H-FALR-23-1230-001-A, Black Start Up Scenario and Procedures Rev 3
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ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
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PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
CLIENT
02021 A
:
PT PERTAMINA (PERSERO)
PROJECT TITLE :
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL
LOCATIONS
BLANG LANCANG, LHOKSEUMAWE, ACEH UTARA
:
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
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PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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3
31-May-11
Issued for Bidding
FE
IRA
ADN/AB
2
27-May-11
Issued for Approval
FE
IRA
ADN
1
20-May-11
Issued for Review
FE
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0
09-May-11
Issued for Internal Review
FE
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REV
DATE
DESCRIPTION
PREPARED
CHECKED
APPROVED
TABLE OF CONTENT SEC. TITLE
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ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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INTRODUCTION.........................................................................................................................3 PROCESS DESCRIPTION...........................................................................................................3 REFERENCE DOCUMENT.........................................................................................................4 OVERALL DESCRIPTION..........................................................................................................4 4.1 SHIP BERTHING/ARM CONNECTION............................................................................4 4.2 SHIP UNLOADING.............................................................................................................4 4.3 LNG STORAGE TANK.......................................................................................................6 4.4 BOIL-OFF HANDLING......................................................................................................9 4.5 VAPORIZER AND SEND OUT SYSTEM........................................................................11 4.6 HOLDING MODE (NO LOADING/UNLOADING)........................................................12 5. BLACK START-UP PROCEDURE............................................................................................13 5.1 PURPOSE...........................................................................................................................13
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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5.2 INITIAL START UP OVERVIEW.....................................................................................14 5.3 STEP BY STEP START-UP ARUN LNG RECEIVING - HUB REGASIFICATION TERMINAL FACILITY.............................................................................................................15
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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1. INTRODUCTION This document presents the black Start UP Scenario for the ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL. This philosophy base on availability of existing Arun facilities especially power management which one will be used for Arun LNG Receiving –Hub and Regasification Terminal .
2. PROCESS DESCRIPTION The Arun LNG Receiving -Hub & Regasification Terminal is designed to receive LNG from Tangguh & Badak. The normal production rate is 280 MMSCFD of Send out gas and expandable to 400 MMSCFD. LNG from LNG ship is transferred to LNG Storage Tank (F-6001/F-6002/ F-6003/F-
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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6005) by Cargo Pump. The unloading flow rate is 10,000 m 3/hr and 5,000 m3/hr with discharge pressure cargo pump is 10 barg.
BOG produces increase
significantly when unloading due to heat in leak a long pipe, heat loss in motor Cargo Pump, and LNG Tank. BOG will be out from top of LNG Tank (F-6001/F-6002/ F-6003/F-6005), BOG will be split become two stream, one stream as BOG Return to ship and another stream flow to BOG Compressor (K-6801A/BC/D). Discharge BOG Compressor flows to BOG Cooler (E-7501A) to get outlet temperature 33 0C. It is used as HP Fuel Gas for Power Generator and PDPA (Local Company of Aceh Province) and PT. PLN. If there is excess HP Fuel Gas, it is will be recompressed by BOG Booster Compressor (K-2501A) to 52 kg/cm 2g. Discharge BOG Booster Compressor will be combined with the outlet LNG Vaporizer to reduce load of LNG Vaporizer and will be sent to customer.
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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LNG is pumped by Primary LNG Transfer Pumps (G-2306 A/B) or LNG Transfer Pump (G-2304A/B/C) to LNG Vaporizer (E-2302A/B/C) with discharge pressure 52 kg/cm 2g. LNG will be vaporized until 50C by Sea Water Supply from Sea Water Pumps. Then vapor LNG will be sent to customer and for fuel gas make up if consumption of HP Fuel Gas is increasing. It is heated by electric heater to get the temperature of fuel gas is appropriate with specification of HP fuel gas. The existing equipment will be reused are including:
1 LNG Loading Dock (Berth-2)
LNG Storage Tank (F-6001/6002/6003/6005)
LNG Circulation Pump (G-6802A/B/C/D/E)
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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BOG Compressor (K-6801 A/B/C/D)
BOG After Cooler (E-7501A)
BOG Booster Compressor (K-2501A)
LNG loading pump (G-6801A/B/C/D/L/M, for HUB Terminal)
As operating experience is acquired, and if conditions warrant, it may be possible to modify certain procedures to meet a given situation as long as these modifications are in keeping with safe operating practices and the design limitations of the equipment/system involved. 3. REFERENCE DOCUMENT Overall Process Flow Diagram (PFD)
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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Process Flow diagram
Utility Flow diagram
4. OVERALL DESCRIPTION 4.1
SHIP BERTHING/ARM CONNECTION LNG will be delivered by LNG carriers in the range of 75,000m 3 to 135,000m3 (maximum size). It is assumed that at ship arrival, the berthing and mooring maneuvers will be managed by the Port Authorities with the assistance of pilots, tug boats and ship berthing monitoring system.
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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Once the ship has been securely moored to the mooring hooks and communications have been established, the liquid unloading and vapor return arms can be connected. The ship's transfer piping and the liquid arms will then be cooled down. 4.2
SHIP LOADING/UNLOADING The Arun LNG Receiving -Hub & Regasification Terminal is designed to loading / unloading operation. SHIP UNLOADING LNG from the LNG Cargo is pumped into the LNG storage tanks F-6001/6002/ 6003/6005 using the Cargo Pumps. In support of the target “pilot to pilot” port turn-
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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around of 24 hours, discharge times are limited to maximum 18 hours. The unloading system is therefore based on ship pump discharge pressure 10 barg at ship rail flange to allow unloading rates of up to 10,000 m³/h into four storage tanks. With higher pumping capacities, the unloading rates can be increased. With smaller carriers, lower discharge rates are acceptable as the reduced parcel sizes will still allow discharge times of 18 hours. Due to the capacities of LNG tankers and storage tanks, four storage tanks are normally filled in parallel from one ship, with a simultaneous unloading into and sending-out from both tanks. Since LNG is unloaded into a single LNG storage tank unloading rates may be limited. The LNG discharged from the tanker is
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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directed to the storage tanks via 24” two parallel lines, then through 30” headers serving the LNG storage tanks. The actual unloading rates are established on level indications in the onshore storage tanks. 20” storage tanks valves allow balancing the flow into each tank. The quality of LNG being unloaded is monitored on-line via an analyzer located on the jetty, whilst additional manual sampling always remains open to further spot-check the LNG qualities in the plant laboratory. The analysis of incoming LNG is done to supplement the cargo certificates provided with the incoming CIF (Carriage, Insurance & Freight) LNG to ensure LNG is placed appropriately into the LNG storage tanks via top or bottom fill nozzles to avoid roll-over risks.
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
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Fiscal metering of the quantity of LNG unloaded per LNGC will be done based on “tank-dip” surveys of the LNGC. SHIP LOADING As Hub Terminal, loading operation is required. Loading operation is performed by LNG Loading Pumps (Pumps G-6801 A~D/L/M) located in pump station of each tank group. LNG is pumped from LNG Storage Tanks F6001/2 to Berths 2 by LNG Loading Pumps G-6801 A~D/L/M. Each Loading Pump has a capacity 2,724 m3/hr and the design loading rate of 10,900 m3/hr is achieved by four loading pumps. The LNG flows to the pumps
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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through a 48" header that splits into a 30" branch to each pump. The discharge from each pump flows through a 20" branch into a 36" header. Two 30" loading lines connect the Loading Berths to the header.
Three 16" identical arms, each with an Emergency Release Coupling (ERC), are provided for ship loading/unloading, for LNG transfer from/to the storage tanks. A loading arm V6801C, identical 16" arm, is provided to route displaced gas back from/to the ship. The maximum loading/unloading rates will be limited to 5,000 m3/h per arm. Due to the length of the loading/unloading lines and the difference in elevation between the ship deck and the top of the tank, hydraulic pressure drops through piping systems
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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(inclusive of its auxiliaries such as valves, elbows, and strainers) have been reduced as much as feasible. At the end of the ship loading/unloading, the LNG will be purged out of the unloading arms with nitrogen connected at the top of the arm. The LNG is thus driven back into the ship and into the 24" unloading header from the arm apex and the arm flanges are disconnected. Between LNG tanker arrivals, the heat ingress into the loading/unloading lines is removed continuously by circulating a part of the send-out LNG through the unloading system. The circulated LNG is preferably sent to the send-out system to avoid extra BOG generation in
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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the LNG storage tanks, which would trigger extra duty cycles on the BOG compressors and thus increase the terminal electricity consumption. The line-up allows also the return of circulated LNG to the storage tanks. Between two ships unloading, the 16" vapor return line is also connected to the tank vapor space via the boil-off gas header line. 4.3
LNG STORAGE TANK Four LNG tanks, existing F-6001/6002/6003/6005, each having maximum capacity of 127,000m³ are provided. The double wall, single containment tank was selected due to lowest cost and proven record of operation. The working volume is set between a minimum level at which LNG pumps can run at full capacity up to the net positive suction
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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head limit (NPSH limit), and first high level alarm. There is sufficient land area available to meet the sitting requirements of NFPA 59A. The storage tanks are of the single containment type. The tanks have a maximum heat leakage rate of 0.05 % wt per day of the tank contents based on a full tank of LNG. All fill and withdrawal connections, and all other instrumentation nozzles are top entry through the tank roof (and suspended deck where relevant). LNG tanks will be equipped with a top splash plate for distributing the liquid during top-filling operations and an internally vented standpipe to accomplish bottom filling.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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The tanks F-6001/6002 are connected to 24” boil-off header. This boil-off header is connected to the boil-off gas compressors K-6801A/B. The tank F-6003/6005 are connected to 24” boil-off header ant the through the boil-off gas compressor K-6801C/D. Two boil-off header connected with 30” common header, but normally connection of them isolation by manual valve. When unloading partly of boil-off gas from F-6003/6005 split to the vapor return line to the ship via the vapor return blower K-2302A/B, and to the flare system if overpressure in BOG line. The boil-off compressors are two-stage, labyrinth piston type electrically driven compressors. The maximum duty expected from them is for 2 machines running.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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The boil-off gas blowers are single stage dry centrifugal machines driven by electrical motors. This blower operates during LNG unloading to keep pressure of ship LNG storage. The tanks have a design pressure of 0.14 kg/cm 2g. The normal vapor space operating pressures of the LNG storage tanks will range between 0.04 and 0.1 kg/cm 2g, and this pressure will generally be controlled by selective operations of the BOG compressors. During LNGC unloading, the tank pressures are assumed steady at a relatively high level of 0.12 kg/cm2g, whilst the LNG transfer pumps are designed for a steady low vapor pressure of 40 mbarg. The boil-off gas compressors are designed for the LNGC unloading operating mode at highest unloading rate of 10,000m3/h with four storage tanks available in
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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the Terminal at a relatively high constant pressure, without taking any credit for added vapor suppression by gradual increase in vapor pressure. LNG storage tanks are provided with protection systems in order to prevent:
Tank over-filling by extensive level gauging with multiple instruments and a voting regime, acting on different items (e.g. valves & pumps) and coupled to the ESD 1 (shutdown of unloading system)
Over-pressure, primarily via selective operation of BOG compressors, followed by a pressure control valve releasing excess gas to vent at 1.16 kg/cm 2A kg/cm2g, installed on top of the tank and ultimately as last line of defence a set of 2 pressure
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
safety valves (PSVs) at set point 1.173 kg/cm 2A on each tank roof. The overpressure protection covers a combination of atmospheric pressure drop tank rollover (events such as which is the design case of the PSV's), etc.
LNG stratification in the tanks. Several precaution have been taken in the design in order to reduce the possibility of rollover considerably, such as the choice to top and bottom-fill mode together with an extensive temperature / density measuring, a regular renewal of tank contents, and the option to circulate LNG within the storage tanks (via local circulation).
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
Vacuum conditions in the storage tanks are prevented initially by tripping the on-line boil-off gas blowers and BOG compressors, followed by a small injection of high pressure gas in the common boil-off gas header. The ultimate protection of the tanks against vacuum is effected by recycling the LNG pumps on their kickback and finally by a minimum of (4) air vacuum breakers at - 50 mmH2O.
Pump and piping configurations allow for individual tank mixing. Nitrogen injections arrangements in the tank as well as vent lines are provided for tank drying, purging and inerting. A cool-down spray ring is provided to initially cool-down the tank to put in service or to precondition the tank prior to tanker unloading.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
4.4
02021 A
BOIL-OFF HANDLING SHIP UNLOADING Filling of LNG into tank, each tank has a capacity of 127,000m 3 (800,000 bbl) is to be top filling to cool down boil off gas regardless of tank liquid level, loading or no-loading operation. During filling operation necessary to control the filling rates to each tank by adjusting valves on laterals to each tank, observing increase rate of tank level. During ship unloading, the level in the on-shore storage tanks increases causing a vapor displacement. Simultaneously, the level in the ship cargo tanks decreases at the same rate,
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
causing a negative displacement effect and therefore a pressure drop into the ship's cargo tank. To prevent vacuum in the ship's cargo tank, a part of the vapor displaced in the storage tanks is sent back to the ship by means of vapor return blowers K-2302A/B through the boil-off header and MBOG Quenching Vessel D-6804, the 16” vapor return line and the vapor return arm V-6801C. A LNG atomizer is incorporated in the vapor return line. This facilitates is used to cooldown of temperature vapors at start of return gas flow. When the main steady state return flows are established, this atomizer ensures that gas returned to the ship can be maintained
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
at a temperature not warmer than -130°C. Excess injected liquid is trapped in the jetty Blowdown drum D-6802, which can also be used for quick draining of one transfer arm in case of leakage problems. BOG production increase significantly when unloading due to heat in leak a long pipe, heat loss in motor Cargo Pump, pressure drop of control valve and from LNG Tank. BOG will be generated and released to top of LNG Tank. The maximum BOG produced is 65 MMSCFD (54.3 ton/hr), it will be split in two streams, one stream as BOG return to ship (25 MMSCFD) and another stream sent to BOG Compressor (K-6801 A/B/C/D) which is condition 2 (two) BOG Compressor running parallel to handle BOG. Discharge BOG Compressor flows to BOG Cooler (E-7501 A) to get outlet temperature of 33 0C. it is used
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
as HP Fuel Gas for Power Generator (PG) and PDPA (Local Company of Aceh Province) and PT. PLN. If there is excess HP Fuel Gas, it will be recompressed by BBOG Compressor will be combined with the outlet of LNG Vaporizer to reduce load of LNG Vaporizer Excess boil-off gas in the LNG tanks is handled by the boil-off compressors K-6801A/B/C/D and will be sent to fuel gas system. NORMAL OPERATION During normal operation (no ship unloading), boil-off from the storage tank (F6001/6002/6004/6003/6005) is compressed by one of boil-off gas compressor K6801A/B/C/D because total production BOG maximum 12 MMSCFD (9.8 ton/hr). Then compressed gas is sent to the high pressure fuel gas system. This gives the terminal operator
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
the freedom to run a single compressor continuous in part-load condition, or to lower vapor pressures at times of cheaper electricity and minimize running the compressors at day time. The pressure in the storage tank is controlled by operations of the boil-off compressors. Compressed excess vapors are sent to fuel gas system. MINIMUM SEND-OUT OPERATION The minimum send-out will be 70 MMSCFD. This rate allows for boil-off recompression and for running one of Primary LNG Transfer Pump (G-2306A/B).
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
BOIL-OFF COMPRESSOR Four boil-off compressors K-6801A/B/C/D are provided for the boil-off handling. During LNG unloading two BOG compressors are to be operated to cope with the maximum boiloff gas amount 33.5 ton/hr and other for standby. If one of the compressors is trip, then the standby compressor will be operates manually. Each compressor with a rated flow rate of 20,820 kg/h is provide to compress LNG boil-off to 16.5 kg/cm2, to be necessary for delivered to the high fuel gas system. Actual amount of boil-off will be depended on the operating mode.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
The compressor is provided with an anti surge control system which protects the machine from surging by recycling vapor to the vapor space of the LNG storage tanks. This vapor is quenched with LNG to be sprayed into the vapor recycle line upstream of the storage tanks using a series of five LNG atomizing nozzles. Excess gas from the compressor is sent to the high pressure fuel gas system through FV-6826C. Marine Flare pilot and purge gas is supplied via 2" line from compressor discharge or from reverse flow from the high pressure fuel gas system. Quenching LNG is supplied from discharge header of the loading pump or the circulating pump which is on duty depending on the operation mode.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
4.5 SEND OUT SYSTEM Normally LNG send-out is pumped from the storage tanks F-6003 or F-6005 by LNG transfer pump G-2304B (installed in tank F-6003) or G-2304C or Primary LNG Transfer Pump G-2306B (installed in tank F-6005) and sent to LNG vaporizer E-2302A/B/C. The pumps of vertical canned types are provided. They are provided with venting and minimum flow lines returning to the respective LNG tank. Both motor and pump are submerged in the LNG which provides cooling and lubrication for the bearings and motor windings. Transport LNG from storage tank to LNG vaporizer using existing header with size 48” in suction and 12” for discharge. LNG transfer pump G-2304A, are installed in the first tank
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
group which is will be using for HUB terminal. G-2304A will be used if LNG stock from F6003/6005 was limited. A minimum flow bypass line is provided for each pump, the discharges of which are tied into one common 16" intertank transfer line. The small foot plinth also assists in minimizing the size of the noise shelter & crane structure over the booster pump station. The suction header in the LNG transfer pump station is prepared for a parallel operation of 2 LNG transfer pumps and 2 Primary LNG Transfer Pump to achieve the maximum daily send-out rate of 400 MMSCFD.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
These pump sets are provided with individual vent pots to release the vapor from pump and the vapor from the pots is sent back to the individual tank on level control. This line ties into the boil-off gas recycle line, discharging into the top of the tank above the liquid level. The gas produced by the vaporizers will split partly to fuel gas system/new costumer (PDPA) and the fertilizer plants. The gas produced by vaporizers before sent to fuel gas system and PDPA, it pass through a fuel gas heater E-2303 to maintain temperature as per fuel gas specification. Then to the fertilizer plants pass through inlet facilities line and gas metering system before being conveyed to the gas pipeline. There will be a back pressure controller before the gas metering system to maintain a constant pressure to customer. The gas metering system consists of three parallel metering lines (one in stand-by). An on-line
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
gas chromatograph for analyzing the gas composition is included within the gas metering system. Send out gas that is used within for the terminal, will be taken downstream of the LNG vaporizer. The gas pressure is reduced before supplying it to the LNG storage tanks for intermittent make-up as required. The Terminal is able to adjust its high pressure LNG send-out rate between minimum sendout and maximum send-out by increasing or decreasing as required the number of parallel operational pumps and vaporizers, and use minimum flow re-circulation loops as required to trim actual flows. All these send-out capacity changes will be controlled through the PCS system.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
At times of zero send-out (except when suffering from a prolonged black-out) most cryogenic line-work in the Terminal will be kept cold via circulation loops from the LNG tanks to LNG jetty and process area with LNG circulation pumps. 4.6
HOLDING MODE (NO LOADING/UNLOADING) The LNG loading lines are kept cold during the “no loading or unloading” mode by circulating 454 m3/h of LNG from storage tank using one circulation pump in each a group tank.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
Normally, for the existing berth 2 loading line, cold circulation is performed by one circulation pump out of two in the first tank group pump station, G-6802A or B. For the loading line from F-6005 pump station, cold circulation is performed by one circulation pump out of two in F-6005 pump station, G-6802C or D, and for the loading line from F6003 pump station to the loading lines from F-6005 pumps, one circulation pump will be used installed in F-6003 pump station, G-6802E. At zero send-out, no liquid is available for regasification of boil-off in the LNG vaporizers and the compression system will not be able to accommodate the boil-off gas produced in the terminal. This implies that vapor pressures within the Terminal will gradually rise, and if this situation prevails for a longer period (of a few hours) the boil-off is then let-off to the
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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02021 A
vent system under pressure control. As this situation conflicts with the adopted “no venting” philosophies zero send-out should normally be avoided, and only be accepted for exceptional circumstances, such as a persistent pipeline problem, or a longer black-out. 5.
BLACK START-UP PROCEDURE
5.1
PURPOSE The purpose of this document is to describe a general philosophy for the initial start-up of the Arun LNG Receiving – Hub Regasification terminal facilities. Detailed commissioning and start up packages will be developed with the project team during detailed design and upgraded during construction. It also describes the start up of
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
the facilities following a total plant shutdown and blowdown with the facility only on emergency power generation, which is referred to as "black start". The black start procedure is usually completed just before start up. Training and verification on the procedure takes place during final commissioning of the systems. The sequence of activities and details of commissioning will be determined during detailed design. The anticipated duration of each activity will also be defined during this phase in conjunction with equipment vendors, operations and commissioning personnel.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
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02021 A
INITIAL START UP OVERVIEW 5.2.1 Purging Air removal will be required for all systems in hydrocarbon services, including the flare. Water and nitrogen are the preferred inerting materials and will require sufficient gas supplies and the use of temporary connections. Nitrogen supply logistics will be a subject for resolution during detailed design. 5.2.2 Services and Utilities Start-up requires the following services and utilities to be commissioned and operational: • Emergency systems, DCS, Public address system and fire protection system;
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
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02021 A
• Diesel fuel system and distribution • Auxiliary power on diesel fuel and Main Power generation; • Main Instrument air system and portable instrument air package; • Fresh water system and pumps • Fire water system and pumps • Flares, vents. The flare systems will require that propane or LPG backup to the pilot fuel and ignition system is commissioned and sufficient supplies of propane are available until the fuel gas system to the flare pilots is available.
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
As a design consideration, the emergency diesel generator shall be sized to include all the emergency electrical generation loads detailed in the power system philosophy. 5.2.3 Fuel Gas System Priority should be given to starting up the fuel gas system to provide fuel to the Power Generators. Black start power can be initially generated with the essential LNG small pump and Ambient vaporizer. Since no gas will be available prior to the start of production flow to the send out system . Fuel gas will be taken from LNG storage tank. The gas from LNG Storage Tank still in liquid form and need to be vaporizing using 2 Vaporizer using ambient air temperature, two Air
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LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
Ambient Vaporizer will operate alternately to ensure reliability of supply fuel gas. Vaporize gas will flow from Air Ambient Vaporizer to the Power Generation PG-9001A through the fuel gas header line. 5.3
STEP BY STEP START-UP ARUN LNG RECEIVING -HUB REGASIFICATION TERMINAL FACILITY Initial Start-up Arun LNG receiving terminal Facility or after total shut down using Transfer pump from storage tanks. The main step during initial Start up or after total shut down can be done with following execution:
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
KLIENT:
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PT. PERTAMINA (PERSERO)
PT. INTI KARYA PERSADA TEHNIK
PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
There is two option base on LNG availability in LNG Storage Tank : A. if LNG Storage tank level in Low low condition, cooling down of LNG line and Tank should be start from LNG Ship at Berth 2. Start Unloading LNG to LNG Storage Tank until certain Level of LNG at Tank appropriate to starting LNG small Pump. B. If LNG Storage tank in adequate level to start LNG small pump and Air Ambient Vaporizer, Start LNG small pump using portable Generator and send out LNG to Air Ambient Vaporizer to get Fuel gas for running Power Generator A/C Step By Step for Black Start up
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
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KONTRAKTOR:
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PT. PERTAMINA (PERSERO)
PT. INTI KARYA PERSADA TEHNIK
PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
1.
02021 A
Conform diesel fuel available for Emergency Power Generator, Diesel Engine at PG-9001A and Diesel fire Water Pump.
2.
Conform that Power always available for small LNG pump in order to run the pump and Ambient vaporizer ready for operation.
3.
Confirm fire water pond filled by Well Water Pump with raw water
4.
Conform all safety equipment include PSV, emergency relieve valve, etc at condition ready for operation if overpressure condition happen.
5.
Conform all ESD system at stand by condition and ready for operation, PSD will action if deviation un control process happen caused and reach limit high-high or limit low-low signal activated the process shut down. ESD will activated if un control process happen and to avoid hazard condition caused of overpressure, badly leakage,
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
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KONTRAKTOR:
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LOKASI PROYEK :
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PT. PERTAMINA (PERSERO)
PT. INTI KARYA PERSADA TEHNIK
PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
02021 A
environmental problem, etc by isolate inlet and outlet hydrocarbon, isolate heat sources (Electric heater, evaporizer , etc), stop critical equipment by activated ESD from push button in the control room. Detail explanation about ESD refers to ESD Philosophy. 6.
Conform that Marine flare stack ready for operation with fuel gas from LNG Back-up pump G-2305 and LNG Back-up Vaporizer E-2304A/B
7.
Commissioning gas purge to flare header and make sure flare header in positive pressure and ready for receive gas.
8.
START to Operate Emergency Power Generator for supply power requirement to Cooling water pump and Fin fan Cooler
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
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KONTRAKTOR:
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PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
9.
02021 A
START to Operate Diesel Power Generator for supply power requirement to LNG Back-up pump. Note: Diesel Power Generator Designed for 8 hours continuous operation.
10.
Ensure that power available for supply power for LNG Back-up pump and get fuel gas system from Ambient vaporizer.
11.
Line up the system ,and start to run LNG Back-up pump G-2305
12.
Start 1 Power Generator (PG-9001A) for supplying electrical power to LNG Circulation pump and BOG Compressor including cooling water system.
13.
Start LNG Circulation pump and BOG compressor for continuous fuel gas supply to Power Generation A, then stop Emergency Power Generator.
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
KLIENT:
KONTRAKTOR:
NAMA PROYEK :
LOKASI PROYEK :
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PT. PERTAMINA (PERSERO)
PT. INTI KARYA PERSADA TEHNIK
PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
14.
02021 A
Conform Plant Fire Protection include Fire Water system and F&G detector are in operation.
15.
Conform Power Generation C at standby position and ready for operation if needed.
16.
Utility Units include Air system, Fire Protection systems, Fuel gas conditioning include fuel gas electric heater, Power generator, Diesel system, Sea Water Cooling system and Flare system are in operation.
17.
Conform Sea Water line and pump available and ready for operation
18.
Start Sea Water Pump and circulating line to LNG Vaporizer until operating condition
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
KLIENT:
KONTRAKTOR:
NAMA PROYEK :
LOKASI PROYEK :
Rev. No.
: 3
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PT. PERTAMINA (PERSERO)
PT. INTI KARYA PERSADA TEHNIK
PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
19.
02021 A
Start LNG Circulating Pump to cooling down all LNG line gradually to operating condition.
20.
Starts pressurize BOG Compressor System until reach suction operation pressure of BOG compressor used manual by pass valve slowly (keep pressure stable by venting to flare by pressure control if pressure increased suddenly)
21.
Start sealing gas for BOG compressor, lube oil pump, then make sure seal gas and lube oil system on stable condition
22.
Start BOG Compressor with follow the step chart of BOG compressor start up and make sure anti surging valve working well.
23.
Conform fuel gas supply to Main Power Generator A and to flare are in normal condition and under control.
ARUN LNG RECEIVING – HUB & REGASIFICATION TERMINAL Doc. No. : H-FALR-23-1230-001-A
BLACK START-UP SCENARIO AND PROCEDURES
KLIENT:
KONTRAKTOR:
NAMA PROYEK :
LOKASI PROYEK :
Rev. No.
: 3
Page
: of 15
PT. PERTAMINA (PERSERO)
PT. INTI KARYA PERSADA TEHNIK
PROYEK PEMBANGUNAN FASILITAS PENGUMPUL GAS MERBAU DAN FASILITAS PENYERAHAN GAS PAGARDEWA DOH SUMBAGSEL (PAKET-III)
LAPANGAN MERBAU – PAGARDEWA, DAERAH OPERASI HULU (DOH) SUMBAGSEL, INDONESIA
NOMOR PROYEK :
24.
02021 A
Conform LNG Transfer pump and line ready to operation after cooling down to normal operating condition.
25.
Start LNG Transfer Pump to LNG vaporizer to produce Gas for Client and ensure continuous flow fuel gas to Power Generation.
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