Cause and Effect Chart (3)

Doc. No.

TANGGUH LNG BPMIGAS

BP Berau Ltd.

76-IOM-PS-1201

Rev.

Author’s Org.

6A

Project

TLNG

KJP

KJP Doc. No.

S-076-1283-001

Date

26 June, 06

KJP Job Code

J-3400-20-0000

Sheet

1 of 31

3.8 MTPA TRAIN CAPACITY Operation Manual for HC Condensate Storage and Loading

X

Core

Non-core

Lifecycle Code

For Information

For Review

For Approval

X

Released

As-Built

Rev.

Date

Page

Description

Prep’d

Chk’d

App’d

5A

23Feb06

all

For Approval

Suharyono

T. Bessho

M. Ditto

6A 26June06

all

Released

T.Bessho

Y.Kakutani

Y.Kakutani

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PT. Brown & Root Indonesia

A

BP App’d

BP Berau Ltd. Tangguh LNG Project Operation Manual for HC Condensate Storage and Loading

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 2 of 31

CONTENTS 1 2

Introduction.................................................................................................................................4 BASIS OF DESIGN ....................................................................................................................4 2.1 General.........................................................................................................................................4 2.2 Condensate Storage Tank (076-TK-1001) ................................................................................4 2.3 Condensate Loading Pump (076-P-1001 A/B) ..........................................................................5 2.4 Condensate Metering System (076-V-1002)..............................................................................5 2.5 Condensate Loading Arm (076-V-1001) ...................................................................................5 3 PROCESS DESCRIPTION .......................................................................................................5 3.1. General.........................................................................................................................................5 3.2. Condensate Rundown System....................................................................................................5 3.3. Condensate Storage Tank 076-TK-1001 ...................................................................................6 3.4. Condensate Loading System ......................................................................................................7 3.4.1 CONDENSATE LOADING PUMPS 076-P-1001 A/B....................................................................... 7 3.4.2 SHIP LOADING FACILITIES.......................................................................................................... 7 4.1 General.........................................................................................................................................9 4.2 Start-up Procedure .....................................................................................................................9 4.2.1 HC CONDENSATE FILLING TO STORAGE TANK .......................................................................... 9 5.1 General.......................................................................................................................................10 5.2 Normal Operation Procedure ..................................................................................................11 5.2.1 INTRODUCTION ......................................................................................................................... 11 5.2.2 TANK OPERATION .................................................................................................................... 11 5.2.3 SHIP LOADING OPERATION ...................................................................................................... 11 5.2.3.1 Introduction .................................................................................................................... 11 5.2.3.2 ESD Check ..................................................................................................................... 11 5.2.3.3 Start Loading Operation ................................................................................................. 12 5.2.3.4 Loading Operation ......................................................................................................... 13 5.2.4 OPERATING VARIABLES ........................................................................................................... 14 5.2.5 PROCESS CONTROL .................................................................................................................. 14 5.2.5.1 Minimum Flow Control for the Condensate Loading Pumps ........................................ 14 5.2.5.2 Condensate Analyzer ..................................................................................................... 14 6. QUALITY CONTROL.............................................................................................................14 7. NORMAL SHUTDOWN PROCEDURE ...............................................................................15 7.1 General Overall Shutdown Plan..............................................................................................15 7.2 Detailed Step-By-Step Procedure ............................................................................................15 7.2.1 ESD CHECK OF SHIP LOADING OPERATION ............................................................................. 15 7.2.2 NORMAL MAINTENANCE/SHUTDOWN OF STORAGE/LOADING FACILITIES .............................. 16 7.2.3 NORMAL STOP OF LOADING OPERATION ................................................................................. 16 8. EMERGENCY SHUTDOWN .................................................................................................16 8.1 General.......................................................................................................................................16 8.2 Power Failure ............................................................................................................................17 8.3 Instrument Air Failure .............................................................................................................17 8.4 Fires/Serious Leakage...............................................................................................................17 8.5 Equipment Failure ....................................................................................................................18 8.5.1 PUMPS ...................................................................................................................................... 18 8.5.2 LOADING ARM ......................................................................................................................... 18 8.6 Emergency Shutdown System..................................................................................................20 8.6.1 CONDENSATE LOADING SHUTDOWN ........................................................................................ 20 8.6.2 TANK ISOLATION...................................................................................................................... 21 9. Safety Procedure .......................................................................................................................21 9.1. General.......................................................................................................................................21 9.2. Hazardous Material..................................................................................................................22 9.3. Emergency Fire Plan ................................................................................................................22 9.4. Fire Fighting and Protective Equipment ................................................................................23 9.5. Maintenance of Equipment and Housekeeping......................................................................23 9.6. Repair Work..............................................................................................................................23

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9.7. Withdrawal of Samples ............................................................................................................24 9.8. Safe Handling of Volatile and Toxic Materials ......................................................................24 9.9. Respiratory Protection .............................................................................................................24 9.10. Breathing Apparatus (B. A.)....................................................................................................25 10. Isolation Procedure for Maintenance......................................................................................26 10.1. General ......................................................................................................................................26 10.2. Basic Procedures.......................................................................................................................26 10.2.1 Individual Equipment / System Isolation....................................................................................26 10.2.1.1 Tanks....................................................................................................................................26 10.2.1.2 Pumps ..................................................................................................................................27 11. Maintenance Procedure............................................................................................................28 11.1. General ......................................................................................................................................28 11.1.1 ROUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 28 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 28 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 28 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 28 11.1.5 TURNAROUND /INSPECTION MAINTENANCE ............................................................................ 29 11.2. Precautions prior to Maintenance...........................................................................................29 11.3. Preparation for Maintenance ..................................................................................................29 11.3.1 INSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 29 11.3.2 REPLACEMENT OF NITROGEN WITH AIR .................................................................................. 30 11.4. Typical isolation method ..........................................................................................................30 11.4.1 TANKS ...................................................................................................................................... 30 11.4.2 PUMPS ...................................................................................................................................... 30 11.4.3 CLOSE OUT ............................................................................................................................... 30 12. Attachment List.........................................................................................................................31

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1

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 4 of 31

INTRODUCTION The purpose of Unit 076 of Condensate Storage and Loading Facilities is to receive and store the stabilized condensate from the Condensate Stabilization (Unit 011) and Fractionation Unit (Unit 041 & 042), as well as transfer it to ship loading facility located at Combo Dock. All hydrocarbon condensate produced in Tangguh LNG Facility is mainly for export via ship suitable for condensate service. Unit 076 consists of the following major equipment: •

076-TK-1001

Condensate Storage Tank.

•

076-P-1001 A/B

Condensate Loading Pumps.

•

076-V-1002

Condensate Custody Metering System.

•

076-V-1001

Condensate Loading Arm.

2

BASIS OF DESIGN

2.1

General Condensate rundown line and Condensate Storage Tank (076-TK-1001) are designed to handle condensate production for three-3.8 MTPA LNG trains. The condensate is produced in the Condensate Stabilization Unit (Unit 011) and the Debutanizer Column bottom of Units 041 & 042. All streams, then, are combined into a common rundown line and stored in the Condensate storage Tank (076-TK-1001) prior to condensate loading to ship. Condensate rundown line is designed to handle condensate production for 3 LNG trains. The condensate enters the storage tank (076-TK-1001) at atmospheric pressure and 39.6 oC. In the initial two-process operation,The flow rate is expected for 51.0 m3/h. During pipeline pigging operation, condensate flow will increase to 51.2 59.2 m3/h. The condensate RVP and Butane content meet the requirement of condensate specification set out in Project Design Data of 900-DBS-EM-0001 (RVP 0.77 kg/cm 2 A @ 37.8 oC and maximum Butane content 0.5 vol. %).

Detail information refers to Process Flow Diagram Unit 076, Condensate Storage & Loading, Drawing no. 76-UFD-PS-1200.

2.2

Condensate Storage Tank (076-TK-1001) Condensate Storage Tank (076-TK-1001) is an internal floating roof atmospheric tank. The tank nominal capacity is 21,120 m3, and tank-working capacity is selected at 19,080 m3. Design pressure of the tank is atmospheric with design temperature of 20 oC /45 oC. Detail information of this tank is described in the corresponding tank data sheet doc. no. 76-EDS-VM-1351.

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2.3

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 5 of 31

Condensate Loading Pump (076-P-1001 A/B) Condensate Loading Pumps (076-P-1001 A/B) are operated in parallel (no spare philosophy) 2 x 50 % for intermittent service. Each pump has a rated capacity of 750 m3/h. Therefore, the total capacity of condensate loading rate is 1500 m3/h, which capacity is based on the assumption of 12 hours loading duration. Differential head is determined at 112 m, which corresponds to 8.07 kg/cm 2 of differential pressure. At 1,500 m3/h, the loading time typically will be 12 hours, but will vary accordingly to ship size. For details, refer to the pump data sheet of doc. no. 76-EDS-MC-1401.

2.4

Condensate Metering System (076-V-1002) A skid mounted custody transfer metering system is provided to verify the condensate ship loading. Flows are corrected for pressure, temperature and are totalized. The totalized flow, then, is indicated in the DCS along with pressure and temperature. Turbine type flow meter is selected for this purpose. For details, refer to Condensate Metering System Specification (99-SPE-CS-1750).

2.5

Condensate Loading Arm (076-V-1001) During condensate loading to tanker ship, a skid mounted Condensate Loading Arm (076-V-1001) is used to transfer condensate into the ship. Nominal size of loading arm is 10 inch. The loading arm is equipped with Hydraulic Power Unit, accumulator unit, gear pump (drain pump unit), and associated instrumentation and electrical system.

The loading arm is manually operated. The arm is provided with brake cylinders for inboard and outboard drives to prevent the arm from falling down or falling upside down rising rapidly after emergency decoupling in full of fluid or in empty condition respectively. These brake cylinders are able to used for maneuvering the arm by hydraulic power in re-connecting operation and maneuvering operation in normal condition except slewing.

3

PROCESS DESCRIPTION

3.1.

General The Rundown, Storage and Loading Facilities are shown on process flow diagram 76-UFD-PS-1200 and piping & instrumentation diagram 76-PID-PS-1201/ 1211/ 1212.

3.2.

Condensate Rundown System 8 inch nominal pipe size of condensate rundown line is installed from the Condensate Stabilization Unit (unit 011) down to condensate storage area (unit 076) with approximately 2.5 km long runs. A PSV having size of ¾ ” x 1” is placed upstream of shutdown valve 076-USVE-2030, which is provided for thermal relief case. The shutdown valve is intended to isolate Condensate Storage Tank

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(076-TK-1001) caused by High-High Liquid Level (HHLL) inside the tank. In this case, tank HHLL signal sent from either 076-LT-1101 or and 076-LT-1102 (2 out of 2 voting) will initiate 076-US-2040 to close the shutdown valve of 076-USVE-2030. Closing the shutdown valve is also enabled from manual ESD switch (076-HS-2030A) at MCR (Main Control Room) whenever required.

3.3.

Condensate Storage Tank 076-TK-1001 The tank has an internal floating roof of aluminum alloy material. Automatic bleeder vent and emergency roof drain are installed on the floating roof to protect the tank from over pressure and rainwater respectively. In addition to the above, a center vent with screen is employed to ensure atmospheric pressure condition inside the tank. The tank is also provided with an air foam distribution system comprising air foam chamber, deflector and riser pipe.

The tank is provided with water drain system. This enables the removal of any water accumulated within the tank.

During normal operation, a little water is expected to be in the condensate. Water in the tank is detected by water cutting via 8” gage hatch on top of the tank.Hydrocarbon Condensate in Storage Tank (076-TK-1001) shall be sampled periodically. When water is detected, drainopen the 4” drain valve in line 076-GH-1301-4”-1CS1P-NI. Drained water from 076-TK-1001 is captured in the tank dike rainwater sump. Before allowing the captured water to be diverted to the rain water ditch, it must be visually checked for oil (the oil sheen). Only oil free-water is allowed to go to the rainwater ditch. All oil that is collected in the tank dike rainwater sump must be collected in the vacuum tankis sent to oily water collection pit (087-A-1008) , and disposed off in 087-V-1001. .

Level transmitters (076-LT-1101 and 076-LT-1102) are attached provided on the tank using float and differential pressure type respectively. Both transmitters send its signals are sent to SIS 076-US-2040 to indicate the condensate tank level inside the tank. Alarm is also available on the 076-US-2040 for liquid level high (LAH), liquid level low (LAL), liquid level high-high (LAHH) and liquid level low-low (LALL). In this case, LAHH (2 out of 2 voting) or LALL (2 out of 2 voting) shall will initiate the 076-US-2040 to trip and 076-US-2030 and 076-US-2700, respectively to close . This means that the shutdown valve of 076-USVE-2030 located at the inlet of storage tank. inlet will be closed immediately on or LALL (2 out of 2 voting) shall initiate 076-US-2040/2700 to stop the Condensate Loading Pumps (076-P-1001 A/B) will be tripped on LALL. It should be noted that the above-mentioned trip events would never happen at the same time.

During emergency situation, tank isolation is enabled by shutting off the tank inlet ESD valve (076-USVE-2030) and tank outlet ESD valve (076-USVE-2020) from manual ESD switch 076-HS-2030A and 076-HS-2020A on console located in MCR, respectively.

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3.4.

Condensate Loading System

3.4.1

Condensate Loading Pumps 076-P-1001 A/B

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 7 of 31

The condensate is transferred from the tank to the ship loading by Condensate Loading Pumps (076-P-1001 A/B) with a total loading rate of 1,500 m3/h. The two pumps are operated in parallel.

Pump min flow recycle line is provided to ensure the required min flow by the pump. The flow rate can be adjusted using flow control valve 076-FV-1001 located downstream of the pumps. The line is connected to condensate inlet line prior to entering Condensate Storage Tank (076-TK-1001).

The pumps can be started and stopped from field -mounted switch 076-HS-9801/9802 as well as from DCS via 076-HS-2700 A/B. REMOTE and LOCAL indication are available on DCS to show whether the pumps run automatically or locally.

SIS 076-US-2700 can trip the pumps initiated by LALL inside of the storage tank as well as ESD switch of SIS 076-US-2020 (Condensate Storage Tank outlet shutdown valve close) and SIS of condensate loading 076-US-2000 (Condensate Loading Shutdown). During the condensate loading, operator of loading arm can also send trip signal from ESD-1 push button switch (076-HS-3101) located on local panel (loading arm panel). to 076-US-2000. When quick disconnection of loading arm is required, operator can activate ERS manually by using ESD-2 push button (076-HS-3102) located on local panel (loading arm panel). “ESD-2 ACTIVATED” signal is sent to DCS via SIS at the same time.

3.4.2

Ship Loading Facilities A condensate metering system (076-V-1002) with turbine type flow meter is installed on condensate loading line located at the storage area to monitor the totalized flow of the condensate. Pressure, temperature, flow, totalized flow, and pressure drop are indicated via DCS serial link in MCR. A flow control valve (076-HV-1501) is placed at downstream of the custody metering. This valve is operated automatically in accordance with flow computer logic in condensate metering system based on the tanker loading volume and available loading time. This valve can be also adjusted from 076-HIC-1501 on DCS.

Thermal relief valve (076-PSV-8011) with ¾” x 1” size is attached installed on the loading line at downstream of 076-HV-1501 adjacent to the storage tank. The PSV is designed for thermal relief case caused by considering solar radiation.

The loading line is laid from cCondensate sStorage area to Combo Dock area having distance of approximately 2.3 km. An ESD valve (076-USVE-2010) is provided to isolate and protect Condensate Loading Arm (076-V-1001) during loading operation mode. The ESD valve (076-USVE-2010) is actuated by nitrogen bottles. The valve is de-energized to closed by 076-US-2010, which is initiated from hardwired switch located inby signal from SIS of

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076-US-2000 (Condensate Loading Shutdown) as well as from on ship ESD and loading arm local panel ESD (ESD-1) at Combo Dock. The SIS also triggers 076-US-2700 to trip the Condensate Loading Pumps. Consequently, loading operation will be terminated.

The loading arm (076-V-1001) is skid-mounted and has a capacity of 1500 m3/h. Operating pressure at the loading arm is expected at 1.0 kg/cm2G, and operating temperature of 39.6 oC. Design condition of the loading arm is 19.7 kg/cm2G and 20 / 55 oC. The system is suitable for 150 lbs ANSI/ASME rating. Total length of arm assembly is about 18 m with around 6.25 m height.

The system is provided with hydraulic power unit (HPU) to generate power for the loading arm. The HPU consists of two (2) electric motors of 5.5 kW, two (2) hydraulic pumps, pressure relief valve, flow control valves, fittings, associated instrumentation and accessories. In the operating mode, mode selector valves allow connection between control valve and arm brake (drive) cylinders. There are two loading arm operation modes as follows: -

Freewheeling mode

-

Maneuvering mode

Operator shall select the operation mode by mode selector valves. When freewheeling mode is selected, the mode allows enabling the loading arm to follow the tanker’s movement to prevent arm collapse due to large moment on arm nozzles. When maneuvering mode is selected, the mode allows manual loading arm operation by means of hydraulic oil solenoid valves. While, in freewheeling mode, the mode selector valves allow freewheel of cylinders enabling the arm to freely follow the tanker’s movement. In the event of electrical power failure, an accumulator unit, which consists of a vertical cylinder with required pressure, is provided to allows to discharge of the hydraulic oil enabling the operation of emergency release system. The emergency release system (ERS) comprises ERS valve of Double Butterfly Valve (DBFV) and ERS coupler Powered Emergency Release Coupler (PERC). When required (for instance during ESD-2 activated), immediate quick disconnection of the loading arm can be achieved without drainage of the fluid in the arm by using manual push button (ESD-2 push button) on the local panel.

The loading arm is furnished with drainage system. The system includes one (1) drain pump of horizontal-gear type using hydraulic motor driven. The pump has capacity of 5 m3/h and max. discharge pressure of 1.5 kg/cm2G.

Nitrogen bottles are required to purge the loading arm as soon after the completion of loading operation. The estimated number of nitrogen bottles is eight (8).

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4

INITIAL START-UP PROCEDURE

4.1

General

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 9 of 31

Initial condensate filling into the system will be commenced after the start-up of Condensate Stabilization Unit (Unit 011) has been completed. Pre-mechanical completion activities and final inspection of the system shall be carried out prior to introducing the process fluid to ensure CSO (car seal open) has been implemented on valves at the inlet of PSVs and pump minimum flow line. In addition, all piping vents and drains need to be closed and blanked. All instrumentation-tapping points are required to be in the open position. The condensate piping system is to be nitrogen purged and sealed prior to introducing the HC condensate During initial filling of the lines and storage tank within the system, velocity is limited not greater than 0.5 m/sec (0.016 m3/sec), in order to minimize the generation and accumulation of static electricity in the condensate. When liquid is available at the drain valve of the condensate is transferred to 076-USVE-2030, the condensate flow rate can be increased to normal flow.

The condensate piping system is to be nitrogen purged and sealed prior to introducing the condensate. 4.2

Start-up Procedure Reset 076-HS-2030B and 076-HS-2020B at the DCS. Ensure that ESD valves of 011-USVE-2070 at unit 011 B/L (battery limit) and 076-USVE-2030 on the condensate rundown line are in the open position. Ensure that ESD valve 076-USVE-2020 at the tank outlet is also in the open position. Gradually open the Unit 011 battery limit isolation valve slowly and displacing the nitrogen inside the piping to the tank, as the condensate enters the tank.

4.2.1

HC Condensate Filling to Storage Tank −

Ensure that ESD vavles of 011-USVE-2070 at Unit–011 B/L (battery limit) and 076-USVE-2030 at the inlet of HC Condensate Storage Tank (076-TK-1001) are in open position. Ensure that ESD valve of 041/042-USVE-2280 installed on the outlet of Debutanizer Column bottom are still in close position.

−

Ensure that ESD valve of 076-USVE-2020 at the tank outlet is in close position.

−

Gradually open 011-LV-1101 (Condensate Stabilizer Column bottom level control valve) and then packed nitrogen in HC condensate rundown line shall be replaced with HC condensate. The replaced nitrogen shall be purged out from the top of HC Condensate Storage tank to atmosphere.

−

Once the roof and seal operation are satisfactory and the liquid level is sufficient to lift the floating roof of its legs, full rundown flow rate can be established.

Ensure that control valve 076-HV-1501 and isolation valve located at downstream of condensate custody metering (076-V-1002) are in the close position. When there is sufficient condensate inventoried in 076-TK-1001, fill 076-P-1001A/B suction. Open 076-P-1001A/B can vent by cracking open on suction block valve and slowly fill the pump suction.

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Open the pump discharge block valve to allow condensate filling the discharge line. Rundown is now established to tank 076-TK-1001 with all piping fully occupied by liquid and low liquid level indicated in the tank. 4.2.2

HC Condensate Filling to Loading Line −

Ensure that 076-USVE-2020 installed on the tank outlet is in open position.

−

When there is sufficient HC condensate accumulated in the tank, HC condensate should be introduced to loading pumps (076-P-1001 A/B). Pump suction should be filled with HC condensate completely to prevent pump cavitation.

−

HC condensate is delivered to condensate metering system (076-V-1002). HC condensate metering system shall be filled with HC condensate by closing of 076-HV-1501.

−

One of condensate loading pumps is started at full recycle.

−

Once one of condensate loading pumps is operated at full recycle, the other condensate loading pump is started at full recycle.

−

After both condensate loading pumps are operated at full recycle, 076-HV-1501 is opened gradually and HC condensate should be delivered to downstream monitoring the tank level.

−

Increase the pump flowrate by opening of 076-HV-1501. Nitrogen in HC condensate loading line is purged out with HC condensate. Nitrogen is discharged to atmosphere from high point vent and nitrogen connection nozzle at the end of HC condensate loading line near the HC condensate loading arm (076-V-1001).

5

NORMAL OPERATIONS

5.1

General Management of the tank and the loading pumps operation will be carried out from MCR. However the ship loading operation will be under the control and supervision of the Loading Master from Loading Arm Control Panel (LACP) at the loading arm skid.

The ship loading operations (i.e., tanker mooring, communication cable attachment, and loading arm connection) will be managed by the Loading Master after pre-loading meeting onboard (loading coordination). Operators at the LACP and ship tanker operators remain in continuous voice communication during the loading operation.

The rundown, storage and loading facilities area will be normally unmanned and the loading pumps can be started and stopped either remotely from the MCR, or locally if necessary.

The monitoring of the storage, that is, DCS monitor showing pump status, pump operation mode, valve status and tank levels will only be available in the MCR.

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Custody metering system of condensate will report the condensate flow ratetotalized loading quantity and operating condition via DCS serial link to enable monitoring of the loading operation from the MCR.

5.2

Normal Operation Procedure

5.2.1

Introduction Condensate production has been brought into normal flow. And therefore, general description found in the Section 3 of Process Description can be referred to represent the normal operation condition. However, procedures are necessary to be described in detail, in order to give better understanding as well as to develop a standard operation in terms of safety and operability.

5.2.2

Tank Operation As described in the Section 3 of Process Description, the tank level monitoring including LALL, LAL, LAH and LAHH will only be accessed from the DCS. The SIS will take action when the tank level is in LALL or LAHH status. LALL will trip the Condensate Loading Pumps. LAHH will initiate closing the tank inlet ESD valve. When emergency situation arise, operator has to close ESD valves located at both the tank inlet and outlet by ESD switches on the SIS console. All of these ESDV’s status are indicated in the DCS. The quantity of condensate loaded to the ship is reported in the DCS from the Condensate Metering System (076-V-1002) located adjacent to the storage tank area.

5.2.3

Ship Loading Operation

5.2.3.1

Introduction When ship loading is required, it will be coordinated in the pre-loading meeting between the onshore and ship operator. All ship loading operations will be under the control and supervision of the Loading Master.

In accordance with ship loading agreed by both parties, expected condensate rate needs to be specified. ESD test plan is to be arranged. And check lists are to be prepared.

5.2.3.2

ESD Check The emergency shutdown system has to be tested before loading operations commence. Reset the ESD valves and initiate manual trip from any of the locations. After successful test, reset and reopen ESDV's. ESD test steps will be further detailed in the below Section 5.2.3.3.

ESD check of the loading arm system is also required. These are including ESD-1 and ESD-2 test. The objective is to examine whether the emergency release system (ERS) and the SIS are ready prior

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to loading operation. The tests will be performed after connecting the arm to the ship. See the corresponding loading arm vendor manual for further details (076-VDR-TBL-1C050).

5.2.3.3

Start Loading Operation As soon after initial start-up has been completed, the condensate will be introduced into the storage tank (076-TK-1001) with design flow rate as described in the above Section 2. The tank liquid level will rise to a certain level in between low level and high level. The following steps need to be taken to start loading operation: −

Operator has to cCheck the ship tanker capacity and liquid level inside the Condensate Storage Tank (076-TK-1001) tank prior to loading operation. In such case, the pre-loading meeting should resolve this matter.

−

Bring nitrogen bottles from shore side storage area (warehouse) to combo dock. Nitrogen bottles are used to purge the HC condensate loading arm (076-V-1001) after loading operation.

−

Input the total loading volume and loading time on the supervisory computer of Condensate metering system (076-V-1002).

−

Hydraulic Power Unit (HPU) in the loading arm system is to be powered ON.

−

Maneuvering the arm by operator in the Loading Arm Control Panel (LACP) at the loading arm skid manually using a pull rope.

−

Aligning the arm.

−

Connecting the arm to the ship.

−

Open 10” manual isolation valve at the inlet of condensate loading arm.

−

Ensure that ESD valve of 076-USVE-2010 at the inlet of Condensate Loading Arm in combo dock area B/L Combo Dock and 076-USVE-2020 at pump suction at the outlet of Condensate Storage Tank (076-TK-1001) are in the open position.

−

Ensure that suction and discharge of Condensate Loading Pumps (076-P-1001A/B) are in the open position.

Condensate Loading Pump of 076-P-1001A and 076-P-1001B are to be started following switches of 076-HS-2700A and 076-HS-2700B in the DCS for pump minimum flow. Pump minimum flow control valve 076-FV-1001 is set at 340 m3/h. Based on operator judgment, manual start-up of the pump can also be enabled by switching the pump min. control valve 076-FV-1001 in manual operation mode as follows: 1.Crack open 076-FV-1001 manually from the DCS. 2.Start the first of the condensate loading pump. 3.Monitor pump minimum flow rate and slowly open 076-FV-1001 manually from the DCS. When the flow is around 170 m3/h or greater, the second condensate loading pump is started immediately. 4.The condensate loading pumps start is completed. Continue to open 076-FV-1001 the condensate recycle rate up to 340 m3/h, which is the min. flow control valve set point. Switch 076-FIC-1001 to the auto mode. ESD-1 test is carried out as described in the above section 5.2.3.2. by the following ESD push buttons:

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076-HS-2020A 2000A in MCRthe DCS.

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076-HS-2030A in the DCS. 076-HS-2000C in SIS of 076-US-2000 console. 076-HS-3101 (ESD-1) in the Loading Arm Control Panel and ESD-2 test (during the loading arm system test.). 076-HS-2000D of on ship ESD Reset the corresponding SIS after successful ESD tests as follows:ESD-1. 076-HS-2020B in the DCS. 076-HS-2030B in the DCS. 076-HS-2000C on the SIS console. Re-start the condensate loading pump for pump minimum flow

5.2.3.4

−

Start one of the two Condensate Loading Pump at full capacity.

−

Once one Condensate Pump is completely operated at full recycle mode, start second Condensate Loading Pump at full recycle mode.

−

When both Condensate Loading Pump are operated at full recycle, press start loading on the supervisor computer of Condensate metering system (076-V-1002). Control valve 076-HV-1501 has to be is gradually opened according to the preset logic (ramp up) of the Condensate metering system. Initially, operator has to input the required loading time and total loading volume in flow computer. Then, operator is required to press start loading on the flow computer, which its signal is sent to the flow computer as well as the DCS via a serial link. The condensate metering systemThe flow computer The flow computer will start the totalizing and validation.

−

The 076-HV-1501 can also be manually adjusted from the DCS. This means that operator is enabled to override the control valve operation from the DCS if required. Loading Operation Presuming that the agreed flow rate has been achieved, loading operation will be unmanned operation. However, the next actions are required to be taken are as follows: −

The loading master, in In coordination with operators at the MCR and the ship tanker, has to monitor the monitoring tank level, tanker inventory, and totalized flow rate shall be executed via voice communication system.

−

When the amount of condensate loaded to the ship reach 75% of the agreed quantity or greater, the 076-HV-1501 is gradually closed, which will be automatically accomplished by the flow computer. After the loading operation ishas been completed, signal will be sent to the flow computer stop the condensate loading pumps. The totalized volume will be printed out batch report and indicated in the DCS.

−

Close the isolation valve located at the inlet of loading arm as soon after the agreed quantity has been achieved.

Stop the condensate loading pumps. −

The remaining HC condensate to should be drained off from the loading arm by using condensate drain pump 076-P-1002 that has been provided in equipped with the loading arm skid.Bring nitrogen bottles from shore side storage area to loading site.

−

AttachConnect the nitrogen bottles to the ¾” nitrogen connection nozzle that has been provided at loading arm inlet.

−

Open nitrogen connection valve. The following consideration should be taken prior to connecting nitrogen bottles:

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5.2.4

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 14 of 31

ƒ

Nitrogen bottle with full contents is to be provided with standard regulation/ pressure gage top works.

ƒ

Regulator is to be set at 0.5 kg/ cm 2 G.

−

Initially, eight bottles should be provided for the purging operation. But the number of bottles used can be adjusted based on operator experience.

−

After the purging has been completed, detach remove tthe nitrogen bottles and return them to the shore side storage area for refilling and secure storage.

Operating Variables The facility is operated in batches except for condensate receiving from the Condensate Stabilizer column (011-T-1001 A/B) and Debutanizer Column (041/042-T-1002). The operator monitors tank levels, ESD valves status, pump status, ship loading rate and condensate properties (e.g. RVP, pressure, temperature, etc).

5.2.5

Process Control

5.2.5.1

Minimum Flow Control for the Condensate Loading Pumps The Condensate Loading Pumps have a common minimum flow recycle line to maintain their minimum flow requirement. Each pump has 170 m3/h of minimum required pumping rate. A common flow control valve is provided on the minimum flow recycle line. In the case of reducing ship loading rates such as during the initial and last stages of the ship loading operation, condensate from the pumps will be re-circulated through the minimum flow recycle line.

5.2.5.2

Condensate Analyzer In order to check condensate spec., RVP Analyzer (090-AI-1801) is provided on rundown line adjacent to the storage tank. In case that the condensate RVP does not comply with the condensate specification, remedial actions shall be taken in the upstream facilities (i.e. Unit 011 and Unit 041/042). See the corresponding Unit 011/041 operation manual for further details.

6.

QUALITY CONTROL Operators, in this unit, are unable to control of the quality of the condensate products received from the Condensate Stabilization Facilities (Unit 011) and the Fractionation Units (Unit 041 & 042). RVP of the condensate will be reported from the RVP analyzer, and shown in the DCS. Water content of the storage tanks can be determined by laboratory analysis.

Water may enter into the bulk of condensate in the tank from the following sources: 1) With condensate from the Condensate Stabilization Facilities (Unit 011) and or the Fractionation Units (Unit 041 & 042) is in upset conditions.

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2) Rain water due to leakage of the floating roof.

Samples should be taken periodically from the tank to check water content. The water in the tank bottom can be drained and separated by means of bottom water drain system.

Sampling method, procedures and schedule should refer to Laboratory Testing Program as shown in attachment-6.

7.

NORMAL SHUTDOWN PROCEDURE

7.1

General Overall Shutdown Plan Shutdown is classified into normal shutdown and emergency shutdown. A normal shutdown is a scheduled shutdown, while an emergency shutdown is an unscheduled shutdown due to a failure or accident. The emergency shutdown procedures will be shown in Section 8. When shutting down a unit, it is very important to avoid large and/or rapid fluctuations in flows and pressures in order to protect the equipment and recover without causing any adverse effects on the unit. Further, measures must be considered to avoid hazards to human beings and damage to facilities. The shutdown schedule must be reviewed and discussed and all operators must be notified of it in advance.

7.2

Detailed Step-By-Step Procedure Prior to proceeding with a shutdown, notify all utility sections and all other sections concerned.

7.2.1

ESD Check of Ship Loading Operation Normal shutdown due to ESD test is required. The emergency shut-down system should be tested before commencing loading operation. Reset the ESD valves and initiate manual trip from the corresponding SIS console in control room. See the Section 5 for detail information. After successful test, reset and reopen ESDV’s. Procedures for ESD tests of the loading arm are included in the section 5.2.3.3 of Start Loading Operation.

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7.2.2

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 16 of 31

Normal StopMaintenance/Shutdown of Storage/Loading Facilities Normal shutdown of Unit 076 is represented by the following two-activities. (1) Normal stop of loading/transfer/feeding operation. (2) Regular maintenance of equipment.

When the tank undergoes internal inspection or maintenance, complete transfer of condensate is required. Overall maintenance shutdown in Unit 076 is impossible because only single HC Condensate Storage Tank is installed. When additional future HC Condensate Storage Tank is installed, tank maintenance will be available. Therefore, the following individual equipment/facility’s maintenance is available at present.

7.2.3

ƒ

Condensate Loading Pump (076-P-1001A/B).

ƒ

Condensate Metering Pump (076-V-1002).

ƒ

Condensate Loading Arm (076-V-1001).

Normal Stop of Loading Operation The normal stop of loading and transfer operations is carried out with taking into account the following: (1) At the end of loading operation, flow rate will be reduced by closing the 076-HV-1501 gradually. Then, all isolation valves located downstream of the above control valve have to be closed accordingly. (2) Normal stop of the loading pumps are enabled only if the tank level is higher than low-low liquid level, in order to avoid any interruption during loading operation due to pump trip.

8.

EMERGENCY SHUTDOWN

8.1

General (1) An emergency can be caused by the failure of an essential utility supply (power, instrument air, etc.), mechanical failure, a serious leak or fire. In these cases a partial or complete shut-down must be carried out quickly without damaging equipment. (2) A partial failure of a utility may necessitate close monitoring of operating conditions without enforcing an immediate shut-down. (3) At all times the safety of personnel is the first priority consideration. (4) Operators must judge the conditions of an emergency correctly in order to take the first necessary action in an actual emergency, and then appropriate action must be taken according to the changes in the conditions. (5) If a failure is likely to continue for a considerable time, the unit must be shut-down according to normal shut-down procedure after taking the initial necessary action.

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(6) Emergency Shutdown System. The emergency shut-down system is designed to enable the control room and/or field operator at loading site to shutdown the system and/or facility via hardwired switches either on the SIS console or local panel.

Refer to cause and effect diagram of Unit 076 Doc. no. 76-LOG-PS-1150. 8.2

Power Failure Emergency action to be taken (assuming a failure of all power) is described as follows: - All motor driven pumps will stop. - All ESDV are to be automatically closed, therefore, valves in pumping/rundown system should be isolated. - Only the loading pump min. flow control valve of 076-FV-1001 will remain open. - Stop the loading operation and release arms as necessary.

8.3

Instrument Air Failure In general, plant-wide instrument air failure will cause the various control and ESD valves to become in their fail-safe position as well as loss of local pneumatic indication and recording (P1, LI, Fl, etc.).

At a plant-wide air failure, - The feed to tank will stop. - Loading operation will stop. - Pump min. flow will continue to flow. Control valve for min. flow will be kept fully open. The following procedure must be taken at the discretion of the operators. −

8.4

Stop the pumps, which are running with min. flow condition and isolate the corresponding suction and discharge valves.

Fires/Serious Leakage The required action will differ depending on the location/extent of the leaklfire. In general cases, the following steps must be taken.

(1) Notify the fire safety department with the condition reported. Stop hot work being carried out around the area.

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(2) Cut the rundown and/or loading streams related. The necessity for quick release of loading arms to a tanker should be considered (ESD-1). (3) Shutdown any related pumps. (4) Isolate equipment and piping affected by the leak/ fire, if possible pressure build up should be taken into consideration. (5) Switch off power sources if required. It is of the most importance to detect the source of the fire/leak and to stop the supply of flammable materials.

Whenever any emergency situation occurs due to fire at Combo Dock area, which could be initiated from either condensate or diesel system, the same responses to the above shall be applied.

8.5

Equipment Failure

8.5.1

Pumps When one of the condensate loading pumps (076-P-1001A/B) is failed, operators can continue loading operation at the reduced loading rate. When both of the condensate loading pumps (076-P-1001A/B) is failed, operator must stop loading operation and take remedial actions.With the exception of intermittent use, all items of rotating equipment have a spare. The condensate loading pump status along with alarms is available in the DCS. Process value that could lead to the pump trip is liquid low-low level within the condensate storage tank. The following ESD push buttons can also become an event that tripping the condensate loading pumps:

(1)076-HS-2020A on the SIS console to closed ESD valve at the tank outlet. (2)076-HS-2000A on the SIS console to stop loading operation. (3)076-HS-3101 on the Loading Arm Control Panel (LACP) to stop loading operation. (4)076-HS-2000D of on ship ESD to stop loading operation. Power and mechanical failure as well as operator error also need to be considered as a trip event. In such case, operator intervention is required to isolate the pump and take remedial action.

8.5.2

Loading Arm In case of loading arm failure, stop the loading operation immediately and release arm.

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Emergency Release System (ERS) is provided to disconnect the arm whenever emergency situation arises. The ERS consists of ERS valve and ERS coupler. ERS will be initiated manually by operator at jetty. The two-event that could initiate the ERS are ESD-1 and ESD-2 that will be described further in sub chapter 8.6. In case of loading arm failure, stop the loading operation immediately and release arm. Emergency Release System (ERS) is provided to disconnect the arm whenever emergency situation arises. The ERS consists of ERS valve and ERS coupler. ERS will be initiated manually by operator at jetty. The two-event that could initiate the ERS are as follows: (1)ESD-1 When any emergency situation is recognized or 1st alarm happened due to exceeding apex or slew angle limit, the operator shall actuate the ESD-1 switch on the LACP to initiate the following: −A signal will be transmitted to the SIS to close the ESD valve located on the loading line on dock-side and stop the loading pump. − Starting of motor in hydraulic power unit. (2)ESD-2 When audible/ visual annunciation (2nd alarm) is happened due to exceeding limit of apex and slew angle of the arm, operator shall manipulate the ERS manual handle on the hydraulic power unit to actuate the emergency release as follows: Closing ERS valve. Releasing ERS coupler (ERC) after completion of ERS valve closing. The arm is hydraulically blocked. −

Activating ESD-2 switch (076-HS-3102) on LACP and transmitting the ESD-2 signal to the SIS.

Then, the arm in either empty or full of fluid will be retracted by 2 m above the ERC level using hydraulic control by operator to clear the ship manifold area. The arm, then, is stored back. In case of power failure, oil will be discharged from the accumulator unit to initiate the complete emergency release. It should be noted that the emergency release is enabled only if the arm is in the mode of connected. The emergency disconnection shall not be accomplished when the arm is in stored or maneuvering condition.

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8.6

Emergency Shutdown System

8.6.1

Condensate Loading Shutdown

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 20 of 31

In order to minimize the potential for a release of HC Condensate to the environment, the Condensate loading system is protected by two emergency shutdown systems: ESD-1 and ESD-2. (1) ESD-1 ESD-1 allows the rapid shutdown of the loading operation during emergency. ESD-1 is designed for manual or automatic initiation. Manual initiation is by push buttons located in Main Control Room (MCR), Loading Arm Control Panel (LACP) and Condensate ship. Automatic initiation is via an “over-extension signal” from the loading arm's apex limit switch or initiation of ESD-2. ESD-1 initiates the following actions; − Stop Condensate Loading Pump (076-P-1001A/B) − Close shutdown valve (076-USVE-2010) − Start motor in hydraulic power unit, which enables preparation of safety actions to be taken in succeeding ESD-2. (2) ESD-2 ESD-2 uncouples the loading arms quickly when the arms become overextended. This emergency situation of a potential loading arm failure is generated due to the HC condensate ship drifting from its moorings beyond the design operating range of the loading arms. ESD-2 is designed for manual or automatic initiation. Manual initiation is via push buttons on Loading Arm Control Panel (LACP). Automatic initiation is via an “over-extension signal” from the loading arm's apex limit switch. ESD-2 initiates the following actions;

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−

Close DBFV

−

Release PERC after completion of DBFV closing.

−

Transmit ESD-1 requests to 076-US-2000

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8.6.2

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 21 of 31

Tank Isolation When emergency, operator can close ESDV at the inlet and outlet of Condensate Storage Tank (076-TK-1001) by the following push button; (1)Process variable i.e. liquid low-low level inside the storage tank, which is transmitted from both of the following level transmitter: −076-LT-1101 −076-LT-1102 (2)ESD switch has been activated from one of the following ESD push button: −076-HS-2020A on the SIS console to close ESD valve at the tank outlet. −076-HS-2000A on the SIS console to stop loading operation. −076-HS-3101 on the Loading Arm Control Panel (LACP) to stop loading operation. −076-HS-2000D of on ship ESD to stop loading operation. The above ESD switches are manually operated when emergency response is required due to upset condition such as fire, loading arm failure, etc. To bring into normal operation after an emergency situation has been responded and remedial action taken, reset of the corresponding SIS is required as follows: −

076-HS-2020B 2020A in the DCS to opencloses ESDV valve of 076-USVE-2020 at the tank outlet.

−

076-HS-2030B 2030A in the DCS to opencloses ESDV valve of 076-USVE-2030 at the tank inlet.

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.

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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. Gas masks must have fresh cartridges installed after use.

9.2.

Hazardous Material HC condensate (1) All components from explosive mixtures with air within certain limits and are liable to be ignited when a source of ignition is available. The heavier component, the lower is the ignition temperature. (2) High vapor concentrations of all components will cause oxygen deficiency and will act primarily as a sphyxiants without other significant physiological effects, however, lower concentrations will have an anaethetic effect. (3) Condensate contains benzene which is suspected of having carcinogenic properties above a very low threshold value. Benzene TLV-TWA ppm exposure level for eight hours: 10ppm Note: TLV-TWA = Threshold Limit Value-Time Weighted Average

9.2.9.3.

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.

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9.3.9.4. 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.

9.4.9.5.

Maintenance of Equipment and Housekeeping 1.

2. 3. 4. 5. 6. 7. 8.

9.

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.

9.5.9.6. Repair Work 1. 2. 3. 4.

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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

BP Berau Ltd. Tangguh LNG Project Operation Manual for HC Condensate Storage and Loading

6.

7. 8. 9.

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 24 of 31

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.

9.6.9.7. 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.

9.7.9.8. 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.

9.8.9.9. 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

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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.

9.9.9.10. 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.

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10.

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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

Individual Equipment / System Isolation

10.2.1.1

Tanks All tanks 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 10.2.1.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for HC Condensate Storage and Loading

Figure 10.2.1 Tank

MIN FLOW LINE OVERFLOW

OUTLET LINE

INLET LINE

DRAIN

TANK

10.2.1.2 Pumps Normally valved isolation method is applied for isolation of pump suction and discharge lines. If required from the maintenance work nature, blinds will be provided. Refer to Figure 10.2.2. Figure 10.2.2 Pumps

OUTLET LINE INLET LINE

‘Y’ or ‘T’ TYPE SUCTION STRAINER

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BP Berau Ltd. Tangguh LNG Project Operation Manual for HC Condensate Storage and Loading

11.

MAINTENANCE PROCEDURE

11.1.

General

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 28 of 31

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:

• 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.

11.1.2

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.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for HC Condensate Storage and Loading

11.1.5

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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. • 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.

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11.3.2

Doc. No. 76-IOM-PS-1201 KJP Doc. No. S-076-1283-001 Rev. 6A Sheet No. 30 of 31

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

Tanks • 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.

11.4.2

Pumps • Operations to shut down the unit, stop pump motor and depressurize the line and pump. • Operations to nitrogen purge the pump, if required. • Electrical to lock out motor locally and remove relays/fuse/circuit breaker in substation. • Mechanical to spade at inlet and outlet nozzles of said equipment. • Operations to vent, air purge and drain the pump.

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.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for HC Condensate Storage and Loading

12.

ATTACHMENT LIST

Attachment-1 Process Flow Diagram 76-UFD-PS-1200

Attachment-2 P&IDs 76-PID-PS-1201 76-PID-PS-1211 76-PID-PS-1212

Attachment-3 Equipment Data Sheet (list only) 76-EDS-VM-1351 76-EDS-MC-1401 99-SPE-CS-1750

Attachment-4 Instrument Alarm Set Point (list only) 76-SPE-CS-1754

Attachment-5 Cause and Effect Charts (list only) 76-LOG-PS-1150

Attachment-6 Laboratory Sampling Schedule

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