Fuel Gas Syastem Op Manual Compress

Operating Manual Section No.8.
1 Fuel Gas System Rev 02

OPERATING MANUAL
SECTION 8.1
FUEL GAS SYSTEM
SIRTE OIL COMPANY

ATTAHADDY GAS FIELD
02 2003-28- FOR S. D. Y..S. DEVELOPMENT PROJECT
08 APPROVAL K
01 2003-23- FOR S. D. Y..S.
06 APPROVAL K
0 2003-05- FOR REVIEW S. D. Y..S. Document Discipline No. Rev.
31 K
REV DATE DESCRIPTION CKD APP SO MM OP 0002 02
C
Operating Manual Section No.8.1 Fuel Gas System Rev 02
Rev A 01 02 03 04 05 Rev A 01 02 03 04 05
Page Page
All X X X
P&ID- X
C2-184
P&ID- X
C2-801
P&ID- X
FL-9001
X-4101- X
12
X-4101- X
13
X-4101- X
14
X-4101- X
15
02 2003-08-28 For Approval B. MOGA Y.I.SUNG Y.S.KWON

01 2003-06-23 For Approval M. LESANU D.STEPHEN Y.S.KWON
0 2003-05-31 For Review M. LESANU D.STEPHEN Y.S.KWON
Rev Date Issue By Checked Approved
8.1 Fuel Gas System Page 1 of 111

CONTENTS
FLOW PLAN ABBREVIATION TABLE.............................................................................................3
COLOUR CODING..............................................................................................................................10
1. GENERAL DESCRIPTION.........................................................................................................13
A. INTRODUCTION.................................................................................................................13
B. DUTY OF UNIT....................................................................................................................13
C. DESCRIPTION OF THE FLOW........................................................................................14
D. DESIGN BASIS.....................................................................................................................15
E. UTILITIES AND CHEMICALS – DESIGN BASIS.........................................................17
2. OPERATING CONDITIONS AND CONTROLS......................................................................20

A. FUEL GAS SUPER HEATER (E-6401 A/B)......................................................................20
B. FUEL GAS SCRUBBER (D-6401).......................................................................................21
C. LP FUEL GAS HEADER.....................................................................................................21
D. HP FUEL GAS HEADER.....................................................................................................22
E. BLANKET / PILOT / PURGE GAS HEADER.................................................................23
3. EMERGENCY EQUIPMENT.....................................................................................................26
A. GENERAL.............................................................................................................................26
B. SHUTDOWN VALVES.........................................................................................................26
C. EMERGENCY BLOWDOWN VALVES............................................................................27
D. PRESSURE RELIEF VALVES............................................................................................27
E. EMERGENCY ALARMS....................................................................................................28
F. CAR SEALED VALVES.......................................................................................................29
4. PREPARING UNIT FOR INITIAL START-UP.........................................................................31

A. GENERAL.............................................................................................................................31
B. PRE START-UP PROCEDURES........................................................................................31
C. SHUTDOWN VALVES, PRESSURE CONTROL VALVES, HAND CONTROL
VALVES AND PRESSURE SAFETY VALVES..........................................................................53
D. EMERGENCY SHUT DOWN SYSTEM...........................................................................55
5. START-UP......................................................................................................................................57
A. GENERAL.............................................................................................................................57
B. PRELIMINARY CHECKS..................................................................................................57
C. LINING UP OF FUEL GAS SYSTEM................................................................................59

6. NORMAL SHUTDOWN..............................................................................................................65
A. GENERAL.............................................................................................................................65
B. SCHEDULED SHUTDOWN FOR SHORT DURATION................................................65
C. SHUTDOWN FOR MAINTENANCE................................................................................65
7. EMERGENCY SHUTDOWN.......................................................................................................68
A. GENERAL.............................................................................................................................68
B. UTILITY FAILURE.............................................................................................................68
C. OTHER FAILURES.............................................................................................................70
8. MAJOR EQUIPMENT.................................................................................................................72
A. SPECIFICATIONS OF EQUIPMENT...............................................................................72
B. INSTRUMENT SUMMARY................................................................................................76
9. DRAWINGS.......................................................................................................................................95
10. SAFETY.........................................................................................................................................97
A. GENERAL.............................................................................................................................97
B. GOOD HOUSE KEEPING..................................................................................................98
C. MAINTENANCE OF EQUIPMENT..................................................................................98
D. USE OF SAFETY EQUIPMENT........................................................................................98
E. CHEMICAL HAZARDS....................................................................................................100
11. APPENDIX..................................................................................................................................103
A. CONVERSION TABLE......................................................................................................103
B. GENERAL PRE START-UP PROCEDURES..................................................................105
C. OPERATIONAL PROBLEMS – POSSIBLE CAUSES AND REMEDIES..................109
D. MISCELLANEOUS............................................................................................................111

FLOW PLAN ABBREVIATION TABLE
FLOW PLAN ABBREVIATION TABLE – sheet 1
ABBREVIATION WHOLE WORDING
A/G Aboveground
AAH Analyser Alarm High
AE Analyser Element
AI Analyser Indicator
AI Acoustic insulation
A/M Auto/ Manual
AT Analyser Transmitter
AIC Analyser Indicating Controller
ASC Anti surge controller
ARWU Anti-reset wind up
AGC Automatic gain control
BA Burner Alarm
BC Burner Controller
BD Blowdown
BDV Blowdown Valve
BE Burner Element
BG Blanket gas
BRV Breathing Valve
BI Burner Indication
BMS Burner Management System
BS&W Bottom sediment and water
C Compressor
CA Combustion air
CC Insulation for cold conservation
CAD Closed amine drain
CHD Closed Hydrocarbon drain
CSC Car Seal Close
CSO Car Seal Open
CC Corrosion Coupon
CD Continuous drainer

CG Calibration Gauge
CP Corrosion Probe
CO Carbon dioxide
CW Cooling water
CCR Central control room
CVA Choke Valve Adjustable
DF Diesel fuel
D Drum
DG Diesel engine generator
DR Drier
DT Drain trap
DW Potable water
DCS Distributed Control System
E Exchanger
EM Elevated monitor
EH Electric heater
EAL Voltage Low Alarm

EI Voltage Indicator
EL Elevation
ET Electric traced line
ERV Emergency relief vent
EW Eye wash
ESD Emergency shutdown system
FA Flame arrester
F Flare
FA Fresh amine
FB Full bore
FC Fail closed
FG Fuel gas
FL Flare
FN Fan

FM Fixed monitor
FO Fail open
FL Fail locked
FW Fire water, rain water
FAH Flow Alarm High
FIL Filter
FAHH Flow Alarm High-High
FAL Flow Alarm Low
FALL Flow Alarm Low-low
FCV Flow Control Valve
FE Flow Element
FFIC Flow Ratio Indicating Controller
FG Flow Glass
FI Flow Indicator
FIC Flow Indicating Controller
FM Flow Meter
FQI Flow Quantity Indicator (Totalizer)
FR Flow Recorder
FRC Flow Recording Controller
FS Flow Switch
FSH Flow Switch High
FSHH Flow Switch High-high
FSL Flow Switch Low
FSLL Flow Switch Low-low
FPP Fuel preparation panel
FT Flow Transmitter
FX Flow Straightening Vanes
FY Flow Transducer or Function
G Gas

GT Gas turbine driver

GTG Gas Turbine Generator
GL Glycol, MEG
GAP Gap control
GEN Generator
H Heater
HB Hose box for fire water
HD Hydrant for fire water
HC Insulation for heat conservation
HM Heating medium
HBF Hose box foam
HDF Hydrant for foam
HMD Heating medium drain
HIC Hand Indicating Controller
HCV Hand Control Valve
HOA Hand-Off-Automatic
HS Hand Switch
HY Hand Transducer or Function
HZ Hand Positioner
HP Fuel Gas High Pressure Fuel Gas
K Chemical
LP Fuel Gas Low Pressure Fuel Gas
IA Instrument air
II Current Indicator
IP Injection point
I/P Current to Pneumatic Converter
I/F Interface
L Liquid
LA Lean amine
LO Lube oil
LAH Level Alarm High
LAHH Level Alarm High-high
LAL Level Alarm Low
LALL Level Alarm Low-low
LBV Line break valve

LC Level Controller
LC Locked closed
LO Locked open
LCP Local Control Panel
LCS Local control station
LCV Level Control Valve
LG Level Gauge (Glass)
LI Level Indicator
LIC Level Indicator Controller
LR Level Recorder
LRC Level Recorder Controller
LS Level Switch

LSH Level Switch High

LSHH Level Switch High-high
LSL Level Switch Low
LSLL Level Switch Low-low
LT Level Transmitter
LY Level Transducer or Function
M Electric motor drive
MA Mechanical agitator
MM Mobile monitor
MCC Motor control centre
MFD Manifold
MW Demineralised make-up water, process water
MOV Motor Operated Valve
MPBC MOV Push Button Close
MPBO MOV Push Button Open
MPBS MOV Push Button Stop
MV Measurement Variable
MY MOV Logic Function
MZLC MOV Position Indicator Light Closed
MZLO MOV Position Indicator Light Open
MZSC MOV Position Switch Close
MZSO MOV Position Switch Open
N Nitrogen
NC Normally closed
NNF Normally no flow
NO Normally open
NOC Net Oil Computer
P Pump
PA Pressure Discrepancy Alarm
PA Plant air
PL Pig launcher
PP Insulation for personnel protection
PM Pump motor
PR Pig receiver
PW Produced water

PWD Produced water drain
PAH Pressure Alarm High
PAHH Pressure Alarm High-high
PAL Pressure Alarm Low
PALL Pressure Alarm Low-low
PB Push Button (May be prefixed)
PBC Push Button Close
PBO Push Button Open
PC Pressure Controller
PCV Pressure Control Valve
PD Pulsation Dampener

PDAH Pressure Differential Alarm High

PDAL Pressure Differential Alarm Low
PDC Pressure Differential Controller
PDCV Pressure Differential Control Valve
PDI Pressure Differential Indicator
PDR Pressure Differential Recorder
PDSH Pressure Differential Switch High
PDSL Pressure Differential Switch Low
PDT Pressure Differential Transmitter
PI Pressure Indicator
P/I Pneumatic to Current converter
PIC Pressure Indicating Controller
PR Pressure Recorder
PRC Pressure Recorder Controller
PS Pressure Switch
PSE Bursting Disc
PSH Pressure Switch High
PSHH Pressure Switch High-high
PSL Pressure Switch Low
PSLL Pressure Switch Low-low
PSV Pressure Safety Valve
PP Personnel Protection
PT Pressure Transmitter
PY Pressure Transducer
R Refrigerant (propane)
RA Rich amine
RW Raw water
RO Restriction Orifice
RS Removable spool
RTD Resistance temperature detector
ROV Remote Operated Valve
RSP Remote setpoint
SBY Stand by
SC Sample Connection
SE Speed Element

SI Speed Indicator
SO Seal oil
SDV Shutdown Valve
SOV Solenoid Operated Valve
SY Shutdown Relay
SR Stress relieved
SP Setpoint
SS Safety shower
T Tower
TK Tankage
TAH Temperature Alarm High

TAHH Temperature Alarm High-high

TAL Temperature Alarm Low
TALL Temperature Alarm Low-low
TC Temperature Controller
T/C Thermocouple
TCV Temperature Control Valve
TE Temperature Element
TI Temperature Indicator
TIC Temperature Indicating Controller
TR Temperature Recorder
TRC Temperature Recorder Controller
TSH Temperature Switch High
TSO Tight shut-off
TSHH Temperature Switch High-high
TSL Temperature Switch Low
TSLL Temperature Switch Low-low
TT Temperature Transmitter
TV Temperature Valve
TW Thermowell
TY Temperature Transducer or Relay
UA Common Alarm
UCP Unit control panel
UW Treated water, filtered water
WF Wellhead fluid
WH Wellhead
WW Waste water
WV Wing valve
WWD Waste water drain
UASD Common Shutdown Alarm
V Vent
VAH Vibration Alarm High
VAHH Vibration Alarm High-high
VE Vibration Element
VSH Vibration Switch High
VSHH Vibration Switch High-high

X Unidentified Special Equipment
XA Miscellaneous Alarm
XCE Corrosion Probe Element
XCF Corrosion Fitting
XCI Corrosion Indicator
XCP Corrosion Fitting Point
XI Miscellaneous Indicator
XPA PIG Alarm
XPI PIG Indicator
XPS PIG Switch

XS Miscellaneous Switch
XSP Sand Probe
XSV Solenoid Operated Valve (May be prefixed)
XV Miscellaneous Valve
XY Miscellaneous Transducer or Function
ZA Position Fault Alarm
ZLC Position Indicator Light Closed (May be prefixed)
ZLO Position Indicator Light Open (May be prefixed)
ZSC Position Switch Closed (May be prefixed)
ZSO Position Switch Open (May be prefixed)
A/M Auto / Manual
AGC Automatic Gain Control
ARWU Anti-Reset Wind Up
ASC Anti Surge Controller
BS&W Bottom Sediment And Water
CCR Central Control Room
ESD Emergency Shutdown System
FC Fail Closed
FL Fail Locked
FO Fail Open
FPP Fuel Preparation Panel
GAP GAP Control
IA Instrument Air
I/F Interface
LCS Local Control Station
MCC Motor Control Center
RTD Resistance Temperature Detector
RSP Remote Setpoint
SBY Stand By
SP Setpoint
T/C Thermocouple
TSO Tight Shut-Off
UCP Unit Control Panel
May be prefixed:

ABBREVIATION LETTER DESIGNATION
B Blowdown
F Flow
H Hand
L Level
M MOV
P Pressure
T Temperature
S Shutdown
X Miscellaneous

COLOUR CODING
NO FACILITY COLOUR COLOUR DENOMINATION

PER
BRITISH STANDARD BS-5252
01 Steel Structures, walkways, stairways Light BS 00 A 03
and platforms, vessels, exchangers, Gray
plant piping and associated valves
02 Tanks, including firewater tanks, White BS 00 E 55
stairways and platforms associated
with the tank, wellheads and
accessories.
03 Rotating equipment: electric motors, Dark BS 00 A 09
power transformers. Gray
04 Safety valves, railing, ladders and Yellow BS 10 E 53
ladder cages, monorails, tail pipes, car
seal valves, showers.
05 Bonnets of instrumentation control Green BS 14 D 43
valves, instrumentation piping (where
applicable).
06 Transmission pipelines, valves and White BS 00 E 55
accessories.
07 Breathing apparatus station, smoking Green BS 14 D 43
pens, water fountains.
08 Boiler stacks, bonnets of boiler Aluminum BS 02 A 03
superheated safety valves.
09 Valve handwheels. Black BS 00 E 53
10 Cathodic protection, transformer White yellow BS 00 E 55
rectifiers, solar power units, junction Red BS 06 E 55
boxes, groundbed casings. (Band)
11 Road barriers, specified curbs, trip Black/ BS 00 E 53
hazards, width and height limits, access Yellow BS 10 E 55
grounds.
12 Fire fighting equipment and piping Sirte Red SC 127
(firewater tanks to be white red
horizontal band)

BASIC IDENTIFICATION COLOURS
Pipe Contents BIC Remarks

Water Green
Steam Silver-Grey Mineral, vegetable, or animal type
Acids, Alkalis Violet
Gases (except air) Yellow ochre In gaseous or liquid state
Air Light Blue
Other liquids Black
COLOUR INDICATION
Safety Colour Intended For Remarks

Red** Fire fighting All valves must also be
painted in red
It is usually necessary to
Yellow Warning and visibility suppliment with a warning
sign or label
Blue* Fresh water (potable or not) Used in combination with
green BIC
* Known as “auxiliary blue”
** Known as “signal red”
S.O.C. COLOUR CODING
Colour code For

Red* Critical plant shutdown and isolation valves
Blue-Yellow Nitrogen
Green-Yellow Instrument air
Green-Brown Oil
White Hydrocarbons (gas, condensate)
White-Yellow Instrument gas lines
Red buff (= yellow ochre) All other lines
* This must be a different type (hue) or red than the “signal” red used for firefighting
equipment

1. GENERAL DESCRIPTION.........................................................................................................20
A. INTRODUCTION...................................................................................................................20
B. DUTY OF UNIT..................................................................................................................... 20
C. DESCRIPTION OF THE FLOW............................................................................................21
D. DESIGN BASIS......................................................................................................................22
E. UTILITIES AND CHEMICALS – DESIGN BASIS............................................................. 24

1. GENERAL DESCRIPTION
A. INTRODUCTION
The fuel gas in Attahaddy Plant is a common system for both processing trains. The primary source
of the fuel gas is taken from the Condensate Flash Drums (D-5101 / D-5201) and Amine Flash
Drums (D-3103 / D-3203). Make up fuel gas is taken from the export gas stream down stream of
the Mercury Removal Unit (D-7001).
Backup / start up fuel gas can be supplied from the main 36” gas transmission pipeline by back
flowing along the 30” gas export trunk line.
The main users of the fuel gas are the GTG’s, MEG Reboilers and the Heating Medium Furnaces.
Pure sales gas is used for blanketing, purging, and pilot burners start up.
B. DUTY OF UNIT
Design capacity of the Fuel Gas System is summarized in the following table:
Source High Temperature Case Low Temperature Case

HP Fuel LP Fuel B / P/ P Total HP Fuel LP Fuel B / P/ P Total
Gas Gas
Sales 12.7 0 0.42 13.12 12.7 0 0.42 13.12
Gas
Gas From 2.7 5.4 0 8.1 2.6 5.5 0 8.1
Condensate
Flash
Drums
Gas From 0 0.6 0 0.6 0 0.48 0 0.48
Amine
Flash
Drums
Total 15.4 6 0.42 21.82 15.3 5.98 0.42 21.7
Notes: All figures are in MMSCFD.

B / P / P: Blanket / Pilot / Purge

C. DESCRIPTION OF THE FLOW
Vapour from the Condensate Flash Drums (D-5101 / D-5201) is combined and fed to Fuel Gas
Super Heater (E-6401 A / B) which ensures that there is no liquid drop out from the fuel gas. From
the Super Heater (E-6401 A / B), the gas is routed to the Fuel Gas Scrubber (D-6401) to knockout
any liquid carried over.
Vapour from this vessel is distributed along with the export sales gas make-up and the flashed gas
from Amine Flash Drums (D-3103 / D-3203) as follows:
(refer to Utility Flow Diagram C2-0053 in Annex 4 and P&ID C2-0184 in Annex 5).
LP-Fuel Gas (55 PSIG)
The primary source of the LP fuel gas is the outlet vapour of the Fuel Gas Scrubber (D-6401). Gas
from the Amine Flash Drums (D-3103 / D-3203) is also routed to the LP fuel gas system in a 3”
header under pressure control. LP fuel gas is supplied under pressure control. LP fuel gas is
supplied under pressure control in an 8” header to the MEG Reboilers (F-4101 / F-4201) and the
Heating Medium Furnaces (F-3101 A / B / C).
HP Fuel Gas (325 PSIG)
The only users of HP fuel gas which is essentially export sales gas quality are the power
generators. Any Condensate Flash Drums gas which is available after supplying the LP fuel gas is
combined with as much export sales gas as necessary to supply the generators.
The export sales gas line is tied in to the Fuel Gas Scrubber outlet vapour under pressure control
upstream and downstream of the tie-in point. From the gas plant fence, the HP fuel gas is routed to
the Power Plant via a 6” buried pipe line.
A further conditioning of the HP fuel gas is performed upstream of the GTG by heating it up in the
Electric Heater (E-8001) before being passed through the Liquid K.O Drum (D-8001).
A continuous HP fuel gas supply to the GTG is guaranteed by provision of a 6” cross-over

connection taken from the 30” sales gas trunk line downstream of the sales gas shutdown valve
700-SDV-03 and ties-in to the fuel gas system down stream of the shut down valve 640-SDV-01.

Blanket / Pilot / Purge Gas (135 PSIG)
This gas is only supplied from the export sales line downstream of the Mercury Removal Unit (D-
7001) due to its purity and low dew point. The gas is taken under pressure control and distributed
in a network providing blanket gas , pilot gas and purge gas for the entire plant facilities.
The blanket gas is used to maintain pressure in the following chemical storage tanks and surge
vessels:
- Amine Drain Drums D-3102 / D-3202
- Amine Flash Drums D-3103 / D-3203
- Amine Surge Drums D-31105 / D3205
- Amine Storage Tank TK-3001
- Heating Medium Expansion Drum D-3002
- Heating Medium Drain Drum D-3003
- Heating Medium Storage Tank TK-3002
- MEG Flash Drums D-4106 / D-4206
Pilot gas is used to start the pilot burners of the Heating Medium Furnaces (F-3001 A / B / C),
MEG Reboilers (F-4101 / F-4201), and the flare stack.
Purge gas is used to provide continuous purging for the LP and HP flare headers. Purge gas
connections are also provided at the inlet of the Test Separator D-2001, the Production Separators
(D-2101 / D-2201) and the Low Temperature Separators (D-4102 / D-4202) for purging and liquid
drainage during train shutdown.
D. DESIGN BASIS
The Fuel Gas system does comply with the design philosophy that no single piece of equipment
should be responsible for the shutdown of the plant. Therefore, the fuel gas system is equipped so
that all equipment that required maintenance (heat exchangers, control valves) can be taken out of
service without a shutdown of the system.
Fuel gas taken from the Condensate Flash Drums (D-5101 / D-5201) is a saturated vapour with
high CO2 content (7.5-8.5 mole %). Therefore, to avoid the possibility of having liquid in the fuel
gas system, this gas is heated in a double-pipe heat exchanger (E-6401 A / B) up to 225 °F for the
high temperature case and 185°F for the low temperature case. In addition, all the LP and HP fuel
gas lines as well as the Fuel Gas Super Heaters and the Fuel Gas Scrubber are insulated for heat
conservation.

No further conditioning is required for the blanket / pilot / purge gas since it is taken from the
export sales gas line with dew point at 20 °F at 600 psig and water content does not exceed 4 lbs /
MMSCF.
Fuel gas pressure is set according to the design requirement of the end user. Therefore, HP fuel gas
to GTG is set at 325 psig, LP fuel gas to the Heating Medium Furnaces and MEG Reboilers is set
at 55 psig and blanket / pilot / purge gas is set at 135 psig.
Fuel gas composition varies according to how much gas is withdrawn from each source. Tables 1-1
and 1-2 provide fuel composition for the high temperature and low temperature cases respectively.
Table 1-3 provide fuel composition from gas trunk line, which can be used on startup or GTG
operation.
Table 1-1
Fuel Gas Composition for the High Temperature Case
COMPOSITION MOLE%
To header From sources
HP LP BG Downstream* Condensate Flash Dram Rich Amine Flash
D-7001 D-5101/D-5201 Drum D-3103
Nitrogen 0.24 0.11 0.28 0.27 0.10 0.14
CO2 0.96 11.70 1.27 0.09 5.11 9.90
Methane 83.28 68.02 85.91 86.85 66.23 76.93
Ethane 9.98 12.60 8.69 8.83 15.47 6.00
Propane 3.21 4.35 2.45 2.51 6.57 1.92
i-Butane 0.85 1.11 0.59 0.61 1.97 0.18
n-Butane 0.70 0.94 0.47 0.49 1.75 0.36
i-Pentane 0.32 0.42 0.19 0.20 0.90 0.09
n-Pentane 0.16 0.22 0.09 0.09 0.49 0.05
C6’s 0.12 0.18 0.05 0.05 0.44 0.06
C7’s 0.04 0.07 0.01 0.01 0.19 0.02
C8’s 0.02 0.03 0.00 0.00 0.11 0.00
H2O 0.12 0.25 0.00 0.00 0.67 4.33
Table 1-2
Fuel Gas Composition for the Low Temperature Case
COMPOSITION MOLE%
To header From sources
*
HP LP BG Downstream Condensate Flash Dram Rich Amine Flash
D-7001 D-5101/D-5201 Drum D-3103
Nitrogen 0.25 0.11 0.28 0.28 0.11 0.14
CO2 3.21 11.70 1.27 1.27 11.71 11.48

Methane 82.69 68.02 85.91 85.91 67.10 78.44
Ethane 9.46 12.60 8.69 8.69 13.18 5.97
Propane 2.82 4.35 2.45 2.45 4.57 1.89
i-Butane 0.70 1.11 0.59 0.59 1.20 0.15
n-Butane 0.56 0.94 0.47 0.47 1.00 0.28
i-Pentane 0.23 0.42 0.19 0.19 0.45 0.06
n-Pentane 0.14 0.22 0.09 0.09 0.24 0.03
C6’s 0.08 0.18 0.05 0.05 0.19 0.03
C7’s 0.02 0.07 0.01 0.01 0.07 0.01
C8’s 0.01 0.03 0.00 0.00 0.04 0.00
H2O 0.03 0.25 0.00 0.00 0.14 1.52
Table 1-3
Fuel Gas composition from existing 36” Pipeline for starting and Initial Commissioning of
Attahaddy Power Plant
Components High Calorific Gas Normal Calorific Gas Low Calorific Gas
Mole % Case Case Case
N2 0.41 0.79 1.32
CO2 1.58 3.19 4.45
C1 87.21 83.02 78.47
C2 4.91 8.63 12.56
C3 2.41 2.30 2.64
IC4 0.65 0.45 0.26
NC4 0.87 0.56 0.25
IC5 0.53 0.29 0.02
NC5 0.47 0.26 0.02
C6 0.39 0.21 0.01
C7 0.57 0.30 0.00
C8 0.00 0.00 0.00
Total 100.00 100.00 100.00
Mol. Wt. 19.85 20.02 20.19
Gross Heating 1159 1122 1091
Value, BTU/SCF
Net Heating Value 1057 1023 995
BTU/SCF
E. UTILITIES AND CHEMICALS – DESIGN BASIS
The utilities for Fuel Gas System are instrument air and heating medium.

Instrument Air
Three two-stage reciprocating air compressors, C-6301A/B/C, (in Package X- 6301A/B/C) supply
the plant and instrument air requirements. The plant air is distributed from the Plant Air Receiver,
D-6301, and supplies feed to the Instrument Air Dryer Package, X-6302A/B, which contains two
dryer sets. Instrument air is distributed from the Instrument Air Receiver, D-6302, to all users.
The Instrument Air pressure is 125 PSIG.
Heating Medium
Heating medium supply is used by the Fuel Gas Superheaters E-6401 / E-6402 for heating the gas
which comes from Condensate Flash Drums D-5101 / D-5202.
Heating medium supply temperature is 320 F and heating medium return temperature is 265 F.
The chemical composition of heating medium is as follows:
COMPOSITION WT%
H2O 50
TEG 50
Note: No chemicals are required for Fuel Gas System.

2. OPERATING CONDITIONS AND CONTROLS......................................................................27
A. FUEL GAS SUPER HEATER (E-6401 A/B)......................................................................... 27
B. FUEL GAS SCRUBBER (D-6401)........................................................................................ 28
C. LP FUEL GAS HEADER....................................................................................................... 29
D. HP FUEL GAS HEADER.......................................................................................................29
E. BLANKET / PILOT / PURGE GAS HEADER…..…………………………………………31

2. OPERATING CONDITIONS AND CONTROLS
A. FUEL GAS SUPER HEATER (E-6401 A/B)
This is a hairpin type heat exchanger providing 100°F of super heat using the heating medium
supply available at the plant. A 10% over surface design margin has been included in the design. A
100% spare exchanger is installed to facilitate service / maintenance work to be carried out without
causing plant shut down or flaring of Condensate Flash Drum vapour from both trains.
Temperature control is provided by a temperature controller on the warm gas outlet line (640-TIC-
03) which acts on a temperature control valve (640-TCV-03) in the heating medium outlet line. The
same controller is equipped with high and low temperature alarms.
Temperature and pressure of all gas and heating medium inlet and outlet lines to / from the
exchanger are monitored from field by local temperature and pressure gauges.
The set points / operating condition of E-6401 A/B are provided in Table 2-1.
Table 2-1
Set points and alarm levels for Fuel Gas Super Heater (E-6401 A/B)
P&ID TAG/ PROC. DCS REMARKS

LOOP NO UNITS Range Setpoint & Alarms

(0-xxxx) Setpoint High Low
C2-0184 640-TIC-03 °F 400 229 235 180
PSV is not installed on E-6401 A/B. When E-6401 is not in service, make sure that block valve on
Heating Medium Supply line to E-6401 is closed. In order to make sure that pressure of E-6401
A/B will not exceed the design pressure of 500 psig the block valve in gas side downstream of E-
6401 A/B are made to be CSO.
The pressure of E-6401 can exceed 500 psig only in follow scenario:
1) Stop heating medium supply
2) Close inlet block valve of gas side and open outlet block valve of gas side
3) Wait until the shell side temperature to fall below 70 F while keeping shell side
pressure at operating pressure of 350 psia.
4) Close outlet block valve of gas side at below 70 F.
5) Supply heating medium to reach 320 F, which is heating medium supply temperature,
while keeping gas side blocked.
6) Then shell side can rich 500 psig.
B. FUEL GAS SCRUBBER (D-6401)
The Fuel Gas Scrubber (D-6401) is a vertical two-phase separator. A 10% design margin has been
applied to the gas and liquid flow rates for sizing the vessel. The vessel dimensions are 3’-0” ID X
9’-0” H (T/T). The maximum pressure drop across the vessel including the inlet and outlet nozzles
is limited to 2 psi.
High liquid level alarm (640-LAH-01) is provided in the control room to warn the operator in case
of liquid accumulation. Any liquid gathered in the vessel is manually drained.
Pressure in the Fuel Gas Scrubber (D-6401) is monitored in the control room through (640-PI-04)
equipped with high and low pressure alarms.
Set points and alarm levels for D-6401 are provided in Table 2-2.
Table 2-2
Set points and Alarms Levels for The Fuel Gas Scrubber (D-6401)


C2-0184 640-LAH- "WG 7’-6” 80%
01
C2-0184 640-PI-04 psig 600 450 300
C. LP FUEL GAS HEADER
The LP Fuel Gas is under two independent pressure controllers (640-PIC-08) and (640-PIC-10)
installed down stream of two parallel control valves (640-PCV-8) and (640-PCV-10) respectively.
Two controllers and valves are provided to ensure continued operation if one of the loops fails for
any reason. LP fuel gas down stream of the valves is distributed to the end users at pressure of 55
psig.
High and low pressure alarms are provided in the DCS on (640-PIC-08) and (640-PIC-10).
Deviation alarms (640-XA-08) and (640-XA-10) are provided in the DCS and will activate if the
measured variable deviates from the set point by more than 5 psi.
Temperature and pressure gauges (640-TI-02) and (640-PI-08) are provided to monitor temperature
and pressure of the LP fuel gas header from field.
Flow of LP fuel gas is monitored in the DCS by flow indicator (640-FI-02).
Table 2-3 provides the set points and alarm levels for the Low Pressure fuel gas header.
Table 2-3
Set points and alarm levels for the Low Pressure Fuel Gas Header

C2-0184 640-PIC-08 psig 150 55 60 50
C2-0184 640-PIC-10 psig 150 50 65 45
D. HP FUEL GAS HEADER

The HP fuel gas is supplied under one pressure controller (640-PIC-05) and one pressure regulator
640-PCV-04. The two valves drop the HP fuel gas pressure from 670 psig to 325 psig.
Self-regulator 640-PCV-04 is installed for the independent operation of GTG from Gas Plant.
When plant air and DCS are not alive, HP fuel gas can be supplied through 640-PCV-04.
High and low pressure alarms are provided in the DCS on pressure controller (640-PIC-05).
Deviation alarm (640-XA-05) is provided in the DCS and will activate when the measured variable
deviates from the set point by more than 5 psi.
When HP fuel gas pressure is high due to surplus supply of gas than consumption or mal-operation
of PCV or any other reasons, the pressure is released through 640-PCV-07 by venting the fuel gas
to flare.
Total sales gas for fuel is metered up stream of the pressure control valves (640-PCV-04 / 05). The
measured flow is pressure and temperature compensated and displayed in the DCS on (640-FI-03 /
02). HP fuel gas to GTG is measured down stream of the pressure control valves (640-PCV-04 /
05). The measured flow is pressure and temperature compensated and displayed in the DCS on
(640-FI-01 / 02).
Table 2-4 provides set points and alarm levels for HP fuel gas header.
Table 2-4
Set points and alarm levels for the HP Fuel Gas Header

C2-0184 640-PIC-05 psig 600 325 330 320
C2-0184 640-PCV-04 psig 250-450 320
C2-0184 640-PIC-07 psig 600 335 340 N/A
C2-0184 640-FI-03/1 lbs/hr 37,500 N/A N/A N/A Provides input to
totaliser 640-FQI-03
& 700-FY-04/2 or
700-FI-04.
C2-0184 640-FI-01/1 lbs/hr 38,700 N/A N/A N/A

C2-0184 640-PI-13 psig 1,000 N/A N/A N/A Provides input to
& 640-FI-03/2
C2-0184 640-TI-07 °F 400 N/A N/A N/A Provides input to
& to 640-FI-03/2.
Normal temp is
128°F HTC & 78°F
LTC.
C2-0184 640-PI-01 psig 600 N/A N/A N/A Provides input to
& 640-FI-01/2.
C2-0184 640-TI-01 °F 300 N/A N/A N/A Provides input to
& to 640-FI-03/2.
Normal temp is
128°F HTC & 78°F
LTC.
E. BLANKET / PILOT / PURGE GAS HEADER
Two independent pressure controllers (640-PIC-11) and (640-PIC-12) are installed on the blanket /
pilot / purge gas header acting on two parallel control valves (640-PCV-11) and (640-PCV-12)
respectively. These two valves drop the Blanket / Pilot / Purge gas pressure down to 135 psig
before being distributed to units 300, 400, and 900.
High and low pressure alarms are provided in the DCS on (640-PIC-11) and (640-PIC-12).
Deviations alarms (640-XA-11) and (640-XA-12) are provided in DCS and will activate if the
measured variable deviates from the set point by more than 5 PSI.
Temperature and pressure gauges (640-TI-09) and (640-PI-09) are provided to monitor temperature
and pressure of the Blanket / Pilot / Purge gas header from field.
Table 2-5 provides set point and alarm levels for the Blanket / Pilot / Purge gas header.
Table 2-5
Set points and Alarm Levels for the Blanket / Pilot / Purge Gas Header

C2-0184 640-PIC-11 psig 600 135 140 130
C2-0184 640-PIC-12 psig 600 130 140 125

3. EMERGENCY EQUIPMENT..................................................................................................... 34
A. GENERAL.............................................................................................................................. 34
B. SHUTDOWN VALVES.......................................................................................................... 34
C. EMERGENCY BLOWDOWN VALVES............................................................................... 35
D. PRESSURE RELIEF VALVES...............................................................................................35
E. EMERGENCY ALARMS.......................................................................................................36
F. CAR SEALED VALVES ………………………………………………………………….37

3. EMERGENCY EQUIPMENT
A. GENERAL
To ensure safe operation of the fuel gas system of the Attahaddy plant, suitable shutdown valves,
blowdown valves, car sealed valves and pressure relief valves have been provided. All these
facilities are shown on the Piping and Instrument Diagrams in section (9) of this manual. All
pressure relief valves and the blowdown valves in the fuel gas system are connected to the high
pressure relief header.
B. SHUTDOWN VALVES
An emergency shutdown valve (640-SDV-01) is installed on the 6” sales gas make up line down
stream of the Mercury Removal Unit (D-7001). This valve closes in case of emergency (ESD1) and
by DCS push button (640-PBC-01). In this case, fuel gas to GTG’s continue from the 30” sales gas
trunk line.
An emergency shutdown valve (640-SDV-02) is provided on the common inlet gas line to the Fuel
Gas Super Heater (E-6401 A/B) to isolate the fuel gas system in case of ESD1. The same valve is
also closed by DCS push button (640-PBC-02).
A check valve is installed on the heating medium lines up stream of each Super Heater. In addition,
a pressure switch high high (640-PSHH-01A/B) is installed on the heating medium lines
downstream of each Super Heater which provides a signal to close the shutdown valves (640-SDV-
03 A/B) in the event of tube rupture. Thus providing isolation of the heating medium system from
the fuel gas system. This shutdown valve is also closed by DCS push button (640-PBC-03 A/B).
Manual isolation valves on the outlet gas line of each exchanger are normally car seal open (CSO)
to avoid over heating of the gas side if isolated while the heating medium is flowing.
An emergency shutdown valve (640-SDV-04) is provided on the Fuel Gas Scrubber outlet vapour
line to isolate the vessel from HP fuel gas header in case of an emergency (ESD1). The shutdown
valve is also closed by the DCS push button (640-PBC-04).
All emergency shutdown valves are reset from field and reopened only when the differential
pressure across the valve is not higher than 5 psi.

C. EMERGENCY BLOWDOWN VALVES
Depressurization of the fuel gas system between (640-SDV-02) and (640-SDV-04) in case of
emergency (ESD1) is carried out through the blowdown valve (640-BDV-01). This blowdown
valve is also opened by DCS push button (640-PBO-01).
D. PRESSURE RELIEF VALVES
Over-pressure protection of the entire Fuel Gas system is provided in the first instance by the
pressure controller (640-PIC-07) installed on the HP fuel gas header and set at 335 psig. The
pressure controller is equipped with high pressure alarm and acts on the pressure control valve
(640-PCV-07) diverting the extra fuel gas flow to the HP flare header.
Second over pressure protection of the fuel gas system is provided by the pressure relief valves
(640-PSV-01/02) installed on the outlet vapour line of the Fuel Gas Scrubber (D-6401). These
valves are set at 500 psig and sized for full flow of the fuel gas system.
Pressure relief valve (640-PSV-01) is normally on line. The isolation valves upstream and
downstream of (640-PSV-01) are car sealed open. Pressure relief valve (640-PSV-02) is normally
standby. The isolation valves upstream and downstream of (640-PSV-02) are normally car sealed
close and car seal open respectively. If pressure relief valve (640-PSV-01) is removed for
maintenance, then isolation valve upstream of (640-PSV-02) is changed to car sealed open until
(640-PSV-01) is put back to service.
In the event that HP fuel gas header is isolated from the remaining fuel gas system by the shutdown
valve (640-SDV-04), then HP fuel gas header is over pressure protected by the pressure relief
valves (700-PSV-01/02) installed on the export sales gas line and set at 720 psig. Details of
pressure relief valves (700-PSV-01/02) are provided in volume 6 (Mercury Removal Unit & Sales
Gas) of the operating manual.
Pressure relief valves installed in the fuel gas system, their location, set pressure and size are
tabulated as follow:

Service Set Pressure Size Discharge to
Item (PSIG) Inlet pipe”
(Orifice letter)
Outlet pipe”
640-PSV-01/02 Fuel Gas 500 3J4 HP Flare Header
Scrubber
(D-6401)
E. EMERGENCY ALARMS
P&ID TAG/ PROC. ESD

LOOP NO UNITS Range (0- Proc Value Remarks
xxxx)
C2-0184 640-PAHH-01A psig 20 - 180 120 For tube rupture case. Max HM
upset is 180psig.
C2-0184 640-PAHH-01B psig 20 - 180 120 For tube rupture case. Max HM
upset is 180psig.
DCS ALARMS

C2-0184 640-TIC-03 °F 400 229 235 180
C2-0184 640-PI-04 psig 600 - 450 300
C2-0184 640-PIC-05 psig 600 325 330 320
C2-0184 640-PIC-06 psig 600 320 335 310
C2-0184 640-PIC-07 psig 600 335 340 -
C2-0184 640-PIC-08 psig 150 55 60 50
C2-0184 640-PIC-10 psig 150 50 65 45
C2-0184 640-PIC-11 psig 600 135 135 130
C2-0184 640-PIC-12 psig 600 130 140 125
C2-0184 640-LAH- "WG 80%
01

F. CAR SEALED VALVES
Fuel Gas System – CSO
TAG NO. P&ID NO. LINE NO. REMARKS

Unit Type Serial
640 CSO 01 C2 –0184 6”-B7-FG – 64006
640 CSO 02 C2 – 0184 6”-B7-FG – 64007
640 CSO 06 C2 – 184 2”-B7-FG– 64015
640 CSO 10 C2 – 0184 3”-B7-FG-64011
640 CSO 11 C2 – 0184 6”-A15-F-64011
640 CSO 12 C2 – 0184 6”-A15-F-64002
300 CSO 11 C2 – 0139C 2”-B7-FG – 30088
300 CSO 12 C2 – 0139C 2”-A15-F – 30014
300 CSO 13 C2 – 0139C 2”-A15-F – 30013
300 CSO 14 C2 – 0139C 2”-B7-FG – 30090
300 CSO 15 C2 – 0139C 2”-A15-F – 30016
300 CSO 16 C2 – 0139C 2”-A15-F – 30015
300 CSO 17 C2 – 0139C 2”-B7-FG – 30092
300 CSO 18 C2 – 0139C 2”-A15-F – 30018
300 CSO 19 C2 – 0139C 2”-A15-F – 30017
Fuel Gas System – CSC
TAG NO. P&ID NO. LINE NO. REMARKS

Unit Type Serial
640 CSC 01 C2 – 0184 3”-B7-FG – 64008
300 CSC 08 C2 – 0139C 2”-B7-FG – 30089
300 CSC 09 C2 – 0139C 2”-B7-FG – 30091

300 CSC 10 C2 – 0139C 2”-B7-FG – 30093

4. PREPARING UNIT FOR INITIAL START-UP.........................................................................40
A. GENERAL.............................................................................................................................. 40
B. PRE START-UP PROCEDURES........................................................................................... 40
C. SDVs, PCVs, HCVs, PSVs..................................................................................................... 71
D. EMERGENCY SHUT DOWN SYSTEM...............................................................................73

4. PREPARING UNIT FOR INITIAL START-UP
A. GENERAL
During the pre-commissioning period, all components of the plant must be checked to ensure that
they have been installed correctly and are in a state of readiness for the introduction of feedstock.
Faults found during the pre-commissioning activities should be rectified by whichever party is
contractually responsible - Engineering, Contractor, Vendor, Constructor, Main Constructor – until
the specification requirements are fully satisfied. Following the repairs retesting of the item may
be required prior to start-up.
Before commencing feed into the plant a number of equipment specific process operation checks
must be performed. These checks and operations shall be according to the pre start-up procedures.
When all works are completed, the equipment, piping and valves should be lined up for purging
and introduction of hydrocarbons and process materials. All flanges should be tight, plugs, caps
and blank flanges must be installed. The system must have been leak tested. Blinds should be
installed wherever required, before the system is ‘ready for operation’.
The relief and blowdown network system and the required utilities should be available, prior to the
system start-up.
B. PRE START-UP PROCEDURES
Hydrostatic Testing of Piping and Vessels
Verify that all hydrostatic testing of piping and vessels has been completed, witnessed and
approved. Each vessel and associated piping shall be leak tested. It is very important to ensure
that no leaks exist.

Dewatering, Drying, Cleaning Vessels and Piping
The cleaning of piping can be made with air. Refer to 11.C ‘General Pre Start-up Procedures’ for
the general air blowing procedure.
Verify that all vessels have been opened after cleaning to visually inspect for large foreign objects.
Dewatering shall be performed during the air blowing. The air blowing shall continue until the
equipment and piping is clean and dry.
Commissioning of Utilities
Plant/Inst Air System
The instrument and plant air system function checks shall be completed and the system shall be
made ready for service
Analysers
Verify that all Analysers have been calibrated and are ready for service
Pressure Safety Valves
Verify that all PSV’s have been tested within the previous 90 days.
Usually 640-PSV-01 is in service and 640-PSV-02 is on stand-by.
To change over from the in service 640-PSV-01 to the stand-by 640-PSV-02 proceed as follows:
 Open 640-CSC- 01
 Close 640-CSO-10
 Close 640-CSO-12
When 640-PSV-01 is to be removed for maintenance
 Open ¾”VB021 bleed valve for depressurize the line upstream of 640-PSV-01

300-PSV-13A is set at 500 PSIG and protects the Heater Fuel Gas K.O. Drum D-3005A from
overpressure The PSV discharges to the HP Flare Header.
When this valve is in service the upstream line 2”-B7-FG-30088 block valve is car sealed open
(300-CSO-11) and the downstream line 2”-A15-F-30013 block valve is also car sealed open (300-
CSO-13)
Usually 300-PSV-13A is in service and 300-PSV-14A is on stand-by.
To change over from the in service 300-PSV-13A to the stand-by 300-PSV-14A proceed as
follows:
 Open 300-CSC- 08.

 Close 300-CSO-11.
When 300-PSV-13A is to be removed for maintenance
 Open ¾”VB066 bleed valve to depressurize the line upstream of 300-PSV-13A
300-PSV-13B is set at 500 PSIG and protects the Heater Fuel Gas K.O. Drum D-3005B from
overpressure. The PSV discharges to the HP Flare Header.
(300-CSO-14) and the downstream at line 2”-A15-F-30015 block valve is also car sealed open
(300-CSO-16)
Usually 300-PSV-13B is in service and 300-PSV-14B is on stand-by.
To change over from the in service 300-PSV-13B to the stand-by 300-PSV-14B proceed as
follows:
 Open 300-CSC- 09.

When 300-PSV-13A is to be removed for maintenance

 Open ¾”VB066 bleed valve for depressurize the line upstream 300-PSV-13B
300-PSV-13C is set at 500 PSIG and protects the Heater Fuel Gas K.O. Drum D-3005C from
overpressure. The PSV discharges to the HP Flare Header.

(300-CSO-17) and the downstream at line 2”-A15-F-30017 block valve is also car sealed open
(300-CSO-19
Usually 300-PSV-13C is in service and 300-PSV-14C is on stand-by.
To change over from the in service 300-PSV-13C to the stand-by 300-PSV-14C proceed as
follows:
 Open 300-CSC- 10.
When 300-PSV-13C is to be removed for maintenance
 Open ¾”VB066 bleed valve for depressurize the line upstream 300-PSV-13C.
300-PSV-14A is set at 500 PSIG and protects the Heater Fuel Gas K.O. Drum D-3005A from
overpressure. The PSV discharges to the HP Flare Header
When this valve is on stand-by the upstream line block valve is car sealed closed
(640-CSC-08). The downstream line block valve is car sealed open (640-CSO-12).
300-PSV-14B is set at 500 PSIG and protects the Heater Fuel Gas K.O. Drum D-3005B from
300-PSV-14B is set at 500 PSIG and protects the Heater Fuel Gas K.O. Drum D-3005C from
UPS and Emergency Generator
Verify that the UPS system and the Emergency Generator function checks are completed and the
system is ready for service
Shutdown Trips and Instrument Setpoints

Verify that Instrument setpoints, alarms and shutdown trips have been checked and set.
Verify that all PI’S, TI’S, and DCS measurements of pressure and temperature agree or, if they are
some distance away, correspond with one another according to expectation. If not, the end devices
should be replaced or calibrated.
Plant Line-up
Check that the Plant has been Lined-up as required.
Fuel Gas System Air Leak Test
Procedure
Leak testing is most efficiently done by dividing the system into sections with a conveniently sized
grouping of vessels/equipment
Ways of re-using air are managed to optimise air use and time. A smaller system can be
depressured and repressured saving time and material when a leak repair needs the system to be
depressured. Air in the FG System, whether a leak is found or not, could be passed in part onto the
flare and blow down systems.
Safety Caution: When the flare system contains flammable materials. Air must never be purged to
the flare system to avoid the possibility of explosive mixtures occurring within that system.
There are logical and practical limits to the system sizes selected and for the rates of pressure
increase for air going into valved towers, filters or into low pressure rated equipment.
The test pressure is determined by the normal operating conditions, design pressure, type of service
fluid handled and the utility air supply pressure.
If sufficient manpower is available, together with sufficient compressed air supply, it would enable
parallel work on units, or on both trains to be performed. If large leaks are found the repair time
period will probably be reduced.
Fuel gas although a utility system is covered in this section as it is supplied from process gas
streams. (Trunk line, the lines from Sales Gas System to Fuel Gas System, the lines from
Condensate Flashing systems to Fuel Gas system and the lines from the Amine Flash Drum
systems to Fuel Gas system).
The Fuel Gas system after the fire fighting, start-up power, control and other utility systems is the

next in the start-up sequence. The fuel gas and the flare systems have equal priorities for start-up
preparation as they depend on each other to be operational
Leaks are indicated by decreasing test system pressure and may be audible. Pressure reduction
may also be due to a valve leak to another section. The pressure in downstream equipment should
be monitored frequently.
A search is made methodically for leaks at all flanges, valve packing followers and threaded
fittings. All flanges shall be taped up and a detergent solution from plastic spray bottles or with a
brush is applied to the top hole in the tape, at packing or where threads join. Any bubbling of the
solution indicates a leak. Mark and record the leak locations for repair. After repairing leaks,
these shall be re-tested with soapy water solution. After testing and repairs are complete reinstall
the seal tape.
When the test pressure is achieved, the system will be monitored for at least one hour and any
excessive pressure loss over the period will be investigated. Sections undergoing tightness tests
will remain under close supervision and will be depressurised as soon as practicable after the test is
complete.
If leaks cannot be tightened up, for example when a gasket replacement is required, check the
remainder of the system before depressuring. Then all repairs can be attended to together.
There may however be convenient valving to isolate the leak, at a control valve for example.
The FG Air leak test shall be done in three steps as follows:
 At 50 PSIG for all FG systems.

 At 130 PSIG for BG and HP fuel gas systems. The LP system shall be isolated from the
other FG systems using valves and the pressure monitored frequently to ensure it does not
exceed 50 PSIG.
 At 320 PSIG for HP fuel gas system. The BG system shall be isolated from the HP system
using valves and the pressure is monitored frequently to ensure it does not exceed 130
PSIG.
The air supply connection shall be installed at the following:
 Condensate Flash Drums D-5101, at the ¾”VB071 drain valve upstream of 510-PCV-01
on line 3”-B9-FG-51001. Install in the closed position the slip on blind on line 3”-B9-
FG-51001 at the outlet of drum D-5101. 510-PCV-01 shall be in manual mode control,
open 50 per cent.

 Condensate Flash Drums D-5201, at the ¾”VB071 drain valve upstream of 520-PCV- 01
on line 3”-B9-FG-52001. Install in the close position the slip on blind on line 3”-B9-FG-
52001 at the outlet of drum D-5201. 520-PCV-01 shall be in manual mode control, open
50 per cent.
 On the 6”-B6-G-70005 line downstream of the Mercury Removal Unit D-7001.

Downstream of the 6”VB014 valve on line 6”-B6-G-70005 install the air supply
connection on the hydrotest valve. (If not available install one blind with air supply
nozzle downstream of 6”VB014 valve).
 On the 6”-B6-G-70001 line downstream of 700-SDV-03. At the ¾”VB066 vent valve

remove the ¾” plug.
FG System Air Leak Test at 50 PSIG.
Refer to the following P&ID’s C2-0170, C2-0171, C2-0184, C2-0185, C2-0801, C2-0172, C2-0272,
X-4201-014, X-4101-012, C2-0189, C2-0289, C2-0191, C2-0139C, C2-0119, C2-0219, C2-0141A,
C2-0141B, C2-0141C, C2-0138, C2-0144, C2-0135, C2-0145, C2-0110A, C2-0111A, C2-0211A, C2-
0109 4 of 4, C2-0107 4 of 4, C2-0123, C2-0223, C2-0134, C2-0234, C2-0126, C2-0226, C2-0155, C2-
0255, X-4101-013, X-4201-015, C2-0801

VALVE STATUS – sheet 1
The status of the valves included in the procedure is shown in the following tables:
NO. P & ID LINE NUMBER VALVE REMARKS
1 C2-0170 6”-B6-G-70005 6”VB014 Air supply connection

2 C2-0171 6”-B6-FG-70001 6”VB014 Close
3 C2-0171 6”-B6-FG-70001 ¾”VB066 Air supply connection
4 C2-0172 3”-B9-FG-51001 ¾”VB071 Open, for 510-PT-01
5 C2-0172 3”-B9-FG-51001 ¾”VB071 Close, for 510-PT-02
6 C2-0172 3”-B9-FG-51001 3”VB019 Close, upstream 510-PCV-01
7 C2-0172 3”-B9-FG-51002 3”VB019 Open, downstream 510-PCV-01
8 C2-0172 3”-B9-FG-51001 510-PCV-01 Open 50%, manual mode control
10 C2-0172 2”-B9-FG-51011 2”VGL015 Close, by-pass of 510-PCV-01
11 C2-0172 1”-A15-F-51012 1”VB032 Valves of 510-SC-01
13 C2-0272 3”-B9-FG-52001 ¾”VB071 Close, for 520-PT-02
16 C2-0272 3”-B9-FG-52001 520-PCV-01 Open 50%, manual mode control
18 C2-0272 2”-B9-FG-52011 2”VGL015 Close, by-pass of 520-PCV-01
19 C2-0272 1”-A15-F-52012 1”VB032 Valves of 520-SC-01
20 C2-0184 6”-B6-FG-70001 6”VB014 Open
21 C2-0184 6”-B6-G-70005 640-SDV-01 Open
22 C2-0184 6”-B6-G-70005 ¾”VB066 Open, for 640-PI-14
23 C2-0184 6”-B6-G-70005 ¾”VB066 Open, for 640-PT-13
24 C2-0184 6”-B6-G-64001 6”VB014 Open, upstream 640-PCV-05
25 C2-0184 6”-B6-G-64001 640-PCV-05 In Auto Control mode with Setpoint = 325 psig
27 C2-0184 6”-B6-G-64002 6”VB014 Open, upstream 640-PCV-06
28 C2-0184 6”-B6-G-64002 640-PCV-06 In Auto Control mode with Setpoint = 320 psig
31 C2-0184 6”-B7-FG-64004 ¾”VB066 Open, for 640-PI-07
34 C2-0184 6”-B7-FG-64004 6”VB014 Open

35 C2-0184 3”-B7-FG-64012 3”VB013 Open, upstream 640-PIC-07
36 C2-0184 3”-B7-FG-64012 640-PIC-07 In Auto Control mode with Setpoint = 335 psig
37 C2-0184 3”-B7-FG-64012 3”VB013 Open, downstream 640-PIC-07
38 C2-0184 4”-B7-FG-64003 4”VB014 Open
39 C2-0184 4”-B7-FG-64003 4”VB014 Open, upstream 640-PIC-08
40 C2-0184 4”-B7-FG-64003 640-PIC-08 In Auto Control mode with Setpoint = 55 psig

VALVE STATUS– sheet 2
42 C2-0184 4”-B7-FG-64031 4”VB014 Open, upstream 640-PCV-10

43 C2-0184 4”-B7-FG-64031 640-PCV-10 In Auto Control mode with Setpoint = 50 psig
45 C2-0184 8”-B7-FG-64013 1”VB066 Close, valves of 640-SC-01
49 C2-0184 2”-B6-FG-64002 2”VB013 Open
51 C2-0184 2”-B6-FG-64002 640-PCV-11 In Auto Control mode with Setpoint = 135 psig
52 C2-0184 2”-B6-BG-64001 2”VB013 Open, downstream 640-PCV-11
53 C2-0184 2”-B6-BG-64001 ¾”VB066 Open, for 640-PT-12
54 C2-0184 2”-B6-BG-64001 ¾”VB066 Open, for 640-PT-11
55 C2-0184 2”-B6-BG-64001 ¾”VB066 Open, for 640-PI-09
55 C2-0184 2”-B6-BG-64001 2”VB013 Open, to distribution
55 C2-0184 2”-B6-BG-64033 2”VB013 Open, upstream 640-PCV-12
55 C2-0184 2”-B6-BG-64033 640-PCV-12 In Auto Control mode with Setpoint = 130 psig
55 C2-0184 2”-B6-BG-64011 2”VB013 Open, downstream 640-PCV-12
55 C2-0184 6”-B7-FG-64022 640-SDV-04 Open
55 C2-0184 6”-B7-FG-64020 6”VB014 Open, from D-6401
55 C2-0184 2”-B7-FG-64015 2”VB013 Open, 640-CSO-06
55 C2-0184 2”-B7-FG-64015 640-BDV-01 Open
55 C2-0184 2”-A15-F-64006 2”VB017 Open, downstream 640-BDV-01
55 C2-0184 3”-B7-FG-64008 3”VB013 Open, 640-CSC-01
55 C2-0184 6”-A15-F-64001 6”VB055 Open, 640-CSO-11
56 C2-0184 3”-B7-FG-64011 3”VB013 Open, 640-CSO-10
57 C2-0184 6”-A15-F-64002 6”VB055 Open, 640-CS0-12
58 C2-0184 D-6401 2”VB013 Close, vent
59 C2-0184 D-6401 2”VB013 Open, for 640-PI-05 and 640-PT-04
60 C2-0184 D-6401 ¾”VB066 Open, for 640-PI-05
61 C2-0184 D-6401 ¾”VB066 Open, for 640-PT-04
62 C2-0184 D-6401 2”VB013 Open, 2 valves for level glass
63 C2-0184 D-6401 1”VB021 Open, 2 valves for 640-LG-01
64 C2-0184 D-6401 1 ½”VB021 Open, 2 valves for 640-LSH-01
65 C2-0184 D-6401 1”VB021 Close, from level glass

66 C2-0184 D-6401 1”VGL030 Close, from level glass
67 C2-0184 D-6401 2”VB013 Close, bottom of vessel
68 C2-0184 D-6401 2”VB013 Close, to CHD
69 C2-0184 D-6401 2”VB013 Close, for purge vessel
70 C2-0184 6”-B7-FG-64007 ¾”VB066 Open, for 640-PI-12B
71 C2-0184 6”-B7-FG-64006 ¾”VB066 Open, for 640-PI-12A
72 C2-0184 6”-B7-FG-64007 6”VB014 Open, 640-CSO-02


74 C2-0184 2”-B7-HM-64002 ¾”VG036 Open, for 640-PI-10A
75 C2-0184 2”-B7-HM-64001 ¾”VG036 Open, for 640-PI-10B
78 C2-0184 3”-B9-FG-52002 640-SDV-02 Open
79 C2-0184 6”-B9-FG-64010 6”VB020 Open, gas to E-6401B
80 C2-0184 6”-B9-FG-64009 6”VB020 Open, gas to E-6401A
81 C2-0185 1”-B7-FG-42001 1”VB021 Open, to F-4201
82 C2-0185 1”-B7-FG-41001 1”VB021 Open, to F-4101
83 C2-0185 1”-B6-BG-90012 1”VB021 Open, purge gas to HP Flare Header
84 C2-0185 1”-B6-BG-41004 1”VB021 Open, pilot gas to F-4101
85 C2-0185 1”-B6-BG-41001 1”VB021 Open, blanket gas to D-4106
86 C2-0185 1”-B6-BG-42004 1”VB021 Open, pilot gas to F-4201
94 C2-0185 2”-B6-BG-32002 2”VB013 Open, to D-3205
97 C2-0185 ¾”-B6-BG-32049 ¾”VB021 Open, blanket gas to SP-3201
103 C2-0185 ¾”-B6-BG-31049 ¾”VB021 Open, blanket gas to SP-3101
104 C2-0185 2”-B7-FG-91001 2”VB013 Open, LP fuel gas to D-9101
105 C2-0185 2”-B7-FG-92001 2”VB013 Open, LP fuel gas to D-9201
106 C2-0185 2”-B6-BG-30025 2”VB013 Open, blanket gas to TK-3002
107 C2-0185 2”-B6-BG-30001 2”VB013 Open, blanket gas to TK-3001

108 C2-0185 2”-B6-BG-64006 2”VB013 Open, pilot gas to Flare System
111 C2-0185 1 ½”-B6-BG-30029 1 ½”VB021 Open, pilot gas to F-3001C
112 C2-0185 1 ½”-B6-BG-30021 1 ½”VB021 Open, pilot gas to F-3001B
113 C2-0185 1 ½”-B6-BG-30009 1 ½”VB021 Open, pilot gas to F-3001A
117 C2-0185 1”-B6-BG-64012 1”VB021 Open, blanket gas to Flare Purge

118 C2-0185 1”-B6-BG-64014 1”VB021 Open, blanket gas to Flare Purge

119 X-4201-014 1”-B6-BG-42001 1”VB021 Close, upstream 420-PCV-05
120 X-4201-014 1”-A7-BG-42010 1”VB021 Close, downstream 420-PCV-05
121 X-4201-014 1”-B6-BG-42017 1”VGL028 Close, by-pass of 420-PCV-05
122 X-4201-014 1”-A7-BG-42010 1”VB021 Close, upstream 420-PCV-06
124 X-4201-014 2”-A15-F-42026 2”VB001 Close 2 valves
125 X-4201-014 3”-A15-F-42027 3”VB054 Open, 420-CSO-34
126 X-4201-014 3”-A15-F-42030 3”VB054 Open, 420-CSO-33
127 X-4201-014 2”-A7-BG-42013 2”VB001 Open, 420-CSO-32
128 X-4201-014 2”-A7-BG-42015 2”VB001 Close, 420-CSC-08
129 X-4201-014 1”-B7-FG-42001 1”VB021 Open, upstream check valve
130 X-4201-014 1”-B7-FG-42001 1”VB021 Close, downstream check valve
131 X-4101-012 1”-B6-BG-41001 1”VB021 Close, upstream 410-PCV-05
133 X-4101-012 1”-B6-BG-41017 1”VGL028 Close, by-pass of 410-PCV-05
134 X-4101-012 1”-A7-BG-41010 1”VB021 Close, upstream 410-PCV-06
136 X-4101-012 2”-A15-F-41026 2”VB001 Close 2 valves
137 X-4101-012 3”-A15-F-41027 3”VB054 Open, 410-CSO-34
138 X-4101-012 3”-A15-F-41030 3”VB054 Open, 410-CSO-33
139 X-4101-012 2”-A7-BG-41013 2”VB001 Open, 410-CSO-32
140 X-4101-012 2”-A7-BG-41015 2”VB001 Close, 410-CSC-08
141 X-4101-012 1”-B7-FG-41001 1”VB021 Open, upstream check valve
142 X-4101-012 1”-B7-FG-41001 1”VB021 Close, downstream check valve
143 C2-0189 2”-B7-FG-91001 2”VB013 Close
144 C2-0189 2”-B7-FG-91001 2”VGL011 Close
145 C2-0289 2”-B7-FG-92001 2”VB013 Close
146 C2-0289 2”-B7-FG-92001 2”VGL011 Close
147 C2-0191 1”-B6-BG-90012 1”VB021 Close, upstream 900-FI-03
148 C2-0191 1”-A15-F-90018 1”VB021 Close, downstream 900-FI-03
149 C2-0191 1”-B6-BG-90020 1”VGL028 Close, by-pass of 900-FI-03



171 C2-0107 4/4 1”-B6-BG-64012 1“VB021 Close, upstream 200-FI-07
172 C2-0107 4/4 1”-B6-BG-20001 1”VGL028 Close, by-pass of 200-FI-07
173 C2-0107 4/4 1”-B6-BG-64012 1”VB021 Close, downstream 200-FI-07
174 C2-0109 4/4 1”-B6-BG-64014 1”VB021 Close, upstream 200-FI-09
175 C2-0109 4/4 1”-B6-BG-20003 1”VGL028 Close, by pass of 200-FI-09
176 C2-0109 4/4 1”-B6-BG-64014 1”VB021 Close, downstream 200-FI-09
177 C2-0139C 6”-B7-FG-30015 6”VB014 Open, upstream D-3005 A
178 C2-0139C 6”-B7-FG-30021 6”VB014 Open, upstream D-3005 B
179 C2-0139C 6”-B7-FG-30025 6”VB014 Open, upstream D-3005 C
180 C2-0139C 6”-B7-FG-30015 ¾”VB066 Open, for 300-PI-18A
183 C2-0139C 2”-B7-FG-30088 2”VB013 Open, 300-CSO-11
184 C2-0139C 2”A15-F-30013 2”VB054 Open, 300-CSO-13
185 C2-0139C 2”-B7-FG-30089 2”VB013 Open, 300-CSC-08
186 C2-0139C 2”-A15-F-30014 2”VB054 Open, 300-CSO-12
187 C2-0139C 2”-B7-FG-30090 2”VB013 Open, 300-CSO-14
188 C2-0139C 2”-A15-F-30015 2”VB054 Open, 300-CSO-16
189 C2-0139C 2”-B7-FG-30091 2”VB013 Open, 300-CSC-09
190 C2-0139C 2”-A15-F-30016 2”VB054 Open, 300-CSO-15
191 C2-0139C 2”-B7-FG-30092 2”VB013 Open, 300-CSO-16
192 C2-0139C 2”-A15-F-30017 2”VB054 Open, 300-CSO-19
193 C2-0139C 2”-B7-FG-30093 2”VB013 Open, 300-CSC-10
194 C2-0139C 2”-A15-F-30018 2”VB054 Open, 300-CSO-18
195 C2-0139C 6”-B7-FG-30016 6”VB014 Close, from D-3005 A
196 C2-0139C 6”-B7-FG-30022 6”VB014 Close, from D-3005 B
197 C2-0139C 6”-B7-FG-30026 6”VB014 Close, from D-3005 C

198 C2-0139C D-3005A 2”VB013 Open, 2 valves for 300-LSH-01A
199 C2-0139C D-3005A 2”VB013 Open, 2 valves for 300-LG-03A
200 C2-0139C D-3005A 1”VB021 Close, 2 valves for 300-DT-01A
201 C2-0139C D-3005A 1”VB021 Close, by-pass for 300-DT-01A
202 C2-0139C ½”-B7-D-30015 ½”VB021 Close, for 300-DT-01A
203 C2-0139C D-3005B 2”VB013 Open, 2 valves for 300-LSH-01B
204 C2-0139C D-3005B 2”VB013 Open, 2 valves for 300-LG-03B
205 C2-0139C D-3005B 1”VB021 Close, 2 valves for 300-DT-01B
206 C2-0139C D-3005B 1”VB021 Close, by-pass for 300-DT-01B
207 C2-0139C ½”-B7-D-30015 ½”VB021 Close, for 300-DT-01B

208 C2-0139C D-3005C 2”VB013 Open, 2 valves for 300-LSH-01C

209 C2-0139C D-3005C 2”VB013 Open, 2 valves for 300-LG-03C
210 C2-0139C D-3005C 1”VB021 Close, 2 valves for 300-DT-01C
211 C2-0139C D-3005C 1”VB021 Close, by-pass for 300-DT-01C
212 C2-0139C ½”-B7-D-30015 ½”VB021 Close, for 300-DT-01A
213 C2-0119 3”B9-FG-31003 3”VB019 Close, from D-3103
214 C2-0119 2”-B6-BG-31001 2”VB013 Close, upstream 310-PCV-01/1
215 C2-0119 2”-B7-BG-31006 2”VB013 Close, downstream 310-PCV-01/1
216 C2-0119 2”-B6-BG-31041 2”VGL011 Close, by-pass of 310-PCV-01/1
217 C2-0219 3”B9-FG-32003 3”VB019 Close, from D-3203
221 C2-141A 1 ½”-B6-BG-30009 1 ½”VB021 Close, upstream 300-PCV-02A
222 C2-141A 1 ½”-B6-BG-30010 1 ½”VB021 Close, downstream 300-PCV-02A
223 C2-141A 1 ½”-B6-BG-30062 1 ½”VB021 Close, upstream 300-PCV-03A
224 C2-141A 1 ½”-B6-BG-30010 1 ½”VB021 Close, downstream 300-PCV-03A
225 C2-141A 1 ½”-B6-BG-30010 ¾”VB066 Open, for 300-PSL-02A
No. P & ID Line Number Valve Remarks
226 C2-141A 1 ½”-B6-BG-30010 ¾”VB066 Open, for 300-PSH-02A
227 C2-141A 1 ½”-B6-BG-30010 ¾”VB066 Open, for 300-PI-10A
228 C2-141A 1 ½”-B6-BG-30010 ¾”VB066 Open, for 300-PSLL-02A
229 C2-141A 1 ½”-B6-BG-30010 ¾”VB066 Open, for 300-PT-61A
230 C2-141A 1 ½”-B6-BG-30010 300-XV-03A Close
231 C2-141B 1 ½”-B6-BG-30021 1 ½”VB021 Close, upstream 300-PCV-02B
232 C2-141B 1 ½”-B6-BG-30020 1 ½”VB021 Close, downstream 300-PCV-02B
233 C2-141B 1 ½”-B6-BG-30063 1 ½”VB021 Close, upstream 300-PCV-03B
234 C2-141B 1 ½”-B6-BG-30020 1 ½”VB021 Close, downstream 300-PCV-03B
235 C2-141B 1 ½”-B6-BG-30020 ¾”VB066 Open, for 300-PSL-02B
236 C2-141B 1 ½”-B6-BG-30020 ¾”VB066 Open, for 300-PSH-02B
237 C2-141B 1 ½”-B6-BG-30020 ¾”VB066 Open, for 300-PI-10B
238 C2-141B 1 ½”-B6-BG-30020 ¾”VB066 Open, for 300-PSLL-02B
239 C2-141B 1 ½”-B6-BG-30020 ¾”VB066 Open, for 300-PT-61B
240 C2-141B 1 ½”-B6-BG-30020 300-XV-03B Close
241 C2-141C 1 ½”-B6-BG-30029 1 ½”VB021 Close, upstream 300-PCV-02C

242 C2-141C 1 ½”-B6-BG-30030 1 ½”VB021 Close, downstream 300-PCV-02C
243 C2-141C 1 ½”-B6-BG-30064 1 ½”VB021 Close, upstream 300-PCV-03C
244 C2-141C 1 ½”-B6-BG-30030 1 ½”VB021 Close, downstream 300-PCV-03C
245 C2-141C 1 ½”-B6-BG-30030 ¾”VB066 Open, for 300-PSL-02C
246 C2-141C 1 ½”-B6-BG-30030 ¾”VB066 Open, for 300-PSH-02C
247 C2-141C 1 ½”-B6-BG-30030 ¾”VB066 Open, for 300-PI-10C
248 C2-141C 1 ½”-B6-BG-30030 ¾”VB066 Open, for 300-PSLL-02C
249 C2-141C 1 ½”-B6-BG-30030 ¾”VB066 Open, for 300-PT-61C
250 C2-141C 1 ½”-B6-BG-30030 300-XV-03C Close


255 C2-0138 2”-B6-BG-30038 2”VB013 Close, to D-3002
258 C2-0144 2”-B6-BG-30055 2”VGL012 Close, by-pass for 300-PCV-04/1
259 C2-0144 2”-B6-BG-30055 ¾”VB066 Open, for 300-PI-18/1
260 C2-0144 2”-B6-BG-30015 2”VB013 Close, to D-3003
261 C2-0135 2”-B6-BG-30001 2”VB013 Close
264 C2-0135 2”-A16-BG-30002 2”VB013 Close, downstream 300-PCV-07
265 C2-0135 2”-B6-BG-30051 2”VGL012 Close, by-pass for 300-PCV-07
266 C2-0135 2”-A16-BG-30002 ¾”VB069 Open, for 300-PI-22
267 C2-0135 ¾”-A16-BG-30003 ¾”VB069 Open, for 300-PI-21
268 C2-0145 2”-B6-BG-30025 2”VB013 Close,
271 C2-0145 2”-A7-BG-30026 2”VB013 Close, downstream 300-PCV-10
272 C2-0145 2”-A7-BG-30058 2”VGL012 Close, by-pass for 300-PCV-10
273 C2-0145 2”-A7-BG-30026 ¾”VB066 Open, for 300-PI-14
274 C2-0145 ¾”-A7-BG-30028 ¾”VB066 Open, for 300-PI-15
275 C2-0110A 2”-B6-BG-20004 2”VGL012 Close
276 C2-0110A 8”-C4-G-20002 2”VB043 Close
277 C2-0111A 2”-B6-BG-21001 2”VGL036 Close
278 C2-0111A 16”-C4-G-21001 2”VGL036 Close
279 C2-0211A 2”-B6-BG-2001 2”VGL036 Close
280 C2-0211A 16”-C4-G-22001 2”VB043 Close
281 C2-0123 ¾”-B6-BG-31049 ¾”VGL030 Close
282 C2-0123 2”-B6-D-31056 2”VB013 Close
283 C2-0223 ¾”-B6-BG-321049 ¾”VGL030 Close
284 C2-0223 2”-B6-D-321056 2”VB013 Close
287 C2-0134 2”-B6-BG-31026 2”VB013 Close

292 C2-0234 2”-B6-BG-32026 2”VB013 Close
295 C2-0126 2”-B6-BG-31002 2”VB013 Open, upstream 310-PCV-02/1

298 C2-0126 4”-B6-BG-31003 4”VB014 Close

299 C2-0226 2”-B6-BG-32002 2”VB013 Open, upstream 320-PCV-02/1
302 C2-0226 4”-B6-BG-32003 4”VB014 Close
303 C2-0155 2”-B6-BG-41016 2”VGL12 Close
304 C2-0155 2”-C1-G-41016 2”VB030 Close
305 C2-0255 2”-B6-BG-42016 2”VGL12 Close
306 C2-0255 2”-C1-G-42016 2”VB030 Close
307 X-4101-013 1”-B6-BG-41004 ½”VB021 Open, upstream 410-PCV-08
308 X-4101-013 ½”-B6-BG-41019 ½”VB021 Open, upstream 410-PCV-10
309 X-4101-013 ½”-B6-BG-41011 ½”VB021 Close, downstream 410-PCV-08
311 X-4101-013 ½”-B6-BG-41011 ½”VB066 Open, 410-PI-26
312 X-4101-013 ½”-B6-BG-41011 ½”VB066 Open, 410-PSLL-03
313 X-4201-015 1”-B6-BG-42004 ½”VB021 Open, upstream 420-PCV-08
314 X-4201-015 ½”-B6-BG-42019 ½”VB021 Open, upstream 420-PCV-10
317 X-4201-015 ½”-B6-BG-42011 ½”VB066 Open, 420-PI-26
318 X-4201-015 ½”-B6-BG-42011 ½”VB066 Open, 420-PSLL-03
323 C2-0801 6”-B7-FG-80003 ¾”VB066 Open
324 C2-0801 6”-B7-FG-80003 ¾”VB066 Open, for 800-TI-01
329 C2-0801 6”-B7-FG-80002 ¾”VB066 Open
330 C2-0801 6”-B7-FG-80003 6”VB014 Open, inlet in D-8001
331 C2-0801 1”-B6-BG-80001 1”VB021 Close, 2 valves upstream and downstream 800-
FI-05

332 C2-0801 1”-B6-BG-80001 1”VGL028 Close, by-pass for 800-FI-05
333 C2-0801 2”-B7-FG-80011 2”VB013 Open, 800-CSO-01
334 C2-0801 3”-A15-F-80002 3”VB054 Open, 800-CSO-03
335 C2-0801 2”-B7-FG-80031 2”VB013 Open, 800-CSC-01
336 C2-0801 3”-A15-F-80013 3”VB054 Open, 800-CSO-02
337 C2-0801 D-8001 2”VB013 Close, vent
338 C2-0801 D-8001 2”VB013 Open, 800-PI-04
339 C2-0801 D-8001 2”VB013 Open, 2 valves for level glass
340 C2-0801 D-8001 1”VB21 Open, 2 valves for 800-LG-01
341 C2-0801 D-8001 1 ½”VB021 Open, 2 valves for 800-LT-02

342 C2-0801 D-8001 2”VB013 Close, at bottom of vessel

343 C2-0801 D-8001 2”VB013 Close, near VC011
344 C2-0801 2”-B7-D-80007 2”VGL011 Close
345 C2-0801 2”-A15-F-80003 2”VB019 Close
346 C2-0801 6”-B9-FG-80004 6”VB020 Open
347 C2-0801 6”-B9-FG-80004 6”VB020 Open, inlet in EH-8001 A
348 C2-0801 6”-B9-FG-80004 2”VB019 Close
349 C2-0801 6”-B9-FG-80006 6”VB020 Open, inlet in EH-8001 B
350 C2-0801 6”-B9-FG-80006 2”VB019 Close
351 C2-0801 EH-8001 A ¾”VB071 Open, for 800-PI-05
352 C2-0801 1 ½”-B9-FG-80012 1 ½”VB032 Open, 800-CSO-04
353 C2-0801 2”-A15-F-80004 2”VB054 Open, 800-CSO-05
354 C2-0801 EH-8001 B ¾”VB071 Open, for 800-PI-06
355 C2-0801 1 ½”-B9-FG-80014 1 ½”VB032 Open, 800-CSO-06
356 C2-0801 2”-A15-F-80006 2”VB054 Open, 800-CSO-07
357 C2-0801 2”-A15-F-80005 2”VB019 Close
358 C2-0801 6”-B9-FG-80007 6”VB020 Open
359 C2-0801 2”-A15-F-80007 2”VB019 Close
360 C2-0801 6”-B9-FG-80008 6”VB020 Open
361 C2-0801 6”-B9-FG-80007 6”VB020 Close
362 C2-0801 1”-B9-FG-80016 1”VGL034 Close
 Tape all flanges in the FG systems. The tape can be plastic adhesive or masking tape. The
space between the flanges should be airtight after taping. Perforate the tape at its high
point with a pencil or object giving a small hole, ¼-inch or less.
 During the tests access to the area should be controlled. Access ladders/scaffolding should
be installed at such locations where required, until the work is complete.
 Open the air supply valves and increase the pressure in FG systems by a maximum of 40
PSIG/hour. When the pressure reaches 50 PSIG, close the air supply. Perform leak
tests, record data and repair leaks.
 After the leak test has been successfully completed, close the isolating valves 4”VB014 on
the lines: 4”-B7-FG-64003, 4”-B7-FG-64031 and 8”VB014 valves on the lines: 8”-B7-
FG-64013 and 8”-B7-FG-64032.

 Initially not all LP fuel gas consumers shall be in service, these must be isolated from the
FG system using temporary blinds:

NO. P & ID LINE NUMBER SIZE REMARKS
1 C2-0139C 6”-B7-FG-30016 6” Downstream, 6”VB014

4 X-4101-012 1”-B7-FG-41001 1” Downstream, 1”VB021
5 X-4201-014 1”-B7-FG-42001 1” Downstream, 1”VB021
6 C2-0189 2”-B7-FG-91001 2” Upstream, 2”VGL011
7 C2-0289 2”-B7-FG-92001 2” Upstream, 2”VGL011
8 C2-0119 3”-B9-FG-31003 3” Upstream, 3”VC015
9 C2-0219 3”-B9-FG-32003 3” Upstream, 3”VC015
Note: The blind evidence shall be strictly kept including the installation and removal dates Refer to
Annex 01.

Blanket Gas/ Purge/ Pilot Gas Systems Air Leak Test at 130 PSIG.
Refer to the following P&ID’s C2-0170, C2-0171, C2-0184, C2-0185, C2-0801, C2-0172, C2-
0272, X-4201-014, X-4101-012, C2-0189, C2-0289, C2-0191, C2-0139C, C2-0119, C2-0219, C2-
0141A, C2-0141B, C2-0141C, C2-0138, C2-0144, C2-0135, C2-0145, C2-0110A, C2-0111A, C2-
0211A, C2-0109 4 of 4, C2-0107 4 of 4, C2-0123, C2-0223, C2-0134, C2-0234, C2-0126, C2-
0226, C2-0155, C2-0255, X-4101-013, X-4201-015, C2-0801.
The status of the valves included in the procedure are shown in the following table:
1 C2-0184 4”-B7-FG-64003 4”VB014 Close

4 C2-0184 8”-B7-FG-64013 8”VB014 Close, downstream 640-PCV-08
5 C2-0184 8”-B7-FG-64032 8”VB014 Close, downstream 640-PCV-10
6 C2-0185 2”-B7-FG-91001 2”VB013 Close, to D-9101
7 C2-0185 2”-B7-FG-92001 2”VB013 Close, to D-9201
8 C2-0185 1”-B7-FG-41001 1”VB021 Close, to F-4101
9 C2-0185 1”-B7-FG-42001 1”VB021 Close, to F-4101
10 C2-0139C 2”-B7-FG-30089 2”VB013 Close, 300-CSC-08
Note: Status of other valves are as shown for the FG Systems air leak test at 50 PSIG.
 Open the air supply valves and increase the pressure in FG systems by a maximum 40
PSIG/hour. When the pressure reaches130 PSIG, close the air supply. Perform leak
tests, record data and repair leaks.
 After the leak test has been successfully completed, close the isolating valves 2”VB013 on
the lines: 2”-B7-FG-64002, 2”-B7-FG-64011, 2”-B7-FG-64001.
 Initially not all BG/Pilot/Purge fuel gas consumers shall be in service, these must be
isolated from the FG system using temporary blinds.

No. P & ID LINE SIZE REMARKS
1 C2-0119 2”-B7-BG-31006 2” Upstream the 2”VC015

3 C2-0141A 1 ½”-B6-BG-30010 1 ½” Upstream the 300-XV-03A
4 C2-0141B 1 ½”-B6-BG-30020 1 ½” Upstream the 300-XV-03B
5 C2-0141C 1 ½”-B6-BG-30030 1 ½” Upstream the 300-XV-03C
8 C2-0135 2”-B6-BG-30001 2” Downstream the 2”VC012
9 C2-0145 2”-B6-BG-30025 2” Downstream the 2”VB013
10 C2-0109 4/4 1”-A15-F-90036 1” Downstream the 1”VC031
11 C2-0107 4/4 1”-A15-F-90034 1” Downstream the 1”VC031
12 C2-0123 ¾”-B6-BG-31049 2” On the 2” nozzle on BG at SP-3101
13 C2-0223 ¾”-B6-BG-32049 2” On the 2” nozzle on BG at SP-3201
14 C2-0134 2”-B6-BG-31026 2” Upstream the 2”VB013
20 X-4101-012 1”-A7-BG-41002 2” On the drum D-4106
21 X-4101-012 2”-A15-F-41026 2” Upstream the 2”VB001
22 X-4201-014 1”-A7-BG-42002 2” On the drum D-4206
23 X-4201-014 2”-A15-F-42026 2” Upstream the 2”VB001
24 X-4101-013 ½”-B6-BG-41011 ½” Upstream the 410-XV-03
25 X-4101-015 ½”-B6-BG-42011 ½” Upstream the 420-XV-03
Note: The blind evidence shall be strictly kept, including the installation and removal dates Refer to
Annex 02.
HP Gas System Air Leak Test at 320 PSIG.
Refer to the following P&ID’s C2-0170, C2-0171, C2-0184, C2-0185, C2-0801, C2-0172, C2-
0272, X-4201-014, X-4101-012, C2-0189, C2-0289, C2-0191, C2-0139C, C2-0119, C2-0219, C2-
0141A, C2-0141B, C2-0141C, C2-0138, C2-0144, C2-0135, C2-0145, C2-0110A, C2-0111A, C2-
0211A, C2-0109 4 of 4, C2-0107 4 of 4, C2-0123, C2-0223, C2-0134, C2-0234, C2-0126, C2-
0226, C2-0155, C2-0255, X-4101-013, X-4201-015, C2-0801.

The status of the valves included in procedure are shown in the following table:
1 C2-0184 2”-B6-FG-64002 2”VB013 Close

2 C2-0184 2”-B6-FG-64002 2”VB013 Close, upstream the 640-PCV-11
3 C2-0184 2”-B6-FG-64033 2”VB013 Close, upstream the 640-PCV-12
4 C2-0184 2”-B6-BG-64001 2”VB013 Close, downstream the 640-PCV-11
5 C2-0184 2”-B6-BG-64011 2”VB013 Close, downstream the 640-PCV-12
6 C2-0184 2”-B6-BG-64001 2”VB013 Close
7 C2-0184 6”-B6-G-64001 640-PCV-05 In auto mode with setpoint at 325 PSIG
8 C2-0184 6”-B6-G-64002 640-PCV-06 In auto mode with setpoint at 320 PSIG
9 C2-0184 3”-B7-FG-64012 640-PCV-07 In auto mode with setpoint at 335 PSIG
Note: Status of other valves are as shown for the FG Systems air leak test at 130 PSIG.
When the GTG's are ready, perform the leak test to the limit of the GTG's.
 Open the air supply valves and increase the pressure in FG systems by a maximum 40
PSIG/hour. When the pressure reaches 320 PSIG, close the air supply. Perform leak
tests, record data and repair leak.
 After the leak test has been successfully completed, close the isolating valves 6”VB020 v
on the lines: 6”-B9-FG-80007 and 6”-B9-FG-80008 and install 6” temporary blinds down
stream of the 6”VB020 valves. Refer to P&ID C2-0801.
 Install blinds on the drain lines of the Fuel Gas Scrubber D-6401 on the lines: 2”-A8-D-
64002 and 1”-A8-D-64004:
No. P & ID LINE SIZE REMARKS
1 C2-0184 2”-A8-D-64002 2” Upstream the 2”VGL011

2 C2-0184 1”-A8-D-64004 1” Downstream the 1”VGL030
3 C2-0801 6”-B9-FG-80008 6” Downstream the 6”VB020
4 C2-0801 6”-B9-FG-80007 6” Downstream the 6”VB020
Note: The blind evidence shall be strictly kept, including installation and removal dates. Refer to
Annex 03.

The air from the FG systems shall be used to perform the air leak test of the flare systems, which
is described on Section 9. The blanket gas lines to the flare headers and 640-PCV-07 lines shall
be used for this purpose.
Safety Caution: The flare test pressure must be restricted to 40 psig maximum. Senior
Supervision to be present during the testing of this system.
When the pressure in the FG and Flare systems are equal all the valves on the blanket gas to flare
shall be closed. Put the setpoint for 640-PCV-07 at 330 PSIG.
Depressurize the FG systems to atmospheric pressure using 2”VB013 vent valve from the Fuel
Gas Scrubber D-6401.
Using the same air connection points as above, the nitrogen supply shall be fixed for nitrogen
purging of the FG systems.
FG System Nitrogen Purging.
The status of the FG systems is the same as indicated for the air leak test at 50 PSIG.
Nitrogen purging is necessary to displace oxygen remaining in the fuel gas system.
Verify that the Flare System air leak test has been completed successfully and is depressurized.
Safety Caution: Nitrogen is colourless and odourless. Nitrogen acts as a asphyxiant by displacing
air and can cause rapid suffocation, one breath of nitrogen can kill. Work in pairs and wear self
contained (SC) breathing kits when adjacent to nitrogen leaks or nitrogen venting or looking into
vessels that could possibly have a nitrogen content more than is present in air. Areas around the
openings of vessels containing nitrogen can contain high concentrations of nitrogen.
Systems under nitrogen pressure should have a clear visual indication as to the hazard at key
points for example, all flanges, manholes, vents, valves and openings.
 Introduce nitrogen at all supply points and increase the pressure to 30 PSIG.
 Depresurize the FG systems into the flare headers using the BG lines to the flare headers
and 640-PCV-07 control valve.
Safety Caution: When the flare system contains flammable materials. Nitrogen / Air mixtures
must never be purged to the flare system to avoid the possibility of explosive mixtures occurring
within that system.

 Repeat the pressurization and depressurization procedure. Take samples and determine the
oxygen content of the FG systems. The samples shall be taken from: 640-SC-01, D-8001
¾ VB066 drain valve, at the Heaters Fuel Gas K.O. Drums D-3005 A, B and C ¾”VB066
valves. Refer to P & ID C2-0139 C. The oxygen content must be below 2 per cent vol.
If not the purging procedure shall be repeated until this requirement is met. During the
first few purges O2 testers will be used, but the final test will be certified by the laboratory.
Note: When the Flare Systems are ready (oxygen content is below 2 % vol.) (Refer to Section 9)
the fuel gas can be imported from the gas trunk line into the FG systems.
The total volume of the FG systems:
-
Equipment volume D-6401 & E-6401 A; D-8001 & EH-8001A, B; D-3005 A, B, C:
-
68 ft3 + 66 ft3 + 56 ft3 = 190 ft3.
-
Piping volume : HP 6” lines = 115 ft3
LP 6” lines = 260 ft3
BG 2” lines = 35 ft3
-
TOTAL VOLUME = 600 ft3
-
TOTAL VOLUME with 10% margins = 660 ft3
The system will be pressurized three times at 30 psig. So the total amount of nitrogen at normal
conditions , with 10% margins, will be 4560 ft3.
After the first pressurization the oxygen content should be 7 % vol.
After the second pressurization the oxygen content should be 2.33 % vol.
After the third pressurization the oxygen content should be 0.8 % vol.
One nitrogen cylinder has 150 Bar pressure and 2 ft3 capacity. At normal conditions (15 psig and
ambient temperature) one cylinder has 300 ft3 of nitrogen. (99.8 % vol. purity).
To nitrogen purge the Fuel Gas Systems, about 16 cylinders of nitrogen will be required.

C. SHUTDOWN VALVES, PRESSURE CONTROL VALVES, HAND CONTROL VALVES
AND PRESSURE SAFETY VALVES
Verify the PSV's, SDV's, BDV's are complete and working properly, check that the PSV testing has
been completed.
Verify ESD valves have been function tested. For testing use a Castell lock system (or equivalent)
to safely remove power from the trip solenoid. All Emergency Shutdown Valves (SDV's) shall
have facilities for online testing of the solenoid valves without closing the valve. Observe that the
valve moves to a minimum stop and then reenergize the solenoid.
Blowdown valves shall be equipped with the same test facility as the shutdown valves.
Blowdown valves can be opened from the control room using the DCS. Open the valve using the
DCS and close using the local electrical reset pushbutton. Prior to testing the valve, the CSO block
valve upstream of the blowdown valve shall be closed by the Field Operator. The Field Operator
shall then request the Control Room Operator to open the valve and check that the valve indication
on the DCS screen display indicates that the valve is open.
The remote operated valve Open/Close functions on the DCS and any local panel mounted “local
electrical pushbutton’s” should be function tested separately. The speed of opening and closing of
the remote operated valves must also be checked and compared to the speed appropriate to the
process.

After checking that the valve has operated correctly, the Field Operator shall close the valve by
operating the local electrical reset pushbutton. Once the field operator is satisfied that the valve is
closed, the Field Operator shall then request the Control Room Operator to check that valve
indication on the DCS screen display shows hat the valve is closed. Assuming that the close status
of the valve is indicated correctly in DCS, the Field Operator shall open the CSO block valve
upstream of the blowdown valve.
The start-up of the Relief and Blowdown System has to be performed in conjunction with the Fuel
Gas System and with the Flare System.
Check that all valves are in the required start-up position and CSO/CSC as required and blinds in
operating positions as indicated by the P&ID's.
Verify that the control valves have been function tested and conform to the following table:
Fuel Gas System - Control Valves
TAG NO. P&ID NO. LINE NO. SIZE RATING REMARKS

Unit Type Serial SETPOINT
640 PCV 05 C2-0184 6"-B6-G-64001 2" 300#
640 PCV 06 C2-0184 6"-B6-G-64002 2" 300#
640 PCV 07 C2-0184 3"-B7-FG-64012 1 ½" 300# Diffuser 6"
640 PCV 08 C2-0184 4"-B7-FG-64003 1 ½" 300#
640 PCV 10 C2-0184 4"-B7-FG-64031 1 ½" 300#
640 PCV 11 C2-0184 2"-B6-FG-64002 1" 300#
640 PCV 12 C2-0184 2"-B6-FG-64033 1" 300#
640 TCV 03 C2-0184 2"-B7-HM-64007 1 ½" 300#
300 PCV 01A C2-0141A 6"-B7-FG-30016 3" 300#
300 PCV 01B C2-0141B 6"-B7-FG-30022 3" 300#
300 PCV 01C C2-0141C 6"-B7-FG-30026 3" 300#
300 PCV 02A C2-0141A 1 ½"-B6-BG-30010 1” 300#
300 PCV 02B C2-0141B 1 ½"-B6-BG-30020 1” 300#
300 PCV 02C C2-0141C 1 ½"-B6-BG-30030 1” 300#
300 PCV 03A C2-0141A 1 ½"-B6-BG-30062 1” 300#
300 PCV 03B C2-0141B 1 ½"-B6-BG-30063 1” 300#
300 PCV 03C C2-0141C 1 ½"-B6-BG-30064 1” 300#
300 PCV 05 C2-0135 2"-B6-BG-30001 1” 300#
300 PCV 06 C2-0135 2"-B6-BG-30001 1” 300#

300 PCV 07 C2-0135 2"-B6-BG-30001 1” 300#
300 PCV 08 C2-0145 2"-B6-BG-30025 1” 300#
300 PCV 09 C2-0145 2"-B6-BG-30025 1” 300#
300 PCV 10 C2-0145 2"-B6-BG-30025 1” 300#
300 PCV 04/1 C2-0144 2"-B6-BG-30018 1" 300#
300 PCV 01/1 C2-0138 2"-B6-BG-30011 1" 300#
310 PCV 01/1 C2-0119 2"-B7-BG-31006 1" 300#
310 PCV 01/2 C2-0119 3"-A11-FG-31002 1" 300#
310 PCV 02/1 C2-0126 2"-B6-BG-31002 1" 300#
310 PCV 03/1 C2-0134 2"-B6-BG-31025 1" 300#
320 PCV 01/1 C2-0219 2"-B7-BG-32006 1" 300#
320 PCV 01/2 C2-0219 3"-A11-FG-32002 1" 300#
320 PCV 02/1 C2-0226 2"-B6-BG-32002 1" 300#
320 PCV 03/1 C2-0234 2"-B6-BG-32025 1" 300#
510 PCV 01 C2-0172 3"-B9-FG-51001 2" 300#
520 PCV 01 C2-0272 3"-B9-FG-52001 2" 300#
800 PCV 01 C2-0801 6"-B7-FG-80032 3" 300#
800 PCV 03 C2-0801 6"-B7-FG-80002 3" 300#
900 PCV 03 C2-0193 1”-B6-BG-90011 ½” 300#
900 PCV 01 C2-0193 1”-B6-BG-90002 ½” 300#
410 PCV 05 X-4101-12 1”-B6-BG-41001 1” 300#
410 PCV 08 X-4101-13 1”-B6-BG-41004 ½” 300#
410 PCV 10 X-4101-13 ½”-B6-BG-41019 ½” 300#
420 PCV 05 X-4101-14 1”-B6-BG-42001 1” 300#
420 PCV 08 X-4101-15 1”-B6-BG-42004 ½” 300#
420 PCV 10 X-4101-15 ½”-B6-BG-42019 ½” 300#
D. EMERGENCY SHUT DOWN SYSTEM
Verify that all SDV, BDV, CSO, CSC and all ESD systems are complete and that function testing
has been completed.
The Field Operator in co-operation with the Control Room Operator under Train supervisor control
shall check the following:
1. At ESD Level 1:
a. 640-SDVs come to the closed position and in the correct time. Record data.
b. 640-SDVs come to the open position and in the correct time Record data.

2. Check that the CSO valves are open at each position required. Record data.
3. Check that the CSC valves are closed at each position required. Record data.

5. START-UP......................................................................................................................................76
A. GENERAL.............................................................................................................................. 76
B. PRELIMINARY CHECKS..................................................................................................... 76
C. LINING UP OF FUEL GAS SYSTEM.................................................................................. 78

5. START-UP
A. GENERAL
Before start-up and the introduction of feed gas to the system, the pre start-up activities must be
completed, for example leak test and inerting.
Leak tests - Fuel Gas Systems must be tested at maximum operating pressure, prior to gas-in.
Inerting - to remove oxygen from all Fuel Gas System.
To take samples use 640-SC-01 it is a sample connection type 2 Refer to P&ID C2-104 2 of 3).
To take a sample through 640-SC-01 proceed as follows:
 Place in service local pressure indicators PI A and PI B, of sample 640-SC-01.

 Open ¾” valve at inlet and fill with water the Sample Cooler, and close ¾” valve.
 Open 1”VB066 valve to HP Flare Header.
 Open 1” by-pass valve of sample connection.
 Open 1” valve of sample connection from LP Fuel Gas, check the pressure at local PI A
and the temperature at TI of the sample connection.
 Open 1” ball valve at outlet of bottle grade of bottle cradle, check the pressure at PI B.
 Open 1” ball valve at inlet of bottle grade.
 Open the needle valves at inlet at outlet of bottle cradle.
 Close 1” by-pass valve.
 After 1 minute close the needle valves at outlet and inlet bottle cradle.
 Close 1”valve of sample connection from LP Fuel Gas.
 Open by-pass valve for depressurize in HP Flare Header.
 Close 1”VB066 valve to HP Flare Header.
 Close 1” ball valve at outlet bottle cradle.
 Close 1” ball valve at inlet bottle cradle.
 Remove the bottle cradle.
B. PRELIMINARY CHECKS
Check that the following has been completed prior to introducing fuel gas to the System:

 Check upon the reset of the ESD Level 1 all SDV’s go to the open position.
 Check upon the reset of the ESD Level 1 all BDV’s go to the closed position.
 Check that the leak testing has been completed
 Check status of all equipment to confirm the system is ready for start-up.
 Check all instrumentation is complete and ready for operation.
 Check the Flare system is ready for start-up and nitrogen purged and Fuel Gas System
users are ready for start-up.
 All necessary blinds removed.
 Fire-fighting facilities ready for operation.
 All utilities in service.
 All drains and vents closed.

C. LINING UP OF FUEL GAS SYSTEM
The lining up of the Fuel Gas System is as follows:

1. To start up the Fuel Gas System using the start-up gas line.
2. To take gas from the Condensate Flash Drum.
3. To take gas through the sales gas make-up line from the Mercury Removal Unit D-7001,
when the plant produces sale gas.
4. To take gas from the Amine Flash Drum.
Check that the oxygen content of the fuel gas system is less than 2 per cent.
In the first stage of start-up the Gas Turbine Generators take fuel gas from the trunk line.
When the gas plant shall be in optimal production the gas shall be taken from the sales gas make-
up line.
Ensure that the rest of the plant is either oxygen free or positively isolated from the fuel gas
system.
Initial status of the Fuel Gas System:
 6” VB014 near trunk line on start-up line 6”-B6-FG-70001 closed.

 6” VB014 on start-up line 6”-B6-FG-70001 open.
 640-SDV-01 on line 6”-B6-G-70005 open, 6”VB014 on make-up line near sales gas trunk
line closed.
 640-PIC-05 in manual mode closed, both valves of 640-PCV-05, 6”VB014 upstream and
downstream open.
 640-PCV-04 in service, both valves of 640-PCV-04, 6”VB014 upstream and downstream
open.
 640-PCV-07 in automatic mode with setpoint at 335 PSIG, 3”VB013 upstream valve and
6”VB014 downstream valves open.
 640-SDV-04 open.
 4”VB014 on line 4”-B7-FG-64003 to LP Fuel Gas Header open.
 640-PIC-08, 10 in manual mode closed, both valves of 640-PCV-08, 10, mechanical
valves upstream and downstream open.
 640-PIC-11, 12 in manual mode closed, both valve of 640-PCV-11, 12, mechanical valves
upstream and downstream open.
 2”VB013 on line 2”-B6-FG-64002 to BG header open.
 6”VB014 on line 6”-B7-FG-64022 from Fuel Gas Scrubber D-6401 open.

 640-BDV-01 closed and 2”VB013 upstream and downstream valves open.
 640-PSV-01, 02 in service, set at 500 PSIG.
 640-CSO-01 closed
 640-CSO-02 closed
 6”VB020 on 6”-B9-FG-64009 closed upstream of E-6401A
 6”VB020 on 6”-B9-FG-64010 closed upstream E-6401B
 All CSC of Fuel Gas System closed.
 All CSO of Fuel Gas System open.
 All instruments of the HP Fuel Gas System in service:
 All user’s valves closed with a blind installed. Refer to blind list in Annex 1, 2, and 3.
Note: the first user of F.G. shall be the Flare.
 LP Fuel Gas users shall be isolated with blinds.

 HP users – GTG shall be isolated with blinds.
 Blanket Gas users shall be isolated with blinds
 Pilot gas users shall be isolated with blinds
 Purge gas users other than flare shall be isolated with blinds
On completion of the previous preparations, introduce gas from the trunk line, using the start-up
line, in Fuel Gas System:
 Slowly open 6” VB014 on start-up line 6”-B6-FG-70001, near trunk line.

 Raise the pressure by 40 PSIG/hour. Monitor the increase in pressure on 640-PT-13 and
640-PI-14,
 Put to auto control mode 640-PCV-05 and increase the pressure by a maximum of 40
PSIG/hour, increasing the pressure in all of the FG systems to 50 PSIG.
 Put in auto control mode 640-PCV-08 and 640-PCV-10 and increase the pressure to 50
PSIG in LP Fuel Gas System.
 Check the Fuel Gas System for leaks.
 Put to auto control mode 640-PCV-11 and 640-PCV-12 and increase the pressure in
blanket gas system to 50 PSIG.
 Put in service the 800-PCV-05/06 and increase the pressure to 50 PSIG in the HP Fuel
Gas System at the Power Plant.
 Check the F.G. Systems for leaks.
 Increase by 50 PSIG/hour the pressure in the blanket gas and HP Fuel Gas Systems using
640-PCV-06 and 640-PCV-11.
 Check the Fuel Gas Systems for Leaks.
 Increase the pressure in the HP Fuel Gas Systems to 320 PSIG using 640-PCV-05.
 Check the systems for leaks.

Check that all PCV’s are in auto control mode with the correct setpoints as follows:
 640-PIC-05 = 325 PSIG

 640-PCV-04 = 320 PSIG
 640-PIC-07 = 335 PSIG
 640-PIC-08 = 55 PSIG
 640-PIC-10 = 50 PSIG
 640-PIC-11 = 135 PSIG
 640-PIC-12 = 130 PSIG
 800-PCV-05 = 290 PSIG
 800-PCV-06 = 285 PSIG
Fuel Gas to the Flare System.
 Check that the oxygen content in the flare K.O. Drum D-9002 is below 2 per cent O2 vol.
 Open all purge lines to the flare and commence FG to the flare lines.
 Using 640-PCV-07 in manual mode, open by 5 per cent to start FG to the HP Flare
Header.
 Allow the FG to flush the nitrogen from flare lines for twelve hours and then put the flare
pilots in service
Take gas from the Condensate Flash Drum
After the Condensate Flash Drums becomes operational the FG can be sent to the FG System. The
Condensate Flash Drums D-5101 and D-5201 can be put in service as a fuel gas source one by one
or together.
Check the following:

 Check if the oxygen content in the flare K.O. Drum D-9002 is below 2 per cent O2 vol.
 Fuel Gas Superheater is ready for start-up.
 Fuel Gas Scrubber is in commission with gas from trunk line at 320 PSIG.
 640-SDV-02 open.
 Open carefully 640-CSO-01 and 640-CSO-02.
 6”VB020 on 6”-B9-FG-64009 open upstream of E-6401A.
 6”VB020 on 6”-B9-FG-64010 open upstream of E-6401B.
 510-PIC-01/ 520-PIC-01 in manual mode, close both valve 510-PCV-01/ 520-PCV-01,
mechanical valves inlet and outlet open, by-pass valve closed.
Mechanical valves at Heating Medium circulation open:

 At the first open the return lines 640-SDV-03A, 640-SDV-03B
 2”VG011 on 2”-B7-HM-64007
 2”VG011 on 2”-B7-HM-64005
 2”VG011 on 2”-B7-HM-64001
 2”VG011 on 2”-B7-HM-64002
 640-TIC-03 in manual mode close both valve 640-TCV-03, mechanical valves inlet and
outlet open, by-pass valve closed.
 All instrumentation in service.
On completion of the previous preparations and gas-in to 200 unit, introduce fuel gas from
Condensate Flash Drum:
 Place in service 510-PIC-01/ 520-PIC-01 in auto control mode with set point at 350 PSIG.
 Check for leaks from for example, flanges and valves on lines from the Condensate Flash
Drum D-5101/ 5201, to the Fuel Gas Superheater.
 If a level appear in the Fuel Gas Scrubber, drain this to CHD.
 If the Heating Medium system is in service open 640-TCV-03 gradually and monitor the
increase in temperature.
 Near 225 F place in service 640-TIC-03 set at 229 F, Check that the TIC is controlling
satisfactorily.
 Check the operation of all instruments.
Take gas through sales gas make-up line from Mercury Removal Unit D-7001, when the
plant produces sale gas
The sources for the Fuel Gas System are Trunkline and Condensate Flash Drum.
Initial status as follows:
 6”VB014 on line 6”-B6-G-70005 from 18”-B6-G-70004 sales gas line, closed.
 6”VB014 on line 6”-B6-FG-70001 from 30”-B3-G-70020 trunkline, open.
 640-SDV-01 open in ESD system.
Take gas through sales gas make-up line 18”-B6-G-70004 as follows:

 Gradually open 6”VB014 on line 6”-B6-G-70005 from 18”-B6-G-70004 sales gas line.
 Close 6”VB014 on line 6”-B6-FG-70001 from 30”-B3-G-70020 trunkline.
 Close 6”VB014 on line 6”-B6-FG-70001 downstream check valve.
 At all times monitor the pressure in the Fuel Gas System.
Take gas from Amine Flash Drum as follows:
At this stage the Amine Flash Drum is in service and the pressure is controlled by 310-PIC-07
(320-PIC-07 for train 2).

The Amine Flash Drums D-3103 and D-3203 can be put in service as a fuel gas source one by one
or together.
Initial status as follows:

 310-PIC-01/2 / 320-PIC-01/2 in manual mode, both valves closed, 310-PCV-01/2 / 320-
PCV-01/2 mechanical valves inlet and outlet open, by-pass valve closed
Take LP fuel gas from the Amine Flash Drum as follows:

 Gradually open 310-PCV-01/2 / 320-PCV-01/2
 Place 310-PIC-01/2 / 320-PIC-01/2 setpoint to 65/60 PSIG, check the PIC’S are
controlling satisfactorily.
 With explosivimeter check for leaks from flanges, valves and so on on lines from the
Amine Flash Drums D-3103/ D3203.
 Check the operation of all instrumentation.

6. NORMAL SHUTDOWN................................................................................................................835
A. GENERAL.............................................................................................................................. 84
B. SCHEDULED SHUTDOWN FOR SHORT DURATION..................................................... 84
C. SHUTDOWN FOR MAINTENANCE...................................................................................84

6. NORMAL SHUTDOWN
A. GENERAL
To shutdown the Fuel Gas System the principal steps are as follows:
 Close fuel gas users.

 Close fuel gas sources.
 Depressurize the Fuel Gas System to flare.
 Purge the system with nitrogen.
B. SCHEDULED SHUTDOWN FOR SHORT DURATION
Close fuel gas users:

 Close control valves with mechanical valves for each Fuel Gas Header.
 Close one by one all fuel gas users.
 If necessary to prepare part of the system for maintenance, isolate this part of the system,
depressurize, install nitrogen supply connection from N2 cylinder at one drain or vent
valve of the system involved in the procedure and purge the system with nitrogen. The
system will be purged to the flare.
Close fuel gas sources:

 Gradually close 6”VB014 on line 6”-B6-G-70005 from the sales gas line18”-B6-G- 70004.
 With 510-PIC-01 and 520-PIC-01 in manual mode, close control valves 510-PCV-01 and
520-PCV-01 from the Condensate Flash Drum.
 With 310-PIC-01/2 and 320-PIC-01/2 in manual mode, close control valves 310-PCV-
01/2 and 320-PCV-01/2 from the Amine Flash Drum.
Pressure should decrease in the Fuel Gas System as the control valves, that maintain the pressure,
are open.
C. SHUTDOWN FOR MAINTENANCE
The fuel gas system is most important for the operation of the whole complex.
Important instruments and those requiring frequent maintenance are doubled up:
For example, Safety valves and Pressure controllers are double and so on.

For a scheduled shutdown proceed as follows:
Close fuel gas users:

 Close valves at the limit of each user along the distribution headers.
Close fuel gas sources:
 Gradually close 6”VB014 on line 6”-B6-G-70005 from sales gas line 18”-B6-G-70004.
 With 510-PIC-01 and 520-PIC-01 in manual mode, close control valves 510-PCV-01 and
520-PCV-01 from the Condensate Flash Drum.
 With 310-PIC-01/2 and 320-PIC-01/2 in manual mode, close control valves 310-PCV-
01/2 and 320-PCV-01/2 from the Amine Flash Drum.
Pressure should decrease in the Fuel Gas System as the control valves, that maintain the pressure,
are open.
Depressurize the Fuel Gas System to the flare:

 With 640-PIC-07 in manual mode open 640-PCV-07 and depressurize the Fuel Gas
System to the HP Flare Header.
Purge the system with nitrogen (similar to point 5C1) as follows:
 With a temporary hose connection, pressurize the whole system to 30 PSIG.

 Depressurize to almost atmospheric pressure to flare.
 Continue pressurization/depressurization operation until no explosivity is detected in
various points of the system.
Install blinds or turn spectacle blinds where required to isolate the fuel gas system from other
system that are still contain hydrocarbon pressure.

7. EMERGENCY SHUTDOWN..........................................................................................................87
A. GENERAL.............................................................................................................................. 87
B. UTILITY FAILURE................................................................................................................87
C. OTHER FAILURES................................................................................................................89

7. EMERGENCY SHUTDOWN
A. GENERAL
Emergencies shall generally require an immediate and complete stoppage of operation of the Fuel
Gas System, depressurization and in most instances with hydrocarbons eliminated to the maximum
extent possible in the shortest time as determined by the emergency.
Emergency procedures depend mainly on the experience and judgment of the operator.
The quick indication of a utility or equipment failure is very important.
The duration of the failure is an important factor in the selection of the emergency procedure.
Some emergencies can be foreseen, other such as rupture of lines or vessels, cannot be made
failsafe and require the immediate shutdown of the unit.
There are for levels of ESD for the gas plant (ESD 1, 2, 31, 32)
For Fuel Gas System only ESD 1 is applicable
ESD 1 Total plant shutdown with depressurization.
a) Fire detected in a process area (except the Flare Knock Out Drum and associated pumps).
b) Gas detected in any of the plant control buildings or electrical sub-station.
c) Gas detected in the MEG regeneration packages of Train 1 or Train 2.
d) Gas detected in the Heating Medium.
e) Operation of the ESD 1 field push buttons (installed at seven (7) different locations
around the plant).
f) Operation of the ESD 1 push button in the Control Room.
ESD level 2 – Total plant shutdown without depressurization

ESD level 31 – shutdown for Train 1 without depressurization
ESD level 32 – shutdown for Train 2 without depressurization
B. UTILITY FAILURE
Coincident loss of Power from the 13.8 KV buses 1&2
Upon loss of power, the instrument air compressors shall trip. One air compressor is connected to
emergency generator two.

Instrument Air Failure (ESD level 2)
Instrument Air Failure initiate ESD level 2. If one air compressor is not started by emergency
generator all pneumatic operated valves will move to their failure position as follows:
640-PCV-05 closed
640-PCV-07 open
640-PCV-08 closed
640-PCV-10 closed
640-PCV-11 closed
640-PCV-12 closed
640-TCV-03 closed
Also SDV's shall go to the closed position and BDV shall go to the open position as follows:
640-SDV-01 close
640-SDV-02 close
640-SDV-03A close
640-SDV-03B close
640-SDV-04 close
640-BDV-01 open
Depressurizations to the HP Flare Header as follows:
 Through 640-PCV-07 HP Fuel Gas Header.

 Through 640-BDV-01 lines from the Fuel Gas Scrubber.
For the continuous operation of GTG, following actions are required:

 Open 6”VB014 on 6”-b6-fg-70001
 Close 3”VB014 upstream and downstream of 640-PCV-07
Close mechanical valves to protect the control valves of system as follows:
 6”VB014 upstream and downstream of 640-PCV-05 on line 6”-B6-G-64001.

 4”VB014 upstream and downstream of 640-PCV-08, 10 on line 4”-B7-FG-64003.
 2”VB013 upstream and downstream of 640-PCV-11, 12 on line 2”-B7-FG-64002.
 2”VG011 upstream and downstream of 640-TCV-03 on line 2”-B7-HM-64007.
ESD 2 except Instrument Air Failure

If shutdown is not caused by an instrument air failure, the control valves are operated in normal
condition by DCS.
C. OTHER FAILURES
Fuel Gas Superheater Tube Rupture
A check valve is installed on the heating medium line upstream of each Fuel Gas Superheater to
prevent back flow and a pressure switch high-high (640-PSHH-01A/B) is located downstream of
the superheater. In the event of tube rupture, high pressure gas enter into pressure heating medium
tube. The high pressure is detected by 640-PSHH-01 A/B. It will close 640-SDV-03 A/B to
prevent the heating medium system from the high pressure.
The 2”VG011 must be closed in this situation as soon as possible. The check valve and the
valves can pass, therefore the HM Expansion Drum must be monitored carefully.

8. MAJOR EQUIPMENT.......................................................... Error: Reference source not found
A. SPECIFICATIONS OF EQUIPMENT................................................................................... 91
B. INSTRUMENT SUMMARY..................................................................................................97

8. MAJOR EQUIPMENT
A. SPECIFICATIONS OF EQUIPMENT
FUEL GAS SCRUBBER (D-6401)
This is a vertical 2-phase separator. A 10 per cent design margin has been applied to the gas and
liquid flowrates for sizing the vessel. The Fuel Gas Scrubber dimensions are 3’ D x 9’ H (T/T).
The maximum pressure drop across the vessel, including inlet and outlet nozzles, is less than 2
psi.
ITEM: D-6401
Service: FUEL GAS SCRUBBER ASME SECTION VIII, DIV.I

Operating Design
E T
Pressure [psig] [psig] T.L.
T/T : 9’-0”
Maximum 425 500
Minimum 325
Temperature [F] [F] PSV PT
Upper 229 320
Lower 185 25 TI
D-6401
Shell & Heads Internals*
Materials CS(SA516GR70) AISI316L SS A
Corr. Allow 3 mm
HC
Insulation YES (HC) LG
Lining YES H
Lower T.L. elevation above ground
P I.D: 3’-0”
MIN.
D
*Demister is 6” thick mesh, bulk density
12 lb/ft3.xsa 7ft2 T.L
LG
Nozzle Data
Ref No.  Service F
A 1 6” Vapour Inlet
D 1 2” Drain
E 1 2” Vent
F 1 2” Liquid outlet

H 1 8” Hand Hole
P 1 2” Purge Connection
PSV 1 2” Safety valve
T 1 6” Vapour outlet
PT 1 2” Pressure Transmitter
LG 2 2” Level Bridle
TI 1 2” Temperature Indicator

ITEM: D-6401
Service: FUEL GAS SCRUBBER ASME SECTION VIII, DIV. I

PROCESS DESIGN DATA
Case No. 1 2 3 Remarks
Case Description HIGH LOW
TEMPERATURE TEMPERATURE
CASE CASE
Operating Pressure psig 325 325
Temperature F 229 185
Vapour Flowrate lb/h 21,570 21,403 note 1

3
Vapour Density @T, P lb/ft 1.18 1.24
Vapour Viscosity @ T, P cP 0.0144 0.0140
Vapour Mol. Weight 24.5 24.0
Liquid Flowrate lb/h 2,157 2,140 Assumed 10%

Liquid Density @ T, P lb/ft3 42.41 43.81 carry-over
Liquid Viscosity @ T,P cP 0.449 0.551
Liquid Surface Tension dyne/cm
Water Flowrate lb/h

Water Density lb/ft3
Water Viscosity cP
Water Surface Tension dyne/cm
Notes:
1. The vessel is designed as a 2-phase separator capable of operating with the process conditions given in cases 1
and 2 above. A 10 per cent design margin is applied to the gas and liquid flowrates for sizing the separator.
2. The vessel is also capable of operating at all flowrates down to the minimum turndown of 30 per cent for cases 1
and 2.
3. The maximum pressure drop through the separator does not exceed 2 psi including inlet and outlet nozzle losses.
4. BELZONA 1591 has been applied.

FUEL GAS SUPERHEATER (E-6401 A/B).
Fuel gas superheater is a hairpin type heat exchanger providing 100 F of superheat using heating
medium. The exchanger is a TEMA class R exchanger with the feed gas on the external tube and
heating medium on the inside tube. A 10 per cent over-surface design margin has been included in
the design. A 100 per cent spare exchanger is installed to facilitate maintenance work to be
performed without necessitating plant shutdown, or flaring of Condensate Flash Drum vapor from
both trains.
ITEM E-6401 A/B
Service FUEL GAS SUPERHEATER

Size 8”x 84” Type note 2 Arrangement: HORIZONTAL 2 tube passes
Operation Continuous
Heat Exchanged 1,131 MMBtu/h; MTD (Corrected) 112 deg F
2
Transfer Rate: service 79.5 (note 2) Clean 116 (note 2) [btu/h ft degF]
Surf/Unit (Eff) 127ft2 Shells/Unit Surf/Shell (Eff) 127 ft2
Fluid: -Shell Side Fuel gas Tube Side: Heating Medium (50% TEG Solution)
PROCESS DATA Design Case – High Temperature Case

Fluid Allocation Shell Side Tube Side
Total Flow Rate [lb/h] 21.570 22.352
Inlet Outlet Inlet Outlet
Vapour: HC [lb/h] 19.457 19.457 0 0
Water [lb/h] 106 106 0 0
Noncondendensable [lb/h] 2.007 2.007 0 0
Liquid: TEG [lb/h] 0 0 11.176 11.176
Water [lb/h] 0 0 11.176 11.176
Operating temperature [F] 129 229 320 265
Operating Pressure [psig] 335 325 101.4 91.4
Design Temperature Max./ Min. [F] 320/25 400/25
Design Pressure [psig] 500 350
Allowable Pressure Drop/ Calc [psi] 10/ 10/
Vacuum Rating [Inch Hg]
2
Fouling factor [h ft deg F/Btu] 0.001 0.002
Velocity [ft/s] 43 1.36
PHYSICAL PROPERTIES
LIQUID:
Specific Gravity @ 60F 1.084 1.084
Specific Gravity T, P 0.970 0.984

Viscosity @ T,P [cP] 0.496 0.585
Specific Heat [Btu/lb deg F] 0.937 0.903
Thermal Conductivity [Btu/h ft deg F] 0.233 0.232
Enthalpy [Btu/lb] -242.679 -292.278
Pour point [F]
Surface Tension [dyne/cm]
ITEM E-6401 A/B

Shell Side Tube Side
VAPOUR: INLET OUTLET INLET OUTLET

Molecular Weight 24.5 24.5
Density @ T, P [lb/ft3] 1.48 1.18
Viscosity @ T, P [cP] 0.0126 0.0144
Specific Heat [Btu/lb deg F] 0.508 0.536
Thermal Conductivity [Btu/h ft deg F] 0.0192 0.0234
Enthalpy [Btu/lb] -1738.943 -1686.509
Latent Heat of Evaporation [Btu/lb@F]
Material of Construction
Construction Code ASME SECTION VIII. DIV. I TEMA’R’
Shell Side Tube Side
Diameter ID 8” Length 84”
Corrosion Allowance 3 mm O.D. ¾” BWG 14 Pitch: 30 15/16”
Shell Material CS Corrosion Allowance 1.5 mm
Shell Cover Material CS Tube Material CS
Floating Head Material CS Tube Sheet Material CS
Channel Cover Material CS
Double Pipe or Hairpin type Exchanger No. of Tubes 42
Double Pipe allowed: YES Multistage allowed: YES / NO
Process Nozzles Shell side: Inlet: 6 inch Outlet: 6 inch

Tube side: Inlet: 2 inch Outlet: 2 inch

ITEM E-6401 A/B

Notes:
1. The exchanger is designed for 10 per cent oversurface.

2. Hairpin type (Multi tube).

B. INSTRUMENT SUMMARY
INSTRUMENT LIST – sheet 1
UNIT TAG NO. TYPE P&ID NO. LOCATION REMARKS

NO. 1 2 3
640 PI 01 S C2-0184 DCS PAH AND PAL REQUIRED
640 PI 02 D C2-0184 L HP FUEL GAS TO GAS
TURBINE
640 PI 03 D C2-0184 L GAS TO D-6401
640 PI 04 S C2-0184 DCS D-6401
640 PI 05 D C2-0184 L D-6401
640 PI 07 D C2-0184 L HP FUEL GAS TO GAS
TURBINE
640 PI 08 D C2-0184 L TO LP DISTRIBUTION
640 PI 09 D C2-0184 L TO BG DISTRIBUTION
640 PI 10 A D C2-0184 L HM INLET IN E-6401 A
640 PI 10 B D C2-0184 L HM INLET IN E-6401 B
640 PI 11 A D C2-0184 L HM OUTLET E-6401 A
640 PI 11 B D C2-0184 L HM OUTLET E-6401 B
640 PI 12 A D C2-0184 L GAS FROM E-6401A
640 PI 12 B D C2-0184 L GAS FROM E-6401B
640 PI 13 S C2-0184 DCS GAS FROM D-7001
640 PI 14 D C2-0184 L GAS FROM D-7001
640 TI 01 S C2-0184 DCS HP FUEL GAS TO GTG
640 TI 02 D C2-0184 L LP FUEL GAS TO
DISTRIBUTION
640 TI 03 D C2-0184 L HP FUEL GAS TO GTG
640 TI 04 D C2-0184 L GAS TO D-6401
640 TI 05 D C2-0184 L D-6401
640 TI 07 S C2-0184 DCS SALES GAS FROM D-7001
640 TI 08 D C2-0184 L SALES GAS FROM D-7001
640 TI 09 D C2-0184 L BG TO DISTRIBUTION
640 TI 10 A D C2-0184 L HM TO E-6401 A
640 TI 10 B D C2-0184 L HM TO E-6401 B
640 TI 11 A D C2-0184 L HM FROM E-6401 A
640 TI 11 B D C2-0184 L HM FROM E-6401 B
640 FI 01 /1 S C2-0184 DCS HP TO GTG
640 FI 01 /2 S C2-0184 DCS HP TO GTG

640 FI 02 S C2-0184 DCS LP TO DISTRIBUTION
640 FI 03 /1 S C2-0184 DCS SALES GAS FROM D-7001
640 FI 03 /2 S C2-0184 DCS SALES GAS FROM D-7001
640 PT 05 E C2-0184 L HP FUEL GAS
640 PIC 05 S C2-0184 DCS ARWU REQUIRED
640 PT 06 E C2-0184 L HP FUEL GAS


NO. 1 2 3
640 PT 07 E C2-0184 L TO HP FLARE HEADER
640 PT 08 E C2-0184 L LP FUEL GAS
640 PT 10 E C2-0184 L LP FUEL GAS
640 PT 11 E C2-0184 L BG CONTROLER
640 PT 12 E C2-0184 L BG CONTROLER
640 TT 03 E C2-0184 L GAS FROM E-6401 A,B
640 TIC 03 S C2-0184 DCS TAH AND TAL REQUIRED
640 FY 01 S C2-0184 DCS SQUARE ROOT
EXTRACTOR
640 FY 01 /1 S C2-0184 DCS MULTIPLIER
640 FY 01 /2 S C2-0184 DCS DIVIDER
640 FY 01 /3 S C2-0184 DCS CONSTANT
640 FQI 01 S C2-0184 DCS HP TOTALISER
EXTRACTOR
EXTRACTOR
640 FY 03 /1 S C2-0184 DCS MULTIPLER
640 FY 03 /2 S C2-0184 DCS DIVIDER
640 FY 03 /3 S C2-0184 DCS CONSTANT
640 FT 03 E C2-0184 L SALES GAS TO FUEL GAS
MAKE-UP
640 FQI 03 S C2-0184 DCS SALES GAS TOTALISER
640 PT 13 E C2-0184 L PRESSURE TRANSMITTER
640 TE 07 E C2-0184 L TEMPERATURE ELEMENT
640 TT 07 E C2-0184 L TEMPERATURE
TRANSMITTER
640 TW 07 - C2-0184 L TERMOWELL
640 BPBC 01 E C2-0184 L RESET
640 BZSC 01 E C2-0184 L BDV POSITION SWITCH

CLOSED
640 BZSO 01 E C2-0184 L BDV POSITION SWITCH
OPEN
640 BY 01 S C2-0184 ESD ESD SYSTEM LOGIC
FUNCTION
640 BPBO 01 S C2-0184 DCS BDV PUSH BUTTON OPEN
640 BZA 01 S C2-0184 DCS POSITION FAULT
640 BZLC 01 S C2-0184 DCS BDV POSITION INDICATOR
LIGHT CLOSED
640 BZLO 01 S C2-0184 DCS BDW POSITION INDICATOR
LIGHT OPEN


NO. 1 2 3
640 BXSV 01 /1 E C2-0184 L BDV SOLENOID OPERATED
VALVE
640 BXSV 01 /2 E C2-0184 L BDV SOLENOID OPERATED
VALVE
640 SPBO 01 E C2-0184 L RESET
640 SZSC 01 E C2-0184 L SHUTDOWN POSITION
SWITCH CLOSED
640 SZSO 01 E C2-0184 L SHUTDOWN POSITION
SWITCH OPEN
640 SY 01 S C2-0184 ESD ESD SYSTEM LOGIC
FUNCTION
640 SPBC 01 S C2-0184 DCS SHUTDOWN PUSH BUTTON
640 SZA 01 S C2-0184 DCS POSITION FAULT
640 SZLC 01 S C2-0184 DCS SHUTDOWN POSITION
INDICATOR LIGHT CLOSED
640 SZLO 01 S C2-0184 DCS SHUTDOWN POSITION
INDICATOR LIGHT OPEN
640 SXSV 01 /1 E C2-0184 L SHUTDOWN SOLENOID
OPERATED VALVE
OPERATED VALVE
SWITCH CLOSED
SWITCH OPEN
FUNCTION
CLOSE
640 SZLO 02 S C2-0184 DCS SHUTDOWN INDICATOR
LIGHT OPEN

OPERATED VALVE
OPERATED VALVE
640 PSHH 01 A E C2-0184 L PRESSURE SWITCH HIGH-
HIGH
640 PAHH 01 A S C2-0184 DCS HM FROM E-6401 A
640 SPBO 03 A E C2-0184 L RESET
640 SZSC 03 A E C2-0184 L SHUTDOWN POSITION
SWITCH CLOSED
640 SZSO 03 A E C2-0184 L SHUTDOWN POSITION
SWITCH OPEN
640 SY 03 A S C2-0184 ESD ESD SYSTEM LOGIC
FUNCTION
640 SPBC 03 A S C2-0184 DCS SHUTDOWN PUSH BUTTON
CLOSE


NO. 1 2 3
640 SZA 03 A S C2-0184 DCS POSITION FAULT
640 SZLC 03 A S C2-0184 DCS SHUTDOWN POSITION
640 SZLO 03 A S C2-0184 DCS SHUTDOWN POSITION
640 SXSV 03 A/1 E C2-0184 L SHUTDOWN SOLENOID
OPERATED VALVE
640 PSHH 01 B E C2-0184 L PRESSURE SWITCH HIGH-
HIGH
640 PAHH 01 B S C2-0184 DCS HM FROM E-6401 A
640 SPBO 03 B E C2-0184 L RESET
640 SZSC 03 B E C2-0184 L SHUTDOWN POSITION
SWITCH CLOSED
640 SZSO 03 B E C2-0184 L SHUTDOWN POSITION
SWITCH OPEN
640 SY 03 B S C2-0184 ESD ESD SYSTEM LOGIC
FUNCTION
640 SPBC 03 B S C2-0184 DCS SHUTDOWN PUSH BUTTON
CLOSE
640 SZA 03 B S C2-0184 DCS POSITION FAULT
640 SZLC 03 B S C2-0184 DCS SHUTDOWN POSITION
640 SZLO 03 B S C2-0184 DCS SHUTDOWN POSITION
640 SXSV 03 B/1 E C2-0184 L SHUTDOWN SOLENOID
OPERATED VALVE
SWITCH CLOSED
SWITCH OPEN
FUNCTION
CLOSE

SWITCH CLOSED
640 SZLO 04 S C2-0184 DCS SHUTDOWN POSITION
SWITCH OPEN
OPERATED VALVE
OPERATED VALVE
640 RO 01 - C2-0184 L TO HP FLARE
640 LSH 01 E C2-0184 L D-6401
640 LAH 01 S C2-0184 DCS D-6401
640 LG 01 D C2-0184 L D-6401
640 PT 04 E C2-0184 L D-6401


NO. 1 2 3
640 XA 05 S C2-0184 DCS DEVIATION
640 TW 10 A - C2-0184 L TERMOWELL
640 TW 10 B - C2-0184 L TERMOWELL
640 TW 11 A - C2-0184 L TERMOWELL
640 TW 11 B - C2-0184 L TERMOWELL
640 PT 01 E C2-0184 L HP TO GTG
640 TT 01 E C2-0184 L HP TO GTG
640 FE 01 - C2-0184 L FLOW ELEMENT
640 FT 01 E C2-0184 L HP FUEL GAS TO POWER
PLANT
640 FE 02 - C2-0184 L FLOW ELEMENT

DATA SHEET-Sheet 1

REV DATE BY CHK'D APP'D
INSTRUMENT DATA SHEETS 1 04/09/00 J.B.R T.S.K S.K.K
2 18/10/00 J.B.R T.S.K S.K.K
FOR
3 29/06/01 J.B.R Y.N.K K.C.IM
LEVEL SWITCHES 4 18/09/01 J.B.R S.K.K S.K.K UNIT 640
5 09/05/02 J.B.R S.K.K S.K.K
1. Tag No. 640-LSH-01
2. P&ID No. C2-0184
3. Line No. / Vessel No. D-6401
4. Manufacturer Solartron Mobrey
GENERAL
5. Model No. BC3FR4N1H8 / 122
6. Piping Material Class B7
7. Area Classification as per Weatherproof
NEC (Suitable for I.S. service)
8. Type Float
9. Connection Size & Rating 1 1/2" 300# RF
10. Body Material Carbon Steel
11. Center to Center [mm] 356
BODY OR
12. Connection Type External
CAGE
13. Case Mounting Type Top-Side-Bottom
14. Rotatable Head Yes
15. Cooling Fin or Extension N/A
16. Dimensions [mm] -

17. Insertion Depth [mm] N/A
18. Displacer Extension [mm] -
FLOAT OR
19. Displacer or Float Mat'l 316SS
DISPLACER
20. Tube / Union Mat'l Monel 500
21. Set point [mm] 100
(From upper flange)
22. Type Hermetically Sealed, Snap
23. Form 1-DPDT
24. Switch certification -
Enclosure Rating IP-66
25. Electrical Connection 1/2" NPT(F)
26. Rating : Volts (DC / AC) 24V DC
SWITCH 27. Amps. Watts 0.25A
28. Load Type - Ind. Non-Ind. NON IND.
29. Diff : Fixed Adjust YES
30. Adjust. : Int Ext. N/A
31. Contact Actions
Open On Incr. YES YES
Close Level Decr.
32. Upper Fluid
33. Lower Fluid Water (L)
34. Specific Gravity
SERVICE Upper Lower 0.68/0.70
CONDITION 35. Minimum Sp. Gr. Diff.
(High temp. 36. Pressure (psig)
/ Low temp.) Operating Maximum 325 500
37. Temperature (F )
Operating Maximum 229/185 320

DATA SHEET-Sheet 2

FOR 1 19/08/00 J.B.R T.S.K S.K.K
LEVEL GAUGES 2 25/06/01 J.B.R Y.N.K K.C.IM
1 Gauge Column X Cocks X GAUGE COCKS

Assembled with Nipples X 7 Type : Offset X
8 Conn : Vessel 1" 300# RF
GAUGE GLASSES Gage 3/4" NPT (M)
2 Type : Reflex X Transparent Tubular Vent 3/4" NPT (F) + Plug
Large Chamber Weld Pad Drain 3/4" NPT (F) + Plug
3 Conn : Size and Type : 1" 300# RF 9 Material Body CS Trim 316 SS
Top & Bot. Side X Back 10 Min. Rating 550 psig at 600 F
Vent : 3/4" NPT Drain : 3/4" NPT 11 Construction : Quick closing
4 Material FORGED CARBON STEEL (Except as note 3,4) 12 Bonnet : Union
5 Min. Rating 550 psig at 600 F 13 Options : Ball Checks X Renewable Seats X
6 Options : Internal Tube Mica Shield Other
Non-Frost External Jkt 14 Manufacturer : Jerguson
Calb.Scale Ext-Length 15 Model No. : 66
Illuminator
- Power Supply :
- Area Classification :
- Enclosure :
- Cable entry :
Other
Visible C to C Glass Operating (Note 2.)
Rev. Tag No. Length Length Model Press. Temp. Service (Equipment) P&ID No.
(mm) (mm) No. (psig) ( F)
2 640-LG-01 679 683 29 RCH-20 325.3 229/185 D-6401 C2-0184
D-8001
NOTES : 1. All gauge glasses shall be armoured type.
2. High Temp Case / Low Temp. Case
3. Chamber Material : 316LSS, Gauge cock body & trim Material : 316LSS
4. Chamber Material : LTCS, Gauge cock body Material : LTCS, Gauge cock trim Material : 316SS

DATA SHEET-Sheet 3

INSTRUMENT DATA SHEETS 0 31/01/01 J.B.R Y.N.K S.K.K
FOR 1 13/09/01 J.B.R Y.N.K K.C.I
ORIFICE PLATES & FLANGES 2 28/10/01 J.B.R S.K.K S.K.K
UNIT 640
ORIFICE PLATES ORIFICE FLANGES

1 Concentric X Other 7 Taps : Flange X Vena Contracta
2 ISA Standard Other ISO 5167 Pipe Other
3 Bore : Maximum Rate X Nearest 1/8" 8 Tap Size : 1/2" X Other NPTF
4 Material : 304SS 316SS X 9 Type : Weld Neck X Slip On Threaded
Other 10 Material : Steel Other See Below
5 Ring Material & Type 11 Flanges included X By Other
6 MFR & Model No. ISA / Type A 12 Flange Rating See Below
13 Tag No. 640-FE-01 640-FE-02 640-FE-03

14 Service HP Fuel Gas Fuel Gas Sales Gas from
GENERAL to Power Plant to LP Fuel Gas Distribution D-7001
15 Line Number 6"-B7-FG-64004 8"-B7-FG-64013 6"-B6-FG-64001
16 P & ID No. C2-0184 C2-0184 C2-0184
17 Fluid Fuel Gas Fuel Gas Fuel Gas
18 Fluid State Vapor Vapor Vapor
19 Maximum Flow 36694 (lb/h) 15348.3 (lb/h) 35558.6 (lb/h)
20 Normal Flow 33358 (lb/h) 13953 (lb/h) 32326 (lb/h)
21 Pressure (psig) Nor. Max. 325.3 500 55.3 500 672.1 720
22 Temperature (F) Nor. Max. 106 260 168.6 260 127.7 180
23 Specific Gravity at Base (60F)
FLUID 24 Operating Spec.Gravity
DATA 25 Supercomp. Factor
(High temp. 26 Mol. Weight Cp/Cv 19.9 1.236 24.02 1.218 18.71 1.217
/ Low temp.) 27 Operating Viscosity [cP] 0.0118 0.0132 0.0132
28 Quality % or Superheat
29 Base Press. Base Temp.
30 Meter Max. 38700 (lb/h) 16200 (lb/h) 37500(lb/h)
31 Min. Flow 9956.1 (lb/h) 4134.3 (lb/h) 9542.4 (lb/h)
32 Upstream Density (lb/ft3) 1.259 0.252 2.251
33
34 Type of Meter D/P D/P D/P

35 Diff.Range-Dry (in-H2O) 100 100 100
36 Seal Sp.Gr.at 15.6C
METER 37 Static Press. Range
38 Chart or Scale Range
39 Chart Multiplier
40
41 Beta=d/D 0.62 0.47 0.54
42 Orifice Bore Diameter 97.0 (mm) 97.2 (mm) 84.2 (mm)
43 Vent or Drain Hole Drain Drain Drain
44 Vent or Drain Hole Diameter 3 (mm) 3 (mm) 2.38 (mm)
45 Line I.D. Sch 40 Sch 40 Sch STD
PLATE &
46 Plate Thickness 6 mm 6 mm 6 mm
FLANGE
47 Flange Con. Size & Rating ASME 6" 300# RF 8" 300# RF 6" 300# RF
48 Flange Material A105 A105 A105
49 Gasket Material Note 2. Note 2. Note 2.
50 Bolt & Nuts Material Note 2. Note 2. Note 2.
51 Piping Material Class B7 B7 B6
NOTES : 1. Unit : Pressure(psi), Temperature(F), Flow(Liquid : USGPM, Gases : SCFH, Steam or Vapor : LB/h)
* USGPM : US gallon per minutes, SCFH : standard cubic foot per hour
2. Vendor shall provide the Bolt, Nut & Gasket material as per piping specification. (See attached technical note.)

DATA SHEET-Sheet 4

FOR 1 04/10/00 J.B.R T.S.K S.K.K
PRESSURE GAUGES 2 26/10/00 J.B.R T.S.K S.K.K
(DIRECT MOUNTING) 3 13/09/01 J.B.R Y.N.K K.C.I
1 Type : Direct Rdg X 3~15 lb receiver 10 MFR. & Model No. WIKA / 232.30.160
Other 11 Press. Element : Bourdon X Bellows
2 Mounting : Surface Local X Flush Other
3 Dial : Diameter 160mmΦ Color Note 1. 12 Element Mtl : Bronze Steel 316 SS Ti
4 Case : Cast Iron Alumin. Phenol 13 Socket Mtl : Bronze Steel 316 SS Ti
Other 304SS Other
5 Ring : Screwed X Hinged Slip 14 Connection : PT NPT X PF
Std Other 1/2" X 1/4" Other NPT(M)
6 Blow-out Protection : None Back X Disc Bottom X Back
Solid Front X Other 15 Movement : Bronze SS X Nylon
7 Lens : Glass Plastic Shatterproof X Other
8 Option : 1. Siphon Material 16 Diaphragm Seal
2. Snubber Material MFR. Type
3. Pressure Limit Valve Material Wetted Part Mtl Other Mtl
4. Movement Damping Material Fill Fluid
9 Nominal Accuracy Required ±1.0% F.S. Process Conn Gage Conn
Range Pressure (psig) Temperature (? )
Rev. Tag No. Service P&ID No.
(psig) Nor. Max. Nor. Max.
3 640-PI-02 0 - 500 325.3 500 161 260 HP fuel gas to power plant C2-0184
3 640-PI-03 0 - 500 325.3 500 229 260 Fuel gas to D-6401 C2-0184
3 640-PI-05 0 - 500 325.3 500 229 260 D-6401 C2-0184
3 640-PI-06 0 - 500 335.3 500 129 260 Fuel gas to E-6401B C2-0184
3 640-PI-08 0 - 100 55.3 100 214 260 Fuel gas to LP fuel gas dist. C2-0184
3 640-PI-09 0 - 200 135.3 162 95.1 260 Blanket / pilot gas distribution C2-0184
3 640-PI-10A 0 - 250 118.3 210 320 400 Heating medium to E-6401A C2-0184
3 640-PI-10B 0 - 250 118.3 210 320 400 Heating medium to E-6401B C2-0184
3 640-PI-03 0 - 500 325.3 500 229 260 Fuel gas to D-6401 C2-0184
3 640-PI-05 0 - 500 325.3 500 229 260 D-6401 C2-0184
3 640-PI-06 0 - 500 335.3 500 129 260 Fuel gas to E-6401B C2-0184
3 640-PI-08 0 - 100 55.3 100 214 260 Fuel gas to LP fuel gas dist. C2-0184
3 640-PI-09 0 - 200 135.3 162 95.1 260 Blanket / pilot gas distribution C2-0184
3 640-PI-10A 0 - 250 118.3 210 320 400 Heating medium to E-6401A C2-0184
3 640-PI-10B 0 - 250 118.3 210 320 400 Heating medium to E-6401B C2-0184
3 640-PI-11A 0 - 250 113.3 210 265 400 Heating medium from E-6401A C2-0184
3 640-PI-11B 0 - 250 113.3 210 265 400 Heating medium from E-6401B C2-0184
3 640-PI-12A 0 - 500 325.3 500 229 400 Fuel gas from E-6401A C2-0184
3 640-PI-12B 0 - 500 325.3 500 229 400 Fuel gas from E-6401B C2-0184
3 640-PI-14 0 - 1000 670 720 128 180 Sales gas from D-7001 C2-0184
NOTES : 1. All gauges shall have a white background with black scale markings.

DATA SHEET-Sheet 5

FOR 1 04/10/00 J.B.R T.S.K S.K.K
PRESSURE GAUGES 2 26/10/00 J.B.R T.S.K S.K.K
(SAMPLE CONNECTION) 3 13/09/01 J.B.R Y.N.K K.C.I
1 Type : Direct Rdg X 3~15 lb receiver 10 MFR. & Model No. WIKA / 232.30.160
Other 11 Press. Element : Bourdon X Bellows
2 Mounting : Surface Local X Flush Other
3 Dial : Diameter 160mmΦ Color Note 1. 12 Element Mtl : Bronze Steel 316 SS Ti
4 Case : Cast Iron Alumin. Phenol 13 Socket Mtl : Bronze Steel 316 SS Ti
Other 304SS Other
5 Ring : Screwed X Hinged Slip 14 Connection : PT NPT X PF
Std Other 1/2" X 1/4" Other NPT(M)
6 Blow-out Protection : None Back X Disc Bottom X Back
Solid Front X Other 15 Movement : Bronze SS X Nylon
7 Lens : Glass Plastic Shatterproof X Other
8 Option : 1. Siphon Material 16 Diaphragm Seal
2. Snubber Material MFR. Type
3. Pressure Limit Valve Material Wetted Part Mtl Other Mtl
4. Movement Damping Material Fill Fluid
9 Nominal Accuracy Required ±1.0% F.S. Process Conn Gage Conn
Range Pressure (psig) Temperature (? )
(psig) Nor. Max. Nor. Max.
3 640-PI-101A 0 - 100 55.3 100 214 260 Fuel gas to flare header C2-0184
3 640-PI-101B 0 - 100 55.3 100 214 260 Fuel gas to flare header C2-0184
NOTES : 1. All gauges shall have a white background with black scale markings.

DATA SHEET-Sheet 6

FOR 1 18/10/00 J.B.R T.S.K S.K.K
D/P TRANSMITTERS (FLOW) 2 19/04/01 J.B.R Y.N.K K.C.IM
1 Tag No. SEE PAGE 2 & 3 Service SEE PAGE 2 & 3

Manufacturer Hartmann & Braun
Model No. ASK 800/V15990A-43XX10-Y04-050-161-064-070-220-270/557/244/202/142/395/Z2E (For 300-FT-08A/B/C)
Model No. ASK 800/V15990A-45XX14-Y04-050-161-064-070-220-270/557/244/202/142/395/Z2E
(For 410/420-FT-02A/1,02B/1,03A/1,03B/1,12A/1,12B/1)
(Max. Pressure : 800 psig or less)
(Max. Pressure : Over 800 psig up to 2000 psig)
2 Function Record Indicate X Control Blind Trans X
GENERAL 3 Case MFR STD X Nom. Size Color : MFR STD X Other
4 Mounting Flush Surface Yoke X Other
5 Enclosure Class Area Classification Class ? , Div 1, Gr B
Enclosure Rating IP-65
Certification EExia IIC T6 Zone 0
6 Power Supply 117V 60Hz Other AC DC 24 Volts
7 Chart 12 in. Circ. Other Range No.
8 Chart Drive 24 hr Other Elec. Spring Other
9 Scale Type Actual Reading (Model : 416) Range : 1 2 3
10 Transmitter 4~20mA X 10~50mA 0.2~1.0 Kg/Cm2G (3~15 psig) Other
XMTR Output For Receiver See Spec. Sheet
11 Control Modes P=Prop (Gain) I=Integral (Auto-Reset) D=Derivative (Rate)

Sub : s=Slow f=Fast
P PI PD PID If Df Is Ds
Other
12 Action On Meas. increase Output : Increase Decrease
CONTROLLER
13 Auto-Man. SW None MFR STD Other
14 Set Point Adj. Manual External Remote Other
15 Manual Reg. None MFR STD Other
16 Output 4~20mA 10~50mA 0.2~1.0 Kg/Cm2G (3~15 psig) Other
17 Service Flow X Level Diff. Pressure Other

18 Element Type Diaphragm X Bellows Other
19 Material Body (Cover flange) 316SS Ti Element (Isolating diaphragm) 316LSS
20 Rating Overrange 130% of Maximum pressure Body Rating See Note 1.
ELEMENT 21 Diff. Range Fixed Adj. Range SEE PAGE 2 & 3 Set at SEE PAGE 2 & 3
22 Elevation Suppression
23 Elect. Conn. 1/2" NPT-F X
24 Process Conn. 1/2" NPT X Other
25 Options Press Element Range Material

Temp Element Range Material
Filt-Reg Supply Gage Output Gage Charts
OPTIONS Valve Manifold 5-WAY (316LSS)
Cond. Pots Adj. Damp Integral Sq. Rt. Ext.
Other 1) 2" MOUNTING BRACKET WITH U-BOLT & NUTS
2) S.S NAME PLATE
Notes : 1. Body Rating
Model No. : ASK 800/V15990A-43XX10-Y04-050-161-064-070-220-270/557/244/202/142/395/Z2E : 1420 psig

DATA SHEET-Sheet 7

FOR 1 18/10/00 J.B.R T.S.K S.K.K
D/P TRANSMITTERS (FLOW) 2 19/04/01 J.B.R Y.N.K K.C.IM
2a 17/11/02 J.B.R T.S.K S.K.K
Set Range Scale or Adj. Range Scale Range Press. Max. Temp. Max.
(in-H2O) Chart (in-H2O) (psig) (? )
2 640-FT-01 0 - 100 Linear 33.44 - 1000 0 - 38700 (lb/h) 500 260 HP Fuel Gas to Power Plant C2-0184
2 640-FT-02 0 - 100 Linear 33.44 - 1000 0 - 16200 (lb/h) 500 260 Fuel Gas to LP fuel gas dist. C2-0184
2 640-FT-03 0 - 100 Linear 33.44 - 1000 0 - 37500 (lb/h) 720 180 Sales Gas to fuel Gas Make-up C2-0184
Notes :

DATA SHEET-Sheet 8

FOR 1 18/10/00 J.B.R T.S.K S.K.K
PRESSURE SWITCHES 2 13/07/01 J.B.R Y.N.K K.C.I
2a 09/03/03
GENERAL SWITCH
1 Type : Pressure X Vacuum 8 Type : Snap X Micro X
Compound Diff. Press. Other Hermetically Sealed (Gold Plated)
2 Setting : Set in Field Factory Set X 9 Quantity : Single Dual X
Internal X External Dial 10 Form : SPST SPDT X DPDT
3 Dead Band : Fixed X Adj. Min. Other
11 Rating : 1 Amps 125 Volt 60 Hz
ELEMENT Other 1A 30VDC (I.S)
4 Type : Diaphragm X Bourdon Bellows 12 Load : Inductive Non-Inductive X
Other 13 Area Classification Class ? , Div 1 & 2, Gr A,B,C,D
5 Material : Bronze 316 SS Alloy St. Enclosure Rating IP-65
Other 316LSS Certification -
6 Connection : MFR STD Other Size 14 Electrical Connection : 1/2" NPT(F)
Bottom X Back 15 Manufacturer & Model No. : SOR / See Note 1.
7 Mounting : Surface Flush Local X 16 Diaphragm Seal
MFR. Type
Wetted Part Mtl Other Mtl
Fill Fluid
Process Conn Switch Conn
Pressure (psig) Operating
Rev. Tag No. Process Adj. Range Set Point Temp. Service P&ID No.
Nor. Max.
Connection (psig) (psig) (degF)
2 640-PSHH-01A 1/2" NPT(M) 20 ~ 180 120 113 210 265 HM from E-6401A C2-0184
2 640-PSHH-01B 1/2" NPT(M) 20 ~ 180 120 113 210 265 HM from E-6401B C2-0184
NOTES : 1. Model No. : 52RN-JG116-M4-C2A-TT-X2 (Adjustable range : -508~508mmH2O)

6RN-JG5-M4-C2A-TT-X2 (Adjustable range : 20~180 psig)

DATA SHEET-Sheet 9

FOR 1 25/10/00 J.B.R T.S.K S.K.K
RTD TEMPERATURE TRANSMITTERS 2 19/04/01 J.B.R Y.N.K K.C.IM
3 18/07/01 J.B.R Y.N.K K.C.IM
1 Complete Assembly X Other
WELL OR TUBE
HEAD 13 Material 316LSS
2 Screwed Cover Other Note 1. 14 Construction : Tapered X Straight
3 Material Aluminum Elect. Conn. 1/2" NPT-F Drilled X Built-Up Closed-End Tube
4 Nipple Size 1/2" Dim. "N" 150mm Union X 15 Dim.
16 Internal Thread 1/2" NPT
ELEMENT (Note 2.) 17 Process Connection See below "Process Connection" column
5 Platinum X Nickel Other 18 Accessories X Chain & plug
6 Ice Point Resistance 100 ohm at 0? C
7 Single or Dual Single TRANSMITTER
8 Temperature Range See below "TT Range" column 19 Area Classification Class ? , Div 1, Gr B
9 Leads STD X Potted Herm. Sealed Enclosure Rating IP-66
10 Sheath Material 316 SS O.D 6 mm Certification EExia IIC T4 Zone 0
11 Sheath Type Grounded Spring Loaded X 20 Transmitter Output 4 ~ 20 mA DC
12 Connection : 2-Wire 3-Wire X 4-Wire 21 Power Supply 24V DC
Lead Wires Receptacle Terminal Block X 22 Transmitter Type Smart / Hart / Head Mounted
Other Terminal Block Material : Ceramic 23 Manufacturer Hartmann & Braun
24 Model No. TH 02-EX / V11518-5-R-1-2
Process "U" "A" TT Range Temp. (? )

Rev. Tag No. Line No. Service P&ID No.
Connection (mm) (mm) (? ) Nor. Max.
2 640-TE/TT-01 1 1/2" ANSI 300#RF 6"-B7-FG-64004 220 60 0 - 300 161 260 HP Fuel gas to power plant C2-0184
2 640-TE/TT-03 1 1/2" ANSI 300#RF 6"-B7-FG-64007 250 60 0 - 400 229 260 Fuel gas to D-6401 C2-0184
2 640-TE/TT-07 1 1/2" ANSI 300#RF 6"-B6-G-64001 220 60 0 - 400 127.7 320 Sales gas from D-7001 C2-0184
NOTES : 1. Temperature Transmitter to be head mounted.

2. Element type : R.T.D (Resistance Temperature Detector)

DATA SHEET-Sheet 10

INSTRUMENT DATA SHEETS 0 13/11/00 D.G.L. T.S.K. S.K.K.
FOR 1 15/01/01 K.B.M. T.S.K. S.K.K.
PRESSURE SAFETY VALVES 2 16/08/01 K.B.M. T.S.K. S.K.K.
UNIT 640
2a 26/03/03 K.B.M. T.S.K. S.K.K.
1. Tag No. 640-PSV-01 640-PSV-02
2. Service FUEL GAS TO FUEL GAS TO
H.P FLARE HEADER H.P FLARE HEADER
3. Line No./Vessel No. 2"-B7-FG-64011 / 3"-A15-F-64002 2"-B7-FG-64008 / 3"-A15-F-64001
GENERAL
4. P&ID No. PP-17-7-C2-0184 PP-17-7-C2-0184
5. Full/Semi Nozzle Full Full
6. Safety or Relief Safety Safety
7. Conv., Bellow, Pilot Operated Conventional (Note 1) Conventional (Note 1)
8. Bonnet Type Closed Closed
9. Size : Inlet Outlet 3" 4" 3" 4"
CONNECTION 10. Flange Rating or Screwed 600# 150# 600# 150#
11. Type of Facing RF RF RF RF
12. Body and Bonnet ASME SA216 WCC ASME SA216 WCC
13. Seat and Disc 316SS 316SS
14. Resilient Seat Seal - -
MATERIALS
15. Guide and Rings 316SS 316SS
16. Spring INCONEL INCONEL
17. Bellows - -
18. Cap : Screwed or Bolted Screwed Screwed
19. Lever : Plain or Packed No No
20. Test Gag - -
OPTIONS
21.
22.
23.
24. Code API RP 520,526,527 API RP 520,526,527
25. Fire - -
BASIS
26. Others Blocked Outlet Blocked Outlet
27. Corrosive / Erosive Component No No
28. Fluid and State Hydro Carbon / Vapor Hydro Carbon / Vapor
29. Required Capacity 30515 (lb/h) 30515 (lb/h)
30. Mol. Wt. Oper. sp.gr. 19 - 19 -
32. Oper. Press. Set Press. (psig) - 500 - 500
32. Oper. Temp.(℉) Rel. Temp. (℉) 229 78 229 78
33. Back Press. Constant - -
34. (psig) Variable 0 ~ 50 0 ~ 50
35. Total 0 ~ 50 0 ~ 50
FLUID DATA 36. % Allowable Overpressure (Note 2) 10% 10%
37. Overpressure Factor - -
38. Compressibility Factor 0.95 0.95
39. Latent Heat of Vaporization - -
40. Ratio of Specific Heats 1.2 1.2
41. Operating Viscosity (cP) 0.013 0.013
42. Barometric Pressure - -
3
43. Density (lb/ft ) 2.6 2.6
44. Flashing (%) - -
45. Calc. Area sq in. 0.81 0.81
46. Selected Area sq in. 1.287 1.287
47. Orifice Designation J J
48. Manufacturer Dresser (Consolidated) Dresser (Consolidated)
49. Model No. 1912-00JC-4-CC-MS-31-RF-GS-HP 1912-00JC-4-CC-MS-31-RF-GS-HP
50.
Notes : 1. Conventional : Up to 10% back pressure.

Balanced Bellows : Up to 50% back pressure (Vendor to confirm).
Pilot operated : Up to 100% back pressure (Internal pick-up with non flowing type).
2. 10% for blocked discharged , 21% for fire.

DATA SHEET-Sheet 11

INSTRUMENT DATA SHEETS 5 28/08/02 K.B.M. T.S.K. S.K.K.
FOR 2 01/12/00 D.G.L. T.S.K. S.K.K.
SHUT DOWN AND 3 08/01/01 K.B.M. T.S.K. S.K.K.
UNIT 640
BLOW DOWN VALVES 4 11/06/01 K.B.M. T.S.K. S.K.K.
1. Tag No. 640-BDV-01 640-SDV-01
2. Service FUEL GAS TO H.P FLARE SALES GAS MAKE-UP FROM
HEADER D-7001 OUTLET
GENERAL
3. Line No. 2"-B7-FG-64015 6"-B6-G-70005
4. P & ID No. PP-17-7-C2-0184 PP-17-7-C2-0184
5. Fail Action Fail Open Fail Close
6. Fluid (State) Hydro Carbon (Vapor) Gas (Vapor)
7. Fluid Unit lb/h lb/h
8. Flow Rate (Note 1) 95 / 102 9263 / 9969
9. Pressure Design / Operating (psig) (Note 1) 500 / (325 / 325) 720 / (670 / 670)
10. Max. Difference Pressure (psi) (Note 1) - -
PROCESS
11. Temperature Design / Operating (? ) (Note 1) (320 / 25) / (229 / 185) (180 / 25) / (128 / 78)
(Note 1) 3
12. Density (lb/ft ) / Mol. Wt (Note 1) (1.18 / 1.24) / (24.5 / 24) (2.3 / 2.6) / (18.7 / 19)
13. Viscosity (cP) / Spec. Grav. (Note 1) (0.014 / 0.014) / - (0.01 / 0.01) / -
14. Ratio of Specific Heats (Note 1) 1.18 / 1.2 1.217 / 1.215
15. Up / Downstream Press. Valve to Open - -
Max. Difference (psi) Valve to Close 325 670
16. Type / Model Ball (Trunnion) / B4D Ball (Trunnion) / B5
17. Body Size (inch) / Bore Size (inch) 2" / Full Bore 6" / Full Bore
BODY
18. Material ASTM A350 LF2 ASTM A350 LF2
VALVE 19. End Conn. & Rating 2" , 300# RF 6" , 300# RF
(Note 3) 20. Leak Test to API 598 Tight Shut-off Tight Shut-off
21. Bonnet Type Split Body Split Body
TRIM 22. Trim Form ON / OFF ON / OFF
23. Seat & Ball Material ASTM A182 F316 F316 + ENP
24. Stem Material ASTM A182 F316 + ENP 17-4 PH + ENP
25. Type Single Acting Piston Single Acting Piston
26. Air Supply Minimum Supply of 80 psig Minimum Supply of 80 psig
ACTUATOR
27. Handwheel Type No No
28. Mfr & Model ROTORK & RP-015-160A/O2 ROTORK & RP-240-250A/C1
29. Limit Switch(SPDT) (Open/Close) Yes Yes
30. Quantity 2 2
31. Mfr & Model Honeywell & BZ2RW8227.2551.A2 Honeywell & BZ2RW8227.2551.A2
32. Contacts / Rating 120V AC / 5A 120V AC / 5A
SWITCHES
33. Actuation Points Full Open / Full Close Full Open / Full Close
34. Tag No. 640-BZSO / BZSC-01 640-SZSO / SZSC-01
35. Area Classification Class I, Div. 2, Group D Class I, Div. 2, Group D
36. Enclosure Protection EExib IIA T4 Zone 2 (IP 65) EExib IIA T4 Zone 2 (IP 65)
37. Solenoid Valve (Note 2) Yes Yes
38. Supply Voltage 24V DC 24V DC
39. Tag No. 640-BXSV-01/1, -01/2 640-SXSV-01/1, -01/2
ACCESSORIES 40. Area Classification Class I, Div. 2, Group D Class I, Div. 2, Group D
41. Enclosure Protection EExd IIA T4 Zone 2 (IP 55) EExd IIA T4 Zone 2 (IP 55)
42. Air Accumulator No No
43. Others Refer to Technical Notes Refer to Technical Notes
44. Mfr & Model NORGREN, B73G NORGREN, B73G
AIR FILTER 45. Set Pressure 80 psig 80 psig
REGULATOR 46. Supply Gauge Yes Yes
47. Air Supply (Max. / Normal / Min.) (psig) 125 / 115 / 80 125 / 115 / 80
Notes : 1. High/Low temperature case.

2. Vendor shall provide two solenoid valves with terminal block.
3. Refer to page 46 of 46 material specification for others.
4. All valves shall be tested per API 607 for fire safe.
5. Stroking time shall be less than 10 seconds.

DATA SHEET-Sheet 12

FOR 2 01/12/00 D.G.L. T.S.K. S.K.K.
UNIT 640
1. Tag No. 640-SDV-02 640-SDV-03A
2. Service FUEL GAS TO E-6401B HEATING MEDIUM RETURN
GENERAL
3. Line No. 6"-B9-FG-64009 2"-B7-HM-64005
4. P & ID No. PP-17-7-C2-0184 PP-17-7-C2-0184
5. Fail Action Fail Close Fail Close
6. Fluid (State) Fuel Gas (Vapor) Heating Medium (Liquid)
7. Fluid Unit lb/h usgpm
8. Flow Rate (Note 1) 21570 / 21403 46 / 42
PROCESS
(Note 1) 3
12. Density (lb/ft ) / Mol. Wt (Note 1) (1.5 / 1.6) / (24.5 / 24) -
13. Viscosity (cP) / Spec. Grav. (Note 1) (0.01 / 0.01) / - (0.59 / 0.59) / (0.98 / 0.98)
14. Ratio of Specific Heats (Note 1) 1.19 / 1.213 -
16. Type / Model Ball (Trunnion) / B5 Ball (Trunnion) / B4D
BODY
18. Material ASTM A182 F316 ASTM A350 LF2
23. Seat & Ball Material F316 + ENP ASTM A182 F316
24. Stem Material 17-4-PH + ENP ASTM A182 F316 + ENP
ACTUATOR
28. Mfr & Model ROTORK & RP-240-250A/C1 ROTORK & RP-015-160A/C2
30. Quantity 2 2
SWITCHES
34. Tag No. 640-SZSO / SZSC-02 640-SZSO / SZSC-03A
39. Tag No. 640-SXSV-02/1, -02/2 640-SXSV-03A/1, -03A/2


DATA SHEET-Sheet 13

FOR 2 01/12/00 D.G.L. T.S.K. S.K.K.
UNIT 640
1. Tag No. 640-SDV-03B 640-SDV-04
2. Service HEATING MEDIUM RETURN FUEL GAS FROM D-6401
GENERAL
3. Line No. 2"-B7-HM-64004 6"-B7-FG-64020
4. P & ID No. PP-17-7-C2-0184 PP-17-7-C2-0184
5. Fail Action Fail Close Fail Close
6. Fluid (State) Heating Medium (Liquid) Fuel Gas (Vapor)
7. Fluid Unit usgpm lb/h
8. Flow Rate (Note 1) 46 / 42 21570 / 21403
PROCESS
(Note 1) 3
12. Density (lb/ft ) / Mol. Wt (Note 1) - (1.2 / 1.2) / (24.5 / 24)
13. Viscosity (cP) / Spec. Grav. (Note 1) (0.59 / 0.59) / (0.98 / 0.98) (0.01 / 0.01) / -
14. Ratio of Specific Heats (Note 1) - 1.178 / 1.204
16. Type / Model Ball (Trunnion) / B4D Ball (Trunnion) / B5
BODY
18. Material ASTM A350 LF2 ASTM A350 LF2
23. Seat & Ball Material ASTM A182 F316 F316 + ENP
24. Stem Material ASTM A182 F316 + ENP 17-4 PH + ENP
ACTUATOR
28. Mfr & Model ROTORK & RP-015-160A/C2 ROTORK & RP-240-250A/C1
30. Quantity 2 2
SWITCHES
34. Tag No. 640-SZSO / SZSC-03B 640-SZSO / SZSC-04
39. Tag No. 640-SXSV-03B/1, -03B/2 640-SXSV-04/1, -04/2


9. DRAWINGS.....................................................................................................................................121

9. DRAWINGS
Annex 1: Process Flow Diagram for the Fuel Gas System for low and high temperature cases:
SEQUENCE
PFD
C2-0052 Fuel gas system High Temperature Case

C2-0053 Fuel gas system Low Temperature Case
Annex 2: P&ID’s for the Fuel Gas System:
SEQUENCE P&ID FUNCTION IN FUEL GAS

SYSTEM
C2-0171 Sales gas trunkline Start-up gas to Power Plant
C2-0184 Fuel gas conditioning FG regulated
C2-0185 Fuel gas distribution FG distribution
Annex 3: Materials of Construction Diagrams:
SEQUENCE MOC
C2-0072 Amine Absorber

C2-0078 Condensate Unit
C2-0079 Hg Removal & Sales Gas Export
C2-0081 Flare & Blowdown System
C2-0083 Fuel Gas System
Annex 4: Plot Plan. C2-6002

10. SAFETY.........................................................................................................................................123
A. GENERAL............................................................................................................................ 123
B. GOOD HOUSE KEEPING...................................................................................................124
C. MAINTENANCE OF EQUIPMENT................................................................................... 124
D. USE OF SAFETY EQUIPMENTS.......................................................................................124
E. CHEMICAL HAZARDS...................................................................................................... 126

10. SAFETY
A. GENERAL
Safety can no longer be viewed as a ‘separate function’ the responsibility for which is hidden
somewhere in manufacturing, engineering, safety or other departments within the Company.
Safety is everyone’s responsibility. It is a part of each single job. A job performed unsafely is a
job that is incomplete and incorrect.
Accidents can no longer be viewed as ‘unavoidable happenings’, which occur during the normal
course of our work. Accidents are ‘errors’ which can be controlled. If an accident occurs during
the normal course of our work, then that work is not normal. That work or job is incomplete and
incorrect because we have allowed an ‘error’ to occur even though elimination of that error is
within our control.
The safety laws are very important regarding the Fuel Gas System. There is a risk of piping or
system damage which may result in a gas release, and associated fire and/or vapor cloud explosion.
One of the basic safety requirements for all personnel who deal with gas is to know its behaviour if
released. This knowledge is essential in deciding what to do, how to respond, and how to control
an emergency involving gas.
Gas - Ensures early detection

Characteristic Odor of a gas leak.
Gas Density - Explains how a vapour

cloud may disperse.
Gas - Indicates that a gas

High Flammability vapor cloud is likely to
Explode on ignition.
All personnel should receive training to recognize a gas leak and what action is to be taken in such a
situation.

B. GOOD HOUSE KEEPING
a. In order to prevent an accident or fire maintain all equipment and instruments in proper
operating condition.
b. Remove all rubbish and loose materials following maintenance from the unit
c. All road and access ways must be kept free of any kind of material in order not to hinder
the unit access
d. All equipment must be cleaned properly of all debris, sand and oil leaks must be
eliminated
C. MAINTENANCE OF EQUIPMENT
Maintenance work should be properly authorized by a ‘Permit to Work’ issued by the Operation
Supervisor
The ‘Work Permit System’ is widely used in industry, and has been recognized as the most
important and effective ‘safety control tool’ available for the control of work in all plants, facilities
and all equipment.
The categories of work permit include the following:

a. Cold work
b. Hot work
c. Vessel entry.
A ‘Hot Work’ Permit is applied to any activity, which generates sufficient heat to ignite flammable
products and materials. ‘Hot Work’ Permits must be issued only for work on specific equipment
or units. A gas test must be done at the place of work to confirm that flammable gases are not
present.
During the work the area must be monitored for flammable gas and the hot work stopped if any is
detected. Where gas test readings indicate the presence of combustible gas, in any amount, the ‘Hot
Work’ Permit requires the review and signature of the Operations Superintendent.
Any open ends of lines in the ‘hot work’ area which could contain flammable gases or liquids must
be blinded, capped, plugged or disconnected.
D. USE OF SAFETY EQUIPMENT
Work Clothing
Work Clothing must be suitable for protection against common hazards expected in industrial areas
and must be used at all times. Work clothing should be kept as clean as possible.

Head Protection
An approved hard hat consists of a hard impact shell and an adjustable inside cradle and distributed
over the head surface area.
Hand Protection
Use leather palm gloves for work with sharp or rough objects, working with piping, manual
handling and so on to prevent cuts or abrasion.
Foot Protection
To minimize the risk of foot injury, steel-toed shoes or boots are provided for all employees whose
work requires them to be worn.
Eye Protection
Eye protection should be worn depending on the nature of the work being performed, for example,
welding goggles, goggles, safety spectacles, face shield. Eye protection is required in situations
where exposure to flying particles (sand) may exist. Can be ordinary safety glasses, these have
plain, proof glass inside safety frames and must also have attached side shields or goggles,
spectacles with side shields, plastic eye shields.
Ear Protection
For excessive noise levels in situations where it is not possible or practical to reduce the noise level
(up 90 dB) it is necessary to minimize the possibility of hearing damage by the use of hearing
protection devices. There are two types of hearing protection devices used, muff protectors and
plastic foam plugs.
Respiratory Protection Equipment
Minimum 19.5 per cent oxygen is needed for working without supplied air breathing.
Air Purifying – Cartridge/ filter type respirators.
These types of respiratory protection devices filter air contaminants through a medium and
allow free air to be breathed by workers. Purifying types of respirators do not provide
protection in locations where contamination concentration is high or immediately dangerous
to life (for example, oxygen deficiency). When the cartridge or canister is used up, it should
be removed and replaced by a fresh one.

Self-contained breathing air systems, supplied air systems.
Self-contained breathing apparatus is used primarily for emergency work and rescues because
of its mobility. The apparatus consists of a pressurized cylinder, which is worn on the
person’s back, an air pressure reducer, a full-face mask and a carrying harness.
E. CHEMICAL HAZARDS
Leaks in the Fuel Gas System or damage to the system resulting in a gas release, could cause fire
and/or explosion. Fire is a combination of heat, gas and oxygen and is a chain reaction.
A fire is extinguished, by the removal of one or more of these elements.
Heat can be removed by cooling for example, with water/foam, combustion air can be shut off or
diluted with inert gases or solids and fuel gas can be removed by closing valves. It is important to
use the correct extinguishing agent to extinguish the fire.
Safe Handling
 No smoking in the area.

 No hot work in the area unless authorized by a hot work permit
 Request a work permit for all maintenance work.
 Follow standard operating procedures.
Gas Protection
 Ventilation is required for work in enclosed spaces.

 Continually Monitor for gas leakage.
 Use SCBA equipment for non-routine work and emergency where the gas concentration
is present.
Gas Inhalation
 Dizziness, shortness of breath – collapse.

 Suffocation (choking) due to lack of oxygen – death.
 Remove to fresh air. Apply artificial respiration if necessary.
Gas Controls
 Report every gas leak – however small.

 All employees to be instructed periodically in handling precautions.
Fire
 Cool surroundings with water spray.

 Decide whether to extinguish flame if flow is not stopped or surroundings not cooled – re-
ignition or explosion can occur.
 Use CO2, dry chemical to extinguish flame.
Spills
 Report any leaks using emergency telephone number.
 Evacuate area.
 Shut off the gas source if possible.
 Keep personnel and traffic away from the area.

11. APPENDIX.................................................................................................................................. 129
A. CONVERSION TABLE........................................................................................................129
B. GENERAL PRE START-UP PROCEDURES......................................................................133
C. OPERATIONAL PROBLEMS – POSSIBLE CAUSES AND REMEDIES........................ 137
D. MISCELLANEOUS ……………………………………………………………………..140

11. APPENDIX
A. CONVERSION TABLE
UNITS OF LENGTH
UNIT SYMBOL NAME OF UNIT RELATIONSHIP
1 in = 1” Inch 25.4 mm
1ft = 1’ Foot 12 in = 0.3048 m
1 yd Yard 36 in = 3 ft = 0.914398 m
1 mile Mile 1760 yd = 1 609 m
1 mm Millimeter 0.03937 in = 0.00328 ft
1 cm Centimeter 0.3937 in = 0.03281 ft
1m Meter 39.37 in = 3.28084 ft
1 km Kilometer 39 370 in = 3280.84 ft = 1093.62 yd
UNITS OF AREA
1 sq in Square inch 6.4516 cm2 = 645.16 mm2

1 sq ft Square foot 0.0929 m2 = 929.03 cm2
1 sq yd Square yard 0.83612 m2 = 8361.24 cm2
1a Acre 4840 sq yd = 4046.24 m2
1 sq mile Square mile 640 acres = 2.58999 km2
1 cm2 Square centimeter 0.155 sq in
2
1m Square meter 1550sq in = 10.7639sq ft = 1.19599 sq yd
1 km2 Square kilometer 0.3861 sq mile
UNITS OF VOLUME
1 in3 Cubic inch 16.3870 cm3

1 ft3 Cubic foot 0.02832 m3
1 yd3 Cubic yard 0.7646 m3
1 gal (USA) Gallon 3.78543 l
1 fl oz (USA) Fluid ounce 28.413 cm3

1 bus (USA) Bushel 35.24 l = 0.3524 hl
1 bl (USA) Barrel 158.988 l = 1.5898 hl
1 cm3 Cubic centimeter 0.06102 cu in
1 dm3 = 1 l Cubic decimeter = liter 61.0237 cu in = 0.03531 cu ft
1 m3 Cubic meter 35.315 cu ft

UNITS OF CAPACITY
1 gal (USA) Gallon 8 pints = 4 quarts = 3.7853 l

1qt (USA) Quart ¼ gallon = 2 pints = 0.9463 l
1 pt (USA) Pint 1/8 gallon = 0.4732 l
UNITS OF WEIGHT
1 oz Ounce 1/16 lb = 28.3495 g

1 lb Pound 16 oz = 0.453592 Kg
1 sh cwt (USA) Short hundredweight 100 lb = 45.3592 Kg
1 sh tn (USA) Short ton 2000 lb = 907.185 Kg
1g Gram 0.03527 oz = 0.0022 lb
1 Kg Kilogram 2.20462 lb = 35.274 oz
1t Ton 2204.62 lb = 35 274 oz
UNITS OF TEMPERATURE
K Kelvin C =K – 273.15

C Degree Celsius
F Degree Fahrenheit C= (F – 32) X 5 / 9
0 C = 32 F 100 C = 212 F C= (F – 32) X 5 / 9
0 K = - 273.15 C = - 459.67 F C =K – 273.15
UNITS OF PRESSURE
1 lbf / sq in (psi) Pound-force per square inch 0.070307 kgf/cm2 (at)

1 lbf / sq in (psi) Pound-force per square inch 6894.76 N/m2 (Pa)
1 kgf/cm2 (at) Kilogram-force per square centimeter 14.2233335 lbf/sq in
1 N/m2 (Pa) Newton per square meter 0.0000145 lbf/sq in

UNITS OF ENERGY, HEAT AND POWER
1 cal Calorie 4.1868 J

1J Joule 0.23884 cal
1 Btu British Thermal Unit 1055.06 J
1J Joule 0.000948 Btu
1 Btu British Thermal Unit 0.2520 kcal
1 kcal Kilocalorie 3.968254 Btu
1 hp Horse power 0.74570 kW
1 kW Kilowatt 1.341022 hp
1 Btu/h British Thermal Unit 0.293071 W
1W Watt 3.41242 Btu/h
1 Btu/lb British Thermal Unit per pound 2.326 kJ/kg
1 kJ/Kg Kilojoule per kilogram 0.42992 Btu/lb
B. GENERAL PRE START-UP PROCEDURES
Air Blowing
The purpose of air blowing is to remove loose foreign matter from the inside of piping (for
example, welding rods, sand, nuts, bolts, tools).
Applications
The following systems are generally air blown in accordance with Job Specifications Piping
System Pressure Testing JS-MP-6045 and Piping Erection And Testing JS-MP-6044:
 Process piping of the facilities for example, vapor piping, air piping, and inert gas piping.
 low operating temperature systems (for example, Propane Refrigeration).
 hydraulic piping and flare lines.
 Lube Oil systems are air blown before lube oil circulation through filters.
Methodology
During the cleaning operations, the air velocity can be up to 60 m/s. Two main methods shall be

used:
Continuous Air Blowing:
Air is continuously supplied from a source through the lines to carry away the loose material,
normally used for small diameter piping.
Quick Decompression
This method is to have SOC approval for use in each case.
A pipe network is charged with air up to the release pressure of a plastic film fitted on an open pipe
end. When the film is perforated, the pressure inside the network drops quickly providing high
velocities and requires minimum air use for these velocities and effectiveness.
These rupture devices are made using polyethylene film. The film shall be perforated, at the
required release pressure, by a mechanically linked arm. If it malfunctions then the air can be
released manually. The rupture device shall be installed at the one open flange using a temporary
holder. Temporary bolts, nuts and gaskets can be used for the device. Alternatively, a network is
filled with compressed air up to the required pressure and a valve is open quickly at the end of the
system. The pressure in the pipes could be raised up to 90 psig if needed, but design pressure of
the system must not be exceeded (for example,30 to 40 psig for 50 psig design).
Preparations
Items that can be damaged or impede air blowing shall be removed from the pipe before blowing.
As follows:
 Control valves, check valves and relief valves.

 Orifice plates.
 Flowmeters, Venturies, Pitot tubes and rotameters.
 Nozzles, coupons, probes.
 Traps.
 Butterfly valves.
 Expansion bellows.
 Internals of filters and strainers.
 Thermowells.
 Impulse lines for instruments and sample lines shall be disconnected.

 Block valves fully opened and not to be used to control airflow.
 Pipe restraints, clamps, supports shall be fitted as required.
 Equipment to be isolated to avoid dirty air entry.
 Place tarpaulin sheets to protect motors, insulation, and instruments near the air blow out
point.
 Install a baffle sheet perpendicularly to the flow, in order to break the flow.
 Temporary supports specified by engineering may have to be used, when the lines are
disconnected
 Spring supports, spring hangers to be ‘locked’ for air blowing.
Other Preparations:
 Pre-commissioning test sheet ‘Pipework Flushing Form’ PCMT-05 (Refer to attached),

shall be prepared, ready for use.
 The P&ID and Isometric diagrams shall be used to define the extent of air blowing. The
following colors shall be used:
 Yellow for the lines to be flushed.

 Green for the items to be removed.
 Red for the flanges to be disconnected (opened).
 Orange for the items to be isolated.
Safety
High forces can be generated at the air outlet. Therefore, specific safety procedures must be
closely adhered to.
The following precautions shall be taken for the air blowing operations:
 Select time to avoid interference with other activities in the area.

 Restricted access from the outlet points by roping off and install ‘no-entry’ signs.
 Work Permits shall be issued if needed.
 Personnel must be equipped with: ear protection, gloves, coveralls, goggles, safety shoes,
and safety hat.
 Air shall never impinge on any equipment.
Verify Cleanliness.
Principal checks to verify cleanliness are as follows:

‘Colour’ of the air at the exit point. This shall indicate whether rust and dirt remain inside of the
piping. This is usually sufficient for most of the process and utility piping.
Use of a target plate (for example, for compressor suction lines, GT oil system and FG lines).
If the exhaust air appears to be clean install, the target plate and air blow the line. If the plate has
became eroded and pitted or distorted, continue the air blowing.
When the target plate remains clear the pipe is clean.
Ensure that no dirt is re-introduced into the piping during re-assembly following the air blowing.
Reestablish pipe condition as per design support settings and install all instruments, valves, orifice
plates and so forth.
Once all these activities are concluded sign off PCMT-05 for the System. If the pipe system
cleaned, is in more that one system put the original in System Dossier where maximum piping is
present and put copies in other System Dossiers as applicable.
For Fuel Gas System the most important general pre start-up procedure is the leak test procedure.
The test shall be performed as follows:
 Line-up the system to be tested (all system isolations completed, all parts of the system
connected, safety valves operational, all instrument valves checked and operated, drain
valves closed, and so on).
 Pressurize the system to its maximum operating pressure.
 On a pressure recorder place a new recorder chart. Ensure the chart is turning. The
chart shall be marked with system number, date, and time of test start.
 Commence checking flanges, valves, vent plug and so on, for leaks using soap solution.
If necessary, depressurize the system to change gaskets.
 When the pressure is constant, the test shall start and be continued for as least 4 hours,
preferably during the daytime when ambient temperatures are relatively steady.
 Following a successful test, depressurize the system and attach the pressure-recording
chart to the commissioning file documentation.
 Prior to start-up the system shall be nitrogen purged

C. OPERATIONAL PROBLEMS – POSSIBLE CAUSES AND REMEDIES
The following section contains some guidelines, which can be used for troubleshooting and can
help to identifying the cause of abnormal situations in Fuel Gas system operation.
Fuel Gas Superheater
DEVIATION POSSIBLE CAUSE RECOMMENDATION
Abnormal temperature outlet E- Malfunction of Check the performance of the control loop
6401 A/B temperature control 640-TIC-03, 640-TCV-03
system 640-TIC-03
Fuel Gas Scrubber
High liquid level Malfunction of level Check level alarm 640-LAH-01 and level
alarm 640-LAH-01 glass 640-LG-01 and drain D-6401
HP Fuel Header
Low pressure in HP fuel Malfunction of pressure control Check the performance of the control loop
gas supply header system 640-PIC-05, 06, 07 640-PIC-05, 06, 07, 640-PCV-05, 06, 07
Interruption in the fuel gas supply Check fuel gas flow rate from Mercury
from fuel gas source, Mercury Removal Unit by 640-FI-03/1 and 640-FI-
Removal Unit 01/1
Possible liquid carry over into fuel High liquid level in Fuel Gas Check level alarm 640-LAH-01 and level
gas header Scrubber D-6401, malfunction of glass 640-LG-01 and drain D-6401

level alarm 640-LAH-01
High pressure in the H.P. fuel gas Malfunction of pressure control Check the performance of the control loop
supply header system 640-PIC-05, 06,07 640-PIC-05,06,07 640-PCV-05, 06, 07

L.P. Fuel Gas Header
Low pressure in LP fuel gas supply Malfunction of pressure control Check the performance of the control loops
header system 640-PIC-08, 10 640-PIC-08, 10 640-PCV-08, 10
Possible liquid carry over into fuel High liquid level in Fuel Gas Check level alarm 640-LAH-01 and level
gas header Scrubber D-6401,malfunction of glass 640-LG-01 and drain D-6401
level alarm 640-LAH-01
The liquid can be amine solution Check the level of the amine drums and
from amine flash drums D-3103 reduce the flow of the flushing amine at
and D-32303 310-FCV-03 / 320-FCV-03 and check 310-
PDT-05 / 320-PDT-05
High pressure in the L.P. fuel gas Malfunction of pressure control Check the performance of the control loop
supply header system 640-PIC-08, 10 640-PIC-08, 10
Blanket / Purge Gas Header
POSSIBLE CAUSE RECOMMENDATION

DEVIATION
Low pressure in LP fuel gas supply Malfunction of pressure control Check the performance of the control loops
header system 640-PCV-11, 12 640-PCV-11, 12
Possible leak Check for leaks along the LP fuel gas

header
High pressure in the L.P. fuel gas Malfunction of pressure control Check the performance of the control loop
supply header system 640-PIC-11, 12 640-PIC-11, 12 640-PCV-11, 12
Fuel Gas Temperature and Composition

POSSIBLE CAUSE RECOMMENDATION
DEVIATION
Increased temperature from E- Loss of one of two fans at E-5101 To compensate for increase in temperature
5101 from E-5101, the operator should increase
the pressure in the condensate flash drum.
This shall minimize any impact on the fuel
gas composition.
D. MISCELLANEOUS
 All lines and equipment containing gas must be properly bonded and grounded to prevent
static electricity spark.
 Use non-sparking tools for maintenance.
 Minimum 19.5 per cent oxygen is needed for working without supplied air breathing.
 Special attention should be given to the reporting of all incidents especially ‘near-miss’
incidents, as lessons learned from such incidents may help to prevent major accidents in
the future.
Operating Procedure for Sample Connections
The Fuel Gas System is provided with Sample Connections Type 2.

Refer to Appendix 1
They are used to obtain samples for product testing.
For safe operation of this type of sample connection proceed as follows:
 Verify that the Sample Cooler is filled with water.

 If not, verify that the ¾”drain valve of the cooler is closed (Valve 1).
 Open the ¾”valve on demi water and fill the Sample Cooler (Valve 2).
 Verify that the block valves for pressure indicators are open (Valve 8 and 9).
 Verify that valves 4 and 5 are closed and connect the bottle.
 Open the outlet valve from sample connection to flare / process (Valve 6).
 Open the by-pass valve of bottle (Valve 7)

 Open slowly inlet valve in Sample connection (Valve 3) for purge Sample Connection
Lines and monitor the temperature seen at temperature indicator on outlet from the
Sample Cooler.
 Open valves 4 and 5, and also the isolating valve of the bottle (NV1 and NV2).
 Close the by-pass valve (Valve 7)
 After three minutes, close isolating valves NV2 and NV1 (starting with NV2.)
 Close the inlet valve to the Sample connection (Valve 3)
 Open the by-pass valve (Valve 7) to de-pressurize the Sample Connection.
 Close outlet valve from Sample Connection (Valve 6), close valve 4 and 5, and remove
the bottle from connections.

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Operating Manual Section No.8.

1 Fuel Gas System Rev 02

FUEL GAS SYSTEM

SIRTE OIL COMPANY

02 2003-08-28 For Approval B. MOGA Y.I.SUNG Y.S.KWON

8.1 Fuel Gas System Page 1 of 111

FLOW PLAN ABBREVIATION TABLE.............................................................................................3

2. OPERATING CONDITIONS AND CONTROLS......................................................................20

4. PREPARING UNIT FOR INITIAL START-UP.........................................................................31

8.1 Fuel Gas System Page 2 of 111

8.1 Fuel Gas System Page 3 of 111

ABBREVIATION WHOLE WORDING

8.1 Fuel Gas System Page 4 of 111

FLOW PLAN ABBREVIATION TABLE – sheet 2

ABBREVIATION WHOLE WORDING

EAL Voltage Low Alarm

8.1 Fuel Gas System Page 5 of 111

8.1 Fuel Gas System Page 6 of 111

ABBREVIATION WHOLE WORDING

GT Gas turbine driver

8.1 Fuel Gas System Page 7 of 111

8.1 Fuel Gas System Page 8 of 111

ABBREVIATION WHOLE WORDING

LSH Level Switch High

8.1 Fuel Gas System Page 9 of 111

8.1 Fuel Gas System Page 10 of 111

ABBREVIATION WHOLE WORDING

PDAH Pressure Differential Alarm High

8.1 Fuel Gas System Page 11 of 111

8.1 Fuel Gas System Page 12 of 111

ABBREVIATION WHOLE WORDING

TAHH Temperature Alarm High-high

8.1 Fuel Gas System Page 13 of 111

8.1 Fuel Gas System Page 14 of 111

ABBREVIATION WHOLE WORDING

8.1 Fuel Gas System Page 15 of 111

8.1 Fuel Gas System Page 16 of 111

NO FACILITY COLOUR COLOUR DENOMINATION

8.1 Fuel Gas System Page 17 of 111

Pipe Contents BIC Remarks

Safety Colour Intended For Remarks

S.O.C. COLOUR CODING

Colour code For

8.1 Fuel Gas System Page 18 of 111

8.1 Fuel Gas System Page 19 of 111

Source High Temperature Case Low Temperature Case

Notes: All figures are in MMSCFD.

8.1 Fuel Gas System Page 20 of 111

LP-Fuel Gas (55 PSIG)

HP Fuel Gas (325 PSIG)

A continuous HP fuel gas supply to the GTG is guaranteed by provision of a 6” cross-over

8.1 Fuel Gas System Page 21 of 111

8.1 Fuel Gas System Page 22 of 111

8.1 Fuel Gas System Page 23 of 111

E. UTILITIES AND CHEMICALS – DESIGN BASIS

8.1 Fuel Gas System Page 24 of 111

The chemical composition of heating medium is as follows:

Note: No chemicals are required for Fuel Gas System.

8.1 Fuel Gas System Page 25 of 111

8.1 Fuel Gas System Page 26 of 111

A. FUEL GAS SUPER HEATER (E-6401 A/B)

P&ID TAG/ PROC. DCS REMARKS

8.1 Fuel Gas System Page 27 of 111