SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

SKIKDA, ALGERIA
OPERATING MANUAL VOLUME IV, SECTION 5-2:
UNIT 59 DEMINERALIZED WATER

DOCUMENT NO: PP-AAA-PP1-149

KBR
JOB NO.: J6404

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

B JDS Issued for Client Approval 23-Sep-10 GRM BA -

A MDL Issued for Client Approval 26-April-10 ACG BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
2.1 Demineralized Water ......................................................................................................5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running..............................................................................................................6
3.1.1 Demineralized Water Storage Tank 59-MF03 ..............................................................6
3.1.2 Demineralized Water Pumps 59-MJ03 and 59-MJ03-A................................................6
3.2 Typical Operating Parameters ........................................................................................6
3.3 Temporary Operation......................................................................................................7
4.0 START-UP ............................................................................................................ 8
4.1 Demineralized Water Storage Tank ................................................................................8
5.0 SHUTDOWN ....................................................................................................... 10
5.1 Normal Shutdown .........................................................................................................10
5.2 Process Upsets and Production Loss ...........................................................................10
6.0 SAFETY/EMERGENCY SHUTDOWN................................................................ 11
6.1 Safety Critical Shutdown Systems ................................................................................11
6.1.1 I-5930-59-MJ03/03-A Demineralized Water Pumps Trip ............................................11
6.2 Pressure Safety Valve Summary ..................................................................................11
6.3 Fire Protection Equipment ............................................................................................11
7.0 ATTACHMENTS ................................................................................................. 12
7.1 Attachment I: Equipment List ........................................................................................13
7.2 Attachment II: Utility Consumption...............................................................................14

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

1.0 INTRODUCTION
This operating manual relates to Unit 59 Demineralized Water facilities indicated on
Process Flow Diagram PR-59-PR32-001, and P&ID’s PR-59-SYPI-008/009A and
PR-59-SYPI-013.
Demineralized Water is supplied from existing GL1.K facilities and stored in the
Demineralized Water Tank 59-MF03; then distributed to users with the Demineralized
Water Pumps 59-MJ03/A to the following locations:
• Acid Gas Removal Units, Unit 02 and Unit 12, for solvent make-up and flushing
equipment.
• To hose stations in Units 01, 02, 12, 15, 16, 20 and 51.
• Water from the Demineralized Water header also goes to Tempered Water Make-
up Tank 09-MD01 and to the Laboratory.
• Turbine wash water, 16-MJ01 & 16-MJ04

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 F

A
B
E

C
D
H

8
8

DEMINERALIZED WATER SYSTEM

TO ATM
(AT SAFE LOCATION)

7
7
SKIKDA, ALGERIA

59
59 PRV
59
PCV 1038
PCV
1035 1036
NITROGEN

6
6

59-LIC 59 59
1027 LT LT
1027 1038
59
PG
1034
5-2: DEMINERALIZED WATER

59-FIC
1029
59
FV
59 1029
LV

5
5

1027
NEW LNG TRAIN SKIKDA PROJECT

SC

59-FQI
1042
59
59-FI
FT
1042

4
4

1042

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59 DEMIN WATER
PG DISTRIBUTION
1028

59
PT 59 PI
59 1037
1037
FT
1029

3
3

59
PG
1030

59-MF03
OPERATING MANUAL VOLUME IV, SECTION REVISION 0

59
DEMIN WATER PG
1031
STORAGE TANK

2
2
DOCUMENT NO.
PP-AAA-PP1-149

DEMIN WATER
FROM GL.1.K
TO GRADE

59-MJ03
23 NOVEMBER 2010

DEMINERALIZED 59-MJ03A
WATER PUMP DEMINERALIZED
WATER PUMP

1
1

A
B
E

C
D
H

KBR
 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

2.0 SYSTEM DESCRIPTION

2.1 Demineralized Water
Demineralized Water supplied from the existing GL1.K Complex is sent to the
Demineralized Water Storage Tank, 59-MF03 which has a working capacity of 65.3
m3, enough to satisfy Demineralized water for a 24 hour period. The typical
operating level in the tank is 70% which is a capacity of 44.8 m3. As a safeguard, this
tank has an overflow protection, and prior to this a high high liquid level alarm 59-
LAHH-1038. To maintain an oxygen free environment within the tank it has a
nitrogen blanket supplied from the nitrogen header through a pressure control valve.
The Demineralized water from the existing complex must meet at least the following
requirements:
• Conductivity at 20°C: 2 μS/cm Maximum
• pH: 6.8 to 7.5
• Silica: 0.03 ppm
• Iron: 0.05 ppm
• Copper: 0.03 ppm
• Total solids: 1 ppm
A sample station is provided in the Demineralized Water Supply line to the Tank, for
taking routine samples.
The Demineralized Water Pump, 59-MJ03/03-A distributes Demineralized water to
the following systems:
• Acid Gas Removal Unit 02 and Unit 12 for solvent make-up and flushing of
equipment. These requirements are both intermittent. Flushing of equipment
is via hose stations.
• Continuous flow to 12-MD39, Solvent Regeneration Reflux Drum
• Washing of gas turbine blades. This is an infrequent and automated
operation and is required at all the Power Generator Gas Turbines 51-MJ01-
A/B/C/D/E-GT, MR, PR and External Propane Compressor Turbines, 16-
MJ01-GT, 16-MJ04-GT, and 20-MJ01-GT, Feed Gas Compressor Turbine,
01-MJ01-GT and Fuel Gas Compressor Turbine 15-MJ04-GT.
• Make-up to Tempered Cooling Water System, Unit 09, and for use in the
Laboratory Building.
The pump is protected by a minimum flow return to the tank. Only one pump is in
service and the other on standby but must be manually started by the start/stop
switch.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Demineralized
Water System. Refer to Section 3.2 for a list of typical operating variables for this
system.
3.1.1 Demineralized Water Storage Tank 59-MF03
Demineralized water flowing into this tank from the GL1.K facility is controlled by
level controller 59-LIC-1027. This ON-OFF type controller opens water inlet valve
59-LV-1027 when the tank level is low, as measured by transmitter 59-LT-1027.
When the level is high the controller closes the valve. The high and low levels on the
P&ID’s are indicated by level alarm 59-LIC-1027H and 59-LIC-1027L.

To minimize corrosion in the tank a nitrogen blanket is kept in the vapor space.
Nitrogen is admitted through pressure regulator 59-PCV-1035 and any over pressure
is relieved to the atmosphere by back pressure regulator 59-PCV-1036.

3.1.2 Demineralized Water Pumps 59-MJ03 and 59-MJ03-A

These pumps send Demineralized water from Demineralized Water storage Tank 59-
MF03 to the users. The pumps can be manually started and stopped from the DCS
or Local/Remote, preferably Local Start and Remote Stop.

Pump Start/Stop Switch Local/Remote Switch

59-MJ03 59-HS-1032 59-HS-1032A
59-MJ03-A 59-HS-1033 59-HS-1033A

One pump always operates and the other is a spare. A minimum flow through the
pumps is maintained by flow controller 59-FIC-1029, which regulates water from the
discharge back to Demineralized Water Storage Tank 59-MF03 through valve 59-FV-
1029.

3.2 Typical Operating Parameters

The following table contains typical operating variables for the Demineralized Water
System.

Operating Variables for the Demineralized Water System

Tag No. Description Typical Value Units

59-FI-1042 Demineralized Water from GL1.K 2393 / 9974 Kg/hr

Facility Flow Indicator

59-FIC-1029 Demineralized Water Pump 59- 2.9 m3/hr

MJ03/03-A Minimum Flow Controller

59-LIC-1027 Demineralized Water Storage Tank 70 %

59-MF03 Level Controller

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

Operating Variables for the Demineralized Water System

Tag No. Description Typical Value Units

59-PCV-1035 Demineralized Water Storage Tank 5.00 mbarg

Nitrogen Blanket Pressure
Controller

59-PCV-1036 Demineralized Water Storage Tank 10.00 mbarg

59-MF03 back Pressure Regulator

59-PI-1037 Demineralized Water Pump 59- 6.2 barg

MJ03/03-A Discharge Pressure
Indicator

3.3 Temporary Operation

Turbine washing, make-up to Tempered Cooling Water System and preparation of
aMDEA solution are intermittent and infrequent. The only continuous users of
Demineralized Water is the make-up to the Solvent Regenerator Reflux Drum 12-
MD39.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

4.0 START-UP
This section outlines the steps necessary to place the Demineralized Water 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 the system is
purged and ready for start-up.
4.1 Demineralized Water Storage Tank
1. Verify that Demineralized Water is available from GL1.K Facility, to the
Demineralized Water Storage Tank 59-MF03 and that the water meets
specifications.
2. Verify that nitrogen is available from the nitrogen header to the Demineralized
Water Storage Tank.
3. Confirm that the tank has a slight nitrogen pressure.
4. Ensure that flow indicator 59-FI-1042 and flow totalizer 59-FQI-1042 are in
service in the Demineralized water supply line to the tank.
5. Confirm that sample station 59-SC-002 is ready for sampling the
demineralized water to the tank.
6. Notify operating personnel in GL1.K facility that you would like for them to
start a flow of Demineralized Water to Tank 59-MF03.
7. Place Tank level controller 59-LIC-1027 in manual, close 59-LV-1027 and
open valves upstream and downstream of 59-LV-1027.
8. Open bypass valve to start a small flow into Tank 59-MF03.
9. Obtain a sample of the Demineralized water at the sample station and run a
lab analysis and if specifications are met close the bypass valve and open 59-
LV-1027 to begin filling the Demineralized Water Storage Tank 59-MF03.
10. Place 59-LIC-1027 in automatic and continue filling the tank at 70% level.
11. Pressure regulator 59-PCV-1035 should be placed in operation to admit
nitrogen into the tank to maintain 5.00 mbarg nitrogen blanket in the vapor
space.
12. Put back pressure regulator 50-PCV-1036 in operation to relieve any over
pressure in the tank to the atmosphere.
13. Ensure that all tank instrumentation is in service and continue filling the
Demineralized Water Storage Tank until a normal operating level is achieved.
14. Line up valves in the Demineralized Water Pump 59-MJ03/03-A suction and
discharge lines to the open position. Keep valves to users closed.
15. Verify that valves are open in the pump discharge minimum flow line back
through 59-FV-1029 to Demineralized Water Storage Tank 59-MF03, for
pump protection. Place min. flow controller 59-FV-1029 in AUTO mode with a
setpoint of 2.9 m3/hr.
16. Start one of the Demineralized Water Pumps 59-MJ03/03-A and fill the
Demineralized Water Distribution Header, venting at high points.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

17. Observe pump operation, pressure temperature and flow through minimum
flow line.
18. After the pump has run for a while (at least an hour) then switch to the spare
pump and run it for a while thus to check out operation of both pumps.
19. Place all pump instrumentation in service.
20. Notify operators in all Units, that use, the Demineralized water that the system
is in operation ready for them to use.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Demineralized Water
System.
1. If the plant is shutting down for only a short period the system should be left
on with pump on minimum flow back to the Demineralized Water Storage
Tank.
2. In the event of a LNG Plant shutdown being extended, the Demineralized
Water System should be left on line until all the equipment that was in service
is brought back to ambient temperature. Confirm this with the
Operator/Supervisor prior to system shutdown.
3. Place the Demineralized Water Spare Pump 59-MJ03/03-A pump in the ‘off’
position if it isn’t already off.
4. Stop the online Demineralized Water Pump 59-MJ03/03-A.
5. Place tank level controller 59-LIC-1027 in manual and close 59-LV-1027.
6. Leave the tank pressure control system in service if the Tank is not going to
be drained for maintenance.
7. Ensure that valves are closed in the supply lines from the Demineralized
Water header to the users.
8. If the system is going to be drained or maintenance activity is planned ensure
that the Lock Out Tag Out System is in operation.
9. Lock out and Tag out Pump switch gear in the Substation.
5.2 Process Upsets and Production Loss
In the event of an emergency requiring a shutdown of the Demineralized Water
System, the system should be shut down as outlined above in normal shutdown. In
the event of causes and actions, listed below only process upsets or production loss
may occur and not necessarily require the Demineralized Water System to be
shutdown.
1. Loss of Electrical Power
Loss of electrical power to the Demineralized Water Pump 59-MJ03/03-A will
cause the Demineralized Water flow to the distribution header for the users to
stop until the spare pump is started. If it has no electrical power then flow to the
users will stop until power is restored.
2. Lost 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 a
‘fail open’ position while FC valves go to a ‘fail closed’ position.
The following valve will fail open: 59-FV-1029
The following valve will fail closed: 59-LV-1027

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-5930-59-MJ03/03-A Demineralized Water Pumps Trip
The Demineralized Water Pump I-5930 interlock will trip the pumps to prevent
cavitation.
On low-low level alarm 59-LALL-1038 in the Demineralized Water Storage Tank 59-
MF03 the Demineralized Water Pump 59-MJ03/03-A is tripped.
6.2 Pressure Safety Valve Summary

Demineralized Water System Pressure Relief Valve Summary

Set Pressure
Valve Number Description/Location (barg)

59-PRV-1003 Demin Water Tank Relief To Atm 15 mbarg

6.3 Fire Protection Equipment

The Demineralized Water System Fire Protection Equipment Summary contains a
listing of fire protection equipment associated with this system.

Demineralized Water System Fire Protection Equipment Summary

Description Quantity

Feed Gas Metering Area

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

63-SP-012 Hydrant Cabinet 2 Way 1

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

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

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Demineralized Water System.

Demineralized Water System Equipment List

Design Design
Pressure Temp
Equipment No. Description (barg) (ºC)

59-MF03 Demineralized Water Storage Tank 59- 15 mbarg 65/1

MF03 (Max)
0 mbarg
(Min)

59-MJ03/03-A Demineralized Water Pump 59- 6.2 24

MJ03/03-A

59-MJ03/03-A Demineralized Water Pump 59- Rated Capacity: 10.0

MJ03/03-A m3/hr each

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-149
OPERATING MANUAL VOLUME IV, SECTION REVISION 0
5-2: DEMINERALIZED WATER 23 NOVEMBER 2010

7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Demineralized Water System
and their expected consumption.

Demineralized Water System Motor List

Available
Motor Load
Equipment No. Description (kW)

59-MJ03/03-A Demineralized Water Pump 2@11.0 ea

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