SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

SKIKDA, ALGERIA
OPERATING MANUAL VOLUME IV, SECTION 5-1:
UNIT 9 TEMPERED COOLING WATER

DOCUMENT NO: PP-AAA-PP1-148

KBR
JOB NO.: J6404

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

B JDS Issued for Client Approval 23-Sep-10 GRM BA -

A MDL Issued for Client Approval 24-May-10 ACG BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
2.1 Tempered Cooling Water................................................................................................5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running..............................................................................................................6
3.1.1 Tempered Water Circulation Pumps 09-MJ01 & 09-MJ01-A ........................................6
3.1.2 Water Passivation Package 09-ML01 ..........................................................................6
3.1.3 Tempered Water Cooler 09-MC01 ...............................................................................6
3.1.4 Tempered Water Header Tank 09-MD01 .....................................................................6
3.2 Typical Operating Parameters ........................................................................................7
3.3 Temporary Operation......................................................................................................7
4.0 START-UP ............................................................................................................ 8
4.1 Prior to Start-up ..............................................................................................................8
4.2 Steps for Tempered Cooling Water System Start-up ......................................................8
5.0 SHUTDOWN ......................................................................................................... 9
5.1 Normal Shutdown ...........................................................................................................9
5.1.1 Steps for Tempered Cooling Water System Shutdown ................................................9
5.2 Process Upsets and Production Loss .............................................................................9
6.0 SAFETY/EMERGENCY SHUTDOWN................................................................ 11
6.1 Safety Critical Shutdown Systems ................................................................................11
6.1.1 I-0900 Tempered Cooling Water System Unit 09 ESD...............................................11
6.2 Pressure Safety Valve Summary ..................................................................................11
6.3 Fire Protection Equipment ............................................................................................11
7.0 ATTACHMENTS ................................................................................................. 12
7.1 Attachment I: Equipment List ........................................................................................13
7.2 Attachment II: Utility Consumption...............................................................................14

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

1.0 INTRODUCTION
This operating manual relates to the Unit 9 Tempered Cooling Water facilities
indicated on Process Flow Diagram PR-09-PR32-001, and P&ID’s PR-09-SYPI-
001/002/003 and PR-09-SYPI-004.
The purpose of Tempered Cooling Water System, Unit 09, is to provide tempered
cooling water for the machinery in the Feed Conditioning (Unit 01), Refrigeration and
BOG Recycle Compressors (Unit 16), Liquefaction (Unit 15), External Refrigeration
(Unit 20), Air System Package (Unit 56) and Tempered water to pump Seal Coolers
in the following Units, 07, 08, 12, 18, 58, 65 and 76. The make-up water to tempered
water system is demineralized water from Unit 59. The demineralized water is
pumped by Tempered Water Circulation Pump through a Tempered Water Cooler to
each of the users and returns to a Tempered Water Header and back to the
circulation pump to complete the closed circulation system.
The Tempered Water Header Tank is provided at the highest point in the system and
supplies a surge volume for makeup and fluid expansion. The tank ensures a
flooded Tempered Cooling Water System and is filled from the Demineralized Water
System by a control valve 09-LV-1002.

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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

2.0 SYSTEM DESCRIPTION

2.1 Tempered Cooling Water
The Tempered Water Circulation Pump (09-MJ01) circulates water in a closed loop.
The pump takes warm water at nominally 46 °C from the users and pumps it through
the Tempered Water Cooler (09-MC01) which cools it to 39 °C (when the ambient is
24 °C) before returning it to the users. The standby pump (09-MJ01-A) auto-starts
on low discharge pressure.
The Tempered Water Header Tank (09-MD01) is at the highest point in the system
and provides a surge volume for makeup and fluid expansion. This tank, as installed,
ensures a flooded system and is filled from the Demineralized Water System.
Demineralize Water from Demineralized Water Storage Tank 59-MF03 enters the
Tempered Cooling Water System by 09-MD01 level control valve which controls the
flow into the suction line of Tempered Water Circulation Pump 09-MJ01/01-A. A 2”
line is provided from the pump discharge line to tank 09-MD01. A manual valve is
opened in the line to add Demineralized water. The level controller will close the
control valve when the set operating level is established. This tank 09-MD01 has a
high liquid level alarm that warns of overfilling and has an overflow fitting that dumps
excess water to grade in order to avoid over pressurization.
There is a low level alarm 09-LIC-1002 on the drum to allow the operators sufficient
time to bring in demineralized water make up to the system. A low low level alarm
09-LALL1001 is also provided and is an ALARM only.
A sample point allows monitoring of water quality. Batch chemical dosing using the
Water Passivation Package (09-ML01) is used to prevent corrosion, adjust pH and
control growth of micro organisms.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Tempered
Cooling Water System. Refer to Section 3.2 for a list of typical operating variables
for this system.
Demineralized water from Unit 59 and recirculating tempered water feeds Tempered
Water Circulation Pumps 09-MJ01/01-A. Chemicals to adjust the pH and prevent
growth of micro-organisms are added from the Water Passivation Package 09-ML01
at the pump suction. The water is pumped through a Tempered Water Cooler 09-
MC01 where the temperature is reduced to approximately 39 degrees. It is circulated
to all the users for cooling and then returned to the Tempered Water Header and
back to the pumps 09-MJ01/01-A suction.
3.1.1 Tempered Water Circulation Pumps 09-MJ01 & 09-MJ01-A
The pumps are started and stopped manually by the operator. One is running and
the other is a standby. If DCS logic K-0920 detects a low discharge pressure (from
09-PSL-1008) and the standby pump is in Remote mode the standby pump is
automatically started.
Pump Manual Switch Remote Switch
09-MJ01 09-HS-1003 09-HS-1003A
09-MJ01-A 09-HS-1004 09-HS-1004A

3.1.2 Water Passivation Package 09-ML01

Water Passivation Pump 09-ML01-MJ01 is used to pump chemicals from a tote tank
to tempered water return line from the common discharge line of the Tempered
Water Circulation Pumps 09-MJ01/A to the pump suction. The system is operated as
determined by chemical analysis of the tempered water and is operated manually by
the operator who adjust the pump stroke and runs the pump as necessary to control
the water quality. A sample point allows monitoring of water quality, samples are
taken daily and checked for the following:
• ph 5.5-7.5 Max
• Conductivity <10uS/cm Max
• Chloride <3 mg/l Max
• Iron <0.1 mg/l Max
3.1.3 Tempered Water Cooler 09-MC01
This is a fin-fan Cooler consisting of 3 bays each containing 3 fixed speed fans. All 9
fans are started and stopped manually by the operator. The tempered water
temperature is monitored by 09-TI-1009. When the temperature drops to the low
alarm point (during cold weather) the operator should turn some fans off.
3.1.4 Tempered Water Header Tank 09-MD01
This Tempered Water Header Tank is elevated to 129.5 meters and provides a
constant pressure on the system while also providing a constant water flow to the 09-
MJ01/01A pumps. The level in the Tank is controlled by 09-LIC-1002, which opens
valve 09-LV-1002 to bring in more demineralized water to the pump 09-MJ01/01A
suction from Unit 59.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

3.2 Typical Operating Parameters

The following table contains typical operating variables for the Tempered Cooling
Water System.

Operating Variables for the Tempered Cooling Water System

Tag No. Description Typical Value Units

09-LIC-1002 Tempered Water Header Tank 09- 50 %

MD01 Level Control

09-LI-1002A Tempered Water Header Tank 09- 50 %

MD01 Level Indicator

09-TI-1017 Tempered Water Cooler 09-MC01 46 °C

Inlet Temperature Indicator

09-TI-1009 Tempered Water Cooler 09-MC01 39 °C

Outlet Temperature Indicator

09-TI-1020 Tempered Water Cooler 09-MC01 Ambient °C

Air Temperature Entering 09-MC01

09-PI-1008 Tempered Water Circulation Pump 8.0 barg

09-MJ01/01A Discharge Pressure
Indicator

3.3 Temporary Operation

The Tempered Cooling Water is sampled to monitor the water quality. Batch
chemical dosing using the water Passivation Package, 09-ML01 is used as
necessary to prevent corrosion, adjust pH and control growth of micro organisms.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

4.0 START-UP
This section outlines the steps necessary to place the Tempered Cooling Water 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, and the system is ready for start-up.
4.1 Prior to Start-up
1. Confirm that the Passivation Chemical solution is ready and available from the
tote tank through a flexible hose to the suction line for the water Passivation
Pump 09-ML01-MJ01
2. Confirm that Demineralized Water is available from Unit 59 through the
Demineralized Water distribution header and the Tempered Cooling Water make-
up line to the Tempered Cooling Water System.
3. Notify operators in the following units that the Tempered Cooling Water System is
about to be placed in service: Unit 1, Unit 7, Unit 8, Unit 12, Unit 15, Unit 16, Unit
18, Unit 20, Unit 56, Unit 65, and Unit 76.
4. Ensure that the 4” globe valve is open in the jump over line from Tempered Water
supply line to tempered water return line during start-up PR-09 SYPI-002, also
same on PR-09-SYPI-004.
4.2 Steps for Tempered Cooling Water System Start-up
1. Open valve in Demineralized water make-up line from Unit 59 and inventory the
entire Tempered Cooling Water System including the Tempered Water Header
Tank 09-MD01.
2. Place Tempered Water Header Tank 09-MD01 Level Indicator Controller 09-LIC-
1002 in service in automatic mode to control the level by regulating flow through
09-LV-1002. Ensure all instruments are in service for 09-MD01
3. Start one of the Tempered Water Circulation Pumps 09-MJ01/01-A and verify pump
discharge pressure is 8.0 barg and temperature at approximately 46°C. Place the
other pump in standby mode with all pump instrumentation in service.
4. Monitor the inlet 09-TI-1017 and outlet 09-TI-1009 temperatures of Tempered
Water Cooler 09-MC01 and start fans on the air fin coolers as required to maintain
an outlet temperature of 39°C.
5. Ensure that the two 4” valves in the jump over lines that were opened in item 4
above are closed when users are being placed in service.
6. Obtain a sample of the tempered cooling water returning from the users, at sample
station 09-SC-001. Run an analysis and if necessary based on the water quality
place the Water Passivation Pump in service and add a batch of chemical solution
as recommended by the water treatment vendor to adjust pH and control
microbiology and prevent corrosion.
7. Continue to monitor the Tempered Cooling Water System pressures and
temperatures and make adjustments as necessary as users are placed in service.
8. Start more cooling fans as needed to control the Tempered Water Cooler 09-MC01
outlet temperature and monitor fan operations.
9. Monitor the Tempered Water Circulation Pump 09-MJ01/01-A operation.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Tempered Cooling
Water System.
5.1.1 Steps for Tempered Cooling Water System Shutdown
The Tempered Cooling Water System will normally remain in operation if the plant is
shutting down for a short period of time. In the event of an entire plant shutdown for
an extended period of time the Tempered Cooling Water System will remain in
service until all the Units that use the Tempered Cooling Water System have been
shut down and do not need the Tempered Cooling Water.
1. Ensure that the Water Passivation Package is shut down and isolated.
2. Monitor Tempered Water Cooler 09-MC01 inlet and outlet temperatures as
tempered cooling water users shutdown and shutdown fans as required
cooling decreases.
3. Shut down Tempered Water Circulation Pump 09-MJ01/01-A.
4. Verify that all Tempered Cooling Water supply lines to each of the units that
use the water are isolated from the units.
5. Ensure that valves are closed in the demineralized water makeup supply line
to the Tempered Cooling Water System.
6. If the System is going to have maintenance work performed then the portion
to be worked on must be drained and made ready.
5.2 Process Upsets and Production Loss
In the event of an emergency requiring a shutdown of the Tempered Cooling Water
System, the system should be shut down as outlined above. In the event of causes
and actions, listed below only process upsets or production loss may occur and not
necessarily require the Tempered Cooling Water System to be shutdown.
1. Loss of Electrical Power
Loss of electrical power to the Tempered Water Circulation Pump 09-MJ01/01-A
will cause the pump to stop if it is running and will not be able to start it if it is
down, until power is restored. If the standby pump has electrical power to it,
and in remote mode it will automatically start if DCS logic 09-K-0920 detects a
low discharge header pressure from 09-PSL-1008.
Loss of electrical power to both pumps will cause the system to shut down and
Tempered Cooling Water flow to all of the users will stop causing those units to
shutdown or change operations. Principal users of TW are the MR
compressors, the PR compressors, the Fuel Gas Compressor and the Feed
Gas Compressor.
Loss of electrical power to anyone of the Tempered Water Cooler, 09-MC01 fan
motors will stop it if it is running and will not be able to start it if it is down until
power is restored. There are a total of 9 fans, if only one is stopped the outlet
temperature may increase some. If several are stopped the Tempered Water
temperature may increase too much to provide the necessary cooling the water
for the users. The fans should be placed back in service as quickly as power is
restored.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

2. Loss of Instrument Air

Loss of Instrument air to the only control valve in the system, Tempered Water
Header Tank 09-MD01 level control valve, 09-LV-1002 will result in that valve
going to its designated fail safe position. As indicated on the P&ID, FO valves
go to fail open .To keep from flooding the tank out the over flow line to grade
close the valve down stream of the control valve until instrument air supply is
restored.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
There is only one safety interlock associated with the Tempered Cooling Water
System.
6.1.1 I-0900 Tempered Cooling Water System Unit 09 ESD
The Tempered Cooling Water System Unit 09 ESD Interlock I-0900 is the manual trip
of the Tempered Water System. On LNG Train ESD Interlock I-0000 all the Unit 09
equipment will trip.
6.2 Pressure Safety Valve Summary
The Tempered Cooling Water System contains only one pressure relief valve
associated with this system.

Tempered Cooling Water System Pressure Relief Valve Summary

Set Pressure
Valve Number Description/Location (barg)

09-PRV-1010 Water Passivation Pump 09-ML01-MJ01 Discharge 8.1

Relief Back to the Pump Suction Line

6.3 Fire Protection Equipment

The Tempered Cooling Water System Fire Protection Equipment Summary contains
a listing of fire protection equipment associated with this system.

Tempered Cooling Water System Fire Protection Equipment Summary

Description Quantity

BBA Tempered Cooling Water

63-SP-008 Fire Monitor (Grade) 2

63-SP-050 Fire Water Monitor (Elevated) 1

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

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-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Tempered Cooling Water
System.

Tempered Cooling Water System Equipment List

Design Design
Pressure Temp
Equipment No. Description (barg) (ºC)

09-MD01 Tempered Water Header Tank 3.5 85/-7

09-MJ01/01-A Tempered Water Circulation Pump 8.0 62/1

09-MC01 Tempered Water Cooler 10.0 85/-12

09-ML01-MJ01 Water Passivation Pump 4.8 47/30

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-148
OPERATING MANUAL VOLUME IV, SECTION 5-1: REVISION 0
TEMPERED COOLING WATER 23 NOVEMBER 2010

7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Tempered Cooling Water
System and their expected consumption.

Tempered Cooling Water System Motor List

Available
Motor Load
Equipment No. Description (kW)

09-MJ01/01-AM Tempered Water Circulation Pump Electric 2@360 ea.

Motor

09-MC01-M Tempered Water Cooler Electric Fan Motor 9@37.0 ea

09-ML01-MJ01-M Water Passivation Pump Electric Motor 0.25

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