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Operating Philosophy PDF
Operating Philosophy PDF
PHILOSOPHY
OPERATING PHILOSOPHY
TABLE OF CONTENTS
OPERATING PHILOSOPHY
1. INTRODUCTION ................................................................................................................................... 4
1.1. BACKGROUND ........................................................................................................................................ 4
1.2. RU OPERATIONAL PHILOSOPHY ................................................................................................................. 4
1.2.1. Scope ......................................................................................................................................... 4
1.2.2. Objectives .................................................................................................................................. 4
1.3. RU OVERVIEW, SPECIFICATIONS AND UTILITIES SYSTEM .................................................................................. 4
1.3.1. Overview ................................................................................................................................... 4
1.3.2. LNG Buffer Tanks ....................................................................................................................... 4
1.3.3. Gas Pressure and Temperature at Delivery Point ....................................................................... 5
1.3.4. Utility Systems ........................................................................................................................... 5
1.4. ABBREVIATIONS ...................................................................................................................................... 5
2. BASIS OF PHILOSOPHY ......................................................................................................................... 7
2.1. HEALTH ................................................................................................................................................ 7
2.2. SAFETY ................................................................................................................................................. 7
2.3. ENVIRONMENT ....................................................................................................................................... 7
2.4. EMERGENCY EQUIPMENT ......................................................................................................................... 8
2.5. PERSONAL PROTECTIVE EQUIPMENT ........................................................................................................... 8
2.6. EMERGENCY RESPONSE PLAN .................................................................................................................... 8
3. STAFFING, COMPETENCY, DEVELOPMENT AND TRAINING .................................................................... 9
3.1. STAFFING .............................................................................................................................................. 9
3.2. COMPETENCY, DEVELOPMENT AND TRAINING ............................................................................................... 9
4. LNG BUFFER TANK OPERATING PHILOSOPHY ...................................................................................... 10
5. LNG TRANSFER PHILOSOPHY .............................................................................................................. 10
5.1. LNG TRANSFER OPERATIONS .................................................................................................................. 10
5.1.1. LNG Transfer – General Requirements ..................................................................................... 10
5.1.2. LNG Flow Rates........................................................................................................................ 10
5.1.3. Vapour Return ......................................................................................................................... 10
5.1.4. Accidental Cargo Release......................................................................................................... 11
5.1.5. Metering Requirements ........................................................................................................... 11
5.1.6. Completion of Cargo Transfer .................................................................................................. 11
5.2. PARCEL SIZE/OFFLOADING RATE .............................................................................................................. 11
5.3. BOIL OFF GAS ...................................................................................................................................... 11
6. REGASIFICATION OPERATION PHILOSOPHY ........................................................................................ 12
7. GAS DISTRIBUTION SYSTEM OPERATION PHILOSOPHY ....................................................................... 12
7.1. OVERVIEW .......................................................................................................................................... 12
7.2. GAS METERING .................................................................................................................................... 12
8. RELIEF AND VENT SYSTEM OPERATION PHILOSOPHY .......................................................................... 13
8.1. OVERVIEW .......................................................................................................................................... 13
8.2. RELIEF CONTINGENCIES .......................................................................................................................... 13
8.3. BLOWDOWN ........................................................................................................................................ 13
8.4. MANUAL DRAINS AND VENTS .................................................................................................................. 14
9. CONTROL AND SHUTDOWN OPERATION PHILOSOPHY ....................................................................... 15
9.1. SHUTDOWN ......................................................................................................................................... 15
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9.1.1. Hierarchy ................................................................................................................................. 15
9.1.2. Total RU Shutdown .................................................................................................................. 15
9.1.3. Regasification Process Shutdown ............................................................................................ 15
9.1.4. Unit Shutdown ......................................................................................................................... 15
9.2. REGASIFICATION PROCESS CONTROL ......................................................................................................... 16
9.2.1. General .................................................................................................................................... 16
9.2.2. LNG Pumps .............................................................................................................................. 16
9.2.3. LNG Vaporiser Control Requirements....................................................................................... 16
9.3. START‐UP AND RESTART ......................................................................................................................... 16
10. AUTOMATION, INSTRUMENTATION AND COMMUNICATIONS PHILOSOPHY ................................... 17
10.1. SYSTEM REQUIREMENTS ......................................................................................................................... 17
10.1.1. Overall Instrumentation and Control Philosophy ..................................................................... 17
10.1.2. Systems Interface .................................................................................................................... 18
10.1.3. Control Room and Human Machine Interface .......................................................................... 19
10.2. PCS SPECIFIC DESIGN REQUIREMENTS ....................................................................................................... 19
10.2.1. PCS Architecture ...................................................................................................................... 19
10.2.2. Functional Requirements ......................................................................................................... 20
10.2.3. Data Communication ............................................................................................................... 21
10.2.4. Tank Level Measuring Instrumentation ................................................................................... 21
10.3. COMMUNICATIONS PHILOSOPHY .............................................................................................................. 22
10.3.1. Telephone System .................................................................................................................... 22
10.3.2. IT Network ............................................................................................................................... 22
10.3.3. Public Address and General Alarm System ............................................................................... 22
10.3.4. Close Circuit TV and Security System ........................................................................................ 23
10.3.5. Meteorological System ............................................................................................................ 23
10.3.6. Radio Equipment Room ........................................................................................................... 23
11. MISCELLANEOUS OPERATIONAL PHILOSOPHIES ............................................................................. 24
11.1. SIMULTANEOUS OPERATIONS .................................................................................................................. 24
11.2. MATERIALS HANDLING/ACCESSIBILITY/DROPPED OBJECT PROTECTION ............................................................ 24
11.2.1. Materials Handling .................................................................................................................. 24
11.2.2. Accessibility ............................................................................................................................. 24
11.2.3. Impact Protection .................................................................................................................... 25
11.3. GENERAL HOUSEKEEPING ....................................................................................................................... 25
12. MAINTENANCE PHILOSOPHIES ....................................................................................................... 26
12.1. OBJECTIVES ......................................................................................................................................... 26
12.2. SERVICING ........................................................................................................................................... 26
12.3. MAINTENANCE MANAGEMENT ................................................................................................................ 26
12.4. FRONTLINE MAINTENANCE ..................................................................................................................... 27
12.5. MAJOR SHUTDOWNS ............................................................................................................................. 27
12.6. CONDITION MONITORING, TESTING AND INSPECTION ................................................................................... 27
12.7. CERTIFICATION ..................................................................................................................................... 27
12.8. SPARES HOLDING .................................................................................................................................. 28
12.9. PERMIT TO WORK/WORK ORDERS ........................................................................................................... 28
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1. INTRODUCTION
1.1. Background
PT. Pelindo Energi Logistik (PT. PEL) as a subsidiary of PT. Pelindo III, which
engaged in provision of energy and electricity, have been collaborated with PT.
Indonesia Power in LNG Receiving Terminal Project, for supplying gas to the Dual
Fuel Engine Power Plant in Pesanggaran, Bali.
1.2.2. Objectives
The objectives of this operations philosophy are to ensure:
a. Health, Safety and environment (HSE) objectives are achieved;
b. Technical and mechanical integrity are maintained;
c. Life cycle economics are optimised;
d. Legal compliance;
e. To provide an overall vision of how the RU shall be operated.
This document also presents the key operational requirements to be incorporated
into the design of the RU. Operational requirements are set out in general terms; the
detailing of which shall be undertaken in the development of the Basis of Design
(BOD) document.
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The RU can supply gas to Power Plant minimum for 3 hours when the FSU fail to
supply LNG.
1.4. Abbreviations
The abbreviations summarised in Table 1.1 are used throughout this report.
Table 1.1: Abbreviations
Abbreviation Definition
AAV Ambient Air Vaporisers
ALARP As Low As Reasonably Practical
API American Petroleum Institute
BA Breathing Apparatus
BOD Basis of Design
BOG Boil-Off Gas
CBTA Competency Based Training and Assessment
CCR Central Control Room
CCTV Closed Circuit Television
CFC Chlorofluorocarbon
COMPANY PT. Pelindo Energi Logistik
CONTRACTOR LNG Regasification Unit Contractor
dBA Decibel-A weighted scale
ESD Emergency Shutdown
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2. BASIS OF PHILOSOPHY
2.1. Health
Health hazards shall be identified (such as chemicals, toxic material, noise and heat
etc) and appropriate means incorporated into the design to minimise the risk to
personnel from these hazards.
A database of all hazardous materials shall be established during the detailed design
phase of this project. This database shall include Material Safety Data Sheets (MSDS)
for all chemicals to be used on the RU, and shall be available electronically and in hard
copy.
A separate safety management system for handling/storing and treating exposure to
hazardous materials/chemicals shall be developed during the detailed design phase of
this project.
A person qualified to act as a paramedic shall be present on the RU at all times.
Asbestos or materials containing asbestos, tar-coal epoxy coatings and heavy metals
shall not be used in the design of or during the operation of the RU.
Personnel shall not be subjected to passive smoking.
2.2. Safety
The design and operation of the RU shall conform to the requirements of the relevant
local laws and regulation and applicable codes and standards. The safety in design
philosophy shall be one of identification of potential hazards under normal perceived
operating circumstances and designing to reduce the risk from these hazards to
ALARP (As Low As Reasonably Practical).
2.3. Environment
The RU shall meet the local regulation and company requirements in relation to
environmental management. An environmental management plan shall be developed
during detailed design phase of this project, which shall outline any conditions imposed
by local regulators in relation to environmental management.
A design and operating philosophy of energy conservation shall be pursued where
practical.
The use of halon’s or ozone depleting chlorofluorocarbon (CFCs) is prohibited.
Alternatives shall be used which have less effect on the environment (ozone layer).
Flare system is the preferred method to dispose of process vent gases on the RU.
However, if cold venting is proposed then CONTRACTOR shall undertake dispersion
modeling of the vent gases to verify that the system shall meet all safety requirements.
Operational flaring/venting shall be minimised. The operational design approach of the
RU shall be to limit flaring/venting to ALARP.
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8.3. Blowdown
Blowdown and release of gas and liquid to the flare system is not expected to be a
common occurrence. The process shall be designed to retain all fluids within the
equipment under all operating conditions.
Blowdown is expected to occur mainly due to events external to the process e.g. fire
and gas alarm, maintenance etc. Blowdown shall be constrained to hydrocarbon
bearing equipment such as vaporisers, LNG pumps, BOG compression and gas
export.
Emergency blowdown shall comply with the requirements of API STD 521 and sent to
the flare system for disposal. Blowdown of liquid sources shall be minimised;
blowdown of vapour streams is preferred.
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9.1. Shutdown
9.1.1. Hierarchy
The RU shall be in accordance with the safety philosophy document. The RU shall
have two separate programmable shutdown systems as follow:
a. Fire and Gas System (FGS): detects gas, flame, heat and smoke, operates
warning sirens and lamps and electrically isolates power systems and
batteries as well as initiating the release of fire fighting systems;
b. Safety Instrumented System (SIS): detects process parameter excursions
outside normal control band and settings;
c. Loading arm or cryogenic hoses emergency release safety system;
d. Fully integrated with the jetty FGS or SIS system
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safety, the environment or the operation of the combined facilities. The design shall
maintain simplicity in system operation; and shall facilitate diagnostics and
faultfinding of operational issues or the maintenance of equipment.
The system equipment shall be selected based upon well proven design, service
history, reliability and integrity. All system equipment shall be standardised, wherever
possible and practical, with the equipment installed on the RU.
Field devices certified for use in hazardous areas shall utilise Ex ‘d’ (explosion proof)
methods of protection wherever possible and practical.
The general philosophy shall be to utilise Foundation Field Bus (FFB) field devices
for all PCS field devices where appropriate. FFB field devices shall not be used for
accommodation/utility/marine systems services and on the SIS or FGS. The use of
FFB instrumentation for packaged equipment shall be dependant on each vendor’s
standard.
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b. In the event that a vendor does not offer the above common PLC equipment,
COMPANY’s approval shall be sought for the proposed PLC system;
c. Local display shall be provided as part of the UCP for control, monitoring and
diagnostics of the packaged equipment.
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Ethernet based MIS information domain. The workstation shall be able to work as
server to clients in the MIS connected to Ethernet LAN.
The controllers are stand alone process control and data acquisition systems and
interface the field signals to the communication network via I/O termination
assemblies, I/O modules, control processors and network communication modules.
Interfaces to the SIS and FGS shall be carried out on a common control/SIS
Highway. The requirements for this highway shall be addressed in an Emergency
Shutdown System Operating Philosophy to be developed during the detailed design
phase of this project.
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10.3.2. IT Network
The network shall be implemented on CAT9 Structured cable. The telephone system
shall use the same structured cable network. There shall be no differentiation
between the two systems, i.e. same patch panels, numbering and outlet types.
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11.2.2. Accessibility
Good access shall be provided to items of equipment which require frequent (more
than once per year) testing, inspection or maintenance. This shall also apply to the
permanent handling/lifting devices (such as beams, pad eyes) installed for equipment
removal.
Scaffolding or other temporary fixtures shall be used where equipment testing,
inspection or maintenance is less frequent (greater than 2-years).
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12.2. Servicing
The optimum means of servicing equipment shall be carefully assessed against
maximising RU availability. The servicing options, which shall be evaluated, are:
a. Maintain/repair onsite or in the facility workshop; and
b. Remove equipment and repair onshore.
Consistent with the philosophy of minimum staffing, onshore repair or maintenance
shall be pursued. Additionally the option of vendors providing full or part servicing of
equipment shall be reviewed during the design to determine the optimum strategy.
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12.7. Certification
Early in the detailed design phase, the Certifying Authority shall be appointed. The
work scope definition for the Certifying Authority shall be developed in consultation
with the appropriate government department.
An integrated approach shall be developed whereby the Certifying Authority, design
and operations team work together to achieve the desired level of technical integrity.
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