PP Aaa PP1 104

SONATRACH
NEW LNG TRAIN SKIKDA PROJECT
SKIKDA, ALGERIA
OPERATING MANUAL VOLUME I, SECTION 2-3:
UNIT 14 MERCURY REMOVAL
DOCUMENT NO: PP-AAA-PP1-104
KBR
JOB NO.: J6404
0 VAS Issued for Implementation 23-Nov-10 GRM BA AB
B VAS Issued for Client Approval 6-Jun-10 GRM BA -
A VAS Issued for Client Approval 26-Aug-09 GRM BA -
Rev. By Description Date KBR KBR CLIENT
Chkd App App

NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-104
OPERATING MANUAL VOLUME I, SECTION 2-3: REVISION 0
MERCURY REMOVAL 23 NOVEMBER 2010
TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running ................................................................................................................6
3.1.1 Mercury Adsorber, 14-MD01 ..........................................................................................6
3.1.2 Treated Gas Filter, 14-MD02..........................................................................................6
3.2 Typical Operating Parameters ..........................................................................................6
3.3 Temporary Operation........................................................................................................7
3.3.1 Mercury Adsorber...........................................................................................................7
3.3.2 Treated Gas Filter ..........................................................................................................7
4.0 START-UP ............................................................................................................ 8
5.0 SHUTDOWN ....................................................................................................... 10
5.1 Normal Shutdown ...........................................................................................................10
5.2 Emergency Shutdown.....................................................................................................10
6.0 SAFETY .............................................................................................................. 11
6.1 Safety Critical Shutdown Systems..................................................................................11
6.2 Pressure Safety Valve Summary....................................................................................11
6.3 Fire Protection Equipment ..............................................................................................11
7.0 ATTACHMENTS ................................................................................................. 13
7.1 Attachment I: Equipment List ..........................................................................................14
7.2 Attachment II: Utility Consumption.................................................................................15
Page 2 of 15
1.0 INTRODUCTION
This operating manual relates to the facilities indicated on Process Flow Diagram
PR-14-PR32-002 and P&ID PR-14-SYPI-001.
The Mercury Removal System is located downstream of the Dehydration System and
upstream of the Scrub Column System. It is designed to remove mercury from the
feed gas to prevent corrosion in the aluminum equipment of the plant.
Page 3 of 15 KBR
TO 15-MC01
FEED GAS
Treated Gas
14-MD02
Filter
1005
PDI
C
C
1003
PDI
14-MD01
Adsorber
Mercury
FROM 13-MD04
DRIED GAS
Simplified Flow Diagram
Page 4 of 15 KBR
2.0 SYSTEM DESCRIPTION

The Mercury Removal System is located upstream of the Scrub Column System
(Volume I, Section 3-1) and is supplied with feed gas from the Dehydration System
(Volume I, Section 2-2). Feed gas passes downwards through the Mercury Adsorber,
14-MD01, which contains a bed of activated carbon impregnated with sulfur which
reduces the mercury level in the gas to less than 5 ng/Nm³. Failure to reduce
mercury levels could result in mechanical failure of downstream plant and equipment
made from aluminum. The Mercury Adsorber bed has a guaranteed life of at least
9 years.
The gas is then passed through the Treated Gas Filter, 14-MD02, which removes
99.5% of entrained particles of size 10 microns and larger. Changing of the filter
elements is considered to be an infrequent operation. A bypass valve is installed
around the Treated Gas Filter in order to facilitate replacement of filter elements.
Page 5 of 15 KBR
3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Mercury
Removal System. Refer to Section 3.2 for a list of typical operating variables for this
system.
3.1.1 Mercury Adsorber, 14-MD01
Feed gas is supplied from the Dehydration System and passes downwards through
the Mercury Adsorber, 14-MD01. The Mercury Adsorber is operated manually. The
operator should check the pressure drop across the bed as indicated by 14-PDI-1003
to determine when replacement or inspection of the mercury adsorbent bed is
necessary. During the normal operation, the pressure difference indicator, 14-PDI-
1003, should read 0.1 bar and an abnormally high differential pressures could mean
the bed has become fouled and needs to be replaced. A bypass is installed around
the Mercury Adsorber to enable the plant to operate while the adsorber bed is
replaced.
3.1.2 Treated Gas Filter, 14-MD02
After passing through the Mercury Adsorber, 14-MD01, the feed gas is then passed
through the Treated Gas Filter, 14-MD02, to remove 99.5% of entrained particles of
10 microns size and above. These are dust particles formed by erosion of the
activated carbon adsorbent either caused by the initial loading or attrition during
operation. The Treated Gas Filter is operated manually. The operator should check
the pressure drop across the filter as indicated by 14-PDI-1005. If the indicator shows
above 0.1 bar pressure difference across the filter, the filter may need to be serviced.
A bypass is installed around the Treated Gas Filter to enable the plant to operate
while the filter elements are cleaned or changed.
3.2 Typical Operating Parameters
The following table contains typical operating variables for the Mercury Removal
System.
Operating Variables for the Mercury Removal System
Tag No. Description Typical Value Units
14-PDI-1003 Mercury Adsorber Pressure 0.1 bar

Differential Indicator
14-PDI-1005 Treated Gas Filter Pressure 0.1 bar

Differential Indicator
Page 6 of 15 KBR
3.3 Temporary Operation

3.3.1 Mercury Adsorber
After the Mercury Adsorber, 14-MD01, bed has become fouled and needs to be
replaced, the adsorber will be isolated. In the duration of isolation of the Mercury
Adsorber, the feed gas will go through the system bypass and flow directly to the
Scrub Column System. Before the mercury bed is put back into operation, it will be
dried out.
14-MD01
C C
14-MD02
Figure 3.3.1: Mercury Adsorber Bypassed

3.3.2 Treated Gas Filter
After the Treated Gas Filter, 14-MD02, elements have become plugged and needs to
be cleaned or changed, the filter will be isolated. In the duration of isolation of the
Treated Gas Filter, the feed gas will go through the filter bypass and flow directly to
the Scrub Column System. The filter will need to be dried out before returning to
service.
14-MD01
C
14-MD02
Figure 3.3.2: Treated Gas Filter Bypassed
Page 7 of 15 KBR
4.0 START-UP
This section outlines the steps necessary to place the Mercury Removal System in
service. For the purpose of this section of the operating manual, it is assumed that
the following conditions exist: utilities are in service, feed gas is available,
downstream units are ready for feed gas, and system is purged, dried out and ready
for start-up.
Note: Refer to the catalyst MSDS sheet, MD030A-RBHG4_MSDS, to prevent
adsorbent catalyst from fast degrading or forming a potential combustible
environment in the bed during any high temperature application.
1. Pressurize the Mercury Removal System gradually at a rate not to exceed 1 bar
per minute to feed gas pressure using the inlet 2” bypass around the main
isolation valve in line NG-13023-36”.
2. Vent displaced nitrogen to the warm flare header using the bypass to 14-PRV-
1009. Check all flanges valve glands, seals, and instrument connections for
leakage.
Figure 4.0-1: Start-up steps 1 and 2
Page 8 of 15 KBR
3. When pressure across the main isolation valves on downstream and upstream
are equalized, the main 36” isolation valves at the upstream and downstream of
the Treated Gas Filter, 14-MD02, can be opened slowly and bypass valves can
be closed afterwards.
4. Ensure the Mercury Adsorber, 14-MD01, and Treated Gas Filter, 14-MD02,
bypass valves are closed.
PG
1001
C C
14-MD01
14-MD02
C C
Figure 4.0-2: Start-up steps 3 and 4
Page 9 of 15 KBR
5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Mercury Removal
System.
1. Close the inlet isolation valve and 2” bypass valves upstream of Mercury
Adsorber, 14-MD01.
2. Close Treated Gas Filter, 14-MD02, effluent isolation valve.
3. Ensure Mercury Adsorber, 14-MD01, and Treated Gas Filter, 14-MD02, bypass
valves are closed.
4. Ensure isolation valves in line NG-14001-36” between 14-MD01 and 14-MD02
are open.
5. Gradually depressurize system to the warm flare header via the manual bypass
to 14-PRV-1009. Limit depressurization rate to 1 bar per minute.
6. Depressurization is complete when pressure reading on 14-PG-1004 is at near
atmospheric.
C C
14-MD01 TO WARM
FLARE HEADER
PG
1004
C C
C
14-MD02
C C
Figure 5.1: Normal Shutdown

5.2 Emergency Shutdown
In the event of an emergency requiring a shutdown of the Mercury Removal System
the system should be shut down as outlined above.
• Loss of Feed Gas
Loss of feed gas does not create a problem in the Mercury Removal System as the
system can remain static until conditions are stabilized and the gas flow re-
established.
Page 10 of 15 KBR
6.0 SAFETY
6.1 Safety Critical Shutdown Systems
Not applicable.
6.2 Pressure Safety Valve Summary
The Mercury Removal System Pressure Relief Valve Summary contains a listing of
all the pressure relief valves associated with this system.
Mercury Removal System Pressure Relief Valve Summary
Set Pressure
Valve Number Description/Location (barg)
14-PRV-1000A/B Mercury Adsorber Feed/Relief to Warm Flare 75.00

Header
14-PRV-1009 Treated Gas Filter Effluent/Relief to Warm Flare 75.00

Header
6.3 Fire Protection Equipment

The Mercury Removal System Fire Protection Equipment Summary contains a listing
of fire protection equipment associated with this system.
Mercury Removal System Fire Protection Equipment Summary
Description Quantity
BBF - Mole Sieve / Dehydration
63-SP-008 Fire Water Monitor (Grade) 1
63-SP-005 Fire Blanket 1
63-SP-010 Live Hose Reel 2
63-SP-011 Hydrant Cabinet 4-Way 1
63-SP-024 Four Way Hydrant with Monitor 1
63-SP-050 Fire Water Monitor (Elevated) 1
BBH - Acid Gas Removal
63-SP-005 Fire Blanket 1
63-SP-010 Live Hose Reel 1
Page 11 of 15 KBR
Mercury Removal System Fire Protection Equipment Summary
Description Quantity
63-SP-011 Hydrant Cabinet 4-Way 2
63-SP-024 Four Way Hydrant with Monitor 4
63-SP-050 Fire Water Monitor (Elevated) 1
Page 12 of 15 KBR
7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption
Page 13 of 15 KBR
7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Mercury Removal System.
Mercury Removal System Equipment List
Design Design
Equipment Pressure Temp
No. Description (barg) (ºC)
14-MD01 Mercury Adsorber 75.0 85
14-MD02 Treated Gas Filter 75.0 85
Page 14 of 15 KBR
7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Mercury Removal System and
their expected consumption.
Mercury Removal System Motor List
Available
Motor Load
Equipment No. Description (kW)
Not applicable
Page 15 of 15 KBR

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SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

UNIT 14 MERCURY REMOVAL

DOCUMENT NO: PP-AAA-PP1-104

0 VAS Issued for Implementation 23-Nov-10 GRM BA AB

B VAS Issued for Client Approval 6-Jun-10 GRM BA -

A VAS Issued for Client Approval 26-Aug-09 GRM BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

Simplified Flow Diagram

2.0 SYSTEM DESCRIPTION

Operating Variables for the Mercury Removal System

Tag No. Description Typical Value Units

14-PDI-1003 Mercury Adsorber Pressure 0.1 bar

14-PDI-1005 Treated Gas Filter Pressure 0.1 bar

3.3 Temporary Operation

Figure 3.3.1: Mercury Adsorber Bypassed

Figure 3.3.2: Treated Gas Filter Bypassed

Figure 4.0-1: Start-up steps 1 and 2

Figure 4.0-2: Start-up steps 3 and 4

Figure 5.1: Normal Shutdown

Mercury Removal System Pressure Relief Valve Summary

14-PRV-1000A/B Mercury Adsorber Feed/Relief to Warm Flare 75.00

14-PRV-1009 Treated Gas Filter Effluent/Relief to Warm Flare 75.00

6.3 Fire Protection Equipment

Mercury Removal System Fire Protection Equipment Summary

BBF - Mole Sieve / Dehydration

63-SP-008 Fire Water Monitor (Grade) 1

63-SP-005 Fire Blanket 1

63-SP-010 Live Hose Reel 2

63-SP-011 Hydrant Cabinet 4-Way 1

63-SP-024 Four Way Hydrant with Monitor 1

63-SP-050 Fire Water Monitor (Elevated) 1

BBH - Acid Gas Removal

63-SP-005 Fire Blanket 1

63-SP-010 Live Hose Reel 1

Mercury Removal System Fire Protection Equipment Summary

63-SP-011 Hydrant Cabinet 4-Way 2

63-SP-024 Four Way Hydrant with Monitor 4

63-SP-050 Fire Water Monitor (Elevated) 1

7.1 Attachment I: Equipment List

Mercury Removal System Equipment List

14-MD01 Mercury Adsorber 75.0 85

14-MD02 Treated Gas Filter 75.0 85

7.2 Attachment II: Utility Consumption

Mercury Removal System Motor List

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