PP Aaa PP1 112

SONATRACH
NEW LNG TRAIN SKIKDA PROJECT
SKIKDA, ALGERIA
OPERATING MANUAL VOLUME 1, SECTION 3-8:
UNIT 15 HP FUEL GAS SYSTEM
DOCUMENT NO: PP-AAA-PP1-112
KBR
JOB NO.: J6404
2 KM Issued for Implementation 27-July-13 LTP RM
1 KM Issued for Implementation 13-Dec-12 MRC SPD
0 JDS Issued for Implementation 23-Nov-10 GRM BA AB
B JDS Issued for Client Approval 09-Sep-10 GRM BA -
A ACG Issued for Client Approval 05-Feb-10 GRM BA -
Rev. By Description Date KBR KBR CLIENT
Chkd App App

NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-112
OPERATING MANUAL VOLUME I, SECTION 3-8: REVISION 2
HP FUEL GAS SYSTEM 28 July 2013
TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 7
3.1 Normal Running ................................................................................................................7
3.1.1 Fuel Gas Compressor 15-MJ04 .....................................................................................7
3.1.2 Fuel Gas Compressor Intercoolers 15-MC08/09/10 and Fuel Gas Compressor
Aftercooler 15-MC14 .................................................................................................................8
3.1.3 HP Fuel Gas KO & Mixing Drums 15-MD05-A/B ...........................................................8
3.1.4 HP Fuel Gas Heater 15-MC07 .......................................................................................9
3.1.5 Regeneration Gas Trim Cooler, 15-MC11 ...................................................................10
3.2 Typical Operating Parameters ........................................................................................10
3.3 Temporary Operations ....................................................................................................11
3.3.1 Ethane Product From GL1.K Complex .........................................................................11
3.3.2 Start-up Fuel Gas Heater 15-ML02 ..............................................................................11
4.0 START-UP .......................................................................................................... 12
5.0 SHUTDOWN ....................................................................................................... 15
5.1 Normal Shutdown ...........................................................................................................15
5.2 Process Upsets and Production Loss .............................................................................15
6.0 SAFETY/EMERGENCY SHUTDOWN ................................................................ 17
6.1 Safety Critical Shutdown Systems ..................................................................................17
6.1.1 I-1500 - Liquefaction, Unit 15 ESD ...............................................................................17
6.1.2 I-1505 – Start-up Fuel Gas Heater Trip........................................................................17
6.1.3 I-1570 – Fuel Gas Compressor Trip .............................................................................17
6.1.4 I-1573 – Fuel Gas KO Drum from Helium Plant ...........................................................17
6.1.5 I-1592 – Fuel Gas Compressor Depressurize..............................................................17
6.2 Pressure Safety Valve Summary ....................................................................................18
6.3 Fire Protection Equipment ..............................................................................................19
7.0 ATTACHMENTS ................................................................................................. 20
7.1 Attachment I: Equipment List ..........................................................................................21
7.2 Attachment II: Utility Consumption .................................................................................22
Page 2 of 22
1.0 INTRODUCTION
This operating manual relates to the facilities indicated on Process Flow Diagram
PR-15-PR32-006 and P&ID’s PR-15-SYPI-009, PR-15-SYPI-010, PR-15-SYPI-010A,
PR-15-SYPI-011, PR-15-SYPI-011A, PR-15-SYPI-012, PR-15-SYPI-012B, PR-15-
SYPI-19, PR-15-SYPI-20, and PR-15-SYPI-21.
HP Fuel Gas Systems consists of Fuel Gas Return KO Drum, 15-MD06, Fuel Gas
Compressor, 15-MJ04, Intercoolers, 15-MC08/09/10, Aftercooler 15-MC14, HP Fuel
Gas KO and Mixing Drums, 15-MD05A/B, Start up Fuel Gas Heater, 15-ML02, HP
Fuel Gas Heater, 15-MC07, and Regeneration Gas Trim Cooler, 15-MC11.
Fuel Gas Compressor, 15-MJ04 is a four stage, gas turbine-driven centrifugal
compressor which compresses the Nitrogen Stripper, 15-MD04 overheads, ethane
from 07-MC14 and a portion of helium-free gas from the Fuel Gas Return KO Drum,
15-MD06.
After the fuel gas is compressed by 15-MJ04, it is sent to HP Fuel Gas system and a
portion is also used as regeneration gas for the Dehydration Unit.
Fuel Gas Compressor, 15-MJ04 has a suction pressure controller 15-PIC-1500, that
resets turbine output speed controller 15-SIC-1500. The compressor also has anti-
surge controllers for each stage of the compressor.
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Page 4 of 22 KBR
2.0 SYSTEM DESCRIPTION

About 92% of the fuel gas used in the LNG plant is generated as a by product of the
LNG process, principally from the Nitrogen Stripper and the Helium Flash Drum.
Most of the boil off gas comes from ships loading and is returned as fuel gas to the
fuel gas header. Also the HP Fuel Gas System provides regeneration gas for the
dryers in Dehydration Unit. Under normal circumstances, an additional 8% of the fuel
gas is supplied by the feed gas entering the plant. The above three sources provide
the fuel for the gas turbines that drive the compressors and generators used in the
plant.
Approximately 80% of the discharge flow (90t/h) from the Fuel Gas Compressor, 15-
MJ04 flows to the dryers and the remaining portion (about 26t/h) goes to the HP Fuel
gas KO and Mixing Drums, 15-MD05A/B. After passing through the dryers,
regeneration gas returns back to the HP Fuel Gas system upstream of the HP Fuel
Gas KO and Mixing Drums, 15-MD05A/B where it joins together with the HP Make-
up Feed Gas from Unit 01, a portion of boil off gas from BOG Compressor, 71-
MJ01A/B/C, and the excess fuel gas from the Fuel Gas Compressor, 15MJ04.
From the HP Fuel Gas Mixing and KO Drum, 15-MD05A/B, HP fuel gas is heated
through the HP Fuel Gas Heater, 15-MC07 up to 80°C and then it is sent to the gas
turbines of the following compressors listed below.
Equip. Tag Equipment Description Fuel Gas Flow Temp.

(kg/h) (°C)
01-MJ01-GT Feed Gas Compressor Gas Turbine 12163 70
15-MJ04-GT Fuel Gas Compressor Gas Turbine 12622 70
16-MJ01-GT LP/MP MR Compressor Gas Turbine 34307 80
16-MJ04-GT PR/HP MR Compressor Gas Turbine 33987 80
20-MJ01-GT Propane Compressor Gas Turbine 12942 70
51-MJ01-GT Power Generators Gas Turbines 36543 70
The Fuel Gas Compressor 15-MJ04 is a four stage compressor with low, medium,
high and high-high pressure stages. 15-MJ04 is driven by a 31MW rated capacity
Fuel Gas Compressor Gas Turbine, 15-MJ04-GT.
The Fuel Gas Compressor, 15-MJ04 receives 96t/h of main supply from the
overheads of the Nitrogen Stripper, 15-MD04 and additional 20t/h from the
overheads of Fuel Gas Return KO Drum, 15-MD06. When CP1.K ethylene plant
cannot accept the ethane from the Deethanizer System, the ethane stream from
ethane product heater, 07-MC14, can also be sent to the HP Fuel Gas System to the
suction of Fuel Gas Compressor, 15-MJ04.
Page 5 of 22 KBR
The combined streams enter the Fuel Gas Compressor, 15-MJ04 at 0.02 barg and
-25°C with a flow rate of 116t/h and pass through four compression stages. Between
each compression stage, combined fuel gas passes through the Fuel Gas
Compressor Intercoolers 15-MC08/09/10, and after the 4th Compression Stage it
enters the HP Fuel Gas Compressor Aftercooler at 127.4°C and 32.40 barg and exits
at 39°C and 31.92 barg.
The Fuel gas sent to Unit 13 for regeneration is temperature controlled by DCS logic
through temperature controllers 15-TIC-1202 and 13-TIC-1045. For the chilling phase
of regeneration, valves 15-TV-1202A/B divert gas through the tube side of the
Regeneration Trim Cooler, 15-MC11. During all other regeneration phases the Fuel
gas bypasses 15-MC11.
The Fuel Gas Compressor, 15-MJ04 has a suction pressure controller 15-PIC-1500
which adjusts the setpoint of the turbine output speed controller, 15-SIC-1500, to
keep a constant pressure in the Nitrogen Stripper overhead line that feeds into the
Fuel Gas Compressor suction. Each of the five anti-surge valves will open to regulate
flow to the proper stage to maintain sufficient flow to avoid surging the compressor.
Page 6 of 22 KBR
3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Fuel Gas
Compression System. Refer to Section 3.2 for a list of typical operating variables for
this system.
3.1.1 Fuel Gas Compressor 15-MJ04
Fuel Gas Compressor, 15-MJ04, compresses the Nitrogen Stripper overhead
passing through LMR/Helium Rich Exchanger, 15-MC06, and also the portion of
helium-free gas returning from the Helium plant into the Fuel Gas Return KO Drum
15-MD06. The combined fuel gas flows to the low pressure stage at 0.02 barg and
-25°C.
The flow rate of helium-free gas from the helium plant is controlled by 15-FIC-1627.
The set point of 15-FIC-1627 is reset by 15-FY-1540A so that about 98.5% of the gas
sent to the helium plant is returned to the fuel gas system.
Fuel Gas Compressor, 15-MJ04, is driven by the Fuel Gas Compressor Gas Turbine,
15-MJ04-GT. The fuel gas pressure to the Fuel Gas Compressor Gas Turbine,
15-MJ04-GT, from HP Fuel Gas Heater, 15-MC07 is controlled by the 15-PIC-1181.
Fuel Gas Compressor, 15-MJ04, has a suction pressure controller 15-PIC-1500
which adjusts the turbine output speed through the controller 15-SIC-1500 to keep a
constant pressure in the Nitrogen Stripper overhead line that feeds into the Fuel Gas
Compressor suction. Also there is an anti-surge controller for each stage of the
compressor which will operate to avoid surging the compressor. During the startup,
the compressor is gradually brought to the normal operating condition by using five
manual control stations to set recirculation flow rates through the recycle valves from
the DCS. The operator can open any recycle valve by using a manual control station
from the DCS. The anti-surge controller will over-ride the manual setting if necessary
to prevent surge in any stage:
Fuel Gas Compressor Surge Controllers
Manual Controller/Hand
Compressor Stage Surge Controller
Switch
First LP 15-UIC-1501 15-HIC-1501
Second MP 15-UIC-1502 15-HIC-1502
Third HP 15-UIC-1503 15-HIC-1503
Fourth HHP 15-UIC-1504 15-HIC-1504
Fourth HHP 15-UIC-1504 15-HS-1504A
The anti-surge controller limits the compression ratio over all the stages to prevent
the compressor from operating in the surge region in all operating modes. Stage
Page 7 of 22 KBR
surge controller 15-UIC-1501/2/3/4 will override 15-HIC-1501/2/3/4 whenever the

recycle valve is required to open further to prevent 15-MJ04 from surging. The seal
gas to the Fuel Gas Compressor, 15-MJ04 supplied from the Defrost Gas Heater, 15-
ML01, is controlled by 15-PIC-1154. During a compressor trip, solenoid valves 15-
UY-1501/2/3/4 and 15-XY-1504A from the first to the fourth stages will be de-
energized
Fuel Gas Compressor suction temperature is protected from low temperatures by 15-
TT-1127A/B/C with a Low-Low alarm 15-TALL-1127. The compressor can be tripped
by the operator both from DCS and locally by using hand switches 15-HZ-1130 and
15-HZ-1130A. The trip is set at -40oC, since the minimum operating temperature of
the fuel gas compressor is -46oC.
The external seal gas to the Fuel Gas Compressor, 15-MJ04 supplied from the
Defrost Gas Heater, 15-ML01, is controlled by 15-PIC-1154.
The temperature and pressure data for each stage of the compression and the
discharge at the HP Fuel Gas Compressor Aftercooler, 15-MC14 as follows:
Temperature Pressure
Fuel Gas Compressor Operating Data o
C Barg
1st Stage LP Suction -25.05 0.02
1st Stage LP Discharge to 15-MC08 74.97 2.16
2nd Stage MP Suction 39.00 1.68
2nd Stage MP Discharge to 15-MC09 138.31 5.84
3rd Stage HP Suction 39.00 5.36
3rd Stage HP Discharge to 15-MC10 136.78 14.93
4th Stage HHP Suction 39.00 14.45
4th Stage HHP Discharge to 15-MC14 127.39 32.40
4th Stage HHP Discharge Aftercooler 15-MC14 39.00 31.92
3.1.2 Fuel Gas Compressor Intercoolers 15-MC08/09/10 and Fuel Gas

Compressor Aftercooler 15-MC14
Fuel Gas Compressor Intercoolers, 15-MC08/09/10 and Fuel Gas Compressor
Aftercooler 15-MC14 are fin-fan type coolers that cool the compressed gas after each
stage. The LP gas is cooled by 15-MC08. The MP gas is cooled by 15-MC09. The
HP gas is cooled by 15-MC10. The HHP gas is cooled by 15-MC14. Each cooler
consists of 1 bay with 3 fixed speed fin-fans. The operator starts and stops the 3 fan
motors from the DCS and locally in the field as required.
3.1.3 HP Fuel Gas KO & Mixing Drums 15-MD05-A/B
Gas flows into these drums from the BOG Compressor Coolers 71-MC01-A/B/C, fuel
Page 8 of 22 KBR
gas from the Fuel Gas Compressor 15-MJ04, wet regeneration gas from the dryers
and feed gas from the metering system. These gas streams have various
characteristics and they are blended together in these drums. HP Fuel Gas KO &
Mixing Drums 15-MD05-A&B operated in parallel. The mixing drums are designed to
smooth out the changes in heating value as the composition of the Fuel gas
changes. The discharge of the drums normally flows through the HP Fuel Gas
Heater, 15-MC07. There are no level controllers on these drums. In the event of
condensate buildup it is manually drained to the Warm Liquid Header when a DCS
level indicator shows a high level.
The fuel gas stream from the Fuel Gas Compressor 15-MJ04, via 15-MC14, is
controlled by valve 13-FV-1048A. This valve is throttled by flow controller 13-FIC-
1048, along with valve 13-FV1048B in Unit 13, to maintain the flow of fuel gas to the
Unit 13 dryers for regeneration.
The feed gas flow from the Metering System, 01-IC03, is utilized to maintain fuel gas
header pressure. Feed gas make-up is controlled by 15-FIC-1070 and normally flows
about 10-11t/h from feed gas supply to the fuel gas system. The output of this
controller is adjusted by the fuel gas high header pressure controller, 15-PIC-1075B
and low header pressure controller 15-PIC-1075A. The controllers are connected to
the pressure transmitter 15-PT-1075 located downstream of the HP Fuel Gas Heater,
15-MC07. Refer to PFD PR-15-PR32-006 and P&IDs PR-15 SYPI-001A, PR-15-
SYPI-011, and PR-15-SYPI-011A to follow the relationship between the controllers
mentioned for maintaining fuel gas header pressure.
The amount of BOG received from Unit 71 varies depending on the ambient
temperature and number of ships loading. There are three BOG compressors (71-
MJ05A/B/C) that recover boil off gas from the LNG storage tanks. There are three
recycle compressors (15-MJ06 A/B/C) that return about half of the boil off gas to the
scrub column feed line. 15-PIC-1315 controls the suction pressure of the recycle
compressors at a target pressure that is midway between the 15-PIC-1075A and B
controllers.
3.1.4 HP Fuel Gas Heater 15-MC07

The HP Fuel Gas Heater, 15-MC07 heats fuel gas using hot oil produced by Unit 18.
The hot oil heater is available when the Propane Compressor Gas Turbine,
16-MJ04-GT is in operation (see section 3.3.2 when hot oil is not available). The
temperature of fuel gas leaving this heater is controlled by 15-TIC-1187 which
regulates the flow of hot oil through the heater.
Fuel gas temperature for the five power generators, external propane compressor,
fuel gas compressor and the feed gas compressor is controlled by 15-TIC-1173. This
is a split-ranged control loop, throttling gas flow from the heater with valve 15-TV-
1173A and bypassing gas around the heater with valve 15-TV-1173B.
The pressure controller 15-PIC-1159 controls the fuel gas header pressure by
venting the fuel gas to the Warm Flare with valve 15-PV-1159 as necessary.
Page 9 of 22 KBR
3.1.5 Regeneration Gas Trim Cooler, 15-MC11

Fuel gas from the Fuel Gas Compressor Aftercooler, 15-MC14, is cooled further by
the Regeneration Trim Gas Cooler, 15-MC11, before going to the Unit 13
Dehydration dryers. The Regeneration Trim Gas Cooler, 15-MC11, uses the fuel gas
entering the Fuel Gas Compressor, 15-MJ04, as the coolant. Outlet temperature is
adjusted with controller 15-TIC-1202, which throttles HHP fuel gas through the cooler
with valve 15-TV-1202A and bypasses it around the cooler with valve 15-TV-1202B.
This is a split-ranged control loop and DCS logic K-1300 will only operate controller
15-TIC-1202 during the chilling phase of dryer regeneration and the rest of the time
all the fuel gas will be bypassed around the Regeneration Trim Gas Cooler, 15-
MC11, through 15-TV-1202B.
3.2 Typical Operating Parameters

The following table contains typical operating variables for the Fuel Gas Compressor
System.
Operating Variables for the fuel gas compressor System
Tag No. Description Typical Value Units

Feed Gas Flow Control to Fuel
15-FIC-1070 10,777 kg/hr
Gas System Flow Controller
Fuel Gas KO Drum 15-MD06
15-FIC-1627 19,893 kg/hr
Overheads Flow Controller
Seal Gas pressure from 15-ML01
15-PIC-1154 29.3 barg
to 15--MJ04 Pressure Controller
HP Fuel Gas Heater 15-MC07
15-PIC-1159 35 barg
Pressure Controller
Fuel Gas Compressor Turbine
15-PIC-1181 26.6 barg
15-MJ04-GT Fuel Gas Pressure
Controller
Nitrogen Stripper, 15-MD04,
15-PIC-1500 0.26 barg
Overhead Pressure Controller
Fuel Gas temperature controller
15-TIC-1173 70 °C
Downstream of 15-MC07 to
Compressor and Generator
Turbines Temperature Controller
HP Fuel Gas Heater 15-MC07 Hot
15-TIC-1187 80 °C
Oil Temperature Controller
Downstream of 15-MC11,
15-TIC-1202 21/39 °C
Regeneration Gas Temperature
Controller (Chilling/ Cooling)
Startup Fuel Gas Heater 15-ML02
15-TIC-1607 80 °C
Temperature Controller
Page 10 of 22 KBR
3.3 Temporary Operations

3.3.1 Ethane Product From GL1.K Complex
Ethane product from the Skikda GL1.K complex is sent via pipelines to the CP1.K
ethylene plant. When the ethane product cannot go to the CP1.K plant, it must be
rerouted to the existing fuel system or to the flares. Ethane product can be reinjected
into the LNG product via the MCHE up to the limit of ethane concentration in the LNG
specification. However, the entire product flow cannot be accommodated in this
manner, so the remainder will need to be diverted to the fuel system. The ethane
stream from ethane product heater, 07-MC14, is sent to the suction line of HP fuel
gas compressor, 15-MJ04.
3.3.2 Start-up Fuel Gas Heater 15-ML02
Startup Fuel Gas Heater, 15-ML02 is an electric powered heater which is used during
start-ups before Hot Oil Unit, Unit 18, is placed in operation. The operator manually
places Startup Fuel Gas Heater, 15-ML02 in operation by using manual valves.
During start-up the fuel gas from the KO and Mixing Drums 15-MD05-A&B goes
through this heater. The temperature is controlled by 15-TIC-1607 which adjusts the
setpoint of the thyristor controller supplied with the heater.
The temperature controller 15-TIC-1173 and pressure controller 15-PIC-1159 work
the same way as described above in section 3.1.4 for the HP Fuel Gas Heater 15-
MC07.
Page 11 of 22 KBR
4.0 START-UP
Start-Up Fuel Gas Heaters 51-ML02-A/B, fed by essential power from diesel
generators 51-MJ02A-F, heat gas from the main feed gas line, through Coalescer
Filter, 01-MD03, to provide HP fuel to start up Gas Turbine Generators 51-MJ01A-F.
Once Gas Turbine Generators are brought online and are supplying electricity to the
plant, then the Startup Fuel Gas Heater 15-ML02 will be used to heat gas supplied
directly from the main feed gas line downstream Feed Gas Coalescer filters 01-
MD02-A/B or from BOG compressors 71-MJ05A/B/C discharge for the startup of the
plant. Once the Propane Compressor Gas Turbine 16-MJ04-GT is started and hot oil
system Unit 18 is on line, fuel gas will be warmed up through HP Fuel Gas Heater
15-MC07. After this stage HP fuel gas can also be fed from wet regeneration gas
from driers 13-MD02-A/B/C.
When the fuel gas compressor 15-MJ04 is not in service, the regeneration gas
required for the dryers is provided through the bypass line from the downstream of
the Dry Gas Filters, 13-MD04/A to the upstream of the Regeneration Gas Heater, 13-
MC02 in Unit 13 as described in operating manual PP-AAA-PP1-103.
Once Fuel Gas Compressor 15-MJ04 is operating the fuel gas system is fed via the
following sources:
• Nitrogen Stripper overhead.
• Helium Plant returns or bypass if the Helison plant is not operating.
• Compressed BOG from all LNG tanks in GL1.K complex.
• Wet regeneration gas from driers after regeneration.
• Feed gas, as required, to provide a steady pressure on the Fuel Gas header.
During the cooldown of the LNG train, the gas venting from the Helium flash drum
and the Nitrogen Stripper will grow colder. When the temperature of the vent gas
reaches the range of -20 to -40°C, and the continuous flow of vent gas is 15 t/h or
greater, it becomes helpful to start the fuel gas compressor and recover the fuel
being flared and return it to the HP fuel gas system. The fuel gas compressor should
be started in an unloaded condition and brought up to operating conditions as
described below:
This section outlines the steps necessary to place the Fuel Gas Compressor 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, boil off gas
system is in service, downstream units are ready to receive the compressed fuel gas,
electrical power is available and Fuel Gas Compressor and turbine is purged and
ready for start-up.
Note: Before the gas turbine can be fired and started it must be rotated or cranked by
accessory equipment. This is accomplished by an electric induction motor, operating
through a torque converter to provide the cranking torque and speed required by the
turbine for startup. The starting system components also provide slow speed rotation
of the turbine for cooldown purposes after shutdown.
1. Crank and rotate the gas turbine as described in the supplier manual for Gas
Turbine MS5002D.
2. Start Gas Turbine by using the helper motor. When the helper motor brings the
turbine speed to 20% (around 1000 rpm) open valve 15-PV-1181 and introduce
fuel gas to the Fuel Gas Compressor Gas Turbine. Allow turbine speed to
Page 12 of 22 KBR
gradually increase and let the gas turbine run for a 30 to 60 minute period in a
full speed, no load condition. This time period allows for uniform and stabilized
heating of the parts and fluids. Continue with compressor startup steps.
3. Confirm that buffer gas and lube oil systems are in service.
4. Confirm that the external seal gas is supplied from the Defrost Gas Heater, 15-
ML01, through pressure reducing valve 15-PV-1154. This valve is controlled by
DCS controller 15-PIC-1154.
5. Confirm that downstream of the Regeneration Gas Trim Cooler 15-MC11 fuel
gas isolation valve 15-XV-1138 is in manual and closed position.
6. Confirm that Helium Reinjection Gas from the overheads of Fuel Gas Return
KO Drum, 15-MD06 flow control valve15-FV-1627 is manual closed.
7. Confirm that the Helium free fuel gas from the Helium purification plant to the
upstream of Fuel Gas Return KO Drum, 15-MD06 valve 15-ESDV-1622 is
closed. Until the Helium recovery plant starts accepting gas, the Helium flash
drum remains diverted to fuel gas system through the 15-PIC-1082.
8. Confirm that the compressed fuel gas from the HP Fuel Gas Compressor
Aftercooler 15-MC14 downstream isolation valve 15-XV-1145 is in manual and
closed
9. Confirm that the fuel gas from HP Fuel Gas Heater, 15-MC07 to Fuel Gas
Compressor Gas Turbine 15-MJ04-GT control valve 15-PV-1181 is in manual
and closed.
10. Verify that the Startup Gas Heater 15-ML02 is on.
11. Set all the anti surge valves 15-UV-1501, 15-UV-1502, 15-UV-1503, 15-UV-
1504, and 15-XV-1504A in manual and open.
12. Confirm the LP/MP/HP Fuel Gas Compressor Intercooler 15-MC08, 15-MC09,
15-MC10 and HP Fuel Gas Compressor Aftercooler 15-MC14 fans are on.
13. Introduce fuel gas from 15-MC11 to the compressor inlet by opening 15-XV-
1138 and allow compressor suction pressure to increase to normal at 0.02 barg.
14. Set the recirculation flow rates through the anti surge valves by using manual
loaders 15-HIC-1501, 15-HIC-1502, 15-HIC-1503 and 15-HIC-1504, from the
DCS.
15. Monitor temperature and flow rates on through the following control elements:
Stage Suction Discharge Flow rates

Temperature Temperature
1st Stage 15-TE-1140 15-TE-1209 15-FE-1278
2ND Stage 15-TE-1212 15-TE-1215 15-FE-1279
3rd Stage 15-TE-1218 15-TE-1135 15-FE-1280
4th Stage 15-TE-1396 15-TE-1394 15-FE-1133
Page 13 of 22 KBR
16. The anti-surge controller 15-UIC-1501/1502/1503/1504 will over-ride the manual

setting as necessary to prevent surge in any stage.
17. Place suction pressure controller 15-PIC-1500 in automatic mode to regulate
nitrogen stripper pressure.
18. Open downstream of HP Fuel Gas Compressor Aftercooler 15-MC14 isolation
valve 15-XV-1145 to allow discharge of fuel gas compressor to flow through
13-FV-1048A to the HP fuel gas drum.
19. Confirm that 15-ESDV-1146 to the driers is open.
20. When the Helium recovery plant is ready to receive gas, refer to startup section
of the Helium Rich Stream Compressor, 15-MJ05, operating manual, PP-AAA-
PP1-109 to prepare systems to send gas to the Helium plant.
21. Once the Helison Plant notifies it is ready to send Helium free fuel gas back to
the SKIKDA LNG train, open the valve 15-ESDV-1622 to introduce the gas to
the Fuel Gas Return KO Drum, 15-MD06
22. Confirm that Helium-free return flow valve, 15-FV-1627, is open and in auto.
Page 14 of 22 KBR
5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Fuel Gas Compressor
System.
1. Unload the Fuel Gas Compressor by diverting the entire Nitrogen Stripper
overhead flow to flare using 15-PIC-1363.
2. Confirm that all four of the anti surge valves 15-UV-1501/2/3/4 are in manual
and open.
3. Refer to the Helium Compressor, PP-AA-PP1-108, and Helium Separation, PP-
AA-PP1-109, operating manuals to stop sending Helium flash gas to the Helium
plant.
4. Communicate with the Helison Helium Plant to stop receiving Helium-free gas to
the new SKIKDA LNG train.
5. Close downstream isolation valve 15-XV-1145 by using handswitch 15-HS-
1145.
6. Close 15-XV-1138 fuel gas from Regen Gas Trim Cooler 15-MC11
7. Close 15-ESDV-1622, helium free gas to Fuel Gas Return KO Drum
8. Turn off the compressor by using 15-HZ-1130/A.
9. Close fuel gas to the gas turbine, 15-MJ04-GT, using 15-PIC-1181 and close
the block valves up and downstream of 15-PV-1181.
10. Allow gas turbine and compressor to go through the normal cooldown
sequence.
Note: After a shutdown, if the gas turbine restart is attempted without cooldown
operation, the operator should maintain a constant check on vibration velocity as the
unit is brought up to its rated speed. If the vibration velocity exceeds 1.0 inch per
second at any speed, the unit should be shut down and turned with the ratchet for at
least one hour before a second starting attempt is made. If seizure occurs during the
ratchet operation of the gas turbine, the turbine should be shut down and remain idle
for at least 30 hours, or until the rotor is free. The turbine may be turned at any time
during the 30 hour period if it is free; however, audible checks should be made for
rubs.
5.2 Process Upsets and Production Loss
In the event of a change in conditions or trips, the process may become upset and
possibly require shutdown. In the event of an emergency requiring a shutdown of the
Fuel Gas Compressor, the system should be shut down as outlined above. Below
are possible causes for upset and actions to be taken.
1. Loss of Electrical Power
Loss of electrical power will shutdown the Fuel Gas Compressor Intercoolers
15-MC08/09/10 and the Fuel Gas Compressor Aftercooler 15-MC14 which will cause
Fuel Gas Compressor 15-MJ04 to trip. The suction and discharge of the compressor
will also be isolated by the Fuel Gas Interlock Trip I-1570
Page 15 of 22 KBR
2. Loss of Instrument Air

Loss of instrument air will cause control valves to fail to their safe position.
Consequences of the loss of instrument air for the major control and isolation valves
are given below:
• 15-XV-1138, 15-UV-1501/2/3/4, 15-XV-1504A, 15-TV-1202B, 15-BDV-1129, 15-
FV-1627, 15-XV-1099, 15-XV-7111, 15-PV-1154 will fail open
• 13-FV-1048A, 15-FV-1070, 15-ESDV-1160, 15-PV-1159, 15-PV-1181, 15-XV-
7110, 15-XV-1146, 15-TV-1202A and 15-ESDV-1622 will fail close.
• 15-TV-1173A/B, 15-PV-1605 will fail in their last position.
3. Loss of Fuel Gas
On loss of fuel gas to the Fuel Gas Compressor turbine, 15-MJ04-GT, the Fuel Gas
Compressor, 15-MJ04, will trip off-line due to loss of fuel and fire.
4. Loss of Hot Oil
Fuel gas flow to 15-MC07 can be diverted manually to the Start-up Fuel Gas Heater,
15-ML02 at the upstream of 15-XV-1099.
Page 16 of 22 KBR
6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-1500 - Liquefaction, Unit 15 ESD
The Liquefaction Unit ESD Interlock I-1500 is activated by the Plant ESD Interlock I-
0000. The Liquefaction Unit ESD takes action in Fuel Gas Compressor System by
opening fuel gas to the HP Fuel Gas Heater, 15-MC07 isolation valve 15-XV-1099,
and closing fuel gas to Regeneration Gas Trim Cooler 15-MC11 valve 15-ESDV-
1146. Interlock I-1500 trips LP/MP/HP Fuel Gas Compressor Intercooler 15-
MC08/09/10 and HP Fuel Gas Compressor Aftercooler 15-MC14. It also activates the
Fuel Gas Compressor 15-MJ04 trip interlock I-1570.
6.1.2 I-1505 – Start-up Fuel Gas Heater Trip
Startup Fuel Gas Heater Trip Interlock, I-1505 will shutdown the Startup Fuel Gas 15-
ML02 to prevent overheating the fuel gas on Hi-Hi temperature 15-TT-1606 at the
outlet of the Fuel Gas Heater, 15-ML02. Interlock I-1505 also puts Startup Fuel Gas
Heater Controller, 15-TIC-1607 to manual and safe position.
6.1.3 I-1570 – Fuel Gas Compressor Trip
Fuel Gas Compressor Trip Interlock I-1570 will trip the Fuel Gas Compressor 15-
MJ04 and close the compressor suction and discharge isolation valves 15-XV-1138
and 15-XV-1145 for the following conditions: CCR or Local trip 15-HZ-1130/A. Low
suction temperature, 15-TALL-1127A/B/C, high temperature 15-TAHH-
1137/1177/1180/1586 1st – 4th stage, high pressure 15-PAHH-1360 on the final stage
discharge, high level 15-LAHH1350A/B/C in Nitrogen Stripper 15-MD04, on local
isolation 15-HZ-1549 of Helium Rich Gas Flash Drum 15-MD03 or on high Fuel Gas
Compressor 15-MJ04 vibration or displacement.
Additionally, the HIC control for the anti-surge recycle valves (15-UV-
1501/1502/1503/1504) will be forced to manual mode and a safe position for Fuel
Gas Compressor Trip I-1570. The turning gear on the Fuel Gas Compressor will
have a run inhibit when the fuel gas compressor or motor trips on vibration or fuel
gas compressor or gearbox trips due to axial displacement.
6.1.4 I-1573 – Fuel Gas KO Drum from Helium Plant
Fuel Gas KO Drum 15-MD06 from helium plant trip interlock I-1573 will close fuel gas
return isolation valve 15-ESDV-1622 on Hi-Hi level 15-LAHH-1624A/B/C in Fuel Gas
Return KO Drum 15-MD06, or on Fuel Gas Compressor 15-MJ04 trip Interlock I-
1570.
6.1.5 I-1592 – Fuel Gas Compressor Depressurize
Fuel Gas Compressor Depressurize Interlock I-1592 caused by manual switch 15-
HZ-1338 or machine vented trip 15-XS-7490A/B/C from Unit Control Panel will
depressurize the Fuel Gas Compressor 15-MJ04 by opening blowdown valve 15-HV-
1189 after all relevant permissive condition isolation valves: Fuel Gas Compressor
suction isolation valve 15-XV-1138, discharge isolation valve 15-XV-1145, and Fuel
Gas Return KO Drum, 15-MD06 Isolation valve 15-ESDV-1622 are closed.
Page 17 of 22 KBR
6.2 Pressure Safety Valve Summary

The Fuel Gas Compressor System Pressure Relief Valve Summary contains a listing
of all the pressure relief valves associated with this system.
Fuel Gas Compressor System Pressure Relief Valve Summary
Set Pressure
Valve Number Description/Location
(barg)
15-PRV-1152A/B HP Fuel Gas Compressor, 15-MJ04, HHP 40.0

Discharge/Relief to Warm Flare
15-PRV-1153A/B Fuel Gas from 15-MJ04 (LP) Discharge/Relief to 16.0

Cold Flare
15-PRV-1155A/B Seal Gas from 15-ML01/Relief to Warm Flare 35.0

Header
15-PRV-1158A/B Fuel Gas from Upstream of HP Fuel Gas KO and 40.0

Mixing Drum 15-MD05A/B/Relief to Warm Flare
Header
15-PRV-1167A/B Regen Gas from the Downstream of Regeneration 40.0

Gas Trim Cooler 15-MC11/Relief to Warm Flare
Header
15-PRV-1229A/B Helium Free Reinjection Gas from Overheads of 10.3

Fuel Gas Return KO Drum 15-MD06/Relief to
Warm Flare Header
15-PRV-1230A/B Fuel Gas from Overheads of HP Fuel Gas KO and 40.0

Mixing Drum 15-MD05A/Relief to Warm Flare
Header
15-PRV-1231A/B Fuel Gas from Overheads of HP Fuel Gas KO and 40.0

Mixing Drum 15-MD05B/Relief to Warm Flare
Header
15-PRV-1313A/B HP Fuel Gas to Fuel Gas Compressor Gas 34.5

Turbine/Relief to Warm Flare Header
15-PRV-1604A/B Fuel Gas from Downstream of HP Fuel Gas Heater 34.5

15-MC07/Relief to Warm Flare Header
15-PRV-7133 Fuel Gas Scrubber Skid/Relief to Warm Flare 34.5

Header
15-PRV-7134 Fuel Gas Scrubber Skid/Relief to Warm Flare 34.5

Header
Page 18 of 22 KBR
6.3 Fire Protection Equipment

The Fuel Gas Compressor System Fire Protection Equipment Summary is included
in below listing of Liquefaction Unit Fire Protection Equipment
Fuel Gas Compressor System Fire Protection Equipment Summary
Description Quantity
Refrigeration Cooling Area
63-SP-005 Fire Blanket 2
63-SP-008 Fire Water Monitor (Grade) 5
63-SP-010 Live Hose Reel 3
63-SP-011 Hydrant Cabinet 4-Way 2
63-SP-024 Firewater Monitor Mounted on Four Way Hydrant 2
63-SP-050 Fire Water Monitor (Elevated) 3
Page 19 of 22 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 20 of 22 KBR
7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Fuel Gas Compressor
System.
Fuel Gas Compressor System Equipment List
Design Design
Equipment
Description Pressure Temp
No.
(barg) (ºC)
15-MC07 HP Fuel Gas Heater 40 210/-29
15-MC08 LP Fuel Gas Compressor Intercooler 16/FV 145/-12
15-MC09 MP Fuel Gas Compressor Intercooler 40/FV 190/-12
15-MC10 HP Fuel Gas Compressor Intercooler 40/FV 190/-12
15-MC11 Regeneration Gas Trim Cooler 40/FV 185/-175
15-MC14 HP Fuel Gas Compressor Aftercooler 40/FV 200/-12
15-MD05A/B HP Fuel Gas KO and Mixing Drum 40 85/-29
15-MD06 Fuel Gas Return KO Drum 10.3/FV 85/-7
15-MJ04 Fuel Gas Compressor 120,586 kg/hr rated

capacity
15-MJ04-GT Fuel Gas Compressor Gas Turbine 32,590 kW rated duty
15-ML02 Start-up Fuel Gas Heater 40 155/-15
Page 21 of 22 KBR
7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Fuel Gas Compressor System
and their expected consumption.
Fuel Gas Compressor System Electrical Load List
Available
Equipment No. Description Load
(kW)
15-MC08-MJ01/2/3 LP Fuel Gas Compressor Intercooler Fans 18.5 each
15-MC09- MJ01/2/3 MP Fuel Gas Compressor Intercooler Fans 37 each
15-MC10- MJ01/2/3 HP Fuel Gas Compressor Intercooler Fans 30 each
15-MC14-MJ01/2/3 HP Fuel Gas Compressor Aftercooler Fans 30 each
15-MJ04-GT-M Starting Motor 530
15-ML02 Start-up Fuel Gas Heater 1570
Page 22 of 22 KBR

PP Aaa PP1 112

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SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

DOCUMENT NO: PP-AAA-PP1-112

1 KM Issued for Implementation 13-Dec-12 MRC SPD

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

B JDS Issued for Client Approval 09-Sep-10 GRM BA -

A ACG Issued for Client Approval 05-Feb-10 GRM BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

2.0 SYSTEM DESCRIPTION

Equip. Tag Equipment Description Fuel Gas Flow Temp.

01-MJ01-GT Feed Gas Compressor Gas Turbine 12163 70

15-MJ04-GT Fuel Gas Compressor Gas Turbine 12622 70

16-MJ01-GT LP/MP MR Compressor Gas Turbine 34307 80

16-MJ04-GT PR/HP MR Compressor Gas Turbine 33987 80

20-MJ01-GT Propane Compressor Gas Turbine 12942 70

51-MJ01-GT Power Generators Gas Turbines 36543 70

Fuel Gas Compressor Surge Controllers

First LP 15-UIC-1501 15-HIC-1501

Second MP 15-UIC-1502 15-HIC-1502

Third HP 15-UIC-1503 15-HIC-1503

Fourth HHP 15-UIC-1504 15-HIC-1504

Fourth HHP 15-UIC-1504 15-HS-1504A

surge controller 15-UIC-1501/2/3/4 will override 15-HIC-1501/2/3/4 whenever the

1st Stage LP Suction -25.05 0.02

1st Stage LP Discharge to 15-MC08 74.97 2.16

2nd Stage MP Suction 39.00 1.68

2nd Stage MP Discharge to 15-MC09 138.31 5.84

3rd Stage HP Suction 39.00 5.36

3rd Stage HP Discharge to 15-MC10 136.78 14.93

4th Stage HHP Suction 39.00 14.45

4th Stage HHP Discharge to 15-MC14 127.39 32.40

4th Stage HHP Discharge Aftercooler 15-MC14 39.00 31.92

3.1.2 Fuel Gas Compressor Intercoolers 15-MC08/09/10 and Fuel Gas

3.1.4 HP Fuel Gas Heater 15-MC07

3.1.5 Regeneration Gas Trim Cooler, 15-MC11

3.2 Typical Operating Parameters

Operating Variables for the fuel gas compressor System

Tag No. Description Typical Value Units

3.3 Temporary Operations

Stage Suction Discharge Flow rates

1st Stage 15-TE-1140 15-TE-1209 15-FE-1278

2ND Stage 15-TE-1212 15-TE-1215 15-FE-1279

3rd Stage 15-TE-1218 15-TE-1135 15-FE-1280

4th Stage 15-TE-1396 15-TE-1394 15-FE-1133

16. The anti-surge controller 15-UIC-1501/1502/1503/1504 will over-ride the manual

2. Loss of Instrument Air

6.0 SAFETY/EMERGENCY SHUTDOWN

6.2 Pressure Safety Valve Summary

Fuel Gas Compressor System Pressure Relief Valve Summary

15-PRV-1152A/B HP Fuel Gas Compressor, 15-MJ04, HHP 40.0

15-PRV-1153A/B Fuel Gas from 15-MJ04 (LP) Discharge/Relief to 16.0

15-PRV-1155A/B Seal Gas from 15-ML01/Relief to Warm Flare 35.0

15-PRV-1158A/B Fuel Gas from Upstream of HP Fuel Gas KO and 40.0

15-PRV-1167A/B Regen Gas from the Downstream of Regeneration 40.0

15-PRV-1229A/B Helium Free Reinjection Gas from Overheads of 10.3

15-PRV-1230A/B Fuel Gas from Overheads of HP Fuel Gas KO and 40.0

15-PRV-1231A/B Fuel Gas from Overheads of HP Fuel Gas KO and 40.0

15-PRV-1313A/B HP Fuel Gas to Fuel Gas Compressor Gas 34.5

15-PRV-1604A/B Fuel Gas from Downstream of HP Fuel Gas Heater 34.5

15-PRV-7133 Fuel Gas Scrubber Skid/Relief to Warm Flare 34.5

15-PRV-7134 Fuel Gas Scrubber Skid/Relief to Warm Flare 34.5

6.3 Fire Protection Equipment