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Doc. No.
TANGGUH LNG BPMIGAS
T.Bessho
BP Berau Ltd.
77-IOM-PS-1201
Rev.
Author’s Org.
6D
Project
TLNG
KJP
KJP Doc. No.
S-077-1283-001
Date
16 Oct, 06
KJP Job Code
J-3400-20-0000
Sheet
1 of 25
3.8 MTPA TRAIN CAPACITY Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
X
Core
Non-core
Lifecycle Code
For Information
For Review
For Approval
X
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As-Built
Rev.
Date
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Description
Prep’d
5A
24Feb06
All
For Approval
Suharyono
T.Bessho
M.Ditto
Released
T.Bessho
Y.Kakutani
Y.Kakutani
5, 7 to11
Released (consistency check between U-76 and U350)
T Bessho
Y. Kakutani
Y. Kakutani
6C 22 Sep 06
4 to 6
Released
K. Irwan
Y. Kakutani
Y. Kakutani
6D 16 Oct 06
4 to 6
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Y. Kakutani
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6A 17 May06 4, 6 to13, 19,,28 6B
31 Jul 06
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BP App’d
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 2 of 25
CONTENTS 1. Introduction.................................................................................................................................4 2. Basis of Design.............................................................................................................................4 2.1 Diesel Oil ......................................................................................................................................4 2.2 Equipment ...................................................................................................................................4 2.2.1 DIESEL OIL STORAGE TANK (077-TK-1001) ............................................................................. 4 2.2.2 DIESEL OIL TRANSFER PUMP (077-P-1001) ............................................................................... 4 2.2.3 AUTO SHUT OFF NOZZLE (077-V-1002) .................................................................................... 5 2.3 Process Description .....................................................................................................................5 2.3.1 GENERAL .................................................................................................................................... 5 2.3.2 PLANT SHUTDOWN AND PRE-COMMISSIONING ACTIVITIES ........................................................ 5 2.3.3 DIESEL OIL UNLOADING ............................................................................................................ 6 2.3.4 DIESEL OIL REFUELING .............................................................................................................. 6 2.3.5 DIESEL OIL TRANSFER FROM 077-TK-1001 TO 350-TK-1001................................................... 6 2.3.6 DIESEL OIL TRANSFER FROM 0077-TK-1001 TO EDG DAY TANK 061-EDG-1101/TK-11... 6 3. Preparation for initial start-up ..................................................................................................7 4. Initial Start-up Procedure ..........................................................................................................7 4.1 General.........................................................................................................................................7 4.1.2 INITIAL FILLING BY DIESEL OIL UNLOADING PUMP (080-P-1001) ............................................ 7 4.1.3 INITIAL FILLING BY SHIP PUMP .................................................................................................. 8 5. Normal Operation.......................................................................................................................9 5.1 Diesel Oil Unloading Operation.................................................................................................9 5.1.1 UNLOADING TO DIESEL OIL STORAGE TANK (077-TK-1001) BY DIESEL OIL UNLOADING PUMP (080-P-1001) .......................................................................................................................................... 9 5.1.2 UNLOADING TO DIESEL OIL STORAGE TANK (077-TK-1001) BY SHIP PUMP ............................ 9 5.2 Diesel Oil Refueling Operation ..................................................................................................9 5.3 Diesel Oil Transfer from 077-TK-1001 to 350-TK-1001 ...........................................................10 5.4 Operating Variables ....................................................................................................................10 6. Quality Control .........................................................................................................................11 7. Normal Shutdown Procedure ..................................................................................................12 7.1 General.......................................................................................................................................12 7.2 Normal Shutdown .....................................................................................................................12 8. Emergency Shutdown Procedure ............................................................................................12 8.1 General.......................................................................................................................................12 8.2 Power Failure ............................................................................................................................13 8.3 Instrument Air Failure .............................................................................................................13 8.4 Fires/Serious Leakage...............................................................................................................13 8.5 Equipment Failure ....................................................................................................................14 8.5.1 PUMPS ...................................................................................................................................... 14 8.5.2 AUTO SHUT OFF NOZZLE ......................................................................................................... 14 8.6 Emergency Shutdown System..................................................................................................14 8.6.1 TANK ........................................................................................................................................ 14 8.6.2 PUMP ........................................................................................................................................ 14 9. Safety Procedure .......................................................................................................................15 9.1 General.......................................................................................................................................15 9.2 Hazardous Material ..................................................................................................................16 9.3 Emergency Fire Plan ................................................................................................................16 9.4 Fire Fighting and Protective Equipment ................................................................................16 9.5 Maintenance of Equipment and Housekeeping......................................................................16 9.6 Repair Work..............................................................................................................................17 9.7 Withdrawal of Samples ............................................................................................................17 9.8 Safe Handling of Volatile and Toxic Materials ......................................................................18 9.9 Respiratory Protection .............................................................................................................18 9.10 Breathing Apparatus (B. A.)....................................................................................................19 10. Isolation Procedure for Maintenance......................................................................................20 10.1 General ......................................................................................................................................20
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 3 of 25
10.2 Basic Procedures.......................................................................................................................20 10.2.1 INDIVIDUAL EQUIPMENT / SYSTEM ISOLATION........................................................................ 21 10.2.1.1 Tanks............................................................................................................................ 21 10.2.1.2 Pumps........................................................................................................................... 21 11. Maintenance Procedure............................................................................................................22 11.1 General ......................................................................................................................................22 11.1.1 ROUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 22 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 22 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 22 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 22 11.1.5 TURNAROUND /INSPECTION MAINTENANCE ............................................................................ 23 11.2 Precautions prior to Maintenance...........................................................................................23 11.3 Preparation for Maintenance ..................................................................................................23 11.3.1 INSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 23 11.3.2 REPLACEMENT OF NITROGEN WITH AIR .................................................................................. 24 11.4 Typical isolation method ..........................................................................................................24 11.4.1 TANKS ...................................................................................................................................... 24 11.4.2 PUMPS ...................................................................................................................................... 24 11.4.3 CLOSE OUT ............................................................................................................................... 24 12. Attachment List.........................................................................................................................25
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
1.
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 4 of 25
INTRODUCTION This unit covers the diesel oil requirements in the Tangguh LNG plant including its storage and distribution. The diesel oil will be utilized for emergency diesel driven generators (EDG), diesel engines drivers for critical rotating equipment, and for vehicle fuel or other land transportation required by the Tangguh LNG facility. Only one type of diesel oil will be provided in Tangguh LNG plant. Diesel oil will be supplied from the nearest PERTAMINA UPPDN VII located in Sorong, West Papua. Ship tankers (Local LCT transporter) will be utilized to transport the diesel oil from Sorong to the Tangguh LNG plant for a certain period. The diesel will be offloaded at the Combo Dock using a dockside pump or ship pump to transfer the diesel to the Tangguh LNG facility diesel storage tank (077-TK-1001). The diesel fuel is subsequently distributed to the end-users via a small tanker truck.
2.
BASIS OF DESIGN
2.1
Diesel Oil To support the operation as well as the construction activities in the Tangguh LNG facility, diesel fuel oil is required to cover all demand as described in Utility Heat and Material Balance Unit 077 of Doc. No. 77-PLS-PS-1200 and the corresponding utility flow diagram of 77-UFD-PS-1200. Only one type of diesel oil will be provided in Tangguh LNG plant/GPFSB facilities. The diesel properties will refer to diesel fuel specification developed by PERTAMINA as the main diesel supplier. Property of typical diesel oil is attached in Attachment-7. The diesel fuel shall be free of contaminants, sludge and water.
2.2
Equipment
2.2.1
Diesel Oil Storage Tank (077-TK-1001) Diesel Oil Storage Tank of 077-TK-1001 is a cone-roof atmospheric tank. The diesel storage tank has design pressure of atmospheric with the corresponding design temperature of min. 20 oC and max. 48 oC. The tank nominal capacity is 172 m3. While, the tank net working capacity is expected at 150 m3. Detail information of the tank can be found in atmospheric tank data sheet of 77-EDS-VM-1351.
2.2.2
Diesel Oil Transfer Pump (077-P-1001) Diesel Oil Transfer Pump (077-P-1001) is a canned motor pump operated for intermittent service during diesel filling only via a diesel fuel station. The pump has a rated capacity of 20 m3/h.
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 5 of 25
See the pump data sheet of doc. No. 77-EDS-MC-1401 for further details.
2.2.3
Auto Shut Off Nozzle (077-V-1002) Diesel Filling Nozzle of 077-V-1002 is an automatic shut-off nozzle provided to distribute diesel fuel oil to vehicles as well as small tanker truck for further supply to the end-users. The nozzle is designed for maximum working pressure of 3.5 kg/cm2G and design temperature of min. 20 oC and max. 33 oC. Design flowrate is selected at 12 m3/h. The nozzle is equipped with a hose suitable for 150 lbs ANSI/ASME rating. The hose has length of approximately 5 m. Detail information refers to Diesel Filling Nozzle Data Sheet of doc. no. 77-EDS-MC-1482.
2.3
Process Description
2.3.1
General Diesel oil is stored in Diesel Oil Storage Tank (077-TK-1001). The tank is an atmospheric storage tank located in LNG plant facilities. The Diesel Oil Transfer Pump (077-P-1001) transfers diesel from the Diesel Oil Storage Tank to the small tanker truck for distribution. Diesel oil from the storage tank will be supplied to the following end-users as required: (1) Sea water supply pump diesel driver (2) Main firewater pump diesel driver (3) Plant emergency diesel driven generators (EDG’s) (4) Diesel users outside the plant battery limit. (5) Vehicle fuel station
2.3.2
Plant Shutdown and Pre-commissioning activities There are two operating modes that generally define the range of the diesel oil consumption due to plant shut down and pre-commissioning activities. During a total plant shutdown, i.e. no Steam Turbine Generators (STG) running, diesel oil will be mainly be utilized for emergency electrical power generation. A large quantity of diesel oil is required during a total plant shutdown to maintain diesel supply to the emergency diesel generator. The Diesel oil storage tank is designed to provide sufficient capacity for the diesel fuel consumption requirement for a one-week total plant shutdown. During pre-commissioning activities; Emergency Diesel Generators (EDG) will consume diesel oil during around two months until the STG can be started up. Because of the high fuel consumption during this pre-commissioning period the Diesel Storage Tank (077-TK-1001) will have to be
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 6 of 25
refilled regularly. For construction activities, diesel oil will be supplied from temporary facilities provided by EPC contractor. Once the LNG plant will have been commissioned, diesel oil will be loaded to Diesel Storage Tank (077-TK-1001) through diesel oil loading line. Before diesel oil is used for vehicles, complete dewatering shall be implemented from the tank bottom drain.
2.3.3
Diesel Oil Unloading The diesel oil is unloaded at the Combo Dock using a Diesel Oil Unloading Pump (080-P-1001) or ship pump and transferred to Diesel Oil Storage Tank (077-TK-1001) located in the Unit-077 Diesel/Fuel Oil Storage and Transfer area. The diesel oil is also unloaded to Unit-350 Diesel Oil Storage Tank (350-TK-1001). Unloading operation to Unit-350 Diesel Oil Storage Tank is described in Operation Manual for GPFSB and Diesel Oil Storage/Transfer System (350-IOM-PS-1201).
2.3.4
Diesel Oil Refueling During normal operations, vehicles and the periodic test run of emergency diesel generators and the other diesel engine drivers are the only diesel oil consumers. A small tanker truck will periodically transport the diesel oil from the storage tank to the vehicle fuel station located outside the plant fence near the plant main gate. A small amount of diesel oil is also transported to the other diesel users for test run purposes. There is no large quantity of diesel oil consumed during normal plant operations. Therefore, the diesel oil storage tank can be refilled approximately every three months.
2.3.5
Diesel Oil Transfer from 077-TK-1001 to 350-TK-1001 Design flexibility is made in order to allow transferring diesel oil from Diesel Oil Storage Tank (077-TK-1001) to Diesel Oil Storage Tank (350-TK-1001). The operation is enabled by opening block valve located on bypass line around the Diesel Oil Transfer Pump (077-P-1001), which is routed to line 077-FD-1001.
2.3.6
Diesel Oil transfer from 0077-TK-1001 to EDG day tank 061-EDG-1101/TK-11 The maximum capacity of the EDG day tank is 35 m3. The fuel consumption of a single EDG is about 0.72 m3/h under full load condition. The Electrical emergency load can be supplied by 3 EDG’s. The EDG day tank will therefore require refilling about every 12 hours with a minimum of 5 m3 left when refilling starts. Refilling of the EDG day tank is preferably done using a 15 m3 auto tanker every 6 hours or a 30m3 auto tanker truck every 12 hours. There are also an electric and a manual pump mounted on the EDG day tank to fill the tank in case the tanker truck does not have an on board fuel pump. When the plant is in normal operation, the EDG’s will be run for a monthly load test as per Company’s maintenance program. This load testing requires two machines at a time for one hour every month. It results in a fuel consumption of 1.44 m3 (0.72 m3 /EDG X 2 units) versus
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 7 of 25
an available fuel tank capacity of 35 m3. The majority of the fuel could therefore remain in the tank for longer term and end up getting deteriorated To check the diesel quality a fuel sample shall be taken using the sample valve provided at the bottom of the EDG day tank (item 18 on document V-2181-001-1-221 shows the day tank 061-EDG-1101/TK-11) The diesel fuel shall be examined for contamination by water, sludge, sulfur or for degradation by aging. For this purpose a “dip slide” fuel test kit “Dieselcraft” or equal is recommended. This test kit will detect asphaltene, fungus, bacteria and mold. To determine the diesel quality a sample shall be analyzed in a fuel analyzer Zeltex ZX440 XL or equal. If it is determined that the fuel has unacceptable levels of sludge or has biological activity corrective measures shall be taken. Once the day tank is filled with fuel its color can be observed through the level glass on the tank. With fuel stored in the tank a sample shall be taken and analyzed every 6 months but definitely no later than one year after bunkering the fuel. On a monthly basis the diesel tank shall be checked for water contamination, any water shall be immediately drained. Furthermore every 1000 hrs of EDG operation the pre-filter fuel cartridges and every 500 hrs both fuel filters of each EDG shall be replaced with the EDG’s standing still.
3.
PREPARATION FOR INITIAL START-UP Refer to Commissioning Manual (077-PRC-OP-1001).
4.
INITIAL START-UP PROCEDURE
4.1
General Diesel oil for initial filling of the systems is transported by a ship tanker and introduced by Diesel Oil Unloading Pump (080-P-1001) or Ship Pump. Before initial filling, make a final inspection of the systems prior to introducing the process fluid to ensure the followings (1) Valves at PSV inlet/outlet are CSO (2) Pump minimum flow lines valves are LO (3) All instrumentation tapping points are in the open position. (4) Piping vents and drains are closed.
4.1.2
Initial Filling by Diesel Oil Unloading Pump (080-P-1001) (1) Berth a ship tanker at the specified location of Combo Dock. (2) Connect a flexible hose between ship tanker and Unloading Connection (080-HC-1001A). (3) Establish the unloading line from Unloading Connection (080-HC-1001A) to Diesel Oil Storage Tank (077-TK-1001).
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Confirm the following valves are open; -
Block valve just downstream of Unloading Connection (080-HC-1001A)
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 8 of 25
-
Block valve (LO) located at trestle/ shore line battery limit.
-
Suction valve of Diesel Oil Unloading Pump (080-P-1001)
-
Discharge valve of Diesel Oil Unloading Pump (080-P-1001)
-
Block valve on unloading line to 077-TK-1001 (Line No. 077-FD-1001)
Confirm the following valves are closed -
Block valve just upstream of Filling Connection (080-HC-1001B)
-
Bypass valve of Diesel Oil Unloading Pump (080-P-1001)
-
Bypass valve of Diesel Oil Loading Pump (350-P-1001) on line 350-FD-1104-4”
-
Suction valve of Diesel Oil Loading Pump (350-P-1001)
(4) Check level gauge (077-LI-1101B) indicates to be lower than Low Liquid Level (LLL). (5) Check if all of the valve open/close status is correctly set up, or not. (6) Start Diesel Oil Unloading Pump (080-P-1001) by the field hand switch (080-HS-1701). Note : The Diesel Oil Unloading Pump (080-P-1001) and Ship Pump shall not be used simultaneously for unloading diesel oil. Before pump (080-P-1001) start, line-up should be checked., i.e all valve open/close status are correct or not. Pump discharge isolation valve should not use a pressure regulation. (7) Observation of 077-LI-1101A on DCS and field observation of 077-LI-1101B at location adjacent to diesel filling station are available. Operator can also check diesel refueled to each user by means of flow totalizer meter 077-FQI-9021. Before final tank level reaches High Liquid Level (HLL), alert combo dock operator that unloading operation is about to be completed. Note : The maximum tank level is 5490 mm. (8) Check level gauge (077-LI-1101B). (9) Stop Diesel Oil Unloading Pump when required volume is unloaded. (10) Close Discharge valve of Diesel Oil Unloading Pump (080-P-1001). (11) Close the valves which were opened in step (3) except the valves with LO indication. (12) Disconnect the flexible hose at the unloading connection (080-HC-1001A) and drain to the ship tanker. 4.1.3
Initial Filling by Ship Pump (1) Berth a ship tanker at the specified location of Combo Dock. (2) Connect a flexible hose between ship tanker and Unloading Connection (080-HC-1001A). (3) Establish unloading line from Unloading Connection (080-HC-1001A) to Diesel Oil Storage Tank (077-TK-1001). Confirm the following valves are open;
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-
Block valve just downstream of Unloading Connection (080-HC-1001A)
-
Block valve (LO) located at trestle/ shore line battery limit.
-
Bypass valve of Diesel Oil Unloading Pump (080-P-1001)
-
Block valve on unloading line to 077-TK-1001 (Line No. 077-FD-1001)
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 9 of 25
Confirm the following valves are closed -
Block valve just upstream of Filling Connection (080-HC-1001B)
-
Suction valve of Diesel Oil Unloading Pump (080-P-1001)
-
Discharge valve of Diesel Oil Unloading Pump (080-P-1001)
-
Suction valve of Diesel Oil Loading Pump (350-P-1001)
-
Bypass valve of Diesel Oil Loading Pump (350-P-1001) on line 350-FD-1104-4”
-
Discharge valve of Diesel Oil Loading g Pump (350-P-1001)
(4) Check level gauge (077-LI-1101B) indicates to be lower than Low Liquid Level (LLL). (5) Check if all of the valve open/close status is correctly set-up. (6) Start Ship Pump. Note : The Diesel Oil Unloading Pump (080-P-1001) and Ship Pump shall not be used simultaneously for unloading diesel oil. (7) Observation of 077-LI-1101A on DCS and field observation of 077-LI-1101B at location adjacent to diesel filling station are available. Operator can also check diesel refueled to each user by means of flow totalizer meter 077-FQI-9021. Before final tank level reaches HLL (High Liquid Level), alert combo dock operator that unloading operation is about to be completed. Note: The maximum tank level is 5490mm. (8) Stop Ship Pump when required volume is unloaded. (9) Close the valves which were opened in step (3) except the valves with LO indication. (10) Disconnect the flexible hose at the unloading connection (080-HC-1001A) and drain to the ship.
5.
NORMAL OPERATION
5.1
Diesel Oil Unloading Operation
5.1.1
Unloading to Diesel Oil Storage Tank (077-TK-1001) by Diesel Oil Unloading Pump (080-P-1001) See section 4.1.2 in this manual.
5.1.2
Unloading to Diesel Oil Storage Tank (077-TK-1001) by Ship Pump See section 4.1.3 in this manual.
5.2
Diesel Oil Refueling Operation Auto Shut Off Nozzle (077-V-1002) is used to refuel the vehicles such as truck. (1) Establish refueling line from Diesel Oil Storage Tank (077-TK-1001) to Auto Shut Off Nozzle (077-V-1002) Confirm the following valves are open:
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-
Suction valve of Diesel Oil Transfer Pump (077-P-1001).
-
Discharge valve of Diesel Oil Transfer Pump (077-P-1001).
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 10 of 25
Confirm the following valve is closed: -
3” Block valve on unloading line to 077-TK-1001 (Line No. 077-FD-1001)
-
2” Block valve on the line between unloading line (077-FD-1001-3”) and pump min flow line (077-FD-1004-2”).
(2) Check tank level gauge (077-LI-1101B) and confirm required volume is stored. (3) Start Diesel Oil Transfer Pump (077-P-1001) by the field hand switch (077-HS-9801). (4) Take out the Auto Shut Off Nozzle (077-V-1002) and set it to the refueling point of the vehicle. (5) Pull a lever of Auto Shut Off Nozzle (077-V-1002) and start refueling. Refueling automatically stops when liquid level of vehicle fuel tank reaches the level sensor of the Auto Shut Off Nozzle (077-V-1002). (6) Put Auto Shut Off Nozzle (077-V-1002) back to the original location. (7) Stop Diesel Oil Transfer Pump (077-P-1001) by the pushing field hand switch (077-HS-9801). 5.3
Diesel Oil Transfer from 077-TK-1001 to 350-TK-1001 The operation of transferring diesel oil from 077-TK-1001 to 350-TK-1001 is available if supply from ship tanker is disconnected due to ship troubles/bad weather.
(1) Establish lines from 077-TK-1001 to 350-TK-1001 Confirm the following valves/spectacles blind are open: -
Shut down Valve 077-USVE-2010
-
3” Block valve at suction of 077-P-1001
-
2” By pass valve (status NC) on the line between unloading line (077-FD-1001-3”) and pump min flow line (077-FD-1004-2”) as ‘supply valve’ to 350-TK-1001
-
Three 4” block valves on the unloading line to 350-TK-1001 (350-FD-1104-4”).
Confirm the following valves are closed: -
Block valve at discharge line of 077-P-1001 (after check valve and ¾” drain).
-
3” NC-Block valve at unloading line to 077-TK-1001 (077-FD-1001).
-
Pump suction valve of 350-P-1001.
-
Pump discharge valve of 350-P-1001.
(2) Start Diesel Oil Transfer Pump (077-P-1001) by pushing the field hand switch (077-HS-9801) (3) Monitor level gauge 350-LI-1171. Note : The maximum tank Level is 6000 mm. (4) Close ‘supply valve’ or by pass valve at discharge line of 077-P-1001 when required volume is transferred. (5) Stop Diesel Oil Loading Pump. (6) Return all of the related valves to be origin position (before unloading the tank of 350-TK-1001). 5.4
Operating Variables
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The facilities are normally manned and operated intermittently.
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
6.
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 11 of 25
•
When unloading to 077-TK-1001, operators monitor tank level at field (077-LI-1101B) or at MCR (077-LI-1101A) with radio contact in combo dock operators.
•
When using Auto Shut Off Nozzle (077-V-1002), operators monitor inlet pressure of shut off nozzle (077-PG-9203) and total flow rate (077-FQI-9021)
QUALITY CONTROL Operators in this unit have no direct control of the quality of the diesel oil unloaded from the diesel oil supplier. However water may be contaminated in the diesel oil during transportation from the supply depot. To take the following actions for quality control; (1) At the end of initial unloading operation, take a sample from the tank bottom drain and do a visual inspection. If water in pipeline is carried over, water shall be drawn off from the tank bottom. (2) On weekly basis, water in Diesel Oil Storage Tank (077-TK-1001) shall be drained out, water shall be drawn off from tank bottom.
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
7.
NORMAL SHUTDOWN PROCEDURE
7.1
General
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 12 of 25
Shut-downs can be classified into normal shut-down and emergency shut-down. A normal shut-down is a scheduled shut-down, while an emergency shut-down is an unscheduled shut-down due to a failure or accident. The emergency shut-down procedures are shown in Section 8. When shutting down a unit, it is most 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 shut-down schedule must be reviewed and discussed and all operators must be notified of it in advance.
7.2
Normal Shutdown Normal shutdown of Unit 077 is represented by the following two activities. (1) Normal stop of refueling operation (2) Regular maintenance of equipment Note that the complete transfer of diesel oil is required when Diesel Storage Tank (077-TK-1001) undergoes internal inspection or maintenance.
8.
EMERGENCY SHUTDOWN PROCEDURE
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. (6) Emergency Shut-down System
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Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 13 of 25
The emergency shut-down system is designed to enable the control room and/or field operator to remotely shut-down the system and/or facility. Refer to Cause and Effect Chart of Unit 077.
8.2
Power Failure Power failure will not cause an emergency situation. Because Diesel Oil Transfer Pump (077-P-1001) and Diesel Oil Unloading Pump (080-P-1001) will stop, stop unloading/refueling activities.
8.3
Instrument Air Failure Plant-wide instrument air failure will cause the various control and ESD valves to assume their fail-safe position as well as loss of local pneumatic indication and recording (P1, LI, Fl, etc.). At a plant-wide air failure, - Loading operation will stop.
The following procedure must be taken at the discretion of the operators. - Stop the pumps which are running with min. flow condition and isolate the valves
8.4
Fires/Serious Leakage The required action will differ depending on the location/extent of the leak fire. In general cases, the following steps must be taken. (1) Stop hot work being carried out around the area. Notify the fire safety department about the situation. (2) Stop unloading and/or refueling activities. (3) Shut-down any related pumps. (4) Stop Unit 076 HC Condensate Loading if affected area is the combo dock. (5) Isolate equipment and piping affected by the leak fire, if possible pressure build up should be taken into consideration. (6) 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.
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8.5
Equipment Failure
8.5.1
Pumps
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 14 of 25
Pump bypass for Diesel Oil Transfer Pump (077-P-1001) is provided. Refuel by gravity flow.
8.5.2
Auto Shut Off Nozzle In case of failure, the following equipment at another area is available for refueling. -
Filling station with an auto shut off nozzle at GPFSB area
-
Vehicle Fuel Station (077-V-1001)
8.6
Emergency Shutdown System
8.6.1
Tank A high level shut-down function is provided for Diesel Oil Storage Tank (077-TK-1001) to protect the tank from overflow.
8.6.2
Pump A low level shut-down function is provided for Diesel Oil Transfer Pump (077-P-1001) to protect the pump from loss of suction.
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9.
SAFETY PROCEDURE
9.1
General
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 15 of 25
To prevent accidents it is of the utmost importance that all personnel be instructed properly of the following subject:
- The leaks and responsibilities of the operators - The methods to accomplish this in a safe manner
The following safety regulations cover operations of particular concern to the personnel responsible for the unit. They are intended to supplement any existing general plant safety regulations which cover all units; reference should be made to the latter for all points not mentioned below. Mechanical craftsmen working on their unit will be governed by their own departmental safety regulations, but the operator should see that none of the following safety regulations are violated by mechanical workers.
In addition to specifically defined rules and practices, the exercise of good judgment by every person involved is essential to safe operation. An operator should be alert for any situation which might present a personnel hazard. It should also be the responsibility of each person familiar with the plant to warn other workers who enter the plant of possible hazards they could encounter.
All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, and main isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other protective equipment such as hard hats, rubber gloves, etc.
Soda acid or foam type extinguisher must not be used on fire around electrical equipment because the water solution will conduct electricity and may aggravate the difficulty or result in the electrocution of personnel.
Carbon dioxide or dry powder extinguisher may be used safety on electrical fires.
Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered.
Safety hats must be worn when outdoors.
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 16 of 25
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 Diesel Oil is a complex mixture of hydrocarbons from a variety of chemical processes blended to meet standardized product specifications. Composition varies greatly and includes C9 to C20 hydrocarbons. The major effect of exposure to diesel oil is giddiness, headache, central nervous system depression; possible irritation of eyes, nose, and lungs; and dermal irritation.
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.
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.
9.5
Maintenance of Equipment and Housekeeping 1.
2.
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Operating equipment should be checked frequently for signs of leakage, overheating, or corrosion, so that unsafe conditions may be corrected before they result in serious consequences. Unusual conditions should be reported at once. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the equipment must be replaced when repair work is completed. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
4. 5. 6. 7. 8.
9.
9.6
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.
Repair Work 1. 2. 3. 4.
5.
6.
7. 8. 9.
9.7
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 17 of 25
Mechanical work around and operating unit must be kept to a minimum, and the minimum number of men should be used. No mechanical work on the equipment is to be done without a properly authorized work permit. Safety hats must be worn by all personnel in all areas at all times. No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized by a work permit. Catch basins, manholes, and other sewer connections must be properly sealed off to prevent the leakage of gases, which may ignite upon contact with an open flame. No personnel shall enter a vessel for any purpose whatsoever until it has been adequately purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases and an entry permit issued. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not physically strike these lines and avoid operation conditions, which would cause a water hammer to start. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other cleaning purposes. Equipment should not be left open overnight. At the end of each day’s work blanks or spades should be installed to prevent entry of flammable materials due to valve let-by. Welding cylinders should be removed from site to a designate safe area at the end of each working day.
Withdrawal of Samples Samples shall be withdrawn from the unit only by authorized personnel. Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. A container must never be filled to the brim, in order to minimize risk of subsequent spillage.
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When sampling any product liquids, gloves and goggles will be worn.
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BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 18 of 25
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.
9.8
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.
9.9
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 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:
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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.
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 19 of 25
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. 9.10
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.
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 20 of 25
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.
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10.2.1
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 21 of 25
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.
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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PUMP
BP Berau Ltd. Tangguh LNG Project Operation Manual for Unit 077 Diesel/Fuel Oil Storage and Transfer
11.
MAINTENANCE PROCEDURE
11.1
General
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 22 of 25
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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11.1.5
Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 23 of 25
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. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 24 of 25
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 Unit 077 Diesel/Fuel Oil Storage and Transfer
12.
ATTACHMENT LIST
Attachment-1 Process Flow Diagram 77-UFD-PS-1200
Attachment-2 P&IDs 77-PID-PS-1201
Attachment-3 Equipment Data Sheet (list only) 77-EDS-VM-1351 77-EDS-MC-1401 77-EDS-MC-1482
Attachment-4 Instrument Alarm Set Point (list only) 77-SPE-CS-1754
Attachment-5 Cause and Effect Charts (list only) 77-LOG-PS-1150
Attachment-6 Laboratory Sampling Schedule
Attachment-7 Property of typical diesel oil
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Doc. No. 77-IOM-PS-1201 KJP Doc. No. S-077-1283-001 Rev. 6D Sheet No. 25 of 25
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