Train to Maintain Regeneration Gas Heater

CMAS Training Plan
BP Tangguh LNG
Discipline: Mechanical Technician
Unit: Furnace
Element: Air/Gas Heater Tangguh LNG
1: Introduction
Objectives:
The objective of this training plan is to identify and guide the technician to the
site-specific information necessary to prepare for competence assessment
against the BP Mechanical Technician Standards.
Training and subsequent assessment will include all applicable standards of

performance relating to the following five sections within the BP Mechanical
Technician Standards:
1. Implementation of Maintenance Procedures and Adjustments
2. Interrogation and Fault Finding Skills
3. Inspect, Repair Systems for Restoration to Required Performance
4. Return to Service by Component Removal and Replacement
5. Monitor and Assess the Performance and Condition of Equipment.
Use of this Training Plan:
The candidate is then expected to work through this training plan and gather
evidence in his On Job Training evidence file and have the following critical
task sheet signed by a Mechanical Coach for each section completed. During
this period a qualified Technician or Coach will mentor the candidate. There
are some self-assessment questions at the end of the training plan which the
trainee should answer correctly before requesting an assessment from a
Mechanical Coach. However the training plan can be completed one section
at a time and the assessments can be done on each individual section as it is
completed.
The evidence pack should be presented to a Mechanical Coach on the
completion of each relevant task, for inspection and signature. If you have any
questions about how to use this training plan please ask one of your
Mechanical Coaches.
Trainees may only carry out maintenance work under the supervision of
competent technicians.
Prepared By: Tangguh LNG MD (DdS / US)

Page 1 of 17
PAPER COPIES ARE UNCONTROLLED
THE CONTROLLED VERSION OF THIS DOCUMENT IS ON THE ELECTRONIC FILE AT MAINTENANCE DEPARTMENT
January-2009
Unit: Furnace
Element: Air/Gas Heater
2: BOUNDARIES
The boundaries encompassed by this plan:
Commence at the Inlet Gas Flanges
and end at the Outlet Gas Flanges
3: PRE-REQUISITES
Pre-requisites for this element will include all relevant BP GoM Environmental,
Health, and Safety Training.
Additional Requirements include:
• OJT
• Familiarity with Equipment and Vendor Data
• Qualified Personnel
4: DESCRIPTION
After a period of time in the adsorption cycle (normally 16 hours), the molecular sieve
beds become saturated with water and sulfur compounds. The dehydration drum is
taken off adsorption mode and regenerated to remove the water and other adsorbed
components. Before a drum is taken off adsorption mode, another drum that has
completed the regeneration step is put back into adsorption cycle.
Page 2 of 17

January-2009
Unit: Furnace
At the beginning of the regeneration cycle, the bed is at temperature 22°C and pressure
58.5 kg/cm2A of the pre-cooled feed gas.
Prior to entering the molecular sieve bed, the regeneration gas is heated up in the
Regeneration Gas Heater (031/032-F-1001) which is installed in the utility area. First,
the regeneration gas temperature at the inlet of the bed is ramped up from 40°C to
298°C, and then held at 298°C for a certain period at the end of heating cycle.
Automatic temperature control is achieved by adjusting the fuel gas flow rate.
Regeneration Sequence:
The regeneration sequence is completed automatically under normal condition by the
Dehydration Sequence Controller (031/032-KC-1900). Times control all steps but to
advance from the heating to cooling or cooling to standby mode, gas temperature
requirements must also be satisfied. Dehydration sequence valves are interlocked to
match the mode of operation, i.e., regeneration valves and adsorption valves cannot
open the same time, etc. The operator can manually interrupt the sequence with the
auto/manual mode selector switch (031/032-HS-1903).
This will stop the timers and continue operation at the current situation. Once the
interrupt switch is initiated again, the operation continues where it left off before the
interruption. In the event that the Regeneration Gas Heater (031/032-F-1001) trip,
regeneration gas can bypass the regeneration heater through 031/032-FV-1005 and
allow for the cooling cycle to continue in manual mode.
Page 3 of 17

January-2009
Unit: Furnace
Regeneration Gas Heater (031/032-F-1001)

One (1) 100% fired heater to heat regeneration gas for one (1) unit is provided.
Number of heaters: One (1) / unit
Type: Natural draft vertical cylindrical
Manufacturer Kirchner Italia S.P.A
Heat absorption: 7570 kW for unit
Outlet temperature: 298 °C
Fuel: Fuel gas
In general, the working of this Heater is foreseen for a period of 20 years, however an
extraordinary inspection and the subsequence is 4 years.
Table 4.1
NO EQUIP NO MANUFACTURER MODEL / TYPE
1 031/032-F-1001 Kirchner Italia S.P.A Natural Draft Vertical
Cylinerical
Page 4 of 17

January-2009
Unit: Furnace
5: DOCUMENTATION
Documentation for this element is:

Table 5.1
Document Title Document No. Location

Equipment Data Sheet for 031-F-1001
31-EDS-FU-1403
Regenerator Gas Heater
Specification for Regeneration Gas Heater 31-SPE-FU-1475
Operation Manual for Dehydration and
31-IOM-PS-1201
Mercury Removal Unit 031/032
BP Indonesia –
Regeneration Gas Heater Operating & 920-PRC-OP-5133
Network Server
Maintenance Manual 031-VDR-KIR-1804
Heater Installation Manual 031-VDR-KIR-1803
Procedure Refractory and Lining
031-VDR-KIR-1962
Application
Procedure Coils Hydrostatic Test 031-VDR-KIR-1985
BP HSE Procedure, Aug. 2008 BP Tangguh 900-PRC-HS-2050 –
- Indonesia 900-PRC-HS-2254
Task Risk Assessment (23 July 2007) 900-PRC-HS-2170
Permit To Work Procedure (23 July 2007) 900-PRC-HS-2220
\\Bp1jktis001\BP
Energy Isolation – Process Procedure (23
900-PRC-HS-2223 INDONESIA\Tangg
July 2007)
uh Operations HSE
Energy Isolation – Electrical (23 July 2007) 900-PRC-HS-2224
Public\ 3.Procedures
Personal Protection Equipment (23 July
900-PRC-HS-2428
2008)
Waste Management Procedure (23 July
900-PRC-EN-2321
2007)
Integrated Asset Management System BP Indonesia –
(IAMS) Upstream Network
Generic Maintenance Strategy (GMS) and MAXIMO
Planned Maintenance Routines (PMRs) I030 (Planning, Job
Plans)
Page 5 of 17

January-2009
Unit: Furnace
6: CRITICAL TASKS
Table 6.1
The critical tasks for this element are listed in this table.
Task Measures
Locate Device Review Vendor Data
Understand the Potential Impact of

Review Relevant Information
Equipment Shut Down
Isolate Device Energy Isolation & Lock out Tag out
Service Device Inspect Device
Breaking containment ISSOW, SIRP
ESD override procedures, ISSOW,

Incorrect isolation of instrument
communication with MCR
Incorrect calibration Vendor maintenance manuals
MSDS each Chemical required Use proper PPE
Page 6 of 17

January-2009
Unit: Furnace
7: SECTIONS
1. IMPLEMENTATION OF MAINTENANCE PROCEDURES AND ADJUSTMENT
This section is about implementing maintenance procedures under conditions that

make work output complex to achieve in relation to a wide variety of interacting
factors. Activities will involve:
• Maintaining Mechanical Equipment that contains components of which a

significant number are fragile and/or where access for maintenance is
difficult
Refer to:
o Heater Installation Manual; Doc. No. 031-VDR-KIR-1803.
o Specification for Regeneration Gas Heater; Doc. No. 31-SPE-FU-
1475.
o BP LNG Tangguh HSE New Procedure ~ August 2008: 900-PRC-
HS-2050 ~ 900-PRC-HS-2254
o ISSOW; SIRP
• Following maintenance procedures that are complex and/or non-routine,
and being involved in determining the nature of maintenance to be
implemented. The maintenance procedure may be non-intrusive or call
for the dismantling and re-assembly of the equipment
Refer to:
See above
• Working in environmental conditions that might affect the
implementation of maintenance procedures e.g. at height, cold, in
confined spaces, noise, conflicting operations etc
Refer to:
See above
• Implementation of maintenance activities under operational and non-
operational conditions
Refer to:
See above
• Selecting different resources such as time, materials, equipment, support
facilities
Refer to:
See above
• Working under difficult conditions (instrument equipment, mainly fragile
components, environmental conditions, difficult access, need to modify
procedures)
Refer to:
See above
Page 7 of 17

January-2009
Unit: Furnace
7: SECTIONS (Cont’d)

(Cont’d)
• Using different techniques (threading, flanging, soldering, keying)
Refer to:
o Heater Operating and Maintenance Manual; Doc. No. 031-VDR-
KIR-1804, Section 6.
o Specification for Regeneration Gas Heater; Doc. No. 31-SPE-FU-
1475.
HS-2050 ~ 900-PRC-HS-2254
o ISSOW; SIRP; GMS (Generic Maintenance Strategy).
o IAMS (MAXIMO), Asset Registers
• Making adjustments under operational conditions; that require the
equipment to be made safe from any power sources; that require the
equipment to be taken out of operation
Refer to:
See above
• Making adjustments on equipment that fail to meet requirements due to
inconsistent performance outside agreed tolerances
Refer to:
See above
Page 8 of 17

January-2009
Unit: Furnace
7: SECTIONS (cont'd)
2. INTERROGATION AND FAULT FINDING SKILLS
This covers clarifying and diagnosing the cause and extent of faults in equipment.
Activities will involve:
• Working with a wide range of equipment

Refer to:
o Heater Operating and Maintenance Manual; Doc. No. 031-VDR-
KIR-1804.
o Procedure Refractory and lining Application; Doc. No. 031-VDR-
KIR-1962.
HS-2050 ~ 900-PRC-HS-2254
• Applying diagnostic procedures which are either specified or devised in
response to the fault
Refer to:
See above
• Diagnosing problems that arise from differing factors
Refer to:
See above
• Dealing with both qualitative and quantitative information from different
sources i.e. people, records or output from the equipment
Refer to:
See above
• Dealing with different problems such as, breakdown, performance out
with specification or deteriorating conditions
Refer to:
See above
• Dealing with different causes such as, problems inherent in the
equipment, effects of environmental conditions, human error or problems
with materials.
Refer to:
See above
Page 9 of 17

January-2009
Unit: Furnace
3. INSPECT, REPAIR SYSTEMS FOR RESTORATION TO REQUIRED

PERFORMANCE
This section covers repairing equipment components. It requires assessing the
feasibility of carrying out repair work, and then carrying out the work to meet
specifications. Discretion needs to be used to select and modify techniques to achieve
the best possible result. Simple and complex repairs may be necessary, on both fragile
and robust components. Time and cost constraints must be met.
• For details on inspecting and repairing systems for restoration to required

performance,
Refer to:
• Heater Operating and Maintenance Manual; Doc. No. 031-VDR-KIR-1804.
• Specification for Regeneration Gas Heater; Doc. No. 31-SPE-FU-1475.
• Procedure Refractory and Lining Application; Doc. No. 031-VDR-KIR-1962.
• Regeneration Gas Heater Maintenance; Doc. No. 920-PRC-OP-5133.
• BP LNG Tangguh HSE New Procedure – August 2008: 900-PRC-HS-2050 –
900-PRC-HS-2254
• ISSOWM; SIRP; GMS (Generic Maintenance Strategy)
• IAMS (MAXIMO), Asset Registers
Page 10 of 17

January-2009
Unit: Furnace
4. RETURN EQUIPMENT TO SERVICE BY COMPONENT REMOVAL AND

REPLACEMENT
This section covers removing and replacing components from equipment resulting
from breakdown conditions, other problems identified during planned maintenance or
from performance/condition evaluations. There is a requirement to work within
detailed specifications, using non-standard techniques and activities only where the
situation is complex i.e. due to factors such as difficulties in gaining access to plant
and equipment, weather and environmental conditions, and working alongside other
operations.
• Working with both robust and fragile components

Refer to:
o Heater Operating and Maintenance Manual; Doc. No. 031-VDR-KIR-
1804
o Procedure Refractory and Lining Application; Doc. No. 031-VDR-KIR-
1962.
o Regeneration Gas Heater Maintenance; Doc. No. 920-PRC-OP-5133..
o BP LNG Tangguh HSE New Procedure ~ August 2008: 900-PRC-HS-
2050 ~ 900-PRC-HS-2254
• Removing and replacing components in both simple and complex
situations
Refer to:
See above
• Using a variety of different techniques and procedures that are relevant to
the equipment on which work is being done.
Refer to:
See above
• Working in situations where there may be easy or difficult access to the
component.
Refer to:
See above
Page 11 of 17

January-2009
Unit: Furnace
7: SECTIONS (Cont'd)

REPLACEMENT (Cont'd)
• Simple and complex removals of components
Refer to:
1804
o Procedure Refractory and Lining Application; Doc. No. 031-VDR-
KIR-1962.
o Regeneration Gas Heater Maintenance; Doc. No. 920-PRC-OP-5133.
2050 ~ 900-PRC-HS-2254
• Removal of components where there is easy and difficult access
Refer to:
See above
• Removals where there are hazards to people and to existing structures in the
area
Refer to:
See above
• Removal of both robust and fragile components
Refer to:
See above
• Simple and complex replacement of components
Refer to:
See above
• Replacement of components where there is easy and difficult access
Refer to:
See above
Page 12 of 17

January-2009
Unit: Furnace
7: SECTIONS (Cont'd)

REPLACEMENT (Cont'd)
• Replacement of both robust and fragile components
Refer to:
1804.
o Procedure Refractory and Lining Application; Doc. No. 031-VDR-
KIR-1962.
2050 ~ 900-PRC-HS-2254
• Simple and complex replacement of components
Refer to:
See above
• Replacement of components where there is easy and difficult access
Refer to:
See above
All replacement parts must be manufacturer approved. For details of the
parts numbers and any special tools, refer to specific vendor documents
Page 13 of 17

January-2009
Unit: Furnace
5. MONITOR AND ASSESS THE PERFORMANCE AND CONDITION OF

EQUIPMENT
This covers monitoring and assessing the performance and condition of complex
equipment, over a period of time. Discretion needs to be used to select and modify
methods in order to optimize the effectiveness of the monitoring and assessment
process in the existing conditions.
• Working with equipment that is multiple technologies i.e. having
instrument components or single technology interacting with other assets
in a dynamic manner.
Refer to:
1804
1962.
2050 ~ 900-PRC-HS-2254.
• Monitoring in conditions made difficult due to access problems,
disruption to the monitoring process, unusual hazards present or non-
standard demands being placed upon the operation of the equipment.
Refer to:
See above
• Using monitoring methods that might use computer software.
Refer to:
See above
• Use of each different monitoring method i.e. inspection, checking
documentary information and taking instrument readings
Refer to:
See above
• Operating in both normal and abnormal environments
Refer to:
See above
• Production of written and form-based records
Refer to:
See above
• Obtaining data from inspection records, instrument readings,
documentation and reports
Refer to:
See above
Page 14 of 17

January-2009
Unit: Furnace
5. MONITOR AND ASSESS THE PERFORMANCE AND CONDITION OF

EQUIPMENT
• Assessments covering routine and non-routine performance and condition
under normal and abnormal operating arrangements.
Refer to:
1804.
1962.
2050 ~ 900-PRC-HS-2254.
• Using assessment methods to identify current performance and condition,
and to forecast and look for changes in future performance and condition.
Refer to:
See above
Page 15 of 17

January-2009
Unit: Furnace
8: SELF ASSESSMENT QUESTIONS
1. Q What level of authority is required to carry out isolations?

A Designated Person in Charge… See Permit To Work Procedure;
Doc. No. 900-PRC-HS-2220
2. Q What procedural controls must be in place before commencement
of work?
A Energy Isolation & Lock out Tag out, Permit To Work, TRA; Doc.
No. 900-PRC-HS-2223/2226/2220/2170.
2. INTERROGATION AND FAULT FINDING SKILLS
1. Q What is possible cause of extreme temperature of Radiant Tube?

A See Operation and Maintenance Manual for Air/Gas heater Doc.
No. 031-VDR-KIR-1804 Page 15.
2. Q When and why Refractory Lining should be inspected?
A See Operation and Maintenance Manual for Air/Gas heater Doc.
No. 031-VDR-KIR-1804. Page 16.
3. INSPECT, REPAIR SYSTEMS FOR RESTORATION TO REQUIRED PERFORMANCE
1. Q What items are to be inspected during 4 years periodical inspection

on Air/Gas Heater?
A See Operation and Maintenance Manual for Air/Gas heater Doc. No.
031-VDR-KIR-1804 Page 15-17.
2. Q How to clean Radiant Coil and Tube of Air/Gas Heater?

A See Operation and Maintenance Manual for Air/Gas heater Doc. No.
031-VDR-KIR-1804 Page 15.
3. Q Explain how to conduct Hydrostatic Test on Radiant Coil of Air/Gas

Heater?
A See Procedure Coils Hydrostatic Test Doc. No. 031-VDR-KIR-1985
page 113-119.
4. Q What is Audio Inspection/Hammer Test? Explain how to conduct

Hammer Test on Refractory Lining of Air/Gas Heater?
A See Procedure Refractory and Lining Application Doc. No. 031-
VDR-KIR-1962 sheet 13.
Page 16 of 17

January-2009
Unit: Furnace
8: SELF ASSESSMENT QUESTIONS (cont’d)
4. RETURN TO SERVICE BY COMPONENT REMOVAL AND REPLACEMENT
1. Q Who give authorization for equipment to be returned to service?

A See designated Person in Charge as per Permit To Work
Procedure; Doc. No. 900-PRC-HS-2220.
2. Q Before unit return to service, what maintenance activities are to be
carried out?
A See Operation Manual for Dehydration unit 031/032 Doc No 031-
IOM-PS1201-6B, Section 9.4 page 31.
5. MONITOR AND ASSESS THE PERFORMANCE AND CONDITION OF EQUIPMENT
1. Q Where would you locate the work history for this equipment?
A See MAXIMO
Page 17 of 17

January-2009

Train to Maintain Regeneration Gas Heater

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CMAS Training Plan

Training and subsequent assessment will include all applicable standards of

Use of this Training Plan:

Prepared By: Tangguh LNG MD (DdS / US)

The boundaries encompassed by this plan:

Commence at the Inlet Gas Flanges

and end at the Outlet Gas Flanges

PAPER COPIES ARE UNCONTROLLED

PAPER COPIES ARE UNCONTROLLED

Regeneration Gas Heater (031/032-F-1001)

PAPER COPIES ARE UNCONTROLLED

Documentation for this element is:

Document Title Document No. Location

PAPER COPIES ARE UNCONTROLLED

Locate Device Review Vendor Data

Understand the Potential Impact of

Isolate Device Energy Isolation & Lock out Tag out

Service Device Inspect Device

Breaking containment ISSOW, SIRP

ESD override procedures, ISSOW,

Incorrect calibration Vendor maintenance manuals

MSDS each Chemical required Use proper PPE

PAPER COPIES ARE UNCONTROLLED

1. IMPLEMENTATION OF MAINTENANCE PROCEDURES AND ADJUSTMENT

This section is about implementing maintenance procedures under conditions that

• Maintaining Mechanical Equipment that contains components of which a

PAPER COPIES ARE UNCONTROLLED

1. IMPLEMENTATION OF MAINTENANCE PROCEDURES AND ADJUSTMENT

PAPER COPIES ARE UNCONTROLLED

2. INTERROGATION AND FAULT FINDING SKILLS

• Working with a wide range of equipment

PAPER COPIES ARE UNCONTROLLED

3. INSPECT, REPAIR SYSTEMS FOR RESTORATION TO REQUIRED

• For details on inspecting and repairing systems for restoration to required

PAPER COPIES ARE UNCONTROLLED

4. RETURN EQUIPMENT TO SERVICE BY COMPONENT REMOVAL AND

• Working with both robust and fragile components

PAPER COPIES ARE UNCONTROLLED

4. RETURN EQUIPMENT TO SERVICE BY COMPONENT REMOVAL AND

PAPER COPIES ARE UNCONTROLLED

4. RETURN EQUIPMENT TO SERVICE BY COMPONENT REMOVAL AND

PAPER COPIES ARE UNCONTROLLED

5. MONITOR AND ASSESS THE PERFORMANCE AND CONDITION OF

PAPER COPIES ARE UNCONTROLLED

5. MONITOR AND ASSESS THE PERFORMANCE AND CONDITION OF

PAPER COPIES ARE UNCONTROLLED

8: SELF ASSESSMENT QUESTIONS

1. IMPLEMENTATION OF MAINTENANCE PROCEDURES AND ADJUSTMENT

1. Q What level of authority is required to carry out isolations?

2. INTERROGATION AND FAULT FINDING SKILLS

1. Q What is possible cause of extreme temperature of Radiant Tube?

3. INSPECT, REPAIR SYSTEMS FOR RESTORATION TO REQUIRED PERFORMANCE

1. Q What items are to be inspected during 4 years periodical inspection

2. Q How to clean Radiant Coil and Tube of Air/Gas Heater?

3. Q Explain how to conduct Hydrostatic Test on Radiant Coil of Air/Gas

4. Q What is Audio Inspection/Hammer Test? Explain how to conduct

PAPER COPIES ARE UNCONTROLLED

8: SELF ASSESSMENT QUESTIONS (cont’d)

4. RETURN TO SERVICE BY COMPONENT REMOVAL AND REPLACEMENT

1. Q Who give authorization for equipment to be returned to service?

5. MONITOR AND ASSESS THE PERFORMANCE AND CONDITION OF EQUIPMENT

PAPER COPIES ARE UNCONTROLLED