated by the emergency diesel power generator. Number of heaters:
One (1)
Type:
Electric heater in four equal stages by thyristor control
Heat Duty:
0 - 500 kW
Operating pressure:
60.85 - 101.3 kg/cm2A (depends on arrived pressure at ORF)
Outlet temperature:
62 - 76 °C (depends on saturate temperature of LP fuel gas)
2.8
Process Description
2.8.1
HP Fuel Gas System The simplified HP fuel gas configuration is shown in Figure 2-8-1. The compressed BOG which is the primary source for high pressure (HP) fuel gas is distributed to each of the LNG trains equally. The compressed BOG is used as regeneration gas in the Dehydration unit. Since a constant regeneration gas flow is required to keep the regeneration time sequence, the dryer outlet gas could be used as regeneration gas supply when LNG BOG is not available. The hot, wet regeneration gas from the Dehydration drum is cooled down by the Regeneration Gas Cooler (031/032-E-1002) and then condensed water is removed at the Regeneration Gas KO Drum (031/032-D-1003). The water saturated gas from the Regeneration Gas KO Drum is mixed with
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 10 of 38
supplemental gas from AGRU inlet gas as make-up fuel to provide the required HP fuel gas for the Propane Compressor and MR Refrigerant Compressor gas turbine drivers (051/052-CG-1001/1002). The mixed gas heated up to 70°C by HP Fuel Gas Heater (051/052-E-1201) is sent to the HP Fuel Gas Mixing Drum (051/052-D-1201) installed in each LNG train. This drum functions to prevent any liquid carry over and maintain the rate of change of the Wobbe Index within a range of +/- 0.3% per second. The stable HP fuel gas is then distributed to each user. 2.8.2
LP Fuel Gas System The simplified LP fuel gas configuration is shown in Figure 2-8-2. Stabilizer overhead gas and amine HP flash gas from each AGRU provide low pressure (LP) fuel gas. AGRU inlet gas is also utilized from HP fuel gas system through pressure let-down valve to compensate for the shortfall in primarily LP fuel gas sources against total LP fuel gas demand. These wet fuel gas streams are sent to the LP Fuel Gas KO Drum (063-D-1002A/B) located in the utility area. A complete spare LP Fuel Gas KO Drum is provided. The LP fuel gas is then distributed to each user. During the initial plant start-up (in commissioning) or black start-up, the feed gas from downstream of ORF is fed to the LP fuel gas system through the electric Fuel Gas Start-up Heater (063-E-1002). The heated LP fuel gas is supplied to one package boiler which is ready to start-up. The electric source for the Fuel Gas Start-up Heater (063-E-1002) is the emergency diesel power generator.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 11 of 38
021 PIC 1271
021-PV-1271 (Excess BOG by-pass)
031-E-1002 FEED GAS TO LNG TRAIN-1
AGRU
031-KV-1931 031-KV-1929
031-D-1003 091 FI 1074
031 PDG 9205
091-PV-1231C 051-E-1201
031-KV-1982
Regeneration Timer Sequence
031-D-1002A/B/C
091 PIC 1231
091 FI 1073
051-D-1201
(by-pass)
SP
TO APCI PROCESS
051-CG-1002
(Heating) Y-Strainer
TC
091 FIC 1032
α
SR 031-PV-1213A/B
031 PIC 1213
031 FIC 1005
031-PV-1214 031 PIC 1214
(Cooling)
Rump-down (Cooling)
031-KV-1981
091-FV-1032
031-FV-1005
TO LP FUEL GAS SYSTEM
(1-α)
031-KV-1983 031-KV-1984
031-USV-1980 031 FIC 1003
See Figure 3-3-1 for Detail 091-FV-1051B 031-USVE-2511 BOG from BOG Compressor
031-FV-1003 (Heating)
031-USV-1985
(Minimum Firing)
092-FV-1032
031-F-1001
092 FIC 1032
091-FV-1051A
TRAIN - 2 032-USVE-2511
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051-CG-1001
Rump-up
031-KV-1932
031-KV-1930
To Flare
Figure 2-8-1 Simplified HP Fuel Gas Configuration
See Fiture 2-8-2 for Detail
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 12 of 38
091 FIC 1032
SP
063 HIC 1032
yxα
063 FY 1032C
α
y
FLOW RATIO OF TRAIN-1
063 FY 1032D
α
y
To Flare y x (1-α)
091 FT 1032
HP Letdown from Train-1
092 FIC 1032
0-b
b-1
063 PY 1202B
Solid Waste Treatment Incinerator 063 PIC 1202
092-FV-1032
011-PV-1201 021 PIC 1205
from Amine HP Flash Gas Drum in Train-1
021-PV-1205
063-D-1002A/B
022 PIC 1205
from Amine HP Flash Gas Drum in Train-2
022-PV-1205
063 PIC 1201
from ORF for Start-up (NNF)
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Acid Gas Incinerator Regen Gas Heater Boiler Package
011 PIC 1201
from Condensate Stabilizer Unit
Flare Pilot/Purge
SP
092 FT 1032
HP Letdown from Train-2
SPRIT RANGE 063 PY 1202A
091-FV-1032
063-PV-1202B
063-PV-1201
Figure 2-8-2 Simplified LP Fuel Gas Configuration
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 13 of 38
3.
OPERATION VARIABLES AND PROCESS CONTROLS
3.1
External Variables HP/LP fuel gas system is controlled automatically but require the operator to monitor process variables and to intervene when changes occur which would cause the fuel gas system parameters to vary out of the expected or allowable range.
3.1.1
Fuel Gas Composition Change Variation in fuel gas composition caused by changes in the operation of the process units result in fluctuation of heating value of fuel gas to users. Significant change in the fuel gas heating value may result in electrical system disruption, process unit upsets, or fluctuation in the MP and LP steam system pressures. Meanwhile, dynamic simulation results of HP fuel gas system prove that operation pressure and the change rate of Wobbe Index are maintained within allowable rage. Refer to "Dynamic Simulation Fuel Gas System (63-SDY-PS-1726)" for more information.
3.1.2
Electrical Load Change for STG When sudden load change in power demand occurs, the steam balance will be change accordingly. Therefore, the fuel gas balance will change to maintain original set pressures at pressure controlled points. When power load increases, back up supply of AGRU inlet gas will increase. When power load decreases and there is an excess fuel in the system, the excess portion will be flared.
3.1.3
Trip of Fuel Users and Fuel Suppliers Trip of LP fuel gas users and LP fuel gas suppliers will cause the same impact as electrical load change stated above. In case of HP fuel gas user trips, the excess fuel gas will be flared. In case of HP fuel gas supply losses, back up supply of AGRU inlet gas will increase. The following table summarizes the relationship between process control reactions and operator response to be taken by operators s at each single failure of HP/LP fuel gas sources.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 14 of 38
Failure of Fuel Gas Source
System Reaction
Operator Response
HP
Total BOG supply failure
Fuel Gas
(For example, electric load shedding.) Supply of regeneration gas in Dehydration unit is stopped.
031/032-PV-1214 at the downstream of Dryers will open automatically to keep the pressure of the regeneration gas system in Train-1 and Train-2. respectively
To confirm system reaction works properly and check a cause of failure
When BOG supply to No.1 (No.2) LNG train is failed, 31-PV-1214 (032-PV-1214) will open automatically to keep the pressure of the regeneration gas system.
To confirm system reaction works properly and check a cause of failure
HP Fuel Gas
BOG supply failure to single LNG train Warm feed gas from AGRU Train-1 (Train-2)
090-FIC-1051A (090-FIC-1051B) for BOG supply control valve to ”No failed LNG Train” will open widely gradually in auto. Since BOG gas flow rate in “No failed LNG train” will increase, the make-up fuel gas control valve in AGRU inlet, 022-PV-1271 (021-PV-1271), will be closed automatically. 031-PV-1214 (032-PV-1214) will open automatically to keep the pressure of the regeneration gas system in Train-1 (Train-2)
The BOG flow separation ratio to each LNG Train of 90-HS-1061, “a”, shall be changed to 0.0 (1.0) from 0.5, when No.1 (No.2) LNG Train is failed to minimize the loss of BOG to flare. The flow ratio “α” on 063-HIC-1032 to be set to be 0.0 (1.0) from 0.5 and check a cause of failure
091/092-FV-1032 will open automatically to compensate a loss of HP fuel gas from Train-1 (Train-2) HP Fuel gas supply from AGRU inlet in each LNG Train. (For example, 021-PV-1271 (022-PV-1271) is failed close)
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When HP Fuel gas supply from AGRU inlet is failed, HP fuel gas flow rate will be decreased insufficient in the failed LNG Train. To supply sufficient HP fuel gas flow rate to the failed LNG Train, BOG flow rate shall be increased by manual. Since in “No failed LNG train” BOG flow rate will be decreased, HP fuel gas will be supplied by 022-PV-1271 (021-PV-1271) automatically.
Operator shall increase the set value of “a” on 90-HS-1061 from 0.5 to approximately 0.6 to increase BOG flow rate as HP fuel gas by manual.
To confirm system reaction works properly and check a cause of failure
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
LP Fuel Gas
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 15 of 38
Failure of Fuel Gas Source
System Reaction
Operator Response
HP Fuel gas supply from AGRU inlet in each LNG Train, because a part of the the raw feed gas from in AGRU inlet is used for HP/LP make-up fuel gas.
Since LP fuel gas supply is stopped from HP fuel gas header in the failed LNG Train, insufficient LP fuel gas shall be supplied from 092-FV-1032 (091-FV-1032) via 022-PV-1271 (021-PV-1271) in “No failed LNG Train” gradually in auto.
Operator shall change the set point of “a” for 063-HIC-1032 from 0.5 to 1.0 (0.0) to cover the insufficient LP fuel gas flow rate by the fuel gas let down valve in “No failed LNG Train “, 091-FV-1032 (092-FV-1032), immediately.
(For example, 021-PV-1271 (022-PV-1271) is failed close)
022-PV-1271 (021-PV-1271) in “No failed LNG Train” will open more automatically to supply not only insufficient HP fuel gas but also LP fuel gas.
Common LP fuel gas system from HP fuel gas header in each LNG Train. (For example, fuel gas pressure let down valve failure : 091-FV-1032 (092-FV-1032) )
Fuel gas let down valve in “No failed LNG Train”, 091-FV-1032 (092-FV-1032), will open widely to supply the required LP fuel gas gradually.
To confirm system reaction works properly and check a cause of failure. Operator shall change the set point of “a” for 063-HIC-1032 from 0.5 to 1.0 (0.0) to cover the insufficient LP fuel gas flow rate by the fuel gas let down valve in “No failed LNG Train “, 091-FV-1032 (092-FV-1032), immediately. To confirm system reaction works properly and check a cause of failure
3.2
Stabilizer OVHD gas
Both of 091-FV-1032 and /092-FV-1032 will open automatically together to compensate loss of LP fuel the gas
To confirm system reaction works properly and check a cause of failure
HP flash gas from AGRU Train-1 (Train-2)
091-FV-1032 (092-FV-1032) in the failed LNG Train will open automatically to compensate loss of LP fuel gas. Ditto
To confirm system reaction works properly and check a cause of failureDitto
Internal Variables Following four normal operation modes plus one alternative operation mode are considered for LP/HP fuel gas system
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Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 16 of 38
2 Train Holding Mode 2 Train Loading Mode 1 Train Holding Mode 1 Train Loading Mode 2 Train Loading Mode (Max Fuel Gas) For detailed fuel gas balance, refer to UFD "63-UFD-PS-1200~1209". 3.2.1
2 Train Holding Mode Amount of BOG emergence and flash gas from other suppliers are based on two trains operation without product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in fuel gas supply through 021/022-PV-1271 to maintain system pressures in both LP and HP fuel gas.
3.2.2
2 Train Loading Mode Amount of BOG emergence and flash gas from other suppliers are based on two trains operation with product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in fuel gas supply through 021/022-PV-1271 to maintain system pressures in both LP and HP fuel gas.
3.2.3
1 Train Holding Mode Amount of BOG emergence and flash gas from other suppliers are based on one train operation without product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in fuel gas supply through 021-PV-1271 (or 022-PV-1271) to maintain system pressure in LP fuel gas only. Since compressed BOG supply exceeds HP fuel gas demand, excess HP fuel gas is forwarded to LP fuel gas system through 091-FE-1074 (or 092-FE-1074).
3.2.4
1 Train Loading Mode Amount of BOG emergence and flash gas from other suppliers are based on one train operation with product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in fuel gas supply through 021-PV-1271 (or 022-PV-1271) to maintain system pressures in both LP and HP fuel gas.
3.2.5
2 Train Loading Mode (Max Fuel Gas) This operation mode is same condition as normal 2 Train Loading Mode except for fuel gas demand of package boilers which are operated at rated capacity. Amount of BOG emergence and flash gas from other suppliers are based on two trains operation with product loading operation. Warm feed gas from AGRU inlet is utilized as a supplemental fuel gas through 021/022-PV-1271 to maintain system pressures in both LP and HP fuel gas.
3.3
Process Control
3.3.1
Pressure Control on Compressed BOG The simplified control configuration on compressed BOG is shown in Figure 3-3-1. BOG shall be distributed evenly between the two LNG trains for stable supply of fuel gas. The compressed BOG discharge header pressure controller, 090-PIC-1051 resets the compressed BOG flow rate to Train-1 and Train-2 in accordance to the ratio set by 090-HIC-1051. If the BOG
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 17 of 38
discharge header pressure is decreased (or increased), each flow control valve opening of both 090-FV-1051A/B should be more reduced (or enlarged) evenly. The ratio of the flow rate to Train-1 to the total flow rate is defined as “α”. The flow ratio “α” shall be set to be 0.5 in two trains operation by 090-HIC-1051. If Train-2 (or Train-1) is not in operation, the flow ratio “α” shall be set to 1.0 (or 0.0). The compressed BOG arrived pressure at the regeneration system inlet is maintained by 031/032-PIC-1213 and 1214. More flow of compressed BOG bypass through 031/032-PIC-1213 to prevent pressure increase. In case of less flow, the dry sweet gas from the outlet of the mercury removal after filter (031/032-Y-1002) is supplied by 031/032-PIC-1214 to prevent drop in pressure.
Yxα
α
090 FY 1051B Y
Train Flow Ratio
090 HIC 1051
Y
SP 090 FIC 1051B
Y 1-α
090 FY 1051A
090 FT 1051B
To Train - 1
Y x (1-α)
090 PC 1051 SP
BOG from BOG Compressor
090 FIC 1051A
090 FT 1051A
To Train - 2
Figure 3-3-1 Control Scheme on Compressed BOG
3.3.2
Pressure Control on HP Fuel Gas System Wet feed gas from AGRU inlet is supplied to HP fuel gas system by 021/022-PIC-1271 to maintain the inlet pressure of HP fuel gas system. Unexpected transient or emergency conditions such as a gas turbine trip can drive the pressure of the HP fuel gas system out of the desired operating range. In the event of such an upset, a pressure control valve 091/092-PV-1231C limits the rise in pressure in the HP fuel gas system by venting excess gas to flare. 091/092-PV-1231C is designed to relief excess flow of fuel gas consumed by one gas turbine.
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3.3.3
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 18 of 38
Pressure Control on LP Fuel Gas System LP fuel gas is derived from various flow rates of Stabilizer overhead gas and amine HP flash gas from the AGRU in accordance with operating mode, such as one/two train operation or HC slug content of feed gas. In order to maintain LP fuel gas supply pressure, the supply of make up LP fuel gas from HP fuel gas system is controlled using flow controllers 091/092-FIC-1032 reset by 063-PIC-1202 based on the specified flow ratio. The flow ratio of the Train-1 flow rate to the total flow rate is defined as “α”. The “α” shall be set to be 0.5 in two trains operation by 063-HIC-1032. If Train-2 (or Train-1) is not in operation, the flow ratio “α” shall be set to 1.0 (or 0.0). LP fuel gas is released to the wet flare by 063-PV-1202B when the operating pressure is higher than the set point of 063-PIC-1202. 063-PV-1202B is designed to relief 30% excess flow of normal fuel gas consumption.
4.
PREPARATION FOR INITIAL START-UP Refer to Commissioning Procedure (63-PRC-OP-1001).
5.
NORMAL START-UP PROCEDURE This section describes the following start-up procedures of HP/LP fuel gas system Unit 063 (partly Unit 051/052 included). (1) Start-up after the schedule shutdown (including initial start-up/black start-up) (2) Re-start after the emergency shutdown
5.1
Start-up Procedure after a Scheduled Shutdown Start-up procedure after the scheduled maintenance shutdown is applied when Section 4 "Preparation for Initial Start-up" is conducted. During the initial plant start-up in commissioning, one package boiler is operated using diesel oil to generate steam and electric power using a steam turbine. During black start-up, emergency power generators will be used for initial system preparation and firstly one of package boilers (062-F-1001A/B/C) shall start-up so that steam becomes available to generate electric power. As a source of start-up fuel gas for one package boiler, sour natural gas is forwarded from Vorwata-A/B Pipeline through the 2" interconnection piping (016-GF-1701). Prior to introducing the fuel gas, condition of the plant is as follows: -
Fuel gas line in the plant, utility and ORF area is being purged with nitrogen.
-
Emergency diesel power generators (061-EDG-1001A/B/C/D) are being operated.
-
Instrument air system is in service.
-
Flare system is ready for start-up.
-
Start-up Fuel Gas Heater (063-E-1002) is ready for start.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
5.1.1
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 19 of 38
Flare Ignition for Initial Start-up The purpose of this procedure is to introduce the wet feed gas from ORF and to forward LP fuel gas heated by the fuel gas start-up heater (063-E-1002) to the flare system (086-FL-1001/1002/1003) for flare ignition. (1)
Prior to introducing the wet feed gas from ORF, lineup to be confirmed as shown in Figure 5.1.1. Close 2" gate valve "A" which is normally LO and open 2" gate valve "B" which is normally LC. Note that both of the LP Fuel Gas KO Drums (063-D-1002A/B) which have safety relief valves shall be bypassed because the wet flare is not in service yet.
(2)
Commission the Start-up Fuel Gas Heater (063-E-1002). The heater outlet temperature controller 063-TIC-1302 to be set at 75 ºC (adjustable depends on Pipeline pressure).
(3)
Open gradually 2" globe valve at suction of the heater not to exceed 3.5 kg/cm2G at the restriction orifice (063-FO-9001) outlet.
(4)
Purge out nitrogen and ignite pilots of the flares (086-FL-1001/1002/1003).
(5)
When flare pilots ignited, open 2" gate valve "A". 063-PV-1201 to be put in service.
(6)
Perform 2" gate valve "B" locked closed.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 20 of 38
6"
6" Vorwata B Pipe Line 40" Sour NG to LNG Trains Vorwata A Pipe Line 2" Bypass Line To LP Fuel Gas Users
2"
063-D-1002B PG
LC PC A
063-D-1002A 063-E-1002
063-PV-1201
063-LV-1171
To Wet Flare
LC
B Flash gas from operating trains
063-LV-1102
Figure 5.1.1 LP Fuel Gas Lineup for Flare Ignition
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To Wet Flare
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
5.1.2
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 21 of 38
LP Fuel Gas System Start-up The purpose of this procedure is LP fuel gas KO drum to be put in service after flare pilots ignited and introducing fuel gas sources from an operating train.
5.1.3
(1)
Commission the level controller (063-LIC-1102 or 1171) to draw off condensate to the wet flare.
(2)
Commission the excess pressure controller (063-PY-1202B) to prevent over pressure of LP fuel gas header.
(3)
Open 14" inlet gate valve which isolate available LP fuel gas KO drum.
(4)
Purge out nitrogen to the wet flare through 2” bypass valve of 063-PSV-8002 or 8701.
(5)
Open 14" outlet gate valve whose available LP fuel gas KO drum to be put in service.
(6)
Close 2" gate valves on the KO drum bypass line (063-GF-1706).
(7)
When overhead gas of the condensate stabilizer (011-T-1001A/B) and HP flash gas of the amine HP flash gas drum (021/022-D-1001) are available, these flash gases will be introduced respectively.
(8)
Regulate 2" globe valve at suction of the heater to compensate the flash gas introduced from operating train into the LP fuel gas system.
(9)
When AGRU inlet gas through 021/022-PV-1271 is available, put HP fuel let-down flow controller (091/092-FIC-1032) in cascade mode with implementation of the train flow ratio (063-HIC-1032) in accordance with operating LNG trains, i.e., 1.0 for Train-1 operation or 0.0 for Train-2 operation.
(10)
Once the LP fuel gas system is stabilized, close 2" globe valve at suction of the heater and stop the heater. All isolation valves which are related to initial start-up shall be closed.
(11)
The wet feed gas in stagnant line shall be purged out by nitrogen.
Establishment of LP Fuel Gas System for 2 Trains operation The purpose of this procedure is to introduce fuel gas sources from the other operating train which is commissioned secondarily.
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5.1.4
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 22 of 38
(1)
Confirm that 063-HIC-1032 (LP fuel gas flow ratio to LNG Train-1) has been set at 1.0 (0.0). LP fuel gas header pressure is controlled by 091-FV-1032 which set point is given by “FC (091-FIC-1032) - PC (063-PIC-1202)” cascade control.
(2)
Fuel gas let down valve for Train-2, 092-FV-1032 (Train-1, 091-FV-1032) is gradually opened manually. Meanwhile, 091-FV-1032 (092-FV-1032) is controlled to maintain pressure of the common LP fuel gas, 063-PIC-1202.
(3)
In accordance with increasing of the feed gas flow rate to Train-2, the total fuel gas demand is also increased. 092-FV-1032 (091-FV-1032) shall be opened properly by manual. The common LP fuel gas pressure shall be still controlled by 091-FV-1032 (092-FV-1032) by PC-FC cascade control.
(4)
Set 063-HIC-1032 (LP fuel gas flow ratio to LNG Train-1) at 0.5 when flow rate 092-FIC-1032(091-FIC-1032) is close to 091-FIC-1032(092-FIC-1032).
(5)
Put 092-FIC-1032 (091-FIC-1032) in PC-FC cascade mode.
HP Fuel Gas System Start-up without BOG The purpose of this procedure is HP fuel gas system, either Unit 051 or 052, to be put in service during unavailable BOG. (1)
-
Process HP Fuel Gas Heater (051/052-E-1201)
-
Process HP Fuel Gas Mixing Drum (051/052-D-1201)
(2)
Open gradually 3" globe valve on 021/022-PV-1271 bypass not to exceed 26.5 kg/cm2A of down stream pressure (021/022-PG-9220).
(3)
Open manually the excess HP fuel gas pressure control valve (091/092-PV-1231C) to sweep residual nitrogen to the wet flare. When the system is stabilized, put 091/092-PIC-1231 in auto at 25.8 kg/cm2A.
(4)
Commission the LP steam flow controller (091/092-FIC-1332) to supply the LP steam to 051/052-E-1201 and the level controller (091/092-LIC-1232) to draw off condensate to steam condensate header.
(5)
Open manually AGRU inlet gas supply pressure control valve (021/022-PV-1271) and close 3" globe valve on its bypass.
(6)
Put the LP steam flow controller (091/092-FIC-1332) in cascade mode to set HP fuel gas temperature controller (091/092-TIC-1332) at 70 ºC.
(7)
Commission the level controller (051/052-LIC-1131) to draw off condensate to the wet flare.
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Prior to the introduction of AGRU inlet gas through 021/022-PV-1271 to the HP fuel gas system, the following equipment should be lined up.
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 23 of 38
(8)
When adequate HP fuel gas at the HP fuel gas inlet facilities for gas turbines is confirmed after venting to sweep another residual nitrogen to the wet flare, introduce HP fuel gas to the gas turbines (051/052-CG-1001/1002).
(9)
When 091/092-PV-1231C is closed, put 021/022-PV-1271 in auto. Expected set point is 26.25 kg/cm2A. Set point is adjustable in accordance with actual system pressure drop.
(10)
Reset 091/92-PIC-1231 at 26.5 kg/cm2A.
When spent regeneration gas supplied from dry sweet gas are available, these gas can be introduced to the HP fuel gas system at any time. 021/022-PV-1271 will be regulated automatically to compensate introduced spent regeneration gas to the HP fuel gas system.
5.1.5
Establishment of HP Fuel Gas System using Compressed BOG The purpose of this procedure is to introduce compressed BOG to the HP Fuel Gas System which is commissioned secondarily.
5.2
(1)
Confirm that 090-HIC-1051 (compressed BOG flow ratio to LNG Train-1) has been set at 1.0 (0.0). Compressed BOG header pressure is controlled by 090-PIC-1051 which set point is given by FC-PC cascade control.
(2)
Gradually open manually 090-FV-1051A (1051B) at Train-2 (Train-1). Meanwhile, 090-FV-1051B (1051A) will be controlled to maintain pressure at the BOG compressor discharge common header, 090-PIC-1051. Accordingly, the regeneration gas make-up valve 032(031)-PV-1214 will be closed gradually.
(3)
Since excess BOG flow rate in Train-1 will be reduced, the dehydration by-pass valve 031(032)-PV-1213 will be closed gradually.
(4)
Fuel gas make-up control valve, 021(022)-PV-1271 is gradually opened automatically to maintain HP fuel gas pressure.
(5)
Set 090-HIC-1051 (train flow ratio set) at 0.5 when flow rate 090-FIC-1051A (1051B) is close to 090-FIC-1051B (1051A).
(6)
Put 090-FIC-1051A (1051B) in PC-FC cascade.
Re-start Procedure after Emergency Shutdown The following ESD system activation will lead to total emergency shutdown in HP/LP fuel gas system.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 24 of 38
Any one or more of the following ESD systems activation will cause partial emergency shutdown in HP fuel gas system (potentially LP fuel gas system in service). 031(032)-US-2000A Unit 021/031(022/032) Isolation 051(052)-US-2400A Unit 041/051(042/052) Isolation 091(092)-US-2000
Train-1(Train-2) Total Shutdown
The emergency shut-down procedure initiated by the EDS system is given in Section 8 "Emergency Shutdown Procedure".
5.2.1
Re-startup after Total Emergency Shutdown (Black Startup) The re-startup procedure after emergency shutdown of fuel gas system is the same as the startup procedure after scheduled shutdown described in Section 5.1. Before re-starting the operation, confirm that all emergency conditions which caused the unit shutdown have been restored to the normal conditions.
5.2.2
Re-startup after Partial Emergency Shutdown The startup procedure after partial emergency shutdown, namely emergency shutdown of either HP fuel gas system in Train-1 or Train-2, is the same as the procedure of HP fuel gas system startup described in Section 5.1.4 and 5.1.5. Before re-starting the operation, confirm that all emergency conditions which caused the unit shutdown have been restored to the normal conditions.
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6.
NORMAL OPERATION
6.1
General
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 25 of 38
Fuel gas system U-063 (including part of U-051/052) is normally controlled automatically but requires the operator to monitor process variables and to intervene when changes occur which would cause the feed gas parameters to vary outside the expected or allowable range.
6.2
Pressure Set Point Adjustment
6.2.1
Supply Pressure Adjustment of AGRU Inlet Gas Set point of AGRU inlet gas supply pressure controller 021/022-PIC-1271 is adjustable in accordance with actual arrived pressure at HP fuel gas inlet facilities (fuel gas scrubber skid) of gas turbines. To set at 26.25 kg/cm2A is expected to obtain 25.5 kg/cm2A of normal pressure at the inlet facilities. For over pressure controller 091/092-PIC-1231, to set at 26.5 kg/cm2A or set pressure of 021/022-PIC-1271 plus 0.25 kg/cm2 is preferable to prevent periodical flaring.
6.2.2
Over Pressure Control for HP Fuel Gas When one of the two operational trains loses, the increasing of compressed BOG flow rate to the one operational train will affect the flow rate of regeneration gas and the pressure of HP fuel gas header. Pressure rise of downstream of regeneration system results in insufficient deferential pressure at 031(032)-FV-1003 and 031(032)-FV-1005 to pass the required regeneration gas flow rate. Consequently the regeneration gas flow rate through both of control valves will not enable to be secured adequately. For this circumstance, reducing set point of 091(092)-PIC-1231 from 26.5 kg/cm2A to 25.8 kg/cm2A manually shall be required. The total regeneration gas flow will be recovered up to the normal flow rate accordingly. Refer to Section 5.8 in "Dynamic Simulation Fuel Gas System" (63-SDY-PS-1726) for more information.
6.3
Switch-over to Spare LP Fuel Gas KO Drum Since complete spare LP Fuel Gas KO Drum (063-D-1002B) is provided, LP fuel gas system can be operated continuously during 063-D-1002A maintenance. Switch-over to the spare is also required when the level control valve has a trouble even if the bypass valve is available. The system is considered not to isolate only the level control valve using its bypass valve.
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7.
NORMAL SHUTDOWN PROCEDURE
7.1
General
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 26 of 38
Fuel gas system is never totally shutdown since it is the most primary unit to operate the plant. Normal shutdown procedure is started with reducing feed rate and covers up to depressurizing of the system. Outline of the normal shut-down procedure is described below:
7.2
(1)
Decrease the feed rate.
(2)
Cutting off feed from the pipeline.
(3)
Isolating the system which is required for shutdown.
(4)
Depressurizing the systems by diverting gas to the wet flare, if necessary.
HP Fuel Gas System Normal Shutdown (One Train Shutdown) This section covers normal shutdown procedure where one of two LNG train is in scheduled shutdown and the other is being in operation. When Train-1 (Train-2) under min. turndown is going to scheduled shutdown from two LNG trains operation, the following steps are performed: (1)
Gradually close the compressed BOG flow control valve 090-FV-1051B (1051A) by manual. Meanwhile 090-FV-1051A (1051B) is controlled to maintain pressure of the BOG compressor discharge common header by 090-PIC-1051.
(2)
Set 090-HIC-1051(compressed BOG flow ratio to LNG Train-1) at 0.0 (1.0) when the flow rate of 090-FIC-1051B (1051A) is zero.
All compressed BOG is sent to Train-2 (Train-1) and excess gas shall bypass the dehydration unit through 032(031)-PCV-1213. The excess gas is combined with the wet regeneration gas at the overhead of the Regeneration Gas KO Drum 032(031)-D-1003. The mixed gas, namely HP fuel gas, will be sent to two Gas turbines in Train-2 (Train-1). The remaining gas shall be let down to LP fuel gas system by 092(091)-FV-1032. (3)
Gradually close the HP fuel gas let-down valve 091(092)-FV-1032 by manual. Meanwhile 092(091)-FV-1032 is controlled to maintain LP fuel gas pressure by 063-PIC-1032.
(4)
Set 063-HIC-1032 (LP fuel gas flow ratio to LNG Train-1) at 0.0 (1.0) when the flow rate of 091-FIC-1032 (092-FIC-1032) is zero.
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Decrease feed gas flow rate to Train-1 (Train-2) down to zero and ensure the train shutdown.
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
(6)
7.3
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 27 of 38
Isolate the system by closing manually the following ESD and isolation valves.
Tag No.
P&ID
031(032)-USVE-2903
31(32)-PID-PS-1157-S1
Service Dry sweet gas from 031(032)-Y-1002 to Regen gas system
12" Gate Valve at ABL 31(32)-PID-PS-1157-S1
Compressed BOG from compressed BOG header Unit 090 to LNG Train Unit 031(032)
031(032)-USVE-2910
Spent regen gas from HP fuel gas system to LP fuel gas system
91(92)-PID-PS-1153-S4
(7)
Draw off HC contaminated water in Regeneration Gas KO Drum (031(032)-D-1003) as much as possible by opening bypass valves around level control valve (031(032)-LV-1103) before the pressure falls too low, then block in control valves and its bypass valves.
(8)
Draw off HC contaminated water in HP Fuel Gas Mixing Drum (051(052)-D-1201) as much as possible by opening the level control valve (051(052)-LV-1131) before the pressure falls too low, then block in control valves.
(9)
Depressurize HP fuel gas system by opening 091(092)-USVD-2160, if necessary.
LP Fuel Gas System Normal Shutdown (Both Trains Shutdown) LP Fuel Gas System scheduled shutdown is allowed in case of total plant (both LNG Train-1 and Train-2) shutdown only. (1)
Decrease feed gas flow rate to the last operational train down to zero and ensure the LNG Train shutdown.
(2)
Isolate the system by closing the following manual valves at battery limit.
Tag No.
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P&ID
Service
10" Gate Valves at ABL 91/92-PID-PS-1153-S4
HP fuel gas from HP fuel gas system Unit 051/052 to interconnection line Unit 090
6" Gate Valves at ABL 21/22-PID-PS-1154
HP flash gas from amine HP flash drum Unit 021/022 to interconnection line Unit 090
4" Gate Valve at ABL
Overhead gas from condensate stabilizer Unit 011 to interconnection line Unit 090
11-PID-PS-1151
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 28 of 38
(3)
Draw off HC condensate in LP Fuel Gas KO Drum (063-D-1002A/B) as much as possible by opening bypass valves around level control valve (063-LV-1102/1171) before the pressure falls too low, then block in control valves and its bypass valves.
(4)
Depressurize LP fuel gas system by opening 063-PV-1202B which is connected to the wet flare, if necessary.
8.
EMERGENCY SHUTDOWN PROCEDURE
8.1
General Since the system supplies fuel gas to critical equipment in the plant, it is requested to shutdown the fuel gas system after the equipment is stopped safety at emergency conditions.
8.2
Partial Shutdown by Interlock Logic
8.2.1
Shutdown by Train-1(Train-2) Total Shutdown 091(092)-US-2000 When interlock 091(092)-US-2000 is initiated, following services will be shut off by USVE valves. -
Compressed BOG to the LNG Train-1(Train-2) by 031(032)-USVE-2511
-
Dry sweet gas to the regen gas system Unit 031(032) by 031(032)-USVE-2903
-
AGRU inlet gas to the HP fuel gas system Unit 051(052) by 091(092)-USVE-2910
-
HP fuel gas to LP fuel gas system Unit 063 by 091(092)-USVE-2920
-
Amine HP flash gas to LP fuel gas system Unit 063 by 021(022)-USVE-2040
Accordingly, following actions are required to mitigate upset conditions in HP and LP fuel gas systems. (1)
Put 092(091)-FIC-1032 (HP fuel gas to LP fuel gas system) in manual and adjust opening to maintain the LP fuel gas pressure.
(2)
Stabilized the system, set 063-HIC-1032 (let-down HP fuel gas flow ratio from LNG Train-1) 0.0 (1.0) and put 092(091)-FIC-1032 in cascade.
(3)
Put 090-FIC-1051A(1051B) (compressed BOG to LNG Train) in manual and adjust opening to maintain the compressed BOG header pressure.
(4)
Set 090-HIS-1051 (compressed BOG flow ratio to LNG Train-1) at 0.0 (1.0) and put 090-FIC-1051A(1051B) in cascade.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
8.2.2
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 29 of 38
Shutdown by Unit 021/031(022/032) Isolation 031(032)-US-2000A Since 031(032)-US-2000A initiates 051(052)-US-2400A, consequently this cause leads to same circumstance as described in Section 8.2.1.
8.2.3
Shutdown by Unit 041/051(042/052) Isolation 051(052)-US-2400A Since 051(052)-US-2400A initiates 031(032)-US-2000A, consequently this cause leads to same circumstance as described in Section 8.2.1.
8.3
Total Shutdown by Interlock Logic Initiation of Unit 016/011 isolation (016-US-2000A) leads to both LNG Train-1 and Train-2 in shutdown. For this circumstance, AGRU inlet gas supplied to LP fuel gas system is secured by forced opening 091/092-USVE-2929 to prevent simultaneous shutdown of HP and LP fuel gas systems. Therefore LP fuel gas system could be operated using isolated gas inventory in AGRU Unit 021/022 until the fuel gas source is exhausted.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
9.
SAFETY PROCEDURE
9.1
General
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 30 of 38
To prevent accidents it is of the utmost importance that all personnel be instructed properly of the following subject: -
The leaks and responsibilities of the operators
-
The methods to accomplish this in a safe manner
The following safety regulations cover operations of particular concern to the personnel responsible for the unit. They are intended to supplement any existing general plant safety regulations which cover all units; reference should be made to the latter for all points not mentioned below. Mechanical craftsmen working on their unit will be governed by their own departmental safety regulations, but the operator should see that none of the following safety regulations are violated by mechanical workers. In addition to specifically defined rules and practices, the exercise of good judgment by every person involved is essential to safe operation. An operator should be alert for any situation which might present a personnel hazard. It should also be the responsibility of each person familiar with the plant to warn other workers who enter the plant of possible hazards they could encounter. All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, and main isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other protective equipment such as hard hats, rubber gloves, etc. Soda acid or foam type extinguisher must not be used on fire around electrical equipment because the water solution will conduct electricity and may aggravate the difficulty or result in the electrocution of personnel. Carbon dioxide or dry powder extinguisher may be used safety on electrical fires. Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered. Safety hats must be worn when outdoors. Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid is encountered, and are recommended for use while samples are being withdrawn and solutions made up. Fire extinguishers must be recharged immediately after use. All stream and water hose equipment must be put back in place after use. Access to such equipment must not be obstructed.
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Gas masks must have fresh cartridges installed after use.
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9.2
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 31 of 38
Emergency Fire Plan The fire protection system of the plant is designed to prevent fire occurrence, control fire escalation, or extinguish fire within short period of time, assuming there will be no outside fire fighting assistance, with only one major fire at a time.
9.3
Fire Fighting and Protective Equipment Fire hazard status throughout the plant shall be monitored on the Hazard Detection and Monitoring System (HDMS (F&G)) consoles in the main control room and fire and emergency station. Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat radiation. For the detail, refer to 82-SPE-HS-1540 (S-082-1241-019), “Operation Manual for Fire Protection System” and the relevant drawings for fire protection system.
9.4
Maintenance of Equipment and Housekeeping (1)
(2) (3) (4) (5) (6) (7) (8)
(9)
9.5
Repair Work (1) (2) (3) (4)
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Operating equipment should be checked frequently for signs of leakage, overheating, or corrosion, so that unsafe conditions may be corrected before they result in serious consequences. Unusual conditions should be reported at once. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the equipment must be replaced when repair work is completed. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation equipment where they can be knocked off and injure someone below. Access to ladders and fire escapes must be kept clear. Waste material and refuse must be put in proper locations where they will not offer fire or stumbling hazards. Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediately report leaks for repair. In the event that electrical equipment does not function properly, notify the electrical department and stay clear of the equipment until the electrician arrives. Gas cylinders should be stored so that they cannot fall over. Guard caps must remain in place over the valves of cylinders, which are not in use. Care should be taken when installing scaffolding to ensure that the wooden boards do not contact hot equipment and that no part is allowed to impair free access on operational equipment e.g. ladders, stairways, walkways or valves. Scaffolding should be removed immediately on completion of the work in hand. Switch pumps regularly when spares are provided. This will assure start the spare pump will be ready when needed.
Mechanical work around and operating unit must be kept to a minimum, and the minimum number of men should be used. No mechanical work on the equipment is to be done without a properly authorized work permit. Safety hats must be worn by all personnel in all areas at all times. No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized by a work permit. Catch basins, manholes, and other sewer connections must be properly sealed off to prevent the leakage of gases, which may ignite upon contact with an open flame.
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
(5)
(6)
(7) (8) (9)
9.6
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 32 of 38
No personnel shall enter a vessel for any purpose whatsoever until it has been adequately purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases and an entry permit issued. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not physically strike these lines and avoid operation conditions, which would cause a water hammer to start. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other cleaning purposes. Equipment should not be left open overnight. At the end of each day’s work blanks or spades should be installed to prevent entry of flammable materials due to valve let-by. Welding cylinders should be removed from site to a designate safe area at the end of each working day.
Withdrawal of Samples Samples shall be withdrawn from the unit only by authorized personnel. Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. A container must never be filled to the brim, in order to minimize risk of subsequent spillage. When sampling any product liquids, gloves and goggles will be worn. When sampling any material, gas or liquid, the sampling line must be flushed long enough to remove dormant materials to insure that the sample obtained represents the current stream. Pass enough gas through the sample vessel to insure the displacement of the purge gas and to adjust the temperature of the sampler to that the composition is not distorted by condensation or flashing, etc. When the sample composition is representative of the source material, it shall not be distorted by flash vaporization. Certain classes of samples may require inert atmospheres, cooling or special carrying devices. Wear approved personal safety equipment and exercise caution to avoid injuries. When sample cooling is required, operator shall confirm cooling water is flowing properly before taking the sample.
9.7
Safe Handling of Volatile and Toxic Materials The safety rules given below are for the protection of life and limb, and the prevention of property loss. It is expected that plant people will exercise common sense, alertness, and good judgment in carrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consult your supervisor immediately.
9.8
Respiratory Protection Most plant gases, other than air, are harmful to human beings if inhaled in certain concentration. Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may cause death by replacing the air in the lungs or by reaction with the oxygen carried in the blood; examples are hydrogen sulfide carbon monoxide, and smoke. Irritating gases may cause injury or death not only by asphyxiating but also by burns internal and external/ examples are chlorine and sulfur dioxide. To guard against the inhalation of harmful gases:
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Secure a gas test certificate showing the gas condition of the vessel is safe for entry. Stand on the windward side of an operating from which gases escape. Provide proper ventilation. All personnel should become familiar with the accepted method of artificial respiration in order
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 33 of 38
to render assistance to any one overcome by gas, electric shock, or drowning. If anyone is overcome by gas, his rescuer should:
Never attempt a rescue unless an assistant is standing by. Protect himself before attempting a rescue by wearing breathing apparatus. Get the victim to fresh air as soon as possible. Give artificial respiration and send his assistant to call for medical aid.
When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approved test method. Wear the correct type of breathing apparatus, suited to the situation encountered. 9.9
Breathing Apparatus (B. A.) There are four types of breathing apparatus in general plant service. They are the canister type masks, the fresh air hose line B. A., the compressed air self-contained B. A. and the compressed air line trolley B. A. The compressed air self-contained breathing apparatus has a self-contained air supply carried on the back of the user. It is used principally in emergencies. After use, always notify the proper department so that they can recharge the cylinders as soon as possible.
9.9.1
Nitrogen N2 is an inert gas used for purging equipment or maintaining a positive pressure inert gas blanket on a vessel. N2 is neither poisonous nor flammable, but care must be exercised when working inside equipment that has been N2 purged. Adequate ventilation must be provided and appropriate breathing device worn. To breathe an atmosphere high in N2, could result in suffocation. Before entering vessels that have been purged with N2, a check must be made for proper oxygen content prior to entry. Rapid vaporization of liquid nitrogen can cause severe burns on contact with the skin.
9.9.2
Corrosive Materials Whenever containers of corrosive chemicals such as caustic soda and sulfuric acid, are to be opened or emptied, always have a connected water hose handy to flush off and help absorb spilled material and to reduce spread of toxic vapors.
9.9.3
Chemicals No specific chemicals are used in this system.
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10.
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 34 of 38
ISOLATION PROCEDURE FOR MAINTENANCE This section describes the isolation procedures to be taken prior to maintenance work based on the following specification: Maintainability Philosophy (99-PHI-EM-0005) Availability and Sparing Philosophy (99-PHI-PS-0002)
10.1
General It is necessary to isolate trains, items of equipment, or groups of equipment, in order to facilitate shutdown for maintenance, inspection, tie-ins, or loss prevention. As the degree of hazard increases, the measure of protection required must be deeply considered. The degree of hazard is related to the system contents (e.g. flammability, toxicity etc.), pressure and temperature. There are two main methods of isolation which can be used: Positive isolation incorporating the use of spades/spectacle blinds or removable spools and blind flanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entry or for creating safe construction areas within a plant. Valved isolation for less critical duties than those requiring positive isolation, e.g. for control valve maintenance. Valved isolation will also be required to enable positive isolation to be installed or removed without the need for a complete plant shutdown.
10.2
Basic Procedures The basic ideas for method of isolation are shown below. The details will be developed by Owner when actual isolation work will be required. The selection of type of isolation valve and blind/removable spools shall be in accordance with the applicable piping and material specifications. This section considers train or system requiring isolation followed by individual equipment isolation requirements. Sketches below are provided as an aid to develop actual planning for maintenance work.
10.2.1
Train Isolation Refer to Maintainability Philosophy (99-PHI-EM-0005) for Train isolation. Each train is capable of being isolated.
10.2.2
Individual Equipment / System Isolation
10.2.2.1 Horizontal and Vertical Pressure Vessels All vessels where manned entry may be required are provided with spectacle blinds or spade and spacer arrangements on every process inlet and outlet nozzles. Relief valve inlet lines from pressure vessels are normally positively isolated from the vessel by removing the relief valve and blinding the inlet line end. A typical arrangement is shown on Figure 9.2.1.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 35 of 38
Figure 9.2.1 Vertical Pressure Vessel
RELIEF VALVES AND FLARE
GAS OUTLET
VERTICAL VESSEL
INLET LINE
LIQUID OUTLET
10.2.2.2 Shell and Tube Heat Exchangers When removable spool pieces are provided on the piping associated with the tube side connections on shell and tube heat exchangers, the removal of these pieces should be don for the tube bundles for cleaning/maintenance. If required from the maintenance work nature, spectacle blinds will be provided.
Figure 9.2.2 Shell and Tube Heat Exchangers
TUBE SIDE INLET
SHELL SIDE OUTLET
RS
HEAT EXCHANGER SHELL & TUBE
TUBE SIDE OUTLET
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SHELL SIDE INLET
NOTE: BLOCK VALVES NOT REQUIRED IF EXCHANGER NOT SPARED OR BYPASSED
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
11.
MAINTENANCE PROCEDURE
11.1
General
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 36 of 38
INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT AIR FOR BREATHING APPARATUS.
Type of maintenance is classified in the following categories. 11.1.1
Routine/First line/ Maintenance Routine/First Line Maintenance is the daily on-line or off-line visual inspection, lubrication, calibration or minor adjustment of running and static equipment. In addition to the maintenance personnel carrying out the above types of checks/adjustments, the operator shall perform the following routine maintenance activities whilst carrying out his daily checks on the Plant, in order to prevent any minor problems developing into major ones: • • • • • • •
11.1.2
Tightening gland followers on leaking valve packing. Tightening gland followers on leaking pump packing. Checking temperature and pressure gauges for broken glass faces. Checking for correct oil levels in pumps, gearboxes, oil reservoirs. Topping up low oil levels in the above equipment as required. Cleaning pump filters and strainers. Keeping equipment clean and tidy.
Breakdown Maintenance For Breakdown Maintenance, there will be no scheduled checks or servicing. Corrective repairs will be carried out on failure of the Plant or equipment.
11.1.3
Planned Preventive Maintenance Planned Preventive Maintenance will be carried out on a calendar or running hours basis. It will be performed in accordance with the vendors’ recommended frequencies.
11.1.4
Predictive/Condition Based Monitoring Predictive/Condition based maintenance is the most efficient planning option. It uses direct observations and instrument readings for the monitoring of the actual condition of the Plant and equipment, and can trend and forecast when maintenance activities are due to take place.
11.1.5
Turnaround /Inspection Maintenance Turnaround/Inspection Maintenance will be carried out at approximately 3 yearly intervals, and usually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting of safety valves, and inspections and repairs of equipment that cannot be shutdown or removed during Production.
11.2
Precautions prior to Maintenance
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This section covers precautions prior to start maintenance work for a whole or a part of the plant.
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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 37 of 38
• All work must be carried out within the requirements of company Safety & Environmental Policies and Procedures. Prepare all known Work Permits, these must reflect safety issues. Obtain relevant permit to work before starting work. • Inform Operations of the work content of this preventive maintenance procedure and how it will affect them. • All rotating equipment is to be considered energized until proven isolated. • All vessels must be isolated, drained and vented. • Cordon the work area, to prevent unauthorized access. • Prior to commencement of this work ensure that moving/rotating/power generating/energy storing equipment has been isolated in accordance with the relevant permit to work and lock-out / tag-out requirements. • Physically isolate vessels. Only standard blank flanges and spades should be used. No person should enter a vessel unless all directly connected sources of process and utilities fluids have been positively isolated from the vessel. Entry means total body entry or any part of the body. • Operations should check for oxygen, taking samples at several representative places, with a portable analyzer to check for oxygen deficiency. • Prior to commencement of this work it is recommended that the crew will be briefed on what is required and what hazards there are. The crew will be reminded of the location of safety showers, first-aid boxes and telephones. • If welding or any process liable to evolve noxious fumes is to be carried out in the vessel, adequate ventilation should be provided. 11.3
Preparation for Maintenance
The outline of the work sequence begins as below. • • • •
11.3.1
Shutdown of the unit operation and liquid removal Inerting with nitrogen, if required. Installation of isolating blank flanges or spades Replacement with air for entry into the equipment
Installation of blank flanges or spades After inerting have been completed, isolating blank flanges or spades must be installed at locations as required.
11.4
Typical isolation method
11.4.1
Vessels/Drums • • • • • • •
11.4.2
Shell and Tube Type Heat Exchangers • • • • • •
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Erect scaffold for access as required. Operations to close down the system, depressurize and nitrogen purge. Mechanical to spade inlet and outlet nozzles of said equipment. Mechanical to open drum. Operations to air purge and check for oxygen level. Operations to clean. One person to enter another to stand by on watch.
Erect scaffold for access as required. Operations to close down the system and depressurize. Mechanical to swing spectacle inlet and outlet spectacle blinds. Electrical to lock out the three fan motors locally and remove relay/fuse in substation. Mechanical to open as required. Operations to air purge and check for oxygen level.
BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063
Doc. No.63-IOM-PS-1201 KJP Doc. No. S-063-1283-001 Rev. 6B Sheet No. 38 of 38
• Operations to clean
11.4.3
Close out • • • •
Ensure the equipment is left in a safe condition. Remove all tools and debris, clean local area. Note any faults found and comments. Raise a work request if any major corrective work is identified or the performance standards are not met during the above maintenance. • Sign off permit to work and inform area authority of equipment status.
12.
ATTACHMENT LIST
Attachment-1 Process Flow Diagram 63-UFD-PS-1200 63-UFD-PS-1201 63-UFD-PS-1202 63-UFD-PS-1203 63-UFD-PS-1204 63-UFD-PS-1205 63-UFD-PS-1206 63-UFD-PS-1207 63-UFD-PS-1208 63-UFD-PS-1209 Attachment-2 P&IDs 63-PID-PS-1201 63-PID-PS-1202 91-PID-PS-1153-S1 91-PID-PS-1153-S4 Attachment-3 Equipment Data Sheet (List only) 51-EDS-VM-1291 51-EDS-EX-1331 63-EDS-VM-1262 63-EDS-EX-1201 Attachment-4 Instrument Alarm Set Point (List only) 51-SPE-CS-1754 63-SPE-CS-1754 91-SPE-CS-1754 Attachment-5 Cause and Effect Charts (List only) 63-LOG-PS-1150 91-LOG-PS-1150 Attachment-6 Laboratory Sampling Schedule
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