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6A
TANGGUH LNG Project TLNG Author’s Org. KJP
BPMIGAS KJP Doc. No. S-062-1283-001 Date 27 Feb, 06
BP Berau Ltd. KJP Job Code J-3400-20-0000 Sheet 1 of 35
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PT. Brown & Root Indonesia
BP Berau Ltd. Tangguh LNG Project Doc. No. 62-IOM-PS-1201
KJP Doc. No. S-062-1283-001 Rev. 6A
Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 2 of 35
CONTENTS
1. Introduction.................................................................................................................................4
2. Basis of Design.............................................................................................................................4
2.1 General ........................................................................................................................................4
2.2 Design Condition.........................................................................................................................5
2.2.1 SERVICE CONDITIONS ................................................................................................................ 5
2.2.2 BOILER FEED WATER QUALITIES .............................................................................................. 5
2.2.3 STEAM CONSUMERS................................................................................................................... 5
2.3 Special Equipment ......................................................................................................................6
2.3.1 DEAERATORS (062-D-1001A/B)................................................................................................ 6
2.3.2 PACKAGE BOILERS (062-F-1001A/B/C) .................................................................................... 6
2.3.3 STEAM TURBINE GENERATOR SETS ........................................................................................... 6
2.3.4 HEAT RECOVERY STEAM GENERATORS .................................................................................... 7
2.4 Process Description.....................................................................................................................7
2.4.1 STEAM GENERATION.................................................................................................................. 7
2.4.2 STEAM DISTRIBUTION ................................................................................................................ 7
2.4.3 STEAM CONDENSATE RECOVERY AND TREATMENT.................................................................. 8
2.4.4 STEAM TURBINE GENERATOR SYSTEM...................................................................................... 9
3. Process Controls..........................................................................................................................9
3.1 Boiler Feed Water.......................................................................................................................9
3.2 High Pressure Steam ................................................................................................................10
3.3 Low Pressure Steam .................................................................................................................11
3.4 Blowdown System for Boilers ..................................................................................................12
3.5 Clean Steam Condensate..........................................................................................................12
3.6 Suspect Steam Condensate.......................................................................................................12
3.7 Steam Turbine Generator Sets ................................................................................................13
4. Preparation for initial start-up ................................................................................................15
5. Normal Start-up Procedure .....................................................................................................15
5.1 General ......................................................................................................................................15
5.2 Start up of Boiler Feed Water System ....................................................................................15
5.3 Start up of Package Boiler (062-F-1001A/B/C) ......................................................................15
5.4 Introduce HP Steam to HP Steam Header .............................................................................16
5.5 Letdown HP Steam to LP Steam .............................................................................................16
5.6 Introduce LP Steam to Deaerators (062-D-1001A/B)............................................................17
5.7 Start Steam Turbine Generator Set (061-GS-1001A/B/C)....................................................17
5.8 Steam Condensate System .......................................................................................................17
5.9 Letdown HP Steam to MP Steam............................................................................................18
5.10 Start up of Heat Recovery Steam Generator (051/052-F-1101/1102)...................................18
5.11 Start up of the Suspect Condensate Recovery System...........................................................19
6. Normal Operation.....................................................................................................................19
6.1 Water Quality Control .............................................................................................................19
6.1.1 GUIDE LINE .............................................................................................................................. 19
6.1.2 BOILER FEED WATER............................................................................................................... 20
6.1.3 BOILER WATER ........................................................................................................................ 21
6.2 Single Failure of Package Boiler..............................................................................................23
6.3 Single Failure of Steam Turbine Generator...........................................................................23
6.4 Load shedding ...........................................................................................................................23
7. Normal Shutdown Procedure ..................................................................................................24
7.1 Deaerator...................................................................................................................................24
7.2 Package Boiler...........................................................................................................................24
7.3 Steam Turbine Generator System...........................................................................................24
7.4 Heat Recovery Steam Generator.............................................................................................24
7.5 Train Shutdown ........................................................................................................................25
8. Emergency Shutdown Procedure ............................................................................................25
8.1 General ......................................................................................................................................25
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 4 of 35
1. INTRODUCTION
The purpose of Steam System (Unit 062) is to produce and distribute High Pressure steam (HP
steam), High Pressure Saturated steam (HP Sat. steam), Medium Pressure steam (MP steam) and Low
Pressure steam (LP steam) to the plant, and recovery the condensates.
Steam turbine generator (Unit 061) generates electric power to supply power for two trains operation
including the support facilities including community area, administration area, upstream operation
support area, etc
2. BASIS OF DESIGN
2.1 General
Steam is available at four pressure levels, High Pressure (HP) that is based on the optimum steam
turbine design pressure, Low Pressure (LP) that is based on Acid Gas Removal Unit requirements and
fractionation reboilers, Saturated High Pressure (HP SAT.) for stabilizer reboiler and Medium
Pressure (MP) for deethanizer reboiler.
High-pressure steam is produced from Heat Recovery Steam Generators (HRSG) and Package
Boilers. HRSG is installed in the exhaust duct of all Frame 7 gas turbines that drive refrigerant
compressors in the LNG train. Three package boilers are provided to supplement the HP steam from
HRSGs for generating electric power by steam turbine power generators.
Low-pressure steam is produced from back pressure steam turbines, flash drums at continuous blow
down from HRSGs and package boilers and a HP steam to LP steam letdown station.
Steam condensate is categorized as vacuum condensate, clean condensate and suspect condensate.
Suspect condensate is flashed to near atmospheric pressure. The suspect condensate is passed
through a carbon filter followed by mixed bed polisher to remove possible contaminates prior to
deaeration. All steam condensate and make-up water are deaerated prior to being pumped to each
HRSG and package boiler.
Electric power is generated by Steam Turbine Generator Sets 061-GS-1001A/B/C. The steam to
steam turbines is supplied from high pressure steam system.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 5 of 35
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 6 of 35
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 7 of 35
HP Sat. steam is produced by injecting the boiler feed water to decrease the temperature to the almost
saturated condition of 257°C at 40 kg/cm2g by using temperature controller (011-TIC-1306).
MP steam (24 kg/cm2g, 223 °C) is produced from medium pressure letdown station (pressure
reducing and desuperheating). In this letdown station, the high pressure steam is reduced to 24
kg/cm2g, then the boiler feed water is injected to decrease the temperature to the almost saturated
condition of 223 °C by the pressure controller (091/092-PIC-1001) and temperature controller
(091/092-TIC-1471) respectively.
LP steam (3.5 kg/cm2g, 148 °C) is produced from steam turbine starter / helper of refrigerant
compressors (051/052-CS-1001 and 051/052-CS-1002) in process trains. The condition of low
pressure steam from the turbines is slightly superheated therefore it requires some boiler feed water
injection to desuperheat the steam at temperature of 148 °C. It is done by temperature controllers
(091/092-TIC-1314 and 1351). LP letdown station with boiler feed water injection system is also
provided to produce the LP steam from HP steam.
The steam losses in the system will be replaced by make-up water produced from seawater by
desalination, which is mixed with the steam condensate before treatment in the demineralization
package.
_ __ outlet stream from the turbines is low pressure steam. Another main user of HP steam is Steam
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 8 of 35
LP steam produced from the starter/helper turbines is distributed through the LP steam header to Acid
Gas Stripper Reboiler (021/022-E-1002A~D), Feed Gas heater (021/022-E-1005), Scrub Column
Reboiler (041/042-E-1004), Depropanizer Reboiler (041/042-E-1007), Debutanizer Reboiler
(041/042-E-1009), Process HP Fuel Gas Heater (051/052-E-1201) and Defrost Gas Heater
(031/032-E-1004, during startup only) in process train. The LP steam user in utility area is Deaerator
(062-D-1001A/B). However, during startup, the most of the LP steam required for Acid Gas Stripper
Reboiler is produced from letdown system located in utility area. Therefore the LP steam header is
also provided in utility area and is designed considering the start-up and emergency conditions.
The MP steam header is controlled by MP letdown station, and LP steam header is controlled by LP
letdown station, LP Steam Control Condenser and Starter/Helper Steam Turbine governors also.
The HP steam header is controlled by master boiler combustion control.
The exhaust steam from Steam Turbine Generator Sets (061-GS-1001A/B/C) is condensed by Air
Cooled Surface Condenser (061-E-1001A/B/C) and collected in Condensate Recovery Drum
(061-D-1001A/B/C) as vacuum condensate. The vacuum condensate is pumped-out by Condensate
Pump (061-P-1001A/B/C) and returned directly to Deaerators (062-D-1001A/B) with clean steam
condensates.
Suspect steam condensates in process area that have a possibility to be contaminated by hydrocarbon
are collected in the Condensate Flash Drum (051/052-D-1104) in process area, which is operated at
almost atmospheric pressure. The flashed vapor is condensed in Condensate Flash Drum Vent
Condenser (051/052-E-1105), and then the steam condensate is returned back to the flash drum. The
steam condensate from 051/052-D-1104 is pumped-out by Condensate Return Pump
(051/052-P-1102A/B) and cooled in Steam Condensate Cooler (051/052-E-1107) from around
100 °C to 50 °C in order to get the best performance of demineralization package.
The suspect steam condensate is sent to the Activated Carbon Filter (064-V-1006) for removal of any
residual hydrocarbons. The treated condensate plus the desalinated water make-up are fed to the
Mixed Bed Polisher (064-V-1003) in demineralization unit for further treatment, and finally fed to
Deaerators (062-D-1001A/B).
Deaerator will remove the gaseous dissolved in the steam condensate. Deaerator will be operated at
1.0 kg/cm2g and 120 °C. Low pressure steam is used as the medium to removes the gaseous in
_ __ deaerator upper section. Free gaseous steam condensate (boiler feed water) is collected in the drum
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 9 of 35
of lower section of the Deaerator, which is ready to be pumped-out to HRSGs and Packaged Boilers.
Pressure in the Deaerator is controlled by pressure controller, which is installed at LP steam inlet.
The boiler feed water from Deaerators (062-D-1001A/B) is provided with chemical injection
packages (051/052-V-1003, 062-V-1001, 062-V-1002 and 062-V-1003) in order to comply with
specified boiler feed water quality. For this HRSG and Packaged Boiler operation range, the suitable
chemical injection is Phosphate, Oxygen Scavenger, and Neutralization Amine. Oxygen Scavenger
and Neutralization Amine will be injected at the Deaerator and Phosphate will be injected at the
HRSGs and Package Boilers.
Boiler feed water is finally fed to HRSGs and Packaged Boilers by Boiler Feed Water Pump
(062-P-1001A/B/C).
3. PROCESS CONTROLS
The Deaerators receive recovered condensate plus demineralized water required for make up of
losses for steam stripping, blowdown and so on. These condensates and demineralized water are
received to top of heater shell of the Deaerator. There is a level controller on each Deaerator,
062-LIC-1111/1112, which keeps normal level in the Deaerators. The Deaerators will hydraulically
balance to equalize levels between the two Deaerators.
The water is heated up to the saturated temperature in the Deaerators. There is a pressure controller on
each Deaerator, 062-PIC-1211/1212, which keeps normal operating pressure of 1.0kg/cm2g in the
Deaerators by introducing LP steam to the Deaerators.
Boiler feed water from Deaerators is pumped up by two Boiler Feed Water Pumps
(062-P-1001A/B/C) to Package Boilers (062-F-1001A/B/C) and Heat Recovery Steam Generator
(051/052-F-1101/1102) in on-site units.
Two pumps are normally running and the other is stand-by. If the pressure in the discharge line
of the running pumps becomes lower than low set point, the stand-by pump will start automatically to
ensure continued supply of enough boiler feed water.
Oxygen Scavenger is injected in downstream of the deaerators to remove the trace of oxygen
dissolved in the Boiler Feed Water. This is to remove the remaining 0.007 mg/litter dissolved
oxygen from the Boiler Feed Water.
Two reciprocating pumps (including one spare) with a rated capacity of 12.0 liter/h are
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 10 of 35
Neutralizing Amine is injected into the deaerator to adjust the pH of the Boiler Feed Water.
The injection system is designed so that pH in recovered condensate will be around 8.5 to 9.5.
Two reciprocating pumps (including one spare) with a rated capacity of 12.0 liter/h are
provided to serve the deaerators.
Phosphate is injected into the Package Boilers and HRSGs in order to avoid scaling and keep
appropriate pH value in the boiler water.
Injection package is designed so that PO4 concentration in boiler water is 10ppm.
Four reciprocating pumps (including one spare) with a rated capacity of 12 liter/h are provided
to serve the three Package Boilers. And three reciprocating pumps (including one spare) with
a rated capacity of 12 liter/h are provided to serve the two HRSGs in each LNG train.
Injection quantity for each chemical is defined by monitoring analyzer data and sampling
results, and adjusted by manually setting the stroke of the reciprocating pumps of the injection
package. The pump flow rate is confirmed by the calibration pot on suction line of each pump.
Guidelines of the Chemical Injections for water quality control are described in Section 6.1.
Neutralized amine and oxygen scavenger are injected to downstream of the Deaerators. Oxygen
scavenger is injected to remove trace of oxygen dissolved in the boiler feed water. And neutralized
amine is injected to adjust the pH of the boiler feed water and that of the steam condensate.
When the Acid Gas Removal Unit (AGRU) is tripped, the demand for LP steam decreases and LP
steam pressure increases. And the HP steam pressure would increase, because the refrigerant
compressors will change to recycle operation mode due to stopping feed gas and the demand of HP
steam to Steam Turbines will reduce based on decreasing the required power.
At this time, the pressure controller (060-PIC-1201) will control the HP steam header pressure by
burner management system of Package Boilers (062-F-1001A/B/C).
When the boiler operation will be reached at the minimum controllable duty (25% of MCR), further
reduction of the boiler duty will be impossible.
At this condition, the 060-PIC-1202A will ask the 060-PV-1207A/B/C to open through the
hi-selector, which overrides the 060-PIC-1207, to control the HP steam header pressure by disposing
the HP steam to LP steam header.
The LP steam header pressure will increase then 060-PIC-1206A/B will ask the 091/092-PV-1206A
and 060-PV-1206B to open in order to control the LP steam header pressure as explained in the LP
steam control system below.
The 060-PIC-1202B is provided as a final pressure controller if the pressure continues to increase due
to such upset conditions and dump the HP steam to the atmosphere through 060-PV-1202B.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 11 of 35
At low pressure condition, the 060-PIC-1203 through the low selector, which are overridden by
060-PIC-1205, will ask Steam Turbine Starter/Helper (051/052-CS-1001/1002) governor to close
through the high-selector, which overrides the remaining power controller of Steam Turbines, to
control the HP steam header pressure at or above its minimum pressure by reducing the HP steam to
steam turbine drivers
However, there is possibility that LP steam header pressure cannot be maintained at 3.5 kg/cm2g by
control of the steam turbine governors, due to the trips of LP steam users, trips of steam turbine
helper, etc. If the LP steam header pressure continues to decrease, the HP letdown valve
060-PV-1207A/B/C shall control LP steam header at pressure setting of 3.3 kg/cm2g by introducing
the HP steam.
When Gas Turbine temperature control becomes active (exhaust temperature increasing) during the
operation that LP steam header pressure is controlled by governors pressure controller
(060-PIC-1205), Steam Turbine stops to control LP steam header pressure and starts to act as Helper
to produce power to help Gas Turbine.
In that case, LP steam header pressure will be controlled by dumping to LP Steam Control Condenser
(051/052-E-1101). The condenser fans will start with low speed automatically by opening signal to
091/092-PV-1206A. or When high temperature of 091/092-TI-2710 on the condenser vent line is
detected, the fan motor speed will be changed to high speed. The condenser fans will stop
automatically in case of closing 091/092-PV-1206A.
If the LP steam header pressure continues to increase, the pressure control valve of 060-PV-1206B
will open to dump the LP steam to atmosphere at 4.5 kg/cm2g.
From the above explanation, 2 controllers, i.e. 060-PIC-1202A and 060-PIC-1207, will use the
060-PV-1207A/B/C. Hi-selector 060-PY-1207 will select which controller overrides other
controller. In the 060-PY-1207, the higher opening request will override the lower opening request.
Continuous nitrogen purge is required for the vent line of 051/052-E-1101 to prevent air ingress into
steam system. A globe valve facing to Flow Gauge (091-FG-9031) shall be adjusted to flow the
required nitrogen of minimum 2.6Nm3/h.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 12 of 35
Continuous blowdown is flow controlled normally to around 1% of the generated HP steam and up to
a maximum of 3%.
Continuous blowdown is sent to Continuous Blow Down Drum (062-D-1002A/B/C) and flashed at
3.5kg/cm2g for LP steam recovery. Post flashed condensate and intermittent blowdown are sent to
ATM Blowdown Drum (062-D-1003A/B/C) to be flashed at atmosphere. Flashed liquid is drained to
chemical sewer through Boiler Blowdown Cooler (062-E-1002A/B/C).
Intermittent blowdown is done manually from bottom of steam drums, to maintain the boiler water
free from sediments.
Intermittent blowdown is sent to ATM Blowdown Drum (062-D-1003A/B/C) to be flashed at
atmosphere. Flashed liquid is mixed with continuous blowdown and drained to chemical sewer
through Boiler Blowdown Cooler (062-E-1002A/B/C).
Continuous nitrogen purge is required for the vent line of 051/052-E-1103 to prevent air ingress into
steam system. A globe valve facing to Flow Gauge (091-FG-9032) shall be adjusted to flow the
required nitrogen of minimum 5.8Nm3/h.
_ __ each train. This drum is provided with a Condensate Flash Drum Vent Condenser (051/052-E-1105)
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 13 of 35
to minimize loss of steam. The condensate liquid is sent to the demineralized water system through
LP Steam Condensate Cooler (051/052-E-1107) located in utility area by a Condensate Return Pump
(051/052-P-1102A/B). 051/052-LIC-1171 will control the drum level to keep constant by
051/052-LV-1171 at outlet of 051/052-E-1107.
One pump of the Condensate Return Pump is running and the other is stand-by. When liquid
level of the drum is increased to high liquid level by running pump failure stop etc, stand-by pump
will start to run automatically.
Continuous nitrogen purge is required for the vent line of 051/052-E-1105 to prevent air ingress into
steam system. A globe valve facing to Flow Gauge (091-FG-9033) shall be adjusted to flow the
required nitrogen of minimum 2.0Nm3/h.
Motors of Air Cooled Surface Condenser (061-E-1001A/B/C) are on-off controlled by the exhausted
steam pressure (062-PIC-1232A/B/C) at outlet of the steam turbine. Operating fan number is
changed by the high and low pressure signal.
Steam drain collected in a drain pot that is installed on the exhausted steam line is transferred to
Condensate Recovery Drum (061-D-1001A/B/C) by level controlled drain recovery system. The
drain pot liquid level (062-LI-2830AB/BB/CB) start and stop the drain recovery system by
open/close motive steam condensate introducing valve. One drain recovery ejector is operated
and the other is spare.
When the liquid level reaches to high liquid level, one drain recovery ejector starts to drain out
accumulated liquid in the drain pot. And when the liquid level reaches to low liquid level, the
ejector is stopped.
If the drain level reaches high-high liquid level, two out of three transmitters initiate a signal to trip
the steam turbine generator set.
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TO VENT
060-PV-1202B
OPEN AT
PC SET : SET : PC PC 42.8kg/cm2g PC SET :
1203 39kg/cm2g 41kg/cm2g 1202A 1202B 1201 40kg/cm2g
HP STEAM HEADER
SPEED
CONTROLLER
SC
BOILER
BP Berau Ltd. Tangguh LNG Project
POWER HRSG
CONTROLLER 062-F-1001A
051-F-1101
SC
G
BOILER
HIGH 062-F-1001B
SELECTOR PY
061-GS-1001A
PY
1207 HIGH
SELECTOR POWER HRSG
060-PV- CONTROLLER 051-F-1102 G BOILER
1207A/B/C
SC
062-F-1001C
051-CG-1001 061-GS-1001B
Operation Manual for Steam/Steam Condensate/BFW System
PY G
TO VENT
LOW HIGH
SELECTOR SELECTOR 061-GS-1001C
PY
1205
SET : 060-PV-1206B
051-CG-1002
3.3kg/cm2g
PC PC SET : OPEN AT
1207 1205 3.5kg/cm2g 4.5kg/cm2g
LP STEAM HEADER
PC PC
1206A 1206B
TO PROCESS TO PROCESS
AGR
UNIT REBOILERS UNIT REBOILERS
091-PV-1206A
SET :
3.7kg/cm2g
Sheet No. 14 of 35
5.1 General
Check points are as follows:
(1) All equipment including instrument, etc. is ready for use.
(2) Demineralized water, instrument air and emergency electric power are available.
(3) All blinds or spectacle blinds except for Battery Limit have been placed in operation position.
(4) Ensure all vents, drains, and sample connections are closed.
(5) All safety equipment must be properly installed on site, calibrated and operable.
(6) Prepare required chemicals in each chemical vessel.
After all the above checkpoints are checked, start up the Steam System.
Section 5.2 to 5.11 should be followed in order to start up the Air/Nitrogen Steam System.
_ __ (2) Start one Package Boiler (062-F-1001A or B). (062-F-1001C is not connected to
__ RA| emergency power supply.) It is recommend that boiler start-up should only be
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 16 of 35
undertaken locally and not DCS. For the start up procedure of the Package Boilers,
refer to the vendor’ instruction “Operation & Maintenance Manual”
(062-VDR-MCI-1800).
(3) Phosphate Injection Package (062-V-1001) shall be started accordingly. Refer to
Section 6.1 Water Quality Control. Each Package Boiler has dedicated phosphate
injection pump.
(4) Confirm boiler blowdown temperature is under 50oC at outlet of the boiler blowdown
cooler.
(5) After starting the Steam Turbine Generator Sets (062-GS-1001A/B/C) and steam
condensate system, the recovered steam condensate may have rust which was
generated in steam condensate piping during shutdown period. Continuous boiler
blowdown ratio should be increased up to 3% and intermittent blowdown operation
should be done more frequently than usual until boiler water quality meets control
target described in Section 6.1.1.
_ __ (5) Close all low point drains after finishing condensate draining out.
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_ __ (5) When on-spec HP steam is produced from the HRSG and the Gas Turbine operation
__ RA| becomes stable, the HP steam can be introduced to HP steam header gradually. Under
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6. NORMAL OPERATION
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Chemical injection quantities are determined by monitoring analyzer and sampling results, and
adjusted by manually setting the stroke of the metering pumps of the chemical injection packages.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 21 of 35
A) Boiler Blowdown
(1) Continuous Blowdown (Surface Blowdown)
For Package Boilers (062-F-1001A/B/C) and Heat Recovery Steam Generators
(051/052-F-1101/1102), 1% continuous blow down may be considered enough rate at normal
operation. Basis is shown below;
As shown in the above, minimum 0.1% blowdown is required to keep boiler water quality. Normally
1.0% blowdown is a sufficient rate considering operation margin for the target value, however if
quality of boiler water is not stable, increase blow down rate. (3 % is the design rate of continuous
blowdown.) Actual blowdown rate shall be determined according to actual sampling data.
B) Phosphate Injection
Phosphate treatment is adopted for treating of leak hardness in feed water and adjusting pH of boiler
water to inhibit corrosion.
For example, the mole ratio is controlled at 2.8 as typical value to prevent free sodium hydroxide.
For make-up of 2.8 mole ratio phosphate compounds, mix Na3PO4-12H2O and Na2HPO4-12H2O with
mole ratio of 4 and 1. (As weight ratio, 4.25:1. This mixture contains 25.2 % of PO4; hereinafter, this
mixture is called “Phosphate compound”)
(3) Start-up
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 23 of 35
The initial charge is performed to obtain nearly the same water quality at start-up as that in normal
operation so that the initial injection is calculated for the holding water volume of the boiler.
The initial injection amount of phosphate solution is usually determined by the following equation on
the basis of phosphate ion concentration;
A-Start = (F-Ca-H x 0.57 + B-PO4) x Holding water in boiler
where
A-Start = initial injection of phosphate ion (g as PO43-)
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 24 of 35
train is required in addition of above items because one boiler or one STG can not cover two
trains operation.
After load shedding, the remaining train shall be turned down in order to start a BOG
compressor, desalination package and infrastructure.
An entire shutdown of the steam system is only possible during the whole plant shut down. However
equipment or sections of line may require periodically shutdown for maintenance or an inspection. In
that case, only the equipment or the sections shall be isolated.
7.1 Deaerator
(1) Confirm one train is completely shut down.
(2) Close Deaerator (062-V-1001A/B) level control valve (062-LV-1111 or 1112) on
demineralized water line.
(3) Close 10” block valve on the pump minimum flow return line.
(4) Close 20” block valve on boiler feed water outlet line.
(5) Slowly close Deaerator pressure control valve 8062-PV-1211 or 1212) on LP steam line
together with slow closing 14” block valve on recovered condensate line.
(6) Close 4” block valve on steam balance line.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 25 of 35
8.1 General
This section describes the guidelines of shutdown procedure in case of emergencies. However, in
emergencies, required actions by operators may vary because they depend on the actual situation at
the time of emergency. Therefore, it is most important for the operators to determine the cause of
emergency accurately and to understand the exact situation.
9. SAFETY PROCEDURE
9.1 General
To prevent accidents it is of the utmost importance that all personnel be instructed properly of
the following subject:
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 26 of 35
The following safety regulations cover operations of particular concern to the personnel
responsible for the unit. They are intended to supplement any existing general plant safety
regulations which cover all units; reference should be made to the latter for all points not
mentioned below. Mechanical craftsmen working on their unit will be governed by their own
departmental safety regulations, but the operator should see that none of the following safety
regulations are violated by mechanical workers.
In addition to specifically defined rules and practices, the exercise of good judgment by every
person involved is essential to safe operation. An operator should be alert for any situation
which might present a personnel hazard. It should also be the responsibility of each person
familiar with the plant to warn other workers who enter the plant of possible hazards they
could encounter.
All personnel must know the location and use of safety shower, fire extinguisher, plant fire
alarm, and main isolation valves, fire hoses and hydrants, fire blankets, gas masks and
respirators, and other protective equipment such as hard hats, rubber gloves, etc.
Soda acid or foam type extinguisher must not be used on fire around electrical equipment
because the water solution will conduct electricity and may aggravate the difficulty or result in
the electrocution of personnel.
Carbon dioxide or dry powder extinguisher may be used safety on electrical fires.
Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered.
Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid is
encountered, and are recommended for use while samples are being withdrawn and solutions
made up.
Fire extinguishers must be recharged immediately after use. All stream and water hose
equipment must be put back in place after use. Access to such equipment must not be
obstructed.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 27 of 35
_ __ 6. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 28 of 35
hammer to start.
7. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other
cleaning purposes.
8. Equipment should not be left open overnight. At the end of each day’s work blanks or
spades should be installed to prevent entry of flammable materials due to valve let-by.
9. Welding cylinders should be removed from site to a designate safe area at the end of each
working day.
Wear proper personal protective equipment and exercise caution to avoid injuries.
When sample cooling is required, operator shall confirm cooling water is flowing properly
before taking the sample.
Secure a gas test certificate showing the gas condition of the vessel is safe for entry.
Stand on the windward side of an operating from which gases escape.
Provide proper ventilation.
All personnel should become familiar with the accepted method of artificial respiration in
order to render assistance to any one overcome by gas, electric shock, or drowning.
When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the
approved test method.
Wear the correct type of breathing apparatus, suited to the situation encountered.
The compressed air self-contained breathing apparatus has a self-contained air supply carried
on the back of the user.
It is used principally in emergencies.
After use, always notify the proper department so that they can recharge the cylinders as soon
as possible.
9.9.1 Nitrogen
N2 is an inert gas used for purging equipment or maintaining a positive pressure inert gas
blanket on a vessel.
N2 is neither poisonous nor flammable, but care must be exercised when working inside
equipment that has been N2 purged. Adequate ventilation must be provided and appropriate
breathing device worn. To breathe an atmosphere high in N2, could result in suffocation.
Before entering vessels that have been purged with N2, a check must be made for proper
oxygen content prior to entry. Rapid vaporization of liquid nitrogen can cause severe burns on
contact with the skin.
9.9.3 Chemicals
The following chemicals are used in this system. They are hazardous and shall be taken care
when handling them. Plastic gloves, a face shield, overalls, a full PVC suit or chemical resistant
apron, and rubber safety boots shall be worn. The PVC trousers should be outside the boots.
Avoid all contact with and do not inhale the fumes.
- Oxygen Scavenger
- Neutralizing Amine
- Phosphate
Refer to the Material Safety Data Sheet (MSDS) of each chemical.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 30 of 35
This section describes the isolation procedures to be taken prior to maintenance work based on the
following specification:
Maintainability Philosophy (99-PHI-EM-0005)
Availability and Sparing Philosophy (99-PHI-PS-0002)
10.1 General
It is necessary to isolate trains, items of equipment, or groups of equipment, in order to facilitate
shutdown for maintenance, inspection, tie-ins, or loss prevention.
As the degree of hazard increases, the measure of protection required must be deeply considered. The
degree of hazard is related to the system contents (e.g. flammability, toxicity etc.), pressure and
temperature. There are two main methods of isolation which can be used:
Positive isolation incorporating the use of spades/spectacle blinds or removable spools and blind
flanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entry
or for creating safe construction areas within a plant.
Valved isolation for less critical duties than those requiring positive isolation, e.g. for control valve
maintenance. Valved isolation will also be required to enable positive isolation to be installed or
removed without the need for a complete plant shutdown.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 31 of 35
Figure 10.2.1
Horizontal Pressure Vessel
RELIEF VALVES
AND FLARE
HORIZONTAL VESSEL
OIL OUTLET
DRAIN LINES
Figure 10.2.2
Vertical Pressure Vessel
RELIEF VALVES
AND FLARE
GAS OUTLET
VERTICAL
INLET
LINE VESSEL
LIQUID OUTLET
10.2.2.2 Pumps
Normally valved isolation method is applied for isolation of pump suction and discharge lines. If
required from the maintenance work nature, spectacle blinds will be provided. Refer to Figure 9.2.3.
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Figure 10.2.3
Pumps
OUTLET
LINE
INLET
LINE
Figure 10.2.4
Shell and Tube Heat Exchangers
SHELL
SIDE OUTLET
TUBE
SIDE INLET
RS
HEAT EXCHANGER
SHELL & TUBE
TUBE
SIDE OUTLET SHELL NOTE: BLOCK VALVES NOT
SIDE INLET REQUIRED IF EXCHANGER NOT
SPARED OR BYPASSED
11.1 General
INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT
AIR FOR BREATHING APPARATUS.
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Operation Manual for Steam/Steam Condensate/BFW System Sheet No. 34 of 35
• Physically isolate vessels. Only standard blank flanges and spades should be used. No person
should enter a vessel unless all directly connected sources of process and utilities fluids have been
positively isolated from the vessel. Entry means total body entry or any part of the body.
• Operations should check for oxygen, taking samples at several representative places, with a
portable analyzer to check for oxygen deficiency.
• Prior to commencement of this work it is recommended that the crew will be briefed on what is
required and what hazards there are. The crew will be reminded of the location of safety showers,
first-aid boxes and telephones.
• If welding or any process liable to evolve noxious fumes is to be carried out in the vessel,
adequate ventilation should be provided.
11.4.2 Pumps
• Operations to shut down the unit, stop pump motor and depressurize the line and pump.
• Electrical to lock out motor locally and remove relays/fuse/circuit breaker in substation.
• Mechanical to spade at inlet and outlet nozzles of said equipment.
• Operations to vent, air purge and drain the pump.
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• Electrical to lock out fan motor locally and remove relay/fuse in substation.
• Mechanical to remove access panel.
• Operations to check area is hazard free.
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