TITLE: PROCESS DESCRIPTION REPORT

Doc ID: 15-501-EP-RP-001 REV.1A

DESIGN, MANUFACTURING, SUPPLY, INSTALLATION,

CONSTRUCTION & COMMISSIONING OF BQPS RLNG
SPUR PIPELINE PROJECT

PROCESS DESCRIPTION REPORT

Doc. #: 15-501-EP-RP-001

Rev. 1

CLIENT: K-ELECTRIC

GASCO Engineering Pvt Ltd.

501, Amber Estate Building, Shahra-e-Faisal, Karachi, pakistan
Email: info@AGJVengineering.com.pk : T: +92 21 3432 0635-36 & 3432 0770 - 71
 TITLE: PROCESS DESCRIPTION REPORT

Doc ID: 15-501-EP-RP-001 REV.1

REVISION INDEX

1 21-12-2020 Issued for Construction AK IUR MSK

1D 09-11-2020 Re-Issued for Approval AK IUR MSK
1C 06-11-2020 Re-Issued for Approval AK IUR MSK
1B 22-10-2020 Issued for Approval AK IUR MSK
1A 12-10-2020 Issued for Review AK IUR MSK
Rev. Date Description Prepared Checked Approved

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 TITLE: PROCESS DESCRIPTION REPORT

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Table of Contents

1.0 INTRODUCTION.............................................................................................................. 4
2.0 SCOPE OF DOCUMENT ................................................................................................. 5
3.0 PROCESS DESCRIPTION .............................................................................................. 6
4.0 PROCESS HYDRAULICS ............................................................................................... 9
5.0 SAFETY & EMERGENCY INTERLOCKS .................................................................. 9

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 TITLE: PROCESS DESCRIPTION REPORT

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1.0 INTRODUCTION

K-Electric Limited (KE) aims to develop a RLNG Spur Pipeline to fulfill the gas
requirement of the 900 MW RLNG Combined Cycle Power Plant (CCPP) Project.
KE have engaged Gasco engineering Pvt. Ltd. (GEPL) for laying the Pipeline along with
metering for supply of 250 MMSCFD RLNG at 59-85 barg to a delivery point (TP-03 &
TP-04) at the RLNG Supplier’s main pipeline which is connecting the Bin Qasim Power
Station-I(BQPS-I) with the Custody Transfer Station, positioned at 2.0 KM
approximately. This spur pipeline shall connect the delivery point situated at KE’s BQPS-
I with the main pipeline through a tee- off connection as designated by RLNG Supplier in
its facility.
Scope of work includes engineering, procurement, construction, testing and
commissioning (EPCC) of this project, GEPL will execute and commission the project on
turnkey basis, within the stipulated timeline.
This report presents the process description of this project that involves an overall process
operability and instrumentation controls related to pipeline from supplier and delivery
stations.

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 TITLE: PROCESS DESCRIPTION REPORT

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2.0 SCOPE OF DOCUMENT

The scope of this document is to describe the Process Description pertaining new 14”
pipeline project from RLNG Supplier’s main pipeline to KE’s Bin Qasim Power Station-
I.

2.1 Abbreviations

KE K-Electric Limited
GEPL Gasco Engineering Pvt.Ltd.
RLNG Regasified Liquefied Natural Gas
CCPP Combined Cycle Power Plant
BQPS Bin Qasim Power Station
MW Mega Watt
MMSCFD Million Standard Cubic Ft. per Day
ESDV Emergency Shutdown Valve
IG Instrument Gas
FCV Flow Control Valve
PRV Pressure Regulating Valve

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3.0 PROCESS DESCRIPTION

3.1 Existing Facility

Currently FOTCO is supplying 600 MMSCFD RLNG via 30” Pipeline and Engro is
supplying RLNG gas via 24” Pipeline respectively metered through dedicated Custody
Metering station. These two pipelines are combining and total RLNG is routed to
SSGC network via 42” Pipeline.
During RLNG Spur Pipeline project, a new tie-in will be taken from existing 30” line
with the required isolation to transport RLNG to KE BQPS-I, which will further be
reduced into 14” line as per hydraulic requirement.
RLNG will be metered through New Custody Metering station at Supply Station prior
to be routed to KE BQPS-I metering station. The new pipeline will be equipped with
battery limit isolation valves at SSGC fence as well as KE fence.

3.2 Supply Station

The first tie-in will be taken in the supplier side. It starts with 30” tie-in (TP-01) and
converted into 14” pipeline which is designed to handle flow rate of 250 MMSCFD to
KE BQPS-I. The line is designed to provide pressure of 59 barg to 85 barg at KE plant
tie-ins (TP-03 and TP-04). This Supply station will be operated as a small independent
facility adjacent to existing FOTCO plant.
The 14” piping at supplier station is provided with Flow control valve (FCV-001) to be
controlled with FT-001 that will maintain required flow towards the delivery station.
At supplier station, a dedicated gas metering skid (comprises of Flow meter –
Ultrasonic type) is provided on 14” line to meter the gas required for custody transfer.
The metering skid also includes the gas quality monitoring tools i.e Gas
Chromatograph, H2S analyser, Hydrocarbon dew point analyser.

Initially 150 MMSCFD Metering skid will be installed as provided by KE. Later-on,
250 MMSCFD metering skid will be replaced with 150 MMSCFD skid. The future
cold connections with isolation valves are installed for future metering skid of 250
MMSCFD installation.

Automatic Blow down valve (BDV-001) is installed after metering skid considering
safety for emergency shutdown in fire case, as advised by KE. This will provide safety
to personal and asset if any unforeseen event of fire happened. Adequate vent stack is
provided to disperse gas during fire case at a safe location. Line will be isolated during
emergency of fire (2 out 3 voting basis) or gas detection (2 out of 2 voting basis) via
ESDV-005 and ESDV-002 within the Supply Station that will be trigged during auto

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fire detection via fire and Gas detection or a manual call point push button. Same
ESDV will be closed to protect line during pressure high high (PSHH-001A//B/C) at
upstream and pressure low low (PSLL-001 A//B/C) at downstream scenarios via 2 out
of 3 voting scheme.
A manual depressuring line for 14” pipeline is provided and connected to new vent
stack at supply station.

The gas will further route via 14” pipeline and approximately two (02) km at delivery
tie-in point within KE BQPS-I plant.

3.3 Instrument Gas Buffer Vessel (V-15-01)

Supplier side is independent facility, hence provided with Instrument Gas Buffer
Vessel (V-15-01). Two tap-off are taken from 14” line, before and after metering skid.
This will serve driving force for instrument loops/ESDV/BDV/Control valves to
operate as an alternative to instrument air. The instrument air provision is not available
at supplier station.

Pressure will be regulated with pressure regulated valves provided in series. The
pressure regulators shall be of Anti-freeze type at upstream of Instrument Gas Buffer
Vessel (V-15-01). Emergency shutdown valve ESDV-003 is provided at supply line to
isolate the vessel during fire case and pressure high high generated through PSHH-003.
Vessel is also protected with Pressure safety valve PSV-001 on over pressure during
fire case.
This buffer vessel is designed to provide 15min backup to instrument loop and
streamed flow for control valves.

Instrument buffer vessel Design specs are given below:

Vessel Dimension (DxH) 3.5 Ft x 8.0 Ft T/T

Design Pressure 10.3 barg
Design Temperature -29 / 100 oC

3.4 Vent & Dispersion at Supplier Station

The emergency release is considered at a location where dispersion is shown to
appropriately reduce or eliminate exposure to personnel that may be in nearby work
areas (e.g., platforms, tank roofs, etc.) and to confirm equipment is not exposed to a
hazardous situation.
The dispersion calculations are taken into account the most unfavorable concentrations
in the stream to be released and the most unfavorable, yet realistic, weather conditions.
These will depend on the location where dispersion levels need to be calculated.

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The following shall be met for this criterion:

Dispersion shall be such that within the hazardous contour (the area within which either
an ignition source or personnel could be present):
a) The concentration of flammable components is less than the lower flammability
limit; and
b) The resulting concentration of toxic and very toxic substances at locations where
people may be exposed is less than the IDLH (Immediately Dangerous to Life or
Health) value.
When utilizing physical effects modelling to determine hazardous contours,
sensitivities such as atmospheric stability, wind speed, humidity, surface structure etc.
are taken into account where the atmospheric vent handles combustible vapors, the
outlet from the vent should be elevated.
The size of a vent stack is determined by the available pressure drop and by any
minimum velocity required to prevent hazardous conditions due to combustible or toxic
material at grade or working levels. The size is checked to ensure that sonic flow is not
established.
As advised by KE, API 521 is not considered for vent system design hence dispersion
calculation is developed considering the IDLE limits and accordingly vent stack sizing
is performed. Refers to blowdown and vent study 15-501-EP-RP-003 for detailed
dispersion calculation.
Below is dimension finalized for Vent Stack to be installed in Supplier Station:

Height 15 meters
Stack Dia 8 inch

3.5 Delivery Station

The delivery station of the pipeline is situated with-in KE plant boundary limit. Flow is
distributed into two lines i.e. 100 MMSCFD and 150 MMSCFD. The flow distribution
in 100 MMSCFD and 150 MMSCFD piping will be throttled by using manual globe
valves. A dedicated FIT-003 will be installed on 150 MMSCFD line to assist manual
flow regulation whereas FIT-004 will be installed at 100 MMSCFD line to assist flow
regulation in the same line. Delivery line will be isolated during emergency of fire (2
out 3 voting basis) or gas detection (2 out of 2 voting basis) via ESDV-004. Same
ESDV will be closed to protect line during pressure high high (PSHH-002 A//B/C) at
upstream and pressure low low (PSLL-002 A//B/C) at downstream scenarios via 2 out
of 3 voting scheme.

Instrument air is available at delivery station and will be supplied from existing KE
plant. This will serve driving force for instrument loops/ESDV.

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4.0 PROCESS HYDRAULICS

Plant simulation including hydraulics have been performed using Aspen HYSYS V11
version. Process flow diagram (PFD) and heat mass balance (HMB) generated in Aspen
HYSYS is provided in Hydraulic report (15-501-EP-RP-002).

5.0 SAFETY & EMERGENCY INTERLOCKS

For safety and emergency interlocks at Supply and Delivery stations considering
confirmed fire & gas detection, manual push buttons and high high or low low pressure
scenarios, the respective primary safety devices action are defined in Cause and Effect
Diagram (Doc No. 15-501-EP-CE-001).

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