Alarm & Trip Setting List (8)

Doc. No.

TANGGUH LNG BPMIGAS

BP Berau Ltd.

65-IOM-PS-1201

Rev.

Author’s Org.

6A

Project

TLNG

KJP

KJP Doc. No.

S-065-1283-001

Date

27 Feb, 06

KJP Job Code

J-3400-20-0000

Sheet

1 of 20

3.8 MTPA TRAIN CAPACITY Operation Manual for Air/Nitrogen System

X

Core

Non-core

For Information

For Review

For Approval

X

Released

Date

Page

Prep’d

Chk’d

App’d

5A

9Jan’06

All

For Approval

M.Hatanaka

Y.Kakutani

Y.Kakutani

All

Release

M.Hatanaka

Y.Kakutani

Y.Kakutani

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PT. Brown & Root Indonesia

A

As-Built

Rev.

6A 27Feb’06

Description

Lifecycle Code

BP App’d

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

CONTENTS 1. Introduction.................................................................................................................................4 2. Basis of Design.............................................................................................................................4 2.1 General ........................................................................................................................................4 2.2 Design Condition.........................................................................................................................4 2.2.1 INSTRUMENT AIR ....................................................................................................................... 4 2.2.2 UTILITY AIR ............................................................................................................................... 4 2.2.3 NITROGEN DATA ........................................................................................................................ 5 2.3 Special Equipment ......................................................................................................................5 2.3.1 AIR COMPRESSOR (065-C-1001A/B/C) ..................................................................................... 5 2.3.2 AIR DRIER PACKAGE (065-V-1001A/B).................................................................................... 5 2.3.3 NITROGEN GENERATOR PACKAGE (066-V-1001A/B/C) ........................................................... 5 2.3.4 LIQUID NITROGEN VAPORIZATION (066-V-1002A/B)............................................................... 5 2.3.5 LIQUID NITROGEN STORAGE (066-V-1003A/B) ........................................................................ 5 2.4 Process Description.....................................................................................................................6 2.4.1 AIR SYSTEM ............................................................................................................................... 6 2.4.2 NITROGEN SYSTEM .................................................................................................................... 6 2.4.2.1 Nitrogen Generation.......................................................................................................... 6 2.4.2.2 Liquid Nitrogen Storage & Vaporization.......................................................................... 6 3. Process Controls..........................................................................................................................7 3.1 Air System ...................................................................................................................................7 3.2 Nitrogen System ..........................................................................................................................7 4. Preparation for initial start-up ..................................................................................................8 5. Normal Start-up Procedure .......................................................................................................8 5.1 General ........................................................................................................................................8 5.2 Start up of the Air Compressors ...............................................................................................8 5.3 Start up of the Air Drier Package .............................................................................................8 5.4 Pressurization of Air System .....................................................................................................9 5.4.1 UTILITY AIR RECEIVER .............................................................................................................. 9 5.4.2 UTILITY AIR SYSTEM ................................................................................................................. 9 5.4.3 INSTRUMENT AIR SYSTEM ......................................................................................................... 9 5.4.4 BLEED AIR SYSTEM ................................................................................................................. 10 5.5 Start up of the Nitrogen Generation Package ........................................................................10 5.6 Pressurization of Nitrogen System ..........................................................................................10 6. Normal Operation.....................................................................................................................10 6.1 Back up Instrument Air by Nitrogen......................................................................................10 7. Normal Shutdown Procedure ..................................................................................................11 7.1 Air Compressor.........................................................................................................................11 7.2 Air Drier Package .....................................................................................................................11 7.3 Utility Air Receiver/Instrument Air Receiver........................................................................11 7.4 Nitrogen Package ......................................................................................................................11 8. Emergency Shutdown Procedure ............................................................................................11 8.1 General ......................................................................................................................................11 8.2 Loss of Utilities..........................................................................................................................11 8.2.1 POWER FAILURE ...................................................................................................................... 11 8.2.2 INSTRUMENT AIR FAILURE ...................................................................................................... 12 9. Safety Procedure .......................................................................................................................12 9.1 General ......................................................................................................................................12 9.2 Emergency Fire Plan ................................................................................................................13 9.3 Fire Fighting and Protective Equipment ................................................................................13 9.4 Maintenance of Equipment and Housekeeping .....................................................................13 9.5 Repair Work .............................................................................................................................14 9.6 Withdrawal of Samples ............................................................................................................14 9.7 Respiratory Protection .............................................................................................................15 9.8 Breathing Apparatus (B. A.)....................................................................................................15 9.8.1 NITROGEN ................................................................................................................................ 15

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10. Isolatiion Procedure for Maintenance.....................................................................................16 10.1 General ......................................................................................................................................16 10.2 Basic Procedures.......................................................................................................................16 10.2.1 TRAIN ISOLATION .................................................................................................................... 16 10.2.2 INDIVIDUAL EQUIPMENT / SYSTEM ISOLATION........................................................................ 16 10.2.2.1 Vertical Pressure Vessels ................................................................................................ 16 10.2.2.2 Shell and Tube Heat Exchangers .................................................................................... 17 11. Maintenance Procedure............................................................................................................17 11.1 General ......................................................................................................................................17 11.1.1 ROUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 18 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 18 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 18 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 18 11.1.5 TURNAROUND /INSPECTION MAINTENANCE ............................................................................ 18 11.2 Precautions prior to Maintenance...........................................................................................18 11.3 Preparation for Maintenance ..................................................................................................19 11.3.1 INSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 19 11.3.2 REPLACEMENT OF NITROGEN WITH AIR .................................................................................. 19 11.4 Typical isolation method ..........................................................................................................19 11.4.1 VESSELS/DRUMS ...................................................................................................................... 19 11.4.2 SHELL AND TUBE TYPE HEAT EXCHANGERS ........................................................................... 19 11.4.3 CLOSE OUT ............................................................................................................................... 20 12. Attachment List.........................................................................................................................20

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

1.

INTRODUCTION The purpose of Air System (Unit 065) is to produce clean, oil free and dry air for instrument air, utility air and feed air for nitrogen generation packages. The Air System consists of air/water coolers, air compressors, utility air receiver, instrument air drier and instrument air receiver. Bleed air from Frame 7 Gas turbines is used as primary air source of the air system. The purpose of Nitrogen System (Unit 066) is to produce the nitrogen for supplying dry gas seal, purging equipment during start-up and shutdown, make-up to the mixed refrigerant system and purging/blanketing miscellaneous equipment during normal operation. The Nitrogen System (Unit 066) consists of two major facilities: Nitrogen Generation and Liquid Nitrogen Storage & Vaporizer.

2.

BASIS OF DESIGN

2.1

General Bleed air from Frame 7 Gas turbine and air compressors provide clean, dry compressed air for instrument air and, wet compressed air, and feed to the nitrogen generation package. When the bleed air is not enough to supply for whole plant users, air compressor is operated as back up. During utility facilities are operating without both LNG trains operation, air source is only air compressors. Nitrogen generator packages produce gaseous nitrogen only to cover the continuous nitrogen requirement on the plant. High purity liquid nitrogen will be imported from others, then stored in the liquid nitrogen storage and vaporizer packages to cover other intermittent requirement such as purging during shutdown and startup of the train, etc.

2.2

Design Condition

2.2.1

Instrument Air

2.2.2

Supply temperature

Normal Design

50 65

°C °C

Supply pressure

Minimum Design

4.2 10.510.8

kg/cm2G kg/cm2G

Dew point at normal pressure:

-40 °C @Atmospheric Pressure

Utility Air Supply temperature

Normal Design

50 65

°C °C

Supply pressure

Normal Design

8.9 10.510.8

kg/cm2G @ 065-PT-1201 kg/cm2G

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

2.2.3

2.3

Nitrogen Data Supply temperature

Normal Back-up Design

50 °C 20 (min.1) °C 65 °C

Supply pressure

Normal Design

6.0 10.8

Purity:

Max. 0.5% Oxygen

kg/cm2G @Source kg/cm2G

Special Equipment Refer to each equipment data sheet for details (Attachment 3).

2.3.1

Air Compressor (065-C-1001A/B/C) Air compressors to backup air supply are provided. Number of package: Type: Capacity:

2.3.2

Three Screw type, oil free 2000Nm3/h for each

Air Drier Package (065-V-1001A/B) Two 100% air drier packages to generate instrument air are provided. Number of package: Type: Capacity:

2.3.3

Two Pressure Swing Adsorption 2560Nm3/h for each

Nitrogen Generator Package (066-V-1001A/B/C) Three 50% nitrogen generator packages to generate gaseous nitrogen are provided. Number of polisher: Type: Capacity:

2.3.4

Three Pressure Swing Adsorption 480Nm3/h for each

Liquid Nitrogen Vaporization (066-V-1002A/B) Two liquid nitrogen vaporizer trains are provided to vaporize liquid nitrogen to backup gaseous nitrogen. Number of vaporizer train: Heat source: Vaporizing Rate: Continuous operation:

2.3.5

Two Air 3000Nm3/h for each train 10 hours per train

Liquid Nitrogen Storage (066-V-1003A/B) Two liquid nitrogen storage vessels are provided to store liquid nitrogen. Number of vessels: Holding capacity:

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Two 100m3 per vessel

BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

2.4

Process Description

2.4.1

Air System

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Compressed air at 9.5 kg/cm2G and 374 oC supplied from compressor of Frame-7 Gas Turbines in process trains is cooled down to 50 oC by Air/Water Cooler (065-E-1001A/B). The cooled air is combined with compressed air from Air Compressors (065-C-1001A/B/C), if required, and then routed to Utility Air Receiver (065-D-1001) at 9.0 kg/cm2G and 50oC. The purpose of this receiver is mainly to remove free water which may come from the air compressors and bleed air from gas turbines, and also to stabilize utility air pressure before distribution to the system by acting as a surge vessel. Normally, the bleed air control valve is used for balancing all air requirements. Each gas turbine bleed is limited by restriction orifice with the maximum bleed flow at 2000 Nm3/hr. In the discharge line of utility air receiver is equipped with low pressure sensing which will start the stand-by air compressors automatically. From utility air receiver, a portion of compressed air flows to Air Drier Package (065-V-1001A/B) at 8.9 kg/cm2G and 50oC. The air drier is regenerative heatless (Pressure Swing) and desiccant type. The air drier consists of twin drier vessels charged with desiccants, one pre-filter and one after-filter. The moisture content is reduced by passing the air through a drier vessel containing adsorbing desiccant vessels, with each vessel being regenerated alternately. Normally one air drier is in operation with one standby. Dry air from the air drier is routed to the Instrument Air Receiver (065-D-1002) at 8.1 kg/cm2G and 50oC. Instrument air receiver is used to provide a storage place for instrument air before utilized by pneumatically operated instruments and valves and also to stabilize instrument air pressure before distribution to the system by acting as a surge vessel for 5 minutes. Instrument air from the instrument air receiver flows to the instrument air distribution system at 8.0 kg/cm2G and 50oC. Instrument air is distributed through the headers to the instrument air consumers. The instrument air header basically is designed for 3 (three) trains capacity. Instrument air distribution system pressure is controlled by sequentially starting standby air compressor automatically and cutting off the feed to the utility air system and nitrogen system. From utility air receiver, the compressed air connection line to nitrogen generation package will be provided. Utility air from the utility air receiver flows to utility air distribution system. The utility air header basically is designed for 3 (three) trains capacity. The utility air system supplies compressed air for utility hose stations. 2.4.2

Nitrogen System

2.4.2.1

Nitrogen Generation Gaseous nitrogen is produced by Nitrogen Generator Packages (066-V-1001A/B/C) using pressure swing adsorption (PSA) type. These three 50% capacity Nitrogen Generators (2 normal operation and 1 spare) are designed to produce 480 Nm3/h of about 99.5% gaseous nitrogen (GAN) for each generator, which is expected could cover the continuous nitrogen requirement of the plant. Compressed air at 7.58.0 kg/cm2G and 50 oC flows to nitrogen generator packages normally. The nitrogen is separated from air in nitrogen generator packages by means of adsorption process, which selectively adsorbs oxygen, moisture and carbon dioxide. The gaseous nitrogen flows from nitrogen generator package to nitrogen distribution system at 6.56.0 kg/cm2G and 50oC.

2.4.2.2

Liquid Nitrogen Storage & Vaporization

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High purity liquid nitrogen (LIN, less than about 200 ppm O2 content) will be imported from others and stored in Liquid Nitrogen Storage (066-V-1003A/B).

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

The storage will supply nitrogen during period of intermittent peak demand when the gaseous nitrogen production is not adequate, by means of pressure controller installed on the discharge line of vaporizer connected to the gaseous nitrogen header. Liquid Nitrogen Vaporization Package (066-V-1002A/B) will vaporize liquid nitrogen before flowing to nitrogen distribution system at 6.0 kg/cm2G and 20oC normally (minimum 1oC). The nitrogen boil off gas from liquid nitrogen storage tanks of about 0.1% volume per day is released through the self-actuated pressure controllers to atmosphere. In the discharge line of the Liquid Nitrogen Vaporizer, a shut off valve is provided to protect the gaseous nitrogen distribution from low-low temperature.

3.

PROCESS CONTROLS

3.1

Air System Normally, the bleed air from Gas Turbines (051/052-CG-1001/1002) is used as primary feed of the air system and all air compressors are on stand-by. The compressed air pressure controller (065-PIC-1201) controls bleed air pressure to keep 8.9kg/cm2G by the pressure control valve (065-PV-1201) installed on upstream of Air/Water Coolers (065-E-1001A/B). When the air pressure at Utility Air Receiver (065-D-1001) outlet is decreased, the air compressors will be stared automatically in order by the air compressor PLC that set pressure is 8.0kg/cm2G. It is the basic control philosophy of this unit to give priority to the instrument air supply for pneumatic control devices as long as possible. When the compressed air line pressure decreases below 7.5kg/cm2G for any reason, the other compressed air pressure controller (065-PIC-1201B) reduces or stops utility air consumption by closing the pressure control valve (065-PV-1202) installed on the utility air header. In addition, the nitrogen system feed is cut by 065-USV-2810 when the pressure in the instrument air header decreases below 6.0 kg/cm2G. When the pressure in the instrument air header decreases below 4.6 kg/cm2G, the nitrogen back up is automatically started from the liquid nitrogen system. 065-US-2800 opens 065-USV-2800 and starts to control the pressure control valve 065-PV-1203, which operating pressure is 5.5 kg/cm2G. Permissive to start the nitrogen back up is initiated only when nitrogen pressure is higher than instrument air pressure. Air System Pressure Control

3.2

Tag No.

Set Point

Control

065-PIC-1201A

8.9 kg/cm2G

Extraction air pressure control (065-PV-1201)

065-PAL-2700

8.0 kg/cm2G

Start stand-by air compressors (065-C-1001A/B/C)

065-PIC-1201B

7.5 kg/cm2G

Utility air supply restriction (065-PV-1202)

065-US-2810

6.0 kg/cm2G

Nitrogen feed air cutting (065-USV-2810)

065-US-2800

4.6 kg/cm2G

Nitrogen backup start (065-USV-2800/065-PV-1203)

065-PIC-1203

5.5 kg/cm3G

Backup nitrogen pressure control (065-PV-1203)

Nitrogen System For detailed control philosophy of the Nitrogen Package (066-V-1001A/B/C) refer to the vendor operation manual (066-VDR-LND-1802).

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Liquid nitrogen is vaporized in the vaporizer and discharged to the distribution header piping from the package. The liquid nitrogen system has a pressure controller at outlet of the vaporizer and controls the flow rate from the liquid holder to the vaporizer in order to maintain the discharge pressure of the gaseous nitrogen. The setting of the pressure controller (066-PIC-1202) is 6.0 kg/cm2G. Nitrogen distribution header has a flow meter to check the total consumption. The liquid nitrogen storage also has a small vaporizer, which heat source is air, and pressure control devices to maintain the operating pressure of the liquid nitrogen holder. When the holding pressure increases, some of the vapor nitrogen in the holder is discharged to the atmosphere. When the pressure decreases, some of the liquid nitrogen is vaporized and introduced into the vapor space in the holder.

4.

PREPARATION FOR INITIAL START-UP Refer to Commissioning Procedure (65-PRC-OP-1001 / 66-PRC-OP-1001).

5.

NORMAL START-UP PROCEDURE

5.1

General Check points are as follows: (1) All equipment including instrument, etc. is ready for use. (2) Electric power is available. (3) All blinds or spectacle blinds except for Battery Limit have been placed in operation position. (4) Ensure all vents, drains, and sample connections are closed. (5) All safety equipment must be properly installed on site, calibrated and operable. After all the above checkpoints are checked, start up the Air/Nitrogen System. Section 5.4 to 5.6 should be followed in order to start up the Air/Nitrogen System.

5.2

Start up of the Air Compressors Until the extraction air from Gas turbines (051/052-CG-1001/1002) is available, air compressors shall supply compressed air to operating facilities. Start one Air Compressor (065-C-1001A or B) locally using emergency power. For the start up procedure of the Air Compressor (065-C-1001A/B/C), refer to the vendor operation manual 065-VDR-ACC-9801. Even if the gas turbines start to operate, the extraction air pressure will not be sufficient for feeding to air system because of low operation load of the gas turbines during LNG train start-up period. Therefore, air compressors will be continuously operated by the extraction air pressure is sufficient for feeding.

5.3

Start up of the Air Drier Package Start Air Drier Package (065-V-1001A/B) locally. Normally one drier train is operating and the other train is stand-by.

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For the start up procedure of the Air Drier Package (065-V-1001A/B), refer to the vendor operation manual (Later065-VDR-ACD-1800). 5.4

Pressurization of Air System

5.4.1

Utility Air Receiver (1)

Prior to starting the Air Compressor, ensure that plant condition is as follows: - Block and bypass valves for 065-PV-1201 on extraction air line and 065-PV-1202 on utility air lien are closed. - Isolation valves for the air/water cooler (065-E-1001A/B) are closed. - Block valves at the Air Dryer Package (065-V-1001) inlets are closed. - 065-USV-2810 on compressed air line for nitrogen feed is closed. - Isolation valve of nitrogen backup line is closed. - Block valve at the instrument air receiver (065-D-1001) outlet is closed.

5.4.2

(2)

Start one of the air compressors according to the vendor operation manual 065-VDR-ACC-9801.

(3)

Introduce air into Utility Air Receiver (065-D-1001) and pressurize the receiver.

(4)

Observe and ensure if the air trap at the bottom of the receiver operates correctly.

Utility Air System (1)

5.4.3

Instrument Air System

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Gradually open the bypass valve of compressed air low pressure control valve (065-PV-1202) on utility air supply line and introduce utility air into the header piping.

(1)

Introduce compressed air into the drier, and operate the drier according to the vendor operation manual (065-VDR-ACD-1800later).

(2)

Introduce the dried air into Instrument Air Receiver (065-D-1002) and pressurize the receiver.

(3)

Observe and ensure if the drier automatically operates (switching desiccant vessels).

(4)

Slightly open the drain valve and vent valve of Instrument Air Receiver (065-D-1002) and continue opening until the discharged air becomes dry by use of dew point analyzer in the drier package.

(5)

Gradually open the block valve at outlet of Instrument Air Receiver (065-D-1002) to introduce dried air into the instrument air header piping.

(6)

Open vent valves at the ends of header piping to dry out the instrument air header piping to replace wet air with dry air. After drying out, close the vent valves.

(7)

Put compressed air low pressure control valve (065-PV-1202) on utility air supply line in service when the instrument air becomes dry and open the block valves and close the bypass valve of the 065-PV-1202.

(8)

Line up the discharge valve of the stand-by compressors for ready in service. Local control board of the stand-by compressors is set to receive the signal of auto start.

(9)

When liquid nitrogen is ready in the nitrogen system after instrument air system is in operation, open isolation valve to start nitrogen backup and put 065-US-1305 in service.

BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

5.4.4

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Bleed Air System Bleed air shall be extracted from gas turbines after establishing the gas turbine stable operation.

5.5

(1)

Confirm the extraction air pressure is sufficient for feeding air system (over 10.5kg/cm2G).

(2)

Introduce cooling water to Air/Water Cooler (065-E-1001A/B) and confirm the water is flowing.

(3)

Put 065-US-1304 for air temperature high-high trip system in service.

(4)

Open ESD valve on extraction air line at outlet of the gas turbine.

(5)

Gradually open manual valve at downstream of the ESD valve to introduce the extraction air to extraction air header.

(6)

Put extraction air pressure control valve (065-PV-1201) on the extraction air line in service.

(7)

Isolation valves of the cooler (065-E-1001A/B) are gradually opened.

(8)

Observe and ensure if the air traps at the downstream of the coolers operate correctly.

(9)

Air compressors are stopped and changed to stand-by mode, if required.

Start up of the Nitrogen Generation Package For the start up procedure of the Nitrogen Generation Package (066-V-1001A/B/C), refer to the vendor operation manual (066-VDR-LND-1802).

5.6

Pressurization of Nitrogen System After start-up of the Nitrogen Generation Package, nitrogen is introduced into the distribution header and the system is pressurized.

6.

(1)

Open drain valves at the end of each branch of the header piping.

(2)

Slightly open the block valve at the outlet of the package and introduce nitrogen into the system.

(3)

Continue purging air away with nitrogen in each branch until the vented gas becomes dry and the oxygen content becomes less than 0.1%.

(4)

Close the drain valves at each end of the header piping and pressurize the header piping.

(5)

Ensure that the operating pressure of the header is controlled by the pressure controller in the vendor package.

NORMAL OPERATION The unit is normally controlled automatically but requires operator to monitor process conditions.

6.1

Back up Instrument Air by Nitrogen Instrument air system has many protections to continue plant safety operation. The final protection is nitrogen backup to shutdown whole plant safely. In this case, DCS alarm 065-USA-2800 will be initiated to warn the emergency nitrogen backup start.

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ALL OPERATORS SHALL BE WARNED THAT WHEN NITROGEN BACKUP IS STARTED, INSTRUEMNT AIR SYSTEM INCLUDES NITROGEN. NEVER USE INSTRUMENT AIR FOR BREATHING APPARATUS.

7.

NORMAL SHUTDOWN PROCEDURE An entire shutdown of the air/nitrogen systems is only possible during the whole plant shut down. However equipment or sections of line may require periodically shutdown for maintenance or an inspection. In that case, only the equipment or the sections shall be isolated.

7.1

Air Compressor For shutdown procedure of the Air Compressors (065-C-1001A/B/C), refer to the vendor operation manual (065-VDR-ACC-9801).

7.2

Air Drier Package For shutdown procedure of the Air Drier Package (065-V-1001A/B), refer to the vendor operation manual (065-VDR-ACD-1800Later).

7.3

Utility Air Receiver/Instrument Air Receiver When the maintenance for Utility Air Receiver (065-D-1001) / Instrument Air Receiver (065-D-1002) is carried out, the following isolation is required:

7.4

(1)

Open the bypass valve across the vessel and close the block valves on inlet and outlet of the vessel.

(2)

Insert temporary blind at inside of the inlet and outlet block valves of vessel.

Nitrogen Package For shutdown procedure of the Nitrogen Generation package (066-V-1001A/B/C), refer to the vendor operation manual (066-VDR-LND-1802).

8.

EMERGENCY SHUTDOWN PROCEDURE

8.1

General This section describes the guidelines of shutdown procedure in case of emergencies. However, in emergencies, required actions by operators may vary because they depend on the actual situation at the time of emergency. Therefore, it is most important for the operators to determine the cause of emergency accurately and to understand the exact situation. These units supply instrument air and instrument air backup nitrogen to all users. Therefore, these units are required to be operated as long as possible even in emergency situations.

8.2

Loss of Utilities

8.2.1

Power Failure

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When a total power failure occurs and it is impossible to restore the power in a short time, shutdown the whole plant. Air compressors (065-C-1001A/B) will be re-started automatically by emergency

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power. Even if the air compressors are not started by emergency power, instrument air is available by the buffer volume of the Instrument Air Receiver (065-D-1002) for 5 minutes. And finally back up vaporized liquid nitrogen will be introduced in the instrument air system automatically, when required. 8.2.2

Instrument Air Failure Air System The air compressors (065-C-1001A/B/C) and the drier package (065-V-1001A/B) can operate without external instrument air source and the system can supply dried air to the instrument air header. Therefore, instrument air failure is not applicable. However, following valves will be closed in case of an individual air failure. 065-PV-1202 on the utility air header will be closed and the utility air supply to plant header will be stopped. 065-PV-1201 on the bleed air line will be closed and the bleed air will be stopped. The back up air compressors will be started automatically. Nitrogen System When instrument air failure occurs, feed air is cut by closing control valve in the package and gaseous nitrogen generation is stopped accordingly. As long as the Liquid Nitrogen Storage (066-V-1003A/B) is holding liquid nitrogen, the supply of nitrogen will be continued.

9.

SAFETY PROCEDURE

9.1

General 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.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 13 of 20

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. Gas masks must have fresh cartridges installed after use. 9.2

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.

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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

BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

3. 4. 5. 6. 7. 8.

9.5

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.

Repair Work 1. 2. 3. 4.

5.

6.

7. 8. 9.

9.6

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 14 of 20

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. 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

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 15 of 20

adjust the temperature of the sampler to that the composition is not distorted by condensation or flashing, etc. Wear proper personal protective equipment and exercise caution to avoid injuries. 9.7

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:

„ „ „ „

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 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. 9.8

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.

9.8.1

Nitrogen N2 is an inert gas used for purging equipment or maintaining a positive pressure inert gas blanket on a vessel.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 16 of 20

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.

10.

ISOLATIION 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 Vertical Pressure Vessels All vessels where manned entry may be required are provided with temporary blind 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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Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 17 of 20

BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

Figure 10.2.1 Vertical Pressure Vessel

RELIEF VALVES AND FLARE

GAS OUTLET

VERTICAL VESSEL

INLET LINE

DRAIN TO ATM

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 done for the tube bundles for cleaning/maintenance.

Figure 10.2.2 Shell and Tube Heat Exchangers

TUBE SIDE INLET

SHELL SIDE OUTLET RS

HEAT EXCHANGER SHELL & TUBE RS

TUBE SIDE OUTLET

SHELL SIDE INLET

11.

MAINTENANCE PROCEDURE

11.1

General INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT AIR FOR BREATHING APPARATUS.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 18 of 20

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. Checking temperature and pressure gauges for broken glass faces. Checking for correct oil levels in compressors, 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

This section covers precautions prior to start maintenance work for a whole or a part of the plant. • 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.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 19 of 20

• 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 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. 11.3

Preparation for Maintenance

The outline of the work sequence begins as below. • Shutdown of the unit operation • Installation of isolating blank flanges or spades • Replacement with air for entry into the equipment, if required

11.3.1

Installation of blank flanges or spades Isolating blank flanges or spades must be installed at locations as required.

11.3.2

Replacement of Nitrogen with Air Replacement of nitrogen gas with air and safety test for equipment must be performed prior to permitting entry. (1)

Connect temporary air hoses at the appropriate location with utility air or instrument air if required.

(2)

Open the top vent valves and drain off valves to atmosphere of the equipment.

(3)

Introduce air to displace/purge nitrogen gas to atmosphere.

(4)

Continue to purge until oxygen contents are higher than 20% at all point.

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. Mechanical to open as required. Operations to air purge and check for oxygen level. Operations to clean

BP Berau Ltd. Tangguh LNG Project Operation Manual for Air/Nitrogen System

11.4.3

Doc. No. 65-IOM-PS-1201 KJP Doc. No. S-065-1283-001 Rev. 6A Sheet No. 20 of 20

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 ProcessUtility Flow Diagram (To be attached in As Built) Attachment-2 P&IDs (To be attached in As Built) Attachment-3 List of Equipment Data Sheet (To be attached in As Built) Attachment-4 List of Instrument Alarm Set Point (To be attached in As Built) Attachment-5 List of Cause and Effect Charts (To be attached in As Built) Attachment-6 Laboratory Sampling Schedule

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