STS EXE MAW 981 PRO RPT 0001 - Commented

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STS-EXE-MAW-PRO-RPT-
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PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

COMMISSIONING OF SANITARY TREATMENT SYSTEM (STS) MODIFICATION Page: 1 of 20
PROJECT AT GAS PROCESSING KERTIH, PETRONAS GAS BERHAD
PROJECT : PROVISION OF ENGINEERING, PROCUREMENT,

CONSTRUCTION AND COMMISSIONING OF
SANITARY TREATMENT SYSTEM (STS)
MODIFICATION AT GAS PROCESSING KERTIH
(GPK), PETRONAS GAS BERHAD
CLIENT : PETRONAS GAS BERHAD
PO. NO. : 3920133490
CONTRACT NO. : DTC-KTH/PGB-GPU/2020/0011
DOCUMENT TITLE : PROCESS AND OPERATING PHILOSOPHY
DOC. REVIEW : Z
CLASSIFICATION
SECURITY : OPEN
CLASSIFICATION
0 02.11.21 ISSUED AS FINAL NR ZIZ MAR

Prep’d Rev’d App’d Rev’d End’d App’d
Rev Date Description By By By By By By
MAWGSB PGB
© 2020 PETROLIAM NASIONAL BERHAD (PETRONAS). All rights reserved. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or
otherwise) without the permission of the copyright OWNER.
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TABLE OF CONTENT
1.0 INTRODUCTION ....................................................................................................................3
1.1 PROJECT OVERVIEW (BACKGROUND) .................................................................................................... 3
1.2 OBJECTIVE........................................................................................................................................ 4
1.3 DEFINITION ...................................................................................................................................... 4
1.4 ABBREVIATION .................................................................................................................................. 4
2.0 APPLICABLE CODES AND STANDARDS ...................................................................................5
2.1 NATIONAL REGULATORY STANDARD ..................................................................................................... 5
2.2 PETRONAS TECHNICAL STANDARD (PTS) ............................................................................................ 5
2.3 ORDER OF PRECEDENCE ..................................................................................................................... 5
3.0 PROJECT SCOPE ....................................................................................................................5
4.0 PROCESS AND OPERATING PHILOSOPHY ...............................................................................7
4.1 PROCESS AND OPERATING PHILOSOPHY FOR SANITARY PIT AND PUMP .................................... 7
4.1.1 REFERENCE DRAWING/DOCUMENT: ..................................................................................................... 7
4.1.2 FUNCTIONAL DESCRIPTION ................................................................................................................. 7
4.1.3 CONTROLLER/SELECTOR/COMPUTING REQUIREMENT ........................................................................... 10
4.2 PROCESS AND OPERATING PHILOSOPHY FOR SEWERAGE TREATMENT SYSTEM (STS) ............. 12
4.2.1 REFERENCE DRAWING/DOCUMENT: ................................................................................................... 12
4.2.2 FUNCTIONAL DESCRIPTION ............................................................................................................... 12
4.2.3 CONTROLLER/SELECTOR/COMPUTING REQUIREMENT ........................................................................... 14
5.0 CONTROL NARRATIVE ......................................................................................................... 16
5.1 NPS (G2‐984, G2‐983, G3‐984, G‐756 & G4‐984) ........................................................................ 16
5.1.1 AUTO MODE .................................................................................................................................. 12
5.1.2 MANUAL MODE ............................................................................................................................. 17
5.2 NPS (GH‐983) .............................................................................................................................. 17
5.2.1 AUTO MODE .................................................................................................................................. 12
5.2.2 MANUAL MODE ............................................................................................................................. 18
5.3 SEWERAGE TREATMENT SYSTEM (STS) ....................................................................................... 19
5.3.1 AUTO MODE .................................................................................................................................. 12
5.3.2 MANUAL MODE ............................................................................................................................. 20
5.3.3 EMERGENCY STOP ........................................................................................................................... 20
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1.0 INTRODUCTION
1.1. Project Overview (Background)
The objective of this project is to improve and to upgrade existing sewerage treatment
system in GPK Plant and to meet Environment Quality Sewerage 2009 Regulation by 2020.

The existing Sanitary Treatment System consist six (6) numbers of Sanitary Pit and the
Sanitary Pit consist of pumps, electrical power, flow meter, level transmitter etc. The pit
receives and process raw sewage influent from maintenance area, non‐process building,
warehouse and laboratory, control building CCR123 and control building CCR4, then all the
process raw sewage out to the treatment plant, which consist of Parshall Flume, settling tank
and oxidation pond.

All sewage was transfer from one pit to another pit and lastly to the oxidation pond through
pump and underground pipe. The oxidation pond is where biological treatment process
takes place before treated effluent is discharge into the storm sewer.

Sewerage Treatment System (STS) in GPK Plant can be schematically describes as below:

Figure 1.1(a): Existing Sewage Treatment System (STS) at GPK

(NEAR CCR4)
PIT : G4-984
PUMP : P4-982A/B
(ADMIN BUILDING)
OLD TREATMENT
SYSTEM
(NEAR FLARE)
PIT: G3-984
PUMP : P3-981A/B
(NEAR LAB M2-701)
PIT : G2-983
PUMP : P2-981A/B

OXIDATION POND

PIT : G-984 (NEAR WAREHOUSE)
PUMP : P-989A/B PIT : G-756
PUMP : P-754A/B

(NEAR CCR 123)
PIT : G2-984
PUMP : P2-982A/B
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However, based on Situational Assessment, most equipment’s are not functioning (i.e.
pumps, electrical power, flow meter and level transmitter etc.). Other than that, existing
underground pipelines also suspected leak at a few areas which are unable to transfer the
sewage to the oxidation pond.

1.2. Objective
The objective of this report is to present the process and operating philosophy and
assumptions used in Basic Engineering Design for Sewerage Treatment System (STS) at Gas
Processing Kertih (GPK).

1.3. Definition
COMPANY PETRONAS GAS BERHAD
CONTRACTOR M.A.W GLOBAL SDN BHD
VENDOR The party that manufactures or supplies equipment and services to
perform the duties specified by the CONTRACTOR.
SUB‐VENDOR The party or parties that has or have entered a contract with the
VENDOR for the performance of any part of the SCOPE OF WORK.
Third Party A person or company independent of the manufacturer or VENDOR
and shall be appointed by the VENDOR who is responsible to ensure
the item is designed, fabricated, inspected, tested, delivered and
installed in accordance with this Requisition/Purchase Order.
WORK/SERVICES This shall include any authorization for works, services or changes
which will be issued by VENDOR from time to time and shall become
part of the scope of WORK/SERVICES whereby all terms and
conditions of this requisition shall govern.
Project Data Sheets Governing technical documents for the specific item(s) for purchase.
Project Drawings Reference drawings for the specific item(S) for purchase.
Shall Indicate a requirement
Should Indicate a recommendation

1.4. Abbreviation
ANSI American National Standards Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineer
ASTM American Society for Testing and Materials
HAZOP Hazard and Operability Study
ISO International Organisation for Standardisation
MAWG M.A.W Global Sdn Bhd
NACE National Association of Corrosion engineers
P&ID Piping and Instrumentation Diagram
PTS PETRONAS Technical Standard
RAS Return Activated Sludge
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SPAN Suruhanjaya Perkhidmatan Air Negara
MLSS Mixed Liquor Suspended Solid
pH Potential of Hydrogen
DCS Distributed Control System
LCP Local Control Panel
STS Sanitary Treatment System
NPS Network Pumping Station
LCD Liquid Crystal Display

2.0 APPLICABLE CODES AND STANDARDS
This section identifies the latest editions of applicable codes and standards to be used for
this project. As a minimum, the design in accordance with accepted design practices,
applicable sections of the PETRONAS Technical Standard, the relevant sections of the latest
national/international codes, standards and regulations as listed below:

2.1. National Regulatory Standard
Interim Report: (May 2019) Technical Standard for Sewerage System less than 10,000PE
by SPAN

2.2. PETRONAS Technical Standard (PTS)
PTS 12.30.01 Piping Classes – Basic of Design
PTS 12.30.02 Piping General Requirement

2.3. Order of Precedence
In the event that there are conflicts with items or information contained within the
document, the following order of precedence shall be used when interpreting the
information of COMPANY provided documentation and references. Any deviations from the
approved documents shall require COMPANY approval prior to implementation:

1. National or local regulatory standards where the WORK is being performed and/or
where the facilities are to be installed.
2. Contractual requirements and project specific requirements or standards (e.g.
Specifications, Datasheets, Drawings etc.).
3. Other relevant COMPANY standards and procedures such as Petronas Gas Berhad
Standard Procedures, PETRONAS Gas HSE Management Standard etc.
4. The latest PETRONAS Technical Standards (PTS) – June 2018 and its supplementary.
5. International Codes and Practices (e.g. API, ASME, ASTM, ANSI, ISO, AWS, AISC, IEC, BS,
IP & etc.).
Where waiver or non‐compliance to codes and standards are required, the approval from
relevant matrix custodians within COMPANY shall be adhered to.
3.0 PROJECT SCOPE
Existing sewerage system in Gas Processing Kertih (GPK) is consist of four (4) sanitary pit
which collecting sewage flow from nearby buildings and two (2) sanitary pit as intermediate
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sanitary pit. There is also one (1) existing small treatment plant that collecting the sewage
from non‐process area (administration building, surau and cafeteria). Each sanitary is
provide with sanitary pump to transfer collected sewage using underground piping network
to existing Sewerage Treatment System (STS) which consist of Settling Tanks and Bio
Oxidation Ponds. Treated water from existing Bio Oxidation Pond is flows to storm sewer
which leads to river/water body.

Under this project, the following is upgraded:
a) All existing sanitary pumps (inclusive instrumentation and control system) to be changed
to new submersible pump as per SPAN guidelines.
b) All existing UPVC underground pipe for sewage transfer in between sanitary pits and
Sewerage Treatment System (STS) to be changed to Ductile Iron with High Alumina
Internal Cement Lining as per SPAN guidelines.
c) Existing Sewerage Treatment System (STS) to be upgraded to Extended Aeration (EA)
system to treat sewage fluid collected from sanitary pits before released to storm sewer.
However, based on the site assessment and value re ‐ engineering exercise, the following
had been decided:
i) Pit G‐984 will be decommissioned and all the flow from the pit G‐756 will be transfer to
G2‐984 prior to further transfer to EA STS by pumping system.
ii) New Pit, GH‐981 will be construct near to non‐process treatment plant and the sewage
from administration building will be transfer to G2‐983 by pumping system.
The new designed sewerage treatment system at GPK can be schematically described as
figure 3.1 (a) below.

Figure 3.1(a): Proposed Sewage Treatment System (STS) at GPK

(NEAR CCR4)
PIT: G4-984
PUMP: P4-982A/B (ADMIN BUILDING)
PIT: GH-983
PUMP: PH-981A/B
(NEAR FLARE)
PIT: G3-984
PUMP: P3-981A/B
(NEAR LAB M2-701)
PIT: G2-983
PUMP: P2-981A/B

E.A 400 P.E STS

(NEAR WAREHOUSE)
(NEAR CCR 123)
PIT: G-756
PIT: G2-984
PUMP: P-754A/B
PUMP: P2-982A/B
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4.0 PROCESS AND OPERATING PHILOSOPHY

4.1 Process and Operating Philosophy for Sanitary Pit and Pump

4.1.1 Reference Drawing/Document:
a) Process Flow Diagram (PFD), Sanitary System ‐ Dwg No: STS‐EXE‐MAW‐981‐PRO‐PFD‐001
b) Utility Flow Diagram (UFD), Sanitary System ‐ Dwg No: STS‐EXE‐MAW‐981‐PRO‐UFD‐001
c) Utility Flow Diagram (UFD), Sanitary System ‐ Dwg No: STS‐EXE‐MAW‐981‐PRO‐UFD‐002
d) Process Design Basis – Doc No: STS‐EXE‐MAW‐981‐PRO‐DES‐0001

4.1.2 Functional Description
Sanitary Pump is designed to transfer sewerage fluid from Sanitary Pit into the Intermediate
Sanitary Pit or into the Sewerage Treatment System (STS).

a) Below is summary of process control philosophy for sanitary pump:

Table 3.1.2 (a): Operating and Operating Philosophy for Equipment in Sanitary Pit
Service Screen Pump Tag No Operating Philosophy Remark
Tag. No (Pump)
GH‐983 GH‐981 PH‐981A / PH‐981B One Duty & One Standby Local
Automation
G2‐983 G2‐981 P2‐981A / P2‐981B One Duty & One Standby DCS
G‐756 G‐763 P‐754A / P‐754B One Duty & One Standby DCS

b) Sanitary Pump PH‐981A/B shall control by Radar Level Transmitter which able to detect
Low Level (L), High Level (H) and High High Level (HH) according to the level set‐point
settings at LCP. Duty Pump shall start automatically once High Level (H) is detected. Duty
Pump shall stop automatically once achieve the Low Level (L) setting. Meanwhile, Duty
and Standby Pumps shall run automatically once level increase to High High Level (HH)
and both pumps shall stop once level reach back to Low Level (L) setting. Indication Light
as alarm shall light on automatically once level increase to High High Level (HH).
Emergency Stop Button should be located at LCP to shut off Sanitary Pump quickly in
case of any emergency.

c) For others Sanitary Pump P2‐981A/B, P3‐981A/B, P2‐982A/B, P‐754A/B and P4‐982A/B,
it shall control by Radar Level Transmitter which able to detect Low Level (L), High Level
(H) and High High Level (HH) according to the level set‐point settings at DCS. LCP shall
receive command signal from DCS to start and stop the pumps. Duty Pump shall start
automatically once High Level (H) set‐point is detected. Duty Pump shall stop
automatically once achieve the Low Level (L) setting.
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Meanwhile, Duty and Standby Pumps shall start automatically once level increase to
High High Level (HH) set‐point and both pumps shall stop once level reach back to Low
Level (L) set‐point. Start and stop signals also available in DCS for monitoring and control.
Emergency Stop Button should be located at LCP to shut off Sanitary Pump quickly in
case of any emergency.

Figure 3.1.2(b): Level Control by Radar Level Transmitter in Sanitary Pit
Level Settings not as per

P&ID L, 600 mm, H
=1100, HH, 1250 mm

Note: Level Setting for all pit except Pit G3‐984 (L = 400, H = 500, HH = 150)

d) In new Sanitary Pit GH‐983, sewage from Admin Building shall flow through Sanitary
Screen GH‐981 before accumulates in Sanitary Pit. One of Sanitary Pump (P2‐981A/B), as
Duty Pump shall start automatically once High Level (H) set‐point is detected to transfer
sewage into the Sanitary Pit G2‐983. Duty Pump shall stop automatically once achieve
the Low Level (L) set‐point. Meanwhile, Duty and Standby Pumps shall start
automatically once level increase to High High Level (HH) set‐point and both pumps shall
stop once level reach back to Low Level (L) set‐point.

e) In Sanitary Pit G2‐983, sewage from laboratory M2‐701, nearby building and from Pit
GH‐983 shall flow through Sanitary Screen G2‐981 before accumulates in Sanitary Pit.
One of Sanitary Pump (P2‐981A/B), as Duty Pump shall start automatically once High
Level (H) set‐point is detected to transfer sewage into the Sanitary Pit G3‐984. Duty
Pump shall stop automatically once achieve the Low Level (L) set‐point. Meanwhile, Duty
and Standby Pumps shall start automatically once level increase to High High Level (HH)
set‐point and both pumps shall stop once level reach back to Low Level (L) set‐point.

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f) In intermediate Sanitary Pit G3‐984, sewage from Sanitary Pit G2‐983 shall flow through
Sanitary Screen G‐982 before accumulates in Sanitary Pit. One of Sanitary Pump (P3‐
981A/B), as Duty Pump shall start automatically once High Level (H) set‐point is detected
to transfer sewage into the Sewerage Treatment System (STS) (refer 3.2 for Process and
Operating Philosophy of STS). Duty Pump shall stop automatically once achieve the Low
Level (L) set‐point. Meanwhile, Duty and Standby Pumps shall start automatically once
level increase to High High Level (HH) set‐point and both pumps shall stop once level
reach back to Low Level (L) set‐point.

g) In Sanitary Pit G‐984, sewage from Control Building H2‐702 and G‐756 shall flow through
Sanitary Screen G2‐982 before accumulates in Sanitary Pit. One of Sanitary Pump (P2‐
982A/B), as Duty Pump shall start automatically once High Level (H) set‐point is detected
to transfer sewage into the Sewerage Treatment System (STS) (refer 3.2 for Process and
Operating Philosophy of STS). Duty Pump shall stop automatically once achieve the Low
Level (L) set‐point. Meanwhile, Duty and Standby Pumps shall start automatically once
level increase to High High Level (HH) set‐point and both pumps shall stop once level
reach back to Low Level (L) set‐point.

h) In Sanitary Pit G‐756, sewage from Control Room CCR 123 shall flow through Sanitary
Screen G‐763 before accumulates in Sanitary Pit. One of Sanitary Pump (P‐754A/B), as
Duty Pump shall start automatically once High Level (H) set‐point is detected to transfer
sewage into the Sanitary Pit G2‐984. Duty Pump shall stop automatically once achieve
the Low Level (L) set‐point. Meanwhile, Duty and Standby Pumps shall start
automatically once level increase to High High Level (HH) set‐point and both pumps shall
stop once level reach back to Low Level (L) set‐point.
i) In Sanitary Pit G4‐984, sewage from Control Room shall flow through Sanitary Screen G4‐
982 before accumulates in Sanitary Pit. One of Sanitary Pump (P4‐982A/B), as Duty
Pump shall start automatically once High Level (H) set‐point is detected to transfer
sewage into the Sewerage Treatment System (STS) (refer 3.2 for Process and Operating
Philosophy of STS). Duty Pump shall stop automatically once achieve the Low Level (L)
set‐point. Meanwhile, Duty and Standby Pumps shall start automatically once level
increase to High High Level (HH) set‐point and both pumps shall stop once level reach
back to Low Level (L) set‐point.
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4.1.3 Controller/Selector/Computing Requirement
a) Sanitary Pump PH‐981A/B are local automation control by LCP. Two modes are available
for selection:
i) AUTO Mode: Sanitary Pump either selected Sanitary Pump shall start and stop based
on level set‐point setting in Sanitary Pit.
ii) MANUAL Mode: Pump either selected Sanitary Pump shall start manually via local
pushbutton.
Duty Pump shall stop during low level (L) on any mode to protect pump from running
dry.

b) For others Sanitary Pump P2‐981A/B, P3‐981A/B, P2‐982A/B, P‐754A/B and P4‐982A/B,
it shall be start and stop thru LCP automatically by receiving command signal from DCS.
Start and stop signals are also available in DCS for monitoring and control. Two modes
are available for selection at LCP:
i) AUTO Mode: Sanitary Pump either selected Sanitary Pump shall start and stop
based on level in Sanitary Pit via DCS.
ii) MANUAL Mode: Pump either selected Sanitary Pump shall start manually via local
pushbutton.
Duty Pump shall stop during low level (L) on any mode to protect pump from running
dry.

b) Proposed level set‐point settings for Sanitary Pump are as follows:
Table 3.1.3(a): Proposed Level set‐point settings for Sanitary Pit
Sanitary Sanitary Settings Proposed Level Action Remark
Pit No. Pump Set‐point Settings
(mm)NOTE1
GH‐983 PH‐981A/B High High (HH) 1250 Duty & Standby Duty & Standby
Pumps shall start Pumps shall stop
once level reach back
to Low Level (L)
High (H) 1100NOTE2 Duty Pump shall
start
NOTE2
Low (L) 600 Duty Pump shall
stop
G2‐983 P2‐981A/B High High (HH) 1250 Duty & Standby Duty & Standby
Pumps shall start Pumps shall stop
once level reach back
to Low Level (L)
start
NOTE2
stop
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(mm)NOTE1
G3‐984 P3‐981A/B High High (HH) 1050 Duty & Standby Duty & Standby
Pumps shall start Pumps shall stop once
level reach back to
Low Level (L)
start
Low (L) 400NOTE2 Duty Pump shall
stop
G2‐984 P‐982A/B High High (HH) 1250 Duty & Standby Duty & Standby
level reach back to
Low Level (L)
start
stop
G‐756 P‐754A/B High High (HH) 1250 Duty & Standby Duty & Standby
level reach back to
Low Level (L)
start
stop
G4‐984 P‐982A/B High High (HH) 1250 Duty & Standby Duty & Standby
level reach back to
Low Level (L)
start
stop
Note:
(1) Level is from bottom of Sanitary Pit.
(2) Difference between Duty Pump start (Level High) and Duty Pump stop (Level Low) is equal/more
than 450mm as per requirement in Technical Standard for Sewerage System for less than 10000PE
by SPAN.

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4.2 Process and Operating Philosophy for Sewerage Treatment System (STS)

4.2.1 Reference Drawing/Document:
a) Process Flow Diagram (PFD), Sewerage Treatment System –
Dwg No : STS‐EXE‐MAW‐981‐PRO‐PFD‐002
b) Utility Flow Diagram (UFD), Sanitary System –
Dwg No : STS‐EXE‐MAW‐981‐PRO‐UFD‐003
c) Process Design Basis ‐ Doc No: STS‐EXE‐MAW‐981‐PRO‐DES‐0001

4.2.2 Functional Description
Sewerage Treatment System (STS) is designed using Extended Aeration (EA) system in order
to treat all sewage collected from all area in Gas Processing Kertih (GPK) Plant prior to
discharge to storm sewer.

STS are local automation control via LCP at Blower House‐Electrical Room and only certain
signal status such as pump, mixer, blower, analyzer and flow transmitter are being transmit
to DCS for monitoring.

a) Below is summary of process and operating philosophy for equipment within Sewerage
Treatment System (STS):

Table 3.2.29(a): Process and Operating Philosophy for Equipment in STS
Service Operating Philosophy
Equalization Tank Pump One Duty & One Standby (2x100%)

Aeration Tank Pump One Duty & One Standby (2x100%)

Submersible Mixer One Duty (1x100%)

Aeration Blower One Duty & One Standby (2x100%)

b) One of Equalization Tank Pump (P2‐983A/B), as Duty Pump shall start automatically once
High Level (H) set‐point setting is detected by Radar Level Transmitter setting (as
default) to transfer sewage through flow control box into the Anoxic Tank. Duty Pump
shall stop automatically once achieve the Low Level (L) set‐point. Meanwhile, Duty and
Standby Pumps shall start automatically once level increase to High High Level (HH) set‐
point and both pumps shall stop once level reach back to Low Level (L) set‐point.
Equalization Tank Pump shall start and stop from LCP located in Blower House‐Electrical
Room and monitoring signal status shall be transmit to DCS. As safeguarding protection
to avoid dry condition in Equalization Tank, the Float Switch via vendor package is install
at Level Switch Cutt Off Level (LSLL). Proposed level setting for Equalization Tank as table
below:
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Table 3.1.3(a): Proposed Level Settings for Equalization Tank
(mm)NOTE1
G2‐990 PH‐983A/B High High (HH) 2950 Duty & Standby Duty & Standby
Pumps shall Pumps shall stop
start once level reach
back to Low Level (L)
High (H) 1950 Duty Pump shall
start
stop
Level Switch 1350 NOTE2 Duty Pump shall
Cut Off (LSLL) stop
Note:
(1) Level is from bottom of Sanitary Pit.
(2) Set‐point setting for Float Switch.

c) Anoxic Tank Mixer (R2‐982) to operate intermittently base on timer setting for de‐
nitrification process and transfer to Aeration Tank. Anoxic Mixer (R2‐982) shall start and
stop via LCP located in Blower House‐Electrical Room and signal status shall transmit to
DCS for monitoring. If fine tuning of the treatment system is required, timer settings
can be applied at the LCP for the Anoxic Mixer (R2‐982).

d) In the Equalization Tank (G2‐990), the Dissolved Oxygen Analyzer (AT‐03A) shall install
to measure the total oxygen content. Dissolved Oxygen Analyzer (AT‐03A) readings can
be monitor on the LCD at site and DCS. The amount of Dissolve Oxygen shall 2.0mg/l.

e) One of Aeration Tank Pump (P2‐984A/B), to operate intermittently to transfer MLSS to
Anoxic Tank (G2‐992), while the other Aeration Tank Pump is meant as standby.
Aeration Tank Pump (P2‐984A/B) shall start and stop from LCP located in Blower House‐
Electrical Room and signal status shall be transmit to DCS for monitoring.

f) In the Aeration Tank (G2‐993), the Dissolved Oxygen Analyzer (AT‐03B) shall install to
measure the total oxygen content. Dissolved Oxygen Analyzer (AT‐03B) readings can be
monitor on the LCD at site and DCS. The amount of Dissolve Oxygen shall 2.0mg/l.

g) In the Aeration Tank (G2‐993), the Mixer Liquor Suspended Solid (MLSS) Analyzer (AT
004) shall install to measure the total MLSS content. MLSS Analyzer (AT‐004) readings
can be monitor on the LCD at site and DCS.

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h) One of Air Blower (R2‐981A/B) to run alternately (as default) to supply air to
Equalization Tank (G2‐990), Aeration Tank (G2‐993), Secondary Clarifier Tank and
Sludge Holding Tank (G2‐991), while the other Air Blower (R2‐981A/B) is meant as
standby (2x100%). Air Blower (R2‐981A/B) shall start and stop from LCP located in
Blower House‐Electrical Room and signal status shall be transmit to DCS for monitoring.
If fine tuning of the treatment system is required, Timer settings can be applied at the
LCP for the Air Blower (R2‐981A/B).

i) Effluents from Disinfection Chamber (G2‐995) need to pass through Parshall Flume (G2‐
996) before flowing to Final Sampling Point (G2‐997). Inside the Parshall Flume, there is
a pH Analyzer (AT‐002) and Ultrasonic Flow Transmitter (FT‐001) to measure hydrogen‐
ion activity (acidity or alkalinity) in solution and to measure the treated effluent
quantity before discharge to storm sewer. PH Analyzer (AT‐002) and Ultrasonic Flow
Transmitter (FT‐001) readings can be read on the LCD at site and DCS.
4.2.3 Controller/Selector/Computing Requirement
a) Equalization Tank Pump (P2‐983A/B) and Anoxic Tank Mixer (R2‐982) shall start and
stop via LCP located in Blower House‐Electrical Room and signal status shall be transmit
to DCS for monitoring. There are two (2) modes are available for selection at LCP:

i) AUTO Mode: Either selected Equalization Pump shall start and stop via Radar Level
Transmitter which able to detect Low Level (L), High Level (H) and High High Level
(HH) according to the level set‐point settings at LCP. Float Switch to detect Level
Switch Cut Off Level (LSLL) as safeguarding to protect pump from running dry. Mixer
and Blower to start and stop based on timer settings at LCP.

ii) MANUAL Mode: Either selected Equalization Tank Pump, Aeration Tank Pump,
Anoxic Tank Mixer and Aeration Blower to start manually via local pushbutton.
Under manual mode of operation, all the above equipment can be set to start and
stop without any restricted control by turning on the key‐switch at LCP.

b) Aeration Tank Pump (P2‐984A/B), Anoxic Tank Mixer (R2‐982) and Aeration Blower (R2‐
981A/B) to start and stop based on timer settings. Following is the summary of timer
settings for those equipment:

Table 3.2.3.(a): Mixer and Aeration Blower Timer Settings
Equipment Timer Settings Remarks

Aeration Tank Pump 1 hours x 4 times/day Pump to operate intermittently base on

timer setting with cumulative of 4 running

hours per day. Running hours can be

divided evenly within 8 hours with 1 hour

rest interval.

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Equipment Timer Settings Remarks

Anoxic Tank Mixer 5 hours x 4 times/day Mixer to operate intermittently base on
timer setting with cumulative of 20 running
hours per day. Running hours can be
divided evenly within 24 hours with 1 hour
rest interval.
Aeration Blower 12 hours/day Air Blower to operate intermittently base
on timer setting with cumulative of 24
Not tally with timer running hours per day. The relief valve
setings, 24 (continuous) (fix/come together with Air Blower)
or 12 hours / day running controls the pressure of the blowing out.
(Intermittent)

c) PH reading (AT‐002) at Parshall Flume is provided with alarm at DCS for high and low
reading. The following is proposed set point for pH alarm at effluent. Once low reading
is detected, Field Technician shall dose the Sodium Hydroxide (NaOH) in Disinfection
Chamber to reach back neutral pH (7.0). Once high reading is detected, Field Technician
dose the Sulfuric Acid (H2SO4) in Disinfection Chamber to reach back neutral pH (7.0).

Effluent pH Alarm Low (H) 5.5
Effluent pH Alarm High (L) 9.0

d) Dissolve Oxygen reading (AT‐003A/B) at Equalization Tank and Aeration Tank is
provided with alarm at DCS for Low (L) reading monitoring. Once low reading is
detected, Field Technician shall increase speed of blower thru LCP via local automation
until Dissolve Oxygen reading back to normal. Once high reading is detected, Field
Technician shall decrease speed of blower thru LCP via local automation until Dissolve
Oxygen reading back to normal. The following are proposed set‐point for Dissolved
Oxygen alarm at Equalization Tank and Aeration Tank.

Dissolved Oxygen Alarm Low (L), mg/l 1.8
Dissolved Oxygen Alarm High (H), mg/l 2.2

d) Mixed Liquor Suspended Solid (MLSS) reading (AT‐004) at Aeration Tank is provided
with alarm status at DCS for high and low reading monitoring. Once high reading is
detected, Field Technician shall increase the retention time of aeration tank within stop
the Equalization Tank Pump. Once low reading is detected, Field Technician shall fill the
certain amount of MLSS from others Aeration Tank. The following are proposed set
point for MLSS alarm at Aeration Tank.

Aeration Tank MLSS Alarm Low (L), mg/l 2500
Aeration Tank MLSS Alarm High (H), mg/l 5000

Doc No:
0001
Revision: 0

5.0 CONTROL NARRATIVE

The following control narrative will further explain for Sanitary Pit (GH‐983, G2‐984, G2‐983,
G3‐984, G‐756 & G4‐984) operational mode.

Sewerage level inside every individual Sanitary Pit will detected three (3) level setting L, H &
HH by Radar Level Transmitter installed at every individual pits. Each Sanitary Pit has two (2)
pumps A and B in operation based on selector switch selection depending on which one shall
be in Duty and Standby mode at LCP.

Reference Drawing/Documents:
a) Instrument Cable Block Diagram – Dwg No: STS‐EXE‐MAW‐981‐INC‐CBB‐0001
b) Instrument Cause and Effect Matrix – Dwg No: STS‐EXE‐MAW‐981‐INC‐CEM‐0001

5.1 Sanitary Pit (G2‐984, G2‐983, G3‐984, G‐756 & G4‐984)

5.1.1 Auto Mode
In normal operation, Field Technician shall ensure selection of selector switch located at LCP
for each Sanitary Pit shall be at auto mode. The Level Transmitter signals from each Sanitary
Pit will be route to DCS thru Junction Box IJB‐XXX1 to the designated control building to
monitor the sewerage level setting as Analog Input (AI). DCS graphic shall show level setting
and pump start/stop status for each sanitary pit connected to DCS.

Start/stop pump will shall be control by DCS system based on the level set‐point setting from
each Sanitary Pit. Duty Pump shall start when the level reach High Level (H) and stop when
the level reach at Low Level (L). Standby Pump shall start when the level reach High High
Level (HH) and stop when the level reach back at Low Level (L).

Below is the Level Transmitter Analog Input (AI) setting for DCS programming:
j) High High Level (HH)
In the event of Level Transmitter detect High High Level (HH), it shall indicate High High
Level (HH) signal status at DCS. At this state, the DCS will give command signal to start
Standby Pump. Start for Standby Pump and High High Level (HH) indication status shall
be indicated at DCS graphic. Start and stop Indication light for Standby Pump shall be
provided at LCP. Duty & Standby Pump shall start at the same time during this event.
Standby Pump shall stop when the Sanitary Pit reach Low Level (L) and stop indication
status shall be indicated at DCS graphic and LCP via indication light.

ii) High Level (H)
In the event of Level Transmitter detect High Level (H), it shall indicate High Level (H)
signal status at DCS. At this state, the DCS will give command signal to start Duty Pump.
Start for Duty Pump and High Level (H) indication status shall be indicated at DCS
graphic. Start and stop Indication light for Duty Pump shall be provided at LCP. Duty
Pump will be always running even at High High Level (HH). Duty Pump shall stop when
the Sanitary Pit reach Low Level (L) and stop indication status shall be indicated at DCS
graphic and LCP via indication light.
Doc No:
0001
Revision: 0

iii) Low Level (L)
In the event of Level Transmitter detect Low Level (L), it shall indicated the Low Level (L)
signal status at DCS. At this state, the DCS shall give command signal to stop Duty Pump.
Stop for Duty Pump and Low Level (L) indication status shall be indicated at DCS graphic.
Stop Indication light for Duty Pump shall be provided at LCP. This action is to protect the
pump from running dry.

5.1.2 Manual Mode
In abnormalities, Field Technician shall ensure selection of selector switch located at LCP for
each Sanitary Pit shall be at manual mode. The purpose of this operation is to test run both
Duty & Standby Pump for maintenance. Field Technician shall communicate with Panel
Operator during this occasion.
i) Start/Stop
In Manual Mode operation, Field technician shall select the Start/Stop for both Duty
and Standby Pump manually depends on pump availability. Level Transmitter still can
detect level setting as in during auto mode.

In the event of Sanitary Pit in High Level (H) or High High Level (HH), Field Technician
shall push start button for Duty or Standby pump at LCP. At this state, the LCP shall give
signal to start Duty & Standby Pump. Indication light for start shall be light up at LCP.
Panel Operator shall be able to receive start signal indication status at DCS.

In the event of Sanitary Pit in Low Level (L) or High Level (H), when level reach Low Level
(L) Field Technician shall push stop button for Duty Pump and Standby Pump. At this
state, the LCP will give signal command to start Duty & Standby Pump. Indication light
for stop shall be light up at LCP. Panel Operator shall be able to receive stop signal
indication status at DCS.
5.2 NPS (GH‐983) Admin Building‐Non Process Area

5.2.1 Auto Mode
In normal operation, Field Technician shall ensure selection of selector switch located at LCP
shall be at auto mode. The Level Transmitter from each pit shall be route to LCP to monitor
the sewerage level setting.

Start/stop pump shall be control by local automation at LCP based on the level setting. Duty
pump shall start when the level reach High Level (H) and stop when the level reach Low Level
(L). Standby pump shall start when the level reach High High Level (HH) and stop when the
level reach Low Level (L).

Doc No:
0001
Revision: 0

Below is the Level Transmitter setting for local automation:
i) High High Level (HH)
In the event of Level Transmitter detect High High Level (HH), it shall indicate the High
High level (HH) indication at LCP. At this state, the LCP will give command signal to start
Standby Pump. Start for Standby Pump and High High Level (HH) indication shall be
indicated at LCP via indication light. Duty & Standby Pump shall be start at the same
time during this event. Standby pump shall be stop when the Sanitary Pump reach the
Low Level (L) and stop indication shall be indicated at LCP via indication light.

ii) High Level (H)
In the event of Level Transmitter detect High High Level (HH), it shall indicated the High
Level (H) indication at LCP. At this state, the LCP shall give command signal to start Duty
Pump. Start for Duty Pump and High Level (H) indication shall be indicated at LCP via
indication light. Duty Pump shall always running even at High High Level (HH). Duty
pump shall stop when the Sanitary Pit reach Low Level (L) and stop indication shall be
indicate at LCP via indication light.

iii) Low Level (L)
In the event of Level Transmitter detect Low Level (L), it shall indicate Low Level (L)
indication status at LCP. At this state, the LCP shall give command signal to stop Duty
Pump. Stop for Duty Pump and Low Level (L) indication shall be indicate at LCP via
indication light. This action is to protect the pump from running dry.

5.2.2 Manual Mode
In abnormalities, Field Technician shall ensure selection of selector switch located at LCP for
each Sanitary Pit shall be at manual mode. The purpose of this operation is to test run both
Duty & Standby Pump for maintenance. Field Technician shall communicate with Panel
Operator during this occasion.

i) Start/Stop
In Manual Mode operation, Field technician shall select the Start/Stop either Duty and
Standby Pump manually depends on the current situation. Level Transmitter still can
detect level setting as in during auto mode.

In the event of Sanitary Pit in High Level (H) or High High Level (HH). Field Technician
shall push start button for either Duty or Standby Pump at LCP. At this state, the LCP
shall give signal to start Duty or Standby Pump. Indication light for start and High Level
(H) & High High Level (HH) shall be indicated at LCP.

In the event of Sanitary Pit in Low Level (L) or High Level (H), when level reach Low Level
(L) Field Technician shall push stop button for Duty Pump and Standby Pump. At this
state, the LCP shall give signal to stop Duty & Standby Pump. Indication light for stop
and Low Level (L) shall be indicated at LCP.

Typ. Comment
Doc No:
0001
Revision: 0

5.3 Sewerage Treatment System (Sts)

5.3.1 Auto Mode
In normal operation, Field Technician/Chargeman shall ensure selection of selector switch
located at LCP in Blower House‐Electrical Room shall be at auto mode. The Level Transmitter
from STS will be route to LCP to monitor the sewerage level setting.

Start/stop pump shall be control by local automation at LCP in Blower House‐Electrical Room
based on the level setting. Duty pump shall start when the level reach High Level (H) and
stop when the level reach Low Level (L) & Low Low Level (LL). Standby pump shall start when
the level reach High High Level (HH) and stop when the level reach Low Level (L).

Below is the Level Transmitter setting for local automation:
i) High High Level (HH)
In the event of Level Transmitter detect High High Level (HH), it shall indicate High High
Level (HH) indication at LCP via indication light. At this state, the LCP shall give
command signal to start Standby Pump. Start for Standby Pump indication status shall
be indicated at DCS graphic. Run and stop Indication light for Standby Pump shall be
provided at LCP. Duty & Standby Pump shall running at the same time during this event.
Standby pump shall stop when the STS reach the Low Level (L) and stop indication signal
shall indicated at DCS graphic and LCP via indication light.

ii) High Level (H)
In the event of Level Transmitter detect High Level (H), it shall indicated the High Level
(H) indication at LCP via indication light. At this state, the LCP shall give command signal
to start Duty Pump. Start for Duty Pump indication status shall be indicated at DCS
graphic. Start and stop Indication light for Duty Pump shall be provided at LCP. Duty
Pump shall always running even at High High Level (HH). Duty pump shall stop when the
STS reach the Low Level (L) and stop indication shall be indicated at DCS graphic and LCP
via indication light.

iii) Low Level (L)
In the event of Level Transmitter detect Low Level (L), it shall indicate the Low Level (L)
indication status at LCP. At this state, the LCP shall give command signal to stop Duty
Pump and Standby Pump. Stop for both pump indication shall be indicated at DCS
graphic and LCP via indication light. This action is to protect the pump from running dry.

iv) Low Low Level (LL)
In the event of float switch detect Low Low Level (LL), it shall indicate the Low Low Level
(LL) indication status at LCP via indication light. At this state, the LCP shall give
command signal to stop Duty Pump. Stop for Duty Pump and Low Low Level (LL)
indication shall be indicate at LCP via indication light. This action act as safeguarding for
Duty Pump when it is still running below Low Level (L).

Doc No:
0001
Revision: 0

5.3.2 Manual Mode
In abnormalities, Field Technician/Chargeman shall ensure selection of selector switch
located at LCP for STS shall be at manual mode. The purpose of this operation is to test run
both Duty & Standby Pump for maintenance. Field Technician/Chargeman shall
communicate with Panel Operator during this occasion.

i) Start/Stop
In Manual Mode operation, Field technician/Chargeman shall select the start or stop for
both Duty and Standby Pump manually depends on pump availability. Level Transmitter
still can detect level setting as in during auto mode.

In the event of STS in High Level (H) or High High Level (HH). Field Technician/
Chargemen shall push start button for Duty and Standby Pump at LCP. At this state, the
LCP shall give signal to start Duty & Standby Pump. Indication light for start and High
Level (H) & High High Level (HH) shall be indicated at LCP.

In the event of STS in Low Level (L) or High Level (H) when level reach Low Level (L) Field
Technician/Chargeman shall push stop button for Duty Pump and push stop button
when level reach High Level (H) for Standby Pump. At this state, the LCP will give signal
to start Duty & Standby Pump. Indication light for stop and Low Level (L) shall be
indicated at LCP.

In the event of STS in Low Low Level (LL), the LCP shall give signal to stop Duty Pump
automatically as in auto mode operation. Indication light for stop and Low Low Level
(LL) shall be indicated at LCP.

5.3.3 Emergency Stop

If there is any emergency situation at site, Field Technician shall push the emergency stop
button and it shall triggered the signal inside the LCP. It shall give signal to stop Duty &
Standby Pump. Stop indication shall be indicated at LCP via indication light and Panel
Operator shall be able to receive stop signal indication status at DCS.

STS EXE MAW 981 PRO RPT 0001 - Commented

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PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROJECT : PROVISION OF ENGINEERING, PROCUREMENT,

CLIENT : PETRONAS GAS BERHAD

PO. NO. : 3920133490

CONTRACT NO. : DTC-KTH/PGB-GPU/2020/0011

DOCUMENT TITLE : PROCESS AND OPERATING PHILOSOPHY

0 02.11.21 ISSUED AS FINAL NR ZIZ MAR

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

Level Settings not as per

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

Sanitary Sanitary Settings Proposed Level Action Remark

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

5.0 CONTROL NARRATIVE

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND

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