Professional Documents
Culture Documents
6A
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PT. Brown & Root Indonesia
BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 2 of 23
CONTENTS
1. Introduction.................................................................................................................................4
2. Basis of Design.............................................................................................................................4
2.1 General.........................................................................................................................................4
2.2 Design Margin .............................................................................................................................4
2.3 Design Condition.........................................................................................................................4
2.4 Special Equipment ......................................................................................................................5
2.4.1 CONDENSATE STABILIZER COLUMN (011-T-1001A/B) ............................................................. 5
2.4.2 CONDENSATE STABILIZER REBOILER (011-E-1001A/B)............................................................ 5
2.4.3 CONDENSATE PRODUCT COOLER (011-E-1002) ........................................................................ 5
2.5 Process Description .....................................................................................................................5
3. Process Controls..........................................................................................................................6
3.1 Pressure........................................................................................................................................6
3.2 Temperature................................................................................................................................6
3.3 Level .............................................................................................................................................7
4. Preparation for initial start-up ..................................................................................................7
5. Normal Start-up Procedure .......................................................................................................8
5.1 General.........................................................................................................................................8
5.2 Start up of Condensate Stabilization Unit ................................................................................8
5.2.1 START UP OF STABILIZER REBOILER (011-E-1001A/B) ............................................................. 8
5.2.2 START UP OF CONDENSATE STABILIZER COLUMN (011-T-1001A/B) ........................................ 9
6. Normal Operation.....................................................................................................................10
6.1 Condensate Stabilization Unit..................................................................................................10
6.2 Removing Accumulated Water on Trays................................................................................10
7. Normal Shutdown Procedure ..................................................................................................11
7.1 Condensate Stabilizer Switching Operation ...........................................................................11
7.2 Condensate Product Cooler Shut down ..................................................................................13
8. Emergency Shutdown Procedure ............................................................................................14
8.1 General.......................................................................................................................................14
8.2 Loss of Utilities ..........................................................................................................................14
8.2.1 POWER FAILURE ....................................................................................................................... 14
8.2.2 INSTRUMENT AIR FAILURE....................................................................................................... 14
8.2.3 STEAM FAILURE ....................................................................................................................... 14
9. Safety Procedure .......................................................................................................................14
9.1 General.......................................................................................................................................14
9.2 Emergency Fire Plan ................................................................................................................15
9.3 Fire Fighting and Protective Equipment ................................................................................15
9.4 Maintenance of Equipment and Housekeeping......................................................................16
9.5 Repair Work..............................................................................................................................16
9.6 Withdrawal of Samples ............................................................................................................17
9.7 Safe Handling of Volatile and Toxic Materials ......................................................................17
9.8 Respiratory Protection .............................................................................................................17
9.9 Breathing Apparatus (B. A.) ....................................................................................................18
9.9.1 NITROGEN ................................................................................................................................ 18
9.9.2 CORROSIVE MATERIALS........................................................................................................... 18
10. Isolation Procedure for Maintenance......................................................................................18
10.1 General ......................................................................................................................................18
10.2 Basic Procedures.......................................................................................................................19
10.2.1 TRAIN ISOLATION .................................................................................................................... 19
10.2.2 INDIVIDUAL EQUIPMENT / SYSTEM ISOLATION........................................................................ 19
Vertical Pressure Vessels (Column with Reboiler).......................................................................... 19
11. Maintenance Procedure............................................................................................................20
11.1 General ......................................................................................................................................20
11.1.1 ROUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 20
11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 20
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BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 4 of 23
1. INTRODUCTION
The purpose of the Condensate Stabilization Unit (Unit 011) is to stabilize hydrocarbon condensate
from Onshore Receiving Facility (Unit 016) and Dehydration and Mercury Removal (Unit 031) to
meet the product specification, such as Reid Vapor Pressure (Max. 0.77 kg/cm2A@37.8°C) and also
butane content (0.5 % liquid volume max.). Total 30 ton/h condensate is produced .
The Condensate Stabilization Unit is designed for two LNG trains capacity. The Condensate
Stabilization Unit consists of two columns and their associated equipment ( as spare) to prevent plant
shutdown during maintenance of this unit.
Feed to the unit is condensate from ORF (Unit 016) and Dehydration and Mercury Removal Unit
(Unit 031/032). Feed to the column is two-phase flow.
Condensate Stabilization Unit also produces flash gas with high methane content (75-%mol). The
flash gas from the overhead line of Stabilizer Column is sent to LP Fuel Gas System for further
treatment.
Refer to Process Flow Diagrams Unit 011 Condensate Stabilization, drawings no:
11-PFD-PS-1150/1151/1152/1153 (D-011-1223-101/102/103/104).
2. BASIS OF DESIGN
2.1 General
Please refer to S-900-1220-001 for general design data.
The Condensate Stabilization Unit is designed for two LNG Trains capacity.
The Condensate Stabilization (Unit 011) consists of:
- Condensate Stabilizer Column (011-T-1001A/B)
- Condensate Stabilizer Reboiler (011-E-1001A/B)
- Condensate Product Cooler (011-E-1002)
- Water Draw-off Drum (011-D-1002A/B)
- Product specification:
The specifications of condensate product after Condensate Product Cooler are:
¾ RVP @ 37.8oC (100oF) : 0.77 kg/cm2A (10.95 psia)
¾ Max butane content : 0.5 %-liquid volume.
- Operating Condition:
Unit 011 is part of ORF liquid phase treatment. Unit 011 operating condition depends
on ORF arrival feed gas condition as follows (Please refer to 16-IOM-PS-1201 Section
2.3.1): There are four operating conditions that depend on ORF (Unit 016) feed gas
condition:
¾ 50oC, 62.55 kg/cm2A
¾ 26oC, 62.55 kg/cm2A
¾ 74oC, 62.55 kg/cm2A
¾ 26oC, 102.98 kg/cm2A
The ORF feed gas condition of 50oC, 62.55 kg/cm2A is expected as normal operating
condition.
In the Stabilizer Reboiler, liquid is heated and partially vaporized by HP saturated steam. The vapor is
returned back to the column under the chimney tray and passes back up the column. During passing
the trays, returned vapor is stripping the lighter components from the liquid flowing down the
column.
In the reboiler, the saturated liquid is in equilibrium with the vapor. The overflow liquid is returned
back to the bottom of the column as condensate product.
The Stabilizer Columns (011-T-1001A/B) operate at 6 kg/cm2G 7.03 kg/cm2A under pressure
control. The hydrocarbon vapor from the top of the 011-T-1001A/B is sent to the LP Fuel Gas System
without cooling since the temperature of this vapor is about 38 °C.
To meet the product specification, the temperature of the liquid hydrocarbon is controlled with a
TC-FC cascade control of steam supply line.
The high pressure saturated steam (HPSAT) (38 kg/cm2A) is utilized as a heating medium. HP SAT
is generated prior to Stabilizer Reboilers (011-E-1001A/B) entering. Boiler feed water is injected in
011-DPH-1001 and mixed with superheated HP steam to produce high pressure saturated steam.
The steam condensate flow returned to HP Steam Condensate KO Drum (052-D-1104 and
051-D-1104) on each LNG train. The returned steam condensate flow is maintained by individual
LC-FC cascade control. During two LNG trains operation, the steam condensate flow to each train is
maintained evenly.
The stabilized condensate product from the bottom of 011-T-1001A/B flows to the Condensate
Product Cooler (011-E-1002) under level control to cool down its temperature to 40oC. At the initial
stage of Unit 011 start up, off-spec condensate product is expected. The condensate quality is
monitored by online RVP Analyzer 090-AI-1801. When RVP is high, it means off-spec
condensate is produced, Tthe off-spec condensate product shall be routed to wet flare.
After the stabilized product condensate is cooled down to around 40°C by 011-E-1002, it is combined
with the hydrocarbon condensate product from the Debutanizer bottom in the Fractionation Unit
(Unit 041/042). The combined condensate product is sent to and stored in the Condensate Storage
Tank (076-TK-1001).
Water accumulation is expected on tray during operation. Top section trays have higher possibility of
water accumulation because of lower operating temperature. The accumulated water shall be
removed by using water draw off facilities (on the 3 top trays). The oily water to be collected in the
water draw off drums (011-D-1002A/B) shall be sent to Wet Flare KO Drum (086-D-1002).
3. PROCESS CONTROLS
_ __ medium. The TC (Column temperature)-FC (steam flow) cascades are selected to control Stabilizer
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Operation Manual for Condensate Stabilization Unit Sheet No. 7 of 23
Reboiler temperature by controlling steam supply to Stabilizer Reboiler. Split range controller is
adopted applied because of wide operating range of heat duty.
011-FV-2710A/B, located on the HP steam supply line to Stabilizer Reboiler A (011-E-1001A),
controls the various HP steam flow demand from turndown operation in one LNG train to slug
flow handling in two LNG trains operation. When the HP steam flow is less than 20% of design
flowrate, 011-FV-2710B controls small amount of flowrate. When HP steam flowrate is
between 20% and 100%, 011-FV-2710A control the steam flowrate, while 011-FV-2710B is in
fully open. 011-FV-2710A/B, located on the HP steam supply line to Stabilizer Reboiler B
(011-E-1001B) is also used in the same manner as a completely spare stabilizer.
There are three locations (for each stabilizer) for temperature transmitter, which are:
- Stabilizer Tray #8 :011-TE-1471/1342
- Stabilizer vapor return line : 011-TE-1304/1334
- Stabilizer liquid return line : 011-TE-2710/1341
The criteria to select most sensitive temperature are as follow:
1. During Stabilizer Column start up, heat duty is increased in accordance with feed flowrate,
therefore 011-TETIC-1471/1342 to be selected.
2. During steady operation, 011-TIC-2710/1341 to be selected.
3. Urgently on spec production is required during Stabilizer Column upset condition,
011-TI-1303/1333 or 011-TIC-1304/1334 to be selected.
The temperature transmitters selection shall use 011-HS-1501 for Condensate Stabilizer A and
011-HS-1521 for Condensate Stabilzier B.
The HC condensate from Stabilizer Column (011-T-1001A/B) is cooled down to around 40oC
by Condensate Product Cooler (011-E-1002). The condensate product temperature is
monitored by 011-TI-9301. The lower temperature of HC condensate is safer for handling and
storage. Therefore all fin fan motors of Condensate Product Cooler (011-E-1002) should be
always in operation When temperature is higher than 50oC, the operator has to investigate
011-E-1002 to eliminate the high temperature cause.
3.3 Level
Stabilization unit has no pump to transfer condensate to Condensate sStorage tTank (076-TK-1001).
011-LV-1101 controls liquid level in 011-T-1001A/B. When level decrease to LLL, 011-LV-1001
will close, to prevent vapor breakthrough to downstream facilities.
The liquid level in 011 D-1001A/B is controlled by LC-FC cascade control of 011-FV-1011A/B and
011-FV-1031A/B respectively. The steam condensate flow distribution to LNG train is set by
011-HIC-1011 by adjusting “α” parameter. The “α” parameter shall be set as follow:
- When two LNG trains operate, the set point α shall be set to 0.5 to distribute steam
condensate evenly to both HP Steam Condensate Drums (051-D-1104 and 052-D-1104)
- When only LNG Train#1 operates, α shall be set to 1.0.
- When only LNG Train#2 operates, α shall be set to 0.0
- Inerting Operation
- Mechanical Run-in Procedure
- Safety Requirement
For the detail preparation for smooth initial start-up, Rrefer to Commissioning Procedure
(11-PRC-OP-1001).
5.1 General
Check points are as follows:
(1) All equipment including instrument, etc. is ready for use.
(2) Electric power is available.
(3) All blinds or spectacle blinds except for Battery Limit have been placed in operation position.
(4) Ensure all vents, drains, and sample connections are closed.
(5) All safety equipment must be properly installed on site, calibrated and operable.
After all the above checkpoints have been checked, start-up can be proceeded. Start up check list
should be provided and signed by concerned operator.
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BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 9 of 23
a.Check the Stabilizer Reboiler temperature. When temperature reached the normal operating
temperature, the condensate feed can be introduced into Stabilizer.
c. Once warm-up operation of HP steam condensate return line to Condensate Flash Drum
(051-D-1104) is completed, the reboiler and associated piping temperature should be
maintained by manipulating the appropriate set point of 011-FV-2710B and
011-FV-1011A until the feed is introduced to Condensate Stabilizer A (011-T-1001A).
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BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 10 of 23
(5) When temperature, pressure and level of 011-T-1001A are in normal condition, line up the
overhead gas product to LP fuel gas system. Open the block valve located downstream of
011-USVE-2060 and then close gradually the 3” line to wet flare (011-GF-1102).
(6) Check the condensate product specification by sampling check (011-SCA-1002) located
around 011-LV-1101. When on-spec condensate is produced, line up the bottom product to
cCondensate sStorage tTank (076-TK-1001) by opening the block valve located downstream of
011-USVE-2070 and close the 4” line to wet flare (011-GH-1705).
6. NORMAL OPERATION
Methane content
ORF Feed Condition
(%-mol)
50oC;62.55 kg/cm2A 75
26oC;62.55 kg/cm2A 67
74oC;62.55 kg/cm2A 74
26oC;102.98 kg/cm2A 70
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BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 11 of 23
Water is disposed to wet flare KO drum and finally water is treated in the water disposal system
(CPI Separator 087-V-1001), without further analysis. The purpose of water draw- off is only to
check and remove the accumulated water on trays. Water quality is not a concern.
Operating temperature of top tray section is low (around 38oC). The isolation is not required during
water draw off operation.
GH-1004 LO
From ORF A
To 011-T-1001A
LC
B To 011-T-1001B
E F
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Operation Manual for Condensate Stabilization Unit Sheet No. 12 of 23
7. The main bottom liquid line of 011-T-1001B is still blocked. LC 4” valve on the overhead line
(011-GF-1715) shall be opened to discharge the excess vapor to LP fuel gas system..
8. When reboiler temperature is normal, auto control in 011-T-1001B. Then, open the 6” block valve
on the bottom product line allowing the levels in the two columns to be equalized.
9. Monitor the bottom temperature in 011-T-1001B to ensure the bottoms product is still on spec. At
this time, both column levels will be controlled from 011-T-1001A level controller
(011-LIC-1101A).
10. After globe valve (Valve F) is fully open, the main feed valve (Valve B) to 011-T-1001B can be
opened fully (See Fig. 7.1-2). At this time, both columns are sharing the load. Continue to monitor
both columns to ensure that temperatures and pressures shall remain at normal operating condition.
GH-1001
C D
GH-1004 LO
LO
B To 011-T-1001B
E F
11. While main feed line valve (Valve A) to 011-T-1001A is still in fully open, open the bypass
block valve (Valve C) and then followed by globe valve (Valve D) fully open. (See Fig 7.1-3)
GH-1001
C D
GH-1004 LO
LO
B To 011-T-1001B
E F
12. Once the bypass valves in 011-T-1001A are fully open, using the key interlock system between
the block valves, Valve A and Valve B, on the main feed lines to Columns A&B. Close Valve A
on the main feed line to 011-T-1001A. This condition means that the feed flow could be changed
to 011-T-1001B from 011-T-1001A. (See Fig 7.1-4)
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KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 13 of 23
GH-1004 LC
From ORF A
To 011-T-1001A
LO
B To 011-T-1001B
E F
13. Gradually close the globe valve (Valve D) until fully closed and then close bypass block valve
(Valve C) (See Fig. 7.1-5). Monitor the temperature in 011-T-1001A as the feed is removed.
GH-1004 LC
LO
B To 011-T-1001B
14. Valve C and Valve D are fully closed. Once the feed to 011-T-1001A is stopped, then change the
level controller from 011-T-1001A to 011 T-1001B in 011-HS-1522. dDecrease the level in
both columns, by decreasing the set point of the level control in 011-T-1001B until the liquid in
both columns reach low level.
GH-1001 C D
GH-1004 LC
LO
B To 011-T-1001B
E F
15. The bottom line of 011-T-1001A is blocked and stop steam supply to Stabilzier Reboiler A
(011-E-1001A). The condensate products in 011-T-1001A left until cool down. 011-T-1001A is
isolated and then cooled condensate shall be drained out to wet flare KO drum through permanent
HC liquid drain line. Vacuum conditions must be avoided during isolation and draining.
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KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 14 of 23
Close the 3” block valves on inlet and then outlet of each tube bundle. Open the 2” line to wet flare
and liquid drain to reduce the pressure before tube maintenance.
8.1 General
This section describes the guidelines of shutdown procedure in case of emergencies. However, in
emergencies, required actions by operators may vary because they depend on the actual situation at
the time of emergency. Therefore, it is most important for the operators to determine the cause of
emergency accurately and to understand the exact situation.
Unit 011 and 016 shutdown shall be proceeded at the same time, because Unit 011 is one of the liquid
treatment facility for ORF. Unit 011 shutdown is initiated by 016-HS-2000A. After isolation
completed, Unit 011 can be depressurized by opening line to wet (located on 011-USVE-2060
upstream).
Refer to Unit 016 Emergency Shutdown for unit isolation (Doc. No 16-IOM-PS-1201 Sec 8)
9. SAFETY PROCEDURE
9.1 General
To prevent accidents it is of the utmost importance that all personnel be instructed properly of the
following subject:
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BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 15 of 23
The following safety regulations cover operations of particular concern to the personnel responsible
for the unit. They are intended to supplement any existing general plant safety regulations which
cover all units; reference should be made to the latter for all points not mentioned below. Mechanical
craftsmen working on their unit will be governed by their own departmental safety regulations, but
the operator should see that none of the following safety regulations are violated by mechanical
workers.
In addition to specifically defined rules and practices, the exercise of good judgment by every person
involved is essential to safe operation. An operator should be alert for any situation which might
present a personnel hazard. It should also be the responsibility of each person familiar with the plant
to warn other workers who enter the plant of possible hazards they could encounter.
All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, and
main isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other
protective equipment such as hard hats, rubber gloves, etc.
Soda acid or foam type extinguisher must not be used on fire around electrical equipment because the
water solution will conduct electricity and may aggravate the difficulty or result in the electrocution
of personnel.
Carbon dioxide or dry powder extinguisher may be used safety on electrical fires.
Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered.
Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid is
encountered, and are recommended for use while samples are being withdrawn and solutions made
up.
Fire extinguishers must be recharged immediately after use. All stream and water hose equipment
must be put back in place after use. Access to such equipment must not be obstructed.
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Operation Manual for Condensate Stabilization Unit Sheet No. 16 of 23
Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall
be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat
radiation.
For the detail, refer to 82-SPE-HS-1540 (S-082-1241-019), “Operation Manual for Fire Protection
System” and the relevant drawings for fire protection system.
_ __ 9. Welding cylinders should be removed from site to a designate safe area at the end of each
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Operation Manual for Condensate Stabilization Unit Sheet No. 17 of 23
working day.
Secure a gas test certificate showing the gas condition of the vessel is safe for entry.
Stand on the windward side of an operating from which gases escape.
Provide proper ventilation.
All personnel should become familiar with the accepted method of artificial respiration in order
to render assistance to any one overcome by gas, electric shock, or drowning.
When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approved
_ __ test method.
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Operation Manual for Condensate Stabilization Unit Sheet No. 18 of 23
Wear the correct type of breathing apparatus, suited to the situation encountered.
The compressed air self-contained breathing apparatus has a self-contained air supply carried on the
back of the user.
It is used principally in emergencies.
After use, always notify the proper department so that they can recharge the cylinders as soon as
possible.
9.9.1 Nitrogen
N2 is an inert gas used for purging equipment or maintaining a positive pressure inert gas blanket on a
vessel.
N2 is neither poisonous nor flammable, but care must be exercised when working inside equipment
that has been N2 purged. Adequate ventilation must be provided and appropriate breathing device
worn. To breathe an atmosphere high in N2, could result in suffocation.
Before entering vessels that have been purged with N2, a check must be made for proper oxygen
content prior to entry. Rapid vaporization of liquid nitrogen can cause severe burns on contact with
the skin.
This section describes the isolation procedures to be taken prior to maintenance work based on the
following specification:
Maintainability Philosophy (99-PHI-EM-0005)
Availability and Sparing Philosophy (99-PHI-PS-0002)
10.1 General
It is necessary to isolate trains, items of equipment, or groups of equipment, in order to facilitate
shutdown for maintenance, inspection, tie-ins, or loss prevention.
As the degree of hazard increases, the measure of protection required must be deeply considered. The
degree of hazard is related to the system contents (e.g. flammability, toxicity etc.), pressure and
temperature. There are two main methods of isolation which can be used:
Positive isolation incorporating the use of spades/spectacle blinds or removable spools and blind
flanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entry
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Operation Manual for Condensate Stabilization Unit Sheet No. 19 of 23
Valved isolation for less critical duties than those requiring positive isolation, e.g. for control valve
maintenance. Confirm that drains and vents valve are open check that isolation valves are not passing.
Valved isolation will also be required to enable positive isolation to be installed or removed without
the need for a complete plant shutdown.
Figure 10.2.2-1
Column with Reboiler
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Operation Manual for Condensate Stabilization Unit Sheet No. 20 of 23
11.1 General
INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT
AIR FOR BREATHING APPARATUS.
Note 1
Due to the inherent dynamics associated with in-service air fin exchangers over an extended
period, there exists the potential for increased leak frequencies, particularly at flange joints
due to vibration.
_ __ usually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting of
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Operation Manual for Condensate Stabilization Unit Sheet No. 21 of 23
safety valves, and inspections and repairs of equipment that cannot be shutdown or removed during
Production.
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Operation Manual for Condensate Stabilization Unit Sheet No. 22 of 23
• Any combustible material (plastics, paper, woods etc.) must be removed from the heated
system to prevent possible external fire.
• Steam is hazardous service, due to not only temperature and pressure considerations, but
also cause of possible mechanical damage by liquid vaporization or water hammering,
when steam is fed into cold service. Therefore, introduction of steam must be done slowly
and carefully.
• Safety Awareness Program to be implemented by Safety team before the steam out
commences. It should focus on the danger of steam line and heated system, burns etc.
• Toolbox shall be provided in field for required activities and safety measures.
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BP Berau Ltd. Tangguh LNG Project Doc. No. 11-IOM-PS-1201
KJP Doc. No. S-011-1283-001 Rev. 6A
Operation Manual for Condensate Stabilization Unit Sheet No. 23 of 23
Attachment-2 P&IDs
11-PID-PS-1151
11-PID-PS-1152
11-PID-PS-1153
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