LTJ Ins 002 - (Ifb)

Contract No : Document No.
LTJ-INS-002
PROCESS CONTROL PHILOSOPHY
Revision :1 Status : IFB
Revision Date : 04-03-2019
Doc type: Report Discipline: Instrument
Page 1 of 11
DESIGN ENGINEERING LNG TERMINAL

JAWA TIMUR PHASE-1
1 04/03/2019 IFB ISSUED FOR BID AFR DH IM FAP AAR

Iss’d Chc Apprv’d Apprv’d
Apprv’d
Rev Date Status Description k’d
SENA PGN LNG
LTJ-INS-002
Page 2 of 11
REVISION HISTORICAL SHEET

Rev. Date Page Description
1 04/03/2019 Issued for Bid
LTJ-INS-002
Page 3 of 11
TABLE OF CONTENTS
1. GENERAL ...................................................................................................................................... 4
1.1. SCOPE...........................................................................................................................................4
1.2. SERVICE AND DESCRIPTION ...................................................................................................... 4
2. CONTROL SYSTEM PHILOSOPHY .............................................................................................. 4
2.1. CONTROLLER PHILOSOPHY .......................................................................................................4
2.2. HUMAN MACHINE INTERFACE (HMI) PHYLOSOPHY.................................................................5
2.3. SINGLE LOOP CONTROLLER PHILOSOPHY .............................................................................. 6
3. PROCESS CONTROL .................................................................................................................... 7
3.1. PRESSURE CONTROL .................................................................................................................7
3.2. FLOW CONTROL .......................................................................................................................... 7
3.3. LEVEL CONTROL .......................................................................................................................... 8
3.4. OTHER SPECIFIC INSTRUMENT .................................................................................................8
4. PROCESS CONTROL DESCRIPTION ........................................................................................... 9
4.1. LNG TRANSFER FACILITY ............................................................................................................ 9
4.2. LNG BUFFER TANK AND BOOSTER PUMP .................................................................................9
4.3. REGASIFICATION UNIT ............................................................................................................... 10
4.4. METERING SYSTEM.................................................................................................................... 11
4.5. BOG HANDLING SYSTEM ........................................................................................................... 11
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1. GENERAL
1.1. Scope
This design criteria covers the minimum requirements for process control design of the LNG
Regasification Plant Project PT PGN LNG Indonesia located in Teluk Lamong, Surabaya.
Each control system shall be design, fabricated, and erected to the standards, codes, engineering
practices, and general requirements as per Design Basis.
Control system shall be specified, to be high quality and high degree of safely in accordance with
contractual codes and standards, reliability and to be standard items as far as possible.
1.2. Service and Description
The control system will be design to control equipment and process system (e.g., hydrocarbon, LNG,
air, firewater, utility water). The control system philosophy shall exclude fire protection system in the
area. If require, the fire protection control system shall be design fail safe and activate manually by
operator unless otherwise state in the project specification.
2. CONTROL SYSTEM PHILOSOPHY

The design of control systems shall be in accordance with this specification and API RP554, ISA S-5.3,
IEC-61508-61131-61511, unless otherwise specified in the applicable codes and standards. This
specification is intended to apply to control system normally needed in the process and utilities of the
overall plant facilities.
Process area will cover transfer line from Jetty to ORU, Onshore Regasification Unit ( ORU), and
metering system. Utilities area will cover Instrument air Plant and Emergency power system ( Backup
power).
2.1. Controller Philosophy
The controller should be designed to continous monitoring all process parameter in the Process and
utilities area.
The control system shall comprise of a distributed architecture with a microprocessor based control
system consisting of discrete types of functional hardware elements interconnected to provide overall
system functionality, i.e. distributed architecture. The system shall also be geographically distributed
with the control and data acquisition functions performed at a remote location (within plant area) and
the control and monitoring of these functions from the control room using cables or wireless
technology. The control system shall be based on an “open” architecture where the system has
inherent capabilities to integrate and exchange information with other systems and/or platforms via
industry standard protocols.The controller network system shall be based on fast dual redundant
Ethernet LAN network. The failure of one network cable shall not have any impact to the operation of
the control system.
The controller and each of its component subsystems (marshalling cabinets, etc) shall fully comply with
the following sparing philosophy. Indicated spare capacity shall be available at the time of completion
of the completion phase of the project as follows:
 I/O Modules - 30% installed, wired and fully functional I/O of all types used.
 I/O Racks - 20% spare rack.
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 Memory - 40% spare memory capacity for future process control and functional logic software
modifications.
 Terminal Blocks - 20% spare terminal blocks shall be provided in marshalling cabinets.
 System Cabling - 20% spare pairs over and above the I/O module/rack spare requirements.
 Communication Port - 1 module spare.
All spare quantities shall be rounded up to the nearest whole number.The system shall be designed
such that 20% future expansion can be accommodated without any modification or replacement of
existing equipment, communication systems or software.
The system shall support at least three different levels of access control either via the use of a
removable key and/or by entering a pre-configured password. It shall also be possible to configure
user-specified functions to the following levels.
 Operator Level : This level shall include typical operator functions and not require a key
or password.
 Supervisor Level : This level shall include all the operator functions as well as the pre
configured supervisory functions and shall require a key or password.
 Engineering Level : This level shall include all functions and require a key or password.
The Controller shall be capable of performing all monitoring and control, and operator/interface tasks
normally, associated with conventional main control room, and subsystems, such as analog
controllers,single loop controller, flow computers, recorders, indicators, annunciator, sequential logic,
Vibration Monitoring, etc with scan rate shall be less than 50 ms. Some of the controller tasks shall
include, but are not limited to:
 Closed loop control including manipulation of set point, mode output, and tuning constants
 Indication of control and non-control analog and digital variables
 Alarm annunciation and display
 Real time and historical trending
 Status indication, tabular and graphic displays
 Flow calculations (with P, T, S.G. and super compressibility compensation) and flow integration
and accumulation
 Boolean, compare, and sequence logic functions with calculated outputs used to drive set
points and final control elements
The controller will send signal to Human Machine Interface (HMI) Operator which display the plant
process parameter.
2.2. Human Machine Interface (HMI) Phylosophy
HMI shall have enough capacity to save and display trending data, process alarm, equipment failure
alarm and historical data minimum for 6 months. All Historian data shall be able to save in microsoft
excel format. All alarms shall be able to send to a network printer.
The HMI shall be specifically designed to work with touch screen flat panel displays. The display
modules shall be equipped with a non-glare glass protective cover for the LCD/LED display panels.
Hardware, such as CPU’s and networking equipment, mounted in the HMI shall utilize pull out drawers
or shelves to allow easy access for maintenance and service of the equipment.
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The HMI in main control room shall consist of at least two monitors. One monitor shall normally be
used for alarms. The others shall be capable of the following displays:
 Overview
 Individual loop
 Alarm
 Graphics
 Digital points
 Trending
Graphic displays shall be divided into “standard” and “custom” types. The custom graphic display shall
detail a schematic presentation of the station at different levels, from overview level right through to
equipment detail level. The standard graphic display shall provide the operator with a standard format
for displaying information and are configurable and normally accessible from dedicated function keys.
The graphic displays, together with the keyboards shall provide a complete window to the station for all
control and monitoring requirements. The graphics display shall capable to display process data from
other buses/local networks. Each console shall have the capability of building and displaying minimum
200 pages of custom process graphics depicting process schematics or control models.
The real time data within these displays shall be automatically updated without the need for operator
action with a configurable refresh rate of one (1) seconds or less that shall be approved by the
Company. Graphic call up time shall be one (1) seconds or less.
2.3. Single Loop Controller Philosophy
Single-loop controller is a device dedicated to generating a single control output. This controller
incorporates an operator interface consisting of individual displays of the process variable, the
setpoint, and the output, as well as the means of adjusting the setpoint, the output, switching to
manual operation, or changing ratios.
The following points (not listed in order of importance) should be considered when deciding on the
location for a single-loop controller:
a. Convenience to operating personnel.
b. Convenience to maintenance personnel, accessibility for servicing, and frequency of servicing.
c. Installed cost, based on location.
d. Safety of personnel and equipment.
e. Vibration effects on equipment and its performance.
f. Corrosion caused by the surrounding atmosphere.
g. Weatherproofing and winterizing.
h. Explosion proofing.
i. Protection from fire.
j. Accessibility in the event of fire.
k. Protection from mechanical damage, or damage caused by fire suppression systems.
l. Ambient temperature.
m. Thermal radiation from the sun or hot equipment.
n. Plant philosophy with respect to types of instruments purchased and their location.
o. Manpower availability.
p. Protection from the effects of EM1 (electro magnetic interference) or RF1 (radio frequency
interference).
q. Reliability/availability of controller power source.
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The Single Loop Controller shall be capable of interfacing into Main controller communication link.
Failure of the communication link shall not interfere the single loop controller. All Alarms from single
loop controller shall be display in the HMI.
3. PROCESS CONTROL
3.1. Pressure Control
Pressure control valve shall be design to fail open, LNG vapor trapped shall be vent to a safe location/
flare with a proper design capacity. All pressure vessel shall equipt with pressure control to maintain
pressure of the vessel.
Incase no pressure control valve installed pipeline and pressure vessel shall be designed to
accommodated 1.5 operating pressure.
Consideration must be taken if pressure control does not installed and use PSV as pipe and vessel
protection, PSV location must be consider as close possible to the weak point on the pipe or vessel.
All pressure devices except pressure gauges shall be equipped with easy calibration connections. This
can be accomplished by using a three-way valve, or a tee and valves, or an AGCO PTMVS manifold
on the pressure device input. It shall not be necessary to remove any piping or tubing to calibrate a
pressure device, with the exception of local mounted pressure gauges. Pressure gauges must have
block valves. Normally pressure instruments shall be specified with a range about 30% greater than the
normal operating pressure. For instruments connecting to the process, element material shall be 316
SS or better. Narrow span pressure instruments shall be used in critical control loops. An additional full-
range pressure instrument shall be furnished if full span reading is necessary.
Absolute pressure transmitters shall be provided where absolute pressure is required. Examples are
surge control and flow computers.
3.2. Flow Control
The instrument valves, unit valve and the packing gland must meet or exceed the ratings of the
associated piping class.
Flow control valve shall be designed to fail closed, LNG liquid shall be isolated in case there is a failure
on the flow control valve. Flow control valve shall be designed to allow the operating flow condition at
50 % valve opening. Any deviation from these conditions shall get approval from the company.
Flow control valve for Liquid shall be designed to ensure the pressure drop will not cause vaporization,
consideration must be taken to ensure the linearity of the flow and turbulence effect by minimum
distance of straight line before and after flow control valve.
The selection of the flow measuring devices depends upon the fluid being measured, available
pressure drop, range ability, accuracy, etc. Life of the device, repair ability and easy calibration shall be
considered. Orifice plate shall be used as the flow element for all flow measurement, unless exception
is made due to the particular requirements of the process, or the conditions of the process fluid. Special
devices may be used for special flow applications and should be installed in accordance with the
manufacturer's recommendations or in accordance with a specially engineered installation for specific
requirements. The use of these special flow devices shall be indicated on the P&ID's.
In general, a concentric orifice plate shall be used. An eccentric, segmental, or quarter round bore
orifice plate may be used in services such as dirty services, wet gas, or highly viscous fluids.
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Conventional measurement using orifices shall not be installed in line sizes smaller than 2 inchs,
Integral orifice transmitters may be used for line sizes smaller than 2 inch where flow rate is in the
range of 0 to 2.25 m3/hr (0-10 gpm).
Annubars are a head producing flow element and work similar to pitot tubes. The element is attached
to the process piping generally through the use of a special half coupling welded in place. All
installations of annubars must be removable without a system shutdown; that is, the element can be
retracted from the process pipe and isolated with a ball valve. The preferred mounting orientation is
vertical in a horizontal pipe with the differential pressure transmitter located above the annubar.
Annubars are to be used only on clean liquids or non-condensing gases. The annubar shall be
fabricated from 316 stainless steel. However, other materials may be used if required by the process
conditions.
3.3. Level Control
All separators, scrubbers, flash tanks, reservoirs, storage tanks, and other vessels that normally
contain liquid or occasionally collect liquid must be equipped with level indicators and may be equipped
as necessary with level controls, alarms, or shutdowns. Where two or more level instruments cover the
same general level range, a (single) liquid level column (strong back or bridle) shall be used to
minimize vessel nozzles. Level strong backs shall be 2 inch pipe minimum size and shall be provided
with flanged shutoff valves. Bottom strong back and other bottom level connections must come off the
side of the vessel to prevent junk and dirt from plugging the connection. However, if a side connection
is not practical, a bottom connection with an internal extension of 25 mm (1 inch) to 50 mm (2 inch) into
the vessel is required. Bottom connections must be approved by the Company. Top connection must
also come off horizontally if upper phase is liquid. All level instruments must be accessible for
adjustment and readability from an operating platform or grade. Pressure/temperature rating of level
Instruments must be equal to greater than the pressure/temperature rating of the vessel to which they
are connected.
LNG level detection equipment will be installed outdoors.
Switches shall be of the external float cage type construction and shall have a rating equal to or greater
than the vessel design pressure and temperature. High or low level shutdown switches may be float
actuated devices, piped independently of other level control or alarm devices or monitor switches from
independent transmitters. The float switch shall have side-bottom 1 inch NPT connections. Electrical
switch enclosure shall be explosion proof for Division 1 areas with environmentally or hermitically
sealed switch contacts, or utilize hermetically sealed switch contacts for Division 2 or non-hazard
areas. The float switch shall be connected with 1 inch valves and unions, and a 1/2 inch NPT full port
valve shall be provided on the bottom for draining and rodding. Avoid mercury capsule contacts.
3.4. Other Specific Instrument
Any other specific instrumentation device shall conform to applicable International Engineering
standard which is commonly used in Oil and gas industrial practice. Non conformity equipment shall get
approval from company to be include on the design package.
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4. PROCESS CONTROL DESCRIPTION

4.1. LNG Transfer Facility
There are two main transfer activity inside the LNG transfer facility, the first is LNG loading from LNG
carrier to ORU and/or FSU. The second is LNG unloading from FSU to ORU. The LNG pump of LNG
Carrier or FSU shall be designed to be able to transfer through 2 km LNG transfer pipeline system into
ORU. During LNG transfer process, flow, pressure and temperature along the unloading line to ORU
shall be able to be monitored from the local control room at ORU.
To monitor and operate the LNG transfer activity, flow indication, temperature indication and flow
control valve shall be installed. Flow, pressure and temperature indication shall be installed at the
unloading line to ORU, while the control valve shall be installed at the transfer line to FSU. temperature
local gauge shall also be installed at the LNG transfer line.
Alarm shall be available for the operator to monitor at local control room, the connection status of Jetty-
LNG Carrier LNG transfer line , LNG unloding line and BOG return line, and Jetty-FSU LNG transfer
line ,LNG unloading line and BOG transfer line.
Safety system shall be installed to facilitate ESD-1 and ESD-2 signal, from both ship, FSU or LNGC,
and shore. the ESD signal shall be linked from ship to shore using electronic ESD line before loading
activity is started. Two ESD valve shall be installed, first is an ESDV valve to isolate LNG unloading line
from LNG Carrier, second an ESD valve to drain / de-pressurize the LNG unloading line from LNG
carrier to two sump tank unit. all DBV or double block valve, shall also be considered as an ESD valve.
During ESD-1 signal, all DBV shall close to stop any flow to the LNG unloading line, Isolating valve
shall close to isolate the LNG unloading line, and the ESD drain valve shall open to drain all LNG
trapped inside the loading line to the sump tank. During ESD-2 signal, all procedure from ESD-1 shall
be activated, and all DBV PERC shall activate to disconnect the ship from the dock.
During LNG loading from LNG carrier to FSU, the loading flow rate shall be managed by LNG carrier by
utlizing LNG Carrier LNG Pump. requested loading rate from LNG carrier shall be 1,500 m3/hr, then the
LNG shall be distributed to ORU and FSU. The flowrate to ORU shall be controlled by using flow
control valve restricting the flow to the FSU. The maximum flow rate to the ORU shall be 60 m3/hr.
During LNG unloading from FSU, the unloading flow shall be managed by FSU by utilizing FSU LNG
pump. The requested unloading rate to ORU shall be 60 m3/hr. the unloading rate shall not exceed 60
m3/hr.
4.2. LNG Buffer Tank and Booster Pump
LNG Buffer Tank
The LNG will enter the ORU facility in the LNG Buffer tank with capacity of 2x87 m3. The buffer tank will
store LNG temporary before sending the LNG to Regasification through LNG booster pump. In case of
an emergency trip from ship, the buffer tank will serve as an emergency supply to regasification unit in
order to maintain regasification for approximately 30 minutes before regasification unit will have to shut
down. The LNG from the LNG buffer tank will be delivered using the Booster Pump to the evaporation
unit.
To monitor the operation of the LNG Buffer Tank, pressure, temperature indicator shall be installed at
the tank inlet to monitor feed LNG condition, while Level, pressure and temperature indicator are
installed in the tank. The tank temperature indicator consist of five temperature indication points, at
above pump NPSH, at 50%, 75% and 95% of tank level.
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Alarm shall be avaiable to the operator to monitor at the local control room, the alarm shall cover
pressure high, low, temperature high, low of tank inlet, pressure low-low, low, high of tank, temperature
low for tank, level low-low-, low, high, high-high of tank.
Safety system shall be installed to over filling of the tank and vacuum tank. To prevent over filling, The
buffer tank shall be provided high-high alarm to automatically activate isolation valve at the inlet of the
buffer tank. To prevent vacuum tank, the buffer tank shall be provided with pressure low-low alarm to
automatically trip the LNG booster pump. In case of over pressure in the buffer tank, PSV will operate
to relief the pressure by venting the boil of gas to flare.
During start-up, level measurement may not give accurate reading due to uneven density of the LNG
measured by the DP level Cell, therefore during start-up, to check if the level has been formed at the
tank, operator shall monitor from bottom temperature indicator, if the temperature of the bottom tank
reach stable LNG temperature, around -160 deg C, level formation can be confirmed formed in the
tank. After the bottom temperature has achieved LNG temperature, level can be monitored from level
incator (DP Cell).
LNG Booster Pump
LNG Booster Pump will send HP LNG from LNG Buffer Tank to regasification unit. there are 3 Booster
pump, with the maximum capacity of each booster pump of 33 m3/hr. the nominal flow rate shall be 30
m3/hr with the configuration of two running pump and one idle / standby pump.
To control each of the booster pump discharge flow rate, Motor Variable Speed Drive (VSD) and
Recycle Control Valve, and flow transmitter shall be installed at discharge. The VSD shall serve as the
main flow control final element, while the recycle control valve works as minimum flow protection for the
pump. Operator shall locally adjust the VSD setting according to operational demand. VSD setting shall
refer to pump speed-flow curve.
To monitor and operate the booster pump, two pressure indicator at the suction and discharge with one
shall be pressure transmitter and the other is local pressure gauge, current transducer, start/stop
indication and remote fault indication shall be installed for each booster pump, and also remote
start/stop command to the booster pump and remote speed setting shall be available at ORU local
control room.
Alarm shall be available for operator to monitor at the local control room, pressure for discharge high
and suction low, dishcarge flow low, and motor current low/high.
Safety system shall be installed, to prevent cavitation of the booster pump. In case of low low level
alarm appears in any of both LNG buffer tank, the LNG booster pump shall be tripped. The level low
alarm of the LNG buffer tank shall be the interlock to prevent The booster pump to be started. The
booster pump shall be able to be started if the level low alarm cleared.
4.3. Regasification Unit
The Regasisfication plant consist of eight vaporizing unit, each unit have two vaporizer. The Vaporizing
proceess uses natural draft heat exchange using ambient air. The maximum input capacity of the
regasification plant shall be 7.5 m3/hr of LNG for each evaporator (5,000 NM3/h).
To monitor and control the operation of the vaporizing units, control valve shall be installed at the inlet
of each vaporizing unit. the control valve shall be equipped with open/close limit switches as position
feed back. The control valve shall function as a inlet flow throttling and also as an ESD valve. Operator
shall manually adjust the opening of the valve from the control room to adjust the product flow rate of
LTJ-INS-002
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each of the vaporizing unit. the product of all running vaporizing unit shall be equally distributed.
Temperature and pressure local gauge, and a differential pressure indicator of the inlet and outlet of
each of the vaporizer, shall be installed for each vaporizer, and also temperature indication and flow
indication shall be installed at each vaporizing unit. Temperature indicator, and flow indicator shall also
be installed at the outlet of each of the vaporizing unit.
Alarm shall be available for operator to monitor at the local control room, the control valve open/closed
position, differential pressure high, high-high of each vaporizer, temperature low, low-low and flow low
at the outlet of each of the vaporizing unit.
Safety system shall be installed to prevent LNG carry over to the gas line. The ESD Function of the
valve shall be activated if the outlet temperature of the vaporizing reached low-low limit. the ESD Valve
will operate to close the vaporizing unit inlet valve, tripping the vaporizing unit and a header recycle
valve shall automatically open to a set valve opening, referring to the number of tripped vaprizing unit,
with the maximum of 2 unit trip equal flow rate, to send back the LNG to the buffer tank. This recycle
valve action is intended to prevent the low low temperature in the other vaporizer in the case of
vaporizing unit trip. The recycled LNG will lead higher liquid level in buffer tank which then alert
operator that there should be flow adjustment in the LNG Booster pump.
4.4. Metering System
The 12 inch gas header shall be split, into two 6 inches line, Metering system for custody meter shall
be installed at 6 inch line. Design of metering system shall be approved by the Authorized body of
Indonesian government.
The proposed measurement instrument shall be using Ultrasonic flow meter to ensure gas flow with
minimum restriction, temperature and pressure indication is also necessary to calculate the actual gas
flow. Total flowrate will be designed to accomodate the total regasification capacity. The meter shall be
designed to have minimum of 0.1% accuracy at the minimum flow 1/3 of the rated capacity of the
regasification unit.
4.5. BOG Handling System
Boil of gas from the FSU and Sump Tank will be transferred to the BOG Handling system. The BOG
handling system consist of BOG Compressor skid provided by vendor. BOG shall be compressed using
the BOG compressor to increase the BOG Pressure up to 25.5 barg which then sent to the pipeline.
Excess BOG that cannot be handled by BOG compressor shall be sent to flare.

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Contract No : Document No.

DESIGN ENGINEERING LNG TERMINAL

PROCESS CONTROL PHILOSOPHY

1 04/03/2019 IFB ISSUED FOR BID AFR DH IM FAP AAR

REVISION HISTORICAL SHEET

2. CONTROL SYSTEM PHILOSOPHY

4. PROCESS CONTROL DESCRIPTION

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