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LPG TANK 30 TON & PIPING

Contact Name : LPG TANK 30 TON & PIPING


Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

Purchaser’s Client : PT. ALSTOM POWER ESI


Job Name : Equipment of LPG Fuel System for HTP
Purchase Order Number : P6AM901 / 2

Seller’s Order Number :


Equipment Model Number :
Equipment Type :
Equipment Serial Number :
Equipment Design Data :

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

TABLE OF CONTENT

Page
SOFT COVER 1
TABLE OF CONTENT 2
I. DESIGN 3
II. INSTALLATION 4
III. OPERATION 4
1) Start Up 4
2) Shut Down 5
IV. MAINTENANCE 5
V. TROUBLESHOOTING 6
VI. SAFETY 6
1) Nitrogen 6
2) Cylinder 10
APPENDIX
- Drawings
- Regulator (Tag No. 0QJD15AA001 and 0QJD15AA003)
- Safety Valve (Tag No. 0QJD15AA02 and 0QJD15AA004)
- Valve
- Check Valve (Tag No. 0QJD15AA005 and 0QJD15AA006)
- Cylinder

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________
I. DESIGN

DESCRIPTION DATA

Number of LPG Tank 2 (Two)


Serial Number No. 30T LPG-001
30T LPG-001
Safety Valve
- No of LPG Tank Two
- Make, Model MS ENG, WSLT-50-100
- Set Pressure – Mpa 1.76
- Capacity – kg/h 34022
Size of Tank 30 Ton / each
- Diameter - mm 2500
- Height - mm 3050
- Length – mm 14800
Vaporizer
- No of vaporizer One
- Make, Model Entec, Electric-heating-hot-water heating
- Vaporization capacity (kg/h) 100
- Design Pressure – Mpa 1.8
- Proof test pressure (Mpa) 3.0
- Airtight test pressure (Mpa) 1.8
- Design Temperature ( C ) -25 to 80
- Range of working pressure (Mpa) 0.1 to 1.56
- Liquid-spill prevention mechanism By means of float
- Safety valve setting pressure (Mpa) 1.8
- Heater capacity (kW) 150
- Voltage (V) 380V, 3-phase
- Rated current (A) 228
- Hot water control temperature (C) 60 to 70 (setting at 65 C)
- Hot water superheat prevention (C) 80 (setting at 80 C)
- Liquid inlet flanges KS 20K
- Gas outlet flanges KS 30K 25A
- Width (mm) 1040
- Length (mm) 1300
- Height (mm) 1270
- Capacity of hot water tank (lit) 1050
- Approximate product weight (kg) 720
- Rust-preventive agent supplied (ml) 3150

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

Pressure Regulator
- No of Regulator Two
- Make, Model HWA YOUNG, HYRM - 400
- Set Pressure – Mpa 0.57 – 0.83
- Capacity – kg/h 400
Flash Back Arestor
- No of Flash Back Arestor One
- Make, Model Water Sealed

Discharge Pump
- No of Pump One
- Make, Model SEAHWA, Vane Pump
- Capacity – L/m 200

Piping
- Line Tank to High Temperature Furnace

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________
II. MAJOR EQUIPMENT AND INSTALLATION
 LPG Tank 30 Ton
o Make sure LPG Tank on the right position .
o Connect valve and accessories on the tank properly, such as safety
valve and vent valve. Inject tank with Nitrogen gas to leakage test.
Make sure there are no Nitrogen gas leakages.

 VAPORIZER
Place of instlation
o Select a a place for the systems in a well-ventilated location where any
leaked gas will not remain there
o Whwn installing it indoors, be sure to prepare ventilation opening with
space sufficient for well ventilation
As for the ventilation area, the one of 3 % or more is necessary for the
floor space by two places.
o Take measures such as providing a special housing, fences or walls so
that any unauthorized person will not be admitted in the site
o Set up signs such as “FLAMMABLES” or “KEEP OUT” in order to
make people going in the vicinity be alert to thid hazardous substances
area
o Regulary provide dry chemical extinguishing units (two chemicals or
more of 8 kg) in the site
o NEVER put flammables (including gasoline, kerosene, heavy oil,
timbers etc) around the site
o Install the systems 8 meters or more away from any fire
o Do not install the equipment in the following places :
- Humid place
- Place subject to salt damage
- Place exposed to severe vibration
- Place open to corrosive gas (chlorine, hydrogen sulfide, ammonia,
azone etc.) or dust particles or others adverse substances.
- Be sure to provide a gas alarm unit (s) in the installation site
Instalation
o Connect vaporizer to the installation properly so there will be no
leakage on the connection. Usage of seal tape is highly recommended.
o Make sure water on the center of the water level gauge
o Use specicified items for electricity wires and ground fault interrupters
to be connected to terminal box. Use 125 mm2 x 3C for electric wire
and use 225 A for ground fault interrupter, So 80 C for Elactric wire
conduit.
o Besure to provide explosion-proof electricity work when lead-in wire
is placed because teminal box is constructed explosion-proof.

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________
 REGULATOR
o Connect regulator to the installation properly so there will be no
leakage on the connection. Usage of seal tape is highly recommended.
o Adjust regulator to the required output pressure.

 FLASH BACK ARESTOR


o Connect flash back arestor to the installation properly so there will be
no leakage on the connection.
o Make sure water on the center of the water level gauge.

 DISCHARGE PUMP
o Connect pump to the installation properly so there will be no leakage
on the connection.
o Install Make sure electricity use explosion proof accessories.

 PIPING
o Connect all pipes properly and make sure there are no Nitrogen gas
leakages on all joints. Usage of seal tape is highly recommended.
o Tightened all pipe with U Bolt to the pipe support.

 VALVE
o Connect valve to the pipe properly so there will be no leakage on the
connection.

 SAFETY VALVE
o Connect safety valve to the installation properly so there will be no
leakage on the connection.
o Adjust safety valve so it will work at required pressure. Usage of seal
tape is highly recommended.

 PRESSURE GAUGE
o Connect pressure gauge to the installation properly so there will be no
leakage on the connection. Usage of seal tape is highly recommended.
o Make sure the measurement range of the pressure gauge is suitable.

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

III. PREPARATION AND OPERATIONS MAJOR EQUIPMENT


 VAPORIZER
Preparation for operation
 Nitrogen replacement
Replacement with nitrogen gas those gases remaining in the vaporizer and
outlet / inlet piping
 Water supply
Prior to water supply, add the supplied rust-preventive agent by the
specified amount, and the supply city water untuil water is just to over
flow.
Be sure to use city water. Use of ground water may cause corrosion
 Confirm of valve conditions
Confirm that main liquid inlet valve, gas outlet valve and drain valve
Confirm that the main valve of safety valve is open
 Before turning on the power supply, confirm the following values
Value of insulation resistance of external wiring in heater and control
circuit line : 0.4 M or greater
Value of grounding resistance of grounding work : 100 M or lower

Starting operation of vaporizer


 Turn ON the main breaker of the power supply
 Confirm that the temperature of hot water is 60 °C or higher
 Confirm that drain valve and the reset valve are “Closed” and the main
valve is “Open”
 Gradually open the main liquid inlet valve
 Confirm that the vaporizer pressure is normal
 Gradually open the gas outlet valve to replace nitrogen gas with LP gas
while releasing nitrogen gas in a safe place at the end of piping

Stopping operation of vaporizer


 For short-period operation stop
- Close the gas outlet valve.
- Leave others valve, power supply and the others controls in the
operating condition
 For extended operation stop
- Close the main liquid inlet valve
- Consume all amount of gas in the “Vaporizer” or fully discharge the gas
through the drain valve to a safe place
- Close the gas outlet valve, and turn OFF the power supply (take
sufficient against freezing before turning OFF the power supply)

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

Method of restoration after actuation of liquid-spill prevention valve


If gas is consumed under power failure, lower water level or overload
condition, hot water temperature will lower, LPG liquid level will reise, and
further, the liquid-spill prevention valve will be activated by the float
buoyancy, which will cause stop of gas supply.
If the liquid-spill prevention valve is activated, follow the steps below for
restoration.
 Be sure to close the gas outlet valve
 Ensure that all gas burning devices connected are kept in operation stop
state
 Investigate the cause of shut-off the prevention valve
- Confirm that power is supplied
- Check the water level, and add water if the level is lower than the
specified
- Confirm that the capacity of gas burning devices in service is smaller
than the capacity of vaporizer.
 Close tha inlet an outlet valves
 Open the gas drain valve for release the pressure in vaporizer, so down the
float ball (prevent liquid over flow)
 Close gas drain valve, open inlet and outlet valves and check thr
downstream pressure is increase.
You can use this vaporizer after check downstream pressure is increase.

 FLASH BACK ARESTOR


Check the water level
 Water level check
- Check the water level daily
- Check the water level keeps center of the water level gauge.
- In case of water indicate below than required level. It have to fill the
water to fill the water required level.
 Fill the water
- Close the valve (10) & (11) on the flash back arestor
- Open the water filling valve (9) and pour the water into water filling
device, after then close the valve (9)
- Open the valve (10) & (11) for fill the water into flash back arrester to
required water level
- Water fill to required level
- Close the valve (10) (11)
In Special feature : it install the water filling device so it can filling water
while use the gas.

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________
In case of water change to muddy or change to black color, it have to
change to flash water immediately.
Check the water tank of safety bursting plate
 Intention
- Reduce the blast sound when explosion cause flash back
- In case of explosion. Water rise up to operate the emergency valve lever
for the close the emergency valve
- water tank will protect the damage of safety bursting plate from the
impact of up-side.
 Caution
It have to fill the water always in the water tank
 When the plate changing
- In case of blasting the plate according to flash back
You have to remove the blasted plate and assembling new one
- You have to change the new plate every 6 months
- In case of bubble appears in the water. It become too old for use the
safety bursting plate so it have to change the new one.

Check the efficiency of emergency shut valve & check valve


 Charge the LP gas in the flash back arrester and close the emergency shut
valve by manual
 Open the valve (13) then LP gas will flow out for a little while after then
Lp gas will not more flow out. It is emergency shut valve works normally
 If the valve work normally, please close the valve (13) before operating
 If the LP gas flow out continuously, it seems the emergency shut valve
have some trouble. If the water fow out continuosly, it seems the check
valve have some trouble.
 If you find trouble any trouble in the emergency or check valve you have
to repair the valves.

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

IV. OPERATIONS SYSTEMS


1) START UP (see Drawing P & I D LPG Tank 30 Ton & Piping )
 Make sure there are no Nitrogen gas leakages at the system unit, i.e. at
valves, piping, gas supply unit, pressure gauge, safety valve, and all
connections.
 Start operation can use liquid or gas of LPG
 Open valve of the tank (V4 or V8) and open valve in liquid line on the
systems (V12) if you use a liquid line.
 Or open valve of the tank (V3 or V7) if you use a gas line.
 If you ready to supply gas, then open valve on the gas supply unit (V13,
V14 or V15, V16)
 Make sure the pressure at main pipe (P6) achieved the required pressure.
 If necessary, adjust regulator (R1) or (R2) until required pressure is
achieved.
 Open valve (V18)
 LP Gas is ready for use
 If systems will changed with the others fuel, close V18 and open V19

2) SHUT DOWN
 Close Valve (V18)
 In case LPG will not be used for such a long time, close all valves of all
systems except valve on safety valve .

V. MAINTENANCE
 LPG Tank
o Check surface of tank regularly (i.e. monthly); make sure there are no
corrosions, deep scratches, cracks, or dents. Tank must be repaired and
hydrostatic pressure tested when one or more of the conditions above
are found.
o LPG Tank must get regular hydrostatic pressure test for every 5 years
or shorter period if necessary, depend on how old the cylinder is.

 Vaporizer
Daily inspection
o Frequency of check : Check at starting operation, during operation and
at stopping operation
o Check items : gas leak, pressure, water level, hot water temperature
and confirmation of state that drain valve and reset valve are “Closed”
and main valve of safety valve is “Open”.
o Be sure to exhaust drains collected in VR from the drain valve

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________
Periodic inspection
o Frequency of inspection : Annually
o Check items :
- Check for leakage at relevant parts
- Inspection of equipment auxiliary to thermometer and pressure and
pressure gauge
- Appearance inspection of vaporizer, hot water tank and others
- Replacement of hot water (including rust-preventing agent)
Disassembly and inspection
o Frequency of inspection : Once every three years
o Items for implementation : The following items are added to periodic
inspection :
- Measurement of thickness of heat exchanging part
- Calibration of thermometer and presuure gauge
- Inspection of auxiliary equipment and replacement of deteriorative
parts
- Situation of corrosion of heat exchanger, hot water tank, and others.
- Inspection of air tightness.

Inspection items when in anormally

Symptom No gas Too low Too high Too low


supplied temperature Temperature supply Measures
Causes Of hot water pressure
Gas running out  Replace the container
Gas too much   Reduce the
consumed Consuming rate
Disconnection   Replace the heater
Of heater wire
Failure of MC    Replace MC
Failure of Correction of settings
temperature    or replacement
regulator
Defective
Superheat    Correction of settings
Prevention or replacement
Device
Water shortage   Supply water
Defective level   Replace the switch
switch
Defective water   Replace the gauge
Level gauge

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________
Strainer clogging   Clean strainer
Main liquid
valve and outlet 
valve are left Open the valve
open

 Valve
o Check valve on the tank and systems from any leakage by soaping it
every 3 (three) months or on time system not used.
o Make sure valve working shut and open properly for every 3 (three)
months. If it doesn’t work properly, repair it or replace it.
 Safety Valve
o Safety valve must be calibrated for every year to give warranty it opens
at required pressure.
 Pressure Gauge
o Calibrate pressure gauge for every year to make sure it shows the
correct reading.
 Pressure Regulator
o Check outlet pressure of regulator daily. If outlet pressure incorrect,
adjust it to the required outlet pressure.
 Piping
o Check piping installation from any leakage by soaping it once a year.
Especially on every connection (flanges and drad).
o Make sure there are no corrosions, deep scratches, cracks, or dents. If
found, fix it.
 Flash Back Arestor
o Check flash back arestor from any corrosions. If found, fix it.

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

VI. TROUBLE SHOOTING


Problem Action
Outlet pressure too high Adjust pressure regulator to required outlet
pressure
Make sure vaporizer work properly
Outlet pressure too low Make sure the all valves on systems are
open.
Make sure the LPG tank are not empty.
Make sure vaporizer work properly
Make sure there is no leakage on the
istallation.
Adjust pressure regulator to the required
outlet pressure.
Unstable outlet pressure Pressure regulator may be defective, repair
it or replace it.

VII. LPG

Liquefied Petroleum Gas or LPG ussualy refers to Propane, Butane or


mixture of Propane and Butane

Propane Butane
C3H8 C4H10
Molecular Weight 44.09 58.12
Specific Gravity
Liquid 60 F 0.51 0.58
Water = 1.0
Vapor Pressure Psia bar-a Psia bar-a
at 32 F (0 C) 69.6 4.80 14.9 1.03
60 F (16 C) 105.5 7.28 26.1 1.80
100 F (38 C) 183.7 12.67 49.9 3.44

==========OOO==========

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LPG TANK 30 TON & PIPING
Contact Name : LPG TANK 30 TON & PIPING
Unit Name : EQUIPMENT OF LPG FUEL SYSTEM FOR HTF
Purchaser’s P.O. No. : P6AM901 / 2
Purchaser’s P.O. Date. : 08 NOVEMBER 2006

___________________________________________________________________________

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