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PP Aaa PP1 111
PP Aaa PP1 111
SKIKDA, ALGERIA
OPERATING MANUAL VOLUME I, SECTION 3-7:
UNIT 15 LNG RUNDOWN
KBR
JOB NO.: J6404
TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running ................................................................................................................6
3.1.1 LNG Product Pumps, 15-MJ03/A ...................................................................................6
3.1.2 LNG Rundown Header ...................................................................................................6
3.2 Typical Operating Parameters ..........................................................................................7
3.3 Temporary Operation ........................................................................................................8
4.0 START-UP ............................................................................................................ 9
4.1 Cooldown LNG Product Pumps, 15-MJ03/A ....................................................................9
4.2 LNG Pump Startup ..........................................................................................................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-1500 - Liquefaction, Unit 15 ESD ...............................................................................13
6.1.2 I-1540 - LNG Product Pumps, 15-MJ03/A Trip Interlock .............................................13
6.1.3 I-7110 - LNG Storage, 71-MF01, Isolation Interlock ....................................................13
6.1.4 I-7111 - LNG Loading Pumps, 71-MJ01A/B/C/D 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-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
1.0 INTRODUCTION
This operating manual relates to the LNG Rundown System indicated on Process
Flow Diagrams PR-15-PR32-005, PR-71-PR32-006, PR-71-PR32-007 and P&ID’s
PR-15-SYPI-006A/007, PR-71-SYPI-003/004/005/013 and 013A.
LNG Rundown System consists of the LNG Product Pumps, 15-MJ03/A at the
downstream of the Nitrogen Stripper, 15-MD04, rundown lines from the product
pumps, rundown lines from the existing LNG facility GL.1.K Complex to the LNG
Storage Tank, 71-MF01, and the LNG circulation lines between the storage tank and
the loading arms.
LNG Transfer system circulates a small percentage of the LNG product between the
loading arms and the storage tank. The system is designed to keep these lines at
-160°C temperature and at the liquid phase during the holding mode of the LNG
plant.
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LNG RUNDOWN SYSTEM
BOG System
71-XV-2121
FEED GAS FOR
VACUUM
LNG RUNDOWN
PROTECTION
71-PV-2127 71-ESDV-2130
71-PIC
2127
SKIKDA, ALGERIA
71-PIC
1168
LNG RUNDOWN
TO/FROM
EXISTING GL1.K 71-FIC
71-ESDV-1170 71-ESDV-1169
COMPLEX 1140
71-PV-1168
71-PV-1102
TO / FROM
EXISTING JETTY
71-MF01
NEW LNG TRAIN SKIKDA PROJECT
TANK
71-FIC
2165
TO FUEL GAS
SYSTEM
71-FV2165
Page 4 of 18
OPERATING MANUAL VOLUME I, SECTION 3-7:
15-MD03
71-ESDV-1047
HELIUM RICH GAS
FLASH DRUM
71-ESDV-2122
71-MJ01-A/B/C/D 71-ESDV-2120
15-FV LNG LOADING
1093/4 PUMP
71-ESDV-2301
71-HS
15-FV-1093/94 2110
REVISION 1
15-MD04
NITROGEN
STRIPPER
71-XV-2110 6" LNG CIRCULATION LINE FROM JETTY
15-LIC
1349 71-HIC
2167
DOCUMENT NO.
PP-AAA-PP1-111
71-HV
15-HS 2167
1100/1
15-AT
1096 71-HIC
START / STOP 1004
11 DECEMBER 2012
15-MJ03/A
LNG Product Pump
KBR
NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
The LNG Product Pumps, 15-MJ03/A are centrifugal, vertical pot mounted
submerged motor pumps which receives the LNG product from the bottoms of the
Nitrogen Stripper, 15-MD04 at 0.35 barg and send it to LNG Storage Tank,71-MF01
at -160°C and 6 barg.
During the loading mode of the LNG plant, LNG product from the product pumps
goes directly to the LNG storage tank. However, when the plant is in holding mode, a
small percentage of the LNG product is diverted to the LNG rundown header to keep
the LNG transfer lines between the storage tank and the jetty vapor free at -160°C
and 6 barg.
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the LNG
Rundown System. Please refer to Section 3.2 for a list of typical operating variables
for this system.
3.1.1 LNG Product Pumps, 15-MJ03/A
LNG Product Pumps 15-MJ03 and 15-MJ03A are operated from the DCS with hand
switches 15-HS-1100 and 15-HS-1101, respectively. The pumps can also be
operated locally by switching control from remote to local through the 15-HS-1100A
and 15-HS-1101A.
LNG Product Pumps, 15-MJ03 and 15-MJ03A, transfer LNG from the Nitrogen
Stripper, 15-MD04, to the LNG Storage Tank, 71-MF01. While one of the pumps is
in operation, the other one remains in standby mode.
The DCS logic K-1541 will start the standby pump automatically in the event a high
liquid level is detected in the Nitrogen Stripper, 15-MD04, through the level controller
15-LIC-1349.
During one pump operating mode, if the discharge header pressure drops down to
low alarm level, 15-PSL-1295 will communicate to DCS logic K-1591 to automatically
start the standby pump. After starting the standby pump the DCS will keep both
pumps running until the operator stops the pumps manually.
The minimum flow from the pumps are controlled by flow controller 15-FIC-1093 and
1094 by recycling LNG through the minimum flow control valves 15FV1093 or 1094
back to the Nitrogen Stripper, 15-MD04.
3.1.2 LNG Rundown Header
LNG Product Pumps, 15-MJ03/A transfer the LNG product to the LNG Storage Tank,
71-MF01, through the LNG rundown and loading header.
During the holding mode of the plant, about 5% of the LNG product is diverted to the
16” diameter LNG rundown line and loading header between the storage tank and
the loading arms by opening the 71-HV-1004 through 71-HIC-1004 and 71-XV-2110
through the handswitch 71-HS-2110. The diverted flow goes through the loading
header to the end of the jetty where it joins to a 6” diameter circulation header
coming from to the existing LNG storage tanks. Combined stream connects back to
LNG Storage Tank, 71-MF01 through a 16” rundown line. This way the loading lines
remain filled with LNG product at -160°C and 6 barg and ready to switch quickly to
the loading mode as required. LNG circulation is provided to ensure that all piping in
LNG service is maintained at cryogenic temperatures.
During the loading mode, LNG rundown is directly sent to the LNG Storage Tank, 71-
MF01 and the circulation lines from/to jetty remains closed.
Page 6 of 18 KBR
NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
4.0 START-UP
This section outlines the steps necessary to place the LNG Rundown System in
service. For the purpose of this section of the operating manual, it is assumed that
the following conditions exist: The system and equipment have been pre-
commissioned, tested, commissioning has been completed, including dryout and cool
down and system is purged and ready for start-up.
4.1 Cooldown LNG Product Pumps, 15-MJ03/A
Note: Cooldown applies only after pump has been allowed to warm to ambient
condition or during installation. At all other times the pump should be kept in cold
condition to allow for immediate starting.
1. Open pump vent line to allow venting of the boil-off gas and to allow a small
amount of cold gas to circulate through the pump's internal passages.
2. Close the suction line to prevent cold liquid from splashing onto the side of
the pump.
3. Fill the suction vessel through the fill/drain flange connection provided at the
bottom of the suction vessel at the rate of approximately 2.5 cm of actual
liquid level per minute, stopping at the indicated levels for the minimum
specified time as shown in below table. At no time during the initial cooldown
should liquid be introduced into the suction line flange until the liquid level has
filled the suction vessel. Under no circumstances should the cooldown
procedure be completed in less than six hours.
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
When the liquid level is below the top of electric motor, restarts must be
restricted to allow more time for the motor to reach thermal stabilization. Do not,
under any circumstances, attempt to restart the pump within a shorter time
period than recommended.
Do not consecutively start the pump within short periods of time without
allowing a reasonable amount of time between starts to stabilize the motor at
the pumping temperature. With normal liquid levels, the time between first start
and second start is five minutes, then wait fifteen minutes before the third start
and then wait 30 minutes before restarting again. The number of starts must not
exceed four per hour.
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the LNG Rundown System
1. Verify that the LNG production is at minimum turndown rate and the upstream
units have already started normal shutdown procedures.
2. Verify that the downstream units are ready for normal shutdown.
3. Close the isolation valves 15-ESDV-1176 through handswitch 15-HS-1176 to
stop the LNG product to the storage tank.
4. Verify that the nitrogen stripper level control valve 15-LV-1349 is in manual
and closed.
5. Continue on minimum flow to the suction of the product pumps through
isolation valve 15-ESDV-1543.
6. Verify that the LNG product pump is on full recycle and remains in that mode
if the shutdown is only for a short duration.
7. If the shutdown is for prolonged period of time, place the standby pump in
manual and stop the product pump in operation through the handswitch 15-
HS-1100/ 1101, drain the liquid to the cold flare liquid header and put all the
controllers in manual and closed.
8. Isolate the LNG rundown header and circulation lines and drain the liquid to
the storage tank through the thermal relief header.
5.2 Process Upsets and Production Loss
Listed events described below may cause temporary process upsets and production
loss but not necessarily shutdown of the system. An emergency requiring a shutdown
of the system should be shut down as outlined above.
1. Loss of Electrical Power
Loss of electrical power to any one of the LNG Product Pumps, 15-MJ03/A will cause
the both pumps to stop and they will not be able to restart until the power is restored.
LNG product transfer to the LNG Storage Tank, 71-MF01 and loading jetties will be
stopped.
2. Loss of Instrument Air
Loss of instrument air to any one control valve will result in that valve going to its
designated fail safe position. As indicated on each P&ID, FO valves go to “fail open”
position and FC valves to a “fail closed” position.
The following valves will fail open: 71-PV-1102, 71-HV-1004, & 15-FV-1093 / 1094.
The following valves will fail closed: 15-ESDV-1543, 15-ESDV-1176, 15-LV-1349,
71-ESDV-2120 / 2122 / 2301, 71-HV-2167, 71-XV-2110.
3. Loss of LNG Product
Loss of LNG Product from the Nitrogen Stripper, 15-MD04 to the LNG Product
Pumps, 15-MJ03/A, will cause pumps to run in full minimum recycle mode. LNG
circulation will need to be maintained by the LNG Loading Pumps, 71-MJ01A/B/C/D,
until LNG product flow is re-established.
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
Set Pressure
Valve Number Description / Location
(barg)
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
Description Quantity
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
Design Design
Equipment No. Description Pressure Temp
(barg) (ºC)
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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-111
OPERATING MANUAL VOLUME I, SECTION 3-7: REVISION 1
LNG RUNDOWN 11 DECEMBER 2012
Available
Equipment No. Description Motor Load
(kW)
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