CUSTOMER : GAILINDIALTD. PROJECT :__ NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 OPERATION & MAINTENANCE MANUAL OF INDIRECT WATER BATH HEATER CUSTOMER GAIL INDIA LTD. NATURAL GAS PIPPELINE PROJECT KOCHI- PROJECT + KOOTTANAD-BANGALORE-MANGALORE PHASE 1 HEATER AT IP-1 (FOR FACT-I & BSES) SKID-149 BH-001 dp MULTITEX DOG. No. = SKID-149/08Mi01 Page loft‘CUSTOMER PROJECT GAIL INDIA LTD. NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 INDEX DESCRIPTION PAGE NO. INTRODUCTION 03, 11 OBJECTIVE 03 1.2 AN OVERVIEW OF THE PROCEDURE 03 REQUIRED DATA AND INFORMATION 03 REQUIRED TOOLS AND EQUIPMENTS 03 SAFETY 04 COMMON CHECK POINTS FOR PRE-COMM. WATER BATH HEATER CHECK PRIOR TO STARTING BURNER & BURNER MANAGEMENT FIRST FIRING OF THE SYSTEM DAILY OPERATION SHUT DOWN START-UP AFTER ROUTINE SHUT DOWN, TROUBLE SHOOTING MAINTENANCE CHECK LIST MAINTENANCE LOG P&ID INSTRUMENT DATA SHEET MULTITEX DOG. No. : SKID-149/08MI01CUSTOMER : GAILINDIALTD. PROJECT NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 1.0 INTRODUCTION 414 OBJECTIVE The objective of this manual is to describe the Operation “and Maintenancé of the Indirect Water Bath Heater. AN OVERVIEW OF THE PROCEDURE ) Required Data and Tools for Operation. ) Describe the safety procedure during Operation. ) Safety, ) (a) b) ) (d) Describe the Pre-Commissioning procedure Skid wise. ( ( REQUIRED DATA AND INFORMATIONS. ‘The Operation Team shall acquire a complete set of drawing and data listed below: ) P&ID's ) GA drawing of vessels. ) GA drawings of SKID. ) Operation and maintenance manuals from the item (Instrument / Valves) supplier. ) Data Sheets of Critical Valves and Instruments. f) Signal List, etc. REQUIRED TOOLS AND EQUIPMENTS All necessary tools, test instruments, water, air and electric power shall be available for the Operation Team. Each craftsman such as pipe fitter, millwright, mechanic, instrument technician, or electrician, who is assisting the Operation Team, shall have his general tools available, All necessary tags, warning tapes, barricade tapes and safety supplies shall be available at the site. The following signs in Hindi and English shall be posted at strategic location before proceeding with the appropriate Operation activities: Tags: - No Smoking - Danger, high voltage - _ Donot enter beyond this point Finally, the following safety supplies shall be available to all staff involved in the Operation: Hard Hats Safety Boots Boiler Suits / Coveralls First Aid Kit, etc. Fire Extinguishers, ete MULTITEX DOG. No. : SKID-149/08M01 Page :3 of 14CUSTOMER : GAILINDIALTD. PROJECT NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 SAFETY The objective ofthis section is to’ provide comprehensive safety guideline during installation. The safety of each worker is everybody's concern. Personnel may be ‘Working at varioUs elevations and any slippage in safety procedure may lead to fatal or lost time accident. The foreman, supervisors, engineers, managers and others in the authority should enforce all applicable safety regulations, rules and practices. “Safety Instruction Signs” shall be used where there is a need for general instruction and suggestions relative to safety measures. VALVE TAGGING - Critical valves to be clearly tagged for ‘closed’ or ‘open’ position - No valves to be operated without permission from authorized person. ELECTRICAL TAGGING AND LOCKOUT No person will carryout electrical work of any description (including maintenance, cleaning or testing) in any part of high voltage equipment unless it is, - Isolated and all practical steps taken to lock off from live conductors. - Lock off isolater handles with the isolator in the off position. All auxiiery conductors which may be energised from other ‘live’ sources to be idenified and isolated. Locking mechanism (Key, seal etc.) is controlled by approved authorised person. ‘When an electrical apparatus is a source of danger to people then it must be isolated in a way approved for the appropriate electrical voltage category. The authorising engineer must approved re — energising of any electrical equipment and permit signed off. COMMON CHECK POINTS FOR COMMISSIONING Check all Equipments / Instruments and valves etc. are mounted on the Water Bath Heater with respect to respective P & ID. Any missing or incompleteness shall be recorded. Check physical condition of all the Equipments / Instruments and valves etc. items mounted on the SKID. All shall be in good condition, any damages or abnormalities shall be recorded. All interconnecting piping should be flushed / cleaned / dry to make it free from any contaminants. All instruments should be isolated at the time of Flushing / Cleaning Make sure skid must be dry and free from any contaminants, Hydro test of all interconnecting piping should have been done before interconnection. Leak test (pneumatic) for all flanges / joints to be carried after interconnecting the piping MULTITEX DOG. No. > SKID-149/08MI07 Page: 4a laCUSTOMER : GAIL INDIALTD. PROJECT NATURAL GAS PIPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE f All high points and bends and test limit connection are to be fully opened prior to draining of water to avoid a vacuum environment that could cause damage to piping. After installation following points are to be checked, * Placement of skid with proper foundation and level ‘Shipping blocks / wrapping should be removed from panels and instruments. Interconnecting cables (power, control & instruments) till the skid termination point should be properly laid. Power supply to the instruments should be through proper power distribution. ‘Smooth movement of all isolation valves is to be checked. Physical conditions of all manual gauges (i.e. PG, TG, DPG) to be checked, any damage found, to be recorded. All vent and drain connection should be connected to their respective points. Electrical check points * Check for proper glanding and termination according to the respective JB schedule, Loop check for continuity and termination to be done. * Voltage level to be checked. Site should be clean and free from debris. Nitrogen purging of complete system should be done immediately after pre- commissioning to ensure for removal of oxygen / air from the system. MULTITEX DOC. No. : SKID-149/08MI07 Page: SofaCUSTOMER : GAILINDIALTD. PROJECT : NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 4 6.0 INDIRECT WATER BATH HEATER TAG NO.: BH-001) The =uel Gas Heating System is located in the Gas Supply common area at the downstream of Filer Separator. Conditions: Parameter Unit Gas Flow foreach Heater Kgis. 47.23 Pressure (operating / Normal / design: Kglom2g | 83-87/92 Inlet gas temperature range 7 °C 09 Heater outlet gas temperature after mixing ec 26 Required Temp Rise, EC} 17 The Fuel Gas Indirect Water Bath Heater is Gas fired heater and it is designed as per API 12K Specification. It consists of a water bath wherein a Fire tube and a Gas Tube bundle (process coil) are immersed. The water is heated by the Fire tube and which in turn heat up the fuel gas passing through the process coil. The details of Water Bath Heater are as follows: a. Shell - In order to accommodate 1 No. of Fire Tube with in Lower Half Diameter and 1 Set of Gas Heating Tube Bundle in Upper Half Diameter. Tube Bundle and Fire Tube are removable by Flange. Expansion Tank ~ A cylindrical Horizontal Tank with Dished End is provided and placed on the body of Shell. Expansion tank is connected with Shell through 2 no. of Pipes of 3” flanged connection. The level in the Expansion Tank is monitored with Level Gauge and Level Alarm. Make-up Water is added via Water Inlet fine to Expansion Tank and Separate Nozzle with funnel arrangement is provided for Dosing. Gas Heating Tube Coil Bundle — 1 Set of Pressure Coil of 4" Inlet Header. The Fuel gas enters at 09°C and comes out of water bath heater at 26°C, Fire Tube — The two Nos. burners are fitted in Fire Tubes where fuel gas after combustion transfers the heat to water bath. Fire tube is a serpentine design. There are two Nos. Fire Tubes. Burner — 2 No. of Bumers for Water Bath Heater capable of generating maximum of 2811.876 KW Heat load is provided, as desired. A Gas train comprising of Isolation Valve, Pressure regulator etc. is provided. Indirect Water Bath Heater is capable of heating the maximum fuel gas flow 47.23 Ka/S. The Water Bath is heated to a set point of 85° C, by burning fuel gas in the burner. To prevent the burner gas supply line to freeze due to pressure reduction, supply is taken ‘rom the outlet of the Water Bath Heater. The burner is equipped with ignition transformer and burner flame detector. Fuel Gas line consist of isolating valve, slam shut-off valves, control valves, strainer, flame arrestor for safe operation of heater. MULTITEX DOG. No. : SKID-149/08M/01 Page: 6of laCUSTOMER : GAIL INDIALTD. PROJECT NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 Indirect Water Bath Heater outlet temperature control: The gas temperature downstream the heater will be controlled by PLC Panel. Input for the temperature control comes from thé set point from DCS Control System. * The temperature input for the heater control is determined by the signal from 1 temperature transmitter, which is installed at the outlet of the heater. Indirect Water Bath temperature control: The water bath temperature is controlled by the local control panel. The temperature element measures the temperature and local control panel controls the fuel gas flow through water bath heater. The gas flow into the burner is supplied through a pressure reduction. The pressure reduction is accomplished through a self actuated PRV which reduces the gas pressure from apprx. 3-12 Kg/cme (g) to 0.5 Kg/cm2 (g). MULTITEX DOG. No. : SKID-149/08MI01 Page: TofiaCUSTOMER : GAILINDIALTO. PROJECT : NATURAL GAS PIPPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 7.0 Checks Prior to Starting The initial start up of the Water Bath Heater unit should be conducted by a technician from the “Multitex Filtration Engineers tld. The customer should provide qualified maintenance personnel to assist the technician during the commissioning process. The following is alist of items to be checked prior to start up. a Verify that the mechanical installation has been completed in accordance with any applicable installation drawings and/or procedures supplied by Multitex and/or the site engineers Visually check piping and ductwork installation for compliance with the flow schematics. Verify that all globe valves, strainers, check valves and control valves have been installed with the correct flow direction and orientation, Ensure that all piping to the heater and burner are correctly supported and stress relieved Verify that the discharge piping from any relief valves is piped to a safe location. Install a “skillet” at the relief valve inlet flanges. Verify that all drain valves are closed Open or close all manual valves and/or dampers according to the correct operating position. Refer to the flow diagrams or contact Multitex with questions. Open all pressure gauge and device shut off valves. Verify that the electrical installation is complete and is in compliance with the electrical schematics. Check all safety and control devices to verify that they are correctly installed and have the correct ranges and set points according to the mechanical and electrical diagrams. 8.0 First Firing of the System 1) It is important that a Multitex technician or representative commission the convection heater to ensure safe and correct operation of the equipment. Do not attempt to commission the heater without direct supervision of a Multitex representative. 2) Verify that the recirculation damper is going to be 100% open with the corresponding actuator position 3) The burner should be started and held at low fire to allow the system to slowly warm up. The system should be in “Stand-By" mode of operation. Some bumers require a longer period of either low fire or pilot only operation to cure refractory discharge blocks, 4) The temperature must be increased slowly by placing the Stand-By temperature controller (TIC) in "MANUAL" control mode and increasing the output to the burner in small increments. If there is no process flow while during this process, the chamber temperature can tise very quickly. 5) Adjustments must be made to the fuel and air controls to establish the mechanical limits assoziated with the low fire and high fire settings. These changes should only be made by a qualified Multitex approved start-up technician. MULTITEX DOG. No. + SKID-49/08M/07 Page: SofiaCUSTOMER : GAIL INDIALTD. PROJECT : NATURAL GAS PIPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 CAUTION: Never attempt fo perform any burner tuning without the direct supervision of a qualified burner technician that has been approved by Multitex. 6) Once the initial low fire and high fire settings have been established, the Stand-By mode controller can be placed in automatic mode and allowed to modulate. 7) Alow the burner to reach high fire and check the burner settings to insure that the high fire fuel and air are configured correctly. Make a note of the lower plenum temperature, end wait ‘or the process temperature to reach its required set point. MULTITEX DOG. No. : SKID-149/08M/01 Page :9 oflCUSTOMER : GAIL INDIALTD. PROJECT : NATURAL GAS PIPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE 1 Burner Management System ‘The burner management system described here below is sequenced for automatic / manval (test) operation of the burner from the control panel supplied along with the burner. The bumer control panel will house the necessary interlocks required for the safe operation of the burner in automatic / manual mode. This is achieved by use of hardwired system using solid-state timers, contractors etc. To facilitate operation / monitoring of the bumer operation the control panel will be provided with necessary push buttons indicating lamps on the front side of the contro! panel The controlled elements are the combustion air-blower (which also supplies air for the pre- purge operation), ignition, main valve and control motor for changing the output of bumer from lo-fire to hi-fire and vice-versa, and alarm. The burner flame is continuously monitored using a flame-monitoring device consisting of flame rod mounted on the burner and a relay unit mounted inside the control panel. The sequence of operation of the system will be as under: 1. The main power supply is switched on and subsequently the supply to the contro! panel is switched on. The successful energisation of the control panel is indicated by an indication light (SUPPLY ON) Mode or operation (AUTO / MANUAL) is selected using a selector switch located on the control panel. Let us suppose that the selection is made for AUTO mode gas operation. To initiate the operation of the burner system , the COMUSTION START push button is pressed. This action initiates the blower operation to supply air for the pre- purge operation, Once the blower starts running the pre-purge operation sequence starts. During this ‘operation the combustion air blower delivers the purging air for a fixed duration of time set on a purge timer located in the control panel. Once the pre-purging operation is over, the sequence for initiating the ignition ‘comes into operation. The flame monitoring system is also simultaneously energized alongwith the ignition transformer. Alongwith the energisation of the ignition transformer, a ignition time delay timer is also energized. This timer de- energises the ignition transformer after a set period of time. ‘Once the pre-purging operation is over, the burner is initially lighted on low ‘ire position. The air butterfly valve is connected with control motor by flexible coupling. ‘The movement of this valve is controlled by two position (high / low) Servomotor. During the low fire position’ the servomotor is at ‘low’ position and during high ‘ire the servomotor is at ‘high’ position During initial start-up, as mentioned above the burner is fired at low-fire. The main gas valve opens and the main flame is lighted by the direct spark ignition. The flame sensor, then monitors the main flame continuously. The BURNER ON indicating lamp indicates the establishment of the main flame. IN case the main flame goes out or is. not established, a signal is given to the main gas valve to close, a FLAME OFF alarm is MULTITEX DOG. No, : SKID-149/08MI01 Page: ortCUSTOMER : GAILINDIALTD. PROJECT NATURAL GAS PIPELINE PROJECT KOCHI-KOOTTANAD-BANGALORE- MANGALORE PHASE t given (which has to be acknowledge) and the post-purge operation is initiated, as described below (7). In addition to above an interlock will be provided between the burner operation and presstire switch. . ees ~— 8. In case, the main flame goes off for any reason or in case of normal shutdown, the post-purge operation is initiated. A signal is given to the main gas valve to close and the FLAME OFF alarm is given, which have to be acknowledged, The combustion air blower then supplies air for the post-purge operation for a set duration of time and then the combustion air blower is switched off. €. In case of MANUAL / TEST mode selection all the safety interlocks remain as for the automatic operation except that the push buttons will have to pressed manually. 9.0 Daily Oper: Routine start ups and operation should only be conducted by personnel that have been fully trained in the operation, and are familiar with all system component manufacturers’ operating instructions. 10.0 Shut Down 1) Remove the signal for enabling process control mode 2) Alow the heater to resume “Stand-By” operation, which is the default mode of operation when the run mode is set to "DCS". 3) Tum the burner off 11.0 Start Up After Routine Shutdown Check that all manual valves are in the correct operational position. Visually inspect system for leaks or other problems, Perform any scheduled maintenance on any equipment in the system per the manufacturer's recommendations. Check that the fuel supply is turned on. Energize the control panel. Turn the burner switch to the "ON" position. if all system interlocks and safeties are satisfied, the burner will start and stay at low fire until the low fire hold set point has been reached. The burner will then. modulate as necessary to achieve and maintain the desired set point in standby mode. Check that all pressure gauges are indicating normal operating pressures. Itis recommended that operator attendance be maintained while the system is being heated up. Operators and/or maintenance personnel should periodically check on the system throughout their shift for any signs of trouble. MULTITEX DOG. No. = SKID-149/08M/01 Page: 11 of