PP Aaa PP1 135

SONATRACH
NEW LNG TRAIN SKIKDA PROJECT
SKIKDA, ALGERIA
OPERATING MANUAL VOLUME III, SECTION 2-3:
UNIT 76 GASOLINE STORAGE & TRANSFER
DOCUMENT NO: PP-AAA-PP1-135
KBR
JOB NO.: J6404
1 KM Issued for Implementation (Redlined) 24-Apr-13 CH RM
0 JDS Issued for Implementation 23 Nov 10 GRM BA AB
B JDS Issue for Client Approval 05 Sep 10 GRM BA -
A MDL Issued for Client Approval 10 May 10 ACG BA -
Rev. By Description Date KBR KBR CLIENT
Chkd App App

NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-135
OPERATING MANUAL VOLUME III, SECTION 2-3 REVISION 1
GASOLINE STORAGE & TRANSFER 24-Apr-13
TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
2.1 Gasoline Storage Sphere..................................................................................................5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running ................................................................................................................6
3.1.1 Gasoline Storage Sphere 76-MD03 ...............................................................................6
3.1.2 Gasoline Transfer Pumps 76-MJ03/A ............................................................................6
3.2 Typical Operating Parameters ..........................................................................................6
3.3 Temporary Operation ........................................................................................................7
4.0 START-UP ............................................................................................................ 8
5.0 SHUTDOWN ....................................................................................................... 11
5.1 Normal Shutdown ...........................................................................................................11
5.1.1 Gasoline Storage Sphere .............................................................................................11
5.1.2 Gasoline Transfer Pumps.............................................................................................11
5.2 Process Upsets and Production Loss .............................................................................11
6.0 SAFETY/EMERGENCY SHUTDOWN ................................................................ 12
6.1 Safety Critical Shutdown Systems ..................................................................................12
6.1.1 I-7610 – 76-MD03 Gasoline Storage ...........................................................................12
6.1.2 I-7615 – 76-MD03 Gasoline Export ..............................................................................12
6.2 Pressure Safety Valve Summary ....................................................................................12
6.3 Fire Protection Equipment ..............................................................................................13
7.0 ATTACHMENTS ................................................................................................. 14
7.1 Attachment I: Equipment List ..........................................................................................15
7.2 Attachment II: Utility Consumption .................................................................................16
Page 2 of 16
1.0 INTRODUCTION
This operating manual relates to the Unit 76 Gasoline Storage & Transfer facilities
indicated on Process Flow Diagrams PR-76-PR32-002, PR-07-PR32-006, PR-65-
PR32-002 and P&ID’s PR-76-SYPI-001, PR-71-SYPI-003, PR-07-SYPI-011 and PR-
65-SYPI-002.
The purpose of the Unit 76 Gasoline Storage and Transfer facilities is to provide a
Gasoline Storage Sphere, 76-MD03, for Gasoline Product produced by the
Deisopentanizer in the fractionation section of the new LNG plant as well as the
gasoline produced by the existing units at the Skikda Complex.
Two Gasoline Transfer Pumps 76-MJ03/A are provided to pump gasoline from the
sphere to the refinery complex RA1.K.
Page 3 of 16 KBR
Page 4 of 16 KBR
2.0 SYSTEM DESCRIPTION

2.1 Gasoline Storage Sphere
The gasoline produced by the Deisopentanizer in the fractionation section of the new
LNG plant, as well as, gasoline produced by the existing LNG Units at the Skikda
Complex is stored in the new Gasoline Storage Sphere, 76-MD03.
The Sphere has a working capacity of 3000m3 with maximum operating pressure of
0.91 barg and minimum operating pressure of -0.51 barg. The Sphere has a
maximum operating temperature of 62°C and minimum operating temperature of
1°C. The gasoline will be stored at ambient temperature.
Gasoline product is pumped from the Gasoline Storage Sphere to the Refinery
Complex RA1.K by using the Gasoline Transfer Pumps, 76-MJ03/A; one pump will
be operating and one a spare.
Page 5 of 16 KBR
3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Gasoline
Storage and Transfer System. Refer to Section 3.2 for a list of typical operating
variables for this system.
3.1.1 Gasoline Storage Sphere 76-MD03
Gasoline produced by the Deisopentanizer, 07-MD11, in the fractionation unit is
stored in Gasoline Storage Sphere, 76-MD03. In addition, gasoline produced in Pole
1 and Pole 2 is pumped to 76-MD03 for storage.
Vapor pressure in the sphere will vary as gasoline flows in, is pumped out or due to
ambient temperature fluctuations. Pressure is regulated by dual controllers: low
range controller, 76-PIC-1055A, and high range controller, 76-PIC-1055B. Both
controllers operate from the same pressure transmitter, 76-PT-1055. When the
pressure drops below the set pressure on 76-PIC-1055A, it modulates valve 76-PV-
1055A to bring in feed gas from Unit 15 to increase the pressure. When the pressure
exceeds the set pressure on 76-PIC-1055B, it modulates the valve 76-PV-1055B to
vent excess gas to the Warm Flare header, thereby reducing the pressure.
3.1.2 Gasoline Transfer Pumps 76-MJ03/A
There are two gasoline product pumps; one operating and one spare. The pumps
are started manually from the DCS console or from the field. The pumps have a
common discharge line and a common minimum flow bypass line. The minimum
flow is controlled by 76-FIC-1062 which recycles gasoline back to the sphere through
valve 76-FV-1062. Gasoline pumped to the RA1.K refinery is controlled by 76-FIC-
1061, which throttles pump common discharge valve 76-FV-1061.
3.2 Typical Operating Parameters
The following table contains typical operating variables for the Gasoline Storage and
Transfer System.
Operating Variables for the Gasoline Storage and Transfer System
Tag No. Description Typical Value Units
76-FI-1082 Gasoline from Pole 1 to Gasoline 4,957 kg/h

Storage Sphere, 76-MD03, Flow
Indicator
76-FI-1081 Gasoline from Pole 2 to Gasoline 10,844 kg/h

Storage Sphere, 76-MD-03, Flow
Indicator
76-FIC-1061 Gasoline export from Gasoline 77,625 kg/h

Transfer Pump, 76-MJ03/03A, to
RA1.K Refinery Flow Controller
Page 6 of 16 KBR
Operating Variables for the Gasoline Storage and Transfer System
Tag No. Description Typical Value Units
76-FIC-1062 Gasoline Transfer Pump, 76-

MJ03/03A, minimum flow Recycle
40 m3/h
Flow Controller
76-PG-1058/1059 Pump discharge pressure 27.5 barg
76-LI-1052 Gasoline Storage Sphere, 76-MD03, varies between %

Level Indicator 7 and 90
76-PIC-1055A Gasoline Storage Sphere, 76-MD03, 0.4 barg

Pressure Controller, make up from
Feed Gas
76-PIC-1055B Gasoline Storage Sphere, 76-MD03, 1.4 barg

Pressure Controller vent to Warm
Flare Header
76-TI-1057 Gasoline Storage Sphere, 76-MD03, 39 °C

Temperature Indicator
3.3 Temporary Operation

The Gasoline Storage Sphere, 76-MD03, does not have temporary operations.
Page 7 of 16 KBR
4.0 START-UP
This section outlines the steps necessary to place the Gasoline Storage and Transfer
System in service. For the purpose of this section of the operating manual, it is
assumed that the following conditions exist: The system and equipment have been
pre-commissioned, tested, commissioning has been completed and system is purged
of air and ready for start-up. Ensure fire deluge system and hydrants are lined up and
ready for operation
1. Verify that Sample Station, 07-SC-007, is ready to sample gasoline flow from
Gasoline Product Cooler, 07-MC13 to Gasoline Storage Sphere, 76-MD03.
Pole 1 to Gasoline Storage Sphere, 76-MD03.
4. Confirm that the Warm Liquid Flare System is in service.
5. Confirm that the Warm Flare System is in service.
6. Confirm that all the PRVs in the system are in service with inlet and outlet
valves locked open.
7. Verify that make-up gas is available from the Feed Gas System to prevent
vacuum conditions in Gasoline Sphere, 76-MD03.
8. Verify Pressure Controller, 76-PIC-1055A, is in automatic and 76-PV-1055A
and bypass valve are closed in make-up gas line to 76-MD03.
9. Verify Pressure Controller, 76-PIC-1055B, is in automatic and 76-PV-1055B
and the bypass valve are closed.
10. Open the make-up gas feed isolation valve, 76-ESDV-1050.
11. Verify that isolation valve, 76-ESDV-1079, is closed in the gasoline line from
12. Ensure that the 2” globe valve is closed in the line from the gasoline run down
line to the Warm Liquid Flare.
13. Notify operator in the Pole 1 Unit that the new Gasoline Storage Sphere is
ready to receive gasoline when it meets specification and verify valves are
lined up to do so. Request that they send a low flow of gasoline to start with.
14. Route the flow of gasoline to the Warm Liquid Flare by opening the globe
valve slightly and sample the gasoline flow at sample station, 76-SC-008.
15. When gasoline flow from Pole 1 meets specifications, use 76-HS-1079 to
open 76-ESDV-1079 to send gasoline flow into Gasoline Storage Sphere, 76-
MD03 and close valves in the line from the gasoline rundown lines to the
Warm Liquid Flare. The flow into the Sphere is controlled in Pole 1 area and
indicated on, 76-FI-1082 in the 76-MD03 area.
16. Monitor pressure and temperature of the Sphere and ensure that control
valve 76-PV-1055B opens to vent nitrogen from the Sphere to Warm Flare.
17. Ensure that the 6” valve is closed in the gasoline line from Pole 2 to the
Gasoline Export line to RA1.K Refinery.
Page 8 of 16 KBR
18. Verify that isolation valve, 76-ESDV-1047, is closed in the gasoline line from
19. Ensure that the 3” globe valve is closed in the line from the gasoline rundown
20. Notify operators in the Pole 2 Unit that the new Gasoline Storage Sphere, 76-
MD03 is ready to receive gasoline when it meets specifications and ensure
valves are lined up to do so. Request that they send a low flow to start with.
valve slightly and sample the gasoline flow at Sample Station, 76-SC-007.
22. When gasoline flow from Pole 2 meets specifications, use 76-HS-1047 to
open 76-ESDV-1047 to send gasoline flow into the Gasoline Storage Sphere,
76-MD03 and close valve in the line from the gasoline rundown line to the
Warm Liquid Flare. The gasoline flow into the Sphere is controlled in the Pole
2 area, an indication of the flow is provided on, 76-FI-1081 in the 76-MD03
area.
23. Confirm that isolation valve, 76-ESDV-1051 is closed in the gasoline line from
Gasoline Product Cooler, 07-MC13 to Gasoline Storage Sphere, 76-MD03.
24. Ensure that the 3” globe valve is closed in the line from the gasoline rundown
25. Notify operators in the Deisopentanizer Unit 7 that the new Gasoline Storage
Sphere, 76-MD03 is ready to receive gasoline when it meets specifications
and ensure valves are lined up to do so. Request that they send a low flow of
gasoline to start with.
valve, slightly, and sample the gasoline flow at Sample Station, 07-SC-007.
27. When gasoline flow from 07-MC13 meets specifications, use 76-HS-1051 to
open 76-ESDV-1051 to send gasoline flow into Gasoline Storage Sphere, 76-
MD03, and close valves in the line from the gasoline rundown line to the
Warm Liquid Flare. The flow of gasoline into the Sphere is controlled in the
Deisopentanizer Unit 07 and no flow indication is provided in 76-MD03 area.
28. Place the Gasoline Storage Sphere pressure control system in service.
Pressure is regulated by dual controllers: Low Range Controller, 76-PIC-
1055A and High Range Controller, 76-PIC-1055B. Both controllers operate
from the same pressure transmitter, 76-PT-1055. When the pressure drops
below the set pressure on 76-PIC-1055A, it modulates valve, 76-PV-1055A,
to bring in feed gas from Unit 15 to increase the pressure in 76-MD03. When
the pressure exceeds the set pressure on 76-PIC-1055B, it modulates valve,
76-PV-1055B to vent excess gas to the Warm Flare header, thereby reducing
the pressure. Ensure that the by-pass valves are closed at both 76-PV-
1055A and 76-PV-1055B.
29. Ensure that all instrumentation is in service for the Gasoline Storage Sphere,
76-MD03 and the Gasoline Transfer Pumps, 76-MJ03/03A.
30. When an operating level is established in 76-MD03, notify operators in RA1.K
Refinery where they can line up valves to receive gasoline from 76-MD03,
using 76-MJ03/03A.
Page 9 of 16 KBR
31. Place flow controller, 76-FIC-1061, in manual and close 76-FV-1061 and
ensure bypass valve is closed in gasoline pump discharge line.
32. Use 76-HS-1060 to open 76-ESDV-1060 and line up valves to the open
position in the suction line to Gasoline Transfer Pumps, 76-MJ03/03A and
ensure valves are open upstream and downstream of 76-FIC-1061 and 76-
FIC-1062.
33. Verify that both pumps 76-MJ03/03A are ready to start up.
34. Set minimum flow controller, 76-FIC-1062, partially open in manual
35. Start one of the pumps, 76-MJ03/03A, and circulate back to the Sphere, 76-
MD03, through minimum flow controller, 76-FIC-1062. Place in auto mode
with a flow set point of 40m3/h.
36. Obtain a sample of the gasoline at Sample Station, 76-SC-006, and have
analysis run. If it meets specification and RA1.K Refinery is ready to receive
gasoline from the Gasoline Storage Sphere, start a low flow through 76-FV-
1061 bypass valve to the refinery to pressure up the line.
37. Open 76-FV-1061, close by-pass valve and place Flow Controller, 76-FIC-
1061, in automatic at the desired rate and ensure that Totalizer, 76-FQI-1061,
is in service.
38. Monitor the system temperatures, flows and pressures and pump operation to
verify all is well.
Page 10 of 16 KBR
5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Gasoline Storage and
Transfer System.
5.1.1 Gasoline Storage Sphere
The Gasoline Storage Sphere will normally remain in service unless existing units,
Pole 1 and Pole 2, and the Deisopentanizer in Unit 7 all shut down and gasoline flow
to the Gasoline Storage Sphere, 76-MD03, from each of the units is stopped and no
gasoline flow is required to be pumped from the Sphere to RA1.K Refinery.
It is expected that once the Sphere, 76-MD03, is placed in service, it will remain in
service unless it has to be taken out of service for maintenance. All units that supply
gasoline to 76-MD03 will have to be shut down if 76-MD03 is taken out of service.
When units that supply gasoline to Gasoline Storage Sphere shut down, ensure that
the gasoline inlet feed valves from each of the units are closed and blinded.
5.1.2 Gasoline Transfer Pumps
The Gasoline Transfer Pumps, 76-MJ03/A, are shut down except when sending
gasoline to RA1.K Refinery. It is expected the pumps and the line to the refinery will
be left ready for service unless one requires maintenance. If the Refinery is shut
down, ensure that the discharge line to the Refinery is isolated and blinded.
Ensure that the Gasoline Storage Sphere, 76-MD03, pressure control system
remains in service.
5.2 Process Upsets and Production Loss
In the event of an emergency requiring a shutdown of the Gasoline Storage and
Transfer System, the system should be shut down.
1. Loss of Electrical Power
Loss of electrical power to either of the Gasoline Transfer Pumps, 76-MJ03/A,
will cause the pump to stop if it is running and it will not be able to start if it is
down until power is restored. Gasoline flow the RA1.K Refinery will be stopped.
2. Loss of Instrument Air
Loss of Instrument Air to any one control valve will result in that valve going to
its designated fail safe position. As indicated on each P&ID, FO valves go to
the “Fail Open” position and FC valves to a “Fail Closed” position.
The following valve will fail open: 76-FV-1062
The following valves will fail closed: 76-ESDV-1047, 76-ESDV-1051, 76-ESDV-
1079, 76-ESDV-1050, 76-PV-1055A, 76-PV-1055B, 76-ESDV-1060 and 76-FV-
1061.
3. Loss of Feed Gas
Loss of Make-up Feed Gas from the Feed Gas System to the Gasoline Storage
Sphere, 76-MD03, for vacuum prevention, will require the operator to stop
pumping gasoline out of 76-MD03 to RA1.K Refinery to avoid pulling a vacuum
on the Sphere.
Page 11 of 16 KBR
6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-7610 – 76-MD03 Gasoline Storage
The 76-MD03 Gasoline Storage isolation I-7610 interlock will trip feeds into Gasoline
Storage Sphere, 76-MD03.
On high high level or high high pressure in the Gasoline Storage Sphere, 76-MD03,
the inlet feed valves, 76-ESDV-1047, 76-ESDV-1051, 76-ESDV-1079, and 07-ESDV-
1161, will be tripped. On high high pressure the HP Fuel Gas Valve, 76-ESDV-1050,
will trip, and 76-PIC-1055A will be forced closed.
6.1.2 I-7615 – 76-MD03 Gasoline Export
The 76-MD03 Gasoline Storage isolation I-7615 interlock will trip the Gasoline
Storage Sphere Bottoms Outlet to prevent Vapor Breakthrough and to protect Export
Pumps.
On low low level in the Gasoline Storage Sphere, 76-MD03, the Bottoms Isolation
Valve, 76-ESDV-1060, and Gasoline Transfer Pumps, 76-MJ03/A will trip, and 76-
FIC-1061 will be forced closed.
6.2 Pressure Safety Valve Summary
The Gasoline Storage and Transfer System Pressure Relief Valve Summary contains
a listing of all the pressure relief valves associated with this system.
Gasoline Storage and Transfer System Pressure Relief Valve Summary
Set Pressure
Valve Number Description/Location (barg)
76-PRV-1036 Gasoline Header from Pole 1 Relief to the Warm 18.90

Liquid Flare
76-PRV-1037 Gasoline Header from Pole 2 Relief to the Warm 33.00

Liquid Flare
76-PRV-1038 Gasoline Header from Gasoline Product Cooler, 10.50

07-MC13, Relief to the Warm Liquid Flare
76-PRV-1059-A Gasoline Storage Sphere, 76-MD03, Relief to the 5.50

Warm Flare Header
76-PRV-1059-B Gasoline Storage Sphere, 76-MD03, Relief to the 5.50

Warm Flare Header
76-PRV-1080 Gasoline Transfer Pumps, 76-MJ03/03A, 31.50

Discharge Line Relief to Gasoline Storage
Sphere, 76-MD03
Page 12 of 16 KBR
6.3 Fire Protection Equipment

The Gasoline Storage and Transfer System Fire Protection Equipment Summary
contain a listing of fire protection equipment associated with this system.
Gasoline Storage and Transfer System Fire Protection Equipment Summary
Description Quantity
Gasoline Storage Sphere Area
63-SP-008 Firewater Monitor (Grade) 3
63-SP-015 Four-way Hydrant 3
63-SP-011 Hydrant Cabinet 4-Way 3
63-ML07 Automatic deluge system 1
Page 13 of 16 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 14 of 16 KBR
7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Gasoline Storage and
Transfer System.
Gasoline Storage and Transfer System Equipment List
Design Design
Equipment Pressure Temp
No. Description (barg) (ºC)
76-MD03 Gasoline Storage Sphere 3.5 72/-7
76-MJ03/A Gasoline Transfer Pumps 125.0 m3/h capacity
Page 15 of 16 KBR
7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Gasoline Storage and Transfer
System and their expected consumption.
Gasoline Storage and Transfer System Motor List
Available
Motor Load
Equipment No. Description (kW)
76-MJ03/A Gasoline Transfer Pump Electric Motor 2@160 ea.
Page 16 of 16 KBR

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SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

DOCUMENT NO: PP-AAA-PP1-135

1 KM Issued for Implementation (Redlined) 24-Apr-13 CH RM

0 JDS Issued for Implementation 23 Nov 10 GRM BA AB

B JDS Issue for Client Approval 05 Sep 10 GRM BA -

A MDL Issued for Client Approval 10 May 10 ACG BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

2.0 SYSTEM DESCRIPTION

Operating Variables for the Gasoline Storage and Transfer System

Tag No. Description Typical Value Units

76-FI-1082 Gasoline from Pole 1 to Gasoline 4,957 kg/h

76-FI-1081 Gasoline from Pole 2 to Gasoline 10,844 kg/h

76-FIC-1061 Gasoline export from Gasoline 77,625 kg/h

Operating Variables for the Gasoline Storage and Transfer System

Tag No. Description Typical Value Units

76-FIC-1062 Gasoline Transfer Pump, 76-

76-PG-1058/1059 Pump discharge pressure 27.5 barg

76-LI-1052 Gasoline Storage Sphere, 76-MD03, varies between %

76-PIC-1055A Gasoline Storage Sphere, 76-MD03, 0.4 barg

76-PIC-1055B Gasoline Storage Sphere, 76-MD03, 1.4 barg

76-TI-1057 Gasoline Storage Sphere, 76-MD03, 39 °C

3.3 Temporary Operation

6.0 SAFETY/EMERGENCY SHUTDOWN

Gasoline Storage and Transfer System Pressure Relief Valve Summary

76-PRV-1036 Gasoline Header from Pole 1 Relief to the Warm 18.90

76-PRV-1037 Gasoline Header from Pole 2 Relief to the Warm 33.00

76-PRV-1038 Gasoline Header from Gasoline Product Cooler, 10.50

76-PRV-1059-A Gasoline Storage Sphere, 76-MD03, Relief to the 5.50

76-PRV-1059-B Gasoline Storage Sphere, 76-MD03, Relief to the 5.50

76-PRV-1080 Gasoline Transfer Pumps, 76-MJ03/03A, 31.50

6.3 Fire Protection Equipment

Gasoline Storage and Transfer System Fire Protection Equipment Summary

Gasoline Storage Sphere Area

63-SP-008 Firewater Monitor (Grade) 3

63-SP-015 Four-way Hydrant 3

63-SP-011 Hydrant Cabinet 4-Way 3

63-ML07 Automatic deluge system 1

7.1 Attachment I: Equipment List

Gasoline Storage and Transfer System Equipment List

76-MD03 Gasoline Storage Sphere 3.5 72/-7

76-MJ03/A Gasoline Transfer Pumps 125.0 m3/h capacity

7.2 Attachment II: Utility Consumption

Gasoline Storage and Transfer System Motor List

76-MJ03/A Gasoline Transfer Pump Electric Motor 2@160 ea.

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