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Doc. No.

62-IOM-PS-1201 TLNG Authors Org. Date Sheet

Rev. KJP

6A

TANGGUH LNG
BPMIGAS

Project
KJP Doc. No. BP Berau Ltd. KJP Job Code

S-062-1283-001 J-3400-20-0000

27 Feb, 06 1 of 35

3.8 MTPA TRAIN CAPACITY Operation Manual for Steam/Steam Condensate/BFW System

Core
For Information

Non-core
For Review For Approval
X

Lifecycle Code
Released As-Built

Rev. 5A

Date 09Jan06

Page All All For Approval Released

Description

Prepd M.Hatanaka M.Hatanaka

Chkd Y.Kakutani Y.Kakutani

Appd Y.Kakutani Y.Kakutani

BP Appd

6A 27Feb06

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PT. Brown & Root Indonesia

BP Berau Ltd. Tangguh LNG Project Operation Manual for Steam/Steam Condensate/BFW System

Doc. No. 62-IOM-PS-1201 KJP Doc. No. S-062-1283-001 Rev. 6A Sheet No. 2 of 35

CONTENTS 1. 2. 2.1 2.2 2.2.1 2.2.2 2.2.3 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.4 2.4.1 2.4.2 2.4.3 2.4.4 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 6. 6.1 6.1.1 6.1.2 6.1.3 6.2 6.3 6.4 7. 7.1 7.2 7.3 7.4 7.5 8. 8.1 8.2 Introduction.................................................................................................................................4 Basis of Design.............................................................................................................................4 General ........................................................................................................................................4 Design Condition.........................................................................................................................5 SERVICE CONDITIONS ................................................................................................................ 5 BOILER FEED WATER QUALITIES .............................................................................................. 5 STEAM CONSUMERS................................................................................................................... 5 Special Equipment ......................................................................................................................6 DEAERATORS (062-D-1001A/B)................................................................................................ 6 PACKAGE BOILERS (062-F-1001A/B/C) .................................................................................... 6 STEAM TURBINE GENERATOR SETS ........................................................................................... 6 HEAT RECOVERY STEAM GENERATORS .................................................................................... 7 Process Description.....................................................................................................................7 STEAM GENERATION.................................................................................................................. 7 STEAM DISTRIBUTION ................................................................................................................ 7 STEAM CONDENSATE RECOVERY AND TREATMENT.................................................................. 8 STEAM TURBINE GENERATOR SYSTEM...................................................................................... 9 Process Controls..........................................................................................................................9 Boiler Feed Water.......................................................................................................................9 High Pressure Steam ................................................................................................................10 Low Pressure Steam .................................................................................................................11 Blowdown System for Boilers ..................................................................................................12 Clean Steam Condensate..........................................................................................................12 Suspect Steam Condensate.......................................................................................................12 Steam Turbine Generator Sets ................................................................................................13 Preparation for initial start-up ................................................................................................15 Normal Start-up Procedure .....................................................................................................15 General ......................................................................................................................................15 Start up of Boiler Feed Water System ....................................................................................15 Start up of Package Boiler (062-F-1001A/B/C) ......................................................................15 Introduce HP Steam to HP Steam Header .............................................................................16 Letdown HP Steam to LP Steam .............................................................................................16 Introduce LP Steam to Deaerators (062-D-1001A/B)............................................................17 Start Steam Turbine Generator Set (061-GS-1001A/B/C)....................................................17 Steam Condensate System .......................................................................................................17 Letdown HP Steam to MP Steam............................................................................................18 Start up of Heat Recovery Steam Generator (051/052-F-1101/1102)...................................18 Start up of the Suspect Condensate Recovery System...........................................................19 Normal Operation.....................................................................................................................19 Water Quality Control .............................................................................................................19 GUIDE LINE .............................................................................................................................. 19 BOILER FEED WATER............................................................................................................... 20 BOILER WATER ........................................................................................................................ 21 Single Failure of Package Boiler..............................................................................................23 Single Failure of Steam Turbine Generator...........................................................................23 Load shedding ...........................................................................................................................23 Normal Shutdown Procedure ..................................................................................................24 Deaerator...................................................................................................................................24 Package Boiler...........................................................................................................................24 Steam Turbine Generator System...........................................................................................24 Heat Recovery Steam Generator.............................................................................................24 Train Shutdown ........................................................................................................................25 Emergency Shutdown Procedure ............................................................................................25 General ......................................................................................................................................25 Loss of Utilities..........................................................................................................................25

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8.2.1 POWER FAILURE ...................................................................................................................... 25 8.2.2 INSTRUMENT AIR FAILURE ...................................................................................................... 25 8.2.3 COOLING WATER FAILURE ...................................................................................................... 25 9. Safety Procedure .......................................................................................................................25 9.1 General ......................................................................................................................................25 9.2 Emergency Fire Plan ................................................................................................................26 9.3 Fire Fighting and Protective Equipment ................................................................................27 9.4 Maintenance of Equipment and Housekeeping .....................................................................27 9.5 Repair Work .............................................................................................................................27 9.6 Withdrawal of Samples ............................................................................................................28 9.7 Safe Handling of Volatile and Toxic Materials ......................................................................28 9.8 Respiratory Protection .............................................................................................................28 9.9 Breathing Apparatus (B. A.)....................................................................................................29 9.9.1 NITROGEN ................................................................................................................................ 29 9.9.2 CORROSIVE MATERIALS .......................................................................................................... 29 9.9.3 CHEMICALS .............................................................................................................................. 29 10. Isolation Procedure for Maintenance......................................................................................30 10.1 General ......................................................................................................................................30 10.2 Basic Procedures.......................................................................................................................30 10.2.1 TRAIN ISOLATION .................................................................................................................... 30 10.2.2 INDIVIDUAL EQUIPMENT / SYSTEM ISOLATION........................................................................ 30 10.2.2.1 Horizontal and Vertical Pressure Vessels ....................................................................... 30 10.2.2.2 Pumps.............................................................................................................................. 31 10.2.2.3 Shell and Tube Heat Exchangers .................................................................................... 32 11. Maintenance Procedure............................................................................................................32 11.1 General ......................................................................................................................................32 11.1.1 ROUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 33 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 33 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 33 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 33 11.1.5 TURNAROUND /INSPECTION MAINTENANCE ............................................................................ 33 11.2 Precautions prior to Maintenance...........................................................................................33 11.3 Preparation for Maintenance ..................................................................................................34 11.3.1 INSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 34 11.4 Typical isolation method ..........................................................................................................34 11.4.1 VESSELS/DRUMS ...................................................................................................................... 34 11.4.2 PUMPS ...................................................................................................................................... 34 11.4.3 SHELL AND TUBE TYPE HEAT EXCHANGERS ........................................................................... 34 11.4.4 AIR FIN COOLERS ................................................................................................................ 3435 11.4.5 CLOSE OUT ............................................................................................................................... 35 12. Attachment List.........................................................................................................................35

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1.

INTRODUCTION The purpose of Steam System (Unit 062) is to produce and distribute High Pressure steam (HP steam), High Pressure Saturated steam (HP Sat. steam), Medium Pressure steam (MP steam) and Low Pressure steam (LP steam) to the plant, and recovery the condensates. Steam turbine generator (Unit 061) generates electric power to supply power for two trains operation including the support facilities including community area, administration area, upstream operation support area, etc

2. 2.1

BASIS OF DESIGN General Steam is available at four pressure levels, High Pressure (HP) that is based on the optimum steam turbine design pressure, Low Pressure (LP) that is based on Acid Gas Removal Unit requirements and fractionation reboilers, Saturated High Pressure (HP SAT.) for stabilizer reboiler and Medium Pressure (MP) for deethanizer reboiler. High-pressure steam is produced from Heat Recovery Steam Generators (HRSG) and Package Boilers. HRSG is installed in the exhaust duct of all Frame 7 gas turbines that drive refrigerant compressors in the LNG train. Three package boilers are provided to supplement the HP steam from HRSGs for generating electric power by steam turbine power generators. Low-pressure steam is produced from back pressure steam turbines, flash drums at continuous blow down from HRSGs and package boilers and a HP steam to LP steam letdown station. HP SAT. steam is produced by desuperheating system from HP steam. MP steam is produced by a letdown station from HP steam to MP steam. HP SAT., MP and LP steam are used as the heating medium for the LNG facilities and associated facilities. Steam condensate is categorized as vacuum condensate, clean condensate and suspect condensate. Suspect condensate is flashed to near atmospheric pressure. The suspect condensate is passed through a carbon filter followed by mixed bed polisher to remove possible contaminates prior to deaeration. All steam condensate and make-up water are deaerated prior to being pumped to each HRSG and package boiler. Electric power is generated by Steam Turbine Generator Sets 061-GS-1001A/B/C. The steam to steam turbines is supplied from high pressure steam system.

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2.2 2.2.1

Design Condition Service Conditions Operating Condition at Source Pressure kg/cm2G High Pressure Steam Medium Pressure Steam Low Pressure Steam Boiler Feed Water 40.5 Temperature o C 400 Operating Condition at B.L. of User Unit Pressure kg/cm2G Min.40 Temperature o C 400 Mechanical Design Condition Pressure kg/cm2G 44.7 Temperature o C 425

24.0

223

Min.24

221

27.5

250

3.5

148

Min.3.3

148

5.3

175

59.0

120

78.0

148

2.2.2

Boiler Feed Water Qualities Component Sodium Chloride Total Hardness Total Iron Silica pH Conductivity @25oC Total Suspended Solid Oil & Grease Total Copper micro S/cm mg/l mg/l mg/l mg/l as CaCO3 mg/l as CaCO3 mg/l as CaCO3 mg/l Fe mg/l SiO2 Boiler Feed Water < 0.05 < 0.05 Nil < 0.005 < 0.02 8.5 9.5 < 0.2 < 0.1 Nil < 0.01

2.2.3

Steam Consumers High Pressure Steam (HP Steam) Steam Turbine Generator Set (061-GS-1001A/B/C) Steam Turbine Driver for 051/052-C-1001/1004 (051/052-CS-1001) Steam Turbine Driver for 051/052-C-1002/1003 (051/052-CS-1002) Condensate Stabilizer Reboiler (011-E-1001A/B) Deethanizer Reboiler (041/042-E-1005)

High Pressure Saturated Steam (HP SAT. Steam) Medium Pressure Steam (MP Steam) -

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Low Pressure Steam (LP Steam) 2.3 Acid Gas Stripper Reboiler (021/022-E-1002A/B/C/D) Feed Gas Heater (021/022-E-1005) Defrost Gas Heater (031/032-E-1004) Scrub Column Reboiler (041/042-E-1004) Depropanizer Reboiler (041/042-E-1007) Debutanizer Reboiler (041/042-E-1009) Process Fuel Gas Heater (051/052-E-1201) Deaerator (062-D-1001A/B)

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

2.3.1

Deaerators (062-D-1001A/B) Two deaerators are provided. Number of deaerators: Two Type: Spray tray Capacity: 51,5724kg/h for each Operation pressure: 1.0kg/cm2G Residual oxygen: less than 0.007 mg/l Normally two deaerators are operating in parallel. One deaerator has a capacity to cover one train operation with common facility.

2.3.2

Package Boilers (062-F-1001A/B/C) Three 50% package boilers to generate HP steam are provided. Number of boilers: Type: Capacity: Steam pressure: Steam temperature: Fuel: Three (Three for continuous operation) Water tube with economizer 160ton/h (MCR) for each 40.5 kg/cm2G at boiler package Battery Limit 400 C Fuel gas

HP steam is primary supplied by HRSGs (051/052-F-1101/1102) and Package Boilers (062-F-1001 A/B/C) are designed to supplement HP steam Peak load operation at 110 % of MCR (maximum continuous rating) for 2 hours is considered on package boiler design. For the steam system design, 3% of boiler blow down is considered. Normal blowdown ratio will be less than 1%. The boilers operation load is controlled by HP steam header pressure controller. 2.3.3 Steam Turbine Generator Sets (061-GS-1001A/B/C) Three 50% steam turbine generators are provided to supply power for two trains operation including the outside fence supporting facilities.

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Number of the units: Type: Power generated: Inlet Steam:

Three (Three for continuous operation) Full condensing turbine 35 MW / each HP steam

BP Berau Ltd. Tangguh LNG Project Operation Manual for Steam/Steam Condensate/BFW System

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Condensing pressure: Condenser: 2.3.4

0.4 kg/cm2A A-frame air cooled surface condenser with condensate pump / ejector

Heat Recovery Steam Generators (051/052-F-1101/1102) Heat recovery steam generators are provided to produce HP steam by recovering the heat of gas turbines flue gas. Number of the units: Type: Steam pressure: Steam temperature: Steam production rate: Four (dedicated to each Frame 7 Gas Turbine) Water tube with economizer 40.5 kg/cm2G at package B/L 400 C 132 t/h each

2.4 2.4.1

Process Description Steam Generation HP steam is produced at 40 kg/cm2g and 400 C at Heat Recovery Steam Generator (HRSG) (051/052-F-1101/1102) installed at the exhaust stack of Gas Turbine driver of C3/HP MR compressors (051/052-CG-1001) and LP MR/MP MR compressors (051/052-CG-1002), and supplemented from a Package Boilers (062-F-1001A/B/C). HP Sat. steam is produced by injecting the boiler feed water to decrease the temperature to the almost saturated condition of 257C at 40 kg/cm2g by using temperature controller (011-TIC-1306). MP steam (24 kg/cm2g, 223 C) is produced from medium pressure letdown station (pressure reducing and desuperheating). In this letdown station, the high pressure steam is reduced to 24 kg/cm2g, then the boiler feed water is injected to decrease the temperature to the almost saturated condition of 223 C by the pressure controller (091/092-PIC-1001) and temperature controller (091/092-TIC-1471) respectively. LP steam (3.5 kg/cm2g, 148 C) is produced from steam turbine starter / helper of refrigerant compressors (051/052-CS-1001 and 051/052-CS-1002) in process trains. The condition of low pressure steam from the turbines is slightly superheated therefore it requires some boiler feed water injection to desuperheat the steam at temperature of 148 C. It is done by temperature controllers (091/092-TIC-1314 and 1351). LP letdown station with boiler feed water injection system is also provided to produce the LP steam from HP steam. The steam losses in the system will be replaced by make-up water produced from seawater by desalination, which is mixed with the steam condensate before treatment in the demineralization package.

2.4.2

Steam Distribution Steam is distributed through the steam headers to the steam consumers. The steam header from utility area to the process train basically is designed for 2 (two) train capacity. HP steam is mainly sent to drive Steam Turbine Starter/Helper of refrigerant compressors (051/052-CS-1001 and 051/052-CS-1002), which provide additional driver power to the compressor string driven by Frame-7 gas turbines in process train. Since the turbines are back pressure types, the outlet stream from the turbines is low pressure steam. Another main user of HP steam is Steam Turbine Generator Set (061-GS-1001A/B/C) in utility area.

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HP sat. steam is sent to Condensate Stabilizer Reboiler (011-E-1001) in Condensate Stabilization Unit (Unit011). MP steam produced from letdown station is sent to Deethanizer Reboiler (041/042-E-1005) in process train through the MP steam header. LP steam produced from the starter/helper turbines is distributed through the LP steam header to Acid Gas Stripper Reboiler (021/022-E-1002A~D), Feed Gas heater (021/022-E-1005), Scrub Column Reboiler (041/042-E-1004), Depropanizer Reboiler (041/042-E-1007), Debutanizer Reboiler (041/042-E-1009), Process HP Fuel Gas Heater (051/052-E-1201) and Defrost Gas Heater (031/032-E-1004, during startup only) in process train. The LP steam user in utility area is Deaerator (062-D-1001A/B). However, during startup, the most of the LP steam required for Acid Gas Stripper Reboiler is produced from letdown system located in utility area. Therefore the LP steam header is also provided in utility area and is designed considering the start-up and emergency conditions. The MP steam header is controlled by MP letdown station, and LP steam header is controlled by LP letdown station, LP Steam Control Condenser and Starter/Helper Steam Turbine governors also. The HP steam header is controlled by master boiler combustion control. 2.4.3 Steam Condensate Recovery and Treatment Clean steam condensates in process area, mainly Acid Gas Stripper Reboilers (021/022/E-1002A~D), that have no possibility to be contaminated are directly collected at Steam Condensate Flash Drum (051/052-D-1103). The flashed vapor is condensed in Steam Condensate Flash Drum Vent Condenser (051/052-E-1103), and then the steam condensate is returned back to the flash drum. The steam condensate from 051/052-D-1103 is pumped-out by Condensate Return Pump (051/052-P-1101A/B) from process area to Deaerator (062-D-1001A/B) in utility area directly. The exhaust steam from Steam Turbine Generator Sets (061-GS-1001A/B/C) is condensed by Air Cooled Surface Condenser (061-E-1001A/B/C) and collected in Condensate Recovery Drum (061-D-1001A/B/C) as vacuum condensate. The vacuum condensate is pumped-out by Condensate Pump (061-P-1001A/B/C) and returned directly to Deaerators (062-D-1001A/B) with clean steam condensates. Suspect steam condensates in process area that have a possibility to be contaminated by hydrocarbon are collected in the Condensate Flash Drum (051/052-D-1104) in process area, which is operated at almost atmospheric pressure. The flashed vapor is condensed in Condensate Flash Drum Vent Condenser (051/052-E-1105), and then the steam condensate is returned back to the flash drum. The steam condensate from 051/052-D-1104 is pumped-out by Condensate Return Pump (051/052-P-1102A/B) and cooled in Steam Condensate Cooler (051/052-E-1107) from around 100 C to 50 C in order to get the best performance of demineralization package. The suspect steam condensate is sent to the Activated Carbon Filter (064-V-1006) for removal of any residual hydrocarbons. The treated condensate plus the desalinated water make-up are fed to the Mixed Bed Polisher (064-V-1003) in demineralization unit for further treatment, and finally fed to Deaerators (062-D-1001A/B). Deaerator will remove the gaseous dissolved in the steam condensate. Deaerator will be operated at 1.0 kg/cm2g and 120 C. Low pressure steam is used as the medium to removes the gaseous in deaerator upper section. Free gaseous steam condensate (boiler feed water) is collected in the drum

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of lower section of the Deaerator, which is ready to be pumped-out to HRSGs and Packaged Boilers. Pressure in the Deaerator is controlled by pressure controller, which is installed at LP steam inlet. The boiler feed water from Deaerators (062-D-1001A/B) is provided with chemical injection packages (051/052-V-1003, 062-V-1001, 062-V-1002 and 062-V-1003) in order to comply with specified boiler feed water quality. For this HRSG and Packaged Boiler operation range, the suitable chemical injection is Phosphate, Oxygen Scavenger, and Neutralization Amine. Oxygen Scavenger and Neutralization Amine will be injected at the Deaerator and Phosphate will be injected at the HRSGs and Package Boilers. Boiler feed water is finally fed to HRSGs and Packaged Boilers by Boiler Feed Water Pump (062-P-1001A/B/C). 2.4.4 Steam Turbine Generator System HP steam is introduced to the Steam Turbine Generator Sets (061-GS-1001A/B/C) to generate electric power. The exhausted steam from the turbine is fully condensed by Air Cooled Surface Condenser (061-E-1001A/B/C) and the steam condensate flows into Condensate Recovered Drum (061-D-1001A/B/C) by gravity. The steam condensate is transferred to Deaerator (062-D-1001A/B) by Condensate Pump (061-P-1001A/B/C) via Ejector Condenser (061-E-1011A/B/). Vacuum creating system and drain recovery system from the exhausted line are also provided.

3. 3.1

PROCESS CONTROLS Boiler Feed Water Demineralized water in Demineralized Water Tank (064-TK-1003) is pumped up by demineralized a water pump (064-P-1003A/B) to Deaerator (064-D-1001A/B). The Deaerators receive recovered condensate plus demineralized water required for make up of losses for steam stripping, blowdown and so on. These condensates and demineralized water are received to top of heater shell of the Deaerator. There is a level controller on each Deaerator, 062-LIC-1111/1112, which keeps normal level in the Deaerators. The Deaerators will hydraulically balance to equalize levels between the two Deaerators. The water is heated up to the saturated temperature in the Deaerators. There is a pressure controller on each Deaerator, 062-PIC-1211/1212, which keeps normal operating pressure of 1.0kg/cm2g in the Deaerators by introducing LP steam to the Deaerators. Boiler feed water from Deaerators is pumped up by two Boiler Feed Water Pumps (062-P-1001A/B/C) to Package Boilers (062-F-1001A/B/C) and Heat Recovery Steam Generator (051/052-F-1101/1102) in on-site units. Two pumps are normally running and the other is stand-by. If the 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 boiler feed water. Oxygen Scavenger is injected in downstream of the deaerators to remove the trace of oxygen dissolved in the Boiler Feed Water. This is to remove the remaining 0.007 mg/litter dissolved oxygen from the Boiler Feed Water. Two reciprocating pumps (including one spare) with a rated capacity of 12.0 liter/h are provided to serve the deaerators.

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Neutralizing Amine is injected into the deaerator to adjust the pH of the Boiler Feed Water. The injection system is designed so that pH in recovered condensate will be around 8.5 to 9.5. Two reciprocating pumps (including one spare) with a rated capacity of 12.0 liter/h are provided to serve the deaerators. Phosphate is injected into the Package Boilers and HRSGs in order to avoid scaling and keep appropriate pH value in the boiler water. Injection package is designed so that PO4 concentration in boiler water is 10ppm. Four reciprocating pumps (including one spare) with a rated capacity of 12 liter/h are provided to serve the three Package Boilers. And three reciprocating pumps (including one spare) with a rated capacity of 12 liter/h are provided to serve the two HRSGs in each LNG train. Injection quantity for each chemical is defined by monitoring analyzer data and sampling results, and adjusted by manually setting the stroke of the reciprocating pumps of the injection package. The pump flow rate is confirmed by the calibration pot on suction line of each pump. Guidelines of the Chemical Injections for water quality control are described in Section 6.1. Neutralized amine and oxygen scavenger are injected to downstream of the Deaerators. Oxygen scavenger is injected to remove trace of oxygen dissolved in the boiler feed water. And neutralized amine is injected to adjust the pH of the boiler feed water and that of the steam condensate. 3.2 High Pressure Steam The HP steam is normally supplied by the HRSGs (051/052-F-1101/1102) and the Package Boilers (062-F-1001A/B/C). These HRSG and Package Boilers are controlled by DCS. Three package boilers have HP steam generation capacity of 50% x 3. However, all three boilers shall be operated normally. Under normal plant operation, the HP steam header pressure at 40 kg/cm2g is controlled by the pressure controller (060-PIC-1201), which adjusts or controls the steam production from Package Boilers (062-F-1001A/B/C) through its burner management system, satisfying the steam demand for power generation as well. Figure-1 is a Schematic of Unit 062 Steam Complex Control System. When the Acid Gas Removal Unit (AGRU) is tripped, the demand for LP steam decreases and LP steam pressure increases. And the HP steam pressure would increase, because the refrigerant compressors will change to recycle operation mode due to stopping feed gas and the demand of HP steam to Steam Turbines will reduce based on decreasing the required power. At this time, the pressure controller (060-PIC-1201) will control the HP steam header pressure by burner management system of Package Boilers (062-F-1001A/B/C). When the boiler operation will be reached at the minimum controllable duty (25% of MCR), further reduction of the boiler duty will be impossible. At this condition, the 060-PIC-1202A will ask the 060-PV-1207A/B/C to open through the hi-selector, which overrides the 060-PIC-1207, to control the HP steam header pressure by disposing the HP steam to LP steam header. The LP steam header pressure will increase then 060-PIC-1206A/B will ask the 091/092-PV-1206A and 060-PV-1206B to open in order to control the LP steam header pressure as explained in the LP steam control system below. The 060-PIC-1202B is provided as a final pressure controller if the pressure continues to increase due to such upset conditions and dump the HP steam to the atmosphere through 060-PV-1202B. The 060-PIC-1203 is provided as HP steam header low pressure protection.

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At low pressure condition, the 060-PIC-1203 through the low selector, which are overridden by 060-PIC-1205, will ask Steam Turbine Starter/Helper (051/052-CS-1001/1002) governor to close through the high-selector, which overrides the remaining power controller of Steam Turbines, to control the HP steam header pressure at or above its minimum pressure by reducing the HP steam to steam turbine drivers HP Steam Header Pressure Main Control Tag No. 060-PIC-1201 060-PIC-1202A 060-PIC-1202B 060-PIC-1203 3.3 Low Pressure Steam Since the refrigerant compressors speed are controlled by the main GT drivers, the Steam Turbine Starter/Helper (051/052-CS-1001 and 051/052-CS-1002) governors could be utilized to control the LP steam header pressure. The governor pressure controller (060-PIC-1205) through the low-selector, which is overridden by 060-PIC-1203, will maintain the LP Steam Header pressure at 3.5 kg/cm2g under normal plant operation. However, there is possibility that LP steam header pressure cannot be maintained at 3.5 kg/cm2g by control of the steam turbine governors, due to the trips of LP steam users, trips of steam turbine helper, etc. If the LP steam header pressure continues to decrease, the HP letdown valve 060-PV-1207A/B/C shall control LP steam header at pressure setting of 3.3 kg/cm2g by introducing the HP steam. When Gas Turbine temperature control becomes active (exhaust temperature increasing) during the operation that LP steam header pressure is controlled by governors pressure controller (060-PIC-1205), Steam Turbine stops to control LP steam header pressure and starts to act as Helper to produce power to help Gas Turbine. In that case, LP steam header pressure will be controlled by dumping to LP Steam Control Condenser (051/052-E-1101). The condenser fans will start with low speed automatically by opening signal to 091/092-PV-1206A. or When high temperature of 091/092-TI-2710 on the condenser vent line is detected, the fan motor speed will be changed to high speed. The condenser fans will stop automatically in case of closing 091/092-PV-1206A. If the LP steam header pressure continues to increase, the pressure control valve of 060-PV-1206B will open to dump the LP steam to atmosphere at 4.5 kg/cm2g. From the above explanation, 2 controllers, i.e. 060-PIC-1202A and 060-PIC-1207, will use the 060-PV-1207A/B/C. Hi-selector 060-PY-1207 will select which controller overrides other controller. In the 060-PY-1207, the higher opening request will override the lower opening request. Continuous nitrogen purge is required for the vent line of 051/052-E-1101 to prevent air ingress into steam system. A globe valve facing to Flow Gauge (091-FG-9031) shall be adjusted to flow the required nitrogen of minimum 2.6Nm3/h. Set Point 40.0 kg/cm2G 41.0 kg/cm2G 42.8 kg/cm2G 39.0 kg/cm2G Control Package Boiler (062-F-1001A/B/C) load control Open HP-LP Letdown valve (060-PV-1207A/B/C) Open HP steam release valve (060-PV-1202B) 051/052-CS-1001/1002 governor control

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Doc. No. 62-IOM-PS-1201 KJP Doc. No. S-062-1283-001 Rev. 6A Sheet No. 12 of 35

LP Steam Header Pressure Main Control Tag No. 060-PIC-1205 060-PIC-1206A Set Point 3.5 kg/cm2G 3.5 kg/cm2G Control 051/052-CS-1001/1002 governor control Open LP steam dump valve (091/092-PV-1206A) Start LP Steam Control Condenser (051/052-E-1101) with low steed 060-PIC-1206A 051/052-TI-2715 060-PIC-1206B 060-PIC-1207 3.4 <3.5 kg/cm2G 100 C 4.5 kg/cm2G 3.3 kg/cm2G
o

Stop LP Steam Control Condenser (051/052-E-1101) Change motor speed of LP Steam Control Condenser (051/052-E-1101) to high speed Open LP steam release valve (060-PV-1206B) Open HP-LP Letdown valve (060-PV-1207A/B/C)

Blowdown System for Boilers A continuous blowdown line and an intermittent blowdown line are provided for the package boilers. Continuous blowdown is flow controlled normally to around 1% of the generated HP steam and up to a maximum of 3%. Continuous blowdown is sent to Continuous Blow Down Drum (062-D-1002A/B/C) and flashed at 3.5kg/cm2g for LP steam recovery. Post flashed condensate and intermittent blowdown are sent to ATM Blowdown Drum (062-D-1003A/B/C) to be flashed at atmosphere. Flashed liquid is drained to chemical sewer through Boiler Blowdown Cooler (062-E-1002A/B/C). Intermittent blowdown is done manually from bottom of steam drums, to maintain the boiler water free from sediments. Intermittent blowdown is sent to ATM Blowdown Drum (062-D-1003A/B/C) to be flashed at atmosphere. Flashed liquid is mixed with continuous blowdown and drained to chemical sewer through Boiler Blowdown Cooler (062-E-1002A/B/C).

3.5

Clean Steam Condensate Hot clean condensates are collected in Condensate Flash Drum (051/052-D-1103) located in each train. This drum is provided with a Condensate Flash Drum Vent Condenser (051/052-E-1103) to minimize loss of steam. The condensate liquid is sent to the Deaerators by a Condensate Return Pump (051/052-P-1101A/B). 051/052-LIC-1113 will control the drum level to keep constant. One pump of the Condensate Return Pump is running and the other is stand-by. When liquid level of the drum is increased to high liquid level by running pump failure stop etc, stand-by pump will start to run automatically. Continuous nitrogen purge is required for the vent line of 051/052-E-1103 to prevent air ingress into steam system. A globe valve facing to Flow Gauge (091-FG-9032) shall be adjusted to flow the required nitrogen of minimum 5.8Nm3/h.

3.6

Suspect Steam Condensate Suspect steam condensates are collected in Condensate Flash Drum (051/052-D-1104) located in each train. This drum is provided with a Condensate Flash Drum Vent Condenser (051/052-E-1105)

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to minimize loss of steam. The condensate liquid is sent to the demineralized water system through LP Steam Condensate Cooler (051/052-E-1107) located in utility area by a Condensate Return Pump (051/052-P-1102A/B). 051/052-LIC-1171 will control the drum level to keep constant by 051/052-LV-1171 at outlet of 051/052-E-1107. One pump of the Condensate Return Pump is running and the other is stand-by. When liquid level of the drum is increased to high liquid level by running pump failure stop etc, stand-by pump will start to run automatically. Continuous nitrogen purge is required for the vent line of 051/052-E-1105 to prevent air ingress into steam system. A globe valve facing to Flow Gauge (091-FG-9033) shall be adjusted to flow the required nitrogen of minimum 2.0Nm3/h. 3.7 Steam Turbine Generator Sets The normal operation of the Main Steam Turbine Generator is controlled from Main Control Room. Full generator control capabilities are provided in a local generator control room which is not continuously manned. The generator control room is primary used to start up, synchronize, and shutdown the generators. A sequence of events recorder is also provided in the local generator control panel. Data from the turbine controls in the generator control room can be serially linked to the DCS. All substations have hard wiring connection or serial links to the DCS for status, alarm and data logging. For detailed control philosophy of the Steam Turbine Generator Set, 061-GS-1001A/B/C, refer to the vendor operation manual (061-VDR-MES-9801). Motors of Air Cooled Surface Condenser (061-E-1001A/B/C) are on-off controlled by the exhausted steam pressure (062-PIC-1232A/B/C) at outlet of the steam turbine. Operating fan number is changed by the high and low pressure signal. Steam drain collected in a drain pot that is installed on the exhausted steam line is transferred to Condensate Recovery Drum (061-D-1001A/B/C) by level controlled drain recovery system. The drain pot liquid level (062-LI-2830AB/BB/CB) start and stop the drain recovery system by open/close motive steam condensate introducing valve. One drain recovery ejector is operated and the other is spare. When the liquid level reaches to high liquid level, one drain recovery ejector starts to drain out accumulated liquid in the drain pot. And when the liquid level reaches to low liquid level, the ejector is stopped. If the drain level reaches high-high liquid level, two out of three transmitters initiate a signal to trip the steam turbine generator set. Steam condensate stored in the Condensate Recovered Drum (061-D-1001A/B/C) is level controlled and directly sent to Deaerator (062-D-1001A/B) by Condensate Pump (061-P-1001A/B/C). If the condensate level reaches low-low liquid level, the Condensate Pump will be stopped to prevent the pump damage.

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TO VENT 060-PV-1202B PC
1202A 1202B

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PC 1203 SET : 39kg/cm2g PC SET : 41kg/cm2g PC 1201 SET : 40kg/cm2g OPEN AT 42.8kg/cm2g

BP Berau Ltd. Tangguh LNG Project

Operation Manual for Steam/Steam Condensate/BFW System

-2006
HP STEAM HEADER
SPEED CONTROLLER SC POWER CONTROLLER

HRSG 051-F-1101 G

BOILER 062-F-1001A

SC

HIGH SELECTOR PY HIGH SELECTOR POWER CONTROLLER SC

061-GS-1001A

BOILER 062-F-1001B

PY 1207

060-PV1207A/B/C

HRSG 051-F-1102 G

BOILER 062-F-1001C 061-GS-1001B

051-CG-1001

PY HIGH SELECTOR

G 061-GS-1001C

TO VENT

LOW SELECTOR

PY 1205

SET : 3.3kg/cm2g SET : 3.5kg/cm2g

051-CG-1002

060-PV-1206B OPEN AT 4.5kg/cm2g

PC 1207

PC 1205

LP STEAM HEADER

PC PC
1206B 1206A

TO PROCESS UNIT REBOILERS

TO PROCESS UNIT REBOILERS

AGR

SET : 3.7kg/cm2g

091-PV-1206A

TRAIN 2

051-E-1101

TRAIN 1

Doc. No. 62-IOM-PS-1201 KJP Doc. No. S-062-1283-001 Rev. 6A Sheet No. 14 of 35

Figure-1 Schematic of Unit 062 Steam Control System

BP Berau Ltd. Tangguh LNG Project Operation Manual for Steam/Steam Condensate/BFW System

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4.

PREPARATION FOR INITIAL START-UP Refer to Commissioning Procedure (62-PRC-OP-1001).

5. 5.1

NORMAL START-UP PROCEDURE General Check points are as follows: (1) All equipment including instrument, etc. is ready for use. (2) Demineralized water, instrument air and emergency 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 properly installed on site, calibrated and operable. (6) Prepare required chemicals in each chemical vessel. After all the above checkpoints are checked, start up the Steam System. Section 5.2 to 5.11 should be followed in order to start up the Air/Nitrogen Steam System.

5.2

Start up of Boiler Feed Water System (1) (2) (3) Confirm Deaerator (062-V-1001A/B) level controller (062-LIC-1111/1112) is in auto mode. Demineralized water is introduced in Deaerators (062-V-1001A/B) through 062-LV-1111/1112. After built up the liquid level in 062-D-1001A/B, one of Boiler Feed Water Pump (062-P-1001A/ or B/C) is started locally. (062-P-1001C is not connected to emergency power supply.) Gradually open the pump discharge valve (manually). Set stand-by pump to auto mode.

(4) (5)

(6)(5) Oxygen Scavenger Injection Package (062-V-1002) and Neutralizing Amine Injection Package (062-V-1003) are started. As LP steam is not available in this period, Oxygen scavenger feed shall be increased to compensate for the lack of complete deaeration because water is not deaerated. Therefore the oxygen scavenger feed rate is quite larger than that at normal. Refer to Section 6.1 Water Quality Control. (Oxygen scavenger may include stabilized agent to prevent chemical reaction in tank. Nitrogen purge for 062-V-1002 will be required only to use un-stabilized chemical. Chemical suppliers advice is required.) (6) (7) When enough users are available, second pump shall be started locally. Set stand by pump to auto mode locally.

5.3

Start up of Package Boiler (062-F-1001A/B/C) (1) Introduce cooling water to Boiler Blowdown Cooler (062-E-1002A/B/C). Start one Package Boiler (062-F-1001A or B). (062-F-1001C is not connected to emergency power supply.) It is recommend that boiler start-up should only be (2)

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undertaken locally and not DCS. For the start up procedure of the Package Boilers, refer to the vendor instruction Operation & Maintenance Manual (062-VDR-MCI-1800). (3) Phosphate Injection Package (062-V-1001) shall be started accordingly. Refer to Section 6.1 Water Quality Control. Each Package Boiler has dedicated phosphate injection pump. Confirm boiler blowdown temperature is under 50oC at outlet of the boiler blowdown cooler. After starting the Steam Turbine Generator Sets (062-GS-1001A/B/C) and steam condensate system, the recovered steam condensate may have rust which was generated in steam condensate piping during shutdown period. Continuous boiler blowdown ratio should be increased up to 3% and intermittent blowdown operation should be done more frequently than usual until boiler water quality meets control target described in Section 6.1.1.

(4) (5)

5.4

Introduce HP Steam to HP Steam Header (1) (2) Confirm all low point drains on HP steam header are open. Confirm HP steam releasing valve 060-PV-1202B controller (060-PIC-1202B) is in auto mode. Also confirm HP steam LP steam letdown controller (060-PIC-1202A) is in manual mode and closed position. When on-spec HP steam is produced from the package boiler, the HP steam is introduced to HP steam header gradually and pressurizes the header. The boiler should, is will be, operated at minimum load. The steam will be released to atmosphere through 060-PV-1202B. Warm up HP steam header and release steam condensate from low point drains. Caution Hot water with steam will be exhausted from the low point drains. Operators shall pay attention to prevent suffering steam and splash. (5) Close all low point drains after finishing condensate draining out.

(3)

(4)

5.5

Letdown HP Steam to LP Steam (1) Confirm all low point drains on LP steam header are open. And also confirm isolation valves for LP Steam Control Condenser (051/052-E-1101) located at upstream of 091/092-PV-1206A are closed. Confirm LP steam releasing valve 060-PV-1202B controller (060-PIC-12062B) is in auto mode. Confirm LP steam temperature controller (060-TIC-1303) at downstream of HP-LP desuperheater is in manual mode and closed position. Gradually open one of HP-LP letdown control valves 060-PV-1207A by its hand wheel and adjust the flow temperature 060-TIC-1303 under 175oC by opening boiler feed water injection control valve (060-TV-1303A/B) using its hand wheelbypass globe valve. The steam will be released to atmosphere through 060-PV-1206B. Warm up LP steam header and release steam condensate from low point drains. Caution

(2) (3) (4)

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Hot water with steam will be exhausted from the low point drains. Operators shall pay attention to prevent suffering steam and splash. (5) Close all low point drains after finishing condensate draining out.

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5.6

Introduce LP Steam to Deaerators (062-D-1001A/B) (1) (2) For the start up procedure of the Deaerators, refer to the vendors instruction Installation, Operation and Maintenance Manual (062-VDR-TCI-1801). Adjust the oxygen scavenger injection rate. Refer to Section 6.1.

5.7

Start Steam Turbine Generator Set (061-GS-1001A/B/C) (1) Confirm blind flanges at HP steam isolation are open position for one of Steam Turbine Generator Set (061-GS-1001A or B). (061-GS-1001C is not connected to emergency power supply.) Fill demineralized water into Condensate Recovery Drum (061-D-1001A/B/C) up to normal liquid level. Confirm stop valve of the steam turbine is closed and all low point drains on main steam line are open. Equalize HP steam line to open 3 globe valve and release steam condensate from low point drains. Caution Hot water with steam will be exhausted from the low point drains. Operators shall pay attention to prevent suffering steam and splash. (5) (6) (7) (8) Close all low point drains after finishing condensate draining out. Open 18 block valve on main steam line. Open 3 gate valve and gradually open 3 globe valve on vent line with silencer (062-Y-1001A/B/C) at main steam inlet line to warm up of main steam line. Confirm Condensate Recovery Drum (061-D-1001A/B/C) level controller (062-LIC-1227A/B/C) and STG Condensate Recovery Pump (061-P-1001A/B/C) minimum flow controller (062-FIC-1032A/B/C) are in auto mode. Start STG Condensate Recovery Pump (061-P-1001A/B/C) using minimum flow line. Start Air Cooled Surface Condenser system (061-E-1001A/B/C) and vacuum system. For the start up procedure of the surface condenser and vacuum system, refer to the vendors instruction Instruction for Erection, Starting-up and Operating (V-2153-102-A-801). Confirm STG inlet HP steam temperature 062-TI-1326A/B/C indicate above 300oC and close block valve on venting line. Start Steam Turbine Generator. For the start up procedure of the steam turbine generator, refer to the vendors instruction Operation and Maintenance Manual (061-VDR-MES-9801).

(2) (3) (4)

(9) (10)

(11) (12)

5.8

Steam Condensate System (1) Start nitrogen injection to LP Steam Control Condenser (051/052-E-1101) vent pipe and Condensate Flash Drum Vent Condenser (051/052-E-1103) vent pipe. N2 injection rate should be referred to Section 3.3 and 3.5. Confirm Condensate Flash Drum (051/052-D-1103) level controller (051/052-LIC-1113) is in auto mode. Gradually open isolation valves for LP Steam Control Condenser (051/052-E-1101) located at upstream of LP steam dumping control valve (091/092-PV-1206A). LP

(2)

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(3)

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Doc. No. 62-IOM-PS-1201 KJP Doc. No. S-062-1283-001 Rev. 6A Sheet No. 18 of 35

steam will be introduced to the 051/052-E-1101 through restriction orifice 091/092-FO-9011. (4) (5) (6) Gradually open LP steam dumping control valve (091/092-PV-1206A) by its hand wheel. Start LP Steam Control Condenser. When liquid level is built up above normal liquid level in the Condensate Flash Drum (051/052-D-1103), one of Condensate Return Pump (051/052-P-1101A/B) is started locally. Gradually open the pump discharge valve (manually). When the drum water level is stable at normal liquid level, switch over HP steam pressure controller (060-PIC-1201), LP steam temperature controller (060-TIC-1303), HP steam low pressure controller (060-PIC-1203) and LP steam high pressure controller (060-PIC-1206A) to auto control mode, and close boiler feed water injection control valve (060-TV-1303A/B) bypass valve.

(7) (8)

5.9

Letdown HP Steam to MP Steam (1) (2) (3) Confirm Deethanizer Reboiler (041/042-E-1005) is ready for start-up. Confirm all low point drains on MP steam header are open. Confirm MP steam pressure controller (091/092-PIC-1001) and MP steam temperature controller (091/092-TIC-1471) are in manual mode and closed position. Slightly open HP-MP letdown control valve (091/092-PV-1001) by its hand wheel and adjust the flow temperature 091/092-TIC-1471 under 250oC by opening boiler feed water injection control valve (091/092-TV-1471) bypass globe valveusing its hand wheel. Be careful not to exceed MP steam header pressure of 24kg/cm2G, that is PSV set pressure on MP steam header. Warm up MP steam header and release steam condensate from low point drains. Caution Hot water with steam will be exhausted from the low point drains. Operators shall pay attention to prevent suffering the steam and splash. (6) (7) Close all low point drains after finishing condensate draining out. Switch over MP steam temperature controller (091/092-TIC-1471) and MP steam pressure controller (091/092-PIC-1001) to auto control mode, and close boiler feed water injection control valve (091-TV-1471) bypass valve.

(4)

(5)

Operating manual for Unit 041/042 shall also be referred to start up MP steam system because MP steam is used only in Unit 041/042. 5.10 Start up of Heat Recovery Steam Generator (051/052-F-1101/1102) (1) (2) (3) (4) Introduce cooling water to HRSG Blowdown Cooler (051/052-E-1104/1106). For the start up procedure of Heat Recovery Steam Generator, refer to the vendor's instruction Operation & Maintenance Manual (051-VDR-ALP-1800). Phosphate injection package (051/052-V-1003) shall be started. Refer to Section 6.1. Confirm HRSG blowdown temperature is under 50oC at outlet of the HRSG blowdown cooler. When on-spec HP steam is produced from the HRSG and the Gas Turbine operation becomes stable, the HP steam can be introduced to HP steam header gradually. Under

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(5)

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14 ton/minute is preferable HP steam introducing ratio to the header to prevent sudden load decrease of three Package Boiler loads. 5.11 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-up water flow controller (064-FIC-5501) are in auto mode. 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 the demineralization package vendor operation manual (900064-VDR-SAL-1800/1820). Start nitrogen injection to Condensate Flash Drum Vent Condenser, 051/052-E-1105 vent pipe. N2 injection rate should be referred to Section 3.6. Start Condensate Flash Drum Vent Condenser (051/052-E-1105) locally. Start LP Steam Condensate Cooler (051/052-E-1107) locally. Receive steam condensate into Condensate Flash Drum (051/052-D-1104). When liquid level is built up above normal liquid level in the drum, one of Condensate Return Pump (051/052-P-1102A/B) is started locally. Gradually open the pump discharge valve (manually). Set stand-by pump to auto mode locally.

(2)

(3) (4) (5) (6) (7) (8) (9)

6. 6.1

NORMAL OPERATION Water Quality Control The unit is normally controlled automatically but requires operator to monitor process conditions.

6.1.1

Guide Line Guide line for quality control of Boiler Feed Water (i.e. Deaerator outlet water) and Boiler Water for circulation boilers are tabulated below. Bolded value will be adopted for Deaerator (062-V-1001A/B), Package Boilers (062-F-1001A/B/C) and Heat Recovery Steam Generators (051/052-F-1101/1102). Maximum Operating Pressure (kgf/cm2G) Boiler Feed Water pH (at 25 C) Total hardness (mg CaCO3 /lit.) Oil (mg/lit.) Dissolved oxygen (mg O/lit.) Iron (mg Fe/lit.) Copper (mg Cu/lit.) pH (at 25 oC) Total Solids (mg/lit.)
o

9 max. (LP Steam) 7 to 9 1 max. It is preferable keep low It is preferable keep low 0.3 max. 11.0 to 11.8 2500 max.

over 19 up to and incl. 29 (MP Steam) 8.0 to 9.5 Nil. It is preferable keep low 0.1 max. 0.1 max. 9.4 to 10.5 -

over 29 up to and incl. 49 (HP Steam) 8.0 to 9.5 Nil. It is preferable keep low 0.03 max. 0.1 max. 0.05 max. 9.4 to 10.5 -

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Boiler Water

BP Berau Ltd. Tangguh LNG Project Operation Manual for Steam/Steam Condensate/BFW System

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Conductivity (micro-S/cm, at 25 oC) Chloride (mg Cl /lit.) Phosphate (mg PO43- /lit) Silica (mg SiO2 /lit.) Remarks ; 1) Based on JIS B 8223-1989

4000 max. 400 max. 20 to 40 -

800 max. 100 max. 5 to 15 50 max.

600 max. 80 max. 5 to 15 20 max.

2) Concentration unit mg/litter shall be equal to g/ton. (litter is based on water condition at ambient temperature.) Chemical injection quantities are determined by monitoring analyzer and sampling results, and adjusted by manually setting the stroke of the metering pumps of the chemical injection packages. 6.1.2 Boiler Feed Water A) Oxygen Scavenger Non hydrazine chemical is used for this plant to treat the boiler feed water. Component of the chemical is varied by the chemical supplier. Chemical suppliers advice and instruction shall be taken to decide injection rate of the oxygen scavenger. (1) Normal Operation Operation with deaerators, (i.e. normal operation), the injection rate is calculated based on oxygen content (0.007 mg/lit. =0.005 cc/lit.) at the deaerator outlet. (2) Deaerator cold Operation Deaerator will be in cold operation at initial operation until LP steam becomes available. At this period, oxygen scavenger injection is increased since oxygen in feed water is not deaerated. The concentration of dissolved oxygen in the feed water is measured, or the amount of saturated dissolved oxygen is determined from the temperature of the feed water at the open section. Relation between temperature and concentration of dissolved oxygen is shown below; Feed Water Temp. (oC) Dissolved Oxygen (mg O/lit.) B) Neutralization Amine Injection Chemical suppliers advice and instruction shall be taken to decide injection rate of the Neutralized Amine. Cyclohexyl amine is assumed as Neutralization Amine to discuss here. The cyclohexyl amine is injected to adjust the pH and to remove residual CO2 in boiler feed water. However, as deaerated boiler water is used, CO2 content is considered zero. Relation between cyclohexyl amine injection and pH (at zero CO2) is as follows Target pH Cyclohexyl amine injection (mg/ lit.= g/ton -feed water) 8 0.1 8.5 0.3 9 1.0 9.5 3.0 10 11.1 20 9.2 30 7.9 40 6.4 50 5.2

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Example for Normal Operation; Boiler make up water; approx. 50 ton/hr Target pH = 9 Injection of Cyclohexyl amine = 1.0 x 50 = 50 g/hr (Cyclohexyl amine 100% base) 20wt % Cyclohexyl amine solution may be prepared in Neutralization Amine Injection Package (062-V-1003). However, when injection rate is too small, concentration of the solution will be adjusted. 6.1.3 Boiler Water Boiler water quality is controlled with phosphate injection and continuous blowdown. A) Boiler Blowdown (1) Continuous Blowdown (Surface Blowdown) For Package Boilers (062-F-1001A/B/C) and Heat Recovery Steam Generators (051/052-F-1101/1102), 1% continuous blow down may be considered enough rate at normal operation. Basis is shown below; Control Parameter Conductivity Silica (as SiO2) Expected concentration in BFW 0.2 micro-S/cm 0.02 g/ton Control Target in Boiler Water 600 micro-S/cm max. 20 g/ton max. Minimum blowdown to keep target 0.04 % (0.2/600 x100) 0.1 % (0.02/20 x 100)

As shown in the above, minimum 0.1% blowdown is required to keep boiler water quality. Normally 1.0% blowdown is a sufficient rate considering operation margin for the target value, however if quality of boiler water is not stable, increase blow down rate. (3 % is the design rate of continuous blowdown.) Actual blowdown rate shall be determined according to actual sampling data. (2) Intermittent Blowdown (Bottom blowdown) Intermittent blowdown is done manually from bottom of steam drums, to maintain the boiler water free from sediments. For the operating procedure of the Package Boilers, refer to the vendor instruction Operation & Maintenance Manual (062-VDR-MCI-1800). For the operating procedure of the Heat Recovery Steam Generator, refer to the vendor's instruction Operation & Maintenance Manual (051-VDR-ALP-1800). B) Phosphate Injection Phosphate treatment is adopted for treating of leak hardness in feed water and adjusting pH of boiler water to inhibit corrosion. (1) Mole Ratio of Sodium and Phosphate

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Phosphate solution is injected into each steam drum. In the case that demineralized water is used as make-up water, tri-sodium phosphate or a mixture of di-and tri- sodium phosphate is generally used in Na and PO4 mole ratio at the range of 2.6 to 2.8.

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For example, the mole ratio is controlled at 2.8 as typical value to prevent free sodium hydroxide. For make-up of 2.8 mole ratio phosphate compounds, mix Na3PO4-12H2O and Na2HPO4-12H2O with mole ratio of 4 and 1. (As weight ratio, 4.25:1. This mixture contains 25.2 % of PO4; hereinafter, this mixture is called Phosphate compound) Character of each phosphate is listed below; Chemical name Sodium Phosphate (Tri-sodium phosphate) Sodium hydrogen phosphate (Di-sodium phosphate) Phosphate Compound Molecular formula Na3PO4 Na2HPO4 Na2.8H0.2PO4 Appearance Na3PO4-12H2O White crystal Na2HPO4-12H2 O White crystal Na2.8H0.2PO4-12 H2O White crystal Molecular weight 380 358 376 pH (1% solution) 12 8.2 About 12 PO4 (%) 24.9 26.5 25.2

(2) Normal Injection The normal injection of phosphate solution is determined by the following equation on the basis of the concentration of phosphate ion; A-PO4-Normal = {(F-Ca-H x 0.57) + B-PO4 / N} x BFW where A-PO4-Normal = normal injection of phosphate ion (g/hr as PO43-) F-Ca-H = concentration of calcium hardness (as CaCO3) in feed water (mg/lit. CaCO3, in the case that demineralized water is used for make-up of feed water, this is considered zero.) B-PO4 = concentration of phosphate ion to be kept in boiler water (mg/lit.=g/ton as PO43-) N = concentration ratio of Boiler Water (times; = 100/ (blowdown %)) BFW = boiler feed water to each boiler (ton/hr) Example for 062-F-1001A normal operation; BFW = approx. 100 ton/hr B-PO4 = 10 mg/lit.= 10 g/ton N = 100 (normally 1 % continuous blowdown) A-Normal = {( 0 x 0.57 )+ 10 / 100 } x 100 = 10 g/hr 2wt % of Phosphate compound solution to be prepared in 062-V-1001. Phosphate compound (i.e. Na2.8H0.2PO4-12H2O ) includes 25.2 wt% of PO4, therefore dilute 2kg of the compound with 98 kg of deminealized water as ratio and inject by a dedicated reciprocating pump at 6.0 lit./hr. (2.0 lit. = 2000 g solution includes 2000 x0.02 x0.252= 10 g of PO4 ) If PO4 concentration of boiler water decreases, increase the injection rate. (3) Start-up

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The initial charge is performed to obtain nearly the same water quality at start-up as that in normal operation so that the initial injection is calculated for the holding water volume of the boiler. The initial injection amount of phosphate solution is usually determined by the following equation on the basis of phosphate ion concentration; A-Start = (F-Ca-H x 0.57 + B-PO4) x Holding water in boiler where A-Start = initial injection of phosphate ion (g as PO43-) Example for 062-F-1001A B-PO4 = 10 mg/lit. = 10g/ton Holding water in one boiler = approx. 57.1 m3 = 57.1 ton A-Start = (0 x 0.57 + 10) x 57.1 = 571 g as PO43571/0.252 = about 2266 g Thus 2266 g of phosphate compound is required. Dilute the 1 kg of the compound with 19 kg of demineralized water as the ratio and inject with 12 lit./hr ( 100 % of pump capacity). It will take approx. 3.8 hours to inject 571 g of PO4. 6.2 Single Failure of Package Boiler When one of the package boilers trips, HP steam will be supplied by remaining two boilers by increasing steam generation load. However, HP steam is not sufficient during transient period due to limitation of the boiler load increase. Load shedding system will work to continue LNG train operation. Refer to Section 6.4. 6.3 Single Failure of Steam Turbine Generator When one of the steam turbine generators trips, required electrical load will be covered by remaining two steam turbine generators. However, the electrical generation load cannot increase suddenly due to limitation of the steam turbine instant load increase. Load shedding system will work to continue LNG train operation. Refer to Section 6.4. 6.4 Load shedding In case of a Package Boiler (062-F-1001A/B/C) trip or a Steam Turbine Generator Set (061-GS-1001A/B/C) trip, load shedding is required to continue LNG train operation. Shedding items are as follows; BOG Compressors (071-C-1001A/B) Desalination Package (064-V-1001A/B) Infrastructure

Required period of the load shedding is within 10 minutes. After the period, it is possible to restart these items. In case of a Package Boiler (062-F-1001A/B/C) trip or a Steam Turbine Generator Set (061-GS-1001A/B/C) trip during one boiler or one STG maintenance, load shedding of one

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train is required in addition of above items because one boiler or one STG can not cover two trains operation. After load shedding, the remaining train shall be turned down in order to start a BOG compressor, desalination package and infrastructure.

7.

NORMAL SHUTDOWN PROCEDURE An entire shutdown of the steam system is only possible during the whole plant shut down. However equipment or sections of line may require periodically shutdown for maintenance or an inspection. In that case, only the equipment or the sections shall be isolated.

7.1

Deaerator (1) (2) (3) (4) (5) (6) Confirm one train is completely shut down. Close Deaerator (062-V-1001A/B) level control valve (062-LV-1111 or 1112) on demineralized water line. Close 10 block valve on the pump minimum flow return line. Close 20 block valve on boiler feed water outlet line. Slowly close Deaerator pressure control valve 8062-PV-1211 or 1212) on LP steam line together with slow closing 14 block valve on recovered condensate line. Close 4 block valve on steam balance line.

7.2

Package Boiler (1) Steam generation load of the package boiler to shut down shall be gradually reduced to prevent upset of HP steam system. For shutdown procedure of the Package Boilers (062-F-1001A/B/C) refer to the vendors instruction Operation & Maintenance Manual (062-VDR-MCI-1800). Dedicated phosphate injection pump in Phosphate Injection Package (062-V-1001) shall be stopped.

(2)

7.3

Steam Turbine Generator System (1) Power generation load of the steam turbine generator to shut down shall be gradually reduced to prevent upset of power distribution system and HP steam system. For shutdown procedure of the Steam Turbine Generator Sets (061-GS-1001A/B/C) refer to the vendors instruction Operation and Maintenance Manual (061-VDR-MES-9801). Close block valve of HP steam line to vacuum system. Stop Condensate Recovery Pump (061-P-1001A/B/C). Stop Air Cooled Surface Condenser (061-E-1001A/B/C).

(2) (3) (4) 7.4

Heat Recovery Steam Generator (1) Stop Gas Turbine. Refer to shutdown procedure of the Gas Turbine (051/052-CG-1001/1002) and the heat recovery steam generator (051/052-F-1001/1002). Refer to the vendors instruction Operation, Install. & Maintenance Manual (51-NPC-802) for Gas Turbine and Operation & Maintenance Manual (051-VDR-ALP-1800) for HRSG.

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(2)

Dedicated phosphate injection pump in Phosphate Injection Package (051/052-V-1003) shall be stopped.

7.5

Train Shutdown (1) (2) (3) Confirm all on-site process units including the HRSG and the steam turbine drivers are shutdown. Close isolation valves at the train BL Stop dedicated LP Steam Condensate Cooler (051/052-E-1107) located in utility area.

8. 8.1

EMERGENCY SHUTDOWN PROCEDURE 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 at the 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 8.2.1

Loss of Utilities Power Failure All pumps and fans will stop. Also forced draft fans in the package boilers will stop and that leads to the package boilers trip. Accordingly whole plant shut down will occurs. Emergency generator sets will start to run automatically for safety plant shutdown.

8.2.2

Instrument Air Failure When there is an instrument air failure, all control valves will assume their fail safe positions. The fail-safe positions for control valves are either fully open, closed, or maintain last position. All the failure positions are shown on the P&ID. The fail-safe position depends on the service. The operators should be aware of the position of all valves in case of emergency. In the event of total air failure, almost of all facilities can not maintain the operation because most of the systems have a control valve. In this case all pumps should be stopped immediately.

8.2.3

Cooling Water Failure In the event of total cooling water failure, operator should stop 062-P-1001A/B/C, 051/052-P-1101A/B, Package Boiler and Steam Turbine Generators manually to avoid mechanical damage caused by overheating of lubricant and loss of mechanical cooling. At this situation, all process units are shutdown, and the steam, feed water and condensate handling system will be shut down, accordingly.

9. 9.1

SAFETY PROCEDURE 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

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- The methods to accomplish this in a safe manner The following safety regulations cover operations of particular concern to the personnel responsible for the unit. They are intended to supplement any existing general plant safety regulations which cover all units; reference should be made to the latter for all points not mentioned below. Mechanical craftsmen working on their unit will be governed by their own departmental safety regulations, but the operator should see that none of the following safety regulations are violated by mechanical workers. In addition to specifically defined rules and practices, the exercise of good judgment by every person involved is essential to safe operation. An operator should be alert for any situation which might present a personnel hazard. It should also be the responsibility of each person familiar with the plant to warn other workers who enter the plant of possible hazards they could encounter. All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, and main isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other protective equipment such as hard hats, rubber gloves, etc. Soda acid or foam type extinguisher must not be used on fire around electrical equipment because the water solution will conduct electricity and may aggravate the difficulty or result in the electrocution of personnel. Carbon dioxide or dry powder extinguisher may be used safety on electrical fires. Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered. Safety hats must be worn when outdoors. Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid is encountered, and are recommended for use while samples are being withdrawn and solutions made up. Fire extinguishers must be recharged immediately after use. All stream and water hose equipment must be put back in place after use. Access to such equipment must not be obstructed. Gas masks must have fresh cartridges installed after use. 9.2 Emergency Fire Plan The fire protection system of the plant is designed to prevent fire occurrence, control fire escalation, or extinguish fire within short period of time, assuming there will be no outside fire fighting assistance, with only one major fire at a time.

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9.3

Fire Fighting and Protective Equipment Fire hazard status throughout the plant shall be monitored on the Hazard Detection and Monitoring System (HDMS (F&G)) consoles in the main control room and fire and emergency station. Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat radiation. For the detail, refer to 82-SPE-HS-1540, 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. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the equipment must be replaced when repair work is completed. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation equipment where they can be knocked off and injure someone below. Access to ladders and fire escapes must be kept clear. Waste material and refuse must be put in proper locations where they will not offer fire or stumbling hazards. Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediately report leaks for repair. In the event that electrical equipment does not function properly, notify the electrical department and stay clear of the equipment until the electrician arrives. Gas cylinders should be stored so that they cannot fall over. Guard caps must remain in place over the valves of cylinders, which are not in use. Care should be taken when installing scaffolding to ensure that the wooden boards do not contact hot equipment and that no part is allowed to impair free access on operational equipment e.g. ladders, stairways, walkways or valves. Scaffolding should be removed immediately on completion of the work in hand. Switch pumps regularly when spares are provided. This will assure start the spare pump will be ready when needed.

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

9.

9.5

Repair Work 1. 2. 3. 4. Mechanical work around and operating unit must be kept to a minimum, and the minimum number of men should be used. No mechanical work on the equipment is to be done without a properly authorized work permit. Safety hats must be worn by all personnel in all areas at all times. No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized by a work permit. Catch basins, manholes, and other sewer connections must be properly sealed off to prevent the leakage of gases, which may ignite upon contact with an open flame. No personnel shall enter a vessel for any purpose whatsoever until it has been adequately purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases and an entry permit issued. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not physically strike these lines and avoid operation conditions, which would cause a water

5.

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7. 8. 9.

hammer to start. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other cleaning purposes. Equipment should not be left open overnight. At the end of each days work blanks or spades should be installed to prevent entry of flammable materials due to valve let-by. Welding cylinders should be removed from site to a designate safe area at the end of each working day.

9.6

Withdrawal of Samples Samples shall be withdrawn from the unit only by authorized personnel. Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. A container must never be filled to the brim, in order to minimize risk of subsequent spillage. When sampling any product liquids, gloves and goggles will be worn. When sampling any material, gas or liquid, the sampling line must be flushed long enough to remove dormant materials to insure that the sample obtained represents the current stream. Pass enough gas through the sample vessel to insure the displacement of the purge gas and to adjust the temperature of the sampler to that the composition is not distorted by condensation or flashing, etc. Wear proper personal protective 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 in carrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consult your supervisor immediately.

9.8

Respiratory Protection Most plant gases, other than air, are harmful to human beings if inhaled in certain concentration. Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may cause death by replacing the air in the lungs or by reaction with the oxygen carried in the blood; examples are hydrogen sulfide carbon monoxide, and smoke. Irritating gases may cause injury or death not only by asphyxiating but also by burns internal and external/ examples are chlorine and sulfur dioxide. To guard against the inhalation of harmful gases:

Secure a gas test certificate showing the gas condition of the vessel is safe for entry. Stand on the windward side of an operating from which gases escape. Provide proper ventilation. All personnel should become familiar with the accepted method of artificial respiration in order to render assistance to any one overcome by gas, electric shock, or drowning.

If anyone is overcome by gas, his rescuer should:

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Protect himself before attempting a rescue by wearing breathing apparatus. Get the victim to fresh air as soon as possible. Give artificial respiration and send his assistant to call for medical aid. When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approved test method. Wear the correct type of breathing apparatus, suited to the situation encountered. 9.9 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 on a 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 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 oxygen content 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 opened or 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, and rubber safety boots shall be worn. The PVC trousers should be outside the boots. Avoid all contact with and do not inhale the fumes. - Oxygen Scavenger - Neutralizing Amine - Phosphate Refer 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 blind flanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entry or for creating safe construction areas within a plant. Valved isolation for less critical duties than those requiring positive isolation, e.g. for control valve maintenance. Valved isolation will also be required to enable positive isolation to be installed or removed without the need for a complete plant shutdown.

10.2

Basic Procedures The basic ideas for method of isolation are shown below. The details will be developed by Owner when actual isolation work will be required. The selection of type of isolation valve and blind/removable spools shall be in accordance with the applicable piping and material specifications. This section considers train or system requiring isolation followed by individual equipment isolation requirements. Sketches below are provided as an aid to develop actual planning for maintenance work.

10.2.1

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 Isolation 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 pressure vessels are normally positively isolated from the vessel by removing the relief valve and blinding the inlet line end. A typical arrangement is shown on Figure 9.2.1 and 9.2.2.

10.2.2.1 Horizontal and Vertical Pressure Vessels

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Figure 10.2.1 Horizontal Pressure Vessel


RELIEF VALVES AND FLARE

INLET LINE

GAS OUTLET

HORIZONTAL VESSEL

OIL OUTLET

WATER OUTLET (IF REQUIRED)

DRAIN LINES

Figure 10.2.2 Vertical Pressure Vessel

RELIEF VALVES AND FLARE

GAS OUTLET

INLET LINE

VERTICAL VESSEL

LIQUID OUTLET

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

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Figure 10.2.3 Pumps

OUTLET LINE INLET LINE

Y or T TYPE SUCTION STRAINER

PUMP

10.2.2.3 Shell and Tube Heat Exchangers When removable spool pieces are provided on the piping associated with the tube side connections on shell and tube heat exchangers, the removal of these pieces should be don for the tube bundles for cleaning/maintenance. If required from the maintenance work nature, spectacle blinds will be provided.

Figure 10.2.4 Shell and Tube Heat Exchangers

TUBE SIDE INLET RS

SHELL SIDE OUTLET

HEAT EXCHANGER SHELL & TUBE

TUBE SIDE OUTLET

SHELL SIDE INLET

NOTE: BLOCK VALVES NOT REQUIRED IF EXCHANGER NOT SPARED OR BYPASSED

11. 11.1

MAINTENANCE PROCEDURE General INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT AIR FOR BREATHING APPARATUS. Type of maintenance is classified in the following categories.

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

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 of safety valves, and inspections and repairs of equipment that cannot be shutdown or removed during Production.

11.2

Precautions prior to Maintenance

This section covers precautions prior to start maintenance work for a whole or a part of the plant.
All work must be carried out within the requirements of company Safety & Environmental Policies and Procedures. Prepare all known Work Permits, these must reflect safety issues. Obtain relevant permit to work before starting work. Inform Operations of the work content of this preventive maintenance procedure and how it will affect them. All rotating equipment is to be considered energized until proven isolated. All vessels must be isolated, drained and vented. Cordon the work area, to prevent unauthorized access. Prior to commencement of this work ensure that moving/rotating/power generating/energy storing equipment has been isolated in accordance with the relevant permit to work and lock-out / tag-out requirements.

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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 is required 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

Pumps

Operations to shut down the unit, stop pump motor and depressurize the line and pump. 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 oxygen level. Operations to clean

11.4.4

Air Fin Coolers


Operations to shut down the unit.

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BP Berau Ltd. Tangguh LNG Project Operation Manual for Steam/Steam Condensate/BFW System

Doc. No. 62-IOM-PS-1201 KJP Doc. No. S-062-1283-001 Rev. 6A Sheet No. 35 of 35

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 ProcessUtiliy Flow Diagram (To be attached in As Built) Attachment-2 P&IDs (To be attached in As Built) Attachment-3 List of Equipment Data Sheet (To be attached in As Built) Attachment-4 List of Instrument Alarm Set Point (To be attached in As Built) Attachment-5 List of Cause and Effect Charts (To be attached in As Built) Attachment-6 Laboratory Sampling Schedule Attachment-7 MSDS (Later)

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