SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

SKIKDA, ALGERIA
OPERATING MANUAL VOLUME I, SECTION 3-3:
UNIT 15 LNG EXPANDER

DOCUMENT NO: PP-AAA-PP1-107

KBR
JOB NO.: J6404
2 KM Issued for Implementation 22-May-13 MRC RM

1 KM Issued for Implementation 5-Dec-12 MRC SPD

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

B JDS Issued for Client Approval 9-Sep-10 GRM BA -

A ACG Issued for Client Approval 23-Feb-10 VAS BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-107
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS ...................................................................................................... 6
3.1 Normal Running................................................................................................................ 6
3.2 Typical Operating Parameters .......................................................................................... 8
3.3 Temporary Operations...................................................................................................... 8
3.3.1 LNG Expander cooldown ............................................................................................... 8
4.0 START-UP .......................................................................................................... 10
5.0 SHUTDOWN ....................................................................................................... 12
5.1 Normal Shutdown ........................................................................................................... 12
5.2 Process Upsets and Production Loss ............................................................................ 12
6.0 SAFETY/EMERGENCY SHUTDOWN ................................................................ 13
6.1 Safety Critical Shutdown Systems ................................................................................. 13
6.1.1 I-1530 - LNG Expander Trip Interlock .......................................................................... 13
6.1.2 I-1550 - Main Cryogenic Heat Exchanger Trip Interlock.............................................. 13
6.2 Pressure Safety Valve Summary ................................................................................... 14
6.3 Fire Protection Equipment .............................................................................................. 15
7.0 ATTACHMENTS ................................................................................................. 16
7.1 Attachment I: Equipment List ......................................................................................... 17
7.2 Attachment II: Utility Consumption ................................................................................ 18

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-107
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

1.0 INTRODUCTION
This operating manual relates to the facilities indicated on Process Flow Diagram PR-15-
PR32-005 and P&ID PR-15-SYPI-005.
LNG Expander, 15-MJ02, is a vertical in vessel (pot) mounted type expander with integral
submerged generator on a common shaft which generates 1059 KW rated power.
LNG Expander, 15-MJ02, receives the high pressure liquefied natural gas from the cold
bundle of Main Cryogenic Heat Exchanger, 15-MC05, at 44.9 barg and reduces the pressure
of LNG to 20.8 barg before it flows to Helium Rich Gas Flash Drum, 15-MD03.
High pressure LNG flow to the expander is controlled by the 15-TIC-1056 which is cascaded
to the flow controller 15-FIC-1057.

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LNG EXPANDER

LNG EXPANDER 15-MJ02

SKIKDA, ALGERIA

7
7

COLD
LIQUID
HEADER

15-MC06
LMR / HELIUM
15-PV-1063
RICH GAS HEAT
EXCHANGER

6
6

15-PIC 15-TIC 15-FIC 60-100% 15-FY 15-FY

1063 1056 1057 1057E 1057F
15-MC05
MAIN CRYOGENIC
HEAT EXCHANGER
NEW LNG TRAIN SKIKDA PROJECT

15-FV-1057C
15-FY

5
5

0-60% 1057D

15-PIC 15-FY
1073 1057G

15-MD03
HELIUM RICH GAS
FLASH DRUM

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15-FV-1057B

4
4

15-FY
1057K

15-FV-1057A

3
3
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2

15-MD04
15-SIC NITROGEN
3002 G
STRIPPER

2
2
DOCUMENT NO.
PP-AAA-PP1-107

15-MJ02-G
15-MJ02 LNG EXPANDER
LNG EXPANDER GENERATOR

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-107
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

2.0 SYSTEM DESCRIPTION

High pressure LNG production from the top of the “cold” bundle of the MCHE, 15-MC05,
flows into the LNG Expander, 15-MJ02, at 44.9 barg and -146 °C. The low pressure LNG
exiting the expander flows into the Helium Rich Gas Flash Drum, 15-MD03, at 20.8 barg and
-146 °C.
LNG Expander generates power for use by the Plant.
The flow rate of the high pressure LNG feed to the expander is controlled by 15-FIC-1057.
This is a cascade controller with the setpoint coming from LNG temperature controller 15-
TIC-1056 which is set to maintain the desired temperature of LNG by adjusting the flow rate
through the LNG Expander System.
The LNG pressure into the expander is limited by 15-PIC-1063, which vents excess liquid to
the Cold Liquid Header as a last resort, if a high pressure occurs. Excess LNG normally
flows through the LNG Expander by pass 15-FV-1057C to Helium Rich Gas Flash Drum 15-
MD03 as it does when the Expander is out of service.
The Expander is not usually put in service until flow through the system from Main Cryogenic
Heat Exchanger 15-MC05 is at approximately 80% and the whole system has stabilized.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-107
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the LNG Expander 15-
MJ02. Refer to Section 3.2 for a list of typical operating variables for this system.
The LNG pressure into the expander is limited by 15-PIC-1063, which vents excess liquid to
the Cold Liquid Header through 15-PV-1063, as a last resort, if a high pressure occurs.
Excess liquid is normally sent through the Expander bypass valve 15-FV-1057C to 15-
MD03. The operator can also drain liquid manually, to the Cold Liquid Header, by using 15-
HIC-1063, as a last resort.
High Pressure LNG flow rate to the LNG Expander, 15-MJ02, is controlled by flow controller
15-FIC-1057 with its setpoint adjusted by the cascade feed temperature controller 15-TIC-
1056.
Flow controller 15-FIC-1057 controls the LNG flow through 15-FV-1057B by keeping the flow
in between 0 to 60% range and through 15-FV-1057C with a 60 to 100% flow range.
Valve 15-FV-1057B will regulate the flow and the power input to the grid during normal
operation.
If the LNG flow requirement exceeds the expander capacity, the signal from 15-FIC-1057
opens valve 15-FV-1057C which acts as a J-T pressure reducing valve in parallel with the
expander. The operator can also manually set a higher flow through the J-T valve by using
15-HIC-1058 through the action of high selector 15-FY-1057F. If the expander is out of
service, LNG production can be maintained by manually routing all the LNG through the J-T
valve, 15-FV-1057C.
The control system limits the discharge pressure to be at least 2 bar above the LNG bubble
point. Pressure controller 15-PIC-1073 controls the expander discharge valve 15-FV-1057B.
If the pressure difference between the discharge pressure and the LNG bubble point
pressure goes below 2 bar, the controller throttles the discharge valve by using low selector
15-FY-1057G to bring the pressure difference back above 2 bar.
Once the speed reaches 2900 rpm, controllers 15PIC1073 and 15SIC3002 are placed in
Automatic control with setpoints of 15barg and 3025rpm respectively. As expander speed
increases, controller 15-SIC-3002 will take control of valve 15-FV-1057A from 15-HIC-1060
through low selector 15-FY-1057K to maintain the expander at 3025 rpm. The generator
frequency at this time is just higher than the grid frequency of 50 Hertz. When the expander
speed reaches 3025 rpm, the logic will signal the expander to connect to the grid through 15-
HS-1409. Synchronization to the grid will keep the frequency at 3000 rpm.
Upon feedback of connection to the grid through 15-XS-1409, the sequence will ramp down
15-HIC-1060 at a rate of 15%/minute to close trim valve 15-FV-1057A and continue the
ramp up of 15-HIC-1059 at a rate of 15%/minute to increase the power developed. As the
output of 15-HIC-1059 increases, control of discharge valve 15-FV-1057B will transfer to
either flow controller 15-FIC-1057 or outlet pressure controller 15-PIC-1073 as determined
by low selector 15-FY-1057G.

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-107
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

3.2 Typical Operating Parameters

The following table contains typical operating variables for LNG Expander System.

Operating Variables for LNG Expander System

Tag No. Description Typical Value Units

LNG Feed to LNG Expander
15-FIC-1057 741452 kg/hr
Flow Controller
LNG Feed to LNG Expander
15-PIC-1063 44.9 barg
Pressure Controller
15-PIC-1073 LNG Expander Discharge 20.8 barg
Pressure Controller

15-SIC-3002 LNG Expander Speed Controller 3025 rpm

LNG Feed to LNG Expander
15-TIC-1056 -146 °C
Temperature Controller
3.3 Temporary Operations
3.3.1 LNG Expander cooldown
This section outlines the steps necessary to cool down the LNG Expander. For the purpose
of this section of the operating manual, it is assumed that the following conditions exist:
utilities are in service, upstream equipment are cooled down, electrical power is available.
Expander is purged.
Refer to vendor instructions IOM-503012 for detailed explanation of operation.
Note: Cooldown only applies after the expander 15-MJ02 has been allowed to warm up to
ambient conditions or during installation. At all other times the machine should be kept cold
to allow starting.
1. Verify the expander inlet isolation valve 15-XV-1062 is closed.
2. Verify the expander outlet valves 15-FV-1057A and 15-FV-1057B are closed with 15-
HIC-1059 and 15-HIC-1060.
3. Dry spinning of the expander 15-MJ02 may cause bearing damage. Introduction rate of
gas / liquid must always be low enough to avoid spinning.
4. Vent line to cold flare must be opened to allow boil off vapor to pass through.
5. Crack open globe valve from upstream 15-RO-1351 to expander 15-MJ02 bottom line
and allow cold gas to circulate through to cold flare for approximately 8 hours before
allowing any introduction of any liquid.
6. Monitor cooldown rate at 15-TI-1044A-C and 15-TI-1072. If liquid level is detected at
15-LI-1247A close the globe valve upstream of 15-RO-1351 and allow the liquid to boil-
off before cracking open the globe valve again.
7. The vessel must always be filled from the bottom to avoid cold liquid contacting the
machine casings causing thermal shock. Under no circumstances should cooldown be
performed through the suction discharge or other nozzles.
8. When the gas pre-cooling is complete liquid will be introduced through 15-RO-1351 to
expander 15-MJ02 bottom nozzle by further opening the globe valve.
9. Liquid filling rate must not exceed 25mm / minute.

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

10. Under no circumstances should the cooldown procedure be completed in less than 6
hours.
11. Stop filling when the liquid level 15-LI-1247A reaches each hold points in table below
and maintain stable level for the specified time in the table to allow thermal gradients to
reduce.
12. Once the vessel is full ensure that suction and discharge piping are filled and all boil off
vapor is vented out to cold flare.
13. Once the vessel and piping is completely filled and temperatures indicate cooldown is
complete ensure filling and vent lines to flare are closed and proceed with startup as
detailed in section 4.0.

Cooldown of LNG Expander

Level Distance from vessel Reference point on machine Rest time

bottom (mm) (minutes)

1 438 Just below bottom of machine 90

2 1486 At lower bearing 60

3 2195 Middle of generator stator 60

4 2871 At upper bearing 30

5 3404 Vessel full 15

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-107
OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

4.0 START-UP
This section outlines the steps necessary to place the LNG Expander System in service. For
the purpose of this section of the operating manual, it is assumed that the following
conditions exist: utilities are in service, upstream equipment are cooled down and producing
LNG, downstream units are in service receiving LNG at approximately 80%, electrical power
is available; Expander system is purged, cooled, and filled as per vendor manual IOM-
503012 section IV-2, and ready for start-up.
1. Verify the MCHE LNG discharge pressure controller 15-PIC-1063 is in Auto, closed and
LNG flow is going through 15-FV-1057C to Helium Rich Gas Flash Drum 15-MD03.
2. Verify the expander inlet isolation valve 15-XV-1062 is closed.
3. Verify the expander outlet valves 15-FV-1057A and 15-FV-1057B are closed with 15-
HIC-1059 and 15-HIC-1060.
4. Verify isolation valve 15-ESDV-1438 is open with approximately an 80% flow through
bypass 15-FV-1057C to the Helium Separation System.
5. Verify that Main Cryogenic Heat Exchanger outlet LNG temperature is at desired target
-146°C and 15-FIC-1057 is in Auto and Cascaded with setpoint provided by 15-TIC-
1056.
6. Verify expander LNG level is established above the low level alarm 15-LAL-1247 and
cooldown has been completed as per vendor instructions.
7. Open inlet valve 15-XV-1062, and place 15-SIC-3002 and 15-PIC-1073 in Auto from
the DCS. Expander outlet valves 15-FV-1057A and 15-FV-1057B remain closed by 15-
HIC-1059 and 15-HIC-1060 until the expander is started.
8. Verify no boil-off gas is flowing through the vent in inlet lines which would indicate that
cooldown has not been completed and confirm there is no external leakage from pipe
joints.
9. Initiate start sequence from DCS by using hand switch 15-HS-1531 when minimum
LNG flow to system of 593,162 kg/hr (1339 m3/hr) has been reached.
10. The output of manual loading stations 15-HIC-1058, 15-HIC-1059 and 15-HIC-1060 are
automatically forced to 0% to fully close expander discharge valves and place 15-FV-
1057C under the control of 15-FIC-1057.
11. Automatically, 15-HIC-1059 ramps up the output from 0% at a rate of 5% per minute to
gradually open valve 15-FV-1057B.
12. 15-ST-3002A monitors the expander speed and at 2900 rpm holds 15-HIC-1059 and
starts ramping up the output of 15-HIC-1060 at a 5% per minute rate by gradually
opening the valve 15-FV-1057A to trim the expander speed. If no speed is detected
once the valve has opened at least 10%, then the start up sequence will be aborted.
13. During the ramping up of the 15-HIC-1059 and 15-HIC-1060, flow controller 15-FIC-
1057 slowly closes the J-T valve 15-FV-1057C
14. Once the speed reaches 2900 rpm, controllers 15PIC1073 and 15SIC3002 are placed
in Automatic control with setpoints of 15barg and 3025rpm respectively.
15. As expander speed increases, controller 15-SIC-3002 takes control of valve 15-FV-
1057A from 15-HIC-1060 through low selector 15-FY-1057K to maintain the expander
at 3025 rpm.
16. When the expander speed (15-ST-3002) reaches 3025 rpm, the logic signals the
expander to automatically connect to the grid. Also the operator can manually connect

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

the expander to the grid by using the handswitch 15-HS-1409. Synchronization to the
grid frequency locks the speed of the expander at 3000 rpm.
17. Upon feedback of connection to the grid through 15-HS-1409, the sequence ramps
down 15-HIC-1060 to 0% output at a rate of 15% per minute to close trim valve 15-FV-
1057A and continues ramping up 15-HIC-1059 at a rate of 15% per minute to increase
the power developed.
18. As the output of 15-HIC-1059 increases, control of discharge valve 15-FV-1057B
transfers to either flow controller 15-FIC-1057 or outlet pressure controller 15-PIC-1073
as determined by low selector 15-FY-1057G.

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the LNG Expander 15-MJ02
1. Verify controllers 15-SIC-3002 and 15-PIC-1073 are in Auto.
2. Verify 15-FIC-1057 is in auto and cascade with 15-TIC-1056 providing the setpoint.
3. Operator initiates 15-K-1531 Stop Sequence by using handswitch 15-HS-1531
4. Verify that power signal 15-JT-1071 is greater than zero and ENMCS communication is
established.
5. 15-HIC-1059 and 15-HIC-1060 ramp down to 0% at 15% per minute.
6. 15-HIC-1059 and 15-HIC-1060 are automatically released at 0% output when both
discharge valves 15-FV-1057A/B are closed.
7. As discharge valves 15-FV-1057A and B get closed, flow controller 15-FIC-1057 opens
the bypass valve 15-FV-1057C to maintain the desired LNG flow rate
8. When the power generation drops below 50 KW, expander is disconnected from the
grid by15-HS-1409 and its speed gradually decreases.
5.2 Process Upsets and Production Loss
In the event of a change in conditions or trips, the process may become upset and possibly
require shutdown. The LNG Expander System should be shut down as outlined above.
Below are possible causes for upset and actions to be taken.
1. Loss of Instrument Air
Loss of instrument air will cause control valves to fail to their safe position. Consequences of
the loss of instrument air for the major control and isolation valves are given below:
• 15-FV-1057A, 15-FV-1057B, 15-FV-1057C, 15-XV-1062, 15-PV-1063 and 15-ESDV-
1438 will fail close.

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-1530 - LNG Expander Trip Interlock
LNG Expander Trip Interlock I-1530 will isolate trip the LNG Expander, 15-MJ02, to protect
the expander.
On expander inlet high-high temperature 15-TT-1055A/B/C; expander discharge low-low
pressure 15-PT-1263; high-high expander differential pressure 15-PDT-1439; high-high
expander speed 15-ST-3002A/B/C; high high expander seal gas pressure 15-PT-3004;
expander electrical protection trip 15-XS-3008; or manual expander trip 15-HZ-1074/A,
interlock I-1530 will bypass expander feed through 15-FV-1057C, trip the expander breaker,
close expander outlet valves 15-FV-1057A/B. When expander outlet valves 15-FV-1057A/B
are confirmed closed or a 30 second time delay, expander inlet valve 15-XV-1062 will close.
MCHE Trip Interlock I-1550 will also initiate interlock I-1530 as above with the addition that
expander bypass valve 15-FV-1057C will be forced closed.
6.1.2 I-1550 - Main Cryogenic Heat Exchanger Trip Interlock
The Main Cryogenic Heat Exchanger Trip Interlock I-1550 will isolate the MCHE and to stop
the LNG production safely and keep the unit in such a condition that it can be started with a
minimum delay.
On high-high level 15-LT-1090A/B/C Helium Rich Gas Flash Drum, 15-MD03, or high-high
level 15-LT-1350A/B/C Nitrogen Stripper, 15-MD04, manual MCHE trip 15-HZ-1112; manual
PR Compressor trip 16-HZ-1256; MR Compressor Trip Interlock I-1610; PR Compressor
Trip Interlock I-1660; or Unit 15 Shutdown Interlock I-1500, interlock I-1550 will trip the LNG
Expander Trip Interlock I-1530, close LNG expander supply valve 15-ESDV-1438 and close
expander bypass valve 15-FV-1057C.
I-1550 Hi-Hi level trips have no time delay while all other I-1550 trips have a 120 second
time delay.

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

6.2 Pressure Safety Valve Summary

The LNG Expander System Pressure Relief Valve Summary contains a listing of all the
pressure relief valves associated with this system.

LNG Expander System Pressure Relief Valve Summary

Set Pressure
Valve Number Description/Location
(barg)

15-PRV-1078 LNG from LNG Expander, 15-MJ02, downstream 75.00

of 15-FV-1057B/Relief to the Cold Flare Header

15-PRV-1079A/B LNG from LNG Expander, 15-MJ02, upstream of 75.00

15-FV-1057B/Relief to the Cold Flare Header

15-PRV-1240 LNG Expander Feed/Relief to Cold Flare Header 75.00

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

6.3 Fire Protection Equipment

The LNG Expander System Fire Protection Equipment Summary is included in below listing
of Liquefaction Unit Fire Protection Equipment

LNG Expander System Fire Protection Equipment Summary

Description Quantity

Liquefaction Area

63-SP-005 Fire Blanket 1

63-SP-008 Fire Water Monitor (Grade) 3

63-SP-010 Live Hose Reel 2

63-SP-011 Hydrant Cabinet 4-Way 2

63-SP-024 Firewater Monitor Mounted on Four Way Hydrant 3

63-SP-050 Fire Water Monitor (Elevated) 2

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

7.1 Attachment I: Equipment List

The following is a list of equipment associated with the LNG Expander System.

LNG Expander System Equipment List

Equipment Design Design

No. Description Pressure Temp
(barg) (ºC)

15-MJ02 LNG Expander suction pot and head plate 75 -175/75*

15-MJ02 LNG Expander 1,842 m3/hr

Rated capacity

* design minimum temperature -175°C design maximum (non-operating) temperature +75°C

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OPERATING MANUAL VOLUME I, SECTION 3-3: REVISION 2
LNG EXPANDER

7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the LNG Expander System and their
expected consumption.

LNG Expander System Electrical Load List

Available
Equipment No. Description Load
(kW)

Not applicable

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