Alarm & Trip Setting List (4)

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PT. Brown & Root Indonesia

Doc. No. 63-IOM-PS-1201 Rev. 6B

Project TLNG Author’s Org. KJP

KJP Doc. No. S-063-1283-001 Date 20 Oct, 06

KJP Job Code J-3400-20-0000 Sheet 1 of 38

X Core Non-core Lifecycle Code A

For Information For Review For Approval X Released As-Built

Rev. Date Page Description Prep’d Chk’d App’d BP App’d

5A 24 Feb’06 All For Approval T.Kanamaru Y.Kakutani Y.Kakutani

6A 10 May‘06 All For Release Winanto Y. Kakutani Y. Kakutani

6B 20 Oct.06 5, 13,

14,15

Updated as Marked T.Kanamaru Y.Kakutani Y.Kakutani

3.8 MTPA TRAIN CAPACITY

Operation Manual for Fuel Gas System U-063

BPMIGAS

TANGGUH LNG

BP Berau Ltd.

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BP Berau Ltd. Tangguh LNG Project Doc. No.63-IOM-PS-12013.8 MTPA TAIN CAPACITY KJP Doc. No. S-063-1283-001 Rev. 6BOperation Manual for Fuel Gas System Unit 063 Sheet No. 2 of 38

CONTENTS

1. INTRODUCTION.......................................................................................................................4

2. BASIS OF DESIGN ....................................................................................................................4

2.1 General.........................................................................................................................................4 2.2 HP Fuel Gas Consumers Firing Load.......................................................................................5 2.2.1 Compressor Gas Turbines Firing Load...................................................................................... 5 2.3 LP Fuel Gas Consumers Firing Load........................................................................................5 2.3.1 Boiler Firing Load ..................................................................................................................... 5 2.3.2 Fired Heater Firing Load ........................................................................................................... 5 2.3.3 Incinerator Firing Load.............................................................................................................. 5 2.3.4 Miscellaneous Firing Load ........................................................................................................ 5 2.4 HP FG Suppliers Load ...............................................................................................................6 2.4.1 Boil Off Gas (BOG) Supply ...................................................................................................... 6 2.4.2 Dry Sweet Gas Supply............................................................................................................... 6 2.4.3 AGRU Inlet Gas Supply ............................................................................................................ 6 2.5 LP FG Suppliers Load................................................................................................................6 2.5.1 HP Flash Gas Supply ................................................................................................................. 6 2.5.2 Condensate Stabilizer OVHD Gas Supply................................................................................. 6 2.5.3 HP Fuel Gas letdown Supply..................................................................................................... 6 2.5.4 Wet Feed Gas Supply (Black Startup Only) .............................................................................. 6 2.6 Fuel Gas Properties.....................................................................................................................7 2.6.1 HP Fuel Gas Properties.............................................................................................................. 7 2.6.2 LP Fuel Gas Properties .............................................................................................................. 8 2.7 Special Equipment ......................................................................................................................9 2.7.1 HP Fuel Gas Mixing Drum (051/052-D-1201).......................................................................... 9 2.7.2 Fuel Gas Start-up Heater (063-E-1002)..................................................................................... 9 2.8 Process Description.....................................................................................................................9 2.8.1 HP Fuel Gas System .................................................................................................................. 9

2.8.2 LP Fuel Gas System................................................................................................................. 10 3. OPERATION VARIABLES AND PROCESS CONTROLS................................................13

3.1 External Variables ....................................................................................................................13 3.1.1 Fuel Gas Composition Change ................................................................................................ 13 3.1.2 Electrical Load Change for STG.............................................................................................. 13 3.1.3 Trip of Fuel Users and Fuel Suppliers ..................................................................................... 13 3.2 Internal Variables .....................................................................................................................15 3.2.1 2 Train Holding Mode ............................................................................................................. 16 3.2.2 2 Train Loading Mode ............................................................................................................. 16 3.2.3 1 Train Holding Mode ............................................................................................................. 16 3.2.4 1 Train Loading Mode ............................................................................................................. 16 3.2.5 2 Train Loading Mode (Max Fuel Gas) ................................................................................... 16

3.3 Process Control .........................................................................................................................16 3.3.1 Pressure Control on Compressed BOG.................................................................................... 16 3.3.2 Pressure Control on HP Fuel Gas System................................................................................ 17 3.3.3 Pressure Control on LP Fuel Gas System................................................................................ 18

4. PREPARATION FOR INITIAL START-UP ........................................................................18

5. NORMAL START-UP PROCEDURE ...................................................................................18 5.1 Start-up Procedure after a Scheduled Shutdown...................................................................18 5.1.1 Flare Ignition for Initial Start-up.............................................................................................. 19 5.1.2 LP Fuel Gas System Start-up................................................................................................... 21 5.1.3 Establishment of LP Fuel Gas System for 2 Trains operation................................................. 21 5.1.4 HP Fuel Gas System Start-up without BOG............................................................................ 22

5.1.5 Establishment of HP Fuel Gas System using Compressed BOG............................................. 23 5.2 Re-start Procedure after Emergency Shutdown ....................................................................23 5.2.1 Re-startup after Total Emergency Shutdown (Black Startup) ................................................. 24 5.2.2 Re-startup after Partial Emergency Shutdown......................................................................... 24

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6. NORMAL OPERATION.........................................................................................................25 6.1 General.......................................................................................................................................25 6.2 Pressure Set Point Adjustment................................................................................................25 6.2.1 Supply Pressure Adjustment of AGRU Inlet Gas.................................................................... 25 6.2.2 Over Pressure Control for HP Fuel Gas................................................................................... 25

6.3 Switch-over to Spare LP Fuel Gas KO Drum ........................................................................25

7. NORMAL SHUTDOWN PROCEDURE ...............................................................................26 7.1 General.......................................................................................................................................26 7.2 HP Fuel Gas System Normal Shutdown (One Train Shutdown)..........................................26 7.3 LP Fuel Gas System Normal Shutdown (Both Trains Shutdown) .......................................27

8. EMERGENCY SHUTDOWN PROCEDURE .......................................................................28 8.1 General.......................................................................................................................................28 8.2 Partial Shutdown by Interlock Logic ......................................................................................28 8.2.1 Shutdown by Train-1(Train-2) Total Shutdown 091(092)-US-2000....................................... 28 8.2.2 Shutdown by Unit 021/031(022/032) Isolation 031(032)-US-2000A ..................................... 29 8.2.3 Shutdown by Unit 041/051(042/052) Isolation 051(052)-US-2400A ..................................... 29

8.3 Total Shutdown by Interlock Logic.........................................................................................29 9. SAFETY PROCEDURE...........................................................................................................30

9.1 General.......................................................................................................................................30 9.2 Emergency Fire Plan ................................................................................................................31 9.3 Fire Fighting and Protective Equipment ................................................................................31 9.4 Maintenance of Equipment and Housekeeping......................................................................31 9.5 Repair Work..............................................................................................................................31 9.6 Withdrawal of Samples ............................................................................................................32 9.7 Safe Handling of Volatile and Toxic Materials ......................................................................32 9.8 Respiratory Protection .............................................................................................................32 9.9 Breathing Apparatus (B. A.) ....................................................................................................33 9.9.1 Nitrogen ................................................................................................................................... 33

9.9.2 Corrosive Materials.................................................................................................................. 33 9.9.3 Chemicals ................................................................................................................................ 33

10. ISOLATION PROCEDURE FOR MAINTENANCE...........................................................34 10.1 General ......................................................................................................................................34 10.2 Basic Procedures.......................................................................................................................34 10.2.1 Train Isolation ......................................................................................................................... 34 10.2.2 Individual Equipment / System Isolation ................................................................................ 34

10.2.2.1 Horizontal and Vertical Pressure Vessels ........................................................................... 34 10.2.2.2 Shell and Tube Heat Exchangers .................................................................................. 35

11. MAINTENANCE PROCEDURE............................................................................................36 11.1 General ......................................................................................................................................36

11.1.1 Routine/First line/ Maintenance .............................................................................................. 36 11.1.2 Breakdown Maintenance......................................................................................................... 36 11.1.3 Planned Preventive Maintenance............................................................................................. 36 11.1.4 Predictive/Condition Based Monitoring .................................................................................. 36 11.1.5 Turnaround /Inspection Maintenance...................................................................................... 36 11.2 Precautions prior to Maintenance...........................................................................................36 11.3 Preparation for Maintenance ..................................................................................................37 11.3.1 Installation of blank flanges or spades..................................................................................... 37 11.4 Typical isolation method ..........................................................................................................37 11.4.1 Vessels/Drums......................................................................................................................... 37 11.4.2 Shell and Tube Type Heat Exchangers.................................................................................... 37 11.4.3 Close out.................................................................................................................................. 38

12. ATTACHMENT LIST .............................................................................................................38

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1. INTRODUCTION

The Fuel Gas System (Unit-051/052 and 063) is designed to collect, separate liquids, mix and

distribute fuel gas required in the Tangguh LNG plant. The system is also designed to minimizesudden variances in the fuel gas stream composition and conditions arising from various plantoperating conditions and upsets. Another function of the system is to stabilize the fuel Wobbe index

(a function of heating value, gas temperature, and specific gravity) for the gas turbine by heating andmixing the fuel gas properly.

The fuel gas is utilized as the main fuel for the gas turbine drivers for the refrigerant compressors,acid gas incinerator, regeneration gas fired heaters and package boilers. A small amount of fuel gas is

also used for flare purge & pilot gas, and non-hazardous solid waste treatment incinerator.

Based on the requirement of operating pressure, the fuel gas system is divided into two pressurelevels, high-pressure fuel gas (HP) and low-pressure fuel gas (LP). The HP fuel gas is utilized for the

gas turbine drivers for the refrigerant compressors and the LP fuel gas is utilized for package boilers,regeneration gas heaters, acid gas incinerator and other miscellaneous users.

The sources of the HP fuel gas are;

- Boil-off Gas (BOG) leaving the LNG storage and Loading Unit (Unit-071)

- Spent Regeneration Gas from the regeneration gas system (Unit-031/032)

- Sour Natural Gas from Feed Gas KO Drum in the AGRU (Unit-021/022)

The sources of the LP fuel gas are;

- Flash Gas from the stabilizer overhead (Unit-011)

- HP Flash Gas from amine HP flash drum overhead in the AGRU (Unit-021/022)

- HP Fuel Gas let-down gas from HP Fuel Gas System (Unit-051/052)

- Feed gas from the Pipeline and downstream of Onshore Receiving Facilities (ORF) Unit (Initial

Black Start only)

2. BASIS OF DESIGN

2.1 General

The HP fuel gas system (Unit-051/052) and the LP fuel gas system (Unit-063) are designed to supply

HP/LP fuel gas to the plant at any operation mode at either 1 or 2 train operation.

Operation modes considered are as follows;

Holding Mode: LNG production being rundown to LNG tank

LNG is stored in LNG tank and no product loading operation is being done.

Loading Mode: LNG production being rundown to LNG tank

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LNG is stored in LNG tank and LNG loading operation to a tanker is being

done.

It is taken into account that the fuel system can operate at any single failure of fuel gas supplier.

Refer to section 3.1.3 to show the relationship between process control reaction and response tobe taken by operators for process controller reactions and operator responses atin each single

failure of HP/LP fuel gas supplier. The simplified HP/LP fuel gas configurations are shown inFigure 2-8-1 and 2-8-2 respectively.

2.2 HP Fuel Gas Consumers Firing Load

2.2.1 Compressor Gas Turbines Firing Load

The unique HP fuel consumers are Frame 7 gas turbines for 051-CG-1001/1002

(052-CG-1001/1002). They consume a total firing duty of 457 MW per one LNG train.

2.3 LP Fuel Gas Consumers Firing Load

2.3.1 Boiler Firing Load

Three Package Boilers (062-F-1001A/B/C) are required to generate HP steam as below for eachoperating mode:

Operating Mode Electric Load [MW] Steam Load [ton/hr] Firing Duty [MW]

2 Trains Holding Mode 57.0 98.6 x 3 256.1

2 Trains Loading Mode 60.0 95.7 x 3 248.6

1 Train Holding Mode 43.0 78.4 x 3 203.7

1 Train Loading Mode 46.0 79.6 x 3 206.8

2.3.2 Fired Heater Firing Load

The regeneration gas heater (031/032-F-1001) consumes a firing duty of 1.13 - 8.80 MW per one

LNG train.

2.3.3 Incinerator Firing Load

The incinerator (021/022-F-1010) consumes a firing duty of 23.2 MW per one LNG train.

2.3.4 Miscellaneous Firing Load

A small amount of fuel gas is consumed by flare purge & pilot gas (086-FL-1001/1002/1003), and the

non-hazardous solid waste treatment incinerator (089-F-1001).

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2.4 HP FG Suppliers Load

2.4.1 Boil Off Gas (BOG) Supply

Components of BOG are methane (C1) and nitrogen (N2).

Design flow rate of compressed BOG discharged from U-071 is 75.0 ton/hr at 2 Train Loading Mode,39.4 ton/hr at 1 Train Loading Mode. The compressed BOG is distributed to both Train-1 and

Train-2 in which constant flow rate of the compressed BOG is delivered through the regeneration gassystem and excess compressed BOG is delivered bypassing the regeneration gas system.

2.4.2 Dry Sweet Gas Supply

Dry sweet gas is supplied through 031/032-PV-1214 on outlet of the dehydration and mercuryremoval unit as a make-up regeneration gas. It is designed to supply 35.2 ton/hr (2100 kg-mol/h) of

the dry sweet gas in case of unavailability of compressed BOG.

2.4.3 AGRU Inlet Gas SupplyAGRU inlet gas is supplied through 021/022-PV-1271 downstream of the feed gas KO drum(021/022-D-1001) overhead as a backup fuel in each train. It is designed to supply 46.1 ton/hr of the

warm feed gas in case of black startup operation for two gas turbines.

2.5 LP FG Suppliers Load

2.5.1 HP Flash Gas Supply

HP flash gas is supplied through 021/022-PV-1205 on overhead of the amine HP flash drum

(021/022-D-1001) as a primarily LP fuel gas source in each train. The design flow is 4.4 ton/hr pertrain.

2.5.2 Condensate Stabilizer OVHD Gas Supply

Sour natural gas is supplied through 011-PV-1201/1221 on overhead of the condensate stabilizer

(011-T-1001A/B) as a primarily LP fuel gas source. The design flow is 2.3 ton/hr.

2.5.3 HP Fuel Gas letdown Supply

HP fuel gas is supplied through pressure let-down valve 091/092-PV-1032 as a supplementary LP

fuel gas source. The design flow is 28.2 ton/hr per train to cover 200% of normal flow in case loss of

one of two pressure let-down valves.

2.5.4 Wet Feed Gas Supply (Black Startup Only)

Wet feed gas from the Pipeline and/or downstream of ORF Unit is supplied through 063-PV-1201downstream of the fuel gas start-up heater (063-E-1201). The design flow is 14.6 ton/hr based on the

requirement of fuel gas for one package boiler operating at rated capacity. This supplier is used onlyfor initial black start-up.

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2.6 Fuel Gas Properties

2.6.1 HP Fuel Gas Properties

HP fuel gas properties are following conditions at the inlet of the fuel gas scrubber for the gasturbines.

Table 2-6-1 HP Fuel Gas Properties

Operating ModeAGRU Inlet

Gas

2 Train

Holding Mode

2 Train

Loading Mode

1 Train

Holding Mode

1 Train

Loading Mode

Dry Sweet Gas

(BOG trip)

Pressure, kg/cm2G 24.5 24.5 24.5 24.5 24.5 24.5

Temperature, ºC 70 70 70 70 70 70

Composition, mol%

He 0.030 0.433 0.249 0.418 0.059 0.030

H2O 0.148 0.483 0.476 0.458 0.480 0.501

CO2 12.503 0.728 0.510 0.000 0.328 0.005

N2 0.751 7.942 9.307 8.002 8.306 0.858

C1 84.057 90.248 89.338 91.107 90.648 95.779

C2 1.749 0.102 0.071 0.000 0.143 1.989

C3 0.373 0.022 0.015 0.000 0.010 0.425

iC4 0.059 0.003 0.002 0.000 0.002 0.069

nC4 0.069 0.004 0.003 0.000 0.002 0.078

iC5 0.034 0.002 0.001 0.000 0.001 0.038

nC5 0.024 0.001 0.001 0.000 0.001 0.028

C6s 0.026 0.002 0.001 0.000 0.001 0.025

C7s 0.037 0.003 0.002 0.000 0.001 0.033

C8s 0.023 0.002 0.001 0.000 0.001 0.022

C9+ 0.024 0.004 0.003 0.000 0.002 0.020

Aromatics 0.091 0.007 0.005 0.000 0.003 0.084

Sulfur 0.003 0.015 0.014 0.014 0.014 0.016

Molecular Weight 20.23 17.20 17.31 16.97 17.17 16.81

LHV, kJ/kg 35646 42291 41544 43110 42543 48778

LHV, btu/scf 817 824 815 829 828 929

Wobbe Index 39.3 43.0 42.4 43.6 43.2 49.0

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2.6.2 LP Fuel Gas Properties

LP fuel gas properties are following conditions at the LP fuel gas header.

Table 2-6-2 LP Fuel Gas Properties

Operating Mode Black Start-up2 Train

Holding Mode

2 Train

Loading Mode

1 Train

Holding Mode

1 Train

Loading Mode

Pressure, kg/cm2G 3.5 3.5 3.5 3.5 3.5

Temperature, ºC 41.3 27.7 27.8 24.7 23.2

Composition, mol%

He 0.030 0.024 0.024 0.053 0.026

H2O 0.059 0.810 0.817 0.679 0.618

CO2 12.493 18.682 18.758 15.931 16.698

N2 0.751 0.628 0.627 1.162 0.667

C1 84.056 76.731 76.659 79.388 79.044

C2 1.748 1.891 1.885 1.727 1.840

C3 0.373 0.527 0.523 0.454 0.474

iC4 0.059 0.099 0.098 0.083 0.085

nC4 0.069 0.103 0.103 0.088 0.092

iC5 0.034 0.042 0.041 0.037 0.039

nC5 0.024 0.029 0.029 0.026 0.028

C6s 0.028 0.032 0.032 0.029 0.030

C7s 0.044 0.052 0.052 0.046 0.049

C8s 0.038 0.043 0.043 0.038 0.041

C9+ 0.075 0.081 0.081 0.071 0.075

Aromatics 0.115 0.219 0.220 0.180 0.186

Sulfur 0.003 0.008 0.008 0.007 0.006

Molecular Weight 20.33 22.26 22.28 21.43 21.63

LHV, kJ/kg 35730 30545 30485 32364 32083

LHV, btu/scf 823 770 769 786 786

Wobbe Index 41.3 37.7 37.7 39.4 39.4

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2.7 Special Equipment

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

2.7.1 HP Fuel Gas Mixing Drum (051/052-D-1201)

The purpose of the mixing drum is to limit the change rate of Wobbe Index of the fuel gas to the gasturbines. The drum is designed to prevent any liquid carry over and maintain the change rate of the

Wobbe Index within a range of +/- 0.3% per second as required by the gas turbine manufacturer.

There are ten segments in the drum. A central internal pipe distributes fuel gas into the drum throughthree holes in each segment. Pipe is closed at bottom and extends to the required segment length.The holes in each segment face the down-flowing gas.

Number of drums: One (1) / unit

Swing capacity: 46,118 kg/hr (AGRU inlet gas as min. Wobbe Index) 33,537 kg/hr(Dry sweet gas as max. Wobbe Index)

Operating pressure: 26.13 kg/cm2A

Allowable ∆P: 0.3 kg/cm2

2.7.2 Fuel Gas Start-up Heater (063-E-1002)

The purpose of the start-up heater is to heat up the LP fuel gas for starting flare ignitions and

operating one package boiler to prevent hydrate formation by the pressure let-down. The heater isdesigned to be capable of heating the amount of required LP fuel gas to operate one package boiler at

rated capacity. The electric source for the heater is generated by the emergency diesel powergenerator.

Number of heaters: One (1)

Type: Electric heater in four equal stages by thyristor control

Heat Duty: 0 - 500 kW

Operating pressure: 60.85 - 101.3 kg/cm2A (depends on arrived pressure at ORF)

Outlet temperature: 62 - 76 °C (depends on saturate temperature of LP fuel gas)

2.8 Process Description

2.8.1 HP Fuel Gas System

The simplified HP fuel gas configuration is shown in Figure 2-8-1.

The compressed BOG which is the primary source for high pressure (HP) fuel gas is distributed to

each of the LNG trains equally.

The compressed BOG is used as regeneration gas in the Dehydration unit. Since a constantregeneration gas flow is required to keep the regeneration time sequence, the dryer outlet gas could be

used as regeneration gas supply when LNG BOG is not available.

The hot, wet regeneration gas from the Dehydration drum is cooled down by the Regeneration GasCooler (031/032-E-1002) and then condensed water is removed at the Regeneration Gas KO Drum

(031/032-D-1003). The water saturated gas from the Regeneration Gas KO Drum is mixed with

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supplemental gas from AGRU inlet gas as make-up fuel to provide the required HP fuel gas for the

Propane Compressor and MR Refrigerant Compressor gas turbine drivers (051/052-CG-1001/1002).

The mixed gas heated up to 70°C by HP Fuel Gas Heater (051/052-E-1201) is sent to the HP FuelGas Mixing Drum (051/052-D-1201) installed in each LNG train. This drum functions to prevent

any liquid carry over and maintain the rate of change of the Wobbe Index within a range of +/- 0.3% per second. The stable HP fuel gas is then distributed to each user.

2.8.2 LP Fuel Gas System

The simplified LP fuel gas configuration is shown in Figure 2-8-2.

Stabilizer overhead gas and amine HP flash gas from each AGRU provide low pressure (LP) fuel gas.AGRU inlet gas is also utilized from HP fuel gas system through pressure let-down valve tocompensate for the shortfall in primarily LP fuel gas sources against total LP fuel gas demand. These

wet fuel gas streams are sent to the LP Fuel Gas KO Drum (063-D-1002A/B) located in the utility

area. A complete spare LP Fuel Gas KO Drum is provided. The LP fuel gas is then distributed toeach user.

During the initial plant start-up (in commissioning) or black start-up, the feed gas from downstreamof ORF is fed to the LP fuel gas system through the electric Fuel Gas Start-up Heater (063-E-1002).

The heated LP fuel gas is supplied to one package boiler which is ready to start-up. The electricsource for the Fuel Gas Start-up Heater (063-E-1002) is the emergency diesel power generator.

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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063

AGRU

031-KV-1929

TO APCI

PROCESS

FEED GAS

TO LNG

TRAIN-1

031-D-1002A/B/C

031-KV-1930

031-KV-1931

031-KV-1932

031-KV-1982

031FIC1005

031FIC1003

031PIC1214

031-F-1001

031PDG9205

031-KV-1984

031-KV-1983

031-KV-1981

031-USV-1980

031-FV-1005

031-FV-1003

031-PV-1214

TO LP

SY

031PIC1213

031-PV-1213A/B

031-E-1002

031-D-1003

(Cooling)

(Heating)

(Minimum

Firing)

(Excess BOG by-pass)

021PIC1271

021-PV-1271

051-E-1

051-D

091

FIC1032

091-FV-1032

TRAIN - 2

092-FV-1032

092FIC

1032BOG from

BOG

Compressor

See Figure 3-3-1

for Detail

(by-pass)

TC

Regeneration

Timer Sequence

Rump-up

(Heating)

Rump-down

(Cooling)

SP

SR

α

(1-α)

031-USV-1985

091

FI1073

091FI

1074

091-FV-1051B

091-FV-1051A

031-USVE-2511

032-USVE-2511

Figure 2-8-1 Simplified HP Fuel Gas Configuration

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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System Unit 063

091-FV-1032

092-FV-1032

HP Letdownfrom Train-1

HP Letdownfrom Train-2

from CondensateStabilizer Unit

from Amine HP FlashGas Drum in Train-1

from Amine HP Flash

Gas Drum in Train-2

063-D-1002A/B

063-PV-1202B

011-PV-1201

021-PV-1205

022-PV-1205

y x α

063PIC1202

091

FT1032

092FT

1032

011PIC1201

021PIC1205

022PIC1205

from ORF for Start-up(NNF)

063-PV-1201

063PIC1201

α y

y x (1-α)

FLOW RATIOOF TRAIN-1

063PY

1202A

063PY

1202B

SPRIT RANGE

0 - b b - 1

092FIC

1032

091FIC1032

063FY

1032D

063HIC

1032

063FY

1032C

y

SP

SP

α

Figure 2-8-2 Simplified LP Fuel Gas Configuration

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3. OPERATION VARIABLES AND PROCESS CONTROLS

3.1 External Variables

HP/LP fuel gas system is controlled automatically but require the operator to monitor processvariables and to intervene when changes occur which would cause the fuel gas system parameters tovary out of the expected or allowable range.

3.1.1 Fuel Gas Composition Change

Variation in fuel gas composition caused by changes in the operation of the process units result influctuation of heating value of fuel gas to users. Significant change in the fuel gas heating value may

result in electrical system disruption, process unit upsets, or fluctuation in the MP and LP steamsystem pressures. Meanwhile, dynamic simulation results of HP fuel gas system prove that operation

pressure and the change rate of Wobbe Index are maintained within allowable rage. Refer to

"Dynamic Simulation Fuel Gas System (63-SDY-PS-1726)" for more information.

3.1.2 Electrical Load Change for STG

When sudden load change in power demand occurs, the steam balance will be change accordingly.

Therefore, the fuel gas balance will change to maintain original set pressures at pressure controlled points. When power load increases, back up supply of AGRU inlet gas will increase. When powerload decreases and there is an excess fuel in the system, the excess portion will be flared.

3.1.3 Trip of Fuel Users and Fuel Suppliers

Trip of LP fuel gas users and LP fuel gas suppliers will cause the same impact as electrical load

change stated above. In case of HP fuel gas user trips, the excess fuel gas will be flared. In case of HPfuel gas supply losses, back up supply of AGRU inlet gas will increase.

The following table summarizes the relationship between process control reactions and

operator response to be taken by operators s at each single failure of HP/LP fuel gas sources.

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Failure of Fuel Gas Source System Reaction Operator Response

Total BOG supply failure

(For example, electric load

shedding.) Supply of

regeneration gas in

Dehydration unit is

stopped.

031/032-PV-1214 at the

downstream of Dryers will openautomatically to keep the

pressure of the regeneration gas

system in Train-1 and Train-2.

respectively

To confirm system

reaction worksproperly and check a

cause of failure

BOG supply failure to

single LNG train Warm

feed gas from AGRU

Train-1 (Train-2)

When BOG supply to No.1

(No.2) LNG train is failed,

31-PV-1214 (032-PV-1214) will

open automatically to keep the

pressure of the regeneration gas

system.

090-FIC-1051A

(090-FIC-1051B) for BOG

supply control valve to ”No

failed LNG Train” will open

widely gradually in auto.

Since BOG gas flow rate in “No

failed LNG train” will increase,

the make-up fuel gas control

valve in AGRU inlet,

022-PV-1271 (021-PV-1271),will be closed automatically.

031-PV-1214 (032-PV-1214)

will open automatically to keep

the pressure of the regeneration

gas system in Train-1 (Train-2)

091/092-FV-1032 will open

automatically to compensate a

loss of HP fuel gas from Train-1

(Train-2)

To confirm system

reaction works

properly and check a

cause of failure

The BOG flowseparation ratio to

each LNG Train of

90-HS-1061, “a”, shall

be changed to 0.0

(1.0) from 0.5, when

No.1 (No.2) LNG

Train is failed to

minimize the loss of

BOG to flare. The

flow ratio “α” on

063-HIC-1032 to be

set to be 0.0 (1.0) from0.5 and check a cause

of failure

HP

Fuel

Gas

HP

Fuel

Gas

HP Fuel gas supply from

AGRU inlet in each LNG

Train.

(For example,

021-PV-1271

(022-PV-1271) is failed

close)

When HP Fuel gas supply from

AGRU inlet is failed, HP fuel

gas flow rate will be decreased

insufficient in the failed LNGTrain.

To supply sufficient HP fuel gas

flow rate to the failed LNG

Train, BOG flow rate shall be

increased by manual.

Since in “No failed LNG train”

BOG flow rate will be

decreased, HP fuel gas will besupplied by 022-PV-1271

(021-PV-1271) automatically.

Operator shall increase

the set value of “a” on90-HS-1061 from 0.5 to

approximately 0.6 toincrease BOG flow rateas HP fuel gas by

manual.

To confirm systemreaction works properly

and check a cause of

failure

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Failure of Fuel Gas Source System Reaction Operator Response

HP Fuel gas supply from

AGRU inlet in each LNG

Train, because a part of thethe raw feed gas from in

AGRU inlet is used for

HP/LP make-up fuel gas.

(For example, 021-PV-1271

(022-PV-1271) is failedclose)

Since LP fuel gas supply is

stopped from HP fuel gas

header in the failed LNG Train,insufficient LP fuel gas shall be

supplied from 092-FV-1032

(091-FV-1032) via

022-PV-1271 (021-PV-1271) in

“No failed LNG Train”

gradually in auto.

022-PV-1271 (021-PV-1271) in

“No failed LNG Train” will openmore automatically to supply not

only insufficient HP fuel gas butalso LP fuel gas.

Operator shall change

the set point of “a” for

063-HIC-1032 from 0.5to 1.0 (0.0) to cover the

insufficient LP fuel gasflow rate by the fuel gas

let down valve in “No

failed LNG Train “,091-FV-1032(092-FV-1032),immediately.

To confirm system

reaction works properlyand check a cause offailure.

Common LP fuel gas

system from HP fuel gas

header in each LNG Train.

(For example, fuel gas

pressure let down valve

failure : 091-FV-1032

(092-FV-1032) )

Fuel gas let down valve in “No

failed LNG Train”,

091-FV-1032 (092-FV-1032),

will open widely to supply the

required LP fuel gas gradually.

Operator shall change

the set point of “a” for063-HIC-1032 from 0.5

to 1.0 (0.0) to cover theinsufficient LP fuel gas

flow rate by the fuel gaslet down valve in “No

failed LNG Train “,091-FV-1032

(092-FV-1032),immediately.

To confirm system

reaction works properlyand check a cause of

failure

Stabilizer OVHD gas Both of 091-FV-1032 and

/092-FV-1032 will open

automatically together tocompensate loss of LP fuel the

gas

To confirm systemreaction works properly

and check a cause offailure

LP

FuelGas

HP flash gas from AGRUTrain-1 (Train-2)

091-FV-1032 (092-FV-1032) in

the failed LNG Train will open

automatically to compensate

loss of LP fuel gas. Ditto

To confirm system

reaction works

properly and check a

cause of failureDitto

3.2 Internal Variables

Following four normal operation modes plus one alternative operation mode are considered forLP/HP fuel gas system

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2 Train Holding Mode

2 Train Loading Mode

1 Train Holding Mode

1 Train Loading Mode2 Train Loading Mode (Max Fuel Gas)

For detailed fuel gas balance, refer to UFD "63-UFD-PS-1200~1209".

3.2.1 2 Train Holding Mode

Amount of BOG emergence and flash gas from other suppliers are based on two trains operation

without product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall infuel gas supply through 021/022-PV-1271 to maintain system pressures in both LP and HP fuel gas.

3.2.2 2 Train Loading ModeAmount of BOG emergence and flash gas from other suppliers are based on two trains operation with

product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in fuel gassupply through 021/022-PV-1271 to maintain system pressures in both LP and HP fuel gas.

3.2.3 1 Train Holding Mode

Amount of BOG emergence and flash gas from other suppliers are based on one train operationwithout product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in

fuel gas supply through 021-PV-1271 (or 022-PV-1271) to maintain system pressure in LP fuel gasonly. Since compressed BOG supply exceeds HP fuel gas demand, excess HP fuel gas is forwarded

to LP fuel gas system through 091-FE-1074 (or 092-FE-1074).

3.2.4 1 Train Loading Mode

Amount of BOG emergence and flash gas from other suppliers are based on one train operation with product loading operation. Warm feed gas from AGRU inlet compensates for the shortfall in fuel gas

supply through 021-PV-1271 (or 022-PV-1271) to maintain system pressures in both LP and HP fuelgas.

3.2.5 2 Train Loading Mode (Max Fuel Gas)

This operation mode is same condition as normal 2 Train Loading Mode except for fuel gas demand

of package boilers which are operated at rated capacity.

Amount of BOG emergence and flash gas from other suppliers are based on two trains operation with product loading operation. Warm feed gas from AGRU inlet is utilized as a supplemental fuel gas

through 021/022-PV-1271 to maintain system pressures in both LP and HP fuel gas.

3.3 Process Control

3.3.1 Pressure Control on Compressed BOG

The simplified control configuration on compressed BOG is shown in Figure 3-3-1.

BOG shall be distributed evenly between the two LNG trains for stable supply of fuel gas. Thecompressed BOG discharge header pressure controller, 090-PIC-1051 resets the compressed BOGflow rate to Train-1 and Train-2 in accordance to the ratio set by 090-HIC-1051. If the BOG

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3.3.3 Pressure Control on LP Fuel Gas System

LP fuel gas is derived from various flow rates of Stabilizer overhead gas and amine HP flash gas from

the AGRU in accordance with operating mode, such as one/two train operation or HC slug content offeed gas. In order to maintain LP fuel gas supply pressure, the supply of make up LP fuel gas from

HP fuel gas system is controlled using flow controllers 091/092-FIC-1032 reset by 063-PIC-1202 based on the specified flow ratio. The flow ratio of the Train-1 flow rate to the total flow rate isdefined as “α”. The “α” shall be set to be 0.5 in two trains operation by 063-HIC-1032. If Train-2 (or

Train-1) is not in operation, the flow ratio “α” shall be set to 1.0 (or 0.0).

LP fuel gas is released to the wet flare by 063-PV-1202B when the operating pressure is higher thanthe set point of 063-PIC-1202. 063-PV-1202B is designed to relief 30% excess flow of normal fuelgas consumption.

4. PREPARATION FOR INITIAL START-UP

Refer to Commissioning Procedure (63-PRC-OP-1001).

5. NORMAL START-UP PROCEDURE

This section describes the following start-up procedures of HP/LP fuel gas system Unit 063 (partlyUnit 051/052 included).

(1) Start-up after the schedule shutdown (including initial start-up/black start-up)

(2) Re-start after the emergency shutdown

5.1 Start-up Procedure after a Scheduled Shutdown

Start-up procedure after the scheduled maintenance shutdown is applied when Section 4 "Preparation

for Initial Start-up" is conducted.

During the initial plant start-up in commissioning, one package boiler is operated using diesel oil togenerate steam and electric power using a steam turbine. During black start-up, emergency powergenerators will be used for initial system preparation and firstly one of package boilers

(062-F-1001A/B/C) shall start-up so that steam becomes available to generate electric power. As asource of start-up fuel gas for one package boiler, sour natural gas is forwarded from Vorwata-A/B

Pipeline through the 2" interconnection piping (016-GF-1701).

Prior to introducing the fuel gas, condition of the plant is as follows:

- Fuel gas line in the plant, utility and ORF area is being purged with nitrogen.

- Emergency diesel power generators (061-EDG-1001A/B/C/D) are being operated.

- Instrument air system is in service.

- Flare system is ready for start-up.

- Start-up Fuel Gas Heater (063-E-1002) is ready for start.

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5.1.1 Flare Ignition for Initial Start-up

The purpose of this procedure is to introduce the wet feed gas from ORF and to forward LP fuel gas

heated by the fuel gas start-up heater (063-E-1002) to the flare system (086-FL-1001/1002/1003) forflare ignition.

(1) Prior to introducing the wet feed gas from ORF, lineup to be confirmed as shown in Figure5.1.1. Close 2" gate valve "A" which is normally LO and open 2" gate valve "B" which is

normally LC. Note that both of the LP Fuel Gas KO Drums (063-D-1002A/B) which havesafety relief valves shall be bypassed because the wet flare is not in service yet.

(2) Commission the Start-up Fuel Gas Heater (063-E-1002). The heater outlet temperaturecontroller 063-TIC-1302 to be set at 75 ºC (adjustable depends on Pipeline pressure).

(3) Open gradually 2" globe valve at suction of the heater not to exceed 3.5 kg/cm2G at the

restriction orifice (063-FO-9001) outlet.

(4) Purge out nitrogen and ignite pilots of the flares (086-FL-1001/1002/1003).

(5) When flare pilots ignited, open 2" gate valve "A". 063-PV-1201 to be put in service.

(6) Perform 2" gate valve "B" locked closed.

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BP Berau Ltd. Tangguh LNG Project 3.8 MTPA TAIN CAPACITY Operation Manual for Fuel Gas System

LC

063-LV-1102

063-D

LC

0063-D-1002A

2" Bypass Line

PC

063-E-1002063-PV-1201

PG

2"

6"

6"

40" Sour NG to LNG Trains

A

B

Flash gas from operating trains

Figure 5.1.1 LP Fuel Gas Lineup for Flare Ignition

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5.1.2 LP Fuel Gas System Start-up

The purpose of this procedure is LP fuel gas KO drum to be put in service after flare pilots ignited and

introducing fuel gas sources from an operating train.

(1) Commission the level controller (063-LIC-1102 or 1171) to draw off condensate to the wet

flare.

(2) Commission the excess pressure controller (063-PY-1202B) to prevent over pressure of LPfuel gas header.

(3) Open 14" inlet gate valve which isolate available LP fuel gas KO drum.

(4) Purge out nitrogen to the wet flare through 2” bypass valve of 063-PSV-8002 or 8701.

(5) Open 14" outlet gate valve whose available LP fuel gas KO drum to be put in service.

(6) Close 2" gate valves on the KO drum bypass line (063-GF-1706).

(7) When overhead gas of the condensate stabilizer (011-T-1001A/B) and HP flash gas of the

amine HP flash gas drum (021/022-D-1001) are available, these flash gases will beintroduced respectively.

(8) Regulate 2" globe valve at suction of the heater to compensate the flash gas introduced fromoperating train into the LP fuel gas system.

(9) When AGRU inlet gas through 021/022-PV-1271 is available, put HP fuel let-down flowcontroller (091/092-FIC-1032) in cascade mode with implementation of the train flow ratio(063-HIC-1032) in accordance with operating LNG trains, i.e., 1.0 for Train-1 operation or

0.0 for Train-2 operation.

(10) Once the LP fuel gas system is stabilized, close 2" globe valve at suction of the heater andstop the heater. All isolation valves which are related to initial start-up shall be closed.

(11) The wet feed gas in stagnant line shall be purged out by nitrogen.

5.1.3 Establishment of LP Fuel Gas System for 2 Trains operation

The purpose of this procedure is to introduce fuel gas sources from the other operating train which is

commissioned secondarily.

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(1) Confirm that 063-HIC-1032 (LP fuel gas flow ratio to LNG Train-1) has been set at 1.0

(0.0). LP fuel gas header pressure is controlled by 091-FV-1032 which set point is given by“FC (091-FIC-1032) - PC (063-PIC-1202)” cascade control.

(2) Fuel gas let down valve for Train-2, 092-FV-1032 (Train-1, 091-FV-1032) is gradually

opened manually. Meanwhile, 091-FV-1032 (092-FV-1032) is controlled to maintain pressure of the common LP fuel gas, 063-PIC-1202.

(3) In accordance with increasing of the feed gas flow rate to Train-2, the total fuel gas demandis also increased. 092-FV-1032 (091-FV-1032) shall be opened properly by manual. The

common LP fuel gas pressure shall be still controlled by 091-FV-1032 (092-FV-1032) byPC-FC cascade control.

(4) Set 063-HIC-1032 (LP fuel gas flow ratio to LNG Train-1) at 0.5 when flow rate092-FIC-1032(091-FIC-1032) is close to 091-FIC-1032(092-FIC-1032).

(5) Put 092-FIC-1032 (091-FIC-1032) in PC-FC cascade mode.

5.1.4 HP Fuel Gas System Start-up without BOG

The purpose of this procedure is HP fuel gas system, either Unit 051 or 052, to be put in service

during unavailable BOG.

(1) Prior to the introduction of AGRU inlet gas through 021/022-PV-1271 to the HP fuel gas

system, the following equipment should be lined up.

- Process HP Fuel Gas Heater (051/052-E-1201)

- Process HP Fuel Gas Mixing Drum (051/052-D-1201)

(2) Open gradually 3" globe valve on 021/022-PV-1271 bypass not to exceed 26.5 kg/cm2A of

down stream pressure (021/022-PG-9220).

(3) Open manually the excess HP fuel gas pressure control valve (091/092-PV-1231C) to sweepresidual nitrogen to the wet flare. When the system is stabilized, put 091/092-PIC-1231 in

auto at 25.8 kg/cm2A.

(4) Commission the LP steam flow controller (091/092-FIC-1332) to supply the LP steam to051/052-E-1201 and the level controller (091/092-LIC-1232) to draw off condensate to

steam condensate header.

(5) Open manually AGRU inlet gas supply pressure control valve (021/022-PV-1271) and close3" globe valve on its bypass.

(6) Put the LP steam flow controller (091/092-FIC-1332) in cascade mode to set HP fuel gastemperature controller (091/092-TIC-1332) at 70 ºC.

(7) Commission the level controller (051/052-LIC-1131) to draw off condensate to the wet flare.

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(8) When adequate HP fuel gas at the HP fuel gas inlet facilities for gas turbines is confirmed

after venting to sweep another residual nitrogen to the wet flare, introduce HP fuel gas to thegas turbines (051/052-CG-1001/1002).

(9) When 091/092-PV-1231C is closed, put 021/022-PV-1271 in auto. Expected set point is26.25 kg/cm

2A. Set point is adjustable in accordance with actual system pressure drop.

(10) Reset 091/92-PIC-1231 at 26.5 kg/cm2A.

When spent regeneration gas supplied from dry sweet gas are available, these gas can be introducedto the HP fuel gas system at any time. 021/022-PV-1271 will be regulated automatically to

compensate introduced spent regeneration gas to the HP fuel gas system.

5.1.5 Establishment of HP Fuel Gas System using Compressed BOG

The purpose of this procedure is to introduce compressed BOG to the HP Fuel Gas System which iscommissioned secondarily.

(1) Confirm that 090-HIC-1051 (compressed BOG flow ratio to LNG Train-1) has been set at1.0 (0.0). Compressed BOG header pressure is controlled by 090-PIC-1051 which set point

is given by FC-PC cascade control.

(2) Gradually open manually 090-FV-1051A (1051B) at Train-2 (Train-1). Meanwhile,090-FV-1051B (1051A) will be controlled to maintain pressure at the BOG compressordischarge common header, 090-PIC-1051. Accordingly, the regeneration gas make-up

valve 032(031)-PV-1214 will be closed gradually.

(3) Since excess BOG flow rate in Train-1 will be reduced, the dehydration by-pass valve

031(032)-PV-1213 will be closed gradually.

(4) Fuel gas make-up control valve, 021(022)-PV-1271 is gradually opened automatically to

maintain HP fuel gas pressure.

(5) Set 090-HIC-1051 (train flow ratio set) at 0.5 when flow rate 090-FIC-1051A (1051B) isclose to 090-FIC-1051B (1051A).

(6) Put 090-FIC-1051A (1051B) in PC-FC cascade.

5.2 Re-start Procedure after Emergency Shutdown

The following ESD system activation will lead to total emergency shutdown in HP/LP fuel gas

system.

016-US-2000A Unit 016 Isolation

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Any one or more of the following ESD systems activation will cause partial emergency shutdown in

HP fuel gas system (potentially LP fuel gas system in service).

031(032)-US-2000A Unit 021/031(022/032) Isolation

051(052)-US-2400A Unit 041/051(042/052) Isolation

091(092)-US-2000 Train-1(Train-2) Total Shutdown

The emergency shut-down procedure initiated by the EDS system is given in Section 8 "EmergencyShutdown Procedure".

5.2.1 Re-startup after Total Emergency Shutdown (Black Startup)The re-startup procedure after emergency shutdown of fuel gas system is the same as the startup

procedure after scheduled shutdown described in Section 5.1.

Before re-starting the operation, confirm that all emergency conditions which caused the unitshutdown have been restored to the normal conditions.

5.2.2 Re-startup after Partial Emergency Shutdown

The startup procedure after partial emergency shutdown, namely emergency shutdown of either HPfuel gas system in Train-1 or Train-2, is the same as the procedure of HP fuel gas system startup

described in Section 5.1.4 and 5.1.5.

Before re-starting the operation, confirm that all emergency conditions which caused the unit

shutdown have been restored to the normal conditions.

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6. NORMAL OPERATION

6.1 General

Fuel gas system U-063 (including part of U-051/052) is normally controlled automatically butrequires the operator to monitor process variables and to intervene when changes occur which wouldcause the feed gas parameters to vary outside the expected or allowable range.

6.2 Pressure Set Point Adjustment

6.2.1 Supply Pressure Adjustment of AGRU Inlet Gas

Set point of AGRU inlet gas supply pressure controller 021/022-PIC-1271 is adjustable in accordancewith actual arrived pressure at HP fuel gas inlet facilities (fuel gas scrubber skid) of gas turbines. To

set at 26.25 kg/cm2A is expected to obtain 25.5 kg/cm

2A of normal pressure at the inlet facilities. For

over pressure controller 091/092-PIC-1231, to set at 26.5 kg/cm2A or set pressure of021/022-PIC-1271 plus 0.25 kg/cm

2 is preferable to prevent periodical flaring.

6.2.2 Over Pressure Control for HP Fuel Gas

When one of the two operational trains loses, the increasing of compressed BOG flow rate to the oneoperational train will affect the flow rate of regeneration gas and the pressure of HP fuel gas header.Pressure rise of downstream of regeneration system results in insufficient deferential pressure at

031(032)-FV-1003 and 031(032)-FV-1005 to pass the required regeneration gas flow rate.Consequently the regeneration gas flow rate through both of control valves will not enable to be

secured adequately. For this circumstance, reducing set point of 091(092)-PIC-1231 from 26.5kg/cm

2A to 25.8 kg/cm

2A manually shall be required. The total regeneration gas flow will be

recovered up to the normal flow rate accordingly.

Refer to Section 5.8 in "Dynamic Simulation Fuel Gas System" (63-SDY-PS-1726) for moreinformation.

6.3 Switch-over to Spare LP Fuel Gas KO Drum

Since complete spare LP Fuel Gas KO Drum (063-D-1002B) is provided, LP fuel gas system can beoperated continuously during 063-D-1002A maintenance. Switch-over to the spare is also required

when the level control valve has a trouble even if the bypass valve is available. The system is

considered not to isolate only the level control valve using its bypass valve.

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7. NORMAL SHUTDOWN PROCEDURE

7.1 General

Fuel gas system is never totally shutdown since it is the most primary unit to operate the plant.

Normal shutdown procedure is started with reducing feed rate and covers up to depressurizing of the

system.

Outline of the normal shut-down procedure is described below:

(1) Decrease the feed rate.

(2) Cutting off feed from the pipeline.

(3) Isolating the system which is required for shutdown.

(4) Depressurizing the systems by diverting gas to the wet flare, if necessary.

7.2 HP Fuel Gas System Normal Shutdown (One Train Shutdown)

This section covers normal shutdown procedure where one of two LNG train is in scheduled

shutdown and the other is being in operation.

When Train-1 (Train-2) under min. turndown is going to scheduled shutdown from two LNG trains

operation, the following steps are performed:

(1) Gradually close the compressed BOG flow control valve 090-FV-1051B (1051A) by manual.Meanwhile 090-FV-1051A (1051B) is controlled to maintain pressure of the BOGcompressor discharge common header by 090-PIC-1051.

(2) Set 090-HIC-1051(compressed BOG flow ratio to LNG Train-1) at 0.0 (1.0) when the flowrate of 090-FIC-1051B (1051A) is zero.

All compressed BOG is sent to Train-2 (Train-1) and excess gas shall bypass the dehydration unit

through 032(031)-PCV-1213. The excess gas is combined with the wet regeneration gas at theoverhead of the Regeneration Gas KO Drum 032(031)-D-1003.

The mixed gas, namely HP fuel gas, will be sent to two Gas turbines in Train-2 (Train-1). The

remaining gas shall be let down to LP fuel gas system by 092(091)-FV-1032.

(3) Gradually close the HP fuel gas let-down valve 091(092)-FV-1032 by manual. Meanwhile092(091)-FV-1032 is controlled to maintain LP fuel gas pressure by 063-PIC-1032.

(4) Set 063-HIC-1032 (LP fuel gas flow ratio to LNG Train-1) at 0.0 (1.0) when the flow rate of

091-FIC-1032 (092-FIC-1032) is zero.

(5) Decrease feed gas flow rate to Train-1 (Train-2) down to zero and ensure the train shutdown.

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(6) Isolate the system by closing manually the following ESD and isolation valves.

Tag No. P&ID Service

031(032)-USVE-2903 31(32)-PID-PS-1157-S1 Dry sweet gas from 031(032)-Y-1002 toRegen gas system

12" Gate Valve at ABL 31(32)-PID-PS-1157-S1 Compressed BOG from compressed BOG

header Unit 090 to LNG Train Unit

031(032)

031(032)-USVE-2910 91(92)-PID-PS-1153-S4 Spent regen gas from HP fuel gas systemto LP fuel gas system

(7) Draw off HC contaminated water in Regeneration Gas KO Drum (031(032)-D-1003) as muchas possible by opening bypass valves around level control valve (031(032)-LV-1103) before

the pressure falls too low, then block in control valves and its bypass valves.

(8) Draw off HC contaminated water in HP Fuel Gas Mixing Drum (051(052)-D-1201) as muchas possible by opening the level control valve (051(052)-LV-1131) before the pressure fallstoo low, then block in control valves.

(9) Depressurize HP fuel gas system by opening 091(092)-USVD-2160, if necessary.

7.3 LP Fuel Gas System Normal Shutdown (Both Trains Shutdown)

LP Fuel Gas System scheduled shutdown is allowed in case of total plant (both LNG Train-1 and

Train-2) shutdown only.

(1) Decrease feed gas flow rate to the last operational train down to zero and ensure the LNG

Train shutdown.

(2) Isolate the system by closing the following manual valves at battery limit.

Tag No. P&ID Service

10" Gate Valves at ABL 91/92-PID-PS-1153-S4 HP fuel gas from HP fuel gas system Unit051/052 to interconnection line Unit 090

6" Gate Valves at ABL 21/22-PID-PS-1154 HP flash gas from amine HP flash drum

Unit 021/022 to interconnection line Unit090

4" Gate Valve at ABL 11-PID-PS-1151 Overhead gas from condensate stabilizer

Unit 011 to interconnection line Unit 090

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8.2.2 Shutdown by Unit 021/031(022/032) Isolation 031(032)-US-2000A

Since 031(032)-US-2000A initiates 051(052)-US-2400A, consequently this cause leads to same

circumstance as described in Section 8.2.1.

8.2.3 Shutdown by Unit 041/051(042/052) Isolation 051(052)-US-2400A

Since 051(052)-US-2400A initiates 031(032)-US-2000A, consequently this cause leads to same

circumstance as described in Section 8.2.1.

8.3 Total Shutdown by Interlock Logic

Initiation of Unit 016/011 isolation (016-US-2000A) leads to both LNG Train-1 and Train-2 in

shutdown. For this circumstance, AGRU inlet gas supplied to LP fuel gas system is secured by

forced opening 091/092-USVE-2929 to prevent simultaneous shutdown of HP and LP fuel gas

systems. Therefore LP fuel gas system could be operated using isolated gas inventory in AGRU Unit021/022 until the fuel gas source is exhausted.

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9.2 Emergency Fire Plan

The fire protection system of the plant is designed to prevent fire occurrence, control fire escalation,

or extinguish fire within short period of time, assuming there will be no outside fire fighting

assistance, with only one major fire at a time.

9.3 Fire Fighting and Protective Equipment

Fire hazard status throughout the plant shall be monitored on the Hazard Detection and MonitoringSystem (HDMS (F&G)) consoles in the main control room and fire and emergency station.

Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat

radiation.

For the detail, refer to 82-SPE-HS-1540 (S-082-1241-019), “Operation Manual for Fire Protection

System” and the relevant drawings for fire protection system.

9.4 Maintenance of Equipment and Housekeeping

(1) 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.

(2) Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the

equipment must be replaced when repair work is completed.

(3) Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation

equipment where they can be knocked off and injure someone below.

(4) 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.

(5) Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediately

report leaks for repair.

(6) In the event that electrical equipment does not function properly, notify the electrical

department and stay clear of the equipment until the electrician arrives.

(7) 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.

(8) 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.

(9) Switch pumps regularly when spares are provided. This will assure start the spare pump will be

ready when needed.

9.5 Repair Work

(1) Mechanical work around and operating unit must be kept to a minimum, and the minimum

number of men should be used.

(2) No mechanical work on the equipment is to be done without a properly authorized work permit.

(3) Safety hats must be worn by all personnel in all areas at all times.

(4) 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.

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(5) 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.

(6) 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 waterhammer to start.

(7) Do not use light distillates such as gasoline or naphtha to clean machinery or for any other

cleaning purposes.

(8) 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.

(9) Welding cylinders should be removed from site to a designate safe area at the end of each

working day.

9.6 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. Acontainer must never be filled to the brim, in order to minimize risk of subsequent spillage.

When sampling any product liquids, gloves and goggles will be worn.

When sampling any material, gas or liquid, the sampling line must be flushed long enough to remove

dormant materials to insure that the sample obtained represents the current stream. Pass enough gasthrough 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 specialcarrying devices. Wear approved personal safety equipment and exercise caution to avoid injuries.

When sample cooling is required, operator shall confirm cooling water is flowing properly before

taking the sample.

9.7 Safe Handling of Volatile and Toxic Materials

The safety rules given below are for the protection of life and limb, and the prevention of property

loss. It is expected that plant people will exercise common sense, alertness, and good judgment incarrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consult

your supervisor immediately.

9.8 Respiratory Protection

Most plant gases, other than air, are harmful to human beings if inhaled in certain concentration.Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may cause

death by replacing the air in the lungs or by reaction with the oxygen carried in the blood; examplesare 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. Toguard 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

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to render assistance to any one overcome by gas, electric shock, or drowning.

If anyone is overcome by gas, his rescuer should:

Never attempt a rescue unless an assistant is standing by.

Protect himself before attempting a rescue by wearing breathing apparatus.

Get the victim to fresh air as soon as possible.

Give artificial respiration and send his assistant to call for medical aid.

When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approvedtest method.

Wear the correct type of breathing apparatus, suited to the situation encountered.

9.9 Breathing Apparatus (B. A.)

There are four types of breathing apparatus in general plant service. They are the canister type masks,the fresh air hose line B. A., the compressed air self-contained B. A. and the compressed air line

trolley B. A.

The compressed air self-contained breathing apparatus has a self-contained air supply carried on the

back of the user.

It is used principally in emergencies.

After use, always notify the proper department so that they can recharge the cylinders as soon as possible.

9.9.1 Nitrogen

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

N2 is neither poisonous nor flammable, but care must be exercised when working inside equipment

that has been N2 purged. Adequate ventilation must be provided and appropriate breathing deviceworn. To breathe an atmosphere high in N2, could result in suffocation.

Before entering vessels that have been purged with N2, a check must be made for proper oxygencontent prior to entry. Rapid vaporization of liquid nitrogen can cause severe burns on contact with

the skin.

9.9.2 Corrosive Materials

Whenever containers of corrosive chemicals such as caustic soda and sulfuric acid, are to be openedor emptied, always have a connected water hose handy to flush off and help absorb spilled material

and to reduce spread of toxic vapors.

9.9.3 Chemicals

No specific chemicals are used in this system.

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10. 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 blindflanges, 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 valvemaintenance. Valved isolation will also be required to enable positive isolation to be installed orremoved 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 Ownerwhen 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 maintenancework.

10.2.1 Train Isolation

Refer to Maintainability Philosophy (99-PHI-EM-0005) for Train isolation.

Each train is capable of being isolated.

10.2.2

Individual Equipment / System Isolation10.2.2.1 Horizontal and Vertical Pressure Vessels

All vessels where manned entry may be required are provided with spectacle blinds or spade and

spacer arrangements on every process inlet and outlet nozzles. Relief valve inlet lines from pressurevessels are normally positively isolated from the vessel by removing the relief valve and blinding the

inlet line end. A typical arrangement is shown on Figure 9.2.1.

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11. MAINTENANCE PROCEDURE

11.1 General

INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENTAIR 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.

• Tightening gland followers on leaking pump packing.

• Checking temperature and pressure gauges for broken glass faces.

• Checking for correct oil levels in pumps, gearboxes, oil reservoirs.

• Topping up low oil levels in the above equipment as required.

• Cleaning pump filters and strainers.

• Keeping equipment clean and tidy.

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 directobservations and instrument readings for the monitoring of the actual condition of the Plant andequipment, and can trend and forecast when maintenance activities are due to take place.

11.1.5 Turnaround /Inspection Maintenance

Turnaround/Inspection Maintenance will be carried out at approximately 3 yearly intervals, and

usually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting ofsafety 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.

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• All work must be carried out within the requirements of company Safety & EnvironmentalPolicies 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/energystoring equipment has been isolated in accordance with the relevant permit to work and lock-out /

tag-out requirements.

• Physically isolate vessels. Only standard blank flanges and spades should be used. No person

should enter a vessel unless all directly connected sources of process and utilities fluids have been positively isolated from the vessel. Entry means total body entry or any part of the body.

• Operations should check for oxygen, taking samples at several representative places, with a

portable analyzer to check for oxygen deficiency.

• Prior to commencement of this work it is recommended that the crew will be briefed on what isrequired and what hazards there are. The crew will be reminded of the location of safety showers,first-aid boxes and telephones.

• If welding or any process liable to evolve noxious fumes is to be carried out in the vessel,

adequate ventilation should be provided.

11.3 Preparation for Maintenance

The outline of the work sequence begins as below.

• Shutdown of the unit operation and liquid removal

• Inerting with nitrogen, if required.

• Installation of isolating blank flanges or spades

•

Replacement with air for entry into the equipment

11.3.1 Installation of blank flanges or spades

After inerting have been completed, isolating blank flanges or spades must be installed at locations as

required.

11.4 Typical isolation method

11.4.1 Vessels/Drums

• 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 Shell and Tube Type Heat Exchangers

• Erect scaffold for access as required.

• Operations to close down the system and depressurize.

• Mechanical to swing spectacle inlet and outlet spectacle blinds.

• Electrical to lock out the three fan motors locally and remove relay/fuse in substation.• Mechanical to open as required.

• Operations to air purge and check for oxygen level.

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• Operations to clean

11.4.3 Close out

• Ensure the equipment is left in a safe condition.

• Remove all tools and debris, clean local area.• Note any faults found and comments.

• Raise a work request if any major corrective work is identified or the performance standards are

not met during the above maintenance.

• Sign off permit to work and inform area authority of equipment status.

12. ATTACHMENT LIST

Attachment-1 Process Flow Diagram

63-UFD-PS-120063-UFD-PS-120163-UFD-PS-1202

63-UFD-PS-1203

63-UFD-PS-120463-UFD-PS-120563-UFD-PS-1206

63-UFD-PS-120763-UFD-PS-1208

63-UFD-PS-1209

Attachment-2 P&IDs

63-PID-PS-120163-PID-PS-1202

91-PID-PS-1153-S191-PID-PS-1153-S4

Attachment-3 Equipment Data Sheet (List only)

51-EDS-VM-129151-EDS-EX-133163-EDS-VM-1262

63-EDS-EX-1201

Attachment-4 Instrument Alarm Set Point (List only)

51-SPE-CS-175463-SPE-CS-1754

91-SPE-CS-1754

Attachment-5 Cause and Effect Charts (List only)

63-LOG-PS-115091-LOG-PS-1150

Attachment-6 Laboratory Sampling Schedule

Alarm & Trip Setting List (4)

Documents

Transcript of Alarm & Trip Setting List (4)