Alarm & Trip Setting List (7)

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PT. Brown & Root Indonesia

Doc. No. 64-IOM-PS-1201 Rev. 6B

Project TLNG Author’s Org. KJP

KJP Doc. No. S-064-1283-001 Date 28 Jun, 06

KJP Job Code J-3400-20-0000 Sheet 1 of 28

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 9Jan’06 All For Approval M.Hatanaka Y.Kakutani Y.Kakutani

6A 27Feb’06 All Released M.Hatanaka Y.Kakutani Y.Kakutani

6B 28Jun’06 All Released M.Hatanaka Y.Kakutani Y.Kakutani

3.8 MTPA TRAIN CAPACITY

Operation Manual for Seawater/Water System

BPMIGAS

TANGGUH LNG

BP Berau Ltd.

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Doc. No. 64-IOM-PS-1201KJP Doc. No. S-064-1283-001 Rev. 6BSheet No. 2 of 28 Operation Manual forSeawater/ Water System

BP Berau Ltd. Tangguh LNG Project

CONTENTS

1. Introduction.................................................................................................................................4 2. Basis of Design.............................................................................................................................4

2.1 General ........................................................................................................................................4 2.2 Design Condition.........................................................................................................................4 2.2.1 WATER QUALITIES..................................................................................................................... 4 2.2.2 WATER CONDITIONS.................................................................................................................. 5 2.3 Special Equipment......................................................................................................................6 2.3.1 ELECTROCHLORINATION PACKAGE (078-V-1001) .................................................................... 6 2.3.2 DESALINATION PACKAGE (064-V-1001A/B/C)......................................................................... 6 2.3.3 R EMINERALIZATION PACKAGE (064-V-1002) ........................................................................... 6 2.3.4 DEMINERALIZATION PACKAGE (064-V-1003) ........................................................................... 6 2.3.5 ACTIVE CARBON FILTER PACKAGE (064-V-1006) .................................................................... 6 2.4 Process Description.....................................................................................................................6 2.4.1 SEAWATER I NTAKE .................................................................................................................... 6 2.4.2 DESALINATED WATER SYSTEM ................................................................................................. 7 2.4.3 UTILITY WATER SYSTEM........................................................................................................... 8 2.4.4 POTABLE WATER SYSTEM ......................................................................................................... 8 2.4.5 DEMINERALIZED WATER SYSTEM ............................................................................................. 9 2.4.6 CLOSED COOLING WATER SYSTEM ........................................................................................... 9

3. Process Controls........................................................................................................................10 3.1 Seawater Intake ........................................................................................................................10 3.2 Desalinated Water System .......................................................................................................10 3.3 Potable Water System ..............................................................................................................11 3.4 Demineralized Water System ..................................................................................................11 3.5 Closed Cooling Water System .................................................................................................12

4. Preparation for initial start-up ................................................................................................12 5. Normal Start-up Procedure .....................................................................................................12

5.1 General ......................................................................................................................................12 5.2 Start of Seawater Supply Pumps.............................................................................................12 5.3 Start up of the Electrochlorination Package (078-V-1001) ...................................................13 5.4 Start up of the Desalinated Water System..............................................................................13 5.5 Start up of the Potable Water System.....................................................................................13 5.6 Start up of the Closed Cooling Water System........................................................................14 5.7 Start up of the Demineralized Water System.........................................................................14 5.8 Start up of the Suspect Condensate Recovery System...........................................................14

6. Normal Operation.....................................................................................................................15 6.1 Back up Firewater Operation..................................................................................................15 6.2 Low Level at Seawater Pump Basin........................................................................................15 6.3 Hypochlorite Monitoring .........................................................................................................15 6.4 Residual Chlorine in Potable Water .......................................................................................15 6.5 Operation Number of Active Carbon Filters and Polishers .................................................15 6.6 Chemical Injection into Closed Cooling Water System ........................................................15

7. Normal Shutdown Procedure ..................................................................................................16 7.1 Seawater System Shutdown.....................................................................................................16 7.2 Electrochlorination Package....................................................................................................16 7.3 Desalination Packages ..............................................................................................................16 7.4 Remineralization/Active Carbon Filter/Demineralization Packages ...................................17 7.5 Closed CW Cooler ....................................................................................................................17 7.6 One Train Shutdown ................................................................................................................17

8. Emergency Shutdown Procedure ............................................................................................17 8.1 General ......................................................................................................................................17 8.2 Loss of Utilities..........................................................................................................................17 8.2.1 POWER FAILURE ...................................................................................................................... 17 8.2.2 I NSTRUMENT AIR FAILURE ...................................................................................................... 18

9. Safety Procedure.......................................................................................................................18 _ _ _

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9.1 General ......................................................................................................................................18 9.2 Emergency Fire Plan................................................................................................................19 9.3 Fire Fighting and Protective Equipment................................................................................20 9.4 Maintenance of Equipment and Housekeeping .....................................................................20 9.5 Repair Work .............................................................................................................................20 9.6 Withdrawal of Samples ............................................................................................................21 9.7 Safe Handling of Volatile and Toxic Materials ......................................................................21 9.8 Respiratory Protection.............................................................................................................21 9.9 Breathing Apparatus (B. A.)....................................................................................................22 9.9.1 NITROGEN................................................................................................................................ 22 9.9.2 CORROSIVE MATERIALS .......................................................................................................... 22 9.9.3 CHEMICALS .............................................................................................................................. 22

10. Isolation Procedure for Maintenance......................................................................................23 10.1 General ......................................................................................................................................23 10.2 Basic Procedures.......................................................................................................................23 10.2.1 TRAIN ISOLATION .................................................................................................................... 23 10.2.2 I NDIVIDUAL EQUIPMENT / SYSTEM ISOLATION........................................................................ 23

10.2.2.1 Horizontal and Vertical Pressure Vessels .......................................................................23 10.2.2.2 Pumps..............................................................................................................................24 11. Maintenance Procedure............................................................................................................25

11.1 General ......................................................................................................................................25 11.1.1 R OUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 25 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 25 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 25 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 26 11.1.5 TURNAROUND /I NSPECTION MAINTENANCE............................................................................ 26 11.2 Precautions prior to Maintenance...........................................................................................26 11.3 Preparation for Maintenance ..................................................................................................26 11.3.1 I NSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 26 11.3.2 AIR TEST .................................................................................................................................. 26 11.4 Typical isolation method ..........................................................................................................27 11.4.1 VESSELS/DRUMS...................................................................................................................... 27 11.4.2 PUMPS ...................................................................................................................................... 27 11.4.3 SHELL AND TUBE TYPE HEAT EXCHANGERS........................................................................... 27 11.4.4 AIR FIN COOLERS .................................................................................................................... 27 11.4.5 CLOSE OUT............................................................................................................................... 27

12. Attachment List.........................................................................................................................27

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1. INTRODUCTION

The purpose of Seawater Intake (Unit 078) and Water System (Unit 064) is to produce fresh water for

the LNG Plant by the desalination of seawater drawn from the seawater supply pump. The Watersystem is comprised of the following individual systems

- Seawater Intake (Unit 078)

- Desalinated water system (Unit 064)

- Utility water system (Unit 064)

- Potable water system (Unit 064)

- Demineralized water system (Unit 064)

- Closed cooling water system (Unit 064)

The water system also supplies potable water and utility water to the support facilities including

community area, administration area, upstream operation support area, etc.

2. BASIS OF DESIGN

2.1 General

Desalinated seawater serves as the source, following appropriate treatment, of the utility water,demineralized water and potable water supplies.

Utility water is used for make up to the firewater system, cooling water system, and for such general

plant uses as pad wash down, equipment cleaning and pressure testing.

A demineralized water system is required to supply makeup water to boiler feed water system,makeup water to the AGRU (Acid Gas Removal Unit) for preparation of the acid gas removal solventand wash water for gas turbine. Demineralized water is produced by means of ion exchange

demineralization.

Potable water is supplied for drinking purpose as well as for such uses as safety showers and eye wash

stations, change room showers, toilets, food preparation etc.

2.2 Design Condition

2.2.1 Water Qualities

Component Seawater DesalinatedWater

DemineralizedWater

Potable Water

Calcium (mg/l as CaCO3) 500 500

Magnesium (mg/l as CaCO3) 3,400

Sodium (mg/l as CaCO3) 23,000

Adjusted

<=8.5

Total Cations (mg/l as CaCO3) 29,000Adjusted

Bicarbonate (mg/l as CaCO3) 130

Carbonate (mg/l as CaCO3) N/A

Hydroxide (mg/l as CaCO3) N/A

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2.3 Special Equipment

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

2.3.1 Electrochlorination Package (078-V-1001)

One electrochlorination package is provided.

Number of package: OneDesign capacity: Seawater of 1100m3/h

Normal dosing rate: 1.5ppm as Cl2 Shock dosing: 3.0ppm as Cl2 (4 hours interval / 20 minutes dosing)

2.3.2 Desalination Package (064-V-1001A/B/C)

Three 50% desalination packages to generate desalinated water are provided.

Number of package: ThreeType: Mechanical Vapor Compression

Capacity: 28m3/h for each

2.3.3 Remineralization Package (064-V-1002)

Slow dissolution of calcium and magnesium compounds in the feed water after having increased theaggressiveness of the water by means of CO2 injection. Sodium hypochlorite is injected afterremineralization.

Capacity: 168m3/day

2.3.4 Demineralization Package (064-V-1003)

This package includes three 50% mixed bed polishers to generate demineralized water.

Number of polisher: Three

Type: Mixed bed ion exchangeCapacity: 48m3/h for each polisherRegeneration: Once per three days for each polisher (one polisher per day)

2.3.5 Active Carbon Filter Package (064-V-1006)

This package includes three 50% active carbon filters to treat suspect steam condensate.

Number of filter: ThreeType: Active carbonCapacity: 28m3/h for each filter

2.4 Process Description

2.4.1 Seawater Intake

The Seawater Intake facility consists of Seawater Supply Pumps (078-P-1001A/B/C), Seawater

Intake Screens (078-Y-1001A/B/C), one Electro-chlorination Package (078-V-1001), Seawater

Intake Platform (078-A-1001), and Diesel Day Tank for Seawater Supply Pump (078-TK-1001).

Seawater enters to the seawater pumps through the screen installed in each pump basin.

Two motor driven pumps and one diesel driven pump are provided to accommodate both normaloperation and emergency operation (backup firewater system) including spare pump.

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Normal Condition

During normal operation, one seawater pump driven by motor supplies the required seawater to the

desalination unit and surplus water is discharged to sea via 078-PV-1001A/B that controls seawater

supply pressure. Other two seawater pumps could be considered as spare.

Backup firewater operation

When emergency operation that backup firewater is required, the seawater pumps can handle thefirewater demand of 1040 m3/h. At this condition, two pumps are operating.

Since seawater pumps are utilized as back up, therefore, NFPA requirements for firewater pumps arenot applied.

The minimum level of the desalinated / firewater tank (064-TK-1001) is defined and maintained in

order to keep the need of 4 hours firewater required for fire fighting purpose.

When low-low-level in the desalinated / firewater tank (064-TK-1001) is activated, a stand-by pumpis started to introduce seawater into firewater main.

Chlorination

One Electro-chlorination package is provided to supply the sodium hypochlorite in seawater intake.

Electro-chlorination provides both continuous injection and shock (intermittent) injection.Continuous injection injects the sodium hypochlorite to get adequate concentration (1.5 ppm) thatkills all microorganisms in seawater. However, during long period of this concentration some

microorganism may built the resistance, and therefore shock injection with extremely higherconcentration (additional 1.5 ppm, total 3 ppm that shall be adjusted to achieve free chlorine 0.5 ppm

at desalination package inlet) is required periodically (refer to Section 3.1) to make sure that all

microorganism is killed.

2.4.2 Desalinated Water System

Desalinated water system consists of three (2 operating and 1 spare) Desalination Packages

(064-V-1001A/B/C), one Desalinated Water Tank (064-TK-1001), one Corrosion Inhibitor InjectionPackage (64-V-1005), and two Desalinated Water Pumps (064-P-1001A/B).

Feed to the desalination packages is seawater from the Seawater Intake. The seawater is screened toremove debris and treated with hypochlorite solution to inhibit marine growth prior to delivery to

desalination packages. There are three desalination packages (064-V-1001A/B/C) designed to produce desalinated water with less than 10 ppm of total dissolved solids. Normally, two packages

are in operation. The third one is on stand by.The type of desalination package is Mechanical Vapor Compression (MVC).

In the desalination package, seawater is heated and then evaporated by the application of heat

delivered by compressed vapor to separate out the fresh water from seawater.

The effect of compressing water vapor is obtained by means of an electrically driven, mechanicalcentrifugal compressor. The product from this process will be fresh water (desalinated water) and the

waste product from this process is a high salt concentration brine solution.

The effluent brine from the desalination package is diluted by a part of supply seawater prior todischarging in order to lower the temperature of the effluent to the sea.

A facility to periodically clean the desalination packages with acid is provided. Spent neutralized acid

is drained to the open ditch. Anti scaling chemical is also provided in the package system. Refer tovendor’s operation manual (064-VDR-SKO-1821) for details and cleaning timing.

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Since desalinated water is corrosive, corrosion inhibitor is injected into the desalinated water at

downstream of desalination packages. These packages consist of a vessel to make the solution andmetering pumps to inject the chemical into desalinated water. The corrosion inhibitor should be a

type of forming film on metal surface to prevent increasing Total Dissolved Solids (TDS) indesalinated water, and also shall be suitable for drinking water purpose such as compliant with FDA.

Injection flow rate shall be advised by chemical supplier.

One common Desalinated Water Tank (064-TK-1001) for plant water services and firewater service

is provided to store the desalinated water. Total capacity of this tank is based on 4 hours holding timefor firewater consumption + seven days downstream requirement excluding potable water demand

(Estimated time for maintenance of Seawater Intake is taken about seven days).

Desalinated water from the Desalinated Water Tank is pumped to the following destinations by

Desalinated Water Pump (064-P-1001A/B).

- Utility Water System Header

- Potable Water System

- Demineralized Water System

- Closed Cooling Water System

- Firewater Header (normally no flow)

2.4.3 Utility Water System

Desalinated water from Desalinated Water Tank (064-TK-1001) is directly utilized as utility water.

Utility water is distributed to the entire plant area by using Desalinated Water Pump(064-P-1001A/B) including closed cooling water make-up, and supply water to Remineralisation

Package (064-V-1002) and Demineralisation Packages (064-V-1003). Some of areas are supplied thedesalinated water directly from Desalination Package (064-V-1001A/B/C) as utility water.

The utility water system supplies water to the utility hose stations in the plant and as raw water toupstream berth.

2.4.4 Potable Water System

Potable Water System consists of the Remineralisation Package (064-V-1002), Potable Water Tank(064-TK-1002), and Potable Water Pumps (064-P-1002A/B).

The potable water system is designed to meet the potable water demands at inside plant and outside plant including community area, administration area, upstream operation support area, etc.

The source of supply for potable water is desalinated water from the desalinated water tank.

Desalinated water contains only trace amounts of mineral salts and such is not suitable for direct

human consumption. Calcium and magnesium salts are added to the desalinated water in theRemineralisation Packages (064-V-1002) to make it potable.

Remineralisation Package consists of a carbon dioxide and hypochlorite injection facilities and two

remineraliser beds containing calcium and magnesium salts. Carbon dioxide injection is doneupstream of remineraliser beds to enhance solubility of calcium and magnesium salts. Carbon dioxide

is fed from a manifold of cylinders with charged ones while plant is on stream. After injection ofcarbon dioxide, the water is passed in a downward direction through the remineraliser beds where

remineralisation takes place.

A vessel with an agitator is provided to make hypochlorite solution from pure salts.

Hypochlorite solution is injected downstream of reminaraliser using a metering pump to maintain aresidual chlorine level of 0.3 – 0.6 ppm in potable water. Water from the remineraliser is sent to

Potable Water Tank (064-TK-1002). On-off level controller is provided on Potable Water Tank toavoid overfill.

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Potable Water Pump (064-P-1002A/B), one operating and one spare are provided to supply potable

water to various users.

2.4.5 Demineralized Water System

Demineralized Water System consists of the Demineralization Package (064-V-1003), Active

Carbon Filter Package (064-V-1006), Demineralized Water Tank (064-TK-1003) and DemineralizedWater Pumps (064-P-1003A/B).

The condensate return which has the possibility of being contaminated by hydrocarbon is collected in

Condensate Flash Drum (051/052-D-1104) installed in each LNG train. Condensate Flash DrumVent Condenser (051/052-E-1105) is provided to recover flash steam as condensate into the drum.Condensate Return Pump (051/052-P-1102A/B) transfers the steam condensate to Activated Carbon

Filter Package (064-V-1006) for removal of any residual hydrocarbons via dedicated LP Steam

Condenser Cooler (051/052-E-1107) located in utility area.

The Activated Carbon Filter Package (064-V-1006) consists of three activated carbon filter beds (twooperating and one stand-by). The effluent from the Carbon Filter is combined with the desalinated

water from Desalination Package and then purified in the Demineralization Package (064-V-1003).

The Demineralization Package consists of three mixed bed polishers (two operating and one stand

by).

Mixed bed polisher removes the residual minerals in the feed water by replacing the cation and anionin the feed water with hydrogen and hydrogen oxide.

There are two of regeneration cycles that will be conducted in series i.e. regeneration of cationexchanger and regeneration of anion exchanger.

Once regeneration is initiated, the whole regeneration cycle is fully automatic and feed water is

switched over to stand by mixed bed polisher so that the demineralized water production isuninterrupted. The regeneration waste generated during sodium hydroxide solution circulation or

sulfuric acid solution circulation, and displacement rinse is sent to the Neutralizing Pit (087-A-1005)of Wastewater Treatment System (Unit 087). Effluent water generated during backwash and fast

rinse is also sent to the neutralizing pit.

Demineralized water from the Demineralization Package is sent to Demineralized Water Tank(064-TK-1003). The Tank is sized to hold four hours downstream requirement + consumption for

regeneration.

Level controller is provided on Demineralized Water Tank.

Demineralized Water Pumps (one operating and one stand by) are provided to supply demineralized

water to the Deaerators in the Steam Unit (Unit 062), Acid Gas Removal Unit (as make-updemineralized water), and gas turbines washing at 5 kg/cm

2G.

2.4.6 Closed Cooling Water System

Closed Cooling Water System is comprised of Fresh CW Expansion Vessel (064-TK-1004) forthermal expansion, along with Closed CW Pump (064-P-1004A/B/C) for circulation of cooling water

and Closed CW Cooler (064-E-1001A/B/C). Air is used as cooling medium in the Closed CoolingWater Cooler.

The desalinated water is used as cooling water medium in the Closed Cooling Water System.

Provision is made to add chemicals into the system to control corrosion and scale. To compensatewater leakage during circulation, desalinated water is fed to the closed CW system through Fresh CW

Expansion Vessel (064-TK-1004) on level on-off control.

Closed cooling water is mainly used as mechanical cooling medium for turbines, pumps, generators,

lube oil coolers, etc in process and utility units.

Hot cooling water returning from the users is cooled through Closed CW Cooler (064-E-1001A/B/C)then sent to CW Expansion vessel. The cold cooling water is then re-circulated through the users by

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using Closed CW Pump (064-P-1004A/B/C). Three pumps, two operating and one stand-by are

provided to circulate the cooling water. The cooling water cooler (064-E-1001A/B/C) is Air FinCooler type (two operating and one spare).

The design supply temperature of cooling water is 45oC. The air inlet temperature to Air Fin Cooler

will vary around 29 to 33

o

C.

3. PROCESS CONTROLS

3.1 Seawater Intake

One motor driven Seawater Supply Pumps (078-P-1001A/C) is normally running. Seawater header

pressure is controlled by releasing excess seawater to waste water disposal line by 078-PV-1201A/B.Diesel driven Seawater Supply Pump (078-P-1001B) is stand-by.

When the Desalinated Water Tank (064-TK-1001) liquid level reaches low-low level after using

stored firewater, a primary stand-by seawater supply pump will be started automatically to back upfirewater automatically. If the primary stand-by pump could not start, a secondary stand-by pump

would start automatically. The primary stand-by pump can be selected by 078-HS-1022A from DCS.

Electrochlorination Package (078-V-1001) that is controlled by PLC injects chlorine to the intake pit1.5 ppm continuously to keep 1.5ppm Cl at the seawater supply pump discharge and 3.0 ppm

intermittently 20 minutes every 4 hours. (The injection rate shall be adjusted to achieve free chlorine0.5 ppm at desalination package inlet normally.) For the control details of the ElectrochlorinationPackage, refer to the vendor operation manual “Operation & Maintenance Manual”

(078-VDR-DEC-1803)..

3.2 Desalinated Water System

For detailed control philosophy of the Desalination Package (064-V-1001A/B/C) that is controlled byPLC, refer to the vendor operation manual “Operation & Maintenance Manual”

(064-VDR-SKO-1821). Two packages are normally operated and the other is spare.

Corrosion inhibitor is injected by Corrosion Inhibitor Package (064-V-1005). Injection rate iscontrolled by auto stroke adjustment of the injection pump using 064-FT-1011, desalinated water

flow rate.

Desalinated Water Tank (064-TK-1001) is provided to store the desalinated water. Total capacity of

this tank is based on 4 hours holding time for firewater consumption + seven days downstreamrequirement excluding potable water demand. Liquid level of the tank is controlled by feed water

control valve 064-LV-1101 on-off control.

When water liquid level of the desalinated water tank is decreased to low liquid level of utility water,Desalinated Water Pump (064-P-1001A/B) is stopped to prevent the pump damage. If the pump isnot stopped, Not Stopped alarm will be initiated on DCS in Main control room.

When water liquid level of the tank is reached to low-low liquid level of firewater in case of fire, a

stand-by seawater supply pump will start automatically to backup firewater. Refer to Section 3.1 for

details of seawater pumps control.

One of Desalinated Water Pump (064-P-1001A/B) is normally running and the other is stand-by. If

the pressure in the discharge line of the running pump becomes lower than low set point, the stand-by pump will start automatically to ensure continued supply of enough utility water.

Tank blanketing is provided on Desalinated Water Tank (064-TK-1001) by Nitrogen. The

low-pressure gas blanket fills the void vapor space above the liquid stored in the 064-TK-1001.

The positive pressure gas blanket helps prevent entering of air, moisture and othercontaminants from outside of the tank. The line and equipment at the downstream of

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Desalinated Water Tank (064-TK-1001) are protected against material corrosion caused by O2

(Air) contamination into desalinated water.

The tank blanketing system has been designed to maintain the tank constant pressure

considering a pump liquid pulled out flow rate or tank vapor condensation due to rain or cool

ambient. The slightly positive pressure prevents the tank collapse.In addition, Desalinated Water Tank (064-TK-1001) provides with the breather valve which

protect the tank collapse in failure of Nitrogen blanketing system.

Nitrogen Blanketing System is controlled by 064-PCV-9201. The positive and negative local

pressure indication, 064-PG-9203, shall be provided on top of the tank. The other positive and

negative local pressure indication, 064-PG-9204, shall be installed on the goose neck on the

overflow line. The true tank top operation pressure shall be compensated by considering the

tank vapor static pressure of 13.9 mmH2O from the local pressure indication of 064-PG-9204.

Operator shall observe the pressure gauge 064-PG-9204 on the following checkpoints:

If the operating pressure indicates atmospheric pressure, 064-PCV-9201 is failure

close.

If the operating pressure indicates extremely higher positive pressure (> 12.7 mmH2O),

064-PCV-9201 is failure open.

It is recommended that the O2 contents in desalinated water should be checked by periodical

sampling to ensure that 064-PCV-9201 is operated well.

3.3 Potable Water System

For detailed control philosophy of the Remineralization Package (064-V-1002) that is controlled byPLC, refer to the vendor operation manual “IOM Manuals for Equipment” (064-VDR-SAL-1800)

and “Operation & Maintenance Instruction for the Whole Unit” (064-VDR-SAL-1820).

The remineralization package is on-off controlled by liquid level of Potable Water Tank(064-TK-1002). The potable water tank feed control valve 064-FV-1111 controls flow rate to the

tank. The feed flow controller 064-FIC-1111 is cascaded by on-off control by the tank liquid level.The 064-FV-1111 starts to open at low liquid level and ramp-up water flow rate to 14m3/h in a

minute, and stops the water flow at high liquid level.

One of Potable Water Pump (064-P-1002A/B) is normally running and the other is stand-by. If the

pressure in the discharge line of the running pump becomes lower than low set point, the stand-by pump will start automatically to ensure continued supply of enough potable water.

3.4 Demineralized Water System

For detailed control philosophy of the Activated Carbon Filter Package (064-V-1006) andDemineralization Package (064-V-1003) which both are controlled by PLC, refer to the vendor

operation manual “IOM Manuals for Equipment” (064-VDR-SAL-1800) and “Operation &

Maintenance Instruction for the Whole Unit” (064-VDR-SAL-1820).

To keep minimum velocity in the activated carbon filter bed, demineralized water is supplied as make

up water at inlet of the activated carbon filter package via 064-FCV-5501. Flow rate of minimum16m3/h per filer is maintained.

Number of operating activated carbon filter (one or two) can be selected by 064-HS-5501 from DCS.

The treated steam condensate is mixed with makeup desalinated water from 064-TK-1001 and flows

into Demineralization Package (064-V-1003).

Flow rate of the make up water is controlled by liquid level of Demineralized Water Tank

(064-TK-1003).

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To keep minimum velocity in the mixed bed polisher, demineralized water is supplied as make up

water at inlet of the demineralization package via 064-FCV-1121. Flow rate of minimum 48m3/h per polisher is maintained.

Number of operating polisher (one or two) can be selected by 064-HS-1121 from DCS.

One Demineralized Water Pump (064-P-1003A/B) is normally running and the other is stand-by. Ifthe pressure in the discharge line of the running pump becomes lower than low set point, the stand-by

pump will start automatically to ensure continued supply of enough demineralized water.

3.5 Closed Cooling Water System

Make up desalinated water is introduced to Fresh CW Expansion Vessel (064-TK-1004) via064-LV-1131 by the vessel liquid level. The 064-LV-1131 is on-off controlled by high liquid leveland low liquid level for the valve.

Two Closed CW pumps (064-P-1004A/B/C) are normally running and the other one is stand-by. Ifthe pressure in the discharge line of the running pumps becomes lower than low set point, the

stand-by pump will start automatically to ensure continued supply of enough cooling water.The cooling water required by each user for coolers should be regulated by adjusting the manual

valve at the individual user.

Two Closed CW Coolers (064-E-1001A/B/C) are normally operated and the other is spare. These airfin coolers are cooling down returned hot cooling water to under 45

oC.

4. PREPARATION FOR INITIAL START-UP

Refer to Commissioning Procedure (64-PRC-OP-1001 / 78-PRC-OP-1001).

5. NORMAL START-UP PROCEDURE

5.1 General

Check points are as follows:

(1) All equipment including instrument, etc. is ready for use.

(2) Instrument air and electric power are available.

(3) All blinds or spectacle blinds except for Battery Limit have been placed in operation position.

(4) Ensure all vents, drains, and sample connections are closed.

(5) All safety equipment must be installed on site, calibrated and operable.

(6) Prepare required chemicals in each chemical vessel.

After all the above checkpoints are checked, start up the Water System.

5.2 Start of Seawater Supply Pumps

(1) Confirm the desalination unit is ready to receive seawater.

(2) Confirm seawater header pressure control valve (078-PV-1201A/B) is in auto mode to

keep a pump minimum flow rate.(3) Confirm that discharge valves of Seawater Supply Pumps (078-P-1001A/B/C) are

closed.

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(4) Start one of the pumps locally.

(5) Open the pump discharge valve by manual gradually.

(6) Check seawater header pressure is stable.

(7)

Open remaining pump discharge valves.(8) Select primary stand-by pump from DCS.

(9) Set stand-by pump to auto mode locally.

5.3 Start up of the Electrochlorination Package (078-V-1001)

After a seawater supply pump starts, operation of the Electrochlorination Package (078-V-1001)should be started locally.

For the start up procedure of the Electrochlorination Package, refer to the vendor’s instruction“Operation & Maintenance Manual” (078-VDR-DEC-1803).

5.4 Start up of the Desalinated Water System

(1) Confirm Desalinated Water Tank (064-TK-1001) level controller (064-LIC-1101) is

in auto mode.

(2) Seawater is introduced to a Desalination Package (064-V-1001A/B/C). For the start up procedure of the Desalination Package, refer to the vendor’s instruction “Operation &

Maintenance Manual” (064-VDR-SKO-1821).Off-spec water will be disposed to open ditch.

(3) When on-spec desalinated water is produced from the package, the desalinated wateris introduced to Desalinated Water Tank (064-TK-1001). And also Corrosion

Inhibitor Package (064-V-1005) shall be started.

(4) When required, second desalination package will be started.

(5) After built up the liquid level in Desalinated Water Tank (064-TK-1001), utility water

distribution can be started.

(6) When each user is ready to receive utility water, one of Desalinated Water Pump

(064-P-1001A/B) is started locally.



5.5 Start up of the Potable Water System(1) Confirm Potable Water Tank (064-TK-1002) level controller (064-LIC-1111) and

potable water feed flow controller (064-FIC-1111) are in auto mode.

(2) For the start up procedure of the Remineralization Package (064-V-1002), refer to the

vendor’s instruction “IOM Manuals for Equipment” (064-VDR-SAL-1800) and“Operation & Maintenance Instruction for the Whole Unit” (064-VDR-SAL-1820).

(3) After built up the liquid level in Potable Water Tank (064-TK-1002), potable water

distribution can be started.

(4) One of Potable Water Pump (064-P-1002A/B) is started locally.



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5.6 Start up of the Closed Cooling Water System

(1) Confirm the liquid level in Closed CW Tank (064-TK-1004) is between normal

operation ranges (CV on/off levels).When the liquid level is lower than the normaloperation range, open 3” manual bypass valve of Closed CW Tank (064-TK-1004)

level control valve (064-LV-1131). Close the 3” valve after built up the liquid level in064-TK-1004.

(2) Set Closed CW Tank (064-TK-1004) level controller (064-LIC-1131) is in auto mode.

(3) Confirm isolation valves of users that can receive the cooling water are open.

(4) One of Closed CW Pump (064-P-1004A/B/C) is started locally.


(6) Check water quality and add chemicals, if required. (refer to Section 6.5)

(7) Start second pump locally when the cooling water flow rate (064-FI-1032) is over

2000m3/h.

(8) Open the second pump discharge valve by manual gradually(9) Set stand-by pump to auto mode locally.

5.7 Start up of the Demineralized Water System

(1) Confirm Demineralized Water Tank (064-TK-1003) level controller (064-LIC-1121)and Demineralization package make-up water flow controller (064-FIC-1121) are inauto mode. And set 064-HS-1121 to one polisher train operation.

(2) For the start up procedure of the Demineralization Package (064-V-1003) refer to the

vendor’s instruction “IOM Manuals for Equipment” (064-VDR-SAL-1800) and“Operation & Maintenance Instruction for the Whole Unit” (064-VDR-SAL-1820).

(3) After built up the liquid level in Demineralized Water Tank (064-TK-1003),demineralized water distribution can be started.

(4) When each user is ready to receive demineralized water, one of Demineralized WaterPump (064-P-1003A/B) is started locally.



5.8 Start up of the Suspect Condensate Recovery System

(1) Confirm Condensate Flash Drum (051/052-D-1104) level controller

(051/052-LIC-1171) and Activated Carbon Filer Package (064-V-1006) make-upwater flow controller (064-FIC-5501) are in auto mode.

(2) Start Activated Carbon Filter Package (064-V-1006). For the start up procedure of the

064-V-1006, refer to Operation Manual for Water System (62-IOM-PS-1201) and thedemineralization package vendor operation manual (064-VDR-SAL-1800/1820).

(3) Start nitrogen injection to Condensate Flash Drum Vent Condenser (051/052-E-1105)

vent pipe.

(4) Start Condensate Flash Drum Vent Condenser (051/052-E-1105) locally.

(5) Start LP Steam Condensate Cooler (051/052-E-1107) locally.

(6) Receive steam condensate into Condensate Flash Drum (051/052-D-1104).

(7) When liquid level is built up above normal liquid level in the drum, one of CondensateReturn Pump (051/052-P-1102A/B) is started locally.

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6. NORMAL OPERATION

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

6.1 Back up Firewater Operation

Firewater can be supplied from Desalinated Water Tank (064-TK-1001) for minimum four hours. If afire is continued and the water level in the tank becomes close to firewater low liquid level (800mm

from the tank bottom), operator shall open the manual valve at seawater intake for firewater backup.

When the tank liquid level reaches low-low level after using stored firewater, stand-by seawater

supply pump will be started to back up firewater automatically.

6.2 Low Level at Seawater Pump Basin

When low level alarm is initiated in a seawater pump basin, it may be a sign of plugging seawater

screen. In this case, operator shall change the operating pump in the basin to a stand-by pump andclean the plugged screen. Sodium hypochlorite injection is also switched over to the operating pump

basin.

6.3 Hypochlorite Monitoring

Residual chlorine in seawater is measured at two points; one is seawater supply pump discharge

header and the other is seawater feed line in desalination package. The residual chlorine at thedesalination package should be less than 0.5ppm. If this value is exceeded, the concentration ofhypochlorite solution from Electrochlorination Package should be adjusted.

6.4 Residual Chlorine in Potable Water

Residual chlorine concentration in potable water shall be controlled. When residual chlorineconcentration in the potable water is less than 0.1mg/l at sample points located on Potable WaterTank (064-TK-1002) outlet or Service Water Reservoir (340-TK-1001) outlet, Hypochlorite

injection flow rate in Remineralization Package (064-V-1002) shall be increased.

6.5 Operation Number of Active Carbon Filters and Polishers

Basically one active carbon filter in 064-V-1006 and one polisher in 064-V-1003 are required for one

LNG train operation. And two active carbon filters and two mixed bed ion polishers are required fortwo LNG train operations.

When normal average feed water flow rate to 064-V-1003 (064-FIC-1121 minus 064-FI-1022) is

lower than 49 m3/h, even if two LNG trains operation, operator should select one polisher operation by 064-HS-1121.

6.6 Chemical Injection into Closed Cooling Water System

Chemical injection is performed by manual batch operation. Operator shall check water quality bysampling according to sampling schedule to decide timing of chemical injection. The chemicalinjection volume and timing shall be advised by the chemical supplier.

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A chemical injection pot is provided to inject the chemicals into the secondary cooling water circuit.

The injection point is provided at the closed cooling water pump discharge header, which is tied inwith the cooling water return line to Fresh CW Expansion Vessel (064-TK-1004). Corrosion inhibitor

(and micro-biocide, if required) is intermittently injected after analyzing the cooling water quality.The operation is carried out by the steps as following description. As it is expected that the pot have

been filled by water, the work will start from the pot to be empty.

(1) Confirm inlet valve of a chemical injection pot is closed.

(2) Close outlet valve of the pot.

(3) Open 1” drain valve and 1” valve on chemical filling line to drain out water in the pot.

(4) After the pot is empty, close the drain valve.

(5) Fill chemical through the 4” cap by a hand pump into the pot until the chemical drumis empty.

(6) Close the 1” valve at chemical filling line.

(7) Open the 1” cooling water inlet valve.

(8) Open the globe valve at outlet of the pot and keep it for a few minutes (about 5

minutes).

(9) Close the inlet valve.

Chemical supplier’s advice and instruction shall be taken to decide kinds of chemicals and injectionrate of the chemicals.

7. NORMAL SHUTDOWN PROCEDURE

An entire shutdown of the water system is only possible during the whole plant shut down. Howeverequipment or sections of line may require periodically shutdown for maintenance or an inspection. Inthat case, only the equipment or the sections shall be isolated.

7.1 Seawater System Shutdown

(1) Stop all Desalination Packages (064-V-1001A/B/C). For shutdown procedure of

Desalination Packages (064-V-1001A/B/C), refer to the vendor’s instruction“Operation & Maintenance Manual” (064-VDR-SKO-1821).

(2) Stop Seawater Supply Pumps (078-P-1001A/B/C) and switch over to off positionlocally.

(3) Stop Electrochlorination Package (078-V-1001). For shutdown procedure of the package, refer to the vendor’s instruction “Operation & Maintenance Manual”(078-VDR-DEC-1803).

7.2 Electrochlorination Package

For shutdown procedure of Electrochlorination Package (078-V-1001), refer to the vendor’sinstruction “Operation & Maintenance Manual” (078-VDR-DEC-1803).

7.3 Desalination Packages

(1) Stop the required desalination package. For shutdown procedure of DesalinationPackages (064-V-1001A/B/C), refer to the vendor’s instruction “Operation &Maintenance Manual” (064-VDR-SKO-1821).

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(2) Start stand by desalination package. For start up procedure of Desalination Packages

(064-V-1001A/B/C), refer to the vendor’s instruction “Operation & MaintenanceManual” (064-VDR-SKO-1821).

7.4 Remineralization/Active Carbon Filter/Demineralization Packages

For shutdown procedure of Remineralization Package (064-V-1002), Active Carbon Filter Package(064-V-1006) and Demineralization Packages (064-V-1003), refer to the vendor’s instruction “IOM

Manuals for Equipment” (064-VDR-SAL-1800) and “Operation & Maintenance Instruction for theWhole Unit” (064-VDR-SAL-1820).

7.5 Closed CW Cooler

(1) Start fans of the stand-by Closed CW Cooler (064-E-1001A/B/C) locally.

(2) Open vent valve and gradually open isolation valves at inlet of the cooler to fill water

in the cooler.

(3) After fill up the cooler, close the vent valve.

(4) Open outlet isolation valve of the cooler.

(5) Close isolation valves at inlet/outlet of the cooler that will be stopped.

(6) Stop fans of the cooler locally.

7.6 One Train Shutdown

(1) Confirm all on-site process units are shutdown.

(2) Close isolation valves at the train BL

(3) Stop dedicated LP Steam Condensate Cooler (051/052-E-1107) located in utility area.

(4) Change operation number of active carbon filer in 064-V-1006 and polisher in

064-V-1003 to one for each.

8. EMERGENCY SHUTDOWN PROCEDURE

8.1 General

This section describes the guidelines of shutdown procedure in case of emergencies. However, in

emergencies, required actions by operators may vary because they depend on the actual situation atthe time of emergency. Therefore, it is most important for the operators to determine the cause of

emergency accurately and to understand the exact situation.

8.2 Loss of Utilities

8.2.1 Power Failure

All pumps and air fin coolers will be stopped to supply services to users by a power failure.

Seawater supply pump 078-P-1001B is diesel driven pump. The diesel tank of the pump has eight (8)hours holding volume. Therefore, it can operate for 8 hours without diesel oil make-up, if necessary.

Desalination Package

The desalination packages stop producing desalinated water.

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LP Steam Condensate Cooler

When a partial power failure occurs to the LP Steam Condensate Cooler, hot condensate flows into

the Activated Carbon Filter Package. The hot steam condensate may affect polisher media in

Demineralization Package (064-V-1003). Temperature high alarm at downstream of the coolers will be initiated. In this case, the treated LP steam condensate shall bypass the Demineralization Package

(064-V-1003).

Closed CW Cooler

When a partial power failure occurs to the Closed CW Cooler, temperature of cooling water supplywill gradually rise and finally may cause mechanical damage of users in the worst case. Temperaturehigh alarm at downstream of the coolers will be initiated. Spare cooler is available.

8.2.2 Instrument Air Failure

Seawater Intake

When instrument air failure occurs, pressure control valves (078-PV-1201A/B) will be open by their

failure action. And then the desalination unit feed water may be short. Produced desalinated waterwill be decrease in this case, however, there is no damage to the desalination package.

Operator should adjust the seawater flow rate at 078-FI-1002 by the 078-PV-1201A/B hand wheels to380m3/h.

Desalinated Water System

The desalination packages stop producing desalinated water. Level control valve (064-LV-1101) on

feed line to the desalinated water tank is closed as its failure position.

Demineralized Water System

Make up water to the demineralization package is stopped by closing flow control valve(064-FV-1021) as its failure position.

As minimum flow control valve (064-FV-1121) to the demineralization package is also closed, equaldistribution to polisher media is not expected.

As flow control valve (064-FV-5501) to the activated carbon filter package is closed, equal

distribution to activated carbon filter media is not expected.

Closed CW Cooler

Make up water to the closed CW system is stopped by closing level control valve 064-LV-1131 as its

failure position.

9. SAFETY PROCEDURE

9.1 General

To prevent accidents it is of the utmost importance that all personnel be instructed properly of the

following subject:

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- 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 responsiblefor 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. Mechanicalcraftsmen 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 mechanicalworkers.

In addition to specifically defined rules and practices, the exercise of good judgment by every personinvolved 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 thewater solution will conduct electricity and may aggravate the difficulty or result in the electrocution

of personnel.

Carbon dioxide or dry powder extinguisher may be used safety on electrical fires.

Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered.

Safety hats must be worn when outdoors.

Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid is

encountered, and are recommended for use while samples are being withdrawn and solutions madeup.

Fire extinguishers must be recharged immediately after use. All stream and water hose equipmentmust be put back in place after use. Access to such equipment must not be obstructed.

Gas masks must have fresh cartridges installed after use.

9.2 Emergency Fire Plan

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

or extinguish fire within short period of time, assuming there will be no outside fire fightingassistance, with only one major fire at a time.

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9.3 Fire Fighting and Protective Equipment

Fire hazard status throughout the plant shall be monitored on the Hazard Detection and Monitoring

System (HDMS (F&G)) consoles in the main control room and fire and emergency station.

Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall

be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heatradiation.

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 theequipment 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.

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 water hammer

to start.

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

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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. A

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

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

When sampling any material the sampling line must be flushed long enough to remove dormantmaterials to insure that the sample obtained represents the current stream.

Wear proper personal protective equipment and exercise caution to avoid injuries.

When sample cooling is required, operator shall confirm cooling water is flowing properly beforetaking 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, consultyour 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 causedeath 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

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.

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

test method.

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

9.9 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 linetrolley 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 equipmentthat has been N2 purged. Adequate ventilation must be provided and appropriate breathing device

worn. To breathe an atmosphere high in N2, could result in suffocation.

Before entering vessels that have been purged with N2, a check must be made for proper 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

The following chemicals are used in this system. They are hazardous and shall be taken care when

handling them. Plastic gloves, a face shield, overalls, a full PVC suit or chemical resistant apron, andrubber safety boots shall be worn. The PVC trousers should be outside the boots. Avoid all contactwith and do not inhale the fumes.

- Corrosion Inhibitor

- Sodium Hypochlorite

- De-chlorination

- Anti-foam

- Scale Inhibitor

- Sulfuric Acid

- CausticRefer to the Material Safety Data Sheet (MSDS) of each chemical.

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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 and 9.2.2.

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Figure 10.2.1

Horizontal Pressure Vessel

Figure 10.2.2

Vertical Pressure Vessel

10.2.2.2 Pumps

Normally valved isolation method is applied for isolation of pump suction and discharge lines. Ifrequired from the maintenance work nature, spectacle blinds will be provided. Refer to Figure 9.2.3.

RELIEF VALVES

AND FLARE

GAS OUTLET

LIQUID OUTLET

INLET

LINE

VERTICALVESSEL

INLET

LINE

DRAIN LINES

OIL OUTLET

WATER OUTLET (IF REQUIRED)

GAS OUTLET

RELIEF VALVES

AND FLARE

HORIZONTAL VESSEL

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Figure 10.2.3

Pumps

11. MAINTENANCE PROCEDURE

11.1 General

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.

• 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.

OUTLET

LINE

INLET

LINE

PUMP‘Y’ or ‘T’ TYPE SUCTION

STRAINER

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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 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, andusually 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 duringProduction.

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 & 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/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 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

• Installation of isolating blank flanges or spades

• Replacement with air for entry into the equipment

11.3.1 Installation of blank flanges or spades

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

11.3.2 Air Test

O2 test for equipment must be performed prior to permitting entry.(1) Connect temporary air hoses at the appropriate location with utility air if required.

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

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(3) Introduce air.

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

11.4 Typical isolation method11.4.1 Vessels/Drums

• Erect scaffold for access as required.

• Operations to close down the system and depressurize..

• Mechanical to spade inlet and outlet nozzles of said equipment.

• Mechanical to open drum.

• Operations to air purge and check for toxics and 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 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.

• Mechanical to open as required.• Operations to air purge and check for gas and toxics and oxygen level.

• Operations to clean

11.4.4 Air Fin Coolers

• Operations to shut down the unit and depressurize and air purge.

• Electrical to lock out fan motor locally and remove relay/fuse in substation.

• Mechanical to remove access panel.

• Operations to check area is hazard free.

11.4.5 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 Utility Flow Diagram

Attachment-2 P&IDs

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Attachment-3 List of Equipment Data Sheet

Attachment-4 List of Instrument Alarm Set Point

Attachment-5 List of Cause and Effect Charts

Attachment-6 Laboratory Sampling ScheduleAttachment-7 MSDS (Later)

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Alarm & Trip Setting List (7)

Documents

Transcript of Alarm & Trip Setting List (7)