BOP-Operating Manual

AFAM – RIVERS STATE GOVERNMENT
OPEN CYCLE POWER PLANT Job Number UNIT

032083 00
COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

MANUAL Sh. 1 of 149 Rev. 00
COMMISSIONING AND OPERATING MANUAL
_____
00 Issued for Construction
0A Internal Issue
Rev. Description Prepared Checked Approved Date
Cod. modulo : MDT.GG.QUA.0004 Fg. 01/Rev. 3.96 Cod.file: File dati: 462717286.doc
This document is the property of Saipem who will safeguard its right according to the civil and penal provision of law.
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INDEX
I UNIT 50 - FIRE PROTECTION SYSTEM 13

II UNIT 60 - SERVICE AND POTABLE WATER SYSTEM 42
III UNIT 80 - INSTRUMENT AND SERVICE AIR SYSTEM 68
IV UNIT 40 - OPEN DRAINS 97
V UNIT 70 - FUEL GAS 109
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Cod. modulo : Cod.file: File dati:

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Table of Content
1 INTRODUCTION 10
1.1 FOREWORD 10
1.2 GLOSSARY OF TERMS USED AND UNITS USED 12
I UNIT 50 - FIRE PROTECTION SYSTEM 14
1 DESIGN BASIS 14
1.1 FUNCTION OF THE FIRE PROTECTION SYSTEMS 14
1.2 FEEDSTOCK CHARACTERISTICS 14
1.3 BATTERY LIMIT CONDITIONS 15
1.4 EFFLUENTS 15
1.5 MATERIAL BALANCE 16
1.6 UTILITIES REQUIREMENTS 16
1.7 CHEMICALS 16
2 PROCESS DESCRIPTION 17
2.1 REFERENCES 17
2.2 DETAILED PROCESS DESCRIPTION 18
2.3 ELEMENTS OF PROCESS CONTROL PHILOSOPHY 20
3 COMMISSIONING/ INITIAL START UP 21

3.1 GENERAL 21
3.2 PREPARATION PRIOR TO INITIAL OPERATION 21
3.3 FIREWATER TANK AND PUMPS STARTUP 23
3.4 FIREWATER DELUGE SKIDS 25
4 NORMAL AND SUBSEQUENT START-UP 27

4.1 GENERAL 27
4.2 PRE-START UP CONDITIONS 27
4.3 NORMAL AND SUBSEQUENT START-UP PROCEDURE
27
4.4 CONTROLLER SET POINTS, ALARMS AND TRIP
SETTINGS 30
5 NORMAL OPERATION 31
5.1 OPERATING VARIABLES 31
5.2 SPECIFIC OPERATIONS 32
5.3 PERFORMANCE MONITORING 33
5.4 CORROSION CONTROL AND MONITORING 33
6 NORMAL SHUTDOWN 34
6.1 GENERAL 34
6.2 UNIT 50 SHUTDOWN 34
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7 EMERGENCY SHUTDOWN 38
7.1 GENERAL 38
7.2 UTILITIES FAILURE 38
8 SAFETY 39
8.1 GENERAL 39
8.2 LISTING OF SAFETY EQUIPMENT 39
8.3 FIRE AND GAS DETECTION 40
9 EQUIPMENT LISTS AND DATA SHEETS 41

9.1 DATASHEETS 41
9.2 SAFETY CONCEPT DOCUMENT 41
9.3 FIRE AND GAS DETECTION SYSTEM SPECIFICATION
41
10 DRAWINGS 42
10.1 PIPING AND INSTRUMENTATION DIAGRAMS 42
10.2 PLOT PLAN 42
10.3 FIRE AND SAFETY LAYOUT DRAWINGS 42
10.4 OVERALL FIREWATER RINGMAIN DRAWINGS 42
10.5 LOGIC DIAGRAM 42
10.6 VENDOR INFORMATION 42
II UNIT 60 - SERVICE AND POTABLE WATER SYSTEM 43
1 DESIGN BASIS 43
1.1 GENERAL 43
1.3 PRODUCT SPECIFICATION 44
1.4 EFFLUENTS 45
1.6 UTILITY REQUIREMENTS 45
1.7 CHEMICALS 46
2.1 GENERAL 47

3.1 GENERAL 51
3.3 SERVICE AND POTABLE WATER TANK AND PUMPS
STARTUP 52
3.4 COMMISSIONING/ START UP OF CHLORINATION
PACKAGE 54
3.5 FINAL PREPARATIONS 55
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4.1 GENERAL 56
4.3 NORMAL AND SUBSEQUENT START UP PROCEDURE
56
SETTINGS 57
5.2 SPECIFIC OPERATIONS 59
5.3 PERFORMANCE MONITORING 59
6.1 GENERAL 61
6.2 UNIT 60 SHUTDOWN 61
7.1 GENERAL 63
8 SAFETY 64
8.1 GENERAL 64
8.3 CHLORINE (Cl2) INFORMATION 65

9.1 DATASHEETS 67
9.2 OTHER DOCUMENTS 67
10 DRAWINGS 68
10.2 PLOT PLAN 68
10.3 FIRE AND SAFETY LAYOUT DRAWINGS 68
10.4 LOGIC DIAGRAM 68
III UNIT 80 - INSTRUMENT AND SERVICE AIR SYSTEM 69
1 DESIGN BASIS 69
1.1 GENERAL 69
1.4 EFFLUENTS 70
1.6 CHEMICALS 70
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2.1 GENERAL 71

3.1 GENERAL 74
3.3 PRESSURIZATION AND START UP OF UNIT 80 75
3.4 FINAL PREPARATIONS 77

4.1 GENERAL 78
79
SETTINGS 80
6.1 GENERAL 85
6.2 SHUTDOWN OF INDIVIDUAL EQUIPMENT ITEMS 85
7.1 GENERAL 87
8 SAFETY 88
8.1 GENERAL 88
8.3 SAFETY PRECAUTIONS FOR AIR COMPRESSORS 89
8.4 SAFETY PRECAUTIONS FOR AIR DRYERS 93

9.1 DATASHEETS 96
9.2 CAUSE AND EFFECT CHART 96
10 DRAWINGS 97
10.1 1 PIPING AND INSTRUMENTATION DIAGRAMS 97
10.2 2 PLOT PLANS 97
10.3 3 LOGIC DIAGRAM 97
10.4 4 FIRE AND SAFETY LAYOUT DRAWINGS 97
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10.5 FIRE AND GAS DETECTION SYSTEM LAYOUT

DRAWINGS 97
1 DESIGN BASIS 98
1.1 GENERAL 98
1.2 UNIT CAPACITY 98
1.3 DESIGN CONDITIONS 98
1.4 MATERIALS 99

2.1 PROCESS DESCRIPTION 102

3.1 GENERAL 104
3.3 SANITARY SEWER SYSTEM COMMISSIONING AND
STARTUP 105
3.4 TRM SUMP MANUAL SLUICE 40-SL-001 105
3.5 TRAFO OIL DRAINAGE SYSTEM COMMISSIONING AND
START UP 105
3.6 COMMISSIONING OF TRM SUMP PUMP 40-P-003 105

4.1 GENERAL 106
5 SAFETY 107
5.1 GENERAL 107

6.1 DATASHEETS 108
6.2 OTHER DOCUMENTS 108
7 DRAWINGS 109
7.2 PLOT PLAN 109
7.3 LAYOUT DRAWINGS 109
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V UNIT 70 - FUEL GAS 110
1 DESIGN BASIS 110

1.1 General 110
1.2 UNIT CAPACITY AND GAS QUALITY 111
1.3 PRINCIPLE OF OPERATION 112
1.4 UTILITIES 113

2.1 NATURAL GAS HEATING SECTION 114
2.2 NATURAL GAS FILTRATION AND FLOW
MEASUREMENT 115
2.3 NATURAL GAS PRESSURE REDUCTION 117
2.4 CONTROL PHILOSOPHY AND OPERATIONS
DESCRIPTION 118

3.1 GENERAL 121
3.2 PREPARATION PRIOR TO INITIAL STARTUP 121
3.3 STARTUP METHODS 122
4 NORMAL AND SUBSEQUENT START UP 129

4.1 General 129
4.2 PRE STARTUP CONDITIONS 129
4.3 START UP OF INDIVIDUAL EQUIPMENT ITEMS 129
4.4 STARTUP OF ENTIRE UNIT 70 131

5.1 GENERAL 132
5.2 NORMAL OPERATION 132
5.3 ABNORMAL CONDITIONS – CORRECTIVE ACTIONS 133
5.4 PROCESS VARIABLES 134

6.1 GENERAL 137
6.2 SHUTDOWN OF INDIVIDUAL EQUIPMENT ITEMS 138
6.3 UNIT SHUTDOWN 139
6.4 SYSTEM STAND BY 140

7.1 GENERAL 141
7.2 UTILITIES SHUTDOWN 141
8 SAFETY 142
8.1 GENERAL 142
8.2 RISK LIST, RISK MITIGATION AND
COUNTERMEASURES 142
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8.3 SAFETY PHILOSOPHY AND INTERLOCK DESCRIPTION

144
8.4 FIRE FIGHTING SYSTEM SELECTION 145
9 EQUIPMENT DATASHEET 146

9.1 DATASHEETS 146
9.2 CAUSE-EFFECT MATRIX 146
10 DRAWINGS 147
10.2 PLOT PLAN 147
10.3 LAYOUT DRAWINGS 147
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1 INTRODUCTION
1.1 FOREWORD
The information contained in this operating manual provides a basis for the safe startup, normal
operation, normal shutdown and emergency shutdown of the Utilities & Process System
(Balance of Plant BOP) at the AFAM Project facilities.
This document should be considered as a guide, and SCNL retains the right to modify these
procedures as a function of actual conditions encountered in the field during the pre-
commissioning, commissioning and startup of the plant.
This operating manual gives the process philosophy and describes the initial startup, normal
operation, shutdown and emergency procedures for the BOP. This volume, of necessity,
contains some of the process information since such information must be readily available for
the operating group. The instructions given herein are intended primarily for the use of foreman
and supervisors. They should serve as a basis for the preparation of detailed instructions to be
given to the operators by their foremen and supervisory personnel.
This volume describes the commissioning and operation of the entire unit as a convenient
reference for AFAM OCPP to ensure BOP operates at optimum conditions.
The procedures described in this manual should be considered as operating guides and may
have to be adapted at site. It is the prime responsibility of those in charge of the plant to interpret
the instructions, where necessary, to suit the conditions prevailing at any time and to take into
account local conditions during the preparation and commissioning of the BOP Unit.
It is essential that all personnel in charge of operating the plant read the whole of the operating
instructions and any related engineering manuals before commencing to start up any part of the
unit.
In general, the operating personnel will learn the proper operating procedures by actually
performing the necessary manual operations. Adequate training time must be provided for
extended drills covering all specific operations of both normal and emergency nature during
initial dry runs.
Operators should have their jobs and responsibilities clearly outlined and defined for them. They
should not be given the responsibility to start-up the plant by themselves even after a temporary
emergency shutdown, but should in such case call upon the technical supervisor in charge for
guidance and instructions. During all start-ups, it is recommended that a responsible technical
supervisor, who thoroughly understands the process and the plant in all its chemical and
mechanical aspects, be present. Since this will be less likely during and emergency shutdown,
the operators must be especially well schooled in the emergency shutdown procedures.
In order to cover all disciplines that operations personnel may require, the operating manual has
been issued as follows:
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· Design criteria, giving the basic data are indicated in chapter 1, whereas BOP process
descriptions are included in chapter 2.
· All general and particular procedures concerning Unit preparation for initial and normal
operation are described in chapters 3 to 8.
· To avoid too many references to equipment Manufacturer's manuals, necessary vendor’s

pieces of information are enclosed and/or explained in the relevant chapters.
· Finally, equipment specifications and data sheets, enclosed in chapter 9 give all design
information. Relevant drawings are enclosed in chapter 10 for reference purposes.
To facilitate the preparation for start-up and the coordination between the procedures for start-
up, normal operation and shutdown, the procedures have been separated as far as possible.
This will allow independent activities, and limit the possible bottlenecks and interference.
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1.2 GLOSSARY OF TERMS USED AND UNITS USED
I. Glossary of Terms Used

CPU Central Processing Unit
CEMS Continuos Emission Monitoring System
EOL End Of Line
ESD/F&G Emergency Shut Down / Fire & Gas System
EWS Engineering Work Station
CS Control System
FC Flow Computer
GC Gas Chromatograph
GHV Gas Heating Value
GSCS Gas Station Control Shelter
HMI Human Machine Interface
I/O Input / Output
ISO International Standards Organization
LAN Local Area Network
LFAP Local Fire Alarm Panel
LV Low Voltage
OS Operator Station
MV Medium Voltage
MCC Motor Control Center
PC Personal Computer
P&ID Piping and Instrumentation Diagram
PLC Programmable Logic Controller
RD Relative Density
RS232 EIA standard for point to point serial communications
RS422 EIA standard for two-wire differential unidirectional multi-drop serial
communications
RS485 EIA standard for two-wire differential bidirectional multi-drop serial
communications
RTD Resistance Temperature Detector
SCADA Supervisory Control and Data Acquisition
SIL Safety Integrity Level
GT Turbine Gas
VDU Video Display Unit
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II. Units Used in Designing the Plant
Surface m²
Volume m³
Temperature °C
Length k, m, mm
Pressure bar (g)
Vacuum mm HG, mm H20
Flow (mass) kg/h or T/h
Flow (liquid, for pumps) m³/h
Flow (gas) m³/h, Nm³/h, SCFD or MMSCFD
Mass kg, To
Heat duty kcal/h
Concentrations
* gas %vol, %mol, ppmw, ppmv
* liquid %wt, ppmw, ppmv
Pipe sizes, nominal inches
Electrical power kW
Viscosity cSt or cP
Density kg/m³
Time s, h
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I UNIT 50 - FIRE PROTECTION SYSTEM

1 DESIGN BASIS
1.1 FUNCTION OF THE FIRE PROTECTION SYSTEMS
The Fire Protection Systems installed as part of AFAM-OCPP Project have been provided to cater for
the firewater demands of the process and utility units. The fire water system shall be designed to meet
the design fire water demand as calculated by assuming one major fire in the plant.
The system include one firewater storage tank 50-T-001, two firewater main pumps
50-P-001/ 002, two jockey pumps 50-P-003 A/B, firewater main ring with hydrants and monitors and
deluge system.
The firewater pumps philosophy is 1 x 100% on emergency situation. In particular the design fire water
demand is supplied by electric motor driven pump (50-P-001) which is theprimary fire water source;
100% stand-by shall be provided by diesel engine driven pump (50-P-002) for redundancy.
The jockey pumps have been designed on a 1 x 100% operating basis. One pump operates
continuously on minimum flow recycle in order to ensure that fire water network will be maintained under
pressure
1.2 FEEDSTOCK CHARACTERISTICS
The following sections detail the capacity of the equipment and the characteristics of the firewater.
1.2.1 Unit Capacity
The following fire protection equipment has been installed as part of AFAM-OCPP Project:
Firewater Storage Tank, 50-T-001
Dimensions: 10.5 m ID x 9.15 m high.
Nominal Capacity: 780 m³
Operating Capacity: 600 m³
The firewater storage is sufficient to allow for two (2) hours continuous operation at maximum water
rate required of 300 m³/h.
Firewater Pumps 50-P-001/ 002
One of the Firewater Pumps 50-P-001 has an electric motor driver, the other 50-P-002 is driven by a
diesel engine.
The Firewater Pump electrically driven:
Pump Capacity: 300m³/h
Head: 83 m
Driver Power: 110 kW
The Firewater Pump diesel engine:
Pump Capacity:300m³/h
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Jockey Pumps, 50-P-003 A/B

Pumps are provided on a one operating plus one standby basis.
Pump Capacity: 15 m³/h
Head: 83 m
Min. Stable Flow 15 m³/h
Driver Power: 15 kW
1.2.2 Firewater Characteristics
The make-up water to the firewater Storage Tanks is supplied from potable water distribution system or
by water tankers.
1.3 BATTERY LIMIT CONDITIONS
The fire water system shall be designed to meet the design fire water demand as calculated by
assuming one major fire in the plant.
Fire water demand shall be calculated by summing the following:
a) Either of the following, whichever is larger:
(a.1) the largest fixed fire suppression system demand.
(a.2) any fixed fire suppression system demands that could reasonably be expected to operate
simultaneously during a single event.
b) Water demand for two (2) hose streams (60 m3/h per hose stream).
Based on the above figures, the design fire water demand is set at 300 m3/h as resulted in
Fire Scenario 1:
Description Water Demand
(a.1) Spray System for the protection of the Gas

180 m3/h
Turbine Auxiliary Block Area
(a.2) Not Applicable n.a.
(b) Two (2) Hose Streams 120 m3/h

Total Water Demand 300 m3/h
1.4 EFFLUENTS
There are no effluents from Unit 50.
There may be periodic draining of pump casing and piping to grade. This water will be allowed to soak
away, since there is no open drain provided on the unit.
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1.5 MATERIAL BALANCE
Reference documents:
50-ZA-E-85580 Fire Water Network Calculation Report.
50-ZA-E-85585 Water Spray System Calculation Report.
1.6 UTILITIES REQUIREMENTS
The utilities required by the Unit 50 are instrument air and electric power.
1.7 CHEMICALS
1.7.1 Firewater Biocide
The firewater tanks will periodically be manually shock dosed with a biocide to inhibit the growth of any
algae which may cause blockages and affect the operation of the firewater system.
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2 PROCESS DESCRIPTION
2.1 REFERENCES
The basic engineering documents related to the design of the Fire Protection Systems, Unit-50, are
listed hereafter:
- 50-ZA-E-85580 Fire Water Network Calculation Report.
- 50-ZA-E-85585 Water Spray System Calculation Report.
- 50-MA-E-85590 Fire Water Storage Tank 50-T-001 Data Sheet.
- 50-MA-E-85595 Fire Water Jockey Pumps 50-P-003 A/B Data Sheet.
- 50-MA-E-85600 Fire Water Main/Stand-by Pumps 50-P-001/002 Data Sheet
- 50-MA-E-85605 Level Valve Data Sheet.
- 50-MA-E-85610 Instrumentation Data Sheet.
- 50-ZA-E-85615 Fire Fighting Equipment Supply Specification.
- 50-GD-B-85660 Fire Water Storage and Main Pumps P&ID.
- 50-GD-B-85661 Fire Water Jockey Pumps P&ID.
- 50-GD-B-85665 Fire Water Pumps Controller and Remote Signalizations P&ID.
- 50-GD-B-85670 Fire Water Network Distribution P&ID.
- 50-GD-B-85675 Fire Fighting Equipment Installation Details P&ID.
- 50-GD-B-85680 Deluge Valves Installation Detail P&ID.
- 50-GD-B-85685 Water Spray System Distribution P&ID.
- 50-GD-B-85700 Fire Fighting Protection System Plot Plan.
These documents are enclosed in Chapter 10 of this manual.

It is recommended that the relevant P&ID’s to be studied in conjunction with this chapter.
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2.2 DETAILED PROCESS DESCRIPTION
2.2.1 Firewater System
Fire water is stored in a new dedicated above ground carbon steel tank 50-T-001 having 600 cubic
meters capacity to allow for two (2) hours continuous operation at design fire water demand.
The fire water tank is connected to service/potable water system located on site and is equipped with
local and remote level control for automatic make-up with service/potable water. In addition to the
above, a dedicated line is provided to guarantee the fire water storage tank refilling by road tanker.
50-T-001 operates with the water level being controlled by level controller 50-LIC-050, which maintains
the level in the tank at 7900 mm. Local level indication is also provided. 50-LAL-052 and 50-LALL-051
are also provided, with a set point of 4500 mm/ 2800mm to maintain the minimum necessary firewater
stock and to avoid firewater tank to be empty and damage the pumps.
The design fire water demand shall be supplied by electric motor driven pump which is the primary fire
water source; 100% stand-by shall be provided by diesel engine driven pump for redundancy.
All electric and diesel pumps have the same capacity set to 300 m3/h being this last the design fire
water demand.
In compliance with the above, the following shall be provided:
-No. one (1) – horizontal centrifugal pump 50-P-001 - electric motor driven – rated for 300 m3/h at 8
bar(g) discharge pressure serving as main fire pump unit. This pump can be operated either
automatically or manually, to this purpose it shall be provided with a dedicated local controller and shall
be powered by normal network.
-No. one (1) – horizontal centrifugal pump 50-P-002 - diesel engine driven – rated for 300 m3/h at 8
bar(g) discharge pressure serving as fire pump stand-by unit. This pump can be operated either
automatically or manually, to this purpose it shall be provided with a dedicated local controller. Diesel
engine shall be provided with a diesel oil fuel tank having a capacity calculated as per NFPA 20
requirements.
The fire water network will be maintained under pressure by means of suitable jockey pumps one of
them always running serving as main unit, the other serving as stand by unit and to be started on
request.
In compliance with the above, the following shall be provided:
-No. two (2) – horizontal centrifugal pumps 50-P-003 A/B - electric motor driven – each one rated for 15
m3/h at 8 bar g discharge pressure, one of them serving as jockey pumps main unit, the other serving
as jockey pump stand-by unit.
These pumps can be operated only manually; a double jockey pump controller is provided.
Jockey pump main unit will be powered by emergency power, the stand-by will be powered by normal
network.
Electric motor driven main and jockey pumps, controller and signals shall be generally in compliance
with NFPA 20 latest edition, but need not listed.
Diesel engine driven pump, fuel system, controller, and signals shall be generally in compliance with
NFPA 20 latest edition, but need not be listed.
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As per NFPA 20 all fire water pumps shall supply not less than 150 percent of rated capacity at not less
than 65 percent of total rated head and the total shut-off shall not exceed 140 percent of total rated
head. To avoid firewater pumps and jockey pumps overheating in case of no or low flow operation, each
pump shall be fitted with minimum recirculation valve 3/4”.
The system provides for the following starting of both main and jockey pumps.
Electric motor driven main pump can be started as follows:
· Automatically upon low pressure in the fire water network;
· Manually locally at the pump controllers by start push button;
· Manually remotely from control room by push button.
· Electric motor driven main pump can be stopped manually only at pumps controller by push button.
Diesel engine driven stand-by pump can be started as follows:
· Diesel engine driven stand-by pump can be stopped manually only at pumps controller by push button
Electric motor driven Jockey pumps can be started as follows:
· Manually in CR from the OS.
· Jockey pumps can be stopped manually only at pumps controller by push button.
The jockey pumps 50-P-003A/B maintains the firewater main ring pressure at 8 bar g while there is no
firewater demand. When the firewater demand exceeds the capacity of the Jockey Pump, the main ring
pressure will fall and, when it reaches 6 bar g, a sequential start of the firewater pumps is initiated. Refer
to section 3.2 for more detail.
Dedicated deluge systems have been provided to protect the following items of equipment:
· Step-up transformer 10-TRM
· Auxiliary transformer 10-TRU
· Common services transformer 00-TRS
2.2.2 Other Fire Fighting Facilities
In addition to the dedicated firefighting facilities, hydrants, and monitors have been provided around the
periphery of the process and utility units and at strategic locations within the units.
Carbon Dioxide (CO2) Extinguishing System
A total flooding, gaseous, carbon dioxide fire suppression system shall be provided to protect the
following rotating equipment:
· Gas turbine (thermal block / enclosures and exhaust end bearing tunnel).
· Emergency diesel generator (acoustic protective enclosures).
Carbon dioxide extinguishing system shall be automatically activated by means of fire detection and
shall be designed and installed in compliance with NFPA 12 requirements
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Clean Agent Extinguishing System

A total flooding, gaseous, clean agent fire suppression system shall be provided to protect the following
room / spaces within each prefabricated buildings:
 Control Room false floor
 Instrumentation Room false floor
 Switch Gear / Battery Room false floor.
Clean agent extinguishing system shall be automatically activated by means of fire
detection and shall be designed and installed in compliance with NFPA 2001.
The type of gas to be used as clean agent shall be the FM-200 (HFC-277-ea).
Portable And Mobile Fire Extinguisher
Portable and mobile extinguisher units shall be provided in different areas of the power plant for
immediate use by operators upon fire occurrence.
2.2.3 Fire and Gas Detection Systems
Fire and Gas Detection Systems have been provided in open areas and within buildings in accordance
with the "Fire and gas detection design criteria”.
doc. 00-ZA-E-85010 will be annexed at cap.9.
2.3 ELEMENTS OF PROCESS CONTROL PHILOSOPHY
2.3.1 General
50-T-001 operate with the water level being controlled by level controller 50-LIC-050, which maintains
the levels in the tank at 7900 mm. Local level indication is also provided. 50-LAL-052 and 50-LALL-051
are also provided, with a set point of 4500 mm/ 2800mm to maintain the minimum necessary firewater
stock and to avoid firewater tank to be empty and damage the pumps. Each firewater/ jockey pump is
provided with a dedicated minimum flow valve and spillback line.
2.3.2 Firewater main ring pressure control
In normal operation status (fire water flow less than 15 m3/h - one jockey pump capacity) the fire water
network is maintained under pressure at a required target value by one jockey pump 50-P-003 A or 50-
P-003 B. In emergency operations status (fire water flow in excess to 15 m3/h, one jockey pump
capacity), the pressure in the system will decrease and when will drop down to 6 bar the pressure
transmitters PT-050 and PT-051 will automatically activate the starting sequence which provide for:
· To start immediately the electric motor driven main pump 50-P-001.
· To start the stand-by diesel engine driven fire water pump 50-P-002 if fire water pressure does not reach
8 bar in 20 seconds after main electric motor driven fire water pump 50-P-001 starts (pump failure).
The failure of the main pump to start will not prevent subsequent starting of the stand-by pump.
Suitable manual selector HS-050 located in control room allow the selection of the stand-by pump 50-P-
002 as first pump to start in the case of main pump 50-P-001 is out of service.
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3 COMMISSIONING/ INITIAL START UP
3.1 GENERAL
Prior to initial startup, all pre-commissioning activities must have been completed and the unit must be
ready for operation.
Pre-commissioning covers those activities required to bring the unit to a "ready for startup" condition
following construction. In general, it consists of inspection, checking and testing operations required to
ensure that all components of the unit are properly installed and mechanically complete. The most
important requirement is that the unit can be started up in a controlled, efficient and safe manner.
This pre-commissioning phase is usually performed by the construction forces in close co-ordination
with the operations/commissioning team.
For this purpose, checking sheets (or "mechanical guides") will be issued and filled out on site in close
co-operation between construction and the commissioning team.
Full details of pre-commissioning activities with regard to inspection of equipment items, general checks,
hydrostatic testing, instrumentation functional testing, electrical motor run-in, line and vessel cleaning,
etc., are outside the scope of this document.
Details of the initial startup and commissioning of the Fire Protection Systems are detailed in this
chapter. Operating parameters and adjustments, shutdown and emergency situations are detailed in
Chapters 5 to 7.
The information and procedures described hereafter concern the preliminary operations for the first
startup of a new unit. Procedures are slightly adapted for normal and subsequent start up, as indicated
in Chapter 4.
3.2 PREPARATION PRIOR TO INITIAL OPERATION
It is assumed that all the pre-commissioning/maintenance activities are completed and that the unit has
reached a "ready for startup" status.
Most of the following pre-start up items are routine and are briefly presented as reminders only, as they
refer to pre-commissioning activities.
Ensure that the following requirements are satisfied:
¨ All safety equipment is in place and is fully operable.
¨ All pipe work has been pressure tested and cleaned.
¨ All equipment has been pressure tested, inspected, cleaned, drained and dried.
¨ All equipment is at ambient conditions and full of air (except where otherwise specified).
¨ Chemicals, if required, are available.
¨ Test equipment and special tools, if any, and facilities for their operation are available.
¨ All rotating equipment and their associated drivers have been aligned, run in and lubricated, as required,
following the manufacturers' recommended procedures.
¨ Temporary strainers must be installed where specified and their locations properly recorded for future
reference.
¨ Instrument air is available and commissioned to all instruments. (Refer to section 2.1).
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¨ Electrical power systems have been checked out and commissioned. It is available to all electric drivers
and all instrument boards.
¨ All instruments have been calibrated, loops checked and commissioned. All sensing elements which
were removed from pipe work prior to hydro testing have been reinstalled.
¨ All the CS data links are operational.
¨ Emergency shutdown systems are fully operational and if possible, a dry run has been performed.
¨ All safety relief valves have been tested and are in service. All block valves around relief valves are
locked in the correct position.
¨ All blinds, if any, which were installed in the lines during hydro testing have been removed and replaced
with their relevant spacers.
¨ All utilities have been commissioned, lined up and are ready for use at the unit battery limit.
It is the prime responsibility of those in charge of the plant to ensure that all operations are carried out
satisfactorily.
3.2.1 Preparation of Utilities
3.2.1.1 Instrument Air
This section details the necessary steps to ensure the proper commissioning of the instrument air
system.
The instrument air supply to Unit 50 is provided from the existing distribution system. Instrument air is
used as the motive gas to operate control valves.
It is assumed that the instrument air system is pressurized with dry instrument air up to the Unit 50
battery limit. It is also assumed that all pre-commissioning activities have been carried out, and that the
instrument air system for Unit 50 is under a slight positive pressure of dry air.
The instrument air system will be commissioned in the following way:
· Ensure Unit 50 battery limit valve is closed.
· Close all instrument air regulator valves.
· Open the Unit 50 battery limit valve and pressurize the instrument air header to normal instrument air
pressure.
· Open the air regulator valves to supply air to the control valves.
The instrument air to Unit 50 is now commissioned.
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3.3 FIREWATER TANK AND PUMPS STARTUP
3.3.1 Valve Positions Prior to Start Up

All valves should be in this position as shown on P&ID 50-GD-B-85660 / P&ID 50-GD-B-85661
Valve
Location Line Position
No.
50-V-01 50-T-001 Inlet Isolation Valve. 3”-50-PW-022 Closed
50-V-02 50-T-001 Inlet Isolation Valve. 3”-50-PW-022 Closed
50-V-03 50-T-001 By pass LV- 050 3”-50-PW-022 Closed
50-V-04 50-T-001 Provision for water filling from tanker 4”-50-FW-001 Closed
50-V-05 50-T-001 Open Drain 4”-50-FW-002 Closed
50-V-06 50-T-001 From minimum flow recycle 8”-50-FW-025 Open
50-V-07 50-T-001 Impulse line LT 052 Open
50-V-08 50-T-001 Impulse line LT 051 Open
50-V-09 50-T-001 Firewater Tank Outlet Isolation Valve. 10”-50-FW-004 Closed
50-V-18 50-T-001 Test line 8”-50-FW-025 Open
50-V-10 50-P-001 Suction Line Isolation Valve. 10”-50-FW-015 Closed
50-V-11 50-P-002 Suction Line Isolation Valve. 10”-50-FW-016 Closed
50-V-19 50-P-003A Suction Line Isolation Valve. 3”-50-FW-005 Closed
50-V-20 50-P-003B Suction Line Isolation Valve. 3”-50-FW-006 Closed
50-V-14 50-P-001 Pump Test Line Isolation Valve. 8”-50-FW-019 Closed
50-V-15 50-P-002 Pump Test Line Isolation Valve. 8”-50-FW-020 Closed
50-V-12 50-P-001 Pump Firewater Main ring Isolation Valve. 8”-50-FW-017 Closed
50-V-13 50-P-002 Pump Firewater Main ring Isolation Valve. 8”-50-FW-018 Closed
50-V-21 50-P-003A Pump Firewater Main ring Isolation Valve. 2”-50-FW-007 Closed
50-V-22 50-P-003B Pump Firewater Main ring Isolation Valve. 2”-50-FW-008 Closed
50-V-16 50-P-001 Minimum recycle flow 2”-50-FW-021 Closed
50-V-17 50-P-002 Minimum recycle flow 2”-50-FW-022 Closed
50-V-23 50-P-003A Minimum recycle flow 2”-50-FW-009 Closed
50-V-24 50-P-003B Minimum recycle flow 2”-50-FW-010 Closed
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3.3.2 Filling Firewater Storage Tank 50-T-001

Take in consideration that potable and service water system is running and lined up to firewater system.
Firewater tank is empty and perfectly clean inside and all the instrumentation in place.
Prior to the startup of the Firewater and Jockey Pumps 50-P-001/002/003A/003B, the firewater tank 50-
T-001 must be filled with water in the following manner:
· Open 50-V-01/ V-02, 50-T-001 inlet isolation valve, and car seal.
· 50-LIC-050 should be on MAN mode. Start open gradually up to fully open. Switch to AUTO mode and
set the level limit at 7900mm. The filling of 50-T-001 will take approximately 24 hours if the
potable/service water pumps 60-P-002A/B can be used at max. capacity of 25 m³/hr.
· Open 50-V-09, 50-T-001 Firewater Tank Outlet Isolation Valve and car seal.
· 50-T-001 is now full and ready to be used.
During this operation, check if LLL/ LL level indications are cleared and HH/ HHH level indications will
be activated and LV-050 will close in AUTO mode.
3.3.2.1 Dosing the Firewater with Biocide
The firewater in firewater tank must be dosed with Biocide to prevent the growth of algae.
3.3.3 Commissioning of Jockey Pumps 50-P-003A/B
· Open the flange and remove the “Y” type suction strainers.
Open 50-V-19 and 50-V-20 suction line isolation valves and flush the suction lines.
After visual inspection satisfactory, stop flushing, close back the isolation valves and reinstall the
strainers.
· Open 50-V-19 and 50-V-20 suction line isolation valves for 50-P-003A/B. This will allow the casing of the
pump to fill with water. Lock open the valves.
· Open fully 50-V-23 and 50-V-24, ¾”minimum recycles flow for 50-P-003A/B.
Pumps are ready to be commissioned.
· Ensure the power supply is available and press the green "START" pushbutton located on the local
pumps control panel. Observe the running of the pump, and when running smoothly leave the pump
running at full rate for 3 hours. Record the parameters.
· The pump can be stopped at the local panel by pushing the red "STOP/RESET" pushbutton located on
the local pump control panel.
With the test run complete and the pump stopped the system can be lined up for normal operation.
3.3.4 Commissioning of Firewater Pumps, 50-P-001/002
For the initial start up of the Firewater Pumps 50-P-001/002, the test line will be used. Before this can be
done, however, the minimum flow spillback line must be commissioned to ensure the pump is fully
protected against low flows.
The procedure for starting the pumps and commissioning the minimum flow spillback line is as follows:
· Open 50-V-10 and 50-V-11, suction line isolation valves for 50-P-001/ 002.
This will allow the casing of the pump to fill with water.
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· Open 1” vent valves upstream 50-V-12 and 50-V-13 and make sure the pumps are vented properly.
Close the vent valves.
· Open 50-V-18, 50-T-001 test line, and car seal.
· Open fully 50-V-16 and 50-V-17, minimum recycle flow for 50-P-001 and 50-P-002.
· Ensure the power supply is available and press the green "START" pushbutton located on the local
pump control panel of 50-P-001. Observe the running of the pump, and when running smoothly the test
line can be opened.
· Open gradually up to fully open 50-V-14 and 50-V-15, the pump test line isolation valves for 50-P-001/
002. Leave the pump running at full rate for 3 hours and record the parameters.
· After three hours of running at full rate the pump can be stopped at the local panel by
pushing the red "STOP/RESET" pushbutton located on the local pump control panel.
With the test run complete and the pump stopped the system can be lined up for normal operation:
· Close 50-V-14 and 50-V-15 the pump test line isolation valves for 50-P-001/ 002 and car seal.
3.3.5 Commissioning of Firewater Main Ring
· Restart 50-P-003A on minimum flow.
· Open gradually up to fully open 50-V-21 the jockey pump firewater main ring isolation valve. Lock open
the valve. Leave the pump running at full rate to allow the firewater main ring to be pressurized. Ensure
the main ring is properly vented by opening of hydrants and monitors.
· Restart 50-P-001 on minimum flow.
· Open gradually up to fully open 50-V-12 pump firewater main ring isolation valve. Lock open the valve.
· When firewater main ring is considered properly pressurized and vented the pomp can be stopped and
considered on stand-by.
· Check the automatic starting sequence by giving false signal to PT-050/051. After satisfactory
completion of the test, commissioning of main and jockey fire water pumps and firewater main ring is
completed.
3.4 FIREWATER DELUGE SKIDS
Consider that firewater Main ring is fully operational and lines upstream deluge skids are properly
flushed.
The Firewater Deluge Skids are specialized items of equipment and so all operators must be fully
familiar with the information contained in the Vendor I.O.M.M. before attempting any set up or
maintenance of the skids.
The vendor manual contains a comprehensive commissioning and testing schedule which should be
referred to and followed before lining up the firewater deluge skids, but which falls outside the scope of
this manual.
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3.4.1 Lining up the skid

All valves on the Firewater Deluge Skids should be in the positions shown below (refer to P&ID 50-GD-
B-85680):
Location / Service Position

Water Supply Isolation Valve Locked Open
Deluge Control Valve Closed
Deluge System Isolation Valve Locked Open
Water Supply Isolation Bypass Valve Closed
Water Supply Pressure Gauge Isolation Valve Open
Drain and Test Isolation Valve Locked Closed
PSH Block and Bleed Valve Open
PSH Gauge Block and Bleed Valve Open
PSL Isolation Block and Bleed Valve Open
PSH / Pressure Gauge Isolation Valve Open
Bypass PSH / Pressure Gauge Isolation Valve Open
3-Way Manual Release Valve Closed
Restriction Orifice Bypass Valve Closed
Pressure Gauge Block and Bleed Valve Open
Instrument Air Supply Isolation Valve Open
Air Reservoir Isolation Valve Open
Air Reservoir Drain Valve Closed
Deluge Valve Body Drain Valve Closed
With the valves in the above positions, the Firewater Deluge Skids are ready to be commissioned as
follows:
Ensure instrument air pressure is available to the skid.
Open the battery limit isolation valves in the primary and secondary firewater supply lines.
The Firewater Deluge Skids are now on-line.
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4 NORMAL AND SUBSEQUENT START-UP
4.1 GENERAL
The procedures and instructions laid out in this chapter are to be used to start up
Unit 50 following a shutdown. The shutdown may have been routine as part of normal operation,
turnaround or maintenance.
The recommended start-up procedure is presented in section 3.0.
The following start up procedures are recommended, with the understanding that the judgment of the
operators should dictate which of these steps are required, and in what order, based on the nature of
the preceding shutdown. The initial start-up instructions presented in Chapter 3 should be referred to for
specific details.
4.2 PRE-START UP CONDITIONS
Prior to restarting Unit 50 it is the prime responsibility of those in charge of operations to ensure that the
following criteria have been satisfied:
After a shutdown for turnaround and maintenance, start up orders have to be initiated after ensuring that
all requirements relating to plant acceptance and readiness for restart have been fulfilled. After an
unplanned shutdown the unit must be checked over to ensure that the unit is ready and safe to operate
and that the cause of the shutdown has been rectified.
The restart must be performed in accordance with all RSG-OCPP safety regulations and standing
instructions.
The following shall be assumed for the purpose of the start up procedures in this chapter:
All utility systems are commissioned and available as required to the units.
All instruments and control systems have been checked and are functional.
4.3 NORMAL AND SUBSEQUENT START-UP PROCEDURE
Unit 50 is designed such that it should never have to shut down. There are two firewater pumps, each
with 100% capacity, so that one can be isolated for maintenance while the other provides protection to
the plant. During shutdowns of other units, the Firewater supply must be maintained.
The following sections detail the normal start up of each of the items of equipment connected with Unit
50 after either maintenance or an incident requiring the activation of Unit 50.
4.3.1 Firewater Storage Tank 50-T-001
If 50-T-001 is shut down for maintenance and drained it must first be refilled before being brought back
on-line.
Maintenance on 50-T-001 should only be carried out during periods when all other units are shutdown
and Plant is ready for major overhaul. More information on the shut down and isolation of the Firewater
Storage Tank is contained in Chapter 6 of this manual.
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4.3.1.1 Lining Up 50-T-001 after Maintenance

Open 50-V-01/ V-02, 50-T-001 inlet isolation valve, and car seal.
50-LIC-050 should be on MAN mode. Start open gradually up to fully open. Switch to AUTO mode and
set the level limit at 7900mm.
The filling of 50-T-001 will take approximately 24 hours if the potable/service water pumps 60-P-002A/B
can be used at max. capacity of 25 m³/hr.
Open 50-V-09, 50-T-001 Firewater Tank Outlet Isolation Valve and car seal.
50-T-001 is now full and ready to be used.
4.3.2 Firewater Pump 50-P-001/002
Due to 2 X 100% capacity of the firewater pumps, preventive or routine maintenance can be done at
any time without affecting the plant security.
For major intervention it is recommended, but not essential, that any maintenance on any of the
firewater pumps should be carried out during the shutdowns of other units when the quantity of firewater
required to protect the plant is reduced.
4.3.2.1 Lining Up 50-P-001/002 after Maintenance
After maintenance 50-P-001/002 should be tested using the test line to ensure it is operating correctly
before leaving it on standby. The procedure for lining up and testing is outlined below:
Open 50-V-10 and 50-V-11, suction line isolation valves for 50-P-001/ 002.
This will allow the casing of the pump to fill with water.
Open 1” vent valves upstream 50-V-12 and 50-V-13 and make sure the pumps are vented properly.
Close the vent valves.
Open fully 50-V-16 and 50-V-17, minimum recycle flow for 50-P-001 and 50-P-002.
Ensure the power supply is available and press the green "START" pushbutton located on the local
pump control panel. Observe the running of the pump, and when running smoothly the test line can be
opened. Open gradually up to fully open 50-V-14/ 50-V-15, the pump test line isolation valves for 50-P-
001/ 002.
Leave the pump running at full rate and check the performance.
The pump can be stopped at the local panel.
Close 50-V-14 and 50-V-15, the Pump Test Line Isolation Valves for 50-P-001/ 002 and car seal.
Open fully 50-V-12 and 50-V-13 pumps firewater main ring isolation valves.
Lock open the valves.
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4.3.3 Jockey Firewater Pump 50-P-003A/B

Due to 2 X 100% capacity of the pumps, maintenance can be done at any time without affecting the
plant security.
4.3.3.1 Lining Up 50-P-003A/B After Maintenance
Open 50-V-19 and 50-V-20, suction line isolation valves for 50-P-003A/B.
This will allow the casing of the pump to fill with water. Lock open the valves.
Open fully 50-V-23/ 50-V-24, ¾”minimum recycles flow for 50-P-003A/B.
Open 50-V-21/ 50-V-22 the jockey pumps firewater main ring isolation valves.
Lock open the valves.
Ensure the power supply is available and press the green "START" pushbutton located on the local
pumps control panel. Observe the running of the pump.
The pump can be stopped at the local panel
4.3.4 Firewater Deluge Skids
After an incident involving the activation of one or more of the Firewater Deluge Skids, the skids
involved will have been isolated at their battery limits. The procedure for bringing the affected skids back
on-line is as follows:
Ensure any Pneumatic Heat Detectors which have operated have been replaced with new ones of the
same type and temperature rating.
All valves on the Firewater Deluge Skid should be in the positions shown below (refer to P&ID
50-GD-B-85680):
Location / Service Position
Water Supply Isolation Valve Locked Open
Deluge Control Valve Closed
Deluge System Isolation Valve Locked Open
Water Supply Isolation Bypass Valve Closed
Water Supply Pressure Gauge Isolation Valve Open
Drain and Test Isolation Valve Locked Closed
PSH Block and Bleed Valve Open
PSH Gauge Block and Bleed Valve Open
PSL Isolation Block and Bleed Valve Open
PSH / Pressure Gauge Isolation Valve Open
Bypass PSH / Pressure Gauge Isolation Valve Open
3-Way Manual Release Valve Closed
Restriction Orifice Bypass Valve Closed
Pressure Gauge Block and Bleed Valve Open
Instrument Air Supply Isolation Valve Open
Air Reservoir Isolation Valve Open
Air Reservoir Drain Valve Closed
Deluge Valve Body Drain Valve Closed
Ensure instrument air pressure is available to the skid.
Open the battery limit isolation valves in the primary and secondary firewater supply lines.
The Firewater Deluge Skid is now lined up.
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032083 00

4.4 CONTROLLER SET POINTS, ALARMS AND TRIP SETTINGS
The following tables contain the current controller set points, alarm set points and trip settings for the
instrumentation on Unit 50. The tables contain information for the instrumentation shown on P&IDs only.
4.4.1 UNIT 50 CONTROLLER SET POINTS AND ALARMS
4.4.1.1 Controllers and Alarms

Controller/Alarm Controller Transmitter Function P.&I.D
Tag No. Set Point
Deluge Skid PSH 2 bar Detects rise in water pressure in the deluge systems. 85680
50-PSL-050 6 bar Monitors firewater main ring pressure.
85660
50-PSL-051
50-PSH-050 8 bar Monitors firewater main ring pressure.
85660
50-PSH-051
50-LT-050 Monitors liquid level in 50-T-001.
LAH 7900 mm
LAHH 8000 mm 85660
LALL 4500 mm
LALLL 2800 mm
50-FI-150 N/A Firewater pump test 85660
4.4.2 UNIT 50 TRIP SETTINGS
4.4.2.1 Flow Trips
There are no flow trips on Unit 50.
4.4.2.2 Level Trips
4.4.2.3 Pressure Trips
There are no pressure trips on Unit 50.
4.4.2.4 Temperature Trips
There are no temperature trips on Unit 50.
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5 NORMAL OPERATION
5.1 OPERATING VARIABLES
During the everyday running of the plant, Unit 50 will only "operate" if there is a fire somewhere on the
plant.
5.1.1 Control Philosophy
The function of the Fire Protection System is to meet the firewater requirements of the process and
utility units.
Unit 50 is controlled remotely from the control room or locally using local start/stop panels.
5.1.1.1 Firewater Tank, 50-T-001

Fire water is stored in a new dedicated above ground carbon steel tank 50-T-001 having 600 cubic
meters capacity to allow for two (2) hours continuous operation at design fire water demand.
The fire water tank is connected to service/potable water system located on site and is
equipped with local and remote level control for automatic make-up with service/potable water.
In addition to the above, a dedicated line is provided to guarantee the fire water storage tank refilling by
road tanker.
50-T-001 operate with the water level being controlled by level controller 50-LIC-050, which maintains
the levels in the tank at 7900 mm.
Should the controller either set in “BAD” by the logic or the related transmitter overridden by the suitable
MOS, then the controller will be set in manual, the valve LV-50 will be closed and the set point must not
be set in PV tracking.
Local level indication is also provided. 50-LAL-052 and 50-LALL-051 are also provided, with a set point
of 4500 mm/ 2800mm to maintain the minimum necessary firewater stock and to avoid firewater tank to
be empty and damage the pumps.
5.1.1.2 Firewater Pumps 50-P-001/002

Jockey Pumps 50-P-003A/B
The system provides for the following starting of both main and jockey pumps.
Electric motor driven main pump can be started as follows:
Electric motor driven main pump can be stopped manually only at pumps controller by push button.
Diesel engine driven stand-by pump can be started as follows:
Diesel engine driven stand-by pump can be stopped manually only at pumps controller by push button
Electric motor driven Jockey pumps can be started as follows:
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032083 00

· Manually in CR from the OS.

Jockey pumps can be stopped manually only at pumps controller by push button. In normal operation
status (fire water flow less than 15 m3/h - one jockey pump capacity) the fire water network is
maintained under pressure at a required target values by one jockey pump 50-P-003 A or 50-P-003 B.
In emergency operations status (fire water flow in excess to 15 m3/h, one jockey pump capacity), the
pressure in the system will decrease and when will drop down to 6 bar(g) the pressure transmitters
PT-050 and PT-051 will automatically activate the starting sequence which provide for:
· To start immediately the electric motor driven main pump 50-P-001.
· To start the stand-by diesel engine driven fire water pump 50-P-002 if fire water pressure does not reach
8 bar(g) in 20 seconds after main electric motor driven fire water pump 50-P-001 starts (pump failure).
The failure of the main pump to start will not prevent subsequent starting of the stand-by pump.
Suitable manual selector HS-050 located in control room allow the selection of the stand-by pump 50-P-
002 as first pump to start in the case of main pump 50-P-001 is out of service.
5.1.1.3 Firewater Deluge Skids
Dedicated deluge systems have been provided to protect the following items of equipment:
¨ Step-up transformer 10-TRM
¨ Auxiliary transformer 10-TRU
¨ Common services transformer 00-TRS
The Deluge Skids can be operated by any of the following means:
¨ Detection based on heat sensitive wire [2 loops (2002)].
This will automatically open the deluge valve by releasing the air pressure holding the valve closed, thus
supplying water to the individual deluge nozzles. The drop in the pressure of the air in the heat detector
loop will be picked up by the PSL on the skid, which will alarm in the main control room. The water
pressure downstream of the deluge nozzle should then rise, and when the pressure reaches 2 bar the
PSH will alarm in the main control room. This indicates that the deluge valve has opened, and that water
is flowing to the nozzles.
¨ Local manual actuation by operating the 3 way manual release valve mounted on the skid board.
This will have the effect of venting the air from the heat detector loop, and so opening the deluge valve.
¨ Opening the water supply by-pass isolation valve to admit water into the system downstream of the
deluge valve.
5.2 SPECIFIC OPERATIONS
5.2.1.1 Biocide Dosing of Firewater Storage Tank 50-T-001

The firewater in 50-T-001 must be dosed with Biocide to prevent the growth of algae. The procedure for
the dosing of the firewater is laid out in the operating manual for the existing Unit 50 equipment.
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032083 00

5.3 PERFORMANCE MONITORING
5.3.1 Firewater Pump 50-P-001

Under normal operation the Firewater Pumps will be on permanent standby. To ensure reliable
operation of the pump, a full bore test line is provided to allow periodic testing of the pump and the logic.
The pump should be tested once per month, and should be left running for a minimum of three hours.
The procedure for starting testing the firewater pump is as follows:
· Remove 50-P-001 from the pump start sequence logic, leaving 50-P-002 as the primary firewater pump.
· Close 50-V-12 the firewater main ring isolation valve.
· Ensure 50-V-16 minimum recycle flow valve is open.
Ensure 50-V-18 test line valve is open.
Ensure 50-V-14 pump test line isolation valve is closed.
· Start 50-P-001 using the green "START" pushbutton located on the local pump control panel.
The pump will now operate under minimum flow conditions.
With the pump running satisfactorily, the full bore test line can now be opened:
· Crack open 50-V-14 pump test line isolation valve.
With a flow being registered by 50-FI-150 the flow through the test line can be increased:
· Slowly open 50-V-14 until the flow through the full bore test line, as indicated by
50-FI-150 reaches 300 m³/hr.
Leave the pump running at this flow for three hours. after three hours the pump can be stopped:
· Stop 50-P-001 using the red "STOP" pushbutton located on the local pump control panel.
· Close 50-V-14 pump test line isolation valve and car seal.
· Open 50-V-12 the firewater main ring isolation valve and car seal.
The logic in the firewater pump control panel must now be reset, with 50-P-001 as the primary pump
and 50-P-002 as the secondary pump.
Note: Records of the flow and pressure indications should be kept during the test for future reference, to
ensure constant operation during each test.
5.3.2 Jockey Pumps 50-P-003 A/B
The two Jockey Pumps have been designed so that one will be running, with the other on standby.
Operators should endeavor to equalize the pump running times by logging the running times for each
pump. Pump changeovers should not be used purely for maintenance purposes, but also to avoid
leaving one pump standing for any great length of time as this may result in damage to bearings and
other parts of the pump.
The procedures for taking one pump off-line and bringing the other on-line are outlined in Chapters 6
and 4 of this manual respectively.
5.4 CORROSION CONTROL AND MONITORING
No corrosion is expected within the unit.

The Firewater Tank 50-T-001 and all associated pipework are provided with an appropriate corrosion
allowance, and should be periodically shock dosed with biocide to kill off any bacteria in the water.
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6 NORMAL SHUTDOWN
6.1 GENERAL
A normal shutdown is either a scheduled shutdown or one that is carried out in an orderly manner for
reasons other than emergencies or process trips. The extent of the work to be carried out during the
shutdown will dictate whether a full shutdown of all equipment is necessary.
The actions to be taken prior to a shutdown are dependent upon which equipment items are being taken
out of service and the expected duration of the shutdown.
During a shutdown all equipment must be properly isolated.
A normal shutdown is a scheduled operation and therefore should be carried out in coordination with all
other units, especially as firewater is vital to the safety and operation of the rest of the plant.
While shutdown procedures are being carried out it is the prime responsibility of those in charge of
operations to ensure that all requirements of RSG-OCPP safety regulations and standing operating
procedures are adhered to.
The instructions in this chapter form a basis for developing detailed step-by-step "standing operating
procedures" for the shutdown of Unit 50.
6.2 UNIT 50 SHUTDOWN
Unit 50 is designed such that it should never have to shut down. Firewater tank can be isolated and
maintenance/cleaning carried out on it only when the rest of the plant is shutdown.
There are two firewater pumps, each with 100% capacity, so that one can be isolated for maintenance
while the other provides protection to the plant.
During shutdowns of other units, the firewater supply must be maintained so that all fire hydrants,
monitors and hose reels are fully operational.
The shutdown of equipment following a fire is outlined in section 2.2 of this chapter.
If a complete shutdown of Unit 50 is required, it should be carried out by systematically shutting down
and isolating the individual items that form Unit 50.
The shutdown and isolation of individual items of equipment is outlined in section 2.1 of this chapter.
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6.2.1 Item Shutdown and Isolation

6.2.1.1 Firewater Tank, 50-T-001
Two separate procedures are outlined below; one for isolating the tank and one for isolating and
draining the tank.
6.2.1.1.1 Isolating 50-T-001
Consider the firewater and jockey pumps are stopped and de energized.
The isolation of 50-T-001should be achieved in the following manner:
· Close the following isolation valves:
· 50-V-01/02, 50-T-001 inlet.
· 50-V-09, 50-T-001 firewater outlet.
· 50-V-06, 50-T-001 minimum flow spillback line inlet.
The tank is now isolated.
6.2.1.1.2 Draining 50-T-001
Note: 50-T-001 should only be emptied during plant shutdowns, when the requirement for firewater
protection is substantially/completely reduced. The decision to empty 50-T-001 should be taken well in
advance of the plant shutdown since the emptying of the tank will take time and will place an additional
load on the drainage and water treatment system.
The preparation for the emptying of 50-T-001 should be carried out in the following manner:
Isolate 50-V-01/02, the 50-T-001 inlet.
Consider that firewater pumps are stopped and de energized.
Start 50-P-003A manually from the local pane. Or can be started also from CR.
Pump will now operate under minimum flow conditions whilst also pressurizing the firewater main ring.
Connect a fire hose to a fire hydrant and run the fire hose into the storm water channel.
Start opening and adjust the hydrant valve in order to maintain a good functionability of the jockey
pump. Check constantly the vibrations and amperage of the pump.
The system can now be left to empty 50-T-001
When the level in firewater tank reaches its LLL level as indicated by
50-LALLL-51 in the DCS, 50-P-003A can be stopped and the hydrant valve closed.
De energizes the jockey pumps 50-P-003A/B.
Close 50-V-09, the 50-T-001 firewater outlet isolation valve.
Open the 4" drain valve 50-V-05 to drain the remaining water from the tank.
Start spading the firewater tank.
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6.2.1.2 Firewater Pump 50-P-001/002

The procedures for stopping and isolating the Firewater Pump 50-P-001/002 are outlined in sections
2.1.2.1 and 2.1.2.2 respectively.
6.2.1.2.1 Stopping 50-P-001/002
When it is clear that all firefighting activities have ceased and all danger has passed, the firewater pump
50-P-001/002 can be stopped in the following manner:
Stop the pump using the "STOP/RESET" pushbutton located on the local pump control panel.
This will leave the pump on standby.
6.2.1.2.2 Isolating 50-P-001
If the pump requires to be taken out of service for maintenance the firewater pump start logic in the
firewater pump control panel must first be set up so that 50-P-002 is the primary pump with 50-P-001 as
the secondary. The pump can then be isolated in the following manner (P&ID 50-GD-B-85660):
Close the following valves:
50-V-10, the 50-P-001 suction line isolation valve.
50-V-16, the 50-P-001 minimum recycle valve.
50-V-12, firewater main ring isolation valve.
Ensure 50-V-14, test line isolation valve is closed.
If maintenance on the pump is to be carried out, the pump control panel should be de-energized.
6.2.1.3 Jockey Pumps, 50-P-003 A/B
The procedure for shutting down the jockey pump is as follows (P&ID 50-GD-B-85661):
Note: It is assumed that 50-P-003 B is running and 50-P-003 A is on standby.
Isolate the pump by closing the following valves:
50-V-19, 50-P-003 A suction line isolation valve.
50-V-23, 50-P-003 A minimum recycle valve.
50-V-21, 50-P-003 A firewater main ring isolation valve.
50-P-003 A has now been shut down and isolated.
If maintenance on the pump is to be carried out, the pump control panel should be de-energized.
6.2.1.4 Firewater Deluge Skids
The Firewater Deluge Skids can be shutdown in one of the following ways, depending on how the skid
was activated:
· After an automatic activation, close the water supply isolation valve.
· After a manual activation of the 3-way manual release valve, close this valve, thus restoring the
instrument air pressure to the actuator and closing the deluge control valve.
· After a manual activation of the water supply by-pass isolation valve, close this valve.
· After either an automatic or a manual activation close the water supply battery limit isolation valve, thus
cutting off the flow of water to the skid, and isolating it.
Total isolation of the skid can only be achieved by closing the battery limit isolation valve.
After operation, the skid should be flushed using the procedure taken from the BERMAD vendor
manual.
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6.2.2 Unit Shut down After a Fire

When it is clear that all firefighting activities have ceased and all danger has passed, the activated fire
protection equipment can be shutdown in the following order, using the procedures described in section
2.1 of this chapter:
· Ensure all fire hydrants, monitors, hose reels etc. are turned off.
· Stop the firewater pumps (see section 2.1.2.1), but do not isolate.
· Shutdown any activated firewater deluge skids (see section 2.1.4).
All activated firefighting equipment has now been shutdown.
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7 EMERGENCY SHUTDOWN
7.1 GENERAL
This chapter describes the philosophy and implementation of the safeguarding systems installed on
Unit-50.
In the following sections consideration is given to a range of emergency scenarios.
7.1.1 Safety Interlock System Philosophy
There is no ESD system for Unit 73.
7.2 UTILITIES FAILURE
The following procedure provides the basis for the operation of Unit 50 after the failure of utility systems.
7.2.1 Electrical Power Failure - Machinery and Control System
With regard to the power supply to machinery the following measures have been incorporated into the
power system design in order to mitigate potential problems associated with partial power failure:
One of the firewater pumps, 50-P-001, has an electric motor driver, the other
50-P-002 is driven by a diesel engine.
Jockey pumps 50-P-003A/B are fed from emergency diesel generator.
7.2.2 Instrument Air
The firewater system contain only one air actuated control valve LV-050 and the action is fail close.
Firewater supply to the hydrants, monitors, hose reels and deluge will be maintained and will continue to
operate as normal.
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8 SAFETY
8.1 GENERAL
This chapter contains information on the safety systems installed on Unit 50 for protection from plant
fires and gas leaks.
Also discussed is the nature of the hydrocarbon materials handled by other units on the plant, and
safety precautions.
Unit 50 is an inherently safe unit. It is however part of a plant which handles hazardous materials, and
so sections of this chapter may not be specifically applicable to Unit 50, but are provided to give an
overall safety view of the units nearby and the rest of the plant.
8.1.1 Operator Training
Almost all hydrocarbons and chemicals can be dangerous if not properly handled. Therefore, the
operators should be thoroughly acquainted with the hazardous properties of all materials in use and
should be properly drilled in the correct procedures for handling these materials.
All operators should familiarize themselves with the location and use of fire fighting equipment:
hydrants, hose reels, extinguishers, and of safety equipment: safety showers, eye baths, breathing
apparatus and all other safety equipment installed on the units.
In addition the operators should be thoroughly familiar with basic first aid measures and should be able
to take appropriate action in case of an incident.
Periodic practice drills, and more specifically fire fighting drills should be carried out in order to instruct
the operators in the hazards involved and the proper emergency action required so as ensuring the
maximum protection both for personnel and equipment.
8.1.2 Fire and Explosion Hazards
Unit 50 does not handle hydrocarbons and as such does not pose a serious fire and explosion threat.
There are, however, hydrocarbon processing units nearby which do pose a serious threat and so
information on the fire and explosion hazards are contained in this section for reference.
8.1.2.1 General
All hydrocarbons involve a fire and explosion hazard. The most hazardous liquid petroleum products are
those having a flash point below 55°C: crude oil, condensate, etc. Light hydrocarbon liquids at ambient
conditions can produce vapors which are heavier than air and form an explosive mixture with air.
Therefore special attention should be given to any operation where that risk occurs such as draining or
venting pump casings or vessels, and during sampling operations.
Any leak must be repaired as soon as possible and preventative measures taken immediately (water
spray, steam or nitrogen hoses, sand on liquid pools, etc.).
In addition to the fire and explosion hazards, the operators must also be thoroughly acquainted with the
hazard of Nitrogen that is very dangerous since it is an asphyxiate. However, nitrogen is often
overlooked as a hazardous substance since it is the main constituent of air. For this reason the dangers
of nitrogen must be emphasized and the operators instructed in the procedures and precautions to be
taken before entering a vessel previously inserted.
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8.2 LISTING OF SAFETY EQUIPMENT
8.2.1 General
Unit 50 is provided with a limited range of fire fighting equipment which is designed to be used to deal
with unit fire incidents only. Refer to section 2.2, below.
Before attempting to tackle a unit fire, of any magnitude, the operators must be aware of the nature of
the fire. It is essential that they are familiar with the capabilities and limitations of any particular piece of
fire fighting equipment (e.g. water must not be used on an electrical fire; burning liquid spills should be
tackled with foam, not water).
The first action to be performed on discovery of a unit or a plant fire, (regardless of size), is to raise the
alarm. In this way adequate support in the form of trained fire fighting personnel and mobile fire fighting
equipment will be rapidly mobilized to assist in dealing with the fire. Then, should the incident escalate,
personnel and equipment are already on the scene and prepared.
Operating personnel shall not endanger themselves while attempting to deal with a fire. While small
scale fires can be tackled with hand held extinguishers or steam lances, major fires should be dealt with
from a distance using deluge systems, firewater monitors and fire hoses.
The operators should familiarize themselves with the location and the details of operation of all fire
fighting equipment.
It is the responsibility of the safety officer to periodically check the fire fighting and safety equipment to
ensure that all systems are in full working order. Any items which are noted as being faulty, non-
functional or missing should be immediately reported to the safety officer.
8.2.2 Fire Fighting Equipment
The existing fire hydrant and additional portable dry chemical powder fire extinguishers located close to
the pumps are considered adequate to combat any possible fires.
8.3 FIRE AND GAS DETECTION
Fire and Gas Detection Systems shall include the following inputs:
• smoke and heat addressable point-type detectors (inside shelters)
• flame detectors (in plant areas);
• MCPs activation;
• field thermo-sensitive cables in pair;
• hydrocarbon (CH4) gas detectors;
and outputs
• HVAC systems shut-down;
• audible and visual alarm devices (inside/outside shelters and in plant areas);
• clean agent (FM200) discharge system activation (if applicable);
• active firefighting systems activation in plant areas;
The process plant Fire and Gas Detection System shall be provided with sufficient and
reliable detectors to ensure personnel warning and allow immediate response to minimize damage from
any emergency situation.
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9 EQUIPMENT LISTS AND DATA SHEETS
9.1 DATASHEETS
9.1.1 Main Equipment Datasheets

9.1.1.1 Firewater Storage Tank Datasheets
This section includes the following datasheets:
Firewater Storage Tanks 50-T-001 50-MA-E-98240
9.1.1.2 Firewater and Jockey Pump Datasheets
This section includes the following datasheets:
Firewater Pump, 50-P-001 50-MA-E-98230
Firewater Pump, 50-P-002 50-MA-E-98233
Jockey Pumps, 50-P-003 A/B 50-MA-E-98240
9.1.2 Instrument Datasheets
Refer to document 50-MA-E-85610
9.2 SAFETY CONCEPT DOCUMENT
Enclosed in this section is the following document:

Loss Prevention and Environmental Philosophy 50-ZA-E-85005
9.3 FIRE AND GAS DETECTION SYSTEM SPECIFICATION
Enclosed in this section is the following document:

Fire and Gas Detection Design Criteria 50-ZA-E-85010
FINAL DATA BOOK
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10 DRAWINGS
10.1 PIPING AND INSTRUMENTATION DIAGRAMS
10.1.1 UNIT 50
Enclosed in this section are the following P&IDs:
50-T-001 AND 50-P-001/002 50-GD-B-85660
50-P-003A/B 50-GD-B-85661
10.1.2 BERMAD Deluge Skid Package
Refer to P&ID 50-GD-B-85680
10.2 PLOT PLAN
Enclosed in this section is the following Plot Plan:

FIREFIGHTING PROTECTION SYSTEM PLOT PLAN 50-GB-A-85700
10.3 FIRE AND SAFETY LAYOUT DRAWINGS
Enclosed in this section are the following Fire and Safety Layout Drawings:
INSTRUMENTS AND F&G EQUIPMENT LOCATION LAYOUT 00-SB-A-57504
10.4 OVERALL FIREWATER RINGMAIN DRAWINGS
Enclosed in this section are the following drawings:

FIREWATER NETWORK DISTRIBUTION 50-GD-B-85670
10.5 LOGIC DIAGRAM
Enclosed in this section is the following Logic Diagram:

CAUSE AND EFFECT MATRIX 50-HD-E-85575
10.6 VENDOR INFORMATION
Enclosed in this section are the operating instructions for the Firewater Pump.
AUDOLI E BERTOLA 50-MA-E-98240
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II UNIT 60 - SERVICE AND POTABLE WATER SYSTEM

1 DESIGN BASIS
1.1 GENERAL
1.1.1 Function Of The Service And Potable Water System

The function of Unit 60 is to provide clean/ sterile water and has been designed to meet the peak
demands of all its users simultaneously.
1.1.2 Integration Of Unit 60 In The Overall Plant

The system includes the following items:
· 60-T-003 “Service and Potable Water Tank”
· 60-P-002 A/B “Service and Potable Water Pump”
· 60-PK-004 “Sodium Hypochlorite Dosing Package”
Service/Potable Water is stored in the atmospheric dome roof tank
60-T-003 and then pumped to users, with 2X100% electrical motor driven by horizontal centrifugal
pumps (one operating and one stand-by) 60-P-002 A/B in a closed loop circuit. The water is filled in the
tank by means of a road tanker.
To avoid the microbiological growth, a Biocide is injected into pumps discharge through the Sodium
Hypochlorite Dosing Package 60-PK-004.
1.2.1 Unit Capacity

Service and Potable Water Tank 60-T-003
Working volume 16 m³
Dimensions 2500mm(ID)x5440mm(H)
Service and Potable Water Pumps 60-P-002 A/B
Rated flow 25 m³/h
Head at rated capacity 63m
BHP 6.5 kW
Chlorination Package, 60-PK-004
Chlorinator Type Automatic
Capacity rated 13 l/h
Maximum Required Dosage Concentration 2 ppm chlorine
Design Discharge Pressure 7 bar g
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1.3 PRODUCT SPECIFICATION
The following Service and Potable Water quality have been used for the design of the System:
SERVICE/ POTABLE
PARAMETER UNITS WATERDESIGN ANALYSIS
ANIONS
CHLORIDE mg/l Cl- 31.47
BICARBONATE mg/l HCO3- 10.47
NITRATE mg/l NO3- 0.65
PHOSPHATE mg/l PO4-- 0.95
CARBONATE mg/l CO3-- 0.02
TOTAL ANIONS mg/l CaCO3 43.56
CATIONS
CALCIUM mg/l Ca++ 19
SODIUM mg/l Na+ 23.02
ZINC mg/l Zn++ 0.612
AMMONIUM mg/l NH4+ 0.881
IRON (Bivalent) mg/l Fe++ 0.054
TOTAL CATIONS mg/l CaCO3 43.56
OTHERS
pH VALUE - 7.15
TOTAL SUSPENDEDSOLIDS mg/l 0.2
TOTAL DISSOLVEDSOLIDS mg/l 48.93
OPER. TEMPERATURE °C 31
DES. TEMPERATURE °C 70
CONDUCTIVITY@25°C μS/cm 98
TOTAL ALKALINITY mg/l CaCO3 10.49

TOTAL HARDNESS mg/l CaCO3 19
ASSOCIATED CARBONDIOXIDE mg/l CO2 1.36
DISSOLVED OXIGEN mg/l O2 7.30
DENSITY AT 31°C kg/m3 995.21
Moreover, a maximum free chlorine concentration of 2 ppm is prevised for Service and potable water
distribution loop.
1.4 EFFLUENTS
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There are no effluents from the Potable Water System.

General input design data used for tank and pump sizing are shown below:
Continuous users
· Number of operators in the Plant: 8
· Water consumption per person per day 400 litres
· Average Potable Water for human consumption: 3.2 m3/d
Intermittent users
· Number of safety showers/ hose contemporary in service: 2
· Flow rate required for one safety shower or one hose: 6.8 m3/h
· Gas Turbine Compressor Washing System
· Natural Gas Water Bath Heater
· Secondary Cooling Water Make-up
60-T-003:
· Tank hold-up: 4 days
· Required Tank working Volume: 14 m3
· Selected Tank nominal Volume: 26.7 m3
60-P-002 A/B:
· Required Pump flow rate: 20.4 m3/h
· Selected Pump flow rate: 25 m3/h (See note below)
· Head at rated capacity: 63 m
· BHP: 6.5 kW
Note: Selected pump flow rate takes into account the water consumption for: continuous users, two
contemporary operating safety shower / hose and the biggest intermittent user between the Gas Turbine
Compressor Washing System, Natural Gas Water Bath Heater and Secondary Cooling Water Make-up.
Pumps 60-P-002 A/B are under Emergency Diesel Generator (95-PK-007) backup power to guarantee
Service/ Potable Water supply also during a total power failure scenario.
1.6 UTILITY REQUIREMENTS
The following Utilities and interfaces must be available for a proper operation of the Service and Potable
Water System:
a) Electric power for pumps/ Eletrochlorination/ dosage package operation
b) Instrument air for instrumentation operation.
c) Service Air hose for maintenance operations.
d) Service / Potable Water for hypochlorite solution dilution into 60-PK-004 hypochlorite storage tank and
for hose connection.
1.7 CHEMICALS
The chemical used on Unit 60 is the chlorine used by the chlorination package.
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The Package design is based on the following requirements:

Water Type: Service/Potable Water
Peak flow rate to be treated: 25 m3/h (see note 1 below)
Average flow rate to be treated: 0.133 m3/h
Maximum required dosage concentration: 2 ppm free chlorine
Holdup required for Sodium Hypochlorite Storage Tank (see notes 2, 3 below): eight days at normal
operating case, fifteen days at alternative operating case.
Note 1: intermittent peak value.
Note 2: tank required holdup is referred considering the dosing at the peak flow rate with the maximum
required dosage concentration.
Note 3: for more details about operating cases see SPC n° 60-PA-E-86109, Par. 3.2.
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2.1 GENERAL
2.1.1 References
The basic engineering documents related to the design of the Service and Potable Water System Unit
60 are listed hereafter:
60-GD-B-86552 P&ID – Service and Potable Water System
60-MA-E-86100 Process Data Sheet for Service and Potable Water Pump
60-RA-E-86101 Process Data Sheet for Service and Potable Water Tank
60-PA-E-86109 Duty Specification for Sodium Hypochlorite Dosing Package-
00-ZA-E-86925 Utility Systems Cause & Effect Matrix
These documents are enclosed in Chapters 9 and 10 of this manual.
It is recommended that the relevant P&IDs to be studied in conjunction with this chapter.
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2.2.1 Service/Potable Water

The Unit is designed to cope Service / Potable Water requirements from the following units:
Unit N° Unit Description
Common Items
Gas Turbine Unit
Stack System Unit
Open Drain System Unit
Fire fighting System Unit
Service and Potable Water System Unit
Fuel Gas System Unit
Service and instrument air System Unit
Emergency Diesel System
Taleveras Plant
Service/Potable Water is stored in the atmospheric dome roof tank 60-T-003 having 16 cubic meters
capacity. The water is filled in the tank by means of a road tanker.
LI-061 is locate at fill station with local H level alarm. Local level indication is also provided.
The Service and Potable Water System has different control systems to guarantee the system reliability.
a) Pumps normal operation is one continuosly operating, one stand-by. A pressure controller located on
pumps discharge starts the stand-by pump for low pressure and stop the stand-by pump for high
pressure. Moreover low low level detected on 60-T-003 stops the pumps.
b) A pressure control valve located in the return header of the closed loop (near tank 60-T-003) maintains a
suitable minimum pressure at the furthest user and allows the running of the pumps 60-P-002 A/B at
minimum flow.
c) A flow transmitter is used to elaborate a DCS logic with a continuous output from a free
chlorine analyzer placed on pumps discharge. Then, the resulting output signal is sent to
package 60-PK-004 to dose the correct hypoclorite solution into the closed distribution loop.
2.2.2 Sodium Hypochlorite Dosing Package
The sodium hypochlorite dosing package TAG N° 60 - PK - 004 has been constructed in order to realize
the chlorination of the water in the service.
The metering pump adjusts the flow rate of chlorine injected according to the 4-20 mA signal coming
from instrumentation for reading flow rate FE 061 and residual chlorine AT 061.
The pump stops only in case of alarm of low chlorine level, detected by the local level controller.
The level controller indicates the two levels on the panel, both low and low low, an ON-OFF contact is
present for each indication.
A manual pump for chlorine tank charging is provided.
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Unit 60 is controlled remotely via a CS control panel in the main control room. There are also local
emergency STOP push buttons for the Potable Water Pumps
The level in the tanks is maintained by 60-LI-061 (Tank level is not maintained by any controller related
to this transmitter; this level will provide several alarms (HH, H, L) on the CS Operator Stations in
control room) which has high and low alarms set at 4240 mm and 2100 mm respectively. 60-LT-062 is
used to detect the low low liquid level at 700mm which will cause the running potable water pump to trip.
This liquid level must be exceeded before the pumps can be started.
2.3.1 Pressure Control
60-PIC-061/ 60-PV-061:
a) Function: 60-PIC-061 guarantees a suitable minimum pressure at the furthest point of potable water
distribution ring. The pressure value to be considered as set value for the controller is 3.5 bar measured
upstream valve 60-PV-061.
b) Action: When the pressure falls below the 60-PIC-061 set point, the associated pressure control valve
60-PV-061 tends to close to increase the pressure into the closed distribution loop. Vice versa when the
pressure rises over the set point of 60-PIC-061, the associated pressure control valve 60-PV-061 tends
to open to decrease the pressure into the closed distribution loop.
Should the controller either set in “BAD” by the logic or the related transmitter overridden by the suitable
MOS, then the controller will be set in manual and the set point will follow the controller output (PV
tracking). Due to the above, when the operator will set the controller in “Auto” mode, this will be “bump
less” for the control valve.
60-CS-01:
a) Function: The main pump selected by means of the suitable hand switch 60-HSMS-62 will be manual
started by the operator. 60-CS-01 starts the stand-by pump at low pressure and stops the stand by
pump at high pressure.
The HP and LP values are CS alarms through the 60-PI-062 (LP set value 4 bar,
HP set value 6 bar). Hand switch 60-HSMS-062 is provided to select main/ stand-by pump between the
two pumps 60-P-002 A/B.
The measured pressure value from 60-PT-062 and the main/ stand-by selection from 60-HSMS-062 are
the inputs to 60-PY-062. The resulting output value from
60-PY-062 is then sent to 60-CS-01.
b) Action: when the pressure falls below LP set point, 60-CS-01 starts the stand-by pump. Vice versa,
when the pressure rises above HP set point logic 60-CS-01 stops the stand-by pump.
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2.3.2 Sodium Hypochlorite Dosage Control

60-FIC-061/ 60-FY-061:
a) Function: the Sodium Hypochlorite Dosing Package 60-PK-004 is designed to
dose a sufficient amount of NaClO to maintain a residual free chlorine content of at least 0.1 milligrams
per liter (0.1 ppm) and up to a maximum 2 milligrams per liter
(2 ppm) into Service/ Potable Water closed distribution loop.
NaClO rate is defined on the basis of the amount of Service/ Potable Water to be treated, so the
injection request increases when Service/ Potable Water flow rate increases and will be maximum when
the water flow rate is maximum and minimum when the water flow rate is minimum.
The NaClO rate QNaClO [l/h] is calculated by 60-FY-061 as follow:
QNaClO = QPW *SP*K
where:
SP is the Variable Set Point (desired free chlorine concentration) [mg/l] input by DCS (allowable range
0.05÷ 2.0).
QPW is the Service/ Potable Water flow rate [m3/h] measured by 60-FT-061.
K is a variable and its purpose is to adjust the different units of measurement.
The K formula is the following:
K=0.0008897/(X/100)
where:
X=% w/w of NaClO
Moreover, a free Cl2 analyzer 60-AT-061 measures the residual Cl2 in the
Service/ Potable Water pump discharge line and automatically correct NaClO injection rate changing the
stroke of the injection metering pump inside 60-PK-004.
The NaClO corrected rate Q NaClO corrected is calculated by 60-FY-061 as follows:
Q NaClO corrected = Q NaClO * K1
where:
K1 is the control output of 60-AIC-061; this output is based on a Variable Set Point (desired free Cl 2
inside Service/ Potable Water closed distribution loop) input by DCS (set point= 0.1). The control output
is limited in a range 0.85÷1.15. 60-AIC-061 shall be a PI controller with a low gain and a slow integral
response in order to avoid free Cl2 rate fluctuations.
Therefore the injection metering pump stroke shall be calculated as follows:
Stroke % = (Q NaClO corrected * K2)*100
where
K2 is a constant value equal to 1/injection metering pump design flow rate (injection metering pump
design flow rate expressed in l/h).
Finally, in the case 60-FT-061 returns a “bad value”, no action is required by
60-FY-061 (calculated stroke shall be equal to the last correct value). In case of failure of 60-AT-061 no
correction is required (60-AIC-061 control output =1).
b) Action: Flow Dosage Control for Dosing Skid.
Should the controller 60-AIC-061 either set in “BAD” by the logic or the related transmitter overridden by
the suitable MOS, then the controller will be set in manual, the output set to “1” (output=50%) and the
set point frozen.
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3.1 GENERAL
Details of the initial startup and commissioning of the Service and Potable System are detailed in this
chapter. Operating parameters and adjustments, shutdown and emergency situations are detailed in
Chapters 5 to 7.
startup of a new unit. Procedures are slightly adapted for normal and subsequent start up, as indicated
in Chapter 4.
refer to precommissioning activities.
¨ All pipework has been pressure tested and cleaned.
¨ All equipment is at ambient conditions.
¨ Chemicals are available.
¨ Test equipment and special tools, if any, and facilities for their operation are available.
¨ Temporary strainers must be installed where specified and their locations properly recorded for future
reference.
¨ Instrument air is available and commissioned to all instruments.
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¨ All instruments have been calibrated, loops checked and commissioned. All sensing elements which
were removed from pipework prior to hydro testing have been reinstalled.
¨ All the DCS data links are operational.
¨ Emergency shutdown systems are fully operational and if possible, a dry run has been performed.
¨ All safety relief valves have been tested and are in service. All block valves around relief valves are
¨ All blinds, if any, which were installed in the lines during hydro testing have been removed and replaced
satisfactorily.
3.3 SERVICE AND POTABLE WATER TANK AND PUMPS STARTUP
3.3.1 Valve Positions Prior to Start Up
All valves should be in this position as shown on P&ID 60-GD-B-86552
Valve Number Location/Line Position
60-V-01 60-T-003 Inlet Isolation Valve. Closed
3”-60-PW-002
60-V-02 60-T-003 Inlet Isolation Valve. Closed
2”-60-PW-003
60-V-03 60-T-003 By pass PV- 061 Closed
2”-60-PW-003
60-V-04 60-T-003 Provision for water filling from tanker Open
3”-60-PW-004
60-V-05 60-T-003 Open Drain Closed
3”-60-PW-013
60-V-06 60-T-003 Tank Outlet Isolation Valve. Closed
4”-60-PW-005
60-V-07 60-P-002A Suction Line Isolation Valve. Closed
4”-60-PW-006
60-V-08 60-P-002B Suction Line Isolation Valve. Closed
4”-60-PW-005
60-V-09 60-P-002A Discharge Line Isolation Valve. Closed
3”-60-PW-008
60-V-10 60-P-002B Discharge Line Isolation Valve. Closed
3”-60-PW-008
60-V-11 60-PK-004 Dilution Water Line Closed
1/2”-60-PW-042
60-V-12 60-PK-004 Chlorine Outlet Line Closed
1/2”-60-CH-003
Note: the battery limits of all the users are closed.
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3.3.2 Filling Service and Potable Water Tank 60-T-003

Take in consideration that Service and Potable Water tank is empty and perfectly clean inside and all
the instrumentation in place.
Prior to the startup of the Service and Potable Water Pumps 60-P-002A/B the tank
60-T-003 must be filled with water in the following manner:
Provide a water tanker and fill it with chlorinated water from potable water skid situated in Afam Base.
· Start discharging the water tanker using the filling line of Service and Potable Water Tank 60-T-
003Depending on water tank capacity and availability of treated/ chlorinated water, the filling of 60-T-003
will take approximately 2 days.
· Open 60-V-06 the Tank Outlet Isolation Valve and car seal.
During this operation, check if LL/ L level indications are cleared and H/ HH level indications will be
activated.
Close 60-V-05 the filling line of Service and Potable Water Tank 60-T-003
3.3.3 Commissioning of Service and Potable Water Pumps 60-P-002A/B
· Open the flange and remove the “Y” type suction strainers.
Open 60-V-07 and 60-V-08 suction line isolation valves and flush the suction lines.
After visual inspection satisfactory, stop flushing, close back the isolation valves and reinstall the
strainers.
· Open 60-V-07 and 60-V-08 suction line isolation valves for 60-P-002A/B.
· Open 60-V-09 and 60-V-10 discharge line isolation valves for 60-P-002A/B and once the pumps have
been primed close delivery gate valves.
· Open 60-V-01 and 60-V-02, the 60-T-003 Inlet Isolation Valves and set the pressure at PIC 061 to 3.5
bar AUTO mode.
· Ensure the power supply is available, select both the pumps in manual mode and press the "START"
command located in control room for any of the pumps. Open gradually the delivery valve until fully
open and observe the running of the pump, and when running smoothly leave the pump running at full
rate for 3 hours. Record the parameters.
· The pump can be stopped at the local panel by pushing the red "STOP" emergency pushbutton located
on the local pump control panel or from control room.
· The second pump can be commissioned in the same mode (according to the previous points both
pumps have been already started).
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3.3.4 Commissioning of Service and Potable Water distribution Network.

Restart 60-P-002A and monitor the pressure inside the distribution network and performance of the
pump.
Open the nearest upstream drain valve to the furthest user inlet battery limit and sample the water.
Repeat this operation by systematically opening and closing the drain valves at the user inlet battery
limits, working back to Unit 60
The Potable Water Distribution Network has now been pressurized and sanitized and ready for
next step
3.4 COMMISSIONING/ START UP OF CHLORINATION PACKAGE
Take in consideration that AT- 061/ AT-062 are on line and set point for residual Cl 2 is input by DCS.
Ensure the water level into the 60-T-003 is at the normal range. Top up if necessary.
Ensure that water make-up valve V-11 and sodium hypochlorite outlet valve V-12 are open at the
chemical skid.
With the water flowing around the minimum flow spillback loop, the Chlorination Package can now be
commissioned using the procedure outlined in this chapter.
· Verify the arriving tension to the panel cabinet: 400V+N 50Hz.
· Make sure that the selector switch SA1 is on the position “0” (Pict.1).
· Close all the ball valves of pvc lines: V1.V2, V3, V4, V5, V6.
· Put in action the general switch QS on the position “ON”. The presence of tension is indicated by the
warning light “HLL” (pict.1).
· Push the button “START PLANT” (SBS) (Pict.1). After few seconds the warning lights VERY LOW
LEVEL (HL1)“ for the very low level and LOW LEVEL (HL2) for the low level of chlorine inside the tank
will be activated (pict.1).
· Prepare the water-chlorine solution by pouring at first 50 liters of hypochlorite and 200 liters of water. It
is possible to pour water using the valve V5 (pict.4). Pour water before putting the sodium hypochlorite.
When the chlorination unit and the whole system of water distribution are at speed, it will be possible to
optimize the percentage of chlorine and water in order to obtain an accurate metering and a time as
long as possible before charging the chlorine tank again. After pouring water and, afterwards, chlorine,
the alarm of very low level is turned off.
· Open slowly the valve “V1”permitting the chlorine to flow to the metering pump (pict.5).
· Open the valve “V4” to activate the damping sack (pict.6).
· Slightly open the valve “V2” (pict.7) in order to eliminate the air.
· Activate the metering pump by positioning the selector switch “SELECTOR PUMP” (SA1) on 1 (pict.1);
the pump is activated and as soon as the air inside the pump body and piping is eliminated, close the
valve “V2” (pict.7) and deactivate the metering pump with the selector switch “SA1”.
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· Open the valve V3 (pict.8) and start up the metering pump with the selector switch SA1. During the first
hours of operation the metering pump will inject chlorine at the maximum of its flow rate, and after this,
by means of the processed signal of water flow rate to be chlorinated and residual chlorine, the pump
will decrease the metering in order to keep the quantity of free chlorine measured in the potable water
near the set value (maximum value required = 2 ppm free chlorine).
Level Setting;
Levels are already set as follow:
Low Level 40% (to send signal ON-OFF)
Very Low Level 20% (to send signal ON-OFF and stops the metering pump)
Metering Pump Setting;
The metering pump setting is set as follow:
Stroke adjustment signal: 20 mA = MAXIMUM DOSAGE
Stroke adjustment signal: 4 mA = MINIMUM DOSAGE
Once the tank is full, the level alarms are deactivated. As the chlorine level goes below the low level
threshold, the warning light “LOW LEVEL” is activated (pict.1). In this case a digital free contact is
available on the panel, which can be used in case of external alarm.
· As the chlorine level goes below the very low level threshold, the warning light VERY LOW LEVEL is
activated (pict.1) and the metering pump is stopped. Also in this case a digital free contact is available
on the panel, which can be used in case of external alarm.
· Should a failure of the metering pump occur, will be indicated by the warning lamp THERMIC BLOCK
(HLR) (pict1). As for the pump failure, a digital free contact is available on the panel, which can be used
in case of external alarm.
· If a black-out of power occurs during the normal functioning, the chlorination skid remains deactivated.
In order to reactivate the whole system, it is necessary to push the button of “START PLANT” (SBS)
(Pict.1).
Operatively;
The minimum and maximum flow rate indicated (0,133 mc/h – 25 mc/h) and the value of maximum
residual chlorine (2 ppm) modify automatically the metering regulation of the metering pump.
3.5 FINAL PREPARATIONS
Ensure that any high point vents and low point drains previously opened are now closed.
· Ensure that flow controller 60-PIC-061 is in "AUTOMATIC" with a set point of
3.5 bar.
· Ensure the water level into the 60-T-003 is at the normal range. Top up if necessary.
· Ensure that the Residual Chlorine Analyzer has a set point of max 2 ppm Cl 2 and the Chlorination
Package Skid is fully operational.
Once the Service and Potable Water Network has been flushed and the residual chlorine concentration
at all the battery limit drain valves is at desired range, Potable Water users can now begin to fill and
flush their systems, as required.
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4.1 GENERAL
The procedures and instructions laid out in this chapter are to be used to start up
Unit 60 following a shutdown. The shutdown may have been routine as part of normal operation,
turnaround or maintenance.
The recommended start-up procedure is presented in section 3.0.
The following start up procedures are recommended, with the understanding that the judgment of the
operators should dictate which of these steps are required, and in what order, based on the nature of
the preceding shutdown. The initial start-up instructions presented in Chapter 3 should be referred to for
specific details.
After a shutdown for turnaround and maintenance, start up orders have to be initiated after ensuring that
all requirements relating to plant acceptance and readiness for restart have been fulfilled.
After an unplanned shutdown the unit must be checked over to ensure that the unit is ready and safe to
operate and that the cause of the shutdown has been rectified.
The restart must be performed in accordance with all RSG-OCPP safety regulations and standing
instructions.
The following shall be assumed for the purpose of the start up procedures in this chapter:
All utility systems are commissioned and available as required to the units.
All instruments and control systems have been checked and are functional.
Unit 60 is designed such that it should never have to shut down. There are two service and potable
pumps, each with 100% capacity, so that one can be isolated for maintenance while the other is on line.
During shutdowns of other units, the service water supply must be maintained so that all Safety
Showers and Eyebaths etc. are available and fully functional.
The following sections detail the normal start up of each of the items of equipment connected with Unit
60 after either maintenance or an incident requiring the activation of Unit 60.
4.3.1 Lining Up Service and Potable Water Tank 60-T-003
If 60-T-003 is shut down for maintenance and drained it must first be refilled before being brought back
on-line.
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Maintenance on Service and Potable Water Tank 60-T-003 should only be carried out during periods
when all other units are shutdown and Plant is ready for major overhaul. More information on the shut
down and isolation of the Service and Potable Water Tank is contained in Chapter 6 of this manual.
The procedure is identically with the one described in chapter 3.3.2
· Provide a water tanker and fill it with chlorinated water from potable water skid situated in Afam Base (It
is not mandatory to have a chlorinated water because the water will be eventually chlorinated from 60-
PK-004.)
· Start discharging the water tanker using the filling line of Service and Potable Water Tank 60-T-003
Depending on water tank capacity and availability of treated/ chlorinated water, the filling of 60-T-003 will
take approximately 2 days.
· Open 60-V-06 the Tank Outlet Isolation Valve and car seal.
During this operation, check if LL/ L level indications are cleared and H/ HH level indications will be
activated.
4.3.2 Lining Up Service and Potable Water Pumps 60-P-002A/B
Consider Pump A was under maintenance and Pump B is running in normal conditions.
· Open fully 60-V-07 and 60-V-09 suction and discharge line isolation valves for
60-P-002A.
· Ensure the power supply is available and press the "START" command located in control room.
Observe the running of the pump and when running smoothly, pump B can be stopped.
· The pump can be stopped at the local panel by pushing the red "STOP" emergency pushbutton or from
control room.
4.3.3 Lining Up of Chlorination Package 60-PK-004
Consider level in hypochlorite tank is on normal range and no L/LL alarm is activated.
· Open slowly the valve “V1”permitting the chlorine to flow to the metering pump (pict.5).
· Open the valve “V4” to activate the damping sack (pict.6).
· Slightly open the valve “V2” (pict.7) in order to eliminate the air.
· Activate the metering pump by positioning the selector switch “SELECTOR PUMP” (SA1) on 1 (pict.1);
the pump is activated and as soon as the air inside the pump body and piping is eliminated, close the
valve “V2” (pict.7) and deactivate the metering pump with the selector switch “SA1”.
· Open the valve V3 (pict.8) and start up the metering pump with the selector switch SA1. During the first
hours of operation the metering pump will inject chlorine at the maximum of its flow rate, and after this,
by means of the processed signal of water flow rate to be chlorinated and residual chlorine, the pump
will decrease the metering in order to keep the quantity of free chlorine measured in the potable water
near the set value (maximum value required = 2 ppm free chlorine).
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instrumentation on Unit 60. The tables contain information for the instrumentation shown on P&IDs only.
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4.4.1 Unit 60 Controller Set Points and Alarms

Controller/Alarm Controller Transmitter Function P.&I.D
Tag No. Set Point
60-PIC-062 86552
H 6 bar g Monitors pressure on the network
L 4 bar g
60-AIC-061/062 86552
H 2 ppm Monitors free chlorine
L 0.05 ppm
60-FIC-061 86552
H 25 m3/h Monitors water flow to be treated
L 8 m3/h
60-LT-061 86552
LAHH 4840 mm Monitors liquid level in 60-T-003
LAH 4240 mm
LAL 2100 mm
4.4.2 UNIT 60 TRIP SETTINGS

4.4.2.1 Flow Trips
4.4.2.2 Level Trips

· 60-LSLL-062 is activated at 700 mm and trip service and potable water pumps.
· Local LSLL hypochlorite tank will stop the chemical pump.

There are no pressure trips on Unit 60
There are no temperature trips on Unit 60.
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5 NORMAL OPERATION

The function of Unit 60 is to provide clean/ sterile water and has been designed to meet the peak
demands of all its users simultaneously.
Unit 60 is controlled remotely via a CS control panel in the main control room. There are also local
emergency STOP push buttons for the Potable Water Pumps.
Service/Potable Water is stored in the atmospheric dome roof tank 60-T-003 having 16 cubic meters
capacity. The water is filled in the tank by means of a road tanker.
The level in the tanks is maintained by 60-LI-061 (This is not the logic implemented in the control
system, where the potable water distribution circuit will be controlled by PIC-61 controlling the water
return pressure , the LALL-62 level cause the water pump trip from the ESD system) which has high and
low alarms set at 4240 mm and 2100 mm respectively. 60-LT-062 is used to detect the LL liquid level of
700mm which will cause the running Potable Water Pumps to trip. This liquid level must be exceeded
before the pumps can be started.
The Service and Potable Water System has different controls to guarantee the system reliability.
a) Pumps normal operation is one continuosly operating, one stand-by. A pressure controller located on
pumps discharge starts the stand-by pump for low pressure and stop the stand-by pump for high
pressure. Moreover low low level detected on
1 60-T-003 stops the pumps from the ESD.
b) A pressure control valve located in the return header of the closed loop (near tank 60-T-003) maintains a
suitable minimum pressure at the furthest user and allows the running of the pumps 60-P-002 A/B at
minimum flow.
c) A flow transmitter is used to elaborate a DCS logic with a continuous output from a free chlorine analyzer
placed on pumps discharge. Then, the resulting output signal is sent to package 60-PK-004 to dose the
correct hypoclorite solution into the closed distribution loop.
5.2 SPECIFIC OPERATIONS
Ensure that all safety procedures concerned with the handling of Sodium Hypochlorite are being taken.
5.3 PERFORMANCE MONITORING
The two potable water pumps are designed so that one will be running at any one time, with one on
standby.
Operators should endeavor to give the pumps equal running times by logging the running times for each
pump. Pump changeovers should not be used purely for maintenance purposes, but also to avoid
leaving one pump standing for any great length of time. This may result in damage to bearings and
other parts of the pump.
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No corrosion is expected within the unit.

The Potable Water Tank 60-T-003 is provided with an appropriate corrosion allowance.
Note: Over chlorinating the water could lead to corrosion problems in the Tank and also any metal
pipework or fittings. Over chlorination can also cause a potential health hazard to its domestic users as
well.
For this reason regular sampling of the water is necessary.
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6 NORMAL SHUTDOWN
6.1 GENERAL
other units, especially as firewater is vital to the safety and operation of the rest of the plant.
operations to ensure that all requirements of RSG-OCPP safety regulations and standing operating
procedures are adhered to.
6.2 UNIT 60 SHUTDOWN
Unit 60 is designed such that it should never have to shut down. There are two service and potable
pumps, each with 100% capacity, so that one can be isolated for maintenance while the other is on line.
During shutdowns of other units, the service water supply must be maintained so that all Safety
Showers and Eyebaths etc. are available and fully functional.
If a complete shutdown of Unit 60 is required, it should be carried out by systematically shutting down
and isolating the individual items that form Unit 60.
The shutdown and isolation of individual items of equipment is outlined in section 2.1 of this chapter.
6.2.1 Item Shutdown and Isolation
6.2.1.1 Service and Potable Water Tank 60-T-003

Two separate procedures are outlined below; one for isolating the tank and one for isolating and
draining the tank.
6.2.1.1.1 Isolating 60-T-003
Consider the Service and Potable Water pumps are stopped and de energized.
Also Sodium Hypochlorite dosing package is stopped and de energized.
The isolation of 60-T-003 should be achieved in the following manner:
· Close the following isolation valves:
· 60-V-01/02/03, 60-T-003 inlet valves.
· 60-V-06, 60-T-003 outlet valve.
The tank is now isolated.
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6.2.1.1.2 Draining 60-T-003

Note: 60-T-003should only be emptied during plant shutdowns, when the requirement for service/
potable water is substantially/completely reduced.
The decision to empty 60-T-003 should be taken well in advance of the plant shutdown since the
emptying of the tank will take time.
The preparation for the emptying of 60-T-003should be carried out in the following manner:
· Before stopping the hypochlorite pump and Service and Potable Water pumps, try to reduce as much as
possible the level inside the water tank.
· Stop and de energize the above mentioned pumps.
· Isolate 60-V-01/02/03, the 60-T-003 inlet valves.
· Close 60-V-06, 60-T-003 outlet valve.
· Start opening of 60-V-05, 60-T-003 drain valve. Remaining water will be diverted to storm water
channel.
Start spading the tank.
6.2.1.2 Service and Potable Water Pump 60-P-002A
Two separate procedures are outlined below; one for stopping the pump and one for isolating for
maintenance.
6.2.1.2.1 Stopping Service and Potable Water 60-P-002A

Consider pump 60-P-002B is running and set as main pump.
60-P-002A can be stopped from control room or by pressing local STOP button.
6.2.1.2.2 Isolating Service and Potable Water 60-P-002A
If the pump requires to be taken out of service for maintenance HSMS 062 must first be set up so that
60-P-002B is the primary pump with 60-P-002A as the secondary. The pump can then be isolated in the
following manner (P&ID 60-GD-B-86552):
Close the following valves:
60-V-07, the 60-P-002A suction line isolation valve.
60-V-09, the 60-P-002A discharge isolation valve.
The pump control panel should be de-energized and the casing drains to be open.
6.2.2 Stopping hypochlorite dosing package
To stop the chemical injection pump put the selector SA1 on “0” position.
If maintenance is required, close suction and discharge valves and de energize the pump.
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7.1 GENERAL
This chapter describes the philosophy and implementation of the safeguarding systems installed on Unit
60.
There is a safety interlock system implemented in the DCS as follows:
If the level in Service and Potable Water Tank 60-T-003 falls below 700 mm as measured by 60-LT-062,
then this will cause the running Potable Water Pump(s) to trip and will inhibit any attempt to re-start any
of the pumps until the level in the tanks has risen.
For Sodium Hypochlorite Skid the pump stops in case of alarm of LL chlorine level, detected by the level
controller.
The level controller indicates the two levels on the panel, both L and LL, an ON-OFF contact is present
for each indication.
Both service and potable water pumps are fed from emergency diesel generator.
The firewater system contain only one air actuated control valve PV-061 and the action is fail open.
Potable and service water to the users will be maintained and will continue to operate as
normal
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8 SAFETY
8.1 GENERAL
This chapter contains information on the safety systems installed on Unit 60 for protection from plant
fires and gas leaks.
Also discussed is the nature of the hydrocarbon materials handled by other units on the plant, and
safety precautions.
Unit 60 is an inherently safe unit. It is however part of a plant which handles hazardous materials, and
so sections of this chapter may not be specifically applicable to Unit 60, but are provided to give an
overall safety view of the units nearby and the rest of the plant.
8.1.1 Operator Training
Almost all hydrocarbons and chemicals can be dangerous if not properly handled. Therefore, the
operators should be thoroughly acquainted with the hazardous properties of all materials in use and
should be properly drilled in the correct procedures for handling these materials.
All operators should familiarize themselves with the location and use of fire fighting equipment:
hydrants, hose reels, extinguishers, and of safety equipment: safety showers, eye baths, breathing
apparatus and all other safety equipment installed on the units.
In addition the operators should be thoroughly familiar with basic first aid measures and should be able
to take appropriate action in case of an incident.
Periodic practice drills, and more specifically fire fighting drills should be carried out in order to instruct
the operators in the hazards involved and the proper emergency action required so as ensuring the
maximum protection both for personnel and equipment.
There are, however, hydrocarbon processing units nearby which do pose a serious threat and so
information on the fire and explosion hazards are contained in this section for reference
8.2.1 General
with unit fire incidents only. Refer to section 2.2, below.
Before attempting to tackle a unit fire, of any magnitude, the operators must be aware of the nature of
fire fighting equipment (e.g. water must not be used on an electrical fire; burning liquid spills should be
The first action to be performed on discovery of a unit or a plant fire, (regardless of size), is to raise the
alarm. In this way adequate support in the form of trained fire fighting personnel and mobile fire fighting
equipment will be rapidly mobilized to assist in dealing with the fire. Then, should the incident escalate,
personnel and equipment are already on the scene and prepared.
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scale fires can be tackled with hand held extinguishers or steam lances, major fires should be dealt with
from a distance using deluge systems, firewater monitors and fire hoses.
The operators should familiarize themselves with the location and the details of operation of all fire
fighting equipment.
It is the responsibility of the safety officer to periodically check the fire fighting and safety equipment to
The existing fire hydrant and additional portable dry chemical powder fire extinguishers located close to
the pumps are considered adequate to combat any possible fires.
8.2.3 Safety (Personal Protection) Equipment
In Unit 60 the following types of safety equipment are provided to protect operating personnel during the
execution of their duties:
¨ Eye Baths
An eyebath/face wash unit is provided as part of the Chlorination Package and is located at the
Chlorination skid.
¨ Safety Signs
Throughout Unit 60 numerous safety signs are provided to assist the operators. They describe
various hazards, the location of firefighting equipment, the location of safety equipment and
provide mandatory safety instructions ("wear ear defenders", etc.).
During the makeup of hypochlorite tank, operators must ensure they are wearing impervious gloves, a
facemask, and protective coveralls. These items of equipment are not provided locally, and so the
operator must carry them onto the unit.
8.3 CHLORINE (Cl2) INFORMATION
This section contains information about the physical properties and hazardous properties of chlorine.
Also included is information on the toxic nature of the gas, physiological effects of exposure and first aid
procedures to effect recovery from chlorine poisoning.
The procedures outlined in the following pages are offered as a guide only. Adherence to RSG-OCPP
standing operating procedures for the handling of chlorine and chlorine bearing materials shall be
adhered to at all times and take precedence over this manual.
Physical Properties
* Normal Physical State: Gaseous
* Color: Greenish yellow
* Boiling Point: -34°C
* Melting Point: -101°C
* Molecular Weight: 71
* Specific Gravity (Air = 1): 2.45
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Other characteristics of Cl2 are as follows:

* Has a characteristic acrid odor noticeable in very low concentrations.
* Slightly water soluble:
Temperature °C0 10 15 20 25
g Cl2/100 g H2O 1.46 0.98 0.83 0.71 0.64
* Strong oxidizing agent when moist and corrosive to most common materials except glass, ceramics and
certain plastics.
* Neither flammable nor explosive, but will support combustion.
Exposure Levels and Handling
Exposure to chlorine in the workplace can have the following effects:
Less than 1.0 ppm - Harmless over 8 hour day.
1.0 - 4.0 ppm - Detectable by smell.
3.0 - 4.0 ppm - Physiological irritation.
15.0 + ppm - Progressively harmful.
Gloves, a facemask and coveralls should also be worn whenever handling either liquid or gaseous
chlorine.
First Aid
Any person who comes into contact with chlorine, in any concentration, should follow the following
guidelines:
If Chlorine has got into the eyes then immediately wash out, using plenty of water, for several minutes.
Remove contaminated clothing immediately and wash affected skin with plenty of water.
Seek medical treatment when anyone has symptoms apparently due to inhalation or contact with skin or
eyes.
Persons who have inhaled the fumes must lie down and keep quite still.
Patients must be kept warm.
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9.1 DATASHEETS

9.1.1.1 Potable and Service Water Storage Tank 60-RA-E-86101
9.1.1.2 Potable and Service Water Pumps 60-MA-E-90231
9.1.1.3 Sodium Hypochlorite Dosing Pump 60-MA-E-90281
Instrument Datasheet 00-ZA-E-86328
9.2 OTHER DOCUMENTS
Fire and Gas Detection Design Criteria 50-ZA-E-85010

Utility Systems control narrative 60-ZA-E-86375
Utility Systems Design Basis 60-ZA-E-86000
Albatros Operation and Maintenance Manual 60-MA-E-98713
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10 DRAWINGS
Service and Potable Water System 60-GD-B-86552

Service and Potable Water Distribution 60-GD-B-62802
10.2 PLOT PLAN
Firefighting Protection System Plot Plan 50-GB-A-85700

10.3 FIRE AND SAFETY LAYOUT DRAWINGS
Instruments and F&G Equipment Location Layout 00-SB-A-57504

10.4 LOGIC DIAGRAM
Utility Systems Cause and Effect Matrix 00-ZA-E-86925
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III UNIT 80 - INSTRUMENT AND SERVICE AIR SYSTEM

1 DESIGN BASIS
1.1 GENERAL
1.1.1 Function of the Instrument and Plant Air System

The air compressor and dryer units in the Instrument and Plant Air System have been designed to meet
the base load requirements for the AFAM-OCPP facilities.
The two Air Compressors 80-PK-005A/B are provided as one on duty and one on standby.
The Wet Air Receiver 80-V-001 has been designed to remove any entrained water from the compressed
air supply and to provide sufficient surge volume to meet fluctuating demands without significant
pressure variations.
The two Instrument Air Dryers 80-PK-006A/B are provided with both inlet and outlet filters and operate
on a duty/standby basis. While on standby, the dryers are regenerated following an automatic
regeneration sequence.
The Wet Air Receiver 80-V-001 has been designed to provide sufficient emergency air volume for 15
minutes plant operation at normal instrument air demand in the event of an air supply failure.
1.2.1 Unit Capacity

Air Compressors 80-PK-005A/B
Two 100% units:
Normal Operating Capacity 360 Nm³/hr
Discharge Pressure 8.5 bar g
Discharge Temperature 59°C
Wet Air Receiver 80-V-001
Capacity 10 m³
Operating Pressure 8.5 bar g
Design Pressure 11 bar g
Operating Temperature 59°C
Design Temperature -10 °C / 90°C
Air Dryers 80-PK-006A/B
Normal Capacity 95 Nm³/hr
Inlet Temperature (max) 59°C
Inlet Air Pressure 8.5 bar g
Outlet Dew Point -20 °C @ 8.5 bar g
Design Pressure 11.0 bar
Air Dryer Pre- and After-Filters PD 32 and DDp 32
Design Pressure 16 bar g
HDP set 0.35 bar g
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1.2.2 Feed Characteristics

The air taken into the compressors is at the following conditions:
Pressure 1.013 bar g
Temperature 41°C
Relative humidity 70%
Total Instrument
UNIT Air/Service Air
Consumption
Nm3/h
00-Common Items 2
30-Stack System Unit 24
50-Fire fighting System Unit 2
60-Service and Potable water System Unit 15
70-Fuel Gas System Unit 17
80-Service & Instrument Air System Unit 8
TOTAL INSTRUMENT AIR 68

INSTRUMENT AIR OVERDESIGN 13.5
INSTRUMENT AIR FOR DRYER REGENERATION 13.5
TOTAL SERVICE AIR 200
SERVICE AIR OVERDESIGN 20
TOTAL Consumption for Design 315
1.4 EFFLUENTS
Sour water is drained from the plant air receiver using an automatic drain valve into an open drain .
The only utilty required by unit 80 is power supply

1.6 CHEMICALS
Alumina Desiccant Molecular Sieve
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2.1 GENERAL
Instrument and Service Air will be provided by means of 2X100% electrical motor driven air
compressors (one operating and one stand-by) and sent to a Wet Air Receiver.
From the Wet Air Receiver part of the compressed air will be treated through a dryer package to
produce Instrument Air and the remaining part will be used as Service Air.
The System is a whole package composed of the following main items:
80-PK-005 A/B – Air Compressors Package
80-V-001 – Wet Air Receiver
80-PK-006 A/B – Instrument Air Dryer
2.2.1 Plant Air Production

The outlet from the Instrument Air Compressors 80-PK-005 A/B is fed into the Wet Air Receiver 80-V-
001 where any entrained water is removed. The outlet from
80-V-001 is then routed via UV-081 to the plant air distribution system.
80-PI-081 ensures a minimum pressure of 6.8 bar g in the Instrument Air header. If the pressure falls
below this figure, then the UV-081 valve closes diverting all available air to the Instrument Air system.
2.2.2 Instrument Air Production

The feed to the Instrument Air Dryer Package 80-PK-006 A/B is taken from the outlet of the Wet Air
Receiver 80-V-001. The air passes through one of two pre-filters to remove water droplets before going
through one of two dryers. The outlet from the dryer then goes through one of two after-filters to remove
any entrained dryer desiccant fines and then onto the Instrument Air Header.
The operation cycle of the dryer is repetitive and is controlled by a factory-set timer. While the desiccant
in the first tower dries the compressed air, the desiccant in the second tower is being regenerated and
vice versa.
Regeneration of the desiccant is achieved by means of purge air from the drying tower. The
compressed air entering the dryer is led to one of the towers by means of the bottom selector valve. The
position of the selector valve depends on the condition (activated or not) of the solenoid valves. As the
air flows upwards through the tower, the desiccant adsorbs the water vapor and the compressed air is
dried.
Once the top of the tower is reached, the air leaves the dryer via the outlet valve (= top selector valve).
A small portion of the dried air passes a nozzle, expands to atmospheric pressure and flows downwards
through the other tower, regenerating (drying) the desiccant. The regeneration air is released via the
corresponding solenoid valve and the silencer. The solenoid valves are controlled by the timer.
After a pre-set period, the function of the towers is reversed. The fully regenerated tower will now dry
the air, while the desiccant in the other tower will be regenerated.
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The changeover of the dryers can be controlled manually using the local control panel or automatically
using either a timer or the dew point analyzer in the outlet from the dryers to initiate a changeover.
Function: 80-CS-02 receives an input signal from the pressure transmitter 80-PT-085 located on
instrument air supply header. The outputs signals from 80-CS-02 are:
· The indication to DCS through the 80-PI-085 which is provided of three LP alarm sets. The three LP
alarms sets are for the values of 7.8 bar g (LP alarm),
7.5 bar g (LLP alarm) and 7 bar g (LLLP alarm).
· The signal for the automatic start of the stand-by compressor on low pressure value of 7 bar g (LLLP
alarm value for 80-PI-085).
Action: 80-CS-02 action is the automatic start of the stand-by compressor on low pressure value of 7
bar g.
In particular, the output signal from 80-CS-02 is sent to the hand switch
80-HSMS-085 and from 80-HSMS-085 to the hand switches 80-HSHL-580 (compressor A) and 80-
HSHL-581 (compressor B).
The hand switch 80-HSMS-085 is a main/ stand-by selector, while hand switches
80-HSHL-580/1 are automatic/ manual selectors provided to bypass the automatic start-up of the stand-
by compressor (the 80-CS-02 action).
It is mandatory that the automatic start of the stand-by compressor on low pressure value of 7 bar g
shall override the hand switches 80-HSHL-580/1.
Moreover, both compressors are provided of the following status signals to DCS:
· Local/ remote status signals with 80-XSLR-580 (compressor A) and
80-XSLR-581 (compressor B).
· Running/ stopped status signals with 80-XSHL-580 (compressor A) and
80-XSHL-581 (compressor B).
· Automatic operation status signals with 80-XSAM-580 (compressor A) and
80-XSAM-581 (compressor B).
· General warning status signals with 80-XSAL-580 (compressor A) and
80-XSAL-581(compressor B).
· General shutdown status signals with 80-XSTR-580 (compressor A) and
80-XSTR-581 (compressor B).
· Compressor loaded status signals with 80-XSHD-580 (compressor A) and
80-XSHD-581 (compressor B).
Should the pressure in the Instrument air header fall to the low set pressure of 6.8 bar g, PT-081 will be
activated and will close UV-081 and isolate the plant air header, thus conserving the remaining air for
the instrument air supply
Air to be dried prior to distribution through the Instrument Air system is taken from the outlet of 80-V-001
and fed to the Instrument Air Dryer Package 80-PK-006.
Each dryer unit is provided with a local control panel. The air dryers switching can be done MAN or
AUTO mode. AUTO mode is controlled by a digital timer with a standard setting of 168 hours.
The dryer is equipped with a Pressure Dew Point sensor (PDP sensor), extending the drying time. The
regeneration time is still timer controlled.
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The PDP sensor constantly measures the pressure dew point (PDP) of the air leaving the drying tower.
As long as the PDP temperature is below the set point (-40 °C or -70 °C), the drying tower will keep on
drying, until the PDP temperature exceeds the set point. On that moment the regenerated tower will
start drying the compressed air and the other tower will be regenerated.
As long as the PDP temperature is below the set point, regeneration of the non-drying tower is stopped
after the preset time interval of the timer has elapsed. As a result, reduction of purge air is achieved.
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3.1 GENERAL
A summary of pre-commissioning activities and a checklist to be completed before unit initial operation
are included in Section 2 of this chapter.
Details of the initial startup and commissioning of the Instrument and Plant Air system are detailed in
sections 3 of this chapter. Operating parameters, adjustments, shutdown and emergency situations are
detailed in Chapters 5 to 7.
startup of a new unit. Procedures are slightly adapted for Normal and Subsequent Start Up, as indicated
in Chapter 4 of this manual.
* All firewater systems are pressurized and ready for operation. All firefighting equipment is in place,
operational and has been functionally tested.
* All safety equipment is in place and is fully operable.
* All pipework has undergone pressure testing, cleaning and/or air blowing.
* All equipment has been pressure tested, inspected, cleaned, drained and dried.
* All equipment is at ambient conditions and full of air.
* Chemicals, if required, are available.
* Test equipment and special tools, if any, and facilities for their operation are available.
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* All rotating equipment and their associated drivers have been aligned, run in and lubricated, as required,
* Electrical power systems have been checked out and commissioned. It is available to all electric drivers
* All instruments have been calibrated, loops checked and commissioned. All sensing elements which
* All the DCS data links are operational.
* Emergency shutdown systems are fully operational and if possible, a dry run has been performed.
* All safety relief valves have been tested and are in service. All block valves around relief valves are
* All blinds, if any, which were installed in the lines during hydro testing have been removed and replaced
* All continuous drainer inlet valves are open and all other vents and drains are closed.
satisfactorily.
3.2.1 Nitrogen for Start Up

Bottled nitrogen, regulated to 8 bar g can be used to energize the instruments on Unit 80. This should
be done using a three-way valve with a branch to connect the nitrogen.
Once the compressor is running with dry Instrument Air being produced, the Nitrogen can be removed
by opening the valve on the instrument air line and closing the nitrogen valve.
3.2.2 Unit Purging

Since the unit is used for the production of instrument and plant air, unit purging prior to start-up is not
necessary.
3.3 PRESSURIZATION AND START UP OF UNIT 80
3.3.1 Air Compressor Package 80-PK-005 commissioning and start-up

For the purpose of this section it is assumed that compressor C-005A will be the first compressor to be
started. The procedure for starting the second compressor will be identical.
It is recommended to use a manual start the first time the compressors are started. This will allow the
operator to monitor the conditions during the start-up.
· Check that the electrical connections correspond to the local codes. The installation must be earthed
and protected by fuses in all phases. An isolating switch must be provided.
· Check the connections at the primary sides of transformers (T1 and T2).
· Switch on the voltage. Start the compressor and stop it immediately. Check for correct direction of
rotation while the motor is coasting to a stop. An arrow on the gear casing indicates the correct rotation
direction. If the rotation direction is wrong, switch off the voltage and reverse two incoming electric lines.
· Run the compressor for a few minutes and check that it operates normally.
· Stop the compressor. If necessary, top up the gear casing with oil to the middle of sight-glass (SG).
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Valve Positions Prior to Start Up

Prior to start-up all the valves in the system should be in their normal operating positions shown on the
P&ID 80-GD-B-86553/ 86554 with the following exceptions:
Valve No. Function Position
80-V-01 Compressor 80-PK-005A

Outlet Isolation Valve Open Note (1)
80-V-02 Compressor 80-PK-005B
Outlet Isolation Valve Closed Note (1)
80-V-05 Isolation Valve to UA Header Closed
80-V-06 Air Dryer 80-PK-005A
Inlet Isolation Valve Closed
80-V-07 Air Dryer 80-PK-005B
Inlet Isolation Valve Closed
Note (1): Assumes Compressor 80-PK-005A will be started first. Valve positions should be swapped if
compressor 80-PK-005B will be started first.
Compressor Start
Instrument and Plant Air compressor start can now be performed in the following manner:
* Put the controller in "LOCAL CONTROL"
* Ensure the compressor is switched to "UNLOAD" on the local control panel.
* Press the green compressor "START" button located on the control panel
* With the compressor and cooler fans all running satisfactorily, the compressor can be switched to
"LOADED".
The system will begin to pressurize to the limits defined by the isolation valves described above.
Observe the lube oil level, pressure and temperature to the unit.
Observe vibration levels and if excessive vibration levels exist, the unit should be shut down
immediately and the cause determined.
With C-005A running satisfactorily, controller can be switched to AUTOMATIC.
When automatic operation LED (1) is alight, the Elektronikon regulator is automatically controlling the
compressor: the air delivery is matched to the air consumption; the compressor will start and stop
whenever necessary.
Keep all doors closed during operation.
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3.3.2 Instrument Air Dryers 80-PK-006A/B commissioning and start up

Dryer Regeneration
Before the dryer packages can be brought on-line they must first be regenerated to remove any
moisture from the desiccant molecular sieve.
This example of regeneration prior to start-up is only applicable for the commissioning and after
replacement of the desiccant. Since once the unit is operational there will always be at least one dryer
fully regenerated.
· Close the air supply towards the PDP sensor.
· close the external outlet valveV-08
· Remove the silencers to prevent the silencers from getting clogged by the desiccant and wear a dust
mask, safety glasses and ear protection. (This is only required at initial start-up or after the desiccant
was replaced).
· Slowly open the external inlet valveV-06.
· Check the connections of the dryer for air leaks and remedy if necessary.
· Select the MANUAL mode for sequence of regeneration.
· Switch the dryer package 80-PK-006A ON by putting main switch S1 in position I.
· Let the dryer operate for several hours with the external outlet valve closed.
· In case the silencers were removed, refit the silencers.
· Gradually open the external outlet valve V-08 and start pressurization of instrument air header.
· Open the air supply towards the PDP sensor.
If the application allows air that is not dried optimally, the valve towards the air consumer may be
opened even before the optimal PDP is reached. In this case however it will take more time for the
desiccant to dry completely.
At initial start-up, and especially when the dryer is loaded from the beginning, it can take a long time
before the dew point is reached. For a dew point of -70 ˚C (-94 ˚F), it can take up to more than 10 days
before this value is reached.
It is therefore recommended to operate the dryer for a number of days with the outlet valve closed.
Switch the second dryer package ON and start regeneration.
Once both dryer packages have been regenerated, and the rest of Unit 80 pressurized, switch the
regeneration sequence in AUTO mode.
3.4 FINAL PREPARATIONS
* Inspect the liquid level in wet air receiver 80-V-001 and manually drain the vessel if necessary.
* Ensure all continuous drains are open.
* Ensure the set point of the pressure Controller for air compressors is set at 8.5 bar g and that the
controller is in ""REMOTE".
* Ensure 80-V-01 and 80-V-02 compressors outlet isolation valves are open.
* Wet air receiver bypass valve V-04 to be closed and V-03 to be open.
Utility air header isolation valves V-05 and V-09 to be open.
* Ensure 80-V-06 and 80-V-07 air dryer inlet valves are open and 80-V-08 air dryer outlet valve is open.
Unit 80 is now running and generating Instrument and Plant Air to all its users.
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4.1 GENERAL
The procedures and instructions laid out in this chapter are to be used to start Unit 80 following a
shutdown. The shutdown may have been routine as part of normal operation, turnaround or
maintenance etc., or as a result of an ESD.
None of the preceding reasons for shutdown will necessitate as time consuming a pre-start procedure
as that performed prior to initial startup, as described in chapter 3.
A reasonable degree of experience will enable the operators to carry out a number of the previously
described operations in parallel.
The recommended start up procedure is presented in section 3
The following start up procedures are recommended with the understanding that the judgment of the
operators should dictate which of these steps are required and in what order, based on the nature of the
preceding shutdown. The initial startup instructions presented in chapter 3 should be referred to for
specific details.
* After a shutdown for turnaround and maintenance, startup orders have to be initiated after ensuring that
all requirements relating to plant acceptance and readiness for restart have been fulfilled.
* After an ESD or any unplanned shutdown the unit must be checked over to ensure that the unit is ready
and safe to operate and that the cause of the shutdown has been rectified.
* The restart must be performed in accordance with all SCNL/ RSG OCPP safety regulations and
standing instructions.
The following shall be assumed for the purpose of the startup procedures in this chapter:
* All utility systems (hydrocarbon and non-hydrocarbon) are commissioned and available as required to
the units.
* All instruments and control systems have been checked and are functional.
Note: Before starting the unit, ensure that all continuous drains are open.
4.2.1 Air Compressor Package 80-PK-005A/B
The pre-start check for the compressor and lube oil system should be carried out as described in
section 3.3.1 of Chapter 3 of this manual.
4.2.2 Air Dryer Package 80-PK-006A/B
The pre-start check for the air dryers should be carried out as described in section 3.4.1 of Chapter 3 of
this manual.
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Following a complete shutdown of Unit 80 it should be re-started in the manner outlined in section 3.3 of
Chapter 3 of this manual.
4.3.1 Re-Start following a Compressor Trip

Following a trip of one of the compressors, the second compressor must be started up within 10 minutes
if a trip of all units is to be avoided. This start up can occur in one of two ways:
Note: It is assumed that compressor C-005A has tripped and C-005B is being started, hence the valve
tags apply to C-005B.
· If both compressors are in the "AUTOMATIC" position then the second compressor will start
automatically.
· If the second compressor is in the "MANUAL" position, then the operator has approximately 10 minutes
(the hold-up time in the Wet Air Receiver) to start the second compressor from the local control panel
* Ensure the discharge line block valve 80-V-02 is open.
* Start the compressor in the "LOADED" position by pressing the green start button.
The compressor will start to feed compressed air to the system.
* Once started and running, the compressor can be switched to the "AUTOMATIC" position.
* Oil pressure and temperature should be observed
* Vibration levels should be observed and the compressor should be shut down if excessive vibration
levels exist.
The second compressor will now be running on "AUTOMATIC" and generating air for the Instrument and
Plant Air System.
In order to provide maximum Instrument and Plant Air availability, the cause of the compressor trip
should be determined and rectified as rapidly as possible.
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instrumentation on Unit 80.
4.4.1 Unit 80 Controller Set Points and Alarms
The table contains information for the instrumentation shown on P&ID only.
Controller Alarm Tag No. Range / Set Point Transmitter Function
80-PT-085 8 bar g Monitors the Instrument Air
pressure to distribution
80-PAL-085 7.8 bar g
80-PALL-085 7.5 bar g
80-PALLL-085 7 bar g Auto start of stand by compressor
80-PT-081 8 bar g Controls the Plant Air to
distribution.
67-PAL-3002 6.8 bar g Close control valve UV-081 to
service air header.
Compressor Package 80-PK-005A/B Controllers and Alarms
Factory setting
Motor running time in star sec 10
Load delay time (star-delta) sec 10
Number of motor starts starts/day 240
Minimum stop time sec 20
Programmed stop time sec 3
Power recovery time (ARAVF) sec 15
Restart delay sec 3
Communication time-out sec 20
Unloading pressure bar g 9
Loading pressure bar g 8
Oil pressure (shut-down warning level) bar g 1.3
Oil pressure (shut-down level) bar g 1.2
Delay at start, oil pressure sec 15
Delay at signal, oil pressure sec 6
Compressor element 1 outlet temperature (shut-down warning level) ˚C 225
Compressor element 1 outlet temperature (shut-down level) ˚C 235
Compressor element 2 outlet temperature (shut-down warning level) ˚C 225
Compressor element 2 outlet temperature (shut-down level) ˚C 235
Compressor element 2 inlet temperature (shut-down warning level) ˚C 65
Compressor element 2 inlet temperature (shut-down level) ˚C 70
Oil temperature (shut-down warning level) ˚C 65
Oil temperature (shut-down level) ˚C 70
Service warning level for DP air filter mbar 44
Delay at signal, DP air filter sec 60
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4.4.1.1 Instrument Air Dryer Package 80-PK-006A/B Controllers and Alarms
Controller Alarm Tag No. Controller Set Point Transmitter Function

80-PDAH 586
80-PDAH 587 0.35 bar Differential pressure across pre/
80-PDAH 588 post filters on instrument air
80-PDAH 589 dryers skid
80-AT -70°C @ atm Monitors the moisture content of
the Instrument Air exiting the
dryer package.
Compressed air effective inlet pressure bar g 8.5
Compressed air inlet temperature ˚C 35
Relative humidity of the air at inlet % 100
Pressure dewpoint (standard version) ˚C -40
Limitations for operation
Limitations valid for all dryers
Maximum compressed air effective inlet pressure bar g 11
Minimum compressed air effective inlet pressure bar g 4.2
Maximum ambient air temperature ˚C 41
Minimum ambient air temperature ˚C 2
Maximum compressed air inlet temperature ˚C 59
4.4.2 Unit 80 Trip Settings

For full details of the actions initiated by the trips tabulated below refer to Chapter 7 and the Cause and
Effect Charts to be found in Chapter 9 of this manual.
4.4.2.1 Flow Trips
4.4.2.2 Level Trips
There are no level trips on Unit 80.
Included in cap.4.1 and 4.1.1
Included in cap.4.1.1
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5 NORMAL OPERATION

The function of Unit 80 is to provide Instrument and Plant Air to the rest of the plant at a pressure of 7.5
bar g at the instruments and the plant air connection points. This is achieved by maintaining a Unit 80
battery limit pressure of 8 bar g.
5.1.2 Instrument and Plant Air Pressure Control

Unit 80 is controlled via the pressure transmitter 80-PT-085 which transmits the signal for AUTO start of
stand by compressor.
If the pressure in the Instrument Air header drops below 6.8 bar g then the pressure valve 80-UV-081 on
the Plant Air to Distribution line will restrict the flow of plant air.
Note: If one of the compressors trips, all other units supplied by Unit 80 should be warned.
If the second compressor also fails to start, or trips, all other units should be informed immediately about
the pending loss of Instrument Air. This will enable them to perform an orderly shutdown using the
Instrument Air hold up in 80-V-001 (approximately 15 minutes).
5.1.3 Compressor Changeover

With one compressor running the other compressor can be left in either LOCAL or AUTOMATIC mode
on the local control panel.
Automatic
If the off-line compressor is left in the automatic start position the following must be ensured before
attempting to start:
* The discharge line block valve is open.
* The compressor is left in the "LOADED" position.
The compressor can then be started by using the green push button at the local control panel.
Once the new compressor is running, the other compressor can be stopped.
Manual
If the second compressor is left in manual then the startup procedure for this compressor is outlined in
section 3.1 of chapter 4 of this manual.
The following important points should be noted:
* Always ensure the discharge line block valve is open before attempting to start the compressor.
* Once started, always ensure the second compressor is running satisfactorily before taking the first
compressor off-line (see section 2.2 of Chapter 6).
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5.1.4 Air Receiver Liquid Level Control

The Wet Air Receiver 80-PK-001 is designed to remove any liquids entrained in the air from the
compressors.
Continuous drains are provided at low points located at the outlet from the compressors and bottom of
Wet air receiver.
Note: These drains should be checked periodically to ensure that they are functioning correctly and are
not blocked.
The level in the wet Air Receiver should be checked once per shift at level glass and any excess liquid
drained away manually.
5.1.5 Instrument Air Dew Point Control

The instrument air supply is passed through a dryer to remove any moisture. The dryers are set up in
pairs with one dryer on-line and the other dryer regenerating. The timing of the changeover between
dryers can be controlled in three ways:
· Dew point control.
The dew point analyzer can be used to initiate the changeover of the dryers when the dew point reaches
its set point.
· Timed.
The dryers can be set up to changeover after a set time. There is an alarm fitted to the dew point
analyzer that will alert the operator if the dew point rises to the high level set point before the dryers are
due to changeover.
· Manually.
On the local control panel it is possible to manually advance the dryer program to initiate a changeover.
5.1.6 Dryer Package Changeover

· Manual operation
If maintenance activity - see note 1 - is required in case of ALARMs shown by the DCS, select the
MANUAL operation.
Both the inlet valves EVP-006A/B -see note 2 - are open and both the dryers are RUNNING (the main
switch S1-see note 3 - of each dryer must be "ON" in position 1)
The operator can choose which dryer to switch off proceeding as follows:
Close the manual inlet valve between the wet air receiver 80-V-001 and the manual outlet valve
between the dryer and the dry air consumer.
Let the dryer run for a period without consumption, to depressurize the vessels.
Switch off the dryer by putting main switch S1 in position 0 "OFF".
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· Automatic operation
Local selector: AUTO position
The air dryers switching is controlled by a digital timer, with a standard setting of 168 hours (variable
locally by the operator).
Both the air dryers must have the on/off switch S1 in position 1 "ON"
1. dryer 80-PK-006A running
2. dryer 80-PK-006B freeze - see note 4
3. inlet valve EVP-006A open
4. inlet valve EVP-006B closed
switching after 168 hours by means of the digital timer
5. dryer 80-PK-006B running
6. inlet valve EVP-006B open
7. inlet valve EVP-006A closed with 20 seconds delay
8. dryer 80-PK-006A freeze
Notes:
(1) For maintenance activities read the general recommendation and safety precautions according to
Chapter 7.1 of the Instruction Manual of the air dryer CD35.
(2) The inlet valves EVP-006A/B are normally open and controlled by means of solenoid valves EV-006A/B
normally closed - the minimum pressure required to operate the inlet valves is 4 bar.
(3) Refer to AIR DRYER ELECTRICAL SCHEMATIC DIAGRAM
(4) "Freeze" the drying cycle: the dryer won't switch towers stopping purge air flow - no loss of compressed
air. For further detail see the Instruction Book of the air dryer CD35
No corrosion is expected within the unit, and all vessels and pipework are provided with an appropriate
corrosion allowance.
Areas where corrosion is most likely to occur are in the liquid drains from the vessels, and at low point
drains in the pipework. During annual shutdowns these areas may be visually or ultrasonically
inspected.
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6 NORMAL SHUTDOWN
6.1 GENERAL
For shutdowns of duration longer than a few days it is recommended that the equipment be completely
drained and steamed out as required.
other units, especially as instrument air is vital to the operation of the rest of the plant.
operations to ensure that all requirements of SCNL-RSG OCPP safety regulations and standing
operating procedures are adhered to.
6.2 SHUTDOWN OF INDIVIDUAL EQUIPMENT ITEMS
6.2.1 General
Unit 80 is designed such that the whole unit should never need to be shut down, i.e. 100% redundancy
available. Both compressors are designed for 100% rated flow and there are two identical sets of dryers
also designed for 100% rated flow. Therefore Instrument and Plant Air supply should be uninterrupted
and available right through other unit shutdowns.
The instructions contained in the following section are guidelines for the safe and orderly shutdown of
individual items within Unit 80.
6.2.2 Shutdown and Isolation of one Instrument and Plant Air Compressor
Normal shutdown of one of the compressors will occur either for maintenance or for a routine
compressor changeover. The method of shutting down the compressor is the same for both cases and
is outlined below:
Note: Before shutting a compressor down ensure that the other compressor has been brought on-line
and is functioning satisfactorily using the procedure outlined in section 3.1 of Chapter 4 of this manual.
* Ensure the compressor is "UNLOADED" before shutting it down.
* Stop the compressor by pressing the red "COMPRESSOR STOP" button on the local control panel.
* Close the compressor discharge line block valve, isolating the compressor.
* Switch off the voltage.
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If maintenance is to be carried out on the compressor then steps must be taken to positively isolate:
Disconnect the compressor from the mains.
Shut off and depressurize the part of the air net which is connected to the outlet valve.
Disconnect the compressor air outlet pipe from the air net.
Drain oil and condensate circuits.
Disconnect the compressor condensate piping from the condensate drain net.
6.2.3 Shutdown and Isolation of one Instrument Air Dryer Package
Normal shutdown of one of the dryer packages will occur either for maintenance reasons, changing the
filters and/or the desiccant, or for a routine dryer package changeover.
The procedure for changing over from one dryer package to the other is outlined in section 1.6 of
Chapter 5 of this manual.
If maintenance is to be carried out on the dryers, filters etc., then steps must be taken to positively
isolate the dryer package from the pressurized system.
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7.1 GENERAL
80.

There is no ESD system for Unit 80.

minutes plant operation at normal instrument air demand in the event of an air supply failure.

The Air network system contain only one air actuated control valve UV-081 and the action is fail close.
Instrument air header will continue to be pressurized from Wet Air Receiver 80-V-001
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8 SAFETY
8.1 GENERAL
This chapter contains information on the safety systems installed on Unit 80 and within the Utility Area,
described by drawing 00-ZB-A-85080 and 50-GB-A-85700, for protection from plant fires and gas leaks.
Unit 80 is considered a zone non-hazardous.
8.2.1 General
The Utility Area is provided with a range of firefighting equipment which can be used to deal with plant
fire incidents. Refer to section 2.2, below.
Before attempting to tackle a plant fire, of any magnitude, the operators must be aware of the nature of
firefighting equipment (e.g. water must not be used on an electrical fire; burning liquid spills should be
scale fires can be tackled with hand held extinguishers, major fires should be dealt with from a distance
using deluge systems, firewater monitors and fire hoses.
The Utility Area is provided with a range of safety equipment to protect operating personnel during the
execution of potentially hazardous activities. These activities include: handling the water treatment
chemicals or changing the molecular sieve for air dryers.
The operators should familiarize themselves with the location and the details of operation of all
firefighting and safety equipment.
It is the responsibility of the safety officer to periodically check the firefighting and safety equipment to
At the Unit 80 Area the following types of firefighting equipment are provided to protect the installed
equipment:
* Fire Hydrant
* Fire Extinguishers
Two different types of fire extinguisher are provided on the Utility Area, namely dry chemical powder,
and CO2. Each of these types is provided as either portable units, (9 kg dry chemical powder, 5 kg
CO2), or as wheeled units (75 kg dry chemical powder, 2 x 9 kg CO2 shelters).
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At the Utility Area the following types of safety equipment are provided to protect operating personnel
during the execution of their duties:
* Safety Signs
Throughout the Utility Area numerous safety signs are provided to assist the operators. They describe
various hazards, the location of firefighting equipment, the location of safety equipment and provide
mandatory safety instructions ("wear ear defenders", etc.).
8.2.4 Fire and Gas Detection

The Utility Area has no fire detection equipment
8.3 SAFETY PRECAUTIONS FOR AIR COMPRESSORS
8.3.1 General precautions

· The operator must employ safe working practices and observe all related work safety requirements and
regulations.
· If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
· Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
· The compressor is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
· Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor,
press the emergency stop button, switch off the voltage and depressurize the compressor. In addition,
the power isolating switch must be opened and locked.
· Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
· The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
· It is not allowed to walk or stand on the roof of the compressor canopy.
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8.3.2 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or non-
observance of the normal caution and care required for installation, operation, maintenance and repair,
even if not expressly stated, will be disclaimed by the manufacturer.
· The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
· Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
· Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
· Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
· The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents that can
lead to internal fire or explosion.
· Arrange the air intake so that loose clothing worn by people cannot be sucked in.
· Ensure that the discharge pipe from the compressor to the after cooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
· No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
· If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch is open and
locked before any maintenance or repair. As a further safeguard, persons switching on remotely
controlled machines shall take adequate precautions to ensure that there is no one checking or working
on the machine. To this end, a suitable notice shall be affixed to the start equipment.
· Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
· The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be
installed near the compressor.
· On machines with automatic start/stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
· In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-
return valves (check valves) must not be relied upon for isolating pressure systems.
· Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure-relieving device or devices as required.
· Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high-temperature piping
must be clearly marked.
· For water-cooled machines, the cooling water system installed outside the machine has to be protected
by a safety device with set pressure according to the maximum cooling water inlet pressure.
· If the ground is not level or can be subject to variable inclination, consult the manufacturer.
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8.3.3 Safety precautions during operation

· Never touch any piping or components of the compressor during operation.
· Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
· Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the
remote start equipment.
· Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
· Never operate the machine below or in excess of its limit ratings.
· Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to
carry out routine checks. Wear ear protectors when opening a door. On compressors without bodywork,
wear ear protection in the vicinity of the machine.
· People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
· Periodically check that:
 All guards are in place and securely fastened
 All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
 There are no leaks
 All fasteners are tight
 All electrical leads are secure and in good order
 Safety valves and other pressure-relief devices are not obstructed by dirt or paint
 Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair,
free of wear or abuse
· If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
· Do not remove any of, or tamper with, the sound-damping material.
· Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure-relieving device or devices as required.
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8.3.4 Safety precautions during maintenance or repair

· Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
· Use only the correct tools for maintenance and repair work.
· Use only genuine spare parts.
· All maintenance work shall only be undertaken when the machine has cooled down.
· A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting
equipment.
· Close the compressor air outlet valve before connecting or disconnecting a pipe.
· Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
· Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
· Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
· Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
· Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
· Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
· Make sure that no tools, loose parts or rags are left in or on the machine.
· All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
· Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly. If removed, check that the coupling guard of the compressor drive shaft has
been reinstalled.
· Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
· Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam-cleaning.
· Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged,
replace it by genuine material from the manufacturer to prevent the sound pressure level from
increasing.
· Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
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8.4 SAFETY PRECAUTIONS FOR AIR DRYERS
8.4.1 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or
nonobservance of the normal caution and care required for installation, operation, maintenance and
repair, even if not expressly stated, will be disclaimed by the manufacturer.
General
· The operator must employ safe working practices and observe all related local work safety requirements
and regulations.
· If any of the following statements does not comply with local legislation, the stricter of the two shall
apply.
· Before carrying out any maintenance, repair work, adjustment or any other non-routine checks, stop the
device. In addition, the power isolating switch must be opened and locked.
Precautions during installation
· Place the device where the ambient air is as cool and clean as possible.
· During installation or any other intervention on one of the connected machines, the machine must be
stopped, de-energized and the isolating switch opened and locked before any maintenance or repair. As
a further safeguard, persons switching on remotely controlled machines shall take adequate precautions
to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall
be affixed to the start equipment.
· The electrical connections must correspond to the local codes. The device must be earthed and
protected against short circuits by fuses in all phases.
· A lockable power isolating switch must be installed near the device.
· For machines controlled by a central control system, a sign stating "This machine may start without
warning" must be affixed near the instrument panel.
· In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-
return valves (check valves) must not be relied upon for isolating pressure systems.
· Never remove or tamper with the safety devices.
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8.4.2 Safety precautions during operation

General precautions
and regulations.
apply.
Precautions during operation
· Never operate the device in the presence of flammable or toxic fumes, vapors or particles.
· Never operate the machine below or in excess of its limit ratings.
· Keep all bodywork doors and panels closed during operation. The doors may be opened for short
periods only, e.g. to carry out routine checks. Wear ear protectors when opening a door if applicable.
· People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB (A)
shall wear ear protectors.
· Periodically check that:
 All guards and fasteners are in place and tight
 All hoses and/or pipes are in good condition, secure and not rubbing
 There are no leaks
 All electrical leads are secure and in good order
 Never remove or tamper with the safety devices.
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8.4.3 Safety precautions during maintenance or repair

General precautions
and regulations.
apply.
Precautions during maintenance or repair
· Use only the correct tools for maintenance and repair work.
· Use only genuine spare parts.
· A warning sign bearing a legend such as "work in progress; do not start" shall be attached to the starting
equipment, including all remote start equipment.
· Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
· Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
· Never use a light source with open flame for inspecting the interior of the device.
· All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
· Before clearing the device for use after maintenance or repair, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly.
· Never use caustic solvents which can damage materials of the air net.
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9.1 DATASHEETS

9.1.1.1 Compressor Package Datasheets
Compressor Package Datasheets 80-MA-E-90271
9.1.1.2 Air Dryer Package Datasheets
Air Dryer Package Datasheets 80-MA-E-90272
9.1.1.3 Wet Air Receiver
Wet Air Receiver 80-MA-E-98421
Instrument Datasheets 00-ZA-E-86328
00-ZA-E-86327
9.2 CAUSE AND EFFECT CHART
Cause And Effect Chart 00-ZA-E-86925
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10 DRAWINGS
10.1 1PIPING AND INSTRUMENTATION DIAGRAMS
Enclosed in this section are the following P&IDs

80-GD-B-86553 P&ID – Instrument Air Compressors Packages
80-GD-B-86554 P&ID – Service and Instrument Air Systems
80-GD-B-62801 P&ID – Service and Instrument Air Distribution
10.2 2PLOT PLANS
Enclosed in this section is the following Plot Plan:

00-GB-A-62030 General Plot Plan
10.3 3LOGIC DIAGRAM
Enclosed in this section is the following Logic Diagram:

00-ZA-E-86925
10.4 4FIRE AND SAFETY LAYOUT DRAWINGS
Enclosed in this section are the following drawings:

50-GB-A-85700
00-ZB-A-85080
10.5 FIRE AND GAS DETECTION SYSTEM LAYOUT DRAWINGS
Enclosed in this section is the following Fire and Gas Detection Layout Drawing:
00-ZB-A-85020
80-MA-E-98416 O&M Manual Compressor and Air Dryer Package
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11 IV UNIT 40 - OPEN DRAINS

1 DESIGN BASIS
1.1 GENERAL
The Unit is composed of two systems:

1 • Sanitary Sewer System
• Trafo Oil Drainage System
1.1.1 Process Purpose
The Sanitary System purpose is to collect sanitary waste from local control building of Rivers
State OCGT Power Plant to a Sanitary Water Pit in order to be disposed by truck.
The Trafo Oil Drainage System purpose is to collect oil, fire water and potentially oily
water (rain water) into two sumps located under the transformers.
1.2 UNIT CAPACITY
40-S-002
Working volume 13 m³
40-S-001
Working volume 166.55 m³
40-S-003
Working volume 8.14 m³
40-P-003
Rated flow 20 m³/h
Head at rated capacity 10 m
BHP 1 kW
1.3 DESIGN CONDITIONS
Here below are reported the most significant data for the aim of this duty specification:
· Maximum ambient humidity: 83%
· Ambient temperature: min/ norm/ max 13/31/41 °C
· Maximum wind speed: 137 Km/h
· Maximum rainfall: 88 mm/h
.
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1.4 MATERIALS
Both basins are built in concrete.

Additionally, the sump 40-S-003/001 water drain pits to be covered with grating and filled of gravel layer
(gravel granulometry 40-60 mm).
General notes valid for the sump 40-S-001 and for sump 40-S-003 water drain pits:
· The gravel shall be of “round type” to avoid the obstruction because of dust deposition.
· The grating supporting the gravel shall be of galvanized iron to avoid both iron oxidation and consequent
reduction of the load capacity and electromagnetic phenomenon that should increase electrical loss in the
transformer with an overheating of itself.
· The kerbed area covered with 300 mm (min) gravel layer shall include also the areas under possible oil
containers, e.g. oil coolers, to promote the fire extinction also under these areas.
1.5.1 Sanitary Sewer System

The Waste Water System designed to collect 3200 l/day (400 l/day of water consumption for estimated
8 persons) with four days of hold-up sump. The pit working volume is 13 m3.
1.5.2 Trafo Oil Drainage Systems
1.5.2.1 Transformer Oil Collection Basins 40-S-001 & 40-S-003
The basin 40-S-001 is sized to contain the oil discharged from the transformer plus ten minutes of the
fire water flow rate.
The basin 40-S-003 is sized to contain the 20% of the oil discharged from both the transformers and the
20% of ten minutes of the firewater flow rate.
As shown on table 1, the main basin (40-S-001) will have a gross working volume of 166.55 m3
considering an oil volume of 53 m3, a fire water volume of 47.5 m3, the gravel Layer and dead volume
for internal elements.
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Table 1: Sumps 40-S-001 & 40-S-003 Process Data
Basin Tag 40-S-001 40-S-003
Transformer 10-TRM 10-TRU,10-TRS
OIL CONTAINED IN THE TRANSFORMER 45 4.85 (1,2)

OIL DENSITY AT THE HIGHEST TEMPERATURE
850 (3) 850 (3)
(80°C)
OIL VOLUME 53 5.7
NET FIREWATER FLOWRATE 285 210
DRAINAGE TIME (4) 10 10
WATER VOLUME 47.5 35
TOTAL VOLUME WATER+ OIL 100.5 45
· Sump (gross) working volume 166.55 8.14 (5)

· Sump dimensions
12.95/8.5/1.45 10.05/6.92/ 0.55
(L / W / H)
Note (1): Preliminary value from TECE/ELTERM Dpt.
Note (2): 3.85 tons is the oil contained in 10-TRU, 1 ton is the oil contained in 10-TRS.
Note (3): Estimated value.
Note (4): According to NFPA 850 Par 3.6.2
Note (5): Volume limited to the containment of the 20% of both 10-TRU & 10-TRS transformers oil and of
the 20% of ten minutes of the fire water flow rate. The sump 40-S-003 has not a storage function; the
configuration of the system is such to allow, through a pipe, the gravity flow into the sump 40-S-001.
1.5.2.2 TRM Sump Pump 40-P-003
The pump 40-P-003 is located inside the basin 40-S-001.
The main input design data used for pump sizing are:
 Maximum rainfall intensity: 88 mm/h
 Basins total area (see table 1 on § 1.5.2.1 ): 179.3 m2
 Design flow rate: 20 m3/h
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1.5.2.3 Potentially Oily Water Pit and Sluice 40-Sl-001

As described above, the Potentially Oily Water Pit task is to collect the first ten millimetres of storm
water considered “potentially oily water”.
After the first 10 minutes from the starting of a rainy event the operator shall intercept this water through
the closing of the manual sluice 40-SL-001.
The main input design data used for pit sizing are:
· Maximum rainfall intensity: 88 mm/h
· Basins total area (see table 1 on § 1.5.2.1): 179.3 m2
· mm of water “potentially contaminated by oil” 10 mm
· The resulting main output data are:
· Pit working volume: 1.74 m3
· Pit design volume: 1.92 m3
· Potentially Oily Water Pit dimensions (L / W / H): 2000 mm x 1200 mm x 2650 mm
Two Service Water hose connections for discontinuous cleaning operations of the Sanitary Water Pit.
The following Utilities and interfaces must be available for a proper operation of the Trafo Oil Drainage
System:
· Electric power for discontinuous maintenance operations.
· Service water hose for sumps maintenance operations.
.
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2.1 PROCESS DESCRIPTION

Sanitary Water from the toilets located in the Local Control Building by gravity is collected
into the Sanitary Water Pit (40-S-002) where a settling of heavier solids occurs, forming sludge
on the bottom of the pit.
The pit is provided with the following facilities:
· High and High High level alarm to indicate when the pit shall be emptied by tanker.
· Two Service Water connections for fluidizing the solids accumulated in the bottoms.
The disposal of waste water by truck will be carried out with the frequency not less than once
every four days.
2.1.2 Trafo Oil Drainage System
The two transformer oil collection basins are:
· 40-S-001 “TRM Collection Sump”
· 40-S-003 “TRU & TRS Collection Pit”
The sump 40-S-001 is placed under the transformer 10-TRM; it shall have a local level indicator (to
allow operator to check daily the sump level), a submersed pump (40-P-003) installed on a drain pit, a
manual sluice
(40-SL-001) and a potentially oily water collection pit.
The sump 40-S-003 is placed under the transformers 10-TRU & 10-TRS.
Normally both basins 40-S-001 & 40-S-003 are empty.
In the case of a rainy event, the potentially oily water, collected under the transformers and
corresponding to the first ten millimetres of rain water, will be collected and sent by gravity into the
potentially oily water pit in the basin 40-S-001 separated from the rest of the basin by a manual sluice
40-SL-001.
Operator shall close manually the sluice 40-SL-001 after ten minutes from the starting of the rainy event
and the potentially oily water trapped in the pit will be unloaded through a tanker. After first ten minutes
of rain, the storm water will be collected in the sump and the submersed pump 40-P-003 will be started
manually and discharged into sump surrounding area, then the sluice 40-SL-001 will be open.
In case of emergency, with a discharge of oil and the start of the fire water system, will be necessary to
let the oil separate from water, then to discharge most of the separated water through the pump 40-P-
003 started manually; the remaining water with oil will be recovered through a road tanker.
A kerbed area, filled with 300 mm of gravel layer (gravel granulometry 40-60 mm), will be located
around the basin 40-S-001.
The kerbed area will be equal to the external perimeter of the transformer (keeping into account also
the space occupied by transformer accessories) increased with at least 20% of the height of the
transformers. .
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No process control is needed in this System.
2.2.2 Trafo Oil Drainage System
Pump 40-P-003 will be provided with a floating type low low level switch for pump trip.
No other process control is needed in this System.
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3.1 GENERAL
startup of a new unit. Procedures are slightly adapted for normal and subsequent start up.
It is assumed that all the pre-commissioning activities are completed and that the unit has reached a
"ready for startup" status.
¨ All pipe work has been pressure tested and cleaned.
¨ All equipment is at ambient conditions.
¨ All instruments have been calibrated, loops checked and commissioned.
¨ All the DCS data links are operational.
satisfactorily.
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3.3 SANITARY SEWER SYSTEM COMMISSIONING AND STARTUP
· Start using water inside Control Room Toilet/ Shower. Check the arrival point N1 at the sanitary pit for
any possible blockage.
· Start building the level. For faster action, open the 1” valves used for flushing-fluidizing the pit bottom
solids.
· Check if alarms HLL and HHLL are activated and close 1” valves.
· Connect a hose and start to empty the sanitary pit using a vacuum truck.
· Check if alarms HHLL and HLL are cleared in control room.
At this stage, commissioning of Sanitary Sewer System can be considered completed.
3.4 TRM SUMP MANUAL SLUICE 40-SL-001
The gate sealing capacity should be checked prior commissioning of Trafo oil drainage system.
· Lower the gate to its fully closed position.
· Start building the level inside potentially oil water pit by using a hose connection from a water truck or
from the hydrant or from the service water system.
· Leakage allowed is 0.2 liters/sec/m.
If this requirement is fulfilled, proceed to the next step of commissioning operation.
3.5 TRAFO OIL DRAINAGE SYSTEM COMMISSIONING AND START UP
It is a good opportunity to correlate commissioning of Trafo oil drainage system with commissioning of
deluge system.
In this case the performance for deluge system can be monitored and in the same time this amount of
water will be used to build up the level inside the pit.
Check for any blockage at 12” pipes for sump 40-S-003 to sump 40-S-001.
After the LL level at 40-S-001 pit is cleared, observe the normal functionality for local level indication.
In this moment TRM Sump Pump 40-P-003 is ready for start up.
3.6 COMMISSIONING OF TRM SUMP PUMP 40-P-003
· Crack open the discharge valve for TRM Sump Pump.

· Ensure the power supply is available and press the "START" command located at local panel.
· Open gradually the delivery valve until fully open and observe the running of the pump, and when
running smoothly leave the pump running at full rate for 3 hours. Record the parameters.
· The pump can be stopped at the local panel by pushing the red "STOP" pushbutton located on the local
pump control panel.
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4.1 GENERAL
40.
There is no interlock system implemented.
4.2.1 Electrical Power Failure
There is no special measure to be taken in order to mitigate potential problems associated with partial
power failure.
4.2.2 Service and potable water
There is no special measure to be taken.
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5 SAFETY
5.1 GENERAL
Unit 40 is an inherently safe unit.

with unit fire incidents only. Refer to section 2 below.

The existing fire hydrant and additional portable dry chemical powder fire extinguisher located close to
the pump are considered adequate to combat any possible fires.
In Unit 40 the following types of safety equipment are provided to protect operating personnel during the
execution of their duties:
¨ Safety Signs
Throughout Unit 40 numerous safety signs are provided to assist the operators. They describe various
hazards, the location of firefighting equipment, the location of safety equipment and provide mandatory
safety instructions ("wear ear defenders", etc.).
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6.1 DATASHEETS

Process Data Sheet for TRM Sump Manual Sluice 40-MA-E-98803
Process Data Sheet for TRM Sump Pump 40-MA-E-98250
Instrument Datasheets 00-ZA-E-86328
6.2 OTHER DOCUMENTS
Duty Specification for Sanitary Water Pit 40-CA-E-86107

Duty specification for Transformer Oil Collection Basins 40-CA-E-86106
Installation and Maintenance TRM Sump Manual Sluice 40-MA-E-98804

Operating and Maintenance, Commissioning and Start Up 50-MA-E-98203
Manual Gruppo Aturia
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7 DRAWINGS
Open Drain System – Transformer Oil Collection Basins 40-GD-B-86550

Open Drain System – Sanitary Water Pit 40-GD-B-86551
7.2 PLOT PLAN

7.3 LAYOUT DRAWINGS

Sanitary sewer system layout 00-CE-A-12021
TRM Sump pump layout and foundation 40-MA-E-98255
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V UNIT 70 - FUEL GAS

1 DESIGN BASIS
1.1 General
1.1.1 Scope
Present document represents the duty specification of Natural Gas fuel supply system for the new
Power Station to be realized in River State (Nigeria).
The Metering and reduction station will be installed to feed an Open Cycle Power Plant based on the
following main equipments:
· Gas Turbine Generator with its auxiliaries
· Balance of Plant
1.1.2 Integration of Unit 70 in the Overall Plant
The System will consist of the main sections listed here below, with piping, valves and all necessary
equipment for fuel conditioning before feeding the Natural Gas to the Gas Turbine fuel supply system:
· Gas heating section: Heating the gas, as required, to comply with the gas turbine superheat requirement
to preclude the deposition of hydrates in the pressure reducing valves (PRV).
Heating the fuel gas also insures that the gas turbine DLN combustion system will operate properly.
· Gas filtration section: Filtering the customer supplied fuel gas of entrained particulate matter that would
be deleterious to the satisfactory operation of the gas turbine.
· Gas flow measurement section: Metering Station
· Gas flow/pressure/temperature control section: Reduction Station to keep pressure at GT fuel supply
terminal point within the specified range.
This is a brief description of the design and operating guidelines for the aforementioned subsystems
performed to bring the fuel gas into compliance with GT manufacturer requirements at GT fuel gas
conditioning skid inlet battery limit.
As far as applicable to the subject of the present specification the following equipments are the typical
components of the fuel gas supply system, object of the present document:
· Filter Separators
· Fuel Gas Heaters
· Automatic Fuel Gas Shutoff Valve
· Pressure Reducing Valve (PRV) Stations
· Pressure Relief valves
· Automatic Fuel Gas Vent / Depressurizing valve
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1.2 UNIT CAPACITY AND GAS QUALITY
1.2.1 Unit Capacity

It will refer to the following P&ID:
70-SD-A-53301 – Natural Gas Metering and Reducing Station P&ID
· 70-E-001A/B Fired Water Bath Heaters
Size (ID X L) 2000 x 7500 mm
Design Condition ATM and @ 90°C
Material Carbon Steel
· 70-M-001A/B Burner
Type Forced Draft
Installed Power 2 Kw
· 70-B-001A/B Air Blowers
· 70-EH-001 Start Up Electric Heater
Size (ID X L) 146 x 1250 mm
Design Condition 60 bar (g) @ 80°C
Heater type Electric
· 70-MS-003 A/B Dust Filters
· 70-MS-002 A/B Dust Filters
1.2.2 Material Balance
Refer to doc. 70-SA-E-53326
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1.3 PRINCIPLE OF OPERATION
The Power plant Gas turbine and associated auxiliaries will be fed by Natural Gas, coming from the pipe
line by means of a flanged inlet header
(INLET SKID 70-ME-004).
Natural gas heating before pressure reducing shall be provided in order to compensate the temperature
drop associated to pressure reduction avoiding the dropping below the dew point of the gas and keeping
the gas temperature within the limits given by the gas turbine manufacturer (no hydrates and liquids
formation): this system shall ensure the minimum temperature of Gas Turbine fuel conditioning skid
battery limits for a stable operation of the GT combustors. However, the gas temperature shall be at
least kept so that no water shall condense from the atmosphere on the external surfaces of the gas line.
After the heating section, Natural Gas will be filtrated in order to separate the solid contaminants.
After filtration, natural gas is routed to the fiscal flow measurement section.
The gas chromatograph (GC) and auxiliaries will be installed downstream the metering section on a
suitable rack (Analyzer cabinet), properly designed and located close to the gas metering skid. The gas
chromatograph shall be specially designed for natural gas composition measurement and heating
value determination, and will consist of the following units as a package in the cabinet:
· Sampling system
· Analyzing unit
· Data converter
The HC Dew Point Analyzer and auxiliaries will be installed at the outlet of the station on a suitable rack
(Analyzer cabinet), properly designed and located close to the outlet skid.
Natural gas Pressure shall be reduced from pipe line pressure up to values suitable for GT feeding.
The gas turbine is equipped with automatic block and bleeds fast acting valves (supplied by GT
manufacturer) for stopping and depressurizing the downstream fuel supply piping up to combustors.
The Natural gas measuring and reduction station is mainly operated by system of automatic valves for
continuous operation and main process parameters are mounted by logical implemented in the control
system: operator action is required only to change the normal operation status or in case of abnormal
conditions which could cause trip activation or shutdown of the equipment.
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1.4 UTILITIES
The utility requirement on Unit 70 is as follows:

· Instrument Air consumption regards the vortex cooler at the AT-519 HC dew point analyzer and the
charge of pneumatic actuator tanks of SSD valves UV-501 and
UV-600 (400 l/min).
· Reported water consumption regards the whole filing of empty 70-E-001A/B (19 m3).
Water evaporation loses approx. 30 l/month.
· Power supply for Control Panels 70-LP-E-001A/B (400 V), Start Up Electrical Heater 70-EH-001 (400
V), and the power supply distribution panel 70-PSD-001 located inside the gas station control shelter
70-CL-001 (230V; 2 feeders from UPS and 1 feeder from ))-PMCC). The power supply distributuion
panel 70-PSD-001 will provide the power supply distribution to the following equipments:
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2.1 NATURAL GAS HEATING SECTION
2.1.1 INLET SKID 70-ME-004

The Power plant Gas turbine and associated auxiliaries will be fed by Natural Gas, coming from
the pipe line by means of a flanged inlet header (INLET SKID 70-ME-004) equipped with:
· 6” inlet ball valve
· Single Depressurization Line complete with
o N 2 manual ball valve
o N 1 manual globe valve NPS 4” #600RF
o N 1 spectacle blind disk 4”#600RF
o N 1 flow reducer orifice plate
o N 1 flame arrestor
· 6” Valve with pneumatic actuator single effect fed by instrument air (Fail Close action in case of air
failure or electric failure) according with 2 solenoid valves UV-7 typical drawing (Normally Energized to
open and De-energized to close) and limit switches. The valve with pneumatic actuator shall be
complete with instrument air reserve pot suitable to guarantee two open/close cycles
· Ancillaries, Valves and Instrumentation.
2.1.2 Water bath heater (70-E-001A/B)
Natural gas heating before pressure reducing shall be provided in order to compensate the temperature
drop associated to pressure reduction avoiding the dropping below the dew point of the gas and keeping
the gas temperature within the limits given by the gas turbine manufacturer (No hydrates and liquids
formation): this system shall ensure the minimum Temperature of Gas Turbine fuel conditioning skid
battery limits for a stable operation of the GT combustors.
However, the gas temperature shall be at least kept so that no water shall condense from the
atmosphere on the external surfaces of the gas line.
The gas heaters shall be fired with natural gas and be equipped with mainly:
· one (1) pressure control valve
· one (1) combined monitor control / slam shut off valve
· On- off valves, safety valves
· Burners
· Burner management system (to be installed in Gas station control shelter 70-CL-001)
· Water make up
· Nitrogen blanketing system (hoses with connections and arrangement to install Bottles rack skid)
· Heat insulation
· Ancillaries, Valves and Instrumentation
The water bath gas heaters shall have stainless steel tube bundles and tube sheets.
Gas heating shall be based on two (2) Natural gas water bath heaters design
(n° 2 parallel lines each designed for 100% of flow rate and 100% of the requested duty), to be installed
immediately downstream of the inlet skid.
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Burners of WBH will be fed by gas extracted from main run pipe downstream of the WBH and upstream
of the filtering and metering station by means of two (2) dedicated pressure filtering/reducing/metering
units (Fuel gas skid 70-ME-003 A/B).
Gas to burners shall be measured by an electronic volume conversion device
(FT, TT, PT), tagged 70-FQI-510.
During Start-Up, Natural Gas needs to be preheated by a dedicated electric startup heater (70-EH-
001), ON/OFF type complete with bypass line in order to guarantee fuel gas preheating during turbine
start-up and normal operation. During normal operative condition, the electrical heater is switched off,
so the supplier shall provide an heating system of fuel gas with tubing inside the hot water bath.
BMS shall carry out the gas temperature control by means of a temperature set point from Control
System that shall implement an algorithm (included in scope of supply) with temperature signals
coming from 3 Temperature Transmitters (2oo3 logic).
These transmitters shall be provided as loose items including thermowell and thermoelement and
complete with the equipment for piping connections (i.e. flange, nozzle and weldolet) at the outlet of the
gas reduction station for temperature control loop.
2.2 NATURAL GAS FILTRATION AND FLOW MEASUREMENT
After the heating section, Natural Gas will be filtrated in order to separate the solid contaminants.
Filtration will be achieved by means Nr. 2 Fiberglass Filtering units (one main and one stand by) 70-
MS-002 A/B, (2 parallel lines each designed for 100% of flow rate), skid mounted, with all required
piping, valves, instrumentation, metallic construction and fittings as required; plugging and/or fouling of
the running filter will be monitored by differential pressure measuring indicating instruments with
remote transmission of signal of high ΔP for alarming in Gas station control system.
2.2.1 Gas Filter Separators (70-MS-002 A/B)
Nr of units: 2 (1+1)
Capacity: 9.8 Kg /s
Design Press: 60 bar (g) 
Design Temp: -10/+80°C
Filtration degree: 98% of solid particles larger ≥ 5 μm
100% of solid particles larger ≥ 10 μm
95% in weight of entrained liquid droplets
Clogging level of filters will be monitored by means of differential pressure indication both locally and
remotely, and a high ΔP alarm will be transmitted remotely.
Filters pressure drop shall not exceed 0.25 bar when new and clean at the design flow at minimum
inlet pressure.
Liquid hold up capacity shall not be less of 12 % of total gross volume of filter shell, liquid accumulation
shall not affect the gas passing part in order to avoid liquid entrainment.
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2.2.2 Natural gas Fiscal flow metering 70-ME-001 A/B

After filtration, natural gas is routed to the fiscal flow measurement section which consists of n°2 (two)
parallel lines 70-ME-001A/B, one in operation and the other in standby, each of them with the following
main components:
· Nr.1 flow meter certified (Special version for High temperature).
· Nr.1 flow computer, installed in the dedicated Metering Panel 70-MP-001, (located in Gas Station
control Shelter 70-CL-001), containing:
· computation units certified by fiscal authority, with printer, temperature/pressure/flow recorder, remote
data transmission module (for remote transmission of pressure, flow, temperature data and alarming in
case of general malfunctioning of the system), serial link (RS 485 modbus protocol), analog output (4-
20mA for Temperature, Pressure, Flow), digital output (SPDT) for computer anomaly.
· redundant power supply with back-up battery (sealed type, automatic recharge).
· devices for protection against overvoltage and transients.
· Armored Eex-i cables (blue cables) to connect flow meters, temperature and pressure
· transmitter to flow computers.
· The system is equipped with a by-pass link in order to compare the measurements of both flow meters
2.2.3 Analysis unit: Gas chromatograph 70-AT-514
The gas chromatograph (GC) and auxiliaries is installed downstream the metering section on a suitable
rack (Analyzer cabinet), properly designed and located close to the gas metering skid. The gas cylinder
rack is installed and protected with a suitable canopy to prevent direct sun radiation and rain.
The sampling system consists of the following sub-systems:
· Sample probe.
· Sample transport/fast loop from sample probe to analyzer cabinet.
· The sample conditioning system (SCS) with associated sample conditioning hardware for each
analyzer.
· Carrier and calibration/validation gas cylinders.
· Utilities and vents.
The sample conditioning system has been designed to provide usable and representative sample
to the analyzers. Each gas cylinder has been provided with two stage pressure regulator, pressure
gauges, manifolds and associated equipment.
The gas chromatograph has been specially designed for natural gas composition measurement and
heating value determination, and will consist of the following units as a package in the cabinet:
· Sampling system
· Analyzing unit
· Data converter
The components measured are C1 to C6+, N2 and CO2
Based on the measured gas components the chromatograph will calculate the following parameters:
• Heating Value
• Relative density
• Standard density
• Compressibility factor at standard condition in accordance with ISO6976
• Wobbe Index
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Gas chromatograph will be interfaced via serial link RS 485 (Modbus protocol) with the metering
computers that provide its power supply.
The controller will have a built-in self-diagnostics with means of indicating and recording malfunction of
analyzer hardware and software to send to Control system in the control room. A HDM device (part of
GC) shall be fitted in the flow computer cabinet (70-MP-00).
2.2.4 Analysis unit: HC Dew Point Analyzer 70-AT-519
The HC Dew Point Analyzer and auxiliaries will be installed at the outlet of the station on a suitable
rack (Analyzer cabinet), properly designed and located close to the outlet skid.
The system will be fed by the metering computers and it will be directly interfaced via HW link to Control
System.
2.3 NATURAL GAS PRESSURE REDUCTION
Natural gas Pressure shall be reduced from pipe line pressure up to values suitable for GT feeding.
2.3.1 Pressure Reduction skid (70-ME-002 A/B)
The pressure reducing section consist of N°2 reducing lines, designed for total flow rate (100%), one in
working condition and the other in stand-by status. Each pressure reducing line consists mainly of two
pilot operated pressure reducing valve top-entry design; one is the main regulator and the other is used
as a monitor/slam shut valve. The operation of these both valves is fully pneumatic; internal high
pressure feed allows the operation of the pneumatic actuator, while the pressure signal coming from
downstream regulates the open position of the valve’s stem.
Each line shall be equipped with:
· One (1) pressure control valve.
· One (1) monitor control valve.
· One (1) fast acting slam shut off valve (built-in the same body of monitor regulator)
· Temperature transmitter for remote control with high / low natural gas temperature alarms.
· Pressure relief valve downstream the PRV sized in order to vent the gas leaking with control valve
closed.
· Piping, valves and fittings as required.
Each pressure reduction line of the main reducing stations, both main section and start-up section, is
equipped with one fast acting SLAM SHUT OFF VALVE (with limits switches) for isolation in case of
overpressure caused by gas leaking through the pressure reducing valves.
Main control valves will have the following features:
· body /trim material: see piping class, referring to P&ID.
· with limits switches.
· “Fail to open” piloted.
· embedded silencer.
· Monitor valves will have the following features:
· body /trim material: see piping class, referring to P&ID.
· “Fail to close” piloted.
· embedded silencer.
· limit switch for active monitor.
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The active regulator normally assures pressure reduction to the setting value. To assure gas supply
continuity in case of failure of the active regulator a second regulator (the monitor regulator) is installed
in series with, and upstream of the active regulator. The monitor regulator is normally wide open as it is
set to regulate to a higher pressure. In the event of an accidental increase of outlet pressure (indicating
failure of the active regulator) the monitor regulator will take over as the main control valve.
During the normal operation, depending from the services one line is working while the other line is in
stand-by. Only in case of a failure of the monitor and main regulator of the operative line, the standby
line will be actives manual switch.
A self-operated overpressure shut off device (slam-shut) operates in the event the outlet pressure
exceeds acceptable a safe value and protects the equipment downstream of the pressure regulators
from over-pressure. The slam-shut devices acts on the pressure regulators and cause them to close
rapidly.
To minimize accidental intervention of the slam-shut device, a peak shaving pilot- operated pop
acting relief valve is installed on the outlet header of the station. This valve is designed to release
relatively small quantities of gas only.
Both pressure reducing lines is supplied with relevant blind disk to prevent any dangerous situation
during maintenance operation of the line.
Pressure setting of each pressure control valve is made in order to assure the operative range of
pressure for function of the gas turbine, according to pressure operative range requested by turbine
supplier.
Equipment has been positioned in order to withstand to fuel consumption as per attached GT load
curves:
· HTCT 682 273 Rev - Start on fuel gas with purging;
· HTCT 682 275 Rev - DE loading and shutdown fuel gas.
Note: typical reference curve, to be used for equipment design. HRSG purging is not applicable.
2.4 CONTROL PHILOSOPHY AND OPERATIONS DESCRIPTION
2.4.1 Automatic Control Description

The unit is mainly operated by a system of automatic valves for continuous operation and main process
parameters are controlled by logics implemented in the control system. For the description of the control
loops, the following conventions where applicable have been followed:
· Control action is selected on the basis that 100% output represents 100% device (valve, louvers, etc.)
open.
· Direct acting controllers are those in which an increase in error (where error is measured variable minus
set point), causes an increase in controller output.
· Similarly, reverse acting controller are those in which an increase in error causes a decrease in
controller output.
· High and low signal selectors refer to the required valve (or machinery) actions, so that a high signal will
open (or close) a valve (or start/stop a machinery), a low signal will close (or open) a valve (or stop/start
machinery).
Appropriate signal conditioning and/or output characterization shall be applied to match the failure
action of final control elements to the above conventions. Where a single controller is used to
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manipulate two or more final control elements, e.g. a split range control scheme, provision shall be
made that in manual mode the Operator can manipulate each final control element independently of the
others.
2.4.2 70-M-001A/B Burner installed in 70-E-001A/B Water Bath Heater
Natural gas temperature control at unit outlet is achieved controlling the water bath heaters 70-E-
001A/B (liquid bath) temperature. Control is achieved with two cascade controllers, controller TICA-521
(master) implemented within the control system regulating gas temperature at unit outlet and TICA-503
(slave) controlling the liquid bath temperature. Measured control variable is the gas temperature
downstream the pressure regulator section, set point temperature of outlet gas is adjusted by operator.
2.4.2.1 Gas Outlet Temperature
Gas outlet temperature is controlled by a master/slave control loop.
Process variable, gas temperature downstream the regulator section is measured prior entering gas
turbine section by three temperature elements. The temperatures measured are then processed by 2
out of 3 average logic by reverse acting PID controller TICA-521, the difference between the Operator
set point and the measured temperature produce a signal (4-20mA) to slave TICA-503.
2.4.2.2 Water bath heater liquid temperature
Water bath heat liquid temperature is controlled by a reverse acting controller TICA-503. TICA-503
controls the bath temperature measured by TT-503 modulating burner power through the servomotor
TY-503. Servomotor TY-503 is mechanically linked with the fuel burner main feed line control
valve TCV-503 and feed air control valve TCV-552 in order to maintain the correct air/fuel ratio while
regulating the burner power. TICA-503 controller set- point is a signal coming from TICA-521 (master)
implemented within the control system, setting the temperature set point as shown in figure 4.3.
Servomotor TY-503 is provided with two limit switches ZSL-503 and ZSH-503 in order to allow BMS to
check the functioning. 70-E-001 Water Bath Heaters are also provided with a safety temperature
switch TSHH-554 shutting off the burner when the temperature of 92°C is reached in the liquid bath.
2.4.3 70-EH-001- Gas Electric Start-up Heater
In order to feed the 70-E-001A/B Water Bath Heaters Burners a gas slipstream is taken downstream the
heating section to compensate the temperature drops caused by the Joule-Thomson effects in the 70-
ME-003A/B natural gas to heaters reducing skid pressure regulators. This condition cannot be satisfied
at start-up where condensates can occurs with the gas stream and heating can’t be achieved because
water bath heaters are not in operation. An electrical heater 70-EH-001 is provided to guarantee smooth
operation when heating up the liquid bath protecting the downstream section. Heater control is designed
to be in hot stand-by thus without needs of any operator intervention. Electric power is supplied to the
heater with an ON/OFF control implemented within the control system. The heater emergency shut
down logic based on high temperature set has been implemented in the ESD.
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2.4.4 Pressure reduction system (self-regulating control)

Pressure at station outlet is regulated by two identical spare (2x100%) reducing lines (skid 70-ME-002),
the main line (70-ME-002A) will be normally online while the spare one will remain isolated by means of
the relevant manual ball valves.
Pressure control is achieved by means of self-regulated pressure control valve PCV-517 that tries to
keep the set pressure of 23.5 bar (g) measured at valve outlet. In case of failure of the main regulator,
signaled by the activation of the ZSH-517 limit switch, which will remain in open position when in fail
state, a monitor regulator valve PCV-516 is provided to control gas outlet pressure to 24.5 and
guarantee continuous operations. A slam-shut device SSV-516 installed on the monitor valve is
provided in order to close the valve when downstream pressure reaches 26 bar (g), this action is
signaled by the activation of the ZSL-516 switch. Operator can confirm the valves status in control room
controlling the relevant limit switches.
The pressure regulator set points are settable and they could be modified during commissioning.
At present the GT requires only one operating status (P=24 bar g), but if GT requires a range of
pressure rather than a fixed value, hypothetically it would be possible to leave online both lines allowing
intervention of the spare one when the main line fails, defining different set points for each valves.
Gas outlet temperature is controlled by ON/OF temperature controller TICA-506 that controls the power
supply by the 70-EH-001 Gas Electrical Heaters. In the particular the controller will power the heater in
order to reach the set point temperature (50°C) at gas outlet measured by TT-506. in normal operations
the gas enters the 70-ME-003A/b skid with the temperature greater than 50°C therefore TICA-506
control Loop will not power the 70-EH-001 heater. Heater is also provided with safety loop consisting in
two temperature switch clamped in the heating elements in order to stop the power supply in case of
over-temperature reaches 72°C TSH-508 power of the heater when the elements reach the temperature
goes down the set point. TSH-505 is safety device cutting off the power of 70-EH-001 heater if the
temperature reaches 380°C, operate the machine after the emergency shutdown. TT-507 is also
provided in order to protect the downstream regulator shutting down the electrical heaters when gas
outlet temperature reaches 80°C.
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3.1 GENERAL
Prior to initial start-up, all pre-commissioning activities must have been completed and the unit must be
Pre-commissioning covers those activities required to bring the unit to a "ready for start-up" condition
from the original as-constructed condition. In general, it consists of inspection, checking & testing
operations required to ensure that all components of the work are properly installed and are
mechanically complete. The most important requirement is that the unit can be started up in a
controlled, efficient and safe manner.
The pre-commissioning phase is usually performed by the construction forces in close coordination with
operations / commissioning team. For this purpose, checking sheets (or "mechanical guides") will be
issued and filled up on-site in close cooperation between construction and commissioning team.
A summary of pre-commissioning activities and a checklist to be completed before unit initial start-up
are included in section 2 of this chapter. Full details of pre-commissioning activities as regards to
inspection of equipment, general plant check, hydrostatic testing, instrument loop checks,
instrumentation functional tests, electrical motor run-in, line and vessel cleaning etc., are not in the
scope of this document and are a separate issue.
The information and procedures described hereafter concern the preliminary operations for start-up of a
new unit. Procedures are slightly adapted for normal and subsequent start-up, as indicated in chapter-4.
3.2 PREPARATION PRIOR TO INITIAL STARTUP
It is assumed that all the pre-commissioning activities are completed and that the unit has reached a
"ready for commissioning" status.
Most of the following prestart up items are routine and are briefly presented as reminders only, as they
All firefighting equipment is in place, operational and has been functionally tested.
All safety equipment is in place and is fully operable.
All pipework has undergone pressure testing, cleaning and/or flushing and draining and drying.
· All equipment has been pressure tested, inspected, cleaned, drained and dried.
· The whole unit was satisfactorily air leak tested at the maximum available dry instrument air pressure.
The unit is under slight nitrogen pressure and the procedures detailed hereafter start from this step, to
be performed as part of commissioning and start up.
· Test equipment and special tools, if any, and facilities for their operation are available.
· Air blowers for the water bath heaters have been aligned, run in and lubricated as required, following the
manufacturer’s recommended procedures.
· Instrument air is available and commissioned to all instruments.
· Service and potable water is available at battery limit.
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· Electrical power systems have been checked out and commissioned. It is available to electric drivers,
startup heater and all instrument boards.
· All instruments have been calibrated, loops checked and commissioned. All sensing elements which
· All the DCS data links are operational.
· Emergency shutdown systems are fully operational and if possible, a dry run has been performed.
· All safety relief valves have been tested and are in service. All block valves around relief valves are
· All blinds, if any, which were installed during hydro testing have been removed and replaced with their
relevant spacers.
3.3 STARTUP METHODS
The system may be started up using two methods. In this section, both methods will be detailed, and the
criteria for selection of startup route will be explained.
The procedures described in this manual should be taken only as an operating guide and subject to
further development at site.
Refer to P&ID 70-SD-A-53301 sheet 1-4 and Alstom HTCT 124566 Fuel Gas Supply
Fuel gas coming from underground pipeline is available at @ 60 bar (g) at battery limit.
3.3.1 Unit 70 startup – System by System
This method will describe nitrogen displacement, pressurization and tightness test for each individual
system.
3.3.1.1 Inlet Skid 70-ME_004
Proceed as follows:
· Ensure all manual block valves and UV-501 is in close position.
· All the drains, vents, sample and nitrogen injection points are isolated.
· All instrumentation is lined up except PDIT 501.
· Start opening V-04 the battery limit inlet valve.
· If no leakage is observed, start opening 1” pressurization valves V-06/07.
· If no leakage is observed, start opening 6” valve V-05 and 1” pressurization valves V-08/09. Check if the
correct indications are shown for PI 601, PT 502, TT 501, TI 601, TI 602A/B and PI 602A/B.
· Line up PDIT 501 and if no alarm at CS, open UV 501.
· Close back the 1” pressurization valves V-06/07 and V-08/09.
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3.3.1.2 Heating Unit 70-E-001A/B
Proceed as follows:
· Ensure all manual block valves are in close position.
· All the drains and vents are isolated.
· 1” by-pass valves for PSV 603 A/B are closed.
· All instrumentation is lined up.
· Start opening 1” pressurization valves V-13/14 and proceed for tightness test of FWB Heater 70-E-001A
fuel gas line. If no leakage observed proceed to open the main isolation valve V-10 and close 1” valves
V-13/14.
· Start opening 1” pressurization valves V-15/16 and proceed for tightness test of FWB Heater 70-E-001B
fuel gas line. If no leakage observed proceed to open the main isolation valve V-11 and close 1” valves
V-15/16.
· Check correct indication for TI 603A/B and TT 502A/B.
· Start opening 1” pressurization valves V-17/18 and check for leakage. When pressurization is
completed, start to open main isolation valves V-22 and V-23 and close 1” pressurization valves V-
17/18.
In order to start-up the unit, the Water Bath Heaters 70-E-001A/B must be filled with water using
provided manual ball valve for make-up water located at the top of the expansion tank. Operator must
begin to fill the vessel up to the normal liquid level pointed out in the level gauge LG-602. Proceed as
follows:
· Open the manual ball valve upstream the make-up water supply line, then open the
globe valve located aside the expansion tank; water will begin to fill the vessel.
· Proceed after a short time to open the drain valve at nozzle N5 to discharge the water from the
vessels in order to leave the vessel cleaned and free from dirty and rust/metal scales. When
the water going out from the drain valve look clean close the drain valve.
· Monitor the vessel filling using LG-602 level gauge, proceed to fill the vessel up to normal operating
liquid level half of the expansion tank (it can take time).
· Close the manual globe valve when the liquid level reaches the normal operating low level.
· Check the correct indication for TI-604, TT-503, LT501 and if LALL-502 is cleared.
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3.3.1.3 Fuel Gas 70-ME-003A/B
Proceed as follows:
· All the drains are isolated.
· 1” by-pass valves for PSV 608 A/B and PSV 609 A/B are closed.
· Start opening 1” inlet valve V-19 and pressurize Start Up Electric Heater
70-EH-001. If no leakage observed proceed to open outlet isolation valve V-20.
· Crack open UV-53 inlet valve to dust filter 70-MS-003A and check for leakage and also check the
pressure downstream PCV 508A. If necessary adjust the pressure set point according to the
specification. Open fully V-56 and V-53.
· Crack open V-54 inlet valve to dust filter 70-MS-003B and check for leakage and also check the
pressure downstream PCV 508B. If necessary adjust the pressure set point according to the
specification. Open fully V-57 and V-54.
· Crack open V-58 and check the pressure downstream PCV 509A. If necessary adjust the pressure set
point according to the specification. Open fully V-58 and V-60.
· Crack open V-59 and check the pressure downstream PCV 509B. If necessary adjust the pressure set
point according to the specification. Close V-54, V-57 and V-59 and maintain only stream A on line.
· Open V-62 upstream manual valve to FQI 510 and if no leakage open downstream valve V-63.
· Open V-65, V-66, V-67 and V-68 and fuel gas is available up to pilot and burner lines.
At this stage, the fuel gas system may be considered ready for normal operations.
In any case, it will be necessary to vent all downstream fuel gas lines to consumers before a consistent
nitrogen-free fuel supply can be achieved.
· Ensure that 70-EH-001 is energized and the on/off control loop is operative.
· Push the main line heater e.g. 70-EH-001A Water Bath Heater start pushbutton
HS-504A1 from control room or HS-504A3 in the field local panel.
· The BMS will begin the ignition sequence lighting the burner.
· Wait until the liquid bath temperature is 85°C using TIC-503, the burner will stop automatically.
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3.3.1.4 Filtering skid 70-MS-002A/B

Proceed as follows:
· All the drains, vents and nitrogen injection points are isolated.
· Start opening 1” pressurization valves V-26/27 and pressurize filter MS-002A up to operating pressure. If
there is no leakage start to open outlet valve V-30 and pressurize the system up to battery limit with
metering skid.
· Start opening 1” pressurization valves V-28/29 and pressurize filter MS-002B up to operating pressure.
Check the correct values for instrumentation.
If there is no leakage, close back the 1” pressurization valves V-28/29 and keep filter MS-002B in stand-
by.
· Open the main inlet valve for filter MS-002A V-24 and close1” pressurization valves V-26/27.
3.3.1.5 Metering skid 70-ME-001A/B

Proceed as follows:
· All the drains, vents, sampling point connection and nitrogen injection points are isolated.
· Start opening 1” pressurization valves V-34/35 and check for leakages and correct indication for TI-
513A, PI-513A and PI-613A. If there is no leakage start to open outlet valve V-38 and pressurize the
system up to battery limit with pressure reducing skid.
· Start opening 1” pressurization valves V-36/37 and check for leakages and correct indication for TI-
513B, PI-513B and PI-613 B. Close back 1” pressurization valves
V-36/37 and maintain stream B on stand-by.
· Open main valve V-32 and close 1” pressurization valves V-34/35.
· Check correct indication for PI-614 and PT-515.
At this moment the gas chromatograph AT-514 can be lined-up and tested as per Vendor specification.
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3.3.1.6 Pressure reducing skid 70-ME-002A/B

Proceed as follows:
· Start opening 1” pressurization valves V-42/43 and monitor the pressure downstream PCV-516A and
PCV-517A. Set point pressure for regulators can be adjusted.
Check the correct indication for instrumentation. If there is no leakage start to open outlet valve V-46
and pressurize the system up to battery limit with outlet skid. Check the correct indication for PT-519
and PI-619.
· Open main inlet valve V-40 and close 1” pressurization valves V-42/43
· Start opening 1” pressurization valves V-44/45 and monitor the pressure downstream PCV-516B and
PCV-517B. Set point pressure for regulators can be adjusted.
· Check the correct indication for instrumentation. If there is no leakage close back
1” pressurization valves V-44/45 and maintain stream B on stand-by.
At this moment the HC Dew Point Analyzer AT-519 can be lined-up and tested as per Vendor
specification.
3.3.1.7 Outlet skid 70-ME-005
Proceed as follows:
· Open V-049.
· Put the manual override for UV-600 and open the actuated valve. If there is no leakage close back UV-
600 and open downstream manual valve V-50.
· Open the battery limit valve V-48 and pressurize the system up to GT fuel gas skid.
· Check for leakage and correct indication of TIC-521A/B/C.
At this stage, the fuel gas system may be considered ready for normal operations.
In any case, it will be necessary to vent all downstream fuel gas lines to consumers before a consistent
nitrogen-free fuel supply can be achieved.
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3.3.2 Unit 70 startup – Entire Unit

3.3.2.1 Plant Pressurization
Plant pressurization is necessary to allow the further startup sequences, principally for the Water Bath
Heater heating.
First off all Operators have to control that the Control Panels are energized and the control system is
able to operate the shutdown valves. Operators shall:
· Check the closure of the 6” manual ball valve at unit inlet V-05.
· Check the closure of the 8” manual ball valve at unit outlet V-48.
· Stroke Open the UV-501 inlet shutdown valve using HS-501 from control room GSCS or using the
manual override located in the actuator.
· Stroke Close the UV-600 blow down valve using HS-601 from GSCS or using the manual override
located in the actuator. Note: UV-505 & UV-601 are interlocked i.e. valve UV-601 can not be opened
while UV-501 is opened and UV-501 can not be opened when UV-600 is open.
· Now Chief Operator must choose the main line and the spare line and open all the route from the inlet to
the outlet of the unit of the main line. For this manual Line “A” will be the main one, Line “B” as spare.
· Check that all the route from the inlet up to the outlet of the main line has all the manual isolation valve
open (as per P&ID).
· Slowly pressurize up to 5 bar (g) all the unit using the 1” bypass at the inlet of the main manual 6”
isolation valve at the inlet skid V-05. The pressure will begin to build up in all the part of main line of the
unit.
· Check that the upstream pressure is equalized in every part of the plant checking on every Pressure
gauge of the main line. Wait until PI-619 on the outlet skid is showing the same pressure of upstream
equipments.
· If there is no leakage proceed to increase the pressure inside the system up to 10 bar (g).
Repeat this pressurization step up to operating pressure.
3.3.2.2 Water Bath Heater 70-M-001AB Burner Start
After the unit main line is pressurized it is necessary to start-up the burners of the Water Bath Heater in
order to heat up the liquid bath to normal operating temperature prior opening the unit outlet.
It is assumed that the Burner Management System BMS panel is energized and that the 70-M-001A/B
burners and relevant gas ramps are ready for operations. It is also assumed that 70-EH-001 is
energized and the on/off control loop is operative.
At start-up condition condensate or condensate droplets can be carried over by the natural gas stream
and interfere with the regulators of the burner fuel gas ramp, for this reason the 70-EH-001 is designed
to be always in hot stand-by in order to heat up the fluid when the temperature drops below 50°C.
Operators shall:
· Push the main line heater e.g. 70-EH-001A Water Bath Heater start pushbutton HS-504A1 or HS-504A3
in field.
· The BMS will begin the ignition sequence lighting the burner
· Wait until the liquid bath temperature is 85°C using temperature gauge TI-604A, the burner will stop
automatically.
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3.3.2.3 Plant Start Up Final Operations

After line A operation is established, Operator must check that the pressure drop in the cartridge filters is
normal (0.2 bar maximum) and check that no other warning are present in the main Train
instrumentation.
Operator has the chance to open the Metering Skid Check Line in order to check the consistency
between FIT-513A and FIT-513-B.
Provision could be made in order to test the Gas Chromatograph and HC dew Point Analyzer.
When the startup operation of the Train A is accomplished chief Operator may have the chance to
pressurize the spare Train B using dedicated pressurized lines in order to speed up the eventual spare
train changeover.
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4 NORMAL AND SUBSEQUENT START UP
4.1 General
During the course of normal operations, it will be necessary to start up the plant after shutting down for
various reasons. After each maintenance turnaround, for example, the fuel gas systems will have to be
brought on line. The fuel gas system will also have to be restarted after a shutdown if the cause is a
mechanical/utilities malfunction.
The following normal startup sequence is recommended, although the judgment and experience of the
operators should be used to adapt these steps, if necessary, to suit the cause of the shutdown and
hence the prevailing startup conditions. It is at all times the responsibility of the shift supervisor to
ensure that the method used for startup is safe and efficient.
4.2 PRE STARTUP CONDITIONS
The exact condition of the system at startup will depend upon the nature of the shutdown of the system.
For the purposes of this manual, the following conditions have been assumed:
· The plant is mechanically complete.
· The natural gas system is oxygen free and under a slight positive fuel gas pressure.
· All the utilities/process lines outside the battery limit of the unit are fully commissioned and ready for
service:
· Natural gas lines upstream and downstream the package
· Water line header
· Utilities supply
· All other valves are in their normal operating positions.
· All temporary items installed in the system for shut-down reasons, i.e. temporary spectacle blinds, have
been removed.
4.3 START UP OF INDIVIDUAL EQUIPMENT ITEMS
4.3.1 Water Bath Heater 70-E-001A

Consider Water Bath Heater 70-E-001B running normally and Water Bath Heater
70-E-001A was under major maintenance.
In order to start-up the unit, the Water Bath Heater 70-E-001A must be filled with water using provided
manual ball valve for make-up water located at the top of the expansion tank. Operator must begin to fill
the vessel up to the normal liquid level pointed out in the level gauge LG-602A. Proceed as follows:
· Open the manual ball valve upstream the make-up water supply line, then open the
globe valve located aside the expansion tank; water will begin to fill the vessel.
· Monitor the vessel filling using LG-602A level gauge, proceed to fill the vessel up to normal operating
liquid level half of the expansion tank. Close the water make up line.
· Ensure all manual block valves for the natural gas are in close position.
· 1” by-pass valves for PSV 603A is closed.
· Start opening 1” pressurization valves V-13/14 and pressurize up to operating value.
If no leakage observed proceed to open the main isolation valve V-10 and close 1” valves V-13/14.
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· Check correct indication for TI 603A and TT 502A.

After the unit main line is pressurized it is necessary to start-up the burners of the Water Bath Heater in
order to heat up the liquid bath to normal operating temperature prior opening the unit outlet.
It is assumed that the Burner Management System BMS panel is energized and that the 70-M-001A
burner and relevant gas ramp is ready for operations.
· Push the main line heater start pushbutton HS-504A1 or HS-504A3 in field.
· The BMS will begin the ignition sequence lighting the burner.
· Wait until the liquid bath temperature is 85°C using temperature gauge TI-604A and TIC-503A, the
burner will stop automatically.
· Start opening the outlet valve V-22. The Water bath heater A is now lined up and both
Heaters are running in parallel.
· Proceed to stop Heater B as per procedure described in chapter 6.2.1.
4.3.2 70-MS-002A/B Filters Cartridges
Two spare skids have been provided for the station, one spare and the other in standby, in order to
allow maintenance and cartridges changeover without stopping the unit.
The need of cartridge changeover is suggested by the high pressure drop across the filter in operation
as per PDIT-512 differential pressure indication (500 mbar should considered as clogging warning
pressure drop).
It is difficult to foresee the frequency of the filters change over, since it will depend on many factors such
as presence of solid particulate, hydrocarbons decomposition phenomena and so on. It is
recommended to record each change-over date so that the frequency of changeover can be monitored
for any problem detection.
In addition, Operators should periodically check (at least once a week) and record the pressure drop
across the operating filter, in order to have the trend of the pressure drop increasing with time so as to
detect any possible trouble.
Proceed as follows:
Switchover the train where maintenance has to be made to the spare one using manual isolation valves.
More precisely:
· Ensure the spare skid filter inlet and outlet isolation valves are closed.
· Proceed to purge for a few minutes venting from the PSV-611 bypass line admitting a slipstream of gas
cracking opening the inlet isolation valve 1”bypass manual globe valves.
· Close the PSV bypass vent line.
· Pressurize the skid to upstream pressure using manual valves bypass.
· Check in PI-611 the filter vessel pressure is equal to upstream.
· Proceed to open first the inlet isolation valve then proceed to open the outlet isolation valve.
· Now both the filter skid are online, Operator should see a pressure drop decrease in the clogged filter.
· When the spare filter is online proceed to stop the main Filter.
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70-MS-003A/B Filters are been installed in order to avoid dust coming inside the burner pressure
reducing fuel gas ramp that could interfere with the regulators operation.
Two spare identical lines have been provided for the 70-ME-003AB skid, one spare and the other in
standby, in order to allow maintenance and cartridges changeover without stopping the unit.
The need of cartridge changeover is matter of Operator choice and has to be done
periodically. It is difficult to foreseen the frequency of the filters change over, since it will depend on
many factors such as presence of solid particulate, hydrocarbons decomposition phenomena and so on.
It is recommended to record each change-over date so that the frequency of changeover can be
monitored for any problem detection.
Proceed as follows:
Switchover the line where maintenance have to be made to the spare one using manual isolation
valves. More precisely:
· Close both the spare line filter inlet and outlet isolation valve.
· Proceed to purge for a few minutes venting from the PSV-609 bypass line admitting a slipstream of gas
cracking opening the inlet isolation valve
· Close the PSV bypass vent line.
· Pressurize the skid to upstream pressure using inlet manual valve.
· Check in PI-608 and PI-609 that the required gas pressure is reached after the two regulators, more
precisely 5 bar (g) and 0.3 bar (g).
· Proceed to open the outlet isolation valve.
· Now both the filter skid are online
When the spare filter is online proceed to stop the main Filter.
4.4 STARTUP OF ENTIRE UNIT 70
The startup of Unit 70 will normally happen only after the entire plant was in shut down or major
overhaul was completed.
4.4.1 After major overhaul
Unit 70 will be restarted exactly as per chapter 3.3.2.
4.4.2 After pressing 70-HS-501 pushbutton
Unit 70 remains partially pressurized.
To restart the unit proceeds to close the main inlet valve V-05 at the Inlet Skid.
When PDIT-501 is at normal value, start opening the shutdown valve UV-501.
Start opening gradually the main valve V-05 till the pressure inside the system became normal.
Restart WBH if necessary.
4.4.3 After pressing 70-HS-600 pushbutton
Unit 70 will be restarted exactly as per chapter 3.3.2.
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5 NORMAL OPERATION
5.1 GENERAL
The purpose of this section is to discuss the operation of the Natural Gas Metering and Reducing
Station. This will include the process variables which can affect the performances, the manual actions
which shall be done for a correct operation of the unit and the abnormal conditions which can occur
causing trip activation or even the complete shutdown of the Natural Gas Metering and Reducing
Station.
5.2 NORMAL OPERATION
Unit should be stable and does not need special advices however are suggested to monitor periodically
the gas supply condition in order to try to prevent any possible trip cause. Any possible upset is
monitored and alarmed to the operator in control room. Spare Train B guarantees the possibility of
continuous operation and allows easy maintenance operation on the Train A.
5.2.1 Manual Operations
5.2.1.1 Performance Monitoring

The following need to be monitored on a regular basis:
· Natural gas supply conditions.
· Natural gas product conditions.
· Gas composition
· HC dew point
On periodic basis the following checks should be carried out:
· Equipment pressure drops.
· Cartridge filters pressure drop.
· Heater performance survey.
· Consistency between instruments.
Check and monitor of these variables can help troubleshooting when process variables suddenly
change. Operators need to hold a register where all these variables are listed.
5.2.1.2 Preventative Maintenance and System Monitoring
It is best to try to anticipate problems before they occur.
This is best done by checking for instrument consistency, comparison with past experience and
utilization of maintenance records. This requires good organization and recording of plant data.
The package is dependent on instrumentation for automatic operation. Any instrumentation faults or
inconsistencies should be investigated immediately or else the automatic operation could be put on
hold. Depending on how close to the design conditions the package is operating, this could result in
either off specification product or in need to limit or stop the process flow through the unit.
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5.2.1.3 Water Bath Heater Liquid Level

70-E-001A/B Water Bath Heater heat the gas stream using an hot water bath directly connected to
the atmosphere through a 4” open vent, for this reason water level is expected to decrease with time.
Water level can be monitored from control room by means of
LIT-501A/B provided with a warning set point in order to warn the Operator when the level is becoming
too low. This allows the water refill prior the Burner trip, caused by the low low level switch LSLL-502A
installed in vessel expansion tank.
Operator must monitor periodically the water level inside the expansion tank, because the liquid level
decrease rate is not predictable and vary greatly depending upon the ambient condition.
In order to refill water inside the water bath heater Operator must use the dedicated manual globe valve
located on the top of the expansion tank and refill up to the normal water level helping with the level
gauge LG-602A/B clearly visible when operating the valve. Operator must take care of avoiding
contact with hot water that may come off from the overflow discharge.
5.3 ABNORMAL CONDITIONS – CORRECTIVE ACTIONS
Safe operation of the unit is managed by the Emergency Shutdown System of the unit (ESD).
Emergencies which occur into Natural Gas Metering and Reducing Station require immediate attention
and investigation to understand and act on the problem. Operator should carefully study in advance and
become familiar with the proper actions to be taken in such situations.
Automatic actions taken on emergency shutdown should protect the equipment from all dangerous
situations.
The overall protective system shall be based on the input (causes) and the output (effects) as
shown on relevant Cause & Effects Diagrams.
The water bath heater included into the Natural Gas Metering and Reducing Station shall be powered
off, and shut-down both locally in field and from GSCS by means of dedicated front panel push buttons
installed on the relevant BMS’s.
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5.4 PROCESS VARIABLES
5.4.1 Pressure Safety Valves sets
Pressure Safety Valve Equipment

Service Set Pressure
TAG TAG
Protection from gas expansion with
PSV-603-A/B N/A 60.0 bar (g)
blocked discharge
PSV-608-A/B N/A Protection from PCV-508A/B failure 8.0 bar (g)
Protection from PCV-509-A/B and
PSV-609-A/B N/A 0.36 bar (g)
SSV-509-A/B leakage
PSV-611-A/B 70-MS-002A/B Dust Filter Overpressure Protection 60.0 bar (g)
Protection from PCV-516-A/B and 27.0 bar (g)
PSV-618-A/B N/A
SSV-516-A/B leakage
5.4.2 0-100% Controllers Set Points
Here below the list of set point values for 0-100% controllers:
Tag No. Service Description Set By Unit
70-E-001-A/B Water Bath Heater TICA-521
TICA-503-A/B °C
Liquid Bath Temperature
Natural Gas Temperature Adjustable by the
TICA-521 °C
Downstream Outlet Skid 70-ME-005 operator
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5.4.3 Set Point List
Here below the list of process alarms available on the operator station .
Low High
Tag No Service Description Low High Unit Trip
Low High
Pressure Upstream 70-ME-002 Reducing
PIT-515 - 40 60 - Bar(g) NO
Section
Pressure Downstream 70-ME-002 Reducing
PIT-518 A - - 30 - Bar(g) NO
Section PCV-517A
Temperature Downstream 70-ME-002 Reducing
TIT-518 A - - 70 - °C NO
Section PCV-517A
Pressure Downstream 70-ME-002 Reducing Bar
PIT-518 B - - 30 - NO
Section PCV-517B (g)
Temperature Downstream 70-ME-002 Reducing
TIT-518 B - - 70 - °C NO
Section PCV-517B
AT-519 Natural Gas Hydrocarbon Dew Point Temp. - - 30 - °C NO
TT-521-
Temp. Downstream 70-ME-005 Outlet Skid - 40 70 - °C NO
A/B/C 2over3
Liquid Bath Temperature Inside Water Bath
TSHH-554A - - - 92 °C YES
Heater 70-E-001A
TSHH-554B - - - 92 °C YES
Heater 70-E-001B
TT-503-A - 55 85 - °C NO
Heater 70-E-001A
TT-503-B - 55 85 - °C NO
Heater 70-E-001B
PdIT Pressure drop across ESD valve UV-501 - - 500 - Mbar NO
PT-502 Natural gas pressure at station inlet - 40 60 - Bar NO
TT-501 Natural gas temperature at station inlet - 0 40 - °C NO
TT-502A Natural gas temperature at WBH outlet - - 72 80 °C YES
TT-502A Natural gas temperature at WBH outlet - - 72 80 °C YES
TSHH-505 Startup electric heater element temperature - - - 380 °C YES
TSHH-505 Startup electric heater element temperature - - 360 - °C NO
Natural gas Temp. at startup electric heater
TT-507 - - - 80 °C YES
outlet
Natural gas temperature at startup electric
TT-506 - - 72 - °C NO
heater outlet
LSLL-502A Liquid level in WBH expansion tank - - - 20 % YES
LSLL-502B Liquid level in WBH expansion tank - - - 20 % YES
PdIT-512A Pressure drop across dust filters cartridges - - 500 - mbar NO
PdIT-512B Pressure drop across dust filters cartridges - - 500 - mbar NO
LSH-511A Liquid level inside dust filter cartridge bucket - - 100 - % YES
LSH-511A Liquid level inside dust filter cartridge bucket - - 100 - % YES
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5.4.4 Self-regulators Set Points
Here below the list of set point values for auto-regulators:
Tag No. Service Description Value Unit
PCV-517A Pressure reduction section Line “A” Main Pressure Regulator 23.5 Bar g
PCV-517B Pressure reduction section Line “B” Main Pressure Regulator 23.5 Bar g
PCV-516A Pressure reduction section Line “A” Monitor Pressure Regulator 24.5 Bar g
PCV-516-B Pressure reduction section Line “B” Monitor Pressure Regulator 24.5 Bar g
First Pressure Reduction Regulator in Line “A” of 70-ME-003-A

PCV-508A 5.0 Bar g
Fuel Gas Skid
Second Pressure Reduction Regulator in Line “A” of 70-ME-003-

PCV-509A 0.3 Bar g
A Fuel Gas Skid
First Pressure Reduction Regulator in Line “B” of 70-ME-003-B

PCV-508B 5.0 Bar g
Fuel Gas Skid
Second Pressure Reduction Regulator in Line “B” of 70-ME-003-
PCV-509B 0.3 Bar g
B Fuel Gas Skid
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6 NORMAL SHUTDOWN
6.1 GENERAL
This section is a guide to be followed during a shut-down of the unit which has been planned for
equipment inspection and maintenance.
Before initiating any planned shut-down, review all records to determine what inspections and repair
work must be accomplished during the shut-down. Prepare a shut-down schedule including plans for
maintenance activities in advance.
Co-ordinate the shutdown with the Operators of other units that could be affected by the shutdown.
Notify all interested parties in advance of the scheduled shut-down so that the shutdown can be well
planned so that its duration minimized.
When shutting down, steps should be taken to ensure the continued availability of utilities and purge
gases for as long as required.
The preparation of the equipment for maintenance is under plant Operators responsibility.
To guarantee safe operations, all the equipment and lines must be purged to safe location. When
purging operation of the unit has been completed, blind disks are to be installed on gaseous
hydrocarbons lines or at battery limit in order to isolate the Natural Gas Metering and Reducing Station
from the other units.
It is necessary to prepare a list of the blind disk installed, with the indication of their position. The blind
disc list will be continuously updated, under the responsibility of the Chief Operator.
All the work permits are to be signed by the Chief Operator, who will in verify advance that:
· All vessels interested to the maintenance operations are hydrocarbons free and are at
atmospheric pressure.
· All the connection are closed or blinded.
· All hot permits are already approved and duly signed by the competent authority.
Each equipment shall be completely purged with nitrogen prior to start-up, before and after equipment
maintenance to prevent dangerous hydrocarbon/air mixtures.
If maintenance to the regeneration system is carried out with the system on-line, then additional care is
required to ensure isolation from the live systems. Isolation procedures for safe maintenance are under
Operator responsibility.
During planned long term shutdown or off line periods, the unit should always be maintained at low
pressure – preferably with nitrogen - to prevent ingress of air.
The procedure for shutdown assumes that the plant is operating normally, no trips are activated, all
controllers are stable and all manual valves are positioned as per relevant P&ID.
Natural gas metering and reduction station does not need any special precaution for a normal
shutdown.
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6.2 SHUTDOWN OF INDIVIDUAL EQUIPMENT ITEMS
6.2.1 Water Bath Heater 70-E-001A/B
Gas heating section it is based on two (2) Natural gas water bath heaters design (n° 2 parallel lines
each designed for 100% of flow rate and 100% of the requested duty) and installed immediately
downstream of the inlet skid.
In order to shut down a unit, make sure that the stand-by one (WBH-001B) is running normally in
parallel with main one (WBH-001A).
Operator can turn off the water bath heater A using dedicated pushbutton HS-504A4 in field or HS-
504A2 in control room
· Close V-65 and V-67 fuel gas valves to pilot and main burner.
Maintain natural gas circulation through both water bath heaters until the water temperature TT-503A
goes below low alarm limit.
Proceed to isolate the natural gas circulation through heater A:
· Start closing main inlet valve V-10. This operation should be done very carefully to avoid any variation
on the fuel gas pressure/ flow downstream this unit.
· Close the outlet valve
The unit is now shutdown.
Depending on type of maintenance activities to be done the system can be
de-energized, depressurized, drained and isolated by spades.
Two spare skids have been provided for the station, one spare and the other in standby in order to allow
maintenance and cartridges changeover without stopping the unit.
The need of cartridge changeover is suggested by the high pressure drop across the filter in operation
as per PDIT-512 differential pressure indication (500 mbar should be considered as clogging warning
pressure drop).
· Proceed to close the clogged filter 6” inlet and outlet manual valves.
· Vent the filter down to the atmospheric pressure using PSV 611 bypass vent line.
· After checking that the filter is depressurized to atmospheric pressure using local pressure gauge PI-
611, proceed to turn the spectacle blind on the vessel nozzle N1, N2 lines in order to positively isolate
the vessel from other pressure sources.
· Drain the filter.
· Once drained, open quick opening flanged head and proceed to replace the cartridges.
· Once the cartridges have been replaced, close the filter.
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70-MS-003A/B Filters are been installed in order to avoid dust coming inside the burner pressure
reducing fuel gas ramp that could interfere with the regulators operation.
Two spare identical lines have been provided for the 70-ME-003AB skid, one spare and the other in
standby, in order to allow maintenance and cartridges changeover without stopping the unit.
The need of cartridge changeover is matter of Operator choice and has to be done
periodically. It is difficult to foreseen the frequency of the filters change over, since it will depend on
many factors such as presence of solid particulate, hydrocarbons decomposition phenomena and so on.
It is recommended to record each change-over date so that the frequency of changeover can be
monitored for any problem detection.
· Proceed to close the clogged filter 1” inlet and outlet manual valves.
· Vent the filter to the atmosphere down to the atmospheric pressure using 1” by-pass valve for PSV
608A/B and also filter drain.
· Once drained, open the flanged head and proceed to replace the cartridge.
· Once the cartridges have been replaced, close the filter.
6.3 UNIT SHUTDOWN
The total shutdown of Unit 70 will normally only happen during planned maintenance outages, when the
entire plant is shut down.
6.3.1 Unit Depressurization
Unit depressurization can be achieved manually only after isolating the system upstream using the
dedicated isolation valve UV-501 provided with pushbutton both in field and in control room.
In order to isolate and blow down the unit Operator have to:
· Push the UV-501 activation button HS-501A or HS-501B or HS-501C.
· Close the manual ball 8” outlet isolation valve.
· Push the UV-600 activation button HS-600B or HS-600C, opening the blow down valve and discharging
all the unit capacity to the atmosphere.
Note: Operator may skip the second step of the procedure in order to depressurize also the
downstream equipment.
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6.4 SYSTEM STAND BY
6.4.1 Short Term Stand By
In case of short term stand-by, the Natural Gas Metering and Reducing Station can be left pressurized
but water bath heater burner system shall be stopped.
When inspecting or doing maintenance on equipment, be sure to ensure no ingress of contaminants
from all sources with a positive isolation, turning the relevant spectacle blind in close position.
6.4.2 Long Term Stand-By
If the system is shut-down for more than four weeks, additional precautions relevant to each individual
equipment shall be then considered.
In particular it is recommended attention to the following:
· Ensure that electrical and instrument enclosures are completely closed and the internals are maintained
dry. If necessary use silica gel bags but remember to remove them before restarting.
· Valves should be occasionally cycled (opened/closed).
It is then strongly recommended the following:
· Drain all vessels/equipment/piping.
· The unit when is not in use, it should be maintained at pressure (minimum 0.5 bar g) with an inert gas
(nitrogen) to prevent ingress of any contaminants from the atmosphere and avoid any possible
dangerous scenarios.
6.4.3 Unit Off-Line
If the system is shall be put off line, recommendations for long term standby should be
considered and additional precautions relevant to each individual equipment shall be then taken.
As per long term stand by guidelines, it is recommended attention to the following:
· Ensure that electrical and instrument enclosures are completely closed and the internals are maintained
dry. If necessary use silica gel bags but remember to remove them before restarting.
· Valves should be occasionally cycled (opened/closed).
It is then strongly recommended the following:
· Drain all vessels/equipment/piping.
· Depressurize and purge all plant equipment. Whenever the unit is not in use, it should be maintained at
pressure (minimum 0.5 bar g) with an inert gas (nitrogen) to prevent ingress of any contaminants from
the atmosphere and avoid any possible dangerous scenarios.
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7.1 GENERAL
Unit can be shut down for emergency contingencies either by means of push buttons located both in
field, in control room and in GSCS or it can be shut down due to external causes by means of software
input from ESD.
Each Train and relevant Electrical Heater can be shut down for emergency contingencies by means of
push buttons located both in field and control room or, similarly, they can be shut down due to external
causes by means of software input from ESD.
7.2 UTILITIES SHUTDOWN
7.2.1 Instrument air
min plant operation at normal instrument air demand.
7.2.2 Potable Water
The level in Water Bath Heater will not be affected.

7.2.3 Power supply
Gas Station Control Shelter and Startup Electrical Heater are connected to Emergency Power supply
system.
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8 SAFETY
8.1 GENERAL
All plant personnel must comply with normal safety rules which generally cover the operation of oil and
gas/refinery plants.
Chief Operator must ensure that all safety rules are complied with in order to safeguard personnel life
and protect equipment from damage.
Fluid sampling shall be performed by authorized personnel with suitable equipment and tools.
Metal vessels shall be grounded during sampling operations to prevent dangerous electrostatic
accumulation. Protective gloves and glasses are necessary for samples above 60 °C or below 0 °C.
It shall be borne in mind that particular caution is always required owing to the presence of hydrogen
sulphide, as this gas is highly dangerous even in small concentrations.
All personnel employed in the plant shall be thoroughly acquainted with the dangers of H2S poisoning
and understand the emergency procedures in case of a toxic gas release. Therefore the personnel
should be equipped with portable H2S detectors.
8.2 RISK LIST, RISK MITIGATION AND COUNTERMEASURES
8.2.1 Toxic and Dangerous Substances
8.2.1.1 Hydrogen Sulphide

Hydrogen sulphide is often present in natural gas stream. It is a highly poisonous gas which can kill
even when inhaled in relatively small amounts.
8.2.1.2 High and Low Temperatures
High and low temperatures are quite likely in gas treating unit however, no extreme temperatures are
expected into Natural Gas Metering and Reducing Station.
Both equipment and piping into the unit has been provided with thermal insulation. These types of
insulation are present:
· Insulation for heat conservation
· Insulation for personnel protection
8.2.1.3 Insulation for Heat Conservation

This type of insulation has been provided where heat conservation is required due to process reasons.
8.2.1.4 Insulation for Personnel Protection
This type of insulation has been provided where there may be burning risk for Operators. All lines and
equipment with an operating temperature higher than 60°C have been insulated in order to avoid skin
contacts with hot surfaces.
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8.2.2 Fire and Extinguishing Procedures
Fire is classified in three main groups:

8.2.2.1 Group “A” Fires
Fire developed by common combustible materials such as wood, paper, fabrics, rubber, etc.
To extinguish these fires quench and/or cool using water, high water content foaming compounds, dry
chemical foams or carbon dioxide.
8.2.2.2 Group “B” Fires
Fires developed by flammable fluids such as gasoline, naphtha, oil, solvents, greases, paints, etc.
These fires will be extinguished by smothering with fire-fighting coverings (e.g. blankets, chemical foam
and sand) or with snuffing compounds (dry powder, carbon dioxide). The following equipment is
recommended in these cases: Chemical foam, dry chemical and CO2 extinguishers.
In the event of fire caused by gas leakage (butane, propane, fuel, gas, etc.) promptly isolate the area
affected by the fire and attack the flames with dry chemical, or CO2 extinguishers.
After the fire has been extinguished, disperse thoroughly any leaking gas to avoid the risk of reignition
or explosion. For this reason, when it is not dangerous to nearby equipment, it is often advisable to
extinguish the fire only when the supply of gas is almost exhausted.
At the same time, the greatest attention will be required to prevent the flames from going out by
themselves (otherwise air might penetrate into the vessel where the gas is contained and cause an
explosion).
Owing to the high heat release during group “B” fires, besides fighting the flames, cool equipment in the
area with water spray.
8.2.2.3 Group “C” Fires
Fires of electrical equipment such as motors, generators, transformers, circuit breakers, cables, boards,
etc.
These fires shall be extinguished by smothering with nonconductive substances. The following
equipment is recommended: dry chemicals, CO2 and carbon tetrachloride extinguishers which can be
directly used on still energized equipment (if necessary) being however very careful to stay at a safe
distance and never come into direct contact with the energized equipment, either with the body or any
part of the extinguisher.
When the electrical department confirms that all equipment in the emergency area has been de
energized, the use of other firefighting means will be possible such as nebulized water or even foam
when the fire is fed by the oil of a transformer, or circuit breaker.
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8.3 SAFETY PHILOSOPHY AND INTERLOCK DESCRIPTION
All the equipments of the Natural Gas Metering and Reducing Station are protected from overpressure
by pressure safety valves. Safety interlocks have been provided to prevent possible overpressure to the
unit and downstream equipment due to mis-operation, abnormal plant conditions or external causes.
8.3.1 Overpressure Protection Description
Natural gas metering and reducing section is mainly composed of four sections with different design
conditions. Such sections are the following:
· High Pressure Section (design pressure: 60.0 bar g): This section includes the sections between the
Inlet Skid “70-ME-004” and the pressure reducing skid “70-ME-002” and lines between these
equipments and up to pressure reducing section.
· Medium Pressure Section (design pressure: 30.0 bar g): This section includes piping between the “70-
ME-002” skid outlet and the unit outlet comprehending the outlet skid “70-ME-005”
· Low Pressure Section (design pressure: 11.0 bar g) : This section includes piping downstream
PCV-508-A/B in the “70-ME-003” fuel gas burner reducing skid up to the water bath heaters burners.
This section also includes the instrument air connections and tubing.
· Atmospheric Section: Includes the Water Bath Heaters 70-E-001-A/B and connected instrumentation.
All these sections are connected one to each other therefore protection has been provided to avoid
possible overpressure of low pressure section due to fluid breakthrough from high pressure sections.
8.3.1.1 High Pressure Section Protection
Protection of Natural Gas Metering and Reducing Station high pressure section from upstream pressure
sources has been provided through PSV-101 at the inlet of the station, the safety shut valve UV-501 and
dedicated pressure safety valves.
8.3.1.2 Medium Pressure Section Protection
Natural Gas Metering and Reducing Station medium pressure section is connected upstream to high
pressure sources. Overpressure protection has been provided in the following way:
· PCV-516-A/B that closes in fail position and is also provided with an integrated slam shut device SSV-
516-A/B that automatically isolate the system from upstream section.
· Downstream lines are provided with PSV-618-A/B sized in order to relief eventual gas slips from the
closed slam shut valves.
8.3.1.3 Low Pressure Section Protection
Natural Gas Metering and Reducing Station low pressure section is connected upstream to high
pressure sources. Overpressure protection has been provided in the following way:
· PCV-508-AB are fail open devices thus the downstream line are provided with PSV-608-A/B sized in
order to relief the whole eventual gas capacity from the full open regulator, based on the valve
manufacturer data.
· PCV-509-A/B close in fail position and are also provided with an integrated slam shut device SSV-509-
A/B that automatically isolate the system from upstream section.
· Downstream lines are provided with PSV-609-A/B sized in order to relief eventual gas slips from the
closed slam shut valves.
8.3.2 Interlocks Protection Description
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032083 00

Interlock protections are associated with the possible process upsets conditions and external events
(such as external fire, gas leakage) to prevent system major damages and scenarios.
Warnings on all process variables are also provided to notify Operators possible malfunctions before trip
are activated.
Interlock protection is programmed and implemented into client ESD panel located in control shelter
whereas all warning and trip are repeated in Control Room. Refer to “Abnormal Conditions” paragraph
in chapter 5.3 “Normal Operation” for detailed description of interlock activation causes and actions.
8.3.2.1 Interlock Testing
All safety trip initiators and outputs shall be checked on a regular basis. No facility for online trip testing
has been provided and thus there are no trip defeat buttons.
It is recommended that the trip system would be checked for 'real' when it is required to stop operation
as an alternative to utilizing a shutdown push button/sequence. It is recommended to simulate the
output signal of each interlock transmitter and verify the correct function of each trip logic and
equipment/device. A different initiator should be checked in rotation.
Operator should keep record of trip system testing.
8.3.3 Manual Shutdown Description
Even if the unit has been provided with an automatic safety & trip system (ESD) which protects the
Natural Gas Metering and Reducing Station from possible damage due to process upset conditions, the
unit is also provided with safety pushbuttons, located either on client control room or in field and in
control shelter as follows:
· HS-505-A/B in control shelter and HS-504-A4 in field, both for the Heaters Emergency shutdown.
· HS-501-C pushbutton in field and HS-501-B in control room that close the UV-501 shutdown valve
isolating the unit and stopping the flow.
8.4 FIRE FIGHTING SYSTEM SELECTION
The above described extinguishing agents shall be applied to fire source and exposures by means of
both fixed and portable facilities as well as by means of fixed dedicated systems as below summarized:
· Fire hydrants;
· Fire water monitors;
· Portable and wheeled dry chemical powder fire extinguishers;
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9 EQUIPMENT DATASHEET
9.1 DATASHEETS
9.1.1 Instruments Datasheet
Instruments Datasheet 70-SA-E-53312

9.1.2.1 Mechanical Data Sheet for Water Bath Heater 70-SA-E-53324

9.1.2.2 Mechanical Data Sheet for Cartridge Filter MS-002 70-SA-E-53320
9.2 CAUSE-EFFECT MATRIX
Cause-Effect Matrix 00-ZA-E-9004
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10 DRAWINGS
Natural Gas Metering and Reducing Station 70-SD-A-53301

Sheet 1-4
ALSTOM fuel gas supply HTCT 124566
Sheet 10 of 11
10.2 PLOT PLAN

General Plot Plan 00-GB-A-62030
10.3 LAYOUT DRAWINGS

F&G detection and safety equipment layout GT area 00-ZB-A-85020
_______________________________


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AFAM – RIVERS STATE GOVERNMENT

OPEN CYCLE POWER PLANT Job Number UNIT

COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

COMMISSIONING AND OPERATING MANUAL

00 Issued for Construction

Rev. Description Prepared Checked Approved Date

COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

I UNIT 50 - FIRE PROTECTION SYSTEM 13

Cod. modulo : Cod.file: File dati:

COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

I UNIT 50 - FIRE PROTECTION SYSTEM 14

3 COMMISSIONING/ INITIAL START UP 21

4 NORMAL AND SUBSEQUENT START-UP 27

Cod. modulo : Cod.file: File dati:

COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

9 EQUIPMENT LISTS AND DATA SHEETS 41

II UNIT 60 - SERVICE AND POTABLE WATER SYSTEM 43

3 COMMISSIONING/ INITIAL START UP 51

Cod. modulo : Cod.file: File dati:

COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

4 NORMAL AND SUBSEQUENT START-UP 56

9 EQUIPMENT LISTS AND DATA SHEETS 67

III UNIT 80 - INSTRUMENT AND SERVICE AIR SYSTEM 69

Cod. modulo : Cod.file: File dati:

COMMISSIONING AND OPERATING SPC.N. 00-ZA-E-90110

3 COMMISSIONING/ INITIAL START UP 74

4 NORMAL AND SUBSEQUENT START-UP 78

9 EQUIPMENT LISTS AND DATA SHEETS 96

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10.5 FIRE AND GAS DETECTION SYSTEM LAYOUT

IV UNIT 40 - OPEN DRAINS 98

IV UNIT 40 - OPEN DRAINS 98

2 PROCESS DESCRIPTION 102

3 COMMISSIONING/ INITIAL START UP 104

4 EMERGENCY SHUTDOWN 106

6 EQUIPMENT LISTS AND DATA SHEETS 108

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V UNIT 70 - FUEL GAS 110

1 DESIGN BASIS 110

2 PROCESS DESCRIPTION 114

3 COMMISSIONING/ INITIAL START UP 121

4 NORMAL AND SUBSEQUENT START UP 129

5 NORMAL OPERATION 132

6 NORMAL SHUTDOWN 137

7 EMERGENCY SHUTDOWN 141

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8.3 SAFETY PHILOSOPHY AND INTERLOCK DESCRIPTION

9 EQUIPMENT DATASHEET 146

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· To avoid too many references to equipment Manufacturer's manuals, necessary vendor’s

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1.2 GLOSSARY OF TERMS USED AND UNITS USED

I. Glossary of Terms Used

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II. Units Used in Designing the Plant