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PT. Brown & Root Indonesia

Doc. No. 76-IOM-PS-1201 Rev. 6A

Project TLNG Author’s Org. KJP

KJP Doc. No. S-076-1283-001 Date 26 June, 06

KJP Job Code J-3400-20-0000 Sheet 1 of 31

X Core Non-core Lifecycle Code A

For Information For Review For Approval X Released As-Built

Rev. Date Page Description Prep’d Chk’d App’d BP App’d

5A 23Feb06 all For Approval Suharyono T. Bessho M. Ditto

6A 26June06 all Released T.Bessho Y.Kakutani Y.Kakutani

3.8 MTPA TRAIN CAPACITY

Operation Manual for HC Condensate Storage and Loading

BPMIGAS

TANGGUH LNG

BP Berau Ltd.

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Doc. No. 76-IOM-PS-1201KJP Doc. No. S-076-1283-001 Rev. 6ASheet No. 2 of 31 Operation Manual for HC Condensate Storage and Loading

BP Berau Ltd. Tangguh LNG Project

CONTENTS

1 Introduction.................................................................................................................................4 2 BASIS OF DESIGN ....................................................................................................................4

2.1 General.........................................................................................................................................4 2.2 Condensate Storage Tank (076-TK-1001) ................................................................................4 2.3 Condensate Loading Pump (076-P-1001 A/B)..........................................................................5 2.4 Condensate Metering System (076-V-1002)..............................................................................5 2.5 Condensate Loading Arm (076-V-1001) ...................................................................................5

3 PROCESS DESCRIPTION .......................................................................................................5 3.1. General.........................................................................................................................................5 3.2. Condensate Rundown System....................................................................................................5 3.3. Condensate Storage Tank 076-TK-1001...................................................................................6 3.4. Condensate Loading System......................................................................................................7 3.4.1 CONDENSATE LOADING PUMPS 076-P-1001 A/B....................................................................... 7 3.4.2 SHIP LOADING FACILITIES.......................................................................................................... 7 4.1 General.........................................................................................................................................9

4.2 Start-up Procedure .....................................................................................................................9 4.2.1 HC CONDENSATE FILLING TO STORAGE TANK .......................................................................... 9 5.1 General.......................................................................................................................................10 5.2 Normal Operation Procedure ..................................................................................................11 5.2.1 I NTRODUCTION......................................................................................................................... 11 5.2.2 TANK OPERATION .................................................................................................................... 11 5.2.3 SHIP LOADING OPERATION ...................................................................................................... 11

5.2.3.1 Introduction....................................................................................................................11 5.2.3.2 ESD Check.....................................................................................................................11 5.2.3.3 Start Loading Operation................................................................................................. 12 5.2.3.4 Loading Operation .........................................................................................................13

5.2.4 OPERATING VARIABLES ........................................................................................................... 14

5.2.5 PROCESS CONTROL .................................................................................................................. 14 5.2.5.1 Minimum Flow Control for the Condensate Loading Pumps ........................................14 5.2.5.2 Condensate Analyzer ..................................................................................................... 14

6. QUALITY CONTROL.............................................................................................................14 7. NORMAL SHUTDOWN PROCEDURE ...............................................................................15

7.1 General Overall Shutdown Plan..............................................................................................15 7.2 Detailed Step-By-Step Procedure ............................................................................................15 7.2.1 ESD CHECK OF SHIP LOADING OPERATION............................................................................. 15 7.2.2 NORMAL MAINTENANCE/SHUTDOWN OF STORAGE/LOADING FACILITIES .............................. 16 7.2.3 NORMAL STOP OF LOADING OPERATION ................................................................................. 16

8. EMERGENCY SHUTDOWN .................................................................................................16 8.1 General.......................................................................................................................................16 8.2 Power Failure ............................................................................................................................17 8.3 Instrument Air Failure.............................................................................................................17 8.4 Fires/Serious Leakage...............................................................................................................17 8.5 Equipment Failure....................................................................................................................18 8.5.1 PUMPS ...................................................................................................................................... 18 8.5.2 LOADING ARM ......................................................................................................................... 18 8.6 Emergency Shutdown System..................................................................................................20 8.6.1 CONDENSATE LOADING SHUTDOWN........................................................................................ 20 8.6.2 TANK ISOLATION...................................................................................................................... 21

9. Safety Procedure.......................................................................................................................21 9.1. General.......................................................................................................................................21 9.2. Hazardous Material..................................................................................................................22 9.3. Emergency Fire Plan ................................................................................................................22

9.4. Fire Fighting and Protective Equipment ................................................................................23 9.5. Maintenance of Equipment and Housekeeping......................................................................23 9.6. Repair Work..............................................................................................................................23

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9.7. Withdrawal of Samples ............................................................................................................24 9.8. Safe Handling of Volatile and Toxic Materials ......................................................................24 9.9. Respiratory Protection .............................................................................................................24 9.10. Breathing Apparatus (B. A.)....................................................................................................25

10. Isolation Procedure for Maintenance......................................................................................26

10.1. General ......................................................................................................................................26 10.2. Basic Procedures.......................................................................................................................26 10.2.1 Individual Equipment / System Isolation....................................................................................26 10.2.1.1 Tanks....................................................................................................................................26 10.2.1.2 Pumps ..................................................................................................................................27

11. Maintenance Procedure............................................................................................................28 11.1. General ......................................................................................................................................28 11.1.1 R OUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 28 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 28 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 28 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 28 11.1.5 TURNAROUND /I NSPECTION MAINTENANCE............................................................................ 29

11.2. Precautions prior to Maintenance...........................................................................................29 11.3. Preparation for Maintenance ..................................................................................................29 11.3.1 I NSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 29 11.3.2 R EPLACEMENT OF NITROGEN WITH AIR .................................................................................. 30 11.4. Typical isolation method ..........................................................................................................30 11.4.1 TANKS...................................................................................................................................... 30 11.4.2 PUMPS ...................................................................................................................................... 30 11.4.3 CLOSE OUT............................................................................................................................... 30

12. Attachment List.........................................................................................................................31

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1 INTRODUCTION

The purpose of Unit 076 of Condensate Storage and Loading Facilities is to receive and store thestabilized condensate from the Condensate Stabilization (Unit 011) and Fractionation Unit (Unit 041

& 042), as well as transfer it to ship loading facility located at Combo Dock.

All hydrocarbon condensate produced in Tangguh LNG Facility is mainly for export via ship suitable

for condensate service.

Unit 076 consists of the following major equipment:

• 076-TK-1001 Condensate Storage Tank.

• 076-P-1001 A/B Condensate Loading Pumps.

• 076-V-1002 Condensate Custody Metering System.

• 076-V-1001 Condensate Loading Arm.

2 BASIS OF DESIGN

2.1 General

Condensate rundown line and Condensate Storage Tank (076-TK-1001) are designed to handle

condensate production for three-3.8 MTPA LNG trains.

The condensate is produced in the Condensate Stabilization Unit (Unit 011) and the Debutanizer

Column bottom of Units 041 & 042. All streams, then, are combined into a common rundown line

and stored in the Condensate storage Tank (076-TK-1001) prior to condensate loading to ship.

Condensate rundown line is designed to handle condensate production for 3 LNG trains.

The condensate enters the storage tank (076-TK-1001) at atmospheric pressure and 39.6oC. In the

initial two-process operation,The flow rate is expected for 51.0 m3/h. During pipeline pigging

operation, condensate flow will increase to 51.2 59.2 m3/h. The condensate RVP and Butane content

meet the requirement of condensate specification set out in Project Design Data of

900-DBS-EM-0001 (RVP 0.77 kg/cm2 A @ 37.8

oC and maximum Butane content 0.5 vol. %).

Detail information refers to Process Flow Diagram Unit 076, Condensate Storage & Loading,

Drawing no. 76-UFD-PS-1200.

2.2 Condensate Storage Tank (076-TK-1001)

Condensate Storage Tank (076-TK-1001) is an internal floating roof atmospheric tank.

The tank nominal capacity is 21,120 m3, and tank-working capacity is selected at 19,080 m

3. Design

pressure of the tank is atmospheric with design temperature of 20 oC /45

oC.

Detail information of this tank is described in the corresponding tank data sheet doc. no.

76-EDS-VM-1351.

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2.3 Condensate Loading Pump (076-P-1001 A/B)

Condensate Loading Pumps (076-P-1001 A/B) are operated in parallel (no spare philosophy) 2 x

50 % for intermittent service.

Each pump has a rated capacity of 750 m3

/h. Therefore, the total capacity of condensate loading rateis 1500 m

3/h, which capacity is based on the assumption of 12 hours loading duration. Differential

head is determined at 112 m, which corresponds to 8.07 kg/cm2of differential pressure.

At 1,500 m3/h, the loading time typically will be 12 hours, but will vary accordingly to ship size.

For details, refer to the pump data sheet of doc. no. 76-EDS-MC-1401.

2.4 Condensate Metering System (076-V-1002)

A skid mounted custody transfer metering system is provided to verify the condensate ship loading.

Flows are corrected for pressure, temperature and are totalized. The totalized flow, then, is indicated

in the DCS along with pressure and temperature. Turbine type flow meter is selected for this purpose.

For details, refer to Condensate Metering System Specification (99-SPE-CS-1750).

2.5 Condensate Loading Arm (076-V-1001)

During condensate loading to tanker ship, a skid mounted Condensate Loading Arm (076-V-1001) is

used to transfer condensate into the ship. Nominal size of loading arm is 10 inch. The loading arm is

equipped with Hydraulic Power Unit, accumulator unit, gear pump (drain pump unit), and associated

instrumentation and electrical system.

The loading arm is manually operated. The arm is provided with brake cylinders for inboard and

outboard drives to prevent the arm from falling down or falling upside down rising rapidly after

emergency decoupling in full of fluid or in empty condition respectively. These brake cylinders are

able to used for maneuvering the arm by hydraulic power in re-connecting operation and

maneuvering operation in normal condition except slewing.

3 PROCESS DESCRIPTION

3.1. General

The Rundown, Storage and Loading Facilities are shown on process flow diagram 76-UFD-PS-1200

and piping & instrumentation diagram 76-PID-PS-1201/ 1211/ 1212.

3.2. Condensate Rundown System

8 inch nominal pipe size of condensate rundown line is installed from the Condensate Stabilization

Unit (unit 011) down to condensate storage area (unit 076) with approximately 2.5 km long runs. A

PSV having size of ¾ ” x 1” is placed upstream of shutdown valve 076-USVE-2030, which is

provided for thermal relief case. The shutdown valve is intended to isolate Condensate Storage Tank

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(076-TK-1001) caused by High-High Liquid Level (HHLL) inside the tank. In this case, tank HHLL

signal sent from either 076-LT-1101 or and 076-LT-1102 (2 out of 2 voting) will initiate

076-US-2040 to close the shutdown valve of 076-USVE-2030. Closing the shutdown valve is also

enabled from manual ESD switch (076-HS-2030A) at MCR (Main Control Room) whenever

required.

3.3. Condensate Storage Tank 076-TK-1001

The tank has an internal floating roof of aluminum alloy material. Automatic bleeder vent and

emergency roof drain are installed on the floating roof to protect the tank from over pressure and

rainwater respectively. In addition to the above, a center vent with screen is employed to ensure

atmospheric pressure condition inside the tank. The tank is also provided with an air foam

distribution system comprising air foam chamber, deflector and riser pipe.

The tank is provided with water drain system. This enables the removal of any water accumulated

within the tank.

During normal operation, a little water is expected to be in the condensate. Water in the tank is

detected by water cutting via 8” gage hatch on top of the tank.Hydrocarbon Condensate in Storage

Tank (076-TK-1001) shall be sampled periodically. When water is detected, drainopen the 4”

drain valve in line 076-GH-1301-4”-1CS1P-NI. Drained water from 076-TK-1001 is captured in the

tank dike rainwater sump. Before allowing the captured water to be diverted to the rain water ditch, it

must be visually checked for oil (the oil sheen). Only oil free-water is allowed to go to the rainwater

ditch. All oil that is collected in the tank dike rainwater sump must be collected in the vacuum tank is

sent to oily water collection pit (087-A-1008) , and disposed off in 087-V-1001. .

Level transmitters (076-LT-1101 and 076-LT-1102) are attached provided on the tank using float

and differential pressure type respectively. Both transmitters send its signals are sent to SIS

076-US-2040 to indicate the condensate tank level inside the tank. Alarm is also available on the

076-US-2040 for liquid level high (LAH), liquid level low (LAL), liquid level high-high (LAHH)

and liquid level low-low (LALL). In this case, LAHH (2 out of 2 voting) or LALL (2 out of 2 voting)

shall will initiate the 076-US-2040 to trip and 076-US-2030 and 076-US-2700, respectively to

close . This means that the shutdown valve of 076-USVE-2030 located at the inlet of storage tank .

inlet will be closed immediately on or LALL (2 out of 2 voting) shall initiate 076-US-2040/2700 to

stop the Condensate Loading Pumps (076-P-1001 A/B) will be tripped on LALL. It should be noted

that the above-mentioned trip events would never happen at the same time.

During emergency situation, tank isolation is enabled by shutting off the tank inlet ESD valve

(076-USVE-2030) and tank outlet ESD valve (076-USVE-2020) from manual ESD switch

076-HS-2030A and 076-HS-2020A on console located in MCR, respectively.

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3.4. Condensate Loading System

3.4.1 Condensate Loading Pumps 076-P-1001 A/B

The condensate is transferred from the tank to the ship loading by Condensate Loading Pumps

(076-P-1001 A/B) with a total loading rate of 1,500 m

3

/h. The two pumps are operated in parallel.

Pump min flow recycle line is provided to ensure the required min flow by the pump. The flow rate

can be adjusted using flow control valve 076-FV-1001 located downstream of the pumps. The line is

connected to condensate inlet line prior to entering Condensate Storage Tank (076-TK-1001).

The pumps can be started and stopped from field -mounted switch 076-HS-9801/9802 as well as from

DCS via 076-HS-2700 A/B. REMOTE and LOCAL indication are available on DCS to show whether

the pumps run automatically or locally.

SIS 076-US-2700 can trip the pumps initiated by LALL inside of the storage tank as well as ESD

switch of SIS 076-US-2020 (Condensate Storage Tank outlet shutdown valve close) and SIS of

condensate loading 076-US-2000 (Condensate Loading Shutdown). During the condensate

loading, operator of loading arm can also send trip signal from ESD-1 push button switch

(076-HS-3101) located on local panel (loading arm panel). to 076-US-2000.

When quick disconnection of loading arm is required, operator can activate ERS manually by

using ESD-2 push button (076-HS-3102) located on local panel (loading arm panel). “ESD-2

ACTIVATED” signal is sent to DCS via SIS at the same time.

3.4.2 Ship Loading Facilities

A condensate metering system (076-V-1002) with turbine type flow meter is installed on condensate

loading line located at the storage area to monitor the totalized flow of the condensate. Pressure,

temperature, flow, totalized flow, and pressure drop are indicated via DCS serial link in MCR. A flow

control valve (076-HV-1501) is placed at downstream of the custody metering. This valve is

operated automatically in accordance with flow computer logic in condensate metering system

based on the tanker loading volume and available loading time. This valve can be also adjusted

from 076-HIC-1501 on DCS.

Thermal relief valve (076-PSV-8011) with ¾” x 1” size is attached installed on the loading line at

downstream of 076-HV-1501 adjacent to the storage tank. The PSV is designed for thermal relief

case caused by considering solar radiation.

The loading line is laid from cCondensate sStorage area to Combo Dock area having distance of

approximately 2.3 km. An ESD valve (076-USVE-2010) is provided to isolate and protect

Condensate Loading Arm (076-V-1001) during loading operation mode. The ESD valve

(076-USVE-2010) is actuated by nitrogen bottles. The valve is de-energized to closed by

076-US-2010, which is initiated from hardwired switch located inby signal from SIS of

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076-US-2000 (Condensate Loading Shutdown) as well as from on ship ESD and loading arm local

panel ESD (ESD-1) at Combo Dock. The SIS also triggers 076-US-2700 to trip the Condensate

Loading Pumps. Consequently, loading operation will be terminated.

The loading arm (076-V-1001) is skid-mounted and has a capacity of 1500 m3/h. Operating pressure

at the loading arm is expected at 1.0 kg/cm2G, and operating temperature of 39.6

oC. Design

condition of the loading arm is 19.7 kg/cm2G and 20 / 55

oC. The system is suitable for 150 lbs

ANSI/ASME rating. Total length of arm assembly is about 18 m with around 6.25 m height.

The system is provided with hydraulic power unit (HPU) to generate power for the loading arm. The

HPU consists of two (2) electric motors of 5.5 kW, two (2) hydraulic pumps, pressure relief valve,flow control valves, fittings, associated instrumentation and accessories. In the operating mode, mode

selector valves allow connection between control valve and arm brake (drive) cylinders.

There are two loading arm operation modes as follows:

- Freewheeling mode

- Maneuvering mode

Operator shall select the operation mode by mode selector valves.

When freewheeling mode is selected, the mode allows enabling the loading arm to follow the

tanker’s movement to prevent arm collapse due to large moment on arm nozzles.

When maneuvering mode is selected, the mode allows manual loading arm operation by means

of hydraulic oil solenoid valves. While, in freewheeling mode, the mode selector valves allow

freewheel of cylinders enabling the arm to freely follow the tanker’s movement.

In the event of electrical power failure, an accumulator unit, which consists of a vertical cylinder

with required pressure, is provided to allows to discharge of the hydraulic oil enabling the

operation of emergency release system. The emergency release system (ERS) comprises ERS valve

of Double Butterfly Valve (DBFV) and ERS coupler Powered Emergency Release Coupler

(PERC). When required (for instance during ESD-2 activated), immediate quick disconnection of

the loading arm can be achieved without drainage of the fluid in the arm by using manual push

button (ESD-2 push button) on the local panel.

The loading arm is furnished with drainage system. The system includes one (1) drain pump ofhorizontal-gear type using hydraulic motor driven. The pump has capacity of 5 m

3/h and max.

discharge pressure of 1.5 kg/cm2G.

Nitrogen bottles are required to purge the loading arm as soon after the completion of loading

operation. The estimated number of nitrogen bottles is eight (8).

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4 INITIAL START-UP PROCEDURE

4.1 General

Initial condensate filling into the system will be commenced after the start-up of Condensate

Stabilization Unit (Unit 011) has been completed. Pre-mechanical completion activities and finalinspection of the system shall be carried out prior to introducing the process fluid to ensure CSO (car

seal open) has been implemented on valves at the inlet of PSVs and pump minimum flow line. In

addition, all piping vents and drains need to be closed and blanked. All instrumentation-tapping

points are required to be in the open position.

The condensate piping system is to be nitrogen purged and sealed prior to introducing the HC

condensate

During initial filling of the lines and storage tank within the system, velocity is limited not greater

than 0.5 m/sec (0.016 m3/sec), in order to minimize the generation and accumulation of static

electricity in the condensate. When liquid is available at the drain valve of the condensate istransferred to 076-USVE-2030, the condensate flow rate can be increased to normal flow.

The condensate piping system is to be nitrogen purged and sealed prior to introducing the condensate.

4.2 Start-up Procedure

Reset 076-HS-2030B and 076-HS-2020B at the DCS.

Ensure that ESD valves of 011-USVE-2070 at unit 011 B/L (battery limit) and 076-USVE-2030 on thecondensate rundown line are in the open position.

Ensure that ESD valve 076-USVE-2020 at the tank outlet is also in the open position.

Gradually open the Unit 011 battery limit isolation valve slowly and displacing the nitrogen inside the

piping to the tank, as the condensate enters the tank.

4.2.1 HC Condensate Filling to Storage Tank

Ensure that ESD vavles of 011-USVE-2070 at Unit–011 B/L (battery limit) and

076-USVE-2030 at the inlet of HC Condensate Storage Tank (076-TK-1001) are in open

position.

Ensure that ESD valve of 041/042-USVE-2280 installed on the outlet of Debutanizer

Column bottom are still in close position.

Ensure that ESD valve of 076-USVE-2020 at the tank outlet is in close position.

Gradually open 011-LV-1101 (Condensate Stabilizer Column bottom level control valve)

and then packed nitrogen in HC condensate rundown line shall be replaced with HC

condensate. The replaced nitrogen shall be purged out from the top of HC Condensate

Storage tank to atmosphere.

− Once the roof and seal operation are satisfactory and the liquid level is sufficient to lift the

floating roof of its legs, full rundown flow rate can be established.

Ensure that control valve 076-HV-1501 and isolation valve located at downstream of condensate custody

metering (076-V-1002) are in the close position.

When there is sufficient condensate inventoried in 076-TK-1001, fill 076-P-1001A/B suction.

Open 076-P-1001A/B can vent by cracking open on suction block valve and slowly fill the pump suction.

When condensate flows from can vent line, close can vent valve.

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Open the pump discharge block valve to allow condensate filling the discharge line.

Rundown is now established to tank 076-TK-1001 with all piping fully occupied by liquid and low liquid

level indicated in the tank.

4.2.2 HC Condensate Filling to Loading Line

Ensure that 076-USVE-2020 installed on the tank outlet is in open position.

When there is sufficient HC condensate accumulated in the tank, HC condensate should

be introduced to loading pumps (076-P-1001 A/B). Pump suction should be filled with HC

condensate completely to prevent pump cavitation.

HC condensate is delivered to condensate metering system (076-V-1002). HC condensate

metering system shall be filled with HC condensate by closing of 076-HV-1501.

One of condensate loading pumps is started at full recycle.

Once one of condensate loading pumps is operated at full recycle, the other condensate

loading pump is started at full recycle.

After both condensate loading pumps are operated at full recycle, 076-HV-1501 is opened

gradually and HC condensate should be delivered to downstream monitoring the tank

level.

Increase the pump flowrate by opening of 076-HV-1501.

Nitrogen in HC condensate loading line is purged out with HC condensate. Nitrogen is

discharged to atmosphere from high point vent and nitrogen connection nozzle at the end

of HC condensate loading line near the HC condensate loading arm (076-V-1001).

5 NORMAL OPERATIONS

5.1 General

Management of the tank and the loading pumps operation will be carried out from MCR. However

the ship loading operation will be under the control and supervision of the Loading Master from

Loading Arm Control Panel (LACP) at the loading arm skid.

The ship loading operations (i.e., tanker mooring, communication cable attachment, and loading arm

connection) will be managed by the Loading Master after pre-loading meeting onboard (loading

coordination). Operators at the LACP and ship tanker operators remain in continuous voice

communication during the loading operation.

The rundown, storage and loading facilities area will be normally unmanned and the loading pumps

can be started and stopped either remotely from the MCR, or locally if necessary.

The monitoring of the storage, that is, DCS monitor showing pump status, pump operation mode,

valve status and tank levels will only be available in the MCR.

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Custody metering system of condensate will report the condensate flow ratetotalized loading

quantity and operating condition via DCS serial link to enable monitoring of the loading operation

from the MCR.

5.2 Normal Operation Procedure

5.2.1 Introduction

Condensate production has been brought into normal flow. And therefore, general description found

in the Section 3 of Process Description can be referred to represent the normal operation condition.

However, procedures are necessary to be described in detail, in order to give better understanding as

well as to develop a standard operation in terms of safety and operability.

5.2.2 Tank Operation

As described in the Section 3 of Process Description, the tank level monitoring including LALL,

LAL, LAH and LAHH will only be accessed from the DCS.

The SIS will take action when the tank level is in LALL or LAHH status. LALL will trip the

Condensate Loading Pumps. LAHH will initiate closing the tank inlet ESD valve.

When emergency situation arise, operator has to close ESD valves located at both the tank inlet and

outlet by ESD switches on the SIS console. All of these ESDV’s status are indicated in the DCS.

The quantity of condensate loaded to the ship is reported in the DCS from the Condensate Metering

System (076-V-1002) located adjacent to the storage tank area.

5.2.3 Ship Loading Operation

5.2.3.1 Introduction

When ship loading is required, it will be coordinated in the pre-loading meeting between the onshore

and ship operator. All ship loading operations will be under the control and supervision of the

Loading Master.

In accordance with ship loading agreed by both parties, expected condensate rate needs to be

specified. ESD test plan is to be arranged. And check lists are to be prepared.

5.2.3.2 ESD Check

The emergency shutdown system has to be tested before loading operations commence. Reset the

ESD valves and initiate manual trip from any of the locations. After successful test, reset and reopen

ESDV's. ESD test steps will be further detailed in the below Section 5.2.3.3.

ESD check of the loading arm system is also required. These are including ESD-1 and ESD-2 test.

The objective is to examine whether the emergency release system (ERS) and the SIS are ready prior

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to loading operation. The tests will be performed after connecting the arm to the ship. See the

corresponding loading arm vendor manual for further details (076-VDR-TBL-1C050).

5.2.3.3 Start Loading Operation

As soon after initial start-up has been completed, the condensate will be introduced into the storage

tank (076-TK-1001) with design flow rate as described in the above Section 2. The tank liquid level

will rise to a certain level in between low level and high level. The following steps need to be taken to

start loading operation:

− Operator has to cCheck the ship tanker capacity and liquid level inside the Condensate Storage

Tank (076-TK-1001) tank prior to loading operation. In such case, the pre-loading meetingshould resolve this matter.

Bring nitrogen bottles from shore side storage area (warehouse) to combo dock. Nitrogen

bottles are used to purge the HC condensate loading arm (076-V-1001) after loading

operation.

Input the total loading volume and loading time on the supervisory computer of

Condensate metering system (076-V-1002).

− Hydraulic Power Unit (HPU) in the loading arm system is to be powered ON.

− Maneuvering the arm by operator in the Loading Arm Control Panel (LACP) at the loading arm

skid manually using a pull rope.

− Aligning the arm.

− Connecting the arm to the ship.

Open 10” manual isolation valve at the inlet of condensate loading arm.

− Ensure that ESD valve of 076-USVE-2010 at the inlet of Condensate Loading Arm in combo

dock area B/L Combo Dock and 076-USVE-2020 at pump suction at the outlet of Condensate

Storage Tank (076-TK-1001) are in the open position.

− Ensure that suction and discharge of Condensate Loading Pumps (076-P-1001A/B) are in theopen position.

Condensate Loading Pump of 076-P-1001A and 076-P-1001B are to be started following switches of

076-HS-2700A and 076-HS-2700B in the DCS for pump minimum flow. Pump minimum flowcontrol valve 076-FV-1001 is set at 340 m

3/h.

Based on operator judgment, manual start-up of the pump can also be enabled by switching the pump

min. control valve 076-FV-1001 in manual operation mode as follows:

1.Crack open 076-FV-1001 manually from the DCS.

2.Start the first of the condensate loading pump.

3.Monitor pump minimum flow rate and slowly open 076-FV-1001 manually from the

DCS. When the flow is around 170 m3/h or greater, the second condensate loading

pump is started immediately.

4.The condensate loading pumps start is completed. Continue to open 076-FV-1001 the

condensate recycle rate up to 340 m3/h, which is the min. flow control valve set point.

Switch 076-FIC-1001 to the auto mode.

ESD-1 test is carried out as described in the above section 5.2.3.2. by the following ESD push

buttons:

076-HS-2020A 2000A in MCR the DCS.

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076-HS-2030A in the DCS.

076-HS-2000C in SIS of 076-US-2000 console.

076-HS-3101 (ESD-1) in the Loading Arm Control Panel and ESD-2 test (during the

loading arm system test.).

076-HS-2000D of on ship ESD

Reset the corresponding SIS after successful ESD tests as follows:ESD-1.

076-HS-2020B in the DCS.

076-HS-2030B in the DCS.

076-HS-2000C on the SIS console.

Re-start the condensate loading pump for pump minimum flow

Start one of the two Condensate Loading Pump at full capacity.

Once one Condensate Pump is completely operated at full recycle mode, start second

Condensate Loading Pump at full recycle mode.

− When both Condensate Loading Pump are operated at full recycle, press start loading on

the supervisor computer of Condensate metering system (076-V-1002). Control valve

076-HV-1501 has to be is gradually opened according to the preset logic (ramp up) of the

Condensate metering system. Initially, operator has to input the required loading time and totalloading volume in flow computer. Then, operator is required to press start loading on the flow

computer, which its signal is sent to the flow computer as well as the DCS via a serial link. The

condensate metering systemThe flow computer The flow computer will start the totalizing and

validation.

− The 076-HV-1501 can also be manually adjusted from the DCS. This means that operator is

enabled to override the control valve operation from the DCS if required.

5.2.3.4 Loading Operation

Presuming that the agreed flow rate has been achieved, loading operation will be unmanned

operation. However, the next actions are required to be taken are as follows:

− The loading master, in In coordination with operator s at the MCR and the ship tanker, has to

monitor the monitoring tank level, tanker inventory, and totalized flow rate shall be executed

via voice communication system.

− When the amount of condensate loaded to the ship reach 75% of the agreed quantity or greater,the 076-HV-1501 is gradually closed, which will be automatically accomplished by the flow

computer. After the loading operation ishas been completed, signal will be sent to the flowcomputer stop the condensate loading pumps. The totalized volume will be printed out batch

report and indicated in the DCS.

− Close the isolation valve located at the inlet of loading arm as soon after the agreed quantity has

been achieved.

Stop the condensate loading pumps.

− The remaining HC condensate to should be drained off from the loading arm by using

condensate drain pump 076-P-1002 that has been provided in equipped with the loading armskid.Bring nitrogen bottles from shore side storage area to loading site.

− AttachConnect the nitrogen bottles to the ¾” nitrogen connection nozzle that has been provided

at loading arm inlet.

− Open nitrogen connection valve. The following consideration should be taken prior to

connecting nitrogen bottles:

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Nitrogen bottle with full contents is to be provided with standard regulation/ pressure

gage top works.

Regulator is to be set at 0.5 kg/ cm2G.

− Initially, eight bottles should be provided for the purging operation. But the number of bottles

used can be adjusted based on operator experience.

− After the purging has been completed, detach remove tthe nitrogen bottles and return them to

the shore side storage area for refilling and secure storage.

5.2.4 Operating Variables

The facility is operated in batches except for condensate receiving from the Condensate Stabilizer

column (011-T-1001 A/B) and Debutanizer Column (041/042-T-1002). The operator monitors

tank levels, ESD valves status, pump status, ship loading rate and condensate properties (e.g. RVP,

pressure, temperature, etc).

5.2.5 Process Control

5.2.5.1 Minimum Flow Control for the Condensate Loading Pumps

The Condensate Loading Pumps have a common minimum flow recycle line to maintain their

minimum flow requirement.

Each pump has 170 m3/h of minimum required pumping rate. A common flow control valve is

provided on the minimum flow recycle line.

In the case of reducing ship loading rates such as during the initial and last stages of the ship loading

operation, condensate from the pumps will be re-circulated through the minimum flow recycle line.

5.2.5.2 Condensate Analyzer

In order to check condensate spec., RVP Analyzer (090-AI-1801) is provided on rundown line

adjacent to the storage tank. In case that the condensate RVP does not comply with the condensate

specification, remedial actions shall be taken in the upstream facilities (i.e. Unit 011 and Unit

041/042). See the corresponding Unit 011/041 operation manual for further details.

6. QUALITY CONTROL

Operators, in this unit, are unable to control of the quality of the condensate products received from

the Condensate Stabilization Facilities (Unit 011) and the Fractionation Units (Unit 041 & 042 ). RVP

of the condensate will be reported from the RVP analyzer, and shown in the DCS. Water content of

the storage tanks can be determined by laboratory analysis.

Water may enter into the bulk of condensate in the tank from the following sources:

1) With condensate from the Condensate Stabilization Facilities (Unit 011) and or the Fractionation

Units (Unit 041 & 042) is in upset conditions.

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2) Rain water due to leakage of the floating roof.

Samples should be taken periodically from the tank to check water content. The water in the tank

bottom can be drained and separated by means of bottom water drain system.

Sampling method, procedures and schedule should refer to Laboratory Testing Program as shown in

attachment-6.

7. NORMAL SHUTDOWN PROCEDURE

7.1 General Overall Shutdown Plan

Shutdown is classified into normal shutdown and emergency shutdown.

A normal shutdown is a scheduled shutdown, while an emergency shutdown is an unscheduled

shutdown due to a failure or accident.

The emergency shutdown procedures will be shown in Section 8.

When shutting down a unit, it is very important to avoid large and/or rapid fluctuations in flows and

pressures in order to protect the equipment and recover without causing any adverse effects on the

unit.

Further, measures must be considered to avoid hazards to human beings and damage to facilities.

The shutdown schedule must be reviewed and discussed and all operators must be notified of it in

advance.

7.2 Detailed Step-By-Step Procedure

Prior to proceeding with a shutdown, notify all utility sections and all other sections concerned.

7.2.1 ESD Check of Ship Loading Operation

Normal shutdown due to ESD test is required. The emergency shut-down system should be tested

before commencing loading operation. Reset the ESD valves and initiate manual trip from the

corresponding SIS console in control room. See the Section 5 for detail information.

After successful test, reset and reopen ESDV’s.

Procedures for ESD tests of the loading arm are included in the section 5.2.3.3 of Start Loading

Operation.

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7.2.2 Normal StopMaintenance/Shutdown of Storage/Loading Facilities

Normal shutdown of Unit 076 is represented by the following two-activities.

(1) Normal stop of loading/transfer/feeding operation.

(2) Regular maintenance of equipment.

When the tank undergoes internal inspection or maintenance, complete transfer of condensate is

required.

Overall maintenance shutdown in Unit 076 is impossible because only single HC Condensate

Storage Tank is installed.

When additional future HC Condensate Storage Tank is installed, tank maintenance will be

available.

Therefore, the following individual equipment/facility’s maintenance is available at present.

Condensate Loading Pump (076-P-1001A/B).

Condensate Metering Pump (076-V-1002).

Condensate Loading Arm (076-V-1001).

7.2.3 Normal Stop of Loading Operation

The normal stop of loading and transfer operations is carried out with taking into account the

following:

(1) At the end of loading operation, flow rate will be reduced by closing the 076-HV-1501 gradually.

Then, all isolation valves located downstream of the above control valve have to be closedaccordingly.

(2) Normal stop of the loading pumps are enabled only if the tank level is higher than low-low liquid

level, in order to avoid any interruption during loading operation due to pump trip.

8. EMERGENCY SHUTDOWN

8.1 General

(1) An emergency can be caused by the failure of an essential utility supply (power, instrument air,

etc.), mechanical failure, a serious leak or fire.

In these cases a partial or complete shut-down must be carried out quickly without damagingequipment.

(2) A partial failure of a utility may necessitate close monitoring of operating conditions withoutenforcing an immediate shut-down.

(3) At all times the safety of personnel is the first priority consideration.

(4) Operators must judge the conditions of an emergency correctly in order to take the first necessary

action in an actual emergency, and then appropriate action must be taken according to the

changes in the conditions.(5) If a failure is likely to continue for a considerable time, the unit must be shut-down according to

normal shut-down procedure after taking the initial necessary action.

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(6) Emergency Shutdown System.

The emergency shut-down system is designed to enable the control room and/or field operator at

loading site to shutdown the system and/or facility via hardwired switches either on the SIS console

or local panel.

Refer to cause and effect diagram of Unit 076 Doc. no. 76-LOG-PS-1150.

8.2 Power Failure

Emergency action to be taken (assuming a failure of all power) is described as follows:

- All motor driven pumps will stop.

- All ESDV are to be automatically closed, therefore, valves in pumping/rundown system should be

isolated.

- Only the loading pump min. flow control valve of 076-FV-1001 will remain open.

- Stop the loading operation and release arms as necessary.

8.3 Instrument Air Failure

In general, plant-wide instrument air failure will cause the various control and ESD valves to become

in their fail-safe position as well as loss of local pneumatic indication and recording (P1, LI, Fl, etc.).

At a plant-wide air failure,

- The feed to tank will stop.

- Loading operation will stop.

- Pump min. flow will continue to flow.

Control valve for min. flow will be kept fully open.

The following procedure must be taken at the discretion of the operators.

− Stop the pumps, which are running with min. flow condition and isolate the corresponding

suction and discharge valves.

8.4 Fires/Serious Leakage

The required action will differ depending on the location/extent of the leaklfire. In general cases, the

following steps must be taken.

(1) Notify the fire safety department with the condition reported. Stop hot work being carried outaround the area.

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(2) Cut the rundown and/or loading streams related. The necessity for quick release of loading arms

to a tanker should be considered (ESD-1).

(3) Shutdown any related pumps.

(4) Isolate equipment and piping affected by the leak/ fire, if possible pressure build up should be

taken into consideration.

(5) Switch off power sources if required.

It is of the most importance to detect the source of the fire/leak and to stop the supply of flammable

materials.

Whenever any emergency situation occurs due to fire at Combo Dock area, which could be initiated

from either condensate or diesel system, the same responses to the above shall be applied.

8.5 Equipment Failure

8.5.1 Pumps

When one of the condensate loading pumps (076-P-1001A/B) is failed, operators can continue

loading operation at the reduced loading rate.

When both of the condensate loading pumps (076-P-1001A/B) is failed, operator must stop

loading operation and take remedial actions.With the exception of intermittent use, all items of

rotating equipment have a spare.

The condensate loading pump status along with alarms is available in the DCS. Process value that

could lead to the pump trip is liquid low-low level within the condensate storage tank.

The following ESD push buttons can also become an event that tripping the condensate loading pumps:

(1)076-HS-2020A on the SIS console to closed ESD valve at the tank outlet.

(2)076-HS-2000A on the SIS console to stop loading operation.

(3)076-HS-3101 on the Loading Arm Control Panel (LACP) to stop loading operation.

(4)076-HS-2000D of on ship ESD to stop loading operation.

Power and mechanical failure as well as operator error also need to be considered as a trip event. Insuch case, operator intervention is required to isolate the pump and take remedial action.

8.5.2 Loading Arm

In case of loading arm failure, stop the loading operation immediately and release arm.

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Emergency Release System (ERS) is provided to disconnect the arm whenever emergency situation

arises. The ERS consists of ERS valve and ERS coupler. ERS will be initiated manually by operatorat jetty. The two-event that could initiate the ERS are ESD-1 and ESD-2 that will be described

further in sub chapter 8.6.

In case of loading arm failure, stop the loading operation immediately and release arm.

Emergency Release System (ERS) is provided to disconnect the arm whenever emergency situation

arises. The ERS consists of ERS valve and ERS coupler. ERS will be initiated manually by operatorat jetty. The two-event that could initiate the ERS are as follows:

(1)ESD-1

When any emergency situation is recognized or 1st alarm happened due to exceeding apex or

slew angle limit, the operator shall actuate the ESD-1 switch on the LACP to initiate the

following:

−A signal will be transmitted to the SIS to close the ESD valve located on the loading line on

dock-side and stop the loading pump.

− Starting of motor in hydraulic power unit.

(2)ESD-2

When audible/ visual annunciation (2

nd

alarm) is happened due to exceeding limit of apex andslew angle of the arm, operator shall manipulate the ERS manual handle on the hydraulic powerunit to actuate the emergency release as follows:

Closing ERS valve.

Releasing ERS coupler (ERC) after completion of ERS valve closing.

The arm is hydraulically blocked.

− Activating ESD-2 switch (076-HS-3102) on LACP and transmitting the ESD-2 signal to

the SIS.

Then, the arm in either empty or full of fluid will be retracted by 2 m above the ERC level usinghydraulic control by operator to clear the ship manifold area. The arm, then, is stored back.

In case of power failure, oil will be discharged from the accumulator unit to initiate the completeemergency release.

It should be noted that the emergency release is enabled only if the arm is in the mode of

connected. The emergency disconnection shall not be accomplished when the arm is in stored ormaneuvering condition.

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8.6 Emergency Shutdown System

8.6.1 Condensate Loading Shutdown

In order to minimize the potential for a release of HC Condensate to the environment, the

Condensate loading system is protected by two emergency shutdown systems: ESD-1 and

ESD-2.

(1) ESD-1

ESD-1 allows the rapid shutdown of the loading operation during emergency.

ESD-1 is designed for manual or automatic initiation.

Manual initiation is by push buttons located in Main Control Room (MCR), Loading Arm

Control Panel (LACP) and Condensate ship.

Automatic initiation is via an “over-extension signal” from the loading arm's apex limit

switch or initiation of ESD-2.

ESD-1 initiates the following actions;

Stop Condensate Loading Pump (076-P-1001A/B)

Close shutdown valve (076-USVE-2010)

Start motor in hydraulic power unit, which enables preparation of safety actions to be

taken in succeeding ESD-2.

(2) ESD-2

ESD-2 uncouples the loading arms quickly when the arms become overextended. Thisemergency situation of a potential loading arm failure is generated due to the HC

condensate ship drifting from its moorings beyond the design operating range of the

loading arms.

ESD-2 is designed for manual or automatic initiation.

Manual initiation is via push buttons on Loading Arm Control Panel (LACP).

Automatic initiation is via an “over-extension signal” from the loading arm's apex limit

switch.

ESD-2 initiates the following actions;

Close DBFV

Release PERC after completion of DBFV closing.

− Transmit ESD-1 requests to 076-US-2000

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8.6.2 Tank Isolation

When emergency, operator can close ESDV at the inlet and outlet of Condensate Storage Tank

(076-TK-1001) by the following push button;

(1)Process variable i.e. liquid low-low level inside the storage tank, which is transmitted from both ofthe following level transmitter:

−076-LT-1101

−076-LT-1102

(2)ESD switch has been activated from one of the following ESD push button:

−076-HS-2020A on the SIS console to close ESD valve at the tank outlet.

−076-HS-2000A on the SIS console to stop loading operation.

−076-HS-3101 on the Loading Arm Control Panel (LACP) to stop loading operation.

−076-HS-2000D of on ship ESD to stop loading operation.

The above ESD switches are manually operated when emergency response is required due to upset

condition such as fire, loading arm failure, etc.

To bring into normal operation after an emergency situation has been responded and remedialaction taken, reset of the corresponding SIS is required as follows:

− 076-HS-2020B 2020A in the DCS to opencloses ESDV valve of 076-USVE-2020 at the tank

outlet.

− 076-HS-2030B 2030A in the DCS to opencloses ESDV valve of 076-USVE-2030 at the tank

inlet.

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:

- The leaks and responsibilities of the operators

- The methods to accomplish this in a safe manner

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.

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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.

Safety hats must be worn when outdoors.

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.

Gas masks must have fresh cartridges installed after use.

9.2. Hazardous Material

HC condensate

(1) All components from explosive mixtures with air within certain limits and are liable to be

ignited when a source of ignition is available. The heavier component, the lower is the

ignition temperature.

(2) High vapor concentrations of all components will cause oxygen deficiency and will act

primarily as a sphyxiants without other significant physiological effects, however, lower

concentrations will have an anaethetic effect.

(3) Condensate contains benzene which is suspected of having carcinogenic properties above

a very low threshold value.

Benzene TLV-TWA ppm exposure level for eight hours: 10ppm

Note: TLV-TWA = Threshold Limit Value-Time Weighted Average

9.2.9.3. Emergency Fire Plan

The fire protection system of the plant is designed to prevent fire occurrence, control fire escalation,

or extinguish fire within short period of time, assuming there will be no outside fire fighting

assistance, with only one major fire at a time.

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9.3.9.4. Fire Fighting and Protective Equipment

Fire hazard status throughout the plant shall be monitored on the Hazard Detection and Monitoring

System (HDMS (F&G)) consoles in the main control room and fire and emergency station.

Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat

radiation.

For the detail, refer to 82-SPE-HS-1540 (S-082-1241-019), “Operation Manual for Fire Protection

System” and the relevant drawings for fire protection system.

9.4.9.5. Maintenance of Equipment and Housekeeping

1. Operating equipment should be checked frequently for signs of leakage, overheating, or

corrosion, so that unsafe conditions may be corrected before they result in serious consequences.

Unusual conditions should be reported at once.

2. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the

equipment must be replaced when repair work is completed.

3. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation

equipment where they can be knocked off and injure someone below.

4. Access to ladders and fire escapes must be kept clear. Waste material and refuse must be put in

proper locations where they will not offer fire or stumbling hazards.

5. Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediately

report leaks for repair.

6. In the event that electrical equipment does not function properly, notify the electrical department

and stay clear of the equipment until the electrician arrives.

7. Gas cylinders should be stored so that they cannot fall over. Guard caps must remain in place

over the valves of cylinders, which are not in use.

8. Care should be taken when installing scaffolding to ensure that the wooden boards do not

contact hot equipment and that no part is allowed to impair free access on operational equipment

e.g. ladders, stairways, walkways or valves. Scaffolding should be removed immediately on

completion of the work in hand.

9. Switch pumps regularly when spares are provided. This will assure start the spare pump will be

ready when needed.

9.5.9.6. Repair Work

1. Mechanical work around and operating unit must be kept to a minimum, and the minimum

number of men should be used.

2. No mechanical work on the equipment is to be done without a properly authorized work permit.

3. Safety hats must be worn by all personnel in all areas at all times.

4. No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized

by a work permit. Catch basins, manholes, and other sewer connections must be properly sealed

off to prevent the leakage of gases, which may ignite upon contact with an open flame.

5. No personnel shall enter a vessel for any purpose whatsoever until it has been adequately

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purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases and

an entry permit issued.

6. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not

physically strike these lines and avoid operation conditions, which would cause a water 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.

9.6.9.7. Withdrawal of Samples

Samples shall be withdrawn from the unit only by authorized personnel.

Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. A

container must never be filled to the brim, in order to minimize risk of subsequent spillage.

When sampling any product liquids, gloves and goggles will be worn.

When sampling any material, gas or liquid, the sampling line must be flushed long enough to remove

dormant materials to insure that the sample obtained represents the current stream. Pass enough gas

through the sample vessel to insure the displacement of the purge gas and to adjust the temperature of

the sampler to that the composition is not distorted by condensation or flashing, etc.

When the sample composition is representative of the source material, it shall not be distorted by

flash vaporization. Certain classes of samples may require inert atmospheres , cooling or special

carrying devices. Wear approved personal safety equipment and exercise caution to avoid injuries.

When sample cooling is required, operator shall confirm cooling water is flowing properly before

taking the sample.

9.7.9.8. Safe Handling of Volatile and Toxic Materials

The safety rules given below are for the protection of life and limb, and the prevention of property

loss. It is expected that plant people will exercise common sense, alertness, and good judgment in

carrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consult

your supervisor immediately.

9.8.9.9. Respiratory Protection

Most plant gases, other than air, are harmful to human beings if inhaled in certain concentration.

Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may causedeath by replacing the air in the lungs or by reaction with the oxygen carried in the blood; examples

are hydrogen sulfide carbon monoxide, and smoke. Irritating gases may cause injury or death not only

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by asphyxiating but also by burns internal and external/ examples are chlorine and sulfur dioxide. To

guard against the inhalation of harmful gases:

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.

If anyone is overcome by gas, his rescuer should:

Never attempt a rescue unless an assistant is standing by.

Protect himself before attempting a rescue by wearing breathing apparatus.

Get the victim to fresh air as soon as possible.

Give artificial respiration and send his assistant to call for medical aid.

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.

9.9.9.10. Breathing Apparatus (B. A.)

There are four types of breathing apparatus in general plant service. They are the canister type masks,

the fresh air hose line B. A., the compressed air self-contained B. A. and the compressed air line

trolley B. A.

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.

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10. ISOLATION PROCEDURE FOR MAINTENANCE

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.

10.2. Basic Procedures

The basic ideas for method of isolation are shown below. The details will be developed by Owner

when actual isolation work will be required. The selection of type of isolation valve and

blind/removable spools shall be in accordance with the applicable piping and material specifications.

This section considers train or system requiring isolation followed by individual equipment isolation

requirements. Sketches below are provided as an aid to develop actual planning for maintenance

work.

10.2.1 Individual Equipment / System Isolation

10.2.1.1 Tanks

All tanks where manned entry may be required are provided with temporary blind arrangements on

every process inlet and outlet nozzles. Relief valve inlet lines from pressure vessels are normally

positively isolated from the vessel by removing the relief valve and blinding the inlet line end. A

typical arrangement is shown on Figure 10.2.1.

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Figure 10.2.1

Tank

10.2.1.2 Pumps

Normally valved isolation method is applied for isolation of pump suction and discharge lines. If

required from the maintenance work nature, blinds will be provided. Refer to Figure 10.2.2.

Figure 10.2.2

Pumps

OUTLET LINE

INLET LINE

PUMP‘Y’ or ‘T’ TYPE SUCTION

STRAINER

DRAIN

TANK

OUTLET

LINE

MIN FLOW

LINE

OVERFLOW

INLETLINE

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11. MAINTENANCE PROCEDURE

11.1. General

INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT

AIR FOR BREATHING APPARATUS.

Type of maintenance is classified in the following categories.

11.1.1 Routine/First line/ Maintenance

Routine/First Line Maintenance is the daily on-line or off-line visual inspection, lubrication,

calibration or minor adjustment of running and static equipment. In addition to the maintenance

personnel carrying out the above types of checks/adjustments, the operator shall perform the

following routine maintenance activities whilst carrying out his daily checks on the Plant, in order to

prevent any minor problems developing into major ones:

• Tightening gland followers on leaking valve packing.

• Checking temperature and pressure gauges for broken glass faces.

• Checking for correct oil levels in compressors, gearboxes, oil reservoirs.

• Topping up low oil levels in the above equipment as required.

• Cleaning pump filters and strainers.

• Keeping equipment clean and tidy.

11.1.2 Breakdown Maintenance

For Breakdown Maintenance, there will be no scheduled checks or servicing. Corrective repairs will

be carried out on failure of the Plant or equipment.

11.1.3 Planned Preventive Maintenance

Planned Preventive Maintenance will be carried out on a calendar or running hours basis. It will be

performed in accordance with the vendors’ recommended frequencies.

11.1.4 Predictive/Condition Based Monitoring

Predictive/Condition based maintenance is the most efficient planning option. It uses direct

observations and instrument readings for the monitoring of the actual condition of the Plant and

equipment, and can trend and forecast when maintenance activities are due to take place.

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11.1.5 Turnaround /Inspection Maintenance

Turnaround/Inspection Maintenance will be carried out at approximately 3 yearly intervals, and

usually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting of

safety valves, and inspections and repairs of equipment that cannot be shutdown or removed during

Production.

11.2. Precautions prior to Maintenance

This section covers precautions prior to start maintenance work for a whole or a part of the plant.

• All work must be carried out within the requirements of company Safety & Environmental

Policies and Procedures. Prepare all known Work Permits, these must reflect safety issues.

Obtain relevant permit to work before starting work.

• Inform Operations of the work content of this preventive maintenance procedure and how it willaffect them.

• All rotating equipment is to be considered energized until proven isolated.

• All vessels must be isolated, drained and vented.

• Cordon the work area, to prevent unauthorized access.

• Prior to commencement of this work ensure that moving/rotating/power generating/energy

storing equipment has been isolated in accordance with the relevant permit to work and lock-out /

tag-out requirements.

• Physically isolate vessels. Only standard blank flanges and spades should be used. No person

should enter a vessel unless all directly connected sources of 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.

11.3. Preparation for Maintenance

The outline of the work sequence begins as below.

• Shutdown of the unit operation

• Installation of isolating blank flanges or spades

• Replacement with air for entry into the equipment, if required

11.3.1 Installation of blank flanges or spades

Isolating blank flanges or spades must be installed at locations as required.

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11.3.2 Replacement of Nitrogen with Air

Replacement of nitrogen gas with air and safety test for equipment must be performed prior to

permitting entry.

(1) Connect temporary air hoses at the appropriate location with utility air or instrument air ifrequired.

(2) Open the top vent valves and drain off valves to atmosphere of the equipment.

(3) Introduce air to displace/purge nitrogen gas to atmosphere.

(4) Continue to purge until oxygen contents are higher than 20% at all point.

11.4. Typical isolation method

11.4.1 Tanks

• Erect scaffold for access as required.

• Operations to close down the system, depressurize and nitrogen purge.

• Mechanical to spade inlet and outlet nozzles of said equipment.

• Mechanical to open drum.

• Operations to air purge and check for oxygen level.

• Operations to clean.

• One person to enter another to stand by on watch.

11.4.2 Pumps

• Operations to shut down the unit, stop pump motor and depressurize the line and pump.

• Operations to nitrogen purge the pump, if required.

• 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.

11.4.3 Close out

•

Ensure the equipment is left in a safe condition.• Remove all tools and debris, clean local area.

• Note any faults found and comments.

• Raise a work request if any major corrective work is identified or the performance standards are

not met during the above maintenance.

• Sign off permit to work and inform area authority of equipment status.

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12. ATTACHMENT LIST

Attachment-1 Process Flow Diagram

76-UFD-PS-1200

Attachment-2 P&IDs

76-PID-PS-1201

76-PID-PS-1211

76-PID-PS-1212

Attachment-3 Equipment Data Sheet (list only)

76-EDS-VM-1351

76-EDS-MC-1401

99-SPE-CS-1750

Attachment-4 Instrument Alarm Set Point (list only)

76-SPE-CS-1754

Attachment-5 Cause and Effect Charts (list only)

76-LOG-PS-1150

Attachment-6 Laboratory Sampling Schedule

cause and effect chart (3)

Documents