IGG TRAINING

TRAINING COURSE

INERT GAS GENERATOR

MODEC FPSO CARIOCA - MV30

PART 2

1 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

IGG TRAINING

CONTROL PANEL –MD-LCP-7200

INTERNAL & EXTERNAL LAYOUT

2 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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LCP – FRONT & TOP VIEW

3 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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LCP – RIGHT SIDE – CENTER VIEW

LOCATION LCP

4 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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LCP – RIGHT SIDE - LEFT VIEW

LOCATION IN LCP

5 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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LCP – RIGHT SIDE – RIGHT VIEW

LOCATION UCP

6 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

 IGG TRAINING

LCP – LEFT SIDE – CENTER VIEW

LOCATION LCP

7 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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LCP – LEFT SIDE – LEFT VIEW

LOCATION IN LCP

8 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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LCP – LEFT SIDE – RIGHT VIEW

LOCATION UCP

9 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

IGG TRAINING ELECTRICAL DRAWINGS

Link to electrical system drawings for MD-LCP-7200

Control panel & junction boxes

10 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

IGG TRAINING
GRAPHIC PANEL - SCADA

The control panel has a computer based SCADA system. This system offer
direct control and monitoring of the IGG system in real time. User can easily
start & stop the system and check status of valves, pumps, motors and etc.

Link to the grapical panel in the SCADA system

11 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

IGG TRAINING
PLC SEQUENCE DIAGRAM

The diagram describe in details with arrows and blocks the behavour of the
PLC control system based on user and system feedback.
Link to the diageram for MD-LCP-7200

PLC sequence control

12 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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ALARMS AND TRIPS

-Any alarm condition is indicated on the SCADA screen (on all
pages) with an alarm banner text description

- The last occurred alarm is described in the alarm-banner by

severity.
-A yellow symbol is a not urgent alarm (NURG)
- A red symbol is a urgent alarm (UGNT)

-an audible alarm will be given by an alarm horn/buzzer.

Link to alarm set points and trip list

13 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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MAINTENANCE AND SERVICE INSTRUCTION

COVERING: RUTINE INSPECTION AND PREVENTION MAINTENANCE,
AND REPAIR AND SPECIAL PRECAUTIONS

14 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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MAINTENANCE AND SERVICE INSTRUCTION

COVERING: RUTINE INSPECTION AND PREVENTION MAITENANCE,
AND REPAIR AND SPECIAL PRECAUTIONS
Before any kind of maintenance or service is carried out, the
manufacturers catalogue must be followed without exceptions.
Detailed reference to manufacturers catalogue are given for each
component.

Maintenance for components must be carried out according to

the manufacturers catalogue in order to maintain full warranty.

The operator must read and understand the dangers with

inert gas as listed in operation and maintenance manual,
whatever the cause, are allowed to maintain or service
the inert gas system before dangers and hazards
regarding inert gas are learned and understood.

15 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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GENERAL

•This Service & Maintenance Instruction is a synopsis of the various

subcontractor and equipment manufacturer’s service/maintenance
instructions.

•The plant particulars to be checked at regular intervals as listed in

the periodical Maintenance table, and any defects or irregularities
found must be rectified as soon as possible.

16 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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INTSRUCTION AND WARNING SIGNS

•These Service & Maintenance Instructions are based on a synopsis of

Equipment manufacturer’s manuals.

•Vital warnings have been transferred to this instruction, but the specific
instructions have priority over this common instruction.

17 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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WARNING AND INSTRUCTIONS

•The safety instructions contained in these instructions, which
represents a danger to personnel if not complied with, are specially
marked by the general danger symbol:

•Warning of danger from electric voltages is given as follows:

•Instructions which are essential to avoid

endangering the machine/package and its
functions are marked by the word Note!

18 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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PERSONNEL QUALIFICATIONS & TRAINING

•The Service & Maintenance and Operating personnel must be

especially qualified for the duties assigned to them. The scope of their
responsibility, competence and supervisory duties must be closely
controlled by a shift manager or discipline supervisor. If the personnel
do not have the required knowledge, they must be trained and
instructed. The supervisors must additionally ensure that personnel
fully understand the content of the Maintenance Instructions.

19 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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SAFETY INSTRUCTIONS FOR MAINTENANCE

AND INSPECTION WORK
•The Operator Company must ensure that all Maintenance and
Inspection work is performed by authorized and qualified personnel
who have thoroughly studied the Service & Maintenance Instructions.

•Work on the IG Generator System is only to be carried out when the

System has been shut down. The means of shutting down the
System, described in the Operating Instruction, must always be
followed.

20 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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SAFETY INSTRUCTIONS FOR MAINTENANCE

AND INSPECTION WORK

•The inert gas system is placed in safe area. However, no work or

maintenance creating electric sparks, metallic sparks, hot spots or
any other source of gas ignition must be carried out before the area
have been declared safe by responsible person. The manufacturer
cannot be held responsible for accidents occurring during
maintenance.

21 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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PERIODICAL MANTENANCE INSTRUCTION

Periodical maintenance cover all maintenance activities that
regularly occurs during the life of the equipment, such as:

•INSPECTIONS (PERIODICAL)
•TESTING (PERIODICAL)
•LUBRICATION (GREASE & OIL)
•CLEANING OR REPLACEMENT (FILTERS, STRAINERS ETC.)
•ADJUSTMENT & CALIBRATION (REGULATORS, INSTRUMENTS ETC.)
•MAIN OVERHAUL (MOTORS, GEARS ETC.)

22 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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PERIODICAL MANTENANCE INSTRUCTION

•Repair activities, caused by breakdown of the machinery, are not

included in Periodical Maintenance. Information regarding such
activities can only be found in the equipment manufacturer’s
individual Service & Maintenance Manuals.

•NOTE:
•IF IG SYSTEM HAS NOT BEEN IN OPERATION FOR
ONE WEEK, START UP THE SYSTEM AND LET IT
RUN FOR APPROX. 30 MINUTES.

23 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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PERIODICAL MANTENANCE TABLE

24 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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FOR DETAILED MAINTENANCE AND SERVICE

INSTRUCTION, PLEASE REFER TO:

OPERATION AND
MAINTENANCE
MANUAL

25 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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TROUBLE SHOOTING
•The fault-tracking chart is intended for first line fault
investigation using process operators. For more detailed
fault-tracking special service personnel must be used,
having detailed knowledge of equipment manufacturer’s
service manuals.

26 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

WARNING!

Exposure to an atmosphere containing less

than 5 % oxygen results in IMMEDIATE
UNCONSCIOUSNESS. If resuscitation is delayed for
more than four minutes, irrever­sible brain damage
will occur. Further delay will kill.

27 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

WARNING!

Even if the oxygen deficiency is not sufficient

to cause unconsciousness, the mind is liable to
become apathetic and complacent, and even if these
symptoms are noticed and an escape is attempted,
physical exertion will aggravate the weakness of
both body and mind.

28 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

WARNING!
An oxygen deficient atmosphere may not
only be present within a cargo tank, but also in
adjacent cargo pump rooms, permanent ballast
tanks, void spaces, at gas exits and within inert gas
plants to be overhauled.

29 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

Toxicity of Hydrocarbon Gases

Inert gas has no effect on the toxic nature of
hydrocarbon gases, and the problem is no different from the
toxicity of hydrocarbon gases on platform without an I.G. system.
Due to the possibility of gas pockets, regeneration, etc., gas
freeing must continue until the entire compartment shows a zero
reading with a reliable combustible gas indicator, or 1 % lower
flammable limit reading, should the instrument have a sensitivity
scale on which a zero reading is impractical

30 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

Inert Gas Toxicity

Any combustion of oil may produce limited amounts of toxic gas such as
Sulphur Dioxide (SO2), Carbon Monoxide (CO) and Oxides of Nitrogen (NO2).
Measurement is the only way to detect the presence of these toxic gases. However
the dilution of toxic components of inert gas can be correlated with the readings of an
approved combustible gas indicator as gas freeing progresses, if the hydrocarbon gas
content of an inerted tank exceeds approximately 2 % by volume before beginning of
gas freeing.
If ventilation of the compartment results in a lower flammable limit reading
of 1 % or less, in conjunction with an oxygen reading of 21 % by volume, toxic trace
gases will have been diluted to a concentration which will be safe to enter.
Alternatively, and disregarding the initial hydrocarbon gas content, continue ventilating
until a steady oxygen reading of 21 % by volume is reached.

31 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

Tank Pressure
Personnel should be advised of the practical hazards when an inerted cargo
tank is maintained at a positive pressure. The pressure must be sufficiently relieved
before opening any tank lids, ullage plugs or tank washing openings.

Do not open any tank lids, hatches, ullage

plugs or tank washing openings without checking
tank pressure. Do not open any of the above, without
depressurising the tank.
Opening under pressure may cause grave
injuries to personnel.

32 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

Electrostatic Hazards
An electrostatic charge can occur in the small partial matter carried in flue
gas. Although the charge is normally of a very low level, much higher levels have
been observed with water mists created by tank washing.
Cargo tanks are usually in an inerted condition and electrostatic ignition is
not a consideration unless the oxygen content of the tank atmosphere is increased by
the entrance of air, or unless it is necessary to inert a tank already containing a
flammable atmosphere.

33 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

Repair of Inert Gas Generating Plant

Inert gas is asphyxiating and extreme caution must be exer­cised at all times
when working on the plant. Being in fresh air during the work is not a safety
guarantee, since inert gas possibly leaking from the plant can still cause
unconsciousness very quickly. The plant should therefore be completely gas free
before any equipment is opened up.
An internal examination of any unit, such as the inert gas scrubber, must
not be performed without following the stan­dard recommendations for entering
enclosed spaces. Blind flanges should be fitted where applicable, or the plant should
be completely isolated.

34 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]

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HSE REQUIREMENTS

WARNING!

The IG Generator must be certified gas free

before any wash can be done. Washing on an IG
system that has not been completely vented may
cause grave injuries to personnel.

35 © Wärtsilä INTERNAL 09/06/2024 [Presentation name / Author]