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EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

Rev.: 0 Date: 03/09/2012 Page: 2 of 517

TITLE: OPERATION AND MAINTENANCE MANUAL

REVISION DESCRIPTION SHEET Rev.

Para.

0

Revision Description For Review

Hold No.

Para.

1

2.3.1

Vendor supplied MSDS of MDEA

2

2.3.2

Vendor supplied MSDS of Antifoam

3

2.3.3

Vendor supplied MSDS of Corrosion Inhibitor

4

2.3.4

Vendor supplied MSDS of Caustic

5

2.3.5

Vendor supplied MSDS of Biocide

6

2.3.6

Vendor supplied MSDS of Scale Inhibitor

7

2.3.7

Vendor supplied MSDS of Oxygen Scavenger

8

2.3.8

Vendor supplied MSDS of Complex Product

9

4.5.4 5.4.3

Instrument Air Compressor loading and unloading pressure set points/lead/lag compressor loading and unloading pressure set points

10

4.11.3.1 4.11.3.2 4.11.3.3 7.2.6

Demineralized Water Package operating set point/alarm and trip set points

11

4.13.3.1 4.13.3.2 4.13.3.4 4.13.3.5 4.13.3.6 4.13.3.7 7.2.8

Steam Generation Package: operating set point/alarm and trip set points

Description of Hold

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

Rev.: 0 Date: 03/09/2012 Page: 3 of 517

TITLE: OPERATION AND MAINTENANCE MANUAL

CONTENTS

SECTION I 1.1 1.2 1.3 1.4

OBJECTIVE ............................................................................. 11 ABBREVIATION ......................................................................... 11 UNITS OF MEASUREMENT ............................................................. 12 GENERAL DESCRIPTION ............................................................... 13

SECTION II 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9

OVERVIEW OF SRU UPGRADE FACILITIES ........................ 20

PROCESS ................................................................................ 21 SRU Upgrade Facilities Overview ................................................... 21 Acid Gas Enrichment Unit (AGEU) .................................................. 21 Sulphur Recover Unit Process Description ......................................... 24 Tail Gas Treatment Unit (TGTU) .................................................... 26 Tail Gas Incinerator ................................................................... 29 Amine Drain System .................................................................. 31 NEW UTILITY FACILITIES.............................................................. 33 Instrument and Plant Air ............................................................. 33 Demineralised Water System ........................................................ 35 Sea Cooling Water System ........................................................... 37 Boiler Feed Water System ........................................................... 39 Steam Generation Package 6848-A-02A/B/C...................................... 41 Fuel Gas System ....................................................................... 44 Effluent and Waste Water Treatment Unit ........................................ 46 FIRE WATER & DELUGE SYSTEM ..................................................... 48 Fire Water System .................................................................... 48 Deluge System ......................................................................... 48

SECTION IV 4.1 4.1.1 4.1.2 4.2 4.2.1

HEALTH SAFETY AND ENVIRONMENT ............................ 15

HEALTH, SAFETY AND ENVIRONMENT (HSE) ....................................... 16 LEAKAGE OF ACID GAS ................................................................ 16 HAZARDS IN HANDLING CHEMICALS ................................................. 17 MDEA .................................................................................... 17 Antifoam ............................................................................... 17 Corrosion Inhibitor .................................................................... 17 Caustic .................................................................................. 17 Biocide .................................................................................. 17 Scale inhibitor ......................................................................... 17 Oxygen Scavenger ..................................................................... 17 Complex Product ...................................................................... 17 Hydrogen Sulphide .................................................................... 17

SECTION III 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.3 3.3.1 3.3.2

INTRODUCTION ...................................................... 10

PROCESS AND CONTROL DESCRIPTION.......................... 50

ACID GAS ENRICHMENT UNIT (AGEU) ............................................... 51 Equipment Specification ............................................................. 51 AGEU PROCESS DESCRIPTION & CONTROL ......................................... 58 SULPHUR RECOVERY UNIT ........................................................... 75 Equipment Details .................................................................... 75

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.6 4.6.1 4.6.2 4.6.3 4.7 4.7.1 4.7.2 4.8 4.8.1 4.8.2 4.8.3 4.9 4.9.1 4.9.2 4.9.3 4.10 4.10.1 4.10.2 4.11 4.11.1 4.11.2 4.11.3 4.12 4.12.1 4.12.2 4.12.3 4.13 4.13.1 4.13.2 4.13.3

Revamped Claus Unit Process Chemistry .......................................... 77 Revamped Claus Unit Process Description ......................................... 78 Sulphur Recovery Unit Process Control ............................................ 79 TAIL GAS TREATMENT UNIT .......................................................... 89 Tail Gas Treatment Unit Equipment Specification ............................... 89 Tail Gas Treatment Unit (TGTU) Process Description............................ 92 Tail Gas Treatment Unit Control Description ..................................... 94 INCINERATOR ......................................................................... 102 Equipment Specification ............................................................ 102 Process Description and Control ................................................... 103 INSTRUMENT AIR PACKAGE.......................................................... 107 Instrument Air Compressor Package ............................................... 107 Instrument Air Dryer Package ...................................................... 108 Instrument Air Package Description ............................................... 109 Instrument Air Package Control Description ..................................... 110 EFFLUENT & WASTE WATER TREATMENT ......................................... 112 Equipment Specification ............................................................ 112 Effluent and Waste Water Treatment Process Description .................... 116 Effluent & Waste Water Treatment Control Description ....................... 118 LP FUEL GAS .......................................................................... 123 Equipment Specification ............................................................ 123 Fuel Gas System Process Description.............................................. 123 SEA COOLING WATER SYSTEM ...................................................... 125 Equipment Specification ............................................................ 125 Sea Cooling Water System Process Description .................................. 126 Sea Cooling Water Control .......................................................... 127 Electrochlorination Package ........................................................ 128 Equipment Specification ............................................................ 128 Electro Chlorination System Description ......................................... 131 Electro chlorination Package Control ............................................. 132 NGL-4 SEA WATER FILTERS.......................................................... 133 Equipment Specification ............................................................ 133 NGL-4 Sea Water Filters S-8840A/B Description ................................. 134 DEMINERALISED WATER SYSTEM ................................................... 134 Equipment specification ............................................................ 134 Demineralised Water System Process Description............................... 138 Demineralised Water System Control description ............................... 141 BOILER FEED WATER DEAERATOR SYSTEM ........................................ 144 Equipment specification ............................................................ 144 Boiler Feed Water De-aerator Description ....................................... 146 Boiler Feed Water Deaerator Control Description ............................... 148 STEAM GENERATION PACKAGE ..................................................... 151 Equipment Specifications ........................................................... 151 Steam Generation Package Process Description ................................. 154 Control Description .................................................................. 165

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.14 4.14.1 4.14.2 4.14.3 4.14.4 4.14.5 4.14.6 4.14.7 4.14.8

CHEMICAL INJECTION SYSTEMS ..................................................... 177 Antifoam Injection Package 9103-A-11 ........................................... 177 Caustic Injection Package 9103-A-13.............................................. 179 Corrosion Inhibitor Injection Package 9103-A-12 ................................ 181 Complex Product Injection Package 6834-A-09 .................................. 184 Oxygen Scavenger Injection Package 6834-A-09................................. 187 Biocide Injection Package 6932-A-06.............................................. 189 Scale Inhibitor Injection Package 6932-A-07 ..................................... 192 Catalyst Injection Package 9101-A-01............................................. 195

SECTION V 5.1 5.2 5.3 5.3.1 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.5 5.5.1 5.6 5.6.1 5.6.2 5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.7.5 5.7.6 5.8 5.8.1 5.8.2 5.9 5.9.1

PRE-REQUISITE FOR START-UP ................................... 198

GENERAL .............................................................................. 199 INTERFACE ACTIVITIES............................................................... 200 START-UP OF UTILITIES.............................................................. 202 Start-up Sequence ................................................................... 202 Instrument Air/Plant Air System ................................................... 202 Pre Start-up Checks.................................................................. 202 Instrument Air compressor Start-up ............................................... 203 Start-up permissive conditions: .................................................... 204 Instrument Air Dryer start-up ...................................................... 208 Instrument Air Dryer Start-up Checks ............................................. 208 Dryer Start ............................................................................ 208 Nitrogen system ...................................................................... 211 Lining up of Nitrogen from existing system to the New Distribution Header 211 Drinking water system ............................................................... 212 Lining up of Drinking Water to existing network ................................ 212 Lining up of Drinking Water to DMW Package .................................... 212 Effluent & Waste Water Treatment system ...................................... 213 Lining up of Waste Water Degasser 6922-V-07 ................................... 213 Lining up of Sour Water Stripper 6922-C-01...................................... 214 Lining up of Stripper Overhead Circulation Pump 6922-P-11A/B ............. 215 Lining up of Sour Water Stripper overhead Sour Gas ........................... 215 Pressurising Waste Water Degasser 6922-V-07 with Nitrogen ................. 215 Lining up of Sour Water Stripper Reboiler ........................................ 216 Flare system .......................................................................... 217 Start-up of LP Flare System ........................................................ 217 LP ACID GAS FLARE SYSTEM......................................................... 218 Fuel Gas System ...................................................................... 219 Line-up Fuel Gas from the Existing 1st Stage Booster Compressor 6701-K-10/20/30 in NGL-3 .......................................................... 219 5.10 Sea cooling water system ........................................................... 220 5.10.1 Pre-start up checks .................................................................. 220 5.10.2 Initial Starting and Lining Up of Sea Cooling Water ............................. 221 5.11 Electro Chlorination Package Start-up ............................................ 221 5.11.1 Normal start-up of Electro Chlorination Plant: .................................. 222 5.12 Chemical Injection System ......................................................... 224

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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5.12.1 5.12.2 5.12.3 5.12.4 5.12.5 5.12.6 5.12.7 5.12.8 5.13 5.13.1 5.13.2 5.13.3 5.14 5.14.1 5.14.2 5.15 5.15.1 5.15.2 5.15.3 5.15.4 5.15.5 5.15.6 5.15.7 5.15.8 5.15.9 5.16 5.17

Complex Product Injection Package (6834-A-09) ................................ 224 Oxygen Scavenger Injection Package (6834-A-09)............................... 225 Biocide Injection Package (6932-A-06)............................................ 226 Scale Inhibitor Injection Package (6932-A-07) ................................... 227 Catalyst Injection Package (9101-A-01)........................................... 228 Antifoam Injection Package (9103-A-11) ......................................... 229 Corrosion Inhibitor Injection Package (9103-A-12) .............................. 230 Caustic Injection Package (9103-A-13)............................................ 231 Demineralized Water System ....................................................... 231 Demineralized Water Unit Start-up ............................................... 231 Demineralized Water Unit Sequence .............................................. 235 Neutralization Pit .................................................................... 238 Boiler Feed Water Deaerator system .............................................. 241 Lining up of Steam Condensate Flash Drum 6834-V-05 ......................... 241 Lining up of BFW Deaerator Package 6834-A-08 ................................. 242 Steam Generation Package Start-up .............................................. 243 Checks for Start-up .................................................................. 243 Water Filling .......................................................................... 244 Fuel Gas Line-up ..................................................................... 245 FD Fan Start-up....................................................................... 245 Burner Start-up ....................................................................... 246 Boiler Normal Start-up .............................................................. 250 Start-up from Cold Condition (Manual Mode) .................................... 251 Start-up from Hot Condition........................................................ 254 Going On Line......................................................................... 254 LEAK CHECKING OF SYSTEMS ....................................................... 255 PURGING............................................................................... 256

SECTION VI 6.1 6.2 6.3 6.3.1 6.3.2 6.3.3 6.3.3.1 6.3.3.2 6.3.4 6.4

SECTION VII 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5

START-UP OF PLANT .............................................. 258

GENERAL .............................................................................. 259 START-UP SEQUENCE ................................................................ 259 START-UP OF PROCESS .............................................................. 260 Start-up of Incinerator 9101-F-14.................................................. 260 Start-Up of Acid Gas Enrichment Unit ............................................ 267 Start-Up of Sulphur Recovery Unit................................................. 283 Start-up of Reaction Furnace (9101-F-01) Burner ............................... 283 Heating Up the System .............................................................. 290 Start-up of Tail Gas Treatment Unit .............................................. 304 RAMP UP OF PLANT LOAD ........................................................... 319

OPERATION & MONITORING ...................................... 320

PROCESS PLANT OPERATION AND MONITORING .................................. 321 Acid Gas Enrichment Unit ........................................................... 321 Sulphur Recovery Unit ............................................................... 326 Tail Gas Treatment Unit ............................................................ 331 Instrumentation ...................................................................... 337 Process On-Stream Analysis and Testing .......................................... 337

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

7.1.6 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8

Tail Gas Incinerator .................................................................. 339 UTILITIES .............................................................................. 341 Instrument Air & Plant Air .......................................................... 341 Effluent & Waste Water Treatment ............................................... 343 Fuel gas system....................................................................... 345 Sea Cooling Water System .......................................................... 345 Electro Chlorination Package....................................................... 346 DM Water Package ................................................................... 348 Boiler feed water system ........................................................... 351 Steam Generation .................................................................... 353

SECTION VIII START-UP AFTER EMERGENCY SHUTDOWN .................... 357 8.1 8.2 8.3 8.4 8.5

GENERAL .............................................................................. 358 Tail Gas Incinerator Restart ........................................................ 358 Acid Gas Enrichment Unit Restart ................................................. 358 Sulphur Recovery Unit Restart ..................................................... 359 TGTU Restart ......................................................................... 359

SECTION IX 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.2 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7

PROCESS ............................................................................... 362 Incinerator ............................................................................ 362 Acid Gas Enrichment Unit ........................................................... 362 Sulphur Recovery Unit ............................................................... 364 Tail Gas Treating Unit ............................................................... 365 UTILITIES .............................................................................. 366 Instrument air package.............................................................. 366 Effluent & Waste Water Treatment Unit ......................................... 368 Electro Chlorination Package....................................................... 368 Chemical Injection Packages ....................................................... 369 DM Water Package ................................................................... 376 Boiler Feed Water System .......................................................... 376 Steam Generation Package ......................................................... 377

SECTION X 10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8

TROUBLE SHOOTING OPERATIONS.............................. 361

PLANNED SHUTDOWN ............................................. 380

Planned Shutdown - Process ........................................................ 381 TGTU Shutdown ...................................................................... 381 SRU Shutdown ........................................................................ 384 Acid Gas Enrichment Unit Shutdown .............................................. 386 Incinerator Shutdown................................................................ 387 UTILITIES .............................................................................. 389 Steam Generation Package Shutdown ............................................ 389 Boiler Feed Water System Shutdown .............................................. 390 DM water package Shutdown ....................................................... 391 Chemical Injection System Shutdown ............................................. 392 Electro Chlorination Package Shutdown .......................................... 395 Sea cooling water Shutdown ....................................................... 396 Fuel Gas system Shutdown.......................................................... 396 Effluent & Waste Water Unit Shutdown .......................................... 397

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

10.2.9 Instrument air Shutdown ............................................................ 398

SECTION XI 11.1 11.2 11.2.1 11.2.2 11.2.3 11.2.4 11.3 11.3.1 11.3.2 11.3.3 11.3.4 11.3.5 11.3.6 11.3.7 11.3.8 11.3.9 11.4 11.4.1 11.4.2 11.4.3 11.4.4 11.4.5 11.4.6

SECTION XII 12.1 12.2 12.2.1 12.2.2 12.3 12.4 12.4.1 12.4.2 12.4.3 12.4.4 12.4.5 12.4.6 12.4.7 12.4.8 12.5

EMERGENCY SHUTDOWN ......................................... 400

GENERAL .............................................................................. 401 PROCESS ............................................................................... 403 Acid Gas Enrichment Unit ........................................................... 403 Sulphur Recovery Unit ............................................................... 411 Tail Gas Treatment Unit ............................................................ 423 Incinerator ............................................................................ 430 UTILITIES .............................................................................. 432 Steam Generation System .......................................................... 432 Boiler Feed Water System .......................................................... 434 DM water system ..................................................................... 437 Chemical Injection System ......................................................... 439 Electro Chlorination System ........................................................ 444 Sea Cooling Water System .......................................................... 444 Fuel Gas System ...................................................................... 445 Effluent Waste Water System ...................................................... 446 Instrument Air Compressors ........................................................ 450 Utility Failure ......................................................................... 450 LP Steam Failure ..................................................................... 451 Sea Cooling Water Failure .......................................................... 451 Instrument Air Failure ............................................................... 452 Power Failure ......................................................................... 452 Boiler Feed Water Failure .......................................................... 452 Fuel Gas Failure ...................................................................... 452

MAINTENANCE ...................................................... 454

General ................................................................................ 455 PREVENTIVE MAINTENANCE ......................................................... 455 Process ................................................................................ 455 UTILITIES .............................................................................. 470 SHUTDOWN MAINTENANCE .......................................................... 485 Catalyst Loading & special procedures ........................................... 485 SRU 1st Stage & 2nd Stage Converters/Hydrogenation Reactor................. 486 Catalyst Activity & Life Expectancy ............................................... 497 Catalyst Preparation ................................................................. 499 Catalyst Management................................................................ 501 SRU Converter Catalyst Rejuvenation: ............................................ 502 SRU Converter Catalyst Stripping .................................................. 503 TGTU Hydrogenation Reactor Catalyst Oxidation: .............................. 505 Hydrogenation Reactor Sulphiding in Series with the SRU ..................... 510 Combustion Air Blower 9102-K-11A lube oil replacement...................... 512

SECTION XIII ANNEXURE ........................................................... 513 13.1 13.2 13.3

PFD/P&ID .............................................................................. 514 HEAT AND MATERIAL BALANCE ..................................................... 514 CAUSE AND EFFECT DIAGRAM....................................................... 514

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13.4 13.5

DESIGN BASIS ......................................................................... 514 MSDS ................................................................................... 514

SECTION XIV REFERENCE DOCUMENTS .......................................... 515

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TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION I

INTRODUCTION

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

1.1

OBJECTIVE The purpose of this Operating & Maintenance Manual (O&M) is to provide guidance to the operators for safe and efficient operation of the Utilities and Processing Facilities at the SRU Upgrade Facilities at Mesaieed. This O&M Manual provides detailed guidance on the start-up, shut-down and safe operation of the Utilities and Processing Facilities at SRU Upgrade Facilities.

1.2

ABBREVIATION AG

Acid Gas

AGEU

Acid Gas Enrichment Unit

AGRU

Acid gas removal unit

ATM

Atmospheric

BCS

Boiler control system

BFW

Boiler Feed Water

BMS

Burner Management System

BSR

Beavon Sulphur Recovery

BTEX

Benzene, Toluene, Ethyl Benzene, Xylene

CCR

Central Control Room

DCC

Desuperheater/Contact Condenser

DCS

Distributed Control System

DMW

Demineralised Water

ECP

Electro Chlorination Package

ESD

Emergency Shutdown

FD

Forced Draft

FV

Flow Control Valve

F&G

Fire and Gas

HAZOP

Hazard & Operability Study

HCV

Hand Control Valve

HMI

Human Machine Interface

HP

High Pressure

HSE

Health, Safety and Environment

ICSS

Integrated Control and Safety System

ITR

Inspection and Test Report

KOD

Knock Out Drum

LCP

Local Control Panel

LCS

Local Control Station

LEL

Lower Explosive Limit

LER

Local Equipment Room

LOR

Local Off Remote

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

1.3

LP

Low Pressure

LPM

litres per minute

LV

Level Control Valve

MCC

Motor Control Centres

MDEA

Methyl Di Ethanol Amine

MMS

Machine Monitoring System

MP

Medium Pressure

MSDS

Material Safety Data Sheet

NGL

Natural Gas Liquids

O&M

Operation & Maintenance

PFD

Process Flow Diagram

P&ID

Piping and Instrument Diagram

PIL

Petrofac International Limited

PPE

Personal Protective Equipment

PSV

Pressure Safety Valve

PV

Pressure Control Valve

QP

Qatar Petroleum

RGG

Reducing Gas Generator

SRU

Sulphur Recovery Unit

TGTU

Tail Gas Treatment Unit

TLV

Threshold Limit Value

TV

Temperature Control Valve

TSV

Temperature Safety Valve

UCP

Unit Control Panel

UEL

Upper Explosive Limit

UPS

Uninterrupted Power Supply

VFD

Variable Frequency Drive

UNITS OF MEASUREMENT Sm3/hr 3

Standard cubic meter per hour

Nm /hr

Normal cubic meter per hour

m³/hr

Cubic meter per hour

l/hr

Litres per hour

T/hr

Tonnes per hour

mg/l

Milligram per Litre

Kg/hr

Kilograms per hour

Bar (a)

Bar absolute

Bar (g)

Bar gauge

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TITLE: OPERATION AND MAINTENANCE MANUAL

mbar

Milli bar

Ppb

Parts Per Billion

ppmv

Parts Per Million by Volume

ppmw

Parts Per Million by Weight

M

Meters

Mm 2

1.4

Milli meters

m

Square meters

Kcal/hr

Kilo calories per hour

kW

Kilo Watt

GENERAL DESCRIPTION The primary objective of the Sulphur Recovery Upgrade project is to comply with State Environmental Regulations. The objective is met by upgrading the existing Sulphur Recovery Facilities at NGL-3, in Mesaieed, to achieve a minimum sulphur recovery of 99.5% during normal operation. The upgrade of the SRU includes routing additional sour gas streams from other NGL plants (NGL-1, 2 and 4) to SRU unit along with NGL-3 AGRU 1 & 2 acid gases. New Process systems that are included in this upgrade project are: •

Acid Gas Enrichment Unit (AGEU)

•

Tail Gas Treating unit (TGTU)

•

Tail Gas Incinerator

•

Existing SRU is upgraded.

New utility systems that are included in this upgrade project are: •

Instrument Air and Plant Air System

•

Nitrogen System

•

Drinking Water System

•

Oily Water Drain System

•

Effluent & Waste Water Treatment System

•

Flare System

•

LP Fuel Gas System

•

Sea Cooling Water System

•

Demineralised Water System

•

Boiler Feed Water Deaerator System

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

•

Steam Generation System

•

Electrical Power System

•

Control and Safety System

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TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION II HEALTH SAFETY AND ENVIRONMENT

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TITLE: OPERATION AND MAINTENANCE MANUAL

2.1

HEALTH, SAFETY AND ENVIRONMENT (HSE) This safety section briefs about the safety features of the Sulphur Recovery Upgrade facilities at Mesaieed which provide safety systems to protect personnel, environment and assets from the threats of production hazards. The safety of the plant facilities is maintained at a minimum risk level by adopting the following safety design aspects: 1. Avoiding Exposure to Potential Hazards 2. Minimising the Potential (frequency) for Hazardous occurrences (release of Hydrocarbons, Hydrocarbon Flammable Gases and any other abnormal hazardous event) 3. Containing and Minimising the Consequence (Fire, Explosion and Toxic Gas releases) of the Hazards 4. Providing the Means of Escape and Evacuation from such Hazards 5. Proving a Safe Working Environment for the Plant Personnel.

2.2

LEAKAGE OF ACID GAS While starting up of Acid Gas System that contains H2S & CO2, it is necessary to take special precautions as follows: 1.

Area around the specific area is barricaded to prevent personnel approaching the worksite.

2.

Personnel carrying out this operation have to take Work Permit and be aware of the hazards associated with Nitrogen (N2), Carbon Di-oxide (CO2) and Hydrogen Sulphide (H2S).

3.

Wear appropriate Personal Protective Equipment (PPE).

4.

As far as possible, the system to be entered is purged using N2/water prior to opening. This also negates the threat of elemental sulphur and associated corrosion and cracking.

5.

Pyrophoric fire prevention measures are put in place (including availability of relevant portable fire extinguishers).

6.

Personnel involved in the operation should wear Breathing Apparatus (BA) sets.

7.

Check H2S concentration frequently after wedge open the flange.

8.

Purging using N2 is continued as necessary.

9.

When H2S concentration is NIL, the ‘All Clear’ is given and normal work activities can recommence.

10. Ensure O2 supply by circulating fresh air through the equipment prior to making vessel entry. 11. Follow PTW of QP.

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TITLE: OPERATION AND MAINTENANCE MANUAL

2.3

HAZARDS IN HANDLING CHEMICALS

2.3.1

MDEA Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.2

Antifoam Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.3

Corrosion Inhibitor Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.4

Caustic Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.5

Biocide Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.6

Scale inhibitor Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.7

Oxygen Scavenger Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.8

Complex Product Refer the Vendor supplied MSDS in Section XIII (Annexure)

2.3.9

Hydrogen Sulphide Accidental Release Measures 1.

Personal Precautions: Keep unnecessary personnel away. Ensure adequate ventilation. Do not touch or walk through spilled material.

2.

Methods of containment: Stop the flow of material, if this is without risk. Eliminate all ignition sources (no smoking, flares, sparks or flames in immediate area). Prevent entry into waterways, sewers, basements or confined areas.

3.

Methods for cleaning up: Avoid dust formation. Vacuum or sweep up material and place in a disposal container.

4.

It is likely that the liquid in the system may contain pyrophoric iron sulphide. Even after steam-out/water washing, this may ignite when drying out in the presence of air. Therefore, water connections for flushing should be readily available

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Hazards Identification 1. Health Hazards: •

Hydrogen Sulphide is a highly toxic gas, rapidly causing death when inhaled in high concentrations. Even at low concentrations irritation of the eyes, nose and throat are possible. The following table illustrates the hazard of varying concentrations: •

TLV for prolonged exposure: 10 ppm

•

Slight symptoms after several hours exposure: 70-150 ppm

•

Maximum Concentrations that can be inhaled for one hour without serious effects: 170-300 ppm

•

Dangerous after exposure of 30 minutes to one hour: 400-700 ppm

•

Fatal in 30 minutes: 700 ppm and above

•

Skin absorption has been reported but is not considered significant

•

Hydrogen Sulphide can be recognized by its “rotten egg” odour. However its odour should never be used as a means of detection because exposure even to low concentrations may dull the sense of smell

•

Acute toxicity: The greatest danger from the inhalation of hydrogen sulphide is from its acute effects; it is not cumulative in action

•

Exposure to moderate concentrations causes headache, dizziness, nausea and vomiting in that order. Continued exposure may cause loss of consciousness, respiratory failure and death if the gas concentration is high enough. In exposures to high concentrations, loss of consciousness may occur rapidly and respiratory failure may follow a few minutes later. After severe exposures to hydrogen sulphide the individual may regain consciousness after several hours of treatment but he may show evidence of permanent severe brain damage. Persons having a significant exposure to hydrogen sulphide may develop a complete and permanent loss of the sense of smell thus destroying any ability to detect the presence of hydrogen sulphide

2. Chronic Exposure Prolonged exposure to low concentrations of Hydrogen Sulphide has an irritant effect on the mucous membranes, eyes and the respiratory tract. Eye effects have been reported at concentrations of 20 ppm or below. First-Aid Measures 1. General Principles: in case of exposure to hydrogen sulphide the patient should be removed to fresh air as quickly as possible. The rescuer must be certain that he is adequately protected against breathing the gas.

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2. Contact with skin and mucous membranes: Skin absorption is very low. Skin discoloration is possible after contact with liquid hydrogen sulphide. If such skin contact is suspected, the area should be thoroughly washed. 3. Contact with eyes: Eye contact with liquid and gas will cause painful irritation. In case of eye contact keep patient in darkened room; apply ice compresses; put ice on forehead. Send for physician. Eye irritation caused by exposure to hydrogen sulphide requires treatment by a physician, preferably an eye specialist. 4. Inhalation: A worker who has been overcome by hydrogen sulphide must be carried at once into uncontaminated atmosphere. If breathing has stopped, mouth to mouth resuscitation should be started immediately. If Oxygen inhalation apparatus is available, Oxygen should be administered by a competent person. Keep the patient quiet and warm. Call a physician immediately. Do not give anything by mouth to an unconscious patient.

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SECTION III OVERVIEW OF SRU UPGRADE FACILITIES

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3.1

PROCESS

3.1.1

SRU Upgrade Facilities Overview The following facilities are part of the Sulphur Recovery Upgrade Project: •

New Acid Gas Enrichment Unit (AGEU)

•

New Tail Gas Treating Unit (TGTU)

•

New Tail Gas Incinerator

•

Existing SRU upgrade/modification

•

Existing SRU upgrade - The SRU plant is upgraded to process the acid gas flow from the two AGRU trains, along with the acid gas streams from NGL 1/2/4 units.

•

Utilities System Upgrade: Sea Water Cooling System, Boiler Feed Water System, Steam Generation System, Instrument/Plant Air System, Fuel Gas System, Waste Water System, Electrical Power System, Control & Safety System.

AGEU & TGTU are provided with common Amine System. Proprietary Amine solvent (Dow Ucarsol HS-103) has been selected for this purpose. 3.1.2

Acid Gas Enrichment Unit (AGEU) Lean acid gas enters the unit at a temperature of 53°C and a pressure of 0.55 barg. This stream is cooled in an Acid Gas Coolers (9103-E-101A/B), before passing to the Lean Acid Gas KO Drum (9103-V-14). The Lean Acid Gas KO Drum allows bulk removal of any condensed/entrained liquid from upstream. The liquid level in the Lean Acid Gas KO Drum is controlled by pumping the liquid via the Acid Gas KO Drum Return Pumps (9103-P-14A/B) to the existing MDEA storage tank. Alternatively, the sour water can be routed to the sour water stripper, via a normally closed isolation valve. Vapour leaves the Lean Acid Gas KO Drum and fed to the Acid Gas Amine Absorber (9103-C-11), at the bottom. The vapour passes upwards through a trayed bed in contact with a lean amine solution. The counter current contact with the amine solution essentially removes all the H2S and some of the mercaptans and part of the CO2 from the vapour stream. If any BTEX exists in the lean acid gas, it is expected that 80-90% will slip directly to the Incinerator. Treated gas leaving the top of the absorber (9103-C-11) goes to the Incinerator (9101F-14). The rich amine solution, containing absorbed acid gas, is combined with solvent from the Tail Gas Amine Absorber (9102-C-12). It is removed from the column by the Acid Gas Rich Amine Pump (9103-P-12A/B). This stream is then heated in the Lean/Rich Exchanger, before it is fed to the Amine Regenerator (9103-C-12). The rich amine flow rate is controlled to maintain the level in the Acid Gas Amine Absorber. The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas Treatment Units are shared with the use of a common solvent.

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In the Amine Regenerator, the rich solution is stripped counter currently with vapours generated by the Amine Regenerator Reboiler. The bottom of the column is maintained at a temperature by regulating the LP steam flow rate into the Regenerator Reboiler (9103-E-13). The stripping action in the lower section removes and releases the contaminants from the solution, such as the acid gases, mercaptans and residual dissolved hydrocarbons. The stripped vapours are cooled in the Regenerator Condenser (9103-E-12), and the Regenerator Condenser Trim Cooler (9103-E-16), by regulating air flow by fans in Regenerator Condenser and adjusting the flow rate of Sea water to the Regenerator Condenser Trim Cooler. Any water and amine in the overhead stream is condensed and collects in the Regenerator Reflux Drum (9103-V-12). The reflux flow rate is controlled by maintaining the liquid level in the Regenerator Reflux Drum. Acid gas from the Regenerator Reflux Drum passes overhead to the Sulphur Recovery Unit. Hot lean amine solution from the Regenerator is pumped to the Amine Surge Tank (9103-T-11) by the Hot Lean Amine Pump (9103-P-17 A/B). The Lean/Rich Exchanger (9103-E-11), Lean Amine Cooler (9103-E-14) and Lean Amine Trim Cooler (9103-E-15) cool the solution prior to the Amine Surge Tank. The lean solution from the Amine Surge Tank is pumped to the Acid Gas Amine Absorber and the Tail Gas Amine Absorber via the Lean Amine Pump (9103-P-13A/B). A slipstream is taken off after the pump and returns to the surge tank through the Lean Amine Filter (9103-S-11), Carbon Filter (9103-S-12) and the Fines Filter (9103-S-13). The filters remove particulate matter from the stream as well as hydrocarbons that accumulate in the Amine solution. The Amine Surge Tank (9103-T-11) receives the recycle flow from the filter circuit and the regenerator. It has the capacity to hold the whole system inventory at shut down. The Amine Surge Tank is maintained at a slightly positive pressure, however not high enough to be able to float on the flare header to maintain pressure and stop ingress of Oxygen. Therefore it is provided with Nitrogen blanketing to prevent air ingress and to minimise the risk of solution degradation.

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Fig. 1 – Acid Gas Enrichment Unit

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3.1.3

Sulphur Recover Unit Process Description The acid gas stream from the gas treating plant enters the Acid Gas KO Drum (9101-V04) where acid water is knocked out and pumped to Amine Sump (9103-V-14). The gas stream flows to exchanger (9101-E-06) for preheating before entering the Reaction Furnace (9101-F-01), where the acid gas is burnt by the high intensity burner with a controlled amount of air. Air is supplied by an electrically driven blower (9101-K01A/B) & preheated by exchanger (9101-E-05). The products of the combustion are cooled in passing through the tube section of the Waste Heat Boiler (9101-E-07) where a 24 barg steam is generated in the shell side. Gases and any condensed liquid sulphur from the Waste Heat Boiler flow to the Sulphur Condenser (9101-E-01) where the gases are cooled and the additional sulphur is condensed. The gases then passes through the Auxiliary Burner (9101-F-02) where they are reheated by burning a split stream of acid gas (or fuel gas) with air, before entering the first Claus Converter (9101-V-01). In this converter the gases flow downwards through a bed of CR 4/8 mm activated alumina, top loaded with a layer of AM 4/8 catalyst. In the converter, additional elemental sulphur is produced and carried over in vapour phase by the hot gases. The exothermic Claus reaction results in a temperature increase through the adiabatic converter. The hot gases leaving the first converter are cooled in the Sulphur Condenser (9101-E-02) by generating 5 barg steam, the condensed sulphur flows to the Sulphur Degassing Pit (9101-T-01/01Z) through Sultraps. The gases from the Sulphur Condenser (9101-E-02) flow through a coalescer equipped with SS wire mesh pads for the removal of any entrained sulphur. The gases then passes through the second stage auxiliary burner (9101-F-03) where they are reheated by burning a split stream of acid gas (or fuel gas) with air, before entering the second Claus Converter (9101-V-02), loaded with a more active catalyst CRS 31 and a layer of AM 4/8 mm catalyst on the top of the bed. The Final Condenser (9101-E-04) ensures cooling of the process gases by preheating the boiler feed water which is used in the Waste Heat Boiler (91 01-E-07) and the two LP steam producing 1st stage & 2nd stage condenser (9101-E-01 & 9101-E-02). The process gases from Final Condenser passes through a Final Separator (9101-V-05) to achieve complete removal of liquid sulphur drops from the process gases. A coalescer is provided in Final Separator (9101-V-05). From final separator, the process gas is routed to Incinerator (9101-F-14), where all remaining sulphur compounds are burnt to sulphur dioxide. Incineration is achieved by burning fuel gas with a slight excess of air at a temperature of 800°C. The incinerated gas is disposed of to the atmosphere via stack (9101-X-11). The sulphur produced in the process is extracted from all sulphur condensers through sultraps and is routed to the Sulphur Degassing Pit (9101-T-01). The sulphur is degassed through AQUISULF sulphur degassing process. The degassed sulphur is then transferred to the Storage Tank 9101-T-02 by Sulphur Transfer Pumps (9101-P-04A/B).

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Fig. 2 - Sulphur Recovery Unit

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3.1.4

Tail Gas Treatment Unit (TGTU) The purpose of the Tail Gas Treating Unit is to reduce the hydrogen sulphide concentration in the tail gas to a level corresponding to >99.5% total sulphur recovery. All residual hydrogen sulphide is oxidised to sulphur dioxide before it is released to the atmosphere. The BSR/Amine process consists of a Beavon Sulphur Recovery (BSR) reducing or hydrogenation section and a selective amine section. The process uses the BSR technology to reduce all sulphur compounds in the SRU tail gas to hydrogen sulphide. This section includes water condensation and separation upstream of the amine section with a caustic circulation system to protect against SO2 breakthrough, which degrades the amine and causes severe corrosion. The amine section uses an amine solution to remove most of the hydrogen sulphide from the treated sulphur plant tail gas while minimising the co-absorption of carbon dioxide. The Claus tail gas from the Final Sulphur Condenser 9101-E-04 is fed to the Reducing Gas Generator (RGG). The purpose of the Reducing Gas Generator is to generate reducing gases (H2 and CO). This is achieved by the combustion of fuel gas with a substoichiometric quantity of air. The production of reducing gases is regulated by controlling the flow of the fuel gas and air. Air flow is set by the outlet temperature of the Reducing Gas Generator 9102-F-01 whilst the fuel gas flow rate is set to be a fixed proportion of the air flow. LP steam is fed to the Reducing Gas Generator to suppress the formation of carbon. The flow rate of the steam is ratio-controlled according to the fuel gas flow rate. The tail gas from the Final Sulphur Condenser is mixed with the hot combustion products in the Reducing Gas Generator to ensure a temperature that will favour the desired reactions in the Hydrogenation Reactor (9102-V-01). The Hydrogenation Reactor contains a fixed bed Cobalt/Molybdenum (CoMo) catalyst. The reactions are exothermic resulting in a temperature rise across the reactor. The gas is cooled by the generation of LP steam in the Reactor Effluent Cooler. The tail gas is then desuperheated and the excess water removed in the Desuperheater/Contact Condenser (9102-C-01). This tower contains an upper packed section, a chimney tray and a lower section containing packing and bubble cap trays. In the lower packed section of the tower (Desuperheater section), tail gas is contacted with a circulating stream of a mildly caustic water solution. This removes sulphur dioxide and cools the tail gas down. The Desuperheater Circulation Pump (9102-P11A/B) pumps the caustic water solution from the bottom of the tower to the top of the packing. Water make up is provided to the lower (Desuperheater) section, under level control, from the top (Contact Condenser) section circulation. The solution is maintained at an alkaline pH of around 9.0 to protect against SO2 breakthrough from the reactor. SO2 causes corrosive conditions in the Desuperheater

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Contact Condenser and the Amine Absorber, and degrades the amine. The pH of the circulating liquid is monitored by a continuous analyser and controlled by periodic, manual addition of fresh caustic solution. An intermittent bleed from this section removes accumulated contaminants from the circuit. The desuperheated gas and water vapour then passes through the (wash) bubble cap trays and the chimney tray into the upper (Contact Condenser) packed section. Here the gas is cooled by direct contact with a circulating water stream. The water is pumped by the Cooling Water Circulation Pump from the chimney tray, through the Contact Condenser Cooler where it is cooled, and back to the top of the tower. The water that is condensed in this section is slightly sour. Some is used as make up on demand to the lower Desuperheater section and the remainder is taken off under level control and sent to effluent treatment. The condensed water loop is kept separate from the water in the desuperheater circulation loop to avoid contamination with salt products that may be formed in the Desuperheater section. The tail gas leaves the Desuperheater Contact Condenser (9102-C-11) at a temperature of approximately 40°C and is sent to the Tail Gas Amine Absorber (9102-C-12) which uses a lean amine solution to remove the hydrogen sulphide from the tail gas, whilst minimising the co-absorption of carbon dioxide. The gas enters at the bottom of the absorber and passes through a packed bed counter current to the lean amine solution that preferentially absorbs H2S. The lean amine solution is supplied from the Amine Regenerator. The Tail Gas Rich Amine Pump (9102-P-16 A/B) pumps the rich solvent solution from the bottom of the Tail Gas Amine Absorber (9102-C-12) to the Acid Gas Amine Absorber (9103-C-11) before it is regenerated in the Amine regenerator (9103-C-12). The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas Treatment Units are shared with the use of a common solvent. The H2S that is stripped from the rich amine solution in the Amine Regenerator is fed to the Sulphur Recovery section, thus closing the recycle loop around the SRU and TGTU sections. Treated gas from the Tail Gas Amine Absorber passes to the Incinerator along with that from the Acid Gas Amine Absorber and from the Sulphur Pit. The incinerator is designed to incinerate all sulphur compounds in the streams under normal operation. It is also used to incinerate additional streams while the TGTU is bypassed or during start-up or abnormal operating conditions. The flue gas is released to the atmosphere through the Stack (9101-X-11).

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Fig. 3 - Tail Gas Treatment Unit

FV-1314

XV-1331

LV-1305

FV-1304

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3.1.5

Tail Gas Incinerator An Incinerator is provided to thermally oxidise all possible sulphur compounds to SO2 in off gas effluents from the Acid Gas Amine Absorber, Tail Gas Amine Absorber, SRU tail gases and vent gases from the sulphur Degassing Package. Moreover all BTEX content of off gas effluent is also destructed. To ensure complete combustion of these sulphur compounds the Incinerator's combustion chamber temperature is maintained at a temperature of about 817°C by burning fuel gas supplied with combustion air in the unit's burner. Combustion air is supplied from 2 x 100% Incinerator Air Blowers (9101-K-12 A/B). The flows of fuel gas and combustion air are each measured by flow and then ratio controlled to ensure the correct amount of excess air is always maintained in the Incinerators combustion chamber to allow the oxidation of the sulphur compounds in the tail and vent gases to take place. An Oxygen analyser located in the Incinerator outlet combustion gases ducting monitors the excess O2 in the Incinerators combustion gases. Adjustments may be made to the fuel gas to air ratio controller to ensure the correct excess of O2 (3% by Mol) is seen in the stack gases. A SOX/NOX analysers, located part way up the Incinerator Stack (9101-X-11), monitors the Incinerator stack gases for SOX/NOX content.

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Fig. 4 - Tail Gas Incinerator

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3.1.6

Amine Drain System Amine drained from pumps and other equipment during times of maintenance and plant overhaul, is collected in the Amine Sump. The Amine Sump Pump must be started manual by operations in order to transfer the amine to the Amine System via the Amine Sump Filter. A differential pressure indicator across the filter monitors the filter pressure drop. In the event that the amine sump pump is not manually stopped when the low level alarm is activated then a low low level switch will stop the pump to prevent loss of suction damage to the pump. To prevent air ingress into the amine sump a small flow of Nitrogen is introduced into the amine sump and allowed to pass out of the sump to the atmosphere through carbon canister.

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Fig. 5 - Amine Sump and Pump

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3.2

NEW UTILITY FACILITIES 3.2.1 Instrument and Plant Air The new air compressor package consists of the following: 1.

Two Air Compressors (6837-K-02A/B) having a capacity of 900 Nm3/hr (dry basis)

2.

One air compressor discharge drum, (6837-V-10) is provided •

Two Instrument Air Dryer packages, (6837-A-03/04) running at 2 X 50%, each dryer capacity is 300 Nm3/hr (dry basis)

•

One Instrument Air Receiver (6837-V-11) with storage capacity to provide instrument air for a period of 20 minutes following a compressor trip

The new Air System will supply instrument and plant air with the following supply battery limit conditions for both instrument and plant air: Design

Operating

Pressure bar (g)

9.7

7.0

Temperature (°C)

85

55/60

The new instrument and plant air headers are connected to the existing NGL-3 instrument and plant air headers respectively through cross over connection lines with (manual isolation valves) for operation flexibility.

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Fig. 6 – Plant/Instrument Air System

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3.2.2

Demineralised Water System The supply of fresh water to the new DMW Package is taken from existing Drinking Water Storage Tanks (6834-T-01 A/B) by means of new Drinking Water Feed Pumps (6834-P-23 A/B, one operating, one standby). Each pump is designed for a flow of 10 m3/h and supplies fresh water to the following users: •

Demineralised Water Package

•

Cross connection to the existing fresh water network

•

Utility water to utility stations, safety showers and eye wash stations.

The Demineralised Package is based on ion exchange technology (similar to the existing DMW Package) and consists of two identical trains. The following equipment items are envisaged to form part of the package: •

Two Cation Exchangers

•

Two Anion Exchangers

•

Two Demineralised-Water Regeneration Pumps

•

two Demineralised-Water Recirculation Pumps

•

One Hydrochloric Acid (HCL) Storage Tank

•

There HCL Injection Pumps

•

One Caustic (NaOH) Storage Tank

•

Three NaOH Injection Pumps

•

One Neutralisation Pit

•

One Neutralisation Pump

The DMW Package operates continuously and automatically and thus requires minimum operator intervention. The package includes the necessary control and safety devices. The Demineralised Water from the DMW Package is routed to Demineralised Water Storage Tank (6834-T-08). Capacity of Demineralised Water Storage Tank is 83 m3. Centrifugal type, DMW Feed Pumps (6834-P-24A/B one running, one standby) are used to supply demineralised water at 3.7 barg pressure and ambient temperature, from DMW Storage Tank to the: •

Steam Condensate Flash Drum (6834-V-05)

•

Amine Surge Tank (9103-T-11)

•

Make-up water to Cooling Water Circulation Pump (9102-P-12 A/B)

•

Start-up water to Stripper Overhead Circulation Pump (6922-P-11 A/B)

•

Make-up water to Amine Regenerator Reflux Drum (9103-V-12)

•

Existing DMW Network System (for operational flexibility, normally no flow).

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Fig. 7 – Demineralized Water System

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3.2.3

Sea Cooling Water System Two Seawater Cooling Pumps 6932-P-04A/B are installed on a new jetty and take suction from the sea. The pumps are vertical-shaft, constant speed centrifugal pumps and are electric motor driven. The seawater cooling pumps have a design capacity of 1600 m3/h (each) at a discharge pressure of 5.0 barg. One pump is normally running, while the other is on standby. Each pump is capable of supplying a normal flow of 1200 m3/h to users for SRU upgrade. The water enters the pump through a suction pipe (stilling tube) to reduce turbulence. A coarse mesh bar suction screen is installed at each pump to prevent seaweed and other debris from entering the seawater supply system. From the common discharge of seawater cooling pumps, seawater stream flows via a new dedicated 24” main supply header to the new Filtration Package Unit (6932-S02A/B). The self cleaning rotary type Seawater Filters (one in operation and one on standby) are capable of removing particle sizes greater than 1000 microns from seawater and each unit is designed for a flow of 1600 m3/h. The filtered water from filters is routed to the heat exchangers located in AGEU/TGTU and other users. The filter skid comprises: •

Two Rotary Filters (6932-S-02A/B) and motors

•

The 2 x 100% filters are equipped with an automatic back-flushing mechanism which operates on intermittent basis

A small portion of the main seawater (cooling water) flow is diverted downstream of the filters to provide seawater supply for the Electro Chlorination Unit (6932-A-05). The Electro Chlorination Unit generates sodium hypochlorite solution. The sodium hypochlorite solution is injected into Sea Cooling Water Pumps suction lines to control growth of marine organisms in the Sea Cooling Water System. There is one dedicated new Electro Chlorination Unit. In addition, a dedicated Biocide Injection Unit (6932-A-06) for effective control of growth of marine organisms and a dedicated Scale Inhibitor Injection Unit (6932-A-07) to prevent formation of mineral scales in the Sea Cooling Water system are also provided for existing as well new Sea Cooling Water Systems. The new Cooling Water System is a once through system and the seawater returned from the SRU upgrade facilities is discharged into existing Seawater Observation Sump (6932-X-01) which has a retention capacity of 60 m3. From the sump the seawater overflows to the sea. To prevent fouling the temperature of cooling water from each exchanger outlet should not exceed the maximum allowable temperature limit of 45°C. A tie in to the existing NGL-3/4 seawater supply system is also provided to supply seawater from the new Sea Water Pumps.

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Fig. 8 – Sea Cooling Water System To Existing Sea Cooling Water System

6932-S-02A/B Cooling Water Filters

9103-E-101 Acid Gas Cooler

9103-E-15 Lean Amine Trim Cooler

9103-E-16 Regenerator Condenser Trim Cooler

9102-E-13A/B Contact Condenser Trim Cooler

6848-T-02 Boiler Blow Down Pit

Steam Generation Package Acid Gas Enrichment Unit

6932-A-05 M

M

Electro Chlorination Package

Sea Cooling Water Pumps

6932-P-04A

6932-A-06 Biocide Injection Package

6932-T-01 Local Chemical Drain Pit

6932-P-04B

6932-A-07 Scale Inhibitor Injection Package

Tail Gas Tr. Unit

To Observation Sump 6932-X-01

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TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.4

Boiler Feed Water System Boiler Feed Water (BFW) is required for the generation of MP and LP steam in the gas fired water Steam Generators (6848-A-02 A/B/C). The Boiler Feed Water, consists of a mixture of LP steam condensate and Demineralised Water make-up. The Boiler Feed Water system includes the following equipment: Description Steam condensate Flash Drum Deaerator Feed Pumps

Equipment Tag No. 6834-V-05 6834-P-20A/B

Steam Condensate Cooler

6834-E-02

Boiler Feed Water Deaerator Package

6834-A-08

Boiler Feed Water Pumps BFW Chemical Injection Package • O2 Scavenger Injection Pumps • Complex Product Injection Pumps

6834-P-22 A/B/C 6834-A-09

The Boiler Feed Water passes through a Steam Condensate Flash Drum 6834-V-05 where the flash steam cools down the inventory to 102°C to prevent cavitations in Deaerator Feed Pumps. The DMW Condensate is pumped by the Deaerator Feed Pumps to the heating section of a Thermal Deaerator where all the free carbon dioxide and the oxygen up to 5 ppb are removed by heating and scrubbing the water with the LP saturated steam at 0.2 barg pressure. The extracted dissolved gases such as O2, CO2 and water vapour are discharged through restriction orifice (68-RO-1305) to atmosphere. A dose of Oxygen Scavenger is injected into the hold up section of the Deaerator to completely eliminate the residual oxygen from the water. The capacity of the holding section in the Deaerator is equivalent to 20 minutes.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 9 – Boiler Feed Water System

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TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.5

Steam Generation Package 6848-A-02A/B/C The MP steam boiler package 6834-A-02A/B/C includes three boilers, two operating and one stand-by. Each boiler has a nominal steam generating capacity of 45 T/h. The Boiler Feed Water enters the external Economizer 6848-E-01A, which is a finned tubes heat exchanger (water/flue gas). The feed water is heated by the flue gas thermal heat in the flue gas path. In case sour fuel gas is used, the boiler feed water is sent to a preheating water circuit installed inside the water drum, before going to the Economiser 6848-E-01A. This is to avoid acid condensation inside the flue gas duct. From the Economizer outlet, the feed water enters into the boiler upper drum called “Steam Drum” 6848-V-02A. Boiler functioning relies on “steam/water natural circulation”, with evaporating rising circuits formed by the hottest tubes of boiler evaporating bank. Remaining tubes acts as downcomers, which feed the rising circuits. In the boiler evaporating tubes, the mixture of saturated water & steam is produced. Then through the steam drum internal separators, the saturated steam is separated from the saturated water droplets. The steam then passes through the steam header and reaches the temperature and pressure controlling stations. The pressure is controlled by a pressure control valve 68-PV-1524 and the temperature is controlled by water injection type Desuperheater 6848-X-03A. The combustion air for the boiler is supplied by a Forced Draft Fan 6848-K-02A, driven by an electric motor. At the inlet of the FD Fan 6848-K-02A, a Grid Filter 6848—03A, a Sand Filter 6848-S-02A and a silencer 6848-X-06A are provided. Downstream of this, the modulating inlet control damper is provided. At the outlet the air passes through a duct that delivers air to wind box. The combustion air measuring device 68-FE-1526 is provided in this duct. Air is supplied to the burners through the wind box. When the combustion takes place, the high temperature flue gas pass through the boiler furnace, enclosed by water cooled tubes. The flue gases at the end of the combustion chamber, turn to 180° and pass through the evaporative convective section. The convective section is located on the right side of the furnace. The flue gases then pass through the Economizer and reach the stack. A Flue Gas Recirculation Fan 6848-K-03A, which takes suction from the flue gas Economizer downstream duct and discharges to the combustion air measuring device 68-FE-1526 provided in combustion air duct, is provided. In order to meet the specified low emissions target, at high boiler load, the burners can be operated in flue gas recirculation mode, the combustion air is mixed with a proper flue gas flow rate (about 15% of nominal flow rate).

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TITLE: OPERATION AND MAINTENANCE MANUAL

The steam generator is provided with one burner, designed to burn both sour and sweet fuel gas. The burner is designed to have a turndown of 10:1. Burner is provided with a pilot which is of high energy type.

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TITLE: OPERATION AND MAINTENANCE MANUAL

XV-1527

TV-1522

PV-1523

Fig. 10 – Steam Generation System

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TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.6

Fuel Gas System LP fuel gas is required for • New Steam Generation Boilers 6848-A-02A/B/C The main normal LP fuel gas supply for the new MP Steam Boiler Package (6848-A-02A/B/C) and Waste Water Degasser (6922-V-07) blanketing is supplied from the first stage suction of the existing Booster Compressors (6701-K-10120/30) in NGL-3. In addition, two back up sources are provided; the first is the fuel gas from (6103-K-01 A/B) with a second backup from existing 30” line to Point B. The new fuel gas supply system will consist of a letdown station, Fuel Gas KO Drum (6236-V-05), and a supply header to the Steam Boilers and Waste Water Degasser. The source pressure from the take-off point is let down to 7 barg through the pressure control valve 62-PV-1301A before entering the LP Fuel Gas KO Drum. The source pressure of the fuel gas from 6103-K-01 A/B is 20 barg whilst that of feed gas from the 30” line is 45 barg. The former is let down to 7 barg through the pressure control valve 62-PV-1301 B and the latter via 62-PV-1302.

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 11 – Fuel Gas System PV-1303

Hydro Carbon Gas Flare Header

To LP Flare

To Steam Boiler Package 6848-A-02A/B/C XV-1301

PV-1301A

From 1st Stage Booster Compressor (6701-K-10/20/30) Suction Header

To LP Hydrocarbon Flare Header

E-19

LP Fuel Gas KO Drum

6236-V-05 XV-1302

PV-1301B

Backup Supply Fuel Gas from 6103-K-01A/B

XV-1303

PV-1302 To Flare Header

Backup Supply Fuel Gas from 30" Existing Line

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TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.7

Effluent and Waste Water Treatment Unit The sour water resulting from the new facilities added as part of the SRU Upgrade Project contains high levels of dissolved sulphides which need to be removed before the waste water can be discharged to the marine environment. The acceptable levels of sulphides is 0.1 mg/l (0.1 ppmw) and to achieve this the sour water is treated in the sour water treatment system. Sour water from various sources is collected in the Degassing Drum, which provides over 20 minutes of hold-up for the waste water. The flow of waste water from Desuperheater/Contact Condenser (9102-C-11) is continuous at a rate of 8.7 m3/h whilst all other sources are intermittent. The sour water from the degasser is continuously pumped under flow control by Waste Water Degasser Pumps (6922-P08A/B) to the Sour Water Stripper Unit for treatment. In the event the Sour Water Treatment System is unavailable due to a process upset, provision exists for manually routing the degasser liquids directly to the Observation Sump (6922-X-04). A balance line between Degassing Drum and Sour Water Stripper 6922-C-01 means that the pressure in the Degassing Drum floats on the stripper operating pressure (i.e. 1.0 barg). A nitrogen supply line is provided to maintain pressure in the drum if it falls below a certain minimum as liquids are pumped out. The sour water from degasser drum is filtered in 6922-S-06 and then preheated in Sour Stripped Water Exchanger 6922-E-01 before feeding to Sour Water Stripper 6922-C-01. The Sour Water Stripper operates at 1.0 barg and has an upper section and a lower tray section. The sour water is stripped by the vapours generated from the Sour Water Stripper Reboiler 6922-E-04. The Reboiler utilises LP steam to heat the sour water that comes from the bottom of the Sour Water Stripper to 126⁰C. The condensed steam from the Reboiler is sent to the LP Condensate system through level control. Reflux for the column is provided by a pump-around system. Water is taken from below tray 33 pumped by Stripper Overheads Circulation Pumps 6922-P-11A/B under flow control, cooled in Stripper Overheads Cooler 6922-E-03 and then returned to the top tray. The stripper overhead acid gases are routed to the AGEU (upstream of 9103-V-14). In the event of high column pressure, excess gases are diverted to LP Acid Gas flare. The stripped water from the stripper is pumped under level control cascaded to a flow controller via Stripped Water Pump 6922-P-10A/B to the Sour/Stripped Water Exchanger 6922-E-01 to preheat the feed to the stripper. The water is then routed to the Stripper Water Cooler 6922-E-02 where it is cooled to 55°C before discharge to the Observation Sump. An analyser is provided in the line to the Observation Sump to monitor the sulphide content of the stripped water stream.

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 12 – Waste Water Treatment Unit Balance Line LP Fuel Gas from 6236-V-05 PV 1315A

PV-1307 Waste Water from Cooling Water Circulation pumps 9102-P-12A/B

PV 1315B

Sour Gas to TGTU

To LP Acid Gas Flare

XV 1312 PV 1307

Pressurised drain from 9102-P-12A/B

Stripper Overheads Cooler 6922-E-03

XV 1313

M

LV-1325

Water for Startup

Sour Water from Regenerator Reflux Drum 9103-P-11A/B

Corrosion Inhibitor

NC

Waste Water Degasser 6922-V-07

FV 1316

FV 1314

Waste Water Stripper 6922-C-01

Stripper Overheads Circulation Pumps 6922-P-11 A/B TV 1327

Sour Water Stripper Reboiler 6922-E-04

Waste Water Degasser Pumps 6922-P-08A/B

Sour Water Filter 6922-S-06

Sour Stripped Water Exchanger 6922-E-01

Desuperheater FV 1315 6922-X-01

From LP Steam

Reboiler Condensate Drum 6922-V-09 LV 1327

LP Condensate

Stripped Water Pumps 6922-P-10A/B

Stripped Water Cooler 6922-E-02

M

FV 1317

Stripped Water to Observation Sump 6922-X-04

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

3.3

FIRE WATER & DELUGE SYSTEM

3.3.1

Fire Water System The fire water ring main for the new Process facilities is connected to the existing 12” ring main and tie-in provided at two existing fire water ring mains 12”-6533-FW-001C12T & 12”-6533-FW-002-C12T. The fire water ring main for the new Utilities is connected to the existing 12” ring main and tie-in provided at two existing fire water ring mains 12”-6533-FW-006-C121 & 12”-6533-FW-107-C120. Fire water ring main is buried with minimum 1 meter cover. Ring main block valves are post indicator type and accessible from surface. Fire hydrants and monitors are located at 1.5 m from road. If the distance is shorter, a crash barrier is provided. The fire hydrants and monitors are located at 15 m from plant/equipment/buildings they intended to protect. All fire hydrants face the plant equipment. Fire hydrants are 4-way outlet hydrant valves with (1000 LPM) inbuilt pressure regulating device. Each hydrant is provided with 6” riser pipe bib nosed 3” branch inlet and 2.5” instantaneous hose connection. Monitors are suitable for manual operation with locking facilities in both horizontal and vertical planes. It is capable of 360° horizontal movement and elevation 75° above and 30° below the horizontal.

3.3.2

Deluge System Deluge Skid is used in the new facilities as per details below. Deluge Skid No. 91-DV-1711

Deluge Valve Size 4”

Equipment protected Hydrogenation Reactor (9101-V-11) Acid Gas Cooler (9103-E-101)

91-DV-1712

8”

Lean Acid Gas KO Drum (9103-V-14) Acid Gas Amine Absorber (9103-C-11)

Deluge valves are activated by: •

Automatically activated upon fire detection via F&G System/fusible plug loop

•

Manually locally activated by hand lever through HCV/Push button at safe distance

•

Manually/remotely activated from F&G console.

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

LC

NC

Air Vessel 6 Lit. Capacity

LO

Fig. 13 – Deluge Valve Typical Installation

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TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION IV

PROCESS AND CONTROL DESCRIPTION

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.1 4.1.1

ACID GAS ENRICHMENT UNIT (AGEU) Equipment Specification Acid Gas Coolers Equipment Tag No. Process Medium (Shell/Tube)

9103-E-101A/B Acid Gas/Sea Water

Design Pressure Shell Side, barg

6.2

Design Pressure Tube Side, barg

8.0

Design Temperature Shell Side, (Max./Min.), °C

175/0

Design Temperature Tube Side, (Max./Min.),°C

85/0

Operating Pressure Shell/Tube Side, barg

0.51/1.7

Operating Temperature, Shell Side (In/Out) °C

63/53

Operating Temperature, Tube Side (In/Out) °C

35/41.76

Design Duty, kW Material of Construction, Shell/Tube

164 SS316L/Titanium Grade 2

Lean Acid Gas KO Drum Equipment Tag No.

9103-V-14

Tower Diameter/Height, mm

3000/7000

Process Medium

Acid Gas

Design Pressure, barg

3.5/FV

Design Temperature, °C (Max./Min.)

175/0

Operating Pressure, barg Operating Temperature, °C Material of Construction, Shell/Internals

0.38 53 CS/SS316L

Acid Gas KO Drum Return Pump Equipment Tag No. Process Medium 3

9103-P-14A/B Sour Water

Capacity, m /hr (Normal/Rated)

5/6.7

Driver Type

Motor

Rated Power, kW Suction Pressure, bar(a) (Rated/Max.)

7.5 1.66/5.23

Discharge Pressure, bar(a)

5.0

Operating Temperature, °C

49

Design Temperature, °C (Max./Min.) Material of Construction - Casing/Impeller

85/0 A351-CF8M/SS316L

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TITLE: OPERATION AND MAINTENANCE MANUAL

Acid Gas Amine Absorber Equipment Tag No.

9103-C-11

Tower Diameter, mm

4100

Tower Height, mm

20040

Tray Nos.

10

Process Medium

Acid Gas/MDEA

Design Pressure, barg (Max./Min.)

3.5/FV

Design Temperature, °C (Max./Min.)

175/0

Operating Pressure, Top/Bottom, barg Operating Temperature, Top/Bottom, °C Material of Construction, Top section Material of Construction, Bottom section Material of Construction, Internals

0.19/0.38 46/58.1 CS+SS316L CLAD CS SS316L

Acid Gas Rich Amine Pumps Equipment Tag No. Process Medium 3

Capacity, m /hr (Normal/Rated) Driver Type Rated Power, kW Suction Pressure, bar(a) (Rated/Max.)

9103-P-12A/B Rich Amine 682/750.2 Motor 195 1.99/6.1

Discharge Pressure, bar(a)

8.5

Operating Temperature, °C

56

Design Temperature, °C (Max./Min.) Material of Construction Casing/Impeller

85/0 A351-CF8M/SS316L

Lean/Rich Amine Exchanger Equipment Tag No. Process Medium

9103-E-11A/B Rich Amine/Lean Amine

Design Pressure Lean Amine Side, barg

14.3

Design Pressure Rich Amine Side, barg

13.6

Design Temperature (Max./Min.)°C Operating Pressure Lean/Rich Amine Side bar(g)

150/0 5.8/5.32

Operating Temperature, Lean Amine Side (In/Out) °C

129/85

Operating Temperature, Rich Amine Side (In/Out) °C

55/101

Design Duty, kW

34669

Material of Construction, Plates

SS 316L

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TITLE: OPERATION AND MAINTENANCE MANUAL

Amine Regenerator Equipment Tag No.

9103-C-12

Tower Diameter, mm

5650

Tower Height, mm

24450

Tray Nos.

24

Design Pressure, barg (Max./Min.)

7.0/FV

Design Temperature, °C (Max./Min.)

175/0

Operating Pressure, Top/Bottom, bar(a)

2.21/2.44

Operating Temperature, Top/Bottom, °C

118/131

Material of Construction, Top section Material of Construction, Bottom section Material of Construction, Internals

CS+SS316L CLAD CS SS316L

Hot Lean Amine Pumps Equipment Tag No. Process Medium 3

Capacity, m /hr (Normal/Rated) Driver Type Rated Power, kW Suction Pressure, bar(a) (Rated/Max.)

9103-P-17A/B Lean Amine 717/789 Motor 195 2.84/8.9

Discharge Pressure, bar(a)

7.8

Operating Temperature, °C

131

Design Temperature, °C (Max./Min.) Material of Construction Casing/Impeller

150/0 A351-CF18M/SS316L

Regenerator Condenser Cooler Equipment Tag No. Type Process Medium

9103-E-12 Forced Draft Air Cooler Acid Gas

No. of Fans

12

Fan Power, kW/Fan

22

Design Pressure, barg

7.0/FV

Design Temperature (Max./Min.)°C

175/0

Operating Pressure bar(a)

2.18

Operating Temperature, (In/Out) °C

118/54

Design Duty, kW

18574

Material of Construction, Header & Tubes

Alloy 825

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TITLE: OPERATION AND MAINTENANCE MANUAL

Regenerator Condenser Trim Cooler Equipment Tag No. Process Medium (Shell/Tube)

9103-E-16 Acid Gas/Sea Water

Design Pressure Shell Side barg (Max./Min.)

8.0/FV

Design Pressure Tube Side barg (Max./Min.)

8.0/FV

Design Temperature Shell Side(Min./Max.) °C

150/0

Design Temperature Tube Side (Min./Max.) °C

85/0

Operating Pressure Shell/Tube Side, barg

1.07/5.0

Operating Temperature, Shell Side (In/Out) °C

54/49

Operating Temperature, Tube Side (In/Out) °C

35/42

Design Duty, kW Material of Construction Shell/Tube

271 SS316L/Titanium Grade-2

Regenerator Reflux Drum Equipment Tag No. Process Medium

9103-V-12 Acid Gas

Drum Diameter, mm

1500

Drum Height, mm

4520

Design Pressure, barg (Max./Min.)

7.0/FV

Design Temperature, °C (Max./Min.)

175/0

Operating Pressure, barg Operating Temperature, °C Material of Construction

1.02 49 SS316

Regenerator Reflux Drum Pumps Equipment Tag No. Process Medium Capacity, m3/hr (Normal/Rated) Driver Type Rated Power, kW Suction Pressure, bar(a) (Rated/Max.) Discharge Pressure, bar(a) Operating Temperature, °C Design Temperature, °C (Max./Min.) Material of Construction, Casing/Impeller

9103-P-11A/B Regenerator Reflux Liquid 26.15/31.4 Motor 22 2.27/8.6 8.41 49 85/0 A351-CF8M/SS316L

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TITLE: OPERATION AND MAINTENANCE MANUAL

Regenerator Reboiler Condensate Pot Equipment Tag No. Process Medium Drum Diameter, mm Drum Height, mm Operating Pressure, barg Operating Temperature, °C Design Pressure, barg (Max./Min.) Design Temperature, °C (Max./Min.) Material of Construction

9103-V-13 Condensate 2100 4100 4.5 155 7.0/FV 185/0 CS

Regenerator Reboiler Equipment Tag No. Process Medium Design Pressure, Shell Side, barg Design Pressure, Tube Side barg Design Temperature, Shell side °C Design Temperature, Tube side °C Operating Pressure, Shell, Side barg Operating Pressure, Tube Side barg Operating Temperature, Shell side °C Operating Temperature, Tube side °C Design Duty, kW Material of Construction, Shell side Material of Construction, Tube side

9103-E-13 Amine 7.0/FV 7.0/FV 150/0 185/0 1.356 4.5 130 159 48413 CS SS316L

Lean Amine Cooler Equipment Tag No.

9103-E-14

Process Medium

Lean Amine

Design Pressure, barg, (Max./Min.)

14.3/FV

Design Temperature °C

175/0

Operating Pressure barg

4.3

Operating Temperature °C

85

Design Duty, kW Material of Construction

30318 Header/Tubes

Alloy 825

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Lean Amine Trim Cooler Equipment Tag No. Process Medium

9103-E-15 Lean Amine

Design Pressure, Lean Amine Side, barg

14.3

Design Pressure, Sea Water Side, barg

8.0

Design Temperature Lean Amine Side °C

90/0

Design Temperature Sea Water Side °C

85/0

Operating Pressure Lean Amine Side barg

5.30

Operating Pressure Sea Water (In/Out) Side barg

2.6

Operating Temperature, Lean Amine Side (In/Out) °C

54/45

Operating Temperature, Sea Water Side (In/Out) °C

35/45

Design Duty, kW

6821

Material of Construction, Plates

Titanium SB265

Amine Surge Tank Equipment Tag No. Process Medium Size (ID/Height), mm Design Pressure, barg (Max./Min.)

9103-T-11 MDEA 1100/5500 0.075/-0.005

Design Temperature, °C (Max./Min.)

85/0

Operating Pressure, barg

0.02

Operating Temperature, °C

45

Material of Construction

CS

Lean Amine Pumps Equipment Tag No. Process Medium 3

Capacity, m /hr, Normal/Rated Driver Type Rated Power, kW Suction Pressure, bar(a) (Rated/Max.)

9103-P-13A/B Lean Amine 835/919 Motor 240 1/1.59

Discharge Pressure, bar(a)

7.50

Operating Temperature, °C

45

Design Temperature, °C

85

Material of Construction, Casing/Impeller

A351-CF8M/SS316L

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TITLE: OPERATION AND MAINTENANCE MANUAL

Lean Amine Filter Equipment Tag No. Process Medium

9103-S-11 Lean Amine

Operating Pressure, barg

2.8

Clean Pressure drop, bar

0.1

Max. Allowed Pressure drop, bar, dirty

0.7

Operating Temperature, °C

45

Design Temperature, °C Design Pressure, barg 3

85/0 9.4

Flow rate, m /hr

184

Material of Construction

CS

Activated Carbon Filter Equipment Tag No. Process Medium

9103-S-12 Lean Amine

Operating Pressure, barg

2.1

Clean Pressure drop, bar

0.3

Max. Allowed Pressure drop, bar

0.7

Operating Temperature, °C

45

Design Temperature, °C

85/0

Design Pressure, barg

9.4

Flow rate, m3/hr

184

Material of Construction

CS

Fines Filter Equipment Tag No. Process Medium

9103-S-13 Lean Amine

Operating Pressure, barg

1.4

Clean Pressure drop, bar

0.1

Max. Allowable Pressure drop, bar

0.7

Operating Temperature, °C

45

Design Temperature, °C Design Pressure, barg 3

85/0 9.4

Flow rate, m /hr

184

Material of Construction

CS

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TITLE: OPERATION AND MAINTENANCE MANUAL

Amine Sump Equipment Tag No. Process Medium Vessel size (ID/T/T) mm

9103-V-10 MDEA 4200/8500

Design Temperature, °C (Max./Min.)

175/0

Design Pressure, barg (Max./Min.)

7.0/FV

Operating Temperature, °C

Ambient

Operating Pressure, barg

0.05

Material of Construction

CS

Amine Sump Pump Equipment Tag No. Process Medium 3

Capacity, m /hr (Normal/Rated) Driver Type

9103-P-15 Amine 11.8 Motor

Rated Power, kW Suction Pressure, bara, Max./Rated Operating Temperature, °C Design Temperature, °C (Max./Min.) Material of Construction, Casing/Impeller

15 8.4/1.03 20 175/0 A351-CF8M/SS316L

Amine Sump Filter Equipment Tag No. Process Medium Size (ID/T/T), mm Design Temperature, °C Design Pressure, barg 3

9103-S-14 Amine 308/920 175/0 17.7

Flow rate, m /hr

10

Material of Construction

CS

4.1.2

AGEU PROCESS DESCRIPTION & CONTROL

4.1.2.1

Acid Gas Enrichment Unit Process Chemistry

The function of the amine solvent is: To enrich the week acid gas stream from the upstream gas sweetening units in an Acid Gas Amine Absorber so that the H2S content of the acid gas is increased to a point that will make the gas easier to process in the downstream SRU. The H2S in the acid gases from the upstream gas sweetening unit are absorbed by amine solvent in the Acid Gas Amine Absorber. Similarly the H2S gases produced in the

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TGTU are absorbed by amine in the Tail Gas Amine Absorber. The combined rich amines from both the absorber are routed to the Amine Regenerator where the H2S is stripped from the amine by heating. The stripped gases from the regenerator system are routed to SRU. Hydrogen Sulphide, H2S or HSH is a weak acid and ionizes in water to form hydrogen ions and sulphide ions. H+ + SH-

HSH

Since it is a weak acid, only a small fraction of the HSH will ionize. Ethanolamines are weak bases and ionize in water to form amine ions and hydroxyl ions: (CH3)z

(CH3)z







(CH2OHCH2)x NHy + H2O Where for MDEA x = 2, y = 0, z = 1

(CH2OHCH2)x NHy+1 + OH-

When H2S dissolves into the solution containing the amine ions, it will react to form a weakly bonded salt of the acid and the base. (CH3)z

(CH3)z







(CH2OHCH2)x NHy+1 + SH(CH2OHCH2)x NHyS The sulphide ion is thus absorbed by the amine solution. This salt formation reaction does not go to completion. As the arrow indicates, and equilibrium level of sulphide ion, SH- remains in the sour gas stream. The overall reaction can be summarized by the following equation: (CH3)z


(CH3)z


(CH2OHCH2)x NHy + H2S (CH2OHCH2)x N HyS Operating variables are adjusted to favour the forward reaction (absorption process) and conversely, adjusted to favour the reverse reaction (regeneration process). 4.1.2.2

Acid Gas Enrichment Unit Process Description

Lean acid gas enters the unit at a temperature of 53°C and a pressure of 0.55 barg. This stream is cooled in Acid Gas Coolers (9103-E-101A/B), before passing to the Lean Acid Gas KO Drum (9103-V-14). The Acid Gas Coolers (9103-E-101A/B) are cooled by sea cooling water. The outlet temperature of the Acid Gas Coolers (9103-E-101A/B) is maintained at 49°C.

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The Lean Acid Gas KO Drum allows bulk removal of any condensed/entrained liquid from upstream. The liquid level in the Lean Acid Gas KO Drum is controlled by pumping the liquid through the Acid Gas KO Drum Return Pumps (9103-P-14A/B) to the existing MDEA storage tank. Alternatively, the sour water can be routed to the sour water stripper, through a normally closed isolation valve. Vapour leaves the Lean Acid Gas KO Drum and fed to the Acid Gas Amine Absorber (9103-C-11), at the bottom. The vapour passes upwards through a trayed section in contact with a lean amine solution. The counter current contact with the amine solution essentially removes all the H2S and some of the mercaptans and part of the CO2 from the vapour stream. If any BTEX exists in the lean acid gas, it is expected that 80-90% will slip directly to the Incinerator. The Acid Gas Amine Absorber (9103-C-11) consists of 10 numbers of valved trays. The feed gas enters below the bottom of the bottom tray. The lean amine enters over the top of the top tray. Lean amine flow to the Acid Gas Amine Absorber is controlled by the flow controller 91-FIC-1501; set point for the controller 91-FIC-1501 is calculated in the block 91-FFY1502 by multiplying the acid gas/lean amine ratio set point (0.02) provided through 91-HIC-1502, with the pressure and temperature compensated acid gas flow (91-FY1502). 91-FIC-1501 regulates the lean amine flow to the acid gas amine absorber via the control valve 91-FV-1501. Acid gas amine absorber (9103-C-11) top pressure is controlled at 0.2 barg by the pressure controller 91-PIC-1502. The pressure is maintained through the pressure control valve 91-PV-1502 located in the treated gas line to the Incinerator. Rich amine from the Tail Gas Amine Absorber enters at the bottom of the column. Treated gas leaving the top of the absorber (9103-C-11) goes to the Incinerator (9101-F-14). The rich amine solution, containing absorbed acid gas, is combined with solvent from the Tail Gas Amine Absorber (9102-C-12). It is removed from the column by the Acid Gas Rich Amine Pump (9103-P-12A/B). This stream is then heated in the Lean/Rich Exchanger, before it is fed to the Amine Regenerator (9103-C-12). The rich amine flow rate is controlled to maintain the level in the Acid Gas Amine Absorber. The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas Treatment Units are shared with the use of a common solvent. The Amine Regenerator 9103-C-12 consists of 24 numbers of valved trays and one chimney tray. The rich amine enters over the top of the 3rd tray from the top. The rich amine flow is controlled by the flow controller 91-FIC-1520B. The pressure of the Regenerator is controlled by supplying nitrogen through a pressure controller 91-PIC1539. The Regenerator Reboiler vapours enter the bottom of the vessel.

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The Reboiler is heated by LP Steam which is drawn from the steam distribution header. Steam flow to the Regenerator Reboiler is controlled by 91-FIC-1503 which regulates the control valve 91-FV-1503. Set point-1 (SP1) for the steam flow control is received from the calculation block 91-FFY-1503A which multiplies the rich amine flow controller 91-FIC-1520A output and manually provided set ratio (118.5) between steam and rich amine through 91-HIC-1503. Set point-2 (SP2) is received from the output of the Regenerator overhead temperature controller 91-TIC-1510. During normal operation SP1 take precedence and when the temperature of the Regenerator over head reaches more than 118°C SP2 will take precedence. In the Amine Regenerator, the rich solution is stripped counter currently with vapours generated by the Amine Regenerator Reboiler. The bottom of the column is maintained at a temperature by regulating the LP steam flow rate into the Regenerator Reboiler (9103-E-13). The stripping action in the lower section removes and releases the contaminants from the solution, such as the acid gases, mercaptans and residual dissolved hydrocarbons. The stripped vapours are cooled in the Regenerator Condenser Cooler (9103-E-12), and the Regenerator Condenser Trim Cooler (9103-E-16), by regulating air flow by fans in Regenerator Condenser Cooler and adjusting the flow rate of Sea water to the Regenerator Condenser Trim Cooler. Any water and amine in the overhead stream is condensed and collects in the Regenerator Reflux Drum (9103-V-12). The liquid collected from the Regenerator Reflux Drum is pumped by the Regnerator Reflux Drum Pumps 9103-P-11 A/B back to the Regenerator. There is a provision to send the liquid to the Waste Water Degasser 6922-V-07. The reflux flow rate is controlled by maintaining the liquid level in the Regenerator Reflux Drum. Acid gas from the Regenerator Reflux Drum passes overhead to the Sulphur Recovery Unit. Hot lean amine solution from the Regenerator is pumped to the Amine Surge Tank (9103-T-11) by the Hot Lean Amine Pump (9103-P-17 A/B). The Lean/Rich Exchanger (9103-E-11), Lean Amine Cooler (9103-E-14) and Lean Amine Trim Cooler (9103-E-15) cool the solution prior to the Amine Surge Tank. The lean solution from the Amine Surge Tank is pumped to the Acid Gas Amine Absorber and the Tail Gas Amine Absorber via the Lean Amine Pump (9103-P-13A/B). A slipstream is taken off after the pump and returns to the surge tank through the Lean Amine Filter (9103-S-11), Activated Carbon Filter (9103-S-12) and the Fines Filter (9103-S-13). The filters remove particulate matter from the stream as well as hydrocarbons that accumulate in the Amine solution. The Amine Surge Tank (9103-T-11) receives the recycle flow from the filter circuit and the Regenerator. It has the capacity to hold the whole system inventory at shut down. The Amine Surge Tank is maintained at a slightly positive pressure, however not high enough to be able to float on the flare header to maintain pressure and stop ingress of Oxygen. Therefore it is provided with Nitrogen blanketing to prevent air ingress and to minimise the risk of solution degradation.

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All the amine drains from the unit is collected in the Amine Sump 9103-V-10. The collected amine is pumped to the Amine Surge Tank through the amine filters. The amine sump is blanketed with nitrogen at a slightly positive pressure. 4.1.2.3

Acid Gas Enrichment Unit Process Control

4.1.2.3.1

Lean Acid Gas Knock Out Drum Level Control

Lean acid gas knock out drum (9103-V-14) level is maintained by ON/OFF gap controller 91-LIC-1501 which controls the acid gas KO drum return pumps (9103-P-14 A/B) & the discharge line control valve 91-LV-1501. 91-LIC-1501 controls the ON/OFF of Acid Gas Knock Out Drum Return Pumps and discharge line valve by sending the signal 0% or 100%. High level of the level controller 91-LIC-1501 starts the duty Acid Gas Knock Out Drum Return Pump & opens the level control valve 91-LV-1501. Low level of the controller closes the level control valve 91-LV-1501 and stops the duty Acid Gas Knock Out Drum Return Pump. Acid Gas Knock Out Drum Return pumps ON or OFF can be done by the controller only when the pumps are in auto mode which is selected through the switch (91-HS-1562 & 91-HS-1563). Controller Tag 91-LIC-1501

Control Description

Unit

Lean Acid Gas KO Drum level control

%

Alarm Low

High

12

37

•

High high level alarm (91-LAHH-1502) in Lean acid gas KO drum closes the acid gas block valve 91-XV-1501

•

Low low level alarm (91-LALL-1503) in Lean acid gas KO drum trips the acid gas return pumps (9103-P-14A/B) and closes the on/off valve 91-XV-1503 located at the liquid outlet line from acid gas KO drum (downstream of the control valve 91-LV-1501)

•

Acid Gas KO Drum Return Pumps discharge control valve 91-LV-1501 closes on instrument air failure

4.1.2.3.2

Acid Gas Absorber Top Pressure Control

Acid gas amine absorber (9103-C-11) top pressure is controlled by the pressure controller 91-PIC-1502. The pressure is maintained through the pressure control valve 91-PV-1502 located in the treated gas line to the Incinerator. Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

91-PIC-1502

Amine absorber top pressure control

bar(g)

0.2

NA

NA

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Acid gas amine absorber top pressure control valve 91-PV-1502 opens on instrument air failure. 4.1.2.3.3

Acid Gas/Lean Amine Flow Ratio Control

Acid gas flow to the acid gas amine absorber (9103-C-11) is measured by 91-FT-1502. Lean amine flow to the Acid Gas Amine Absorber is controlled by the flow controller 91-FIC-1501; set point for the controller 91-FIC-1501 is calculated in the block 91-FFY-1502 by multiplying the acid gas/lean amine ratio set point (0.02) provided through 91-HIC-1502, with the pressure and temperature compensated acid gas flow (91-FY-1502). 91-FIC-1501 regulates the lean amine flow to the acid gas amine absorber via the control valve 91-FV-1501. Control Loop Controller Tag 91-FIC-1501

Control Description Lean amine flow to absorber

Unit 3

m /hr

Alarm

Operating Set Point

Low

High

487

390

536

•

High high level alarm (91-LAHH-1504) in Acid Gas Amine Absorber bottom closes the lean amine ON/OFF valve 91-XV-1504 located at the downstream of 91-FV-1501.

•

Lean amine flow control valve 91-FV-1501 to acid gas amine absorber closes on instrument air failure.

4.1.2.3.4

Acid Gas Amine Absorber Level Control

Rich amine solution from the TGTU Tail Gas Amine Absorber combines with the rich amine at the bottom section of the Acid Gas Amine Absorber. The master level controller 91-LIC-1505 controls the rich amine level at the bottom of the Acid Gas Amine Absorber by controlling the cascaded slave rich amine flow controller 91-FIC-1520B, which regulates the Acid Gas Rich Amine Pumps (9103-P12A/B) discharge flow to Amine Regenerator 9103-C-12 via Lean/Rich Amine Exchanger 9103-E-11A/B through the control valve 91-FV-1520 located at the inlet of the Amine Regenerator 9103-C-12. Controller Tag

•

Control Description

91-LIC-1505

Absorber level control

91-FIC-1520B

Rich amine flow to Amine Regenerator

Alarm

Unit

Operating Set Point

Low

High

%

50

12

86

m3/hr

635

500

NA

High high level alarm (91-LAHH-1504) in Acid Gas Amine Absorber bottom activates the ESD Level-2 shutdown

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Low low level alarm (91-LALL-1516) in Acid Gas Amine Absorber bottom trips the Acid Gas Rich Amine Pumps (9103-P-12A/B)

•

Rich amine flow control valve 91-FV-1520 to Amine Regenerator closes on instrument air failure.

4.1.2.3.5

Acid Gas Rich Amine Pumps Minimum Flow Control

Acid Gas Rich Amine Pumps (9103-P-12A/B) discharge flow is measured by 91-FT-1508 and minimum flow to Acid Gas Amine Absorber bottom is controlled by 91-FIC-1508. The controller 91-FIC-1508 controls the pump minimum flow control valve 91-FV-1508 to Acid Gas Amine Absorber bottom. Controller Tag 91-FIC-1508

Control Description Acid Gas Rich Amine Pump minimum flow

Alarm

Unit

Operating Set Point

Low

High

m3/hr

375

330

NA

•

Low low flow alarm (91-FALL-1510) set at 300 m3/hr in 9103-P-12A/B discharge, trips the Acid Gas Rich Amine Pumps 9103-P-12A/B

•

Pump minimum flow control valve 91-FV-1508 opens on instrument air failure.

4.1.2.3.6

Rich Amine to Regenerator Temperature Control

Rich amine solution leaving the Lean/Rich Amine Exchanger (9103-E-11-A/B) temperature is maintained by the temperature controller 91-TIC-1513. Temperature controller 91-TIC-1513 is located at hot rich amine outlet leaving the exchanger. The output from this controller resets the control valve 91-TV-1513 on the hot lean amine solution bypass line around the Lean/Rich Amine Exchanger. Controller Tag 91-TIC-1513

Control Description Rich Amine to Amine Regenerator temperature Control

Alarm

Unit

Operating Set Point

Low

High

°C

104

99

109

Hot lean amine bypass control valve 91-TV-1513 locks on instrument air failure. 4.1.2.3.7

Amine Regenerator Overhead Pressure Control

Amine regenerator overhead pressure is controlled by the pressure controller 91-PIC1539. The pressure is maintained through the pressure control valve 91-PV-1539 by controlling the nitrogen supply to the Regenerator. 91-PIC-1539 opens the Nitrogen control valve 91-PV-1539 on falling pressure in the Regenerator over head to Regenerator Condenser Cooler.

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Controller Tag 91-PIC-1539

Control Description Amine Regenerator top pressure control

Unit Bar g

Operating Set Point 1.2

Alarm Low 0.95

High 1.4

Amine Regenerator 9103-C-12 top pressure nitrogen control valve 91-PV-1539 opens on instrument air failure. 4.1.2.3.8

Amine Regenerator Level Control

The master level controller 91-LIC-1510 maintains the bottom level of Amine Regenerator by controlling the cascaded slave lean amine flow controller 91-FIC-1530, which regulates the Hot Lean Amine Pumps (9103-P-17A/B) discharge flow to Lean Rich Amine Exchanger through the control valve 91-FV-1530 located at the outlet of Lean Amine Trim Cooler 9103-E-15. Controller Tag

Control Description

91-LIC-1510

Amine Regenerator bottom level control

91-FIC-1530

Lean amine flow to 9103-T-11

Alarm

Unit

Operating Set Point

Low

High

%

50

17

82

m3/hr

669

NA

NA

•

Low low level alarm (91-LALL-1517) in Amine Regenerator bottom trips the Hot Lean Amine Pumps (9103-P-17A/B) and closes the Hot Lean Amine ON/OFF valve 91-XV-1507 to Lean Rich Exchanger

•

High high level alarm (91-LAHH-1509) in Amine Regenerator bottom activates the ESD level-2 shutdown

•

Lean amine outlet flow control valve 91-FV-1530 to Amine Surge Tank closes on instrument air failure

4.1.2.3.9

Hot Lean Amine Pumps Minimum Flow Control

Hot lean amine pumps (9103-P-17A/B) discharge flow is measured by 91-FT-1512 and pumps minimum flow to Amine Regenerator bottom is controlled by 91-FIC-1512. Output of the controller 91-FIC-1512 controls the pump minimum flow control valve 91-FV-1512. Controller Tag 91-FIC-1512

Control Description Hot Lean Amine Pump min flow

Alarm

Unit

Operating Set Point

Low

High

m3/hr

250

220

NA

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Hot Lean Amine Pumps 9103-P-17A/B discharge flow low low alarm (91-FALL-1509) set at 200 m3/hr will activate the tripping of 9103-P-17A/B.

•

Pump minimum flow control valve 91-FV-1512 opens on instrument air failure.

4.1.2.3.10 Regenerator Condenser Cooler Control Temperature of the acid gas flow from the Amine Regenerator overhead is controlled by cooling the fluid to Tmax=54°C in summer and not less than Tmin=49°C in winter using one fixed speed fan (on/off) control, and another two VSD controlled fans working simultaneously. The Regenerator Condenser Cooler outlet temperature is measured by 91-TT-1516 and received by the temperature controller 91-TIC-1516. The output of this controller sends the control signal to control the three fans. In auto mode, the temperature controller maintains the cooler outlet temperature at Tset= (54°C + 49°C)/2=52°C by changing the VSD rates of the following cooler fans: •

9103-EM-12AB

•

9103-EM-12AC

•

9103-EM-12BB

•

9103-EM-12BC

•

9103-EM-12CB

•

9103-EM-12CC

•

9103-EM-12DB

•

9103-EM-12DC

The fixed speed fan (9103-EM-12AA/BA/CA/DA) operates on gap control set point between the values Tmax=54°C & Tmin=49°C. This scheme will be applicable for all the 4 bays simultaneously. Details of control tags are tabulated below: Sl. #

Motor No.

Control Tag

Remarks

1

9103-EM-12AA

91-HS-1512

Fixed speed fan

2

9103-EM-12AA

91-SY-1513

VSD

3

9103-EM-12AA

91-SY-1552

VSD

4

9103-EM-12BA

91-HS-1553

Fixed speed fan

5

9103-EM-12BB

91-HS-1554

VSD

6

9103-EM-12BC

91-HS-1555

VSD

7

9103-EM-12CA

91-HS-1556

Fixed speed fan

8

9103-EM-12CB

91-HS-1557

VSD

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Sl. #

Motor No.

Control Tag

Remarks

9

9103-EM-12CC

91-HS-1558

VSD

10

9103-EM-12DA

91-HS-1559

Fixed speed fan

11

9103-EM-12DB

91-HS-1560

VSD

12

9103-EM-12DC

91-HS-1561

VSD

High high vibration alarm of each fan trips the respective fan motors. 4.1.2.3.11 Regenerator Condenser Trim Cooler Outlet Temperature Control 91-TIC-1502 located at the outlet of the Regenerator Condenser Trim Cooler, maintains the outlet temperature of the acid gas condensate to Regenerator Reflux Drum. The temperature controller adjusts the bypass control valve 91-TV-1502 and maintains the Regenerator Condenser Trim Cooler outlet temperature 91-TT-1502. Controller Tag 91-TIC-1502

Alarm

Control Description

Unit

Operating Set Point

Low

High

Regenerator Condenser Trim Cooler Outlet Temperature

°C

49

44

54

Regenerator Condenser Cooler 9103-E-12 outlet temperature control valve 91-TV-1502 to reflux drum opens on instrument air failure. 4.1.2.3.12 Regenerator Reflux Drums Level Control Bottom level in the Regenerator Reflux Drum level is maintained by controlling the reflux return to the Amine Regenerator via Reflux Drum Pumps 9103-P-11A/B. Regenerator reflux drum bottom level is controlled by the master controller 91-LIC1506 cascaded with the reflux pumps discharge flow slave controller 91-FIC-1531, which regulates the control valve 91-FV-1531 located in the reflux inlet to Amine Regenerator. Controller Tag

Control Description

91-LIC-1506

Regenerator reflux drum level control

91-FIC-1531

Reflux to amine regenerator

Alarm

Unit

Operating Set Point

Low

High

%

50

16

80

m3/hr

26

NA

NA

•

Low low level alarm (91-LALL-1518) in Regenerator Reflux Drum trips the Reflux Drum Pumps (9103-P-11A/B)

•

High high level alarm (91-LAHH-1507) in Regenerator Reflux Drum closes the DM water ON/OFF valve 91-XV-1517 to Regenerator Reflux Drum

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Reflux flow control valve 91-FV-1531 to Amine Regenerator opens on instrument air failure.

•

4.1.2.3.13 Regenerator Reflux Drums Condensate Control Condensate flow to the Regenerator Reflux Drum bottom is measured by 91-FT-1521 and controlled by 91-FIC-1521. Condensate flow is controlled through the control valve 91-FV-1521. Controller Tag

Control Description

91-FIC-1521

Regenerator reflux drum condensate flow control

Alarm

Unit

Operating Set Point

Low

High

m3/hr

0.6

0.4

0.8

•

ESD valve 91-XV-1517 located at the upstream of the control valve 91-FV-1521 closes on high high level alarm 91-LAHH-1507 of Regenerator Reflux Drum

•

Condensate flow control valve 91-FV-1521 closes on instrument air failure.

4.1.2.3.13 Regenerator Reflux Drums Pressure Control A split range pressure controller 91-PIC-1503 is provided to maintain the pressure of Regenerator Reflux Drum (9103-V-12) by controlling the following valves: •

Acid gas control valve 91-PV-1503B (0-50%) to acid gas KO drum 9101-V-04

•

Acid gas control valve 91-PV-1503A (50-100%) to LP Acid Gas Flare

On rising pressure 91-PIC-1503 first opens the acid gas to Acid Gas KO Drum control valve 91-PV-1503B; further increase in pressure causes the pressure controller to open the vent valve 91-PV-1503A to release gases to the LP Acid Gas Flare. Fig. 14 – 91-PIC-1503 Controller Output

The above drawing shows the split range operation of 91-PV-1503A & 91-PV-1503B.

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Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

91-PIC-1503

Regenerator Reflux Drum pressure

bar(g )

1

0.787

1.2

•

ESD valve 91-XV-1516 located at the acid gas to Acid Gas KO Drum control valve downstream

•

Control valve 91-PV-1503B closes on ESD-Level-0, Level-1 & Level-2 shutdown

•

Regenerator Reflux Drum 9103-V-12 pressure control valve 91-PV-1503A to LP flare opens on instrument air failure

•

Regenerator Reflux Drum 9103-V-12 pressure control valve 91-PV-1503B to Acid Gas KO Drum closes on instrument air failure.

4.1.2.3.14 Regenerator Reflux Pumps Minimum Flow Control Regenerator Reflux Pumps (9103-P-11A/B) discharge flow is measured by 91-FT-1505 and minimum flow to Amine Regenerator is controlled by 91-FIC-1505. Output of the controller 91-FIC-1505 controls the pump minimum flow control valve 91-FV-1505. Controller Tag

Control Description

91-FIC-1505

Regenerator Reflux Drum pumps to Regenerator

Alarm

Unit

Operating Set Point

Low

High

m3/hr

20

17.6

NA

•

Low low flow alarm (91-FALL-1506) set at 16 m3/hr trips the Regenerator Reflux Pumps 9103-P-11A/B

•

Pump minimum flow control valve 91-FV-1505 opens on instrument air failure.

4.1.2.3.15 Sour Water Flow Control to Waste Water Degasser Sour water flow from the discharge of Regenerator Reflux Drum Pumps (9103-P-11A/B) to the Waste Water Degasser (6922-V-07) is measured by 91-FT-1532 and sends the signal to the flow controller 91-FIC-1532. 91-FIC-1532 regulates the flow to Waste Water Degasser via the control valve 91-FV1532. Control Loop: Controller Tag 91-FIC-1532

Control Description Sour water flow to Waste Water Degasser

Alarm

Unit

Operating Set Point

Low

High

m3/hr

0.17

NA

NA

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ESD valve 91-XV-1575 located at the downstream of the sour water flow control valve 91-FV-1532 closes on activation of waste water degasser level (69-LI-1311) high high alarm

•

Sour water flow control valve 91-FV-1532 closes on instrument air failure.

4.1.2.3.16 Amine Regenerator Reboiler Temperature Control Temperature in the amine regenerator is to be maintained to allow for optimum H2S stripping from the rich amine. Temperature control is achieved by controlling the steam flow to the Regenerator Reboiler. Steam flow to the Regenerator Reboiler is controlled by 91-FIC-1503 which regulates the control valve 91-FV-1503. Set point-1 (SP1) for the steam flow control is received from the calculation block 91-FFY-1503A which multiplies the rich amine flow controller 91-FIC-1520A output and manually provided set ratio (118.5) between steam and rich amine through 91-HIC-1503. Set point-2 (SP2) is received from the output of the Regenerator overhead temperature controller 91-TIC-1510. During normal operation SP1 take precedence and when the temperature of the Regenerator over head reaches more than 118°C SP2 will take precedence. Controller Tag

Control Description

91-FIC-1503

Steam to Regenerator Re-boiler

91-TIC-1510

Amine Regenerator (9103-C12) overhead

91-FIC-1520A

Rich amine flow control

Alarm

Unit

Operating Set Point

Low

High

Kg/hr

72410

65816

80442

°C

118

113

123

m3/hr

635

500

NA

•

ESD valve 91-XV-1505 located on the upstream of 91-FV-1503 closes on activation of amine regenerator bottom level 91-LI-1509 high high alarm set at 50%

•

Steam control valve 91-FV-1503 to reboiler closes on instrument air failure.

4.1.2.3.17 Regenerator Re-Boiler Condensate Pot Level Control Regenerator Reboiler condensate is collected in the Condensate Pot (9103-V-13). Level of the Condensate Pot is measured by 91-LT-1508 and controlled by throttling the control valve 91-LV-1508 to LC distribution header via 91-LIC-1508. Controller Tag 91-LIC-1508

Control Description Regenerator Re-boiler Condensate Pot level

Alarm

Unit

Operating Set Point

Low

High

%

50

12

86

Reboiler condensate control valve 91-LV-1508 will close on instrument air failure.

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.1.2.3.18 Lean Amine Cooler Temperature Control Temperature of the lean amine from the Lean/Rich Exchanger (9103-E-11) is controlled by cooling the fluid to Tmax=54°C in summer and not less than Tmin=45°C in winter using three fans: one fixed speed fan (on/off) control, and another two VSD controlled fans working simultaneously. The Lean Amine Cooler 9103-E-14 outlet temperature is measured by 91-TT-1518 and controlled by the temperature controller 91-TIC-1518. The output of this controller sends the control signal to control the three fans. In auto mode, the temperature controller maintains the cooler outlet temperature T set= (54°C + 45°C)/2=50°C by changing the following VSD rates: (9103-EM-14AB/AC/BB/BC/CB/CC/DB/DC/EB/EC/FB/FC/GB/GC/HB/HC/IB/IC/JB/JC) The fixed speed fan (9103-EM-14AA/BA/CA/DA/EA/FA/GA/HA/IA/JA) operates on gap control set point between the values Tmax=54°C & Tmin=45°C. This scheme will be applicable for all the 10 bays simultaneously. Details of control tags are tabulated below: Sl. #

Motor No.

Control Tag

Remarks

1.

9103-EM-14AA

91-HS-1514

Fixed speed fan

2.

9103-EM-14AB

91-SY-1515

VSD

3.

9103-EM-14AC

91-SY-1558

VSD

4.

9103-EM-14BA

91-HS-1519

Fixed speed fan

5.

9103-EM-14BB

91-SY-1520

VSD

6.

9103-EM-14BC

91-SY-1521

VSD

7.

9103-EM-14CA

91-HS-1522

Fixed speed fan

8.

9103-EM-14CB

91-SY-1523

VSD

9.

9103-EM-14CC

91-SY-1524

VSD

10.

9103-EM-14DA

91-HS-1525

Fixed speed fan

11.

9103-EM-14DB

91-SY-1526

VSD

12.

9103-EM-14DC

91-SY-1527

VSD

13.

9103-EM-14EA

91-HS-1528

Fixed speed fan

14.

9103-EM-14EB

91-SY-1529

VSD

15.

9103-EM-14EC

91-SY-1530

VSD

16.

9103-EM-14FA

91-HS-1531

Fixed speed fan

17.

9103-EM-14FB

91-SY-1532

VSD

18.

9103-EM-14FC

91-SY-1533

VSD

19.

9103-EM-14GA

91-HS-1534

Fixed speed fan

20.

9103-EM-14GB

91-SY-1535

VSD

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Sl. #

Motor No.

Control Tag

Remarks

21.

9103-EM-14GC

91-SY-1536

VSD

22.

9103-EM-14HA

91-HS-1537

Fixed speed fan

23.

9103-EM-14HB

91-SY-1538

VSD

24.

9103-EM-14HC

91-SY-1539

VSD

25.

9103-EM-14IA

91-HS-1540

Fixed speed fan

26.

9103-EM-14IB

91-SY-1541

VSD

27.

9103-EM-14IC

91-SY-1542

VSD

28.

9103-EM-14JA

91-HS-1543

Fixed speed fan

29.

9103-EM-14JB

91-SY-1544

VSD

30.

9103-EM-14JC

91-SY-1545

VSD

High high vibration alarm of each fan trips the respective fan motors. 4.1.2.3.19 Lean Amine Trim Cooler Outlet Temperature Control 91-TIC-1509 located at the outlet of the Lean Amine Trim Cooler (9103-E-15) maintains the outlet temperature of the lean amine to Amine Surge Tank (9103-T-11). The temperature controller 91-TIC-1509 adjusts the control valve 91-TV-1509 located in the bypass line of Lean Amine Trim Cooler maintains the lean amine outlet temperature. Controller Tag 91-TIC-1509

Alarm

Control Description

Unit

Operating Set Point

Low

High

Lean amine Cooler to amine surge tank

°C

45

40

50

Lean amine cooler bypass control valve 91-TV-1509 closes on instrument air failure. 4.1.2.3.20 Lean Amine Surge Tank Pressure Control A split range pressure controller 91-PIC-1526 is provided to maintain the vapour space of the tank under a slightly positive pressure. On rising pressure in the tank, 91-PIC1526 closes (0-50%) the nitrogen flow to tank via the control valve 91-PV-1526A, on further increase in pressure the pressure controller 91-PIC-1526 opens (50-100%) the vent valve 91-PV-1526B to release gases to the atmosphere. Controller Tag 91-PIC-1526

Control Description Lean amine surge tank (9103-T-11) pressure

Alarm

Unit

Operating Set Point

Low

High

bar(g)

0.02

0.01

0.03

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TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 15 – 91-PIC-1526 Controller Output

The above drawing shows the split range operation of 91-PV-1526A & 91-PV-1526B. •

Amine Surge Tank 9103-T-11 nitrogen line control valve 91-PV-1526A closes on instrument air failure.

•

Amine Surge Tank 9103-T-11 control valve control valve 91-PV-1526B opens on instrument air failure.

4.1.2.3.21 Lean Amine Pumps Minimum Flow Control Lean amine pumps (9103-P-13A/B) discharge flow is measured by 91-FT-1511 and minimum flow to Amine Surge Tank is controlled by 91-FIC-1511. Output of the controller 91-FIC-1511 throttles the pump minimum flow control valve 91-FV-1511. Control Loop: Controller Tag 91-FIC-1511

Control Description Lean Amine Pumps discharge

Alarm

Unit

Operating Set Point

Low

High

m3/hr

375

330

NA

Low low flow (91-FALL-1515) alarm set at 300 m3/hr trips the Lean Amine Pumps 9103-P-13A/B. 4.1.2.3.22 Amine Sump Pressure Control A split range pressure controller 91-PIC-1527 is provided to maintain the vapour space of the tank under a slightly positive pressure. On rising pressure in the tank, 91-PIC1527 closes (0-50%) the nitrogen flow to tank via the control valve 91-PV-1527A, on further rising pressure, the pressure controller 91-PIC-1527 opens (50-100%) the vent valve 91-PV-1527B to release gases to the atmosphere.

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TITLE: OPERATION AND MAINTENANCE MANUAL

The below drawing shows the split range operation of 91-PV-1527A & 91-PV-1527B: Fig. 16 – 91-PIC-1527 Controller Output

Control Loop: Controller Tag 91-PIC-1527

Control Description Amine Sump pressure control

Alarm

Unit

Operating Set Point

Low

High

bar(g)

0.05

0.027

0.07

•

Amine sump 9103-V-10 nitrogen line control valve 91-PV-1527A closes on instrument air failure

•

Amine Sump 9103-V-10 nitrogen control valve 91-PV-1527B opens on instrument air failure.

4.1.2.3.23 Lean Amine Pumps Flow to Filter Lean Amine Pumps (9103-P-13A/B) discharge flow to Lean Amine Filter (9103-S-11) is controlled by 91-FIC-1507. Output of the controller 91-FIC-1507 resets the control valve 91-FV-1507. Controller Tag 91-FIC-1507

Alarm

Control Description

Unit

Operating Set Point

Low

High

Lean Amine Pumps to Lean Amine Filter

m3/hr

155.6

125

NA

Lean Amine Pumps 9103-P-13A/B flow control valve 91-FV-1507 to filter closes on instrument air failure.

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.2 4.2.1

SULPHUR RECOVERY UNIT Equipment Details Process Air Blowers Equipment Tag No. Process Medium Rated Capacity (Dry Base), kg/hr

9101-K-01A/B Air 29478

Inlet Pressure, bar(a)

1.01

Inlet Temperature, °C

43

Discharge Pressure, bar(a)

1.90

Discharge Temperature, °C

49

Design Temperature, °C

120

Drive Type

Motor

Sulphur Degassing Pumps Equipment Tag No. Pump Type

9101-P-03A/B Vertical Centrifugal

Process Medium 3

Liquid Sulphur

Capacity, m /hr (Normal/Rated)

130/130

Suction Pressure, bar(a), Rated/Max.

1.0/1.61

Discharge Pressure, bar(a) Operating Temperature, °C, Normal/Max. Design Temperature, °C Driver Type

8.6 140/160 185 Motor

Rated Power, kW Material of Construction, Casing/Impeller

45 Duplex SS

Sulphur Product Pumps Equipment Tag No. Pump Type

9101-P-04A/B Vertical Centrifugal

Process Medium 3

Liquid Sulphur

Capacity, m /hr (Normal/Rated)

130/130

Suction Pressure, bar(a), Rated/Max.

1.0/1.61

Discharge Pressure, bar(a) Operating Temperature, °C, Normal/Max. Design Temperature, °C Driver Type Rated Power, kW Material of Construction, Casing/Impeller

8.6 140/160 185 Motor 45 Duplex SS

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TITLE: OPERATION AND MAINTENANCE MANUAL

Sulphur Tank Pumps Equipment Tag No.

9101-P-15A/B

Process Medium

Liquid Sulphur

3

Capacity, m /hr (Normal/Rated)

7.4/8.14

Suction Pressure, bar(a), Rated/Max.

0.9/2.5

Discharge Pressure, bar(a)

9.6

Operating Temperature, °C, Normal/Max.

160

Design Temperature, °C

185

Driver Type

Motor

Rated Power, kW Material of Construction, Casing/Impeller

11 A216WCB

Sulphur Degassing Pit Equipment Tag No.

9101-T-01B

Size, (L/W/D), mm

10800/7000/3000

Process Medium Operating Temperature, °C, Normal/Min.

Liquid Sulphur 140/127

Operating Pressure, bar(g)

ATM

Design Temperature, °C

185

Design Pressure, bar(g)

0.02/-0.005

Material of Construction

Reinforced Concrete

Sulphur Degassing Pumps Equipment Tag No. Pump Type

9101-P-09A/B Vertical Centrifugal

Process Medium 3

Liquid Sulphur

Capacity, m /hr (Normal/Rated)

130/130

Suction Pressure, bar(a), Rated/Max.

1.0/1.61

Discharge Pressure, bar(a) Operating Temperature, °C, Normal/Max. Design Temperature, °C Driver Type Rated Power, kW Material of Construction, Casing/Impeller

8.6 140/160 185 Motor 45 A 995 1B/A 995 1B

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TITLE: OPERATION AND MAINTENANCE MANUAL

Sulphur Product Pumps Equipment Tag No. Pump Type

9101-P-10A/B Vertical Centrifugal

Process Medium 3

Liquid Sulphur

Capacity, m /hr (Normal/Rated)

130/130

Suction Pressure, bar(a), Rated/Max.

1.0/1.61

Discharge Pressure, bar(a) Operating Temperature, °C, Normal/Max. Design Temperature, °C Driver Type

8.6 140/160 185 Motor

Rated Power, kW Material of Construction, Casing/Impeller

45 Duplex SS

Catalyst Tank Equipment Tag No.

9101-T-09

Size, (ID/Ht), mm

700/1000

Process Medium

Catalyst

Design Temperature, °C

85

Design Pressure, bar(g)

ATM

Catalyst Metering Pumps Equipment Tag No. Process Medium

9101-P-11A/B Catalyst

Design Temperature, °C

85

Design Pressure, bar(g)

2.0

Drive

Motor

Rated Power, kW

0.55

Steam Ejector Equipment Tag No. 3

4.2.2

9101-X-03

Capacity, Nm /hr

500

Design Temperature, °C

185

Differential Pressure, bar

0.1

Revamped Claus Unit Process Chemistry The function of a SRU is to process H2S rich acid gases to produce liquid elemental Sulphur. The sulphur recovery Claus process combines 2 mols of H2S with 1 mol. of SO2 to form elemental sulphur.

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TITLE: OPERATION AND MAINTENANCE MANUAL

In the modified Claus process some of the H2S rich acid gas is burnt with the correct amount of Oxygen (from air) to oxidise one third of the H2S to SO2: Main Reactions: H2S + 3/2O2 —> SO2 + H2O This reaction produces a high enough temperature to trigger the Claus reaction thermally: 2H2S + SO2 —> 3S + 2H2O The Claus reaction is continued at progressively lower temperatures in the two catalytic stages where the remaining H2S then combines with the SO2 & produce elemental Sulphur. 4.2.3

Revamped Claus Unit Process Description The acid gas stream from the gas treating plant enters the Acid Gas KO Drum (9101-V04) where acid water is knocked out and pumped to Amine Sump 9103-V-10 by the Acid Water Pumps 9101-P-01A/B. The gas stream flows to Acid Gas Preheater (9101-E06) for preheating before entering the Reaction Furnace (9101-F-01), where the acid gas is burnt by the high intensity burner with a controlled amount of air. Air is supplied by an electrically driven Process Air Blower (9101-K-01A/B) & preheated by Air Preheater (9101-E-05). The products of the combustion are cooled in passing through the tube section of the Reaction Furnace Boiler (9101-E-07) where a 24 bar(g) steam is generated in the shell side. Gases and any condensed liquid sulphur from the Reaction Furnace Boiler flow to the Reaction Furnace Condenser (9101-E-01) where the gases are cooled and the additional sulphur is condensed. The gases then passes through the 1st Stage Auxiliary Burner (9101-F-02) where they are reheated by burning a split stream of acid gas (or fuel gas) with air, before entering the 1st Stage Converter (9101-V-01). In this converter the gases flow downwards through a bed of CR 4/8 mm activated alumina, top loaded with a layer of AM 4/8 catalyst. In the converter, additional elemental sulphur is produced and carried over in vapour phase by the hot gases. The exothermic Claus reaction results in a temperature increase through the adiabatic converter. The hot gases leaving the first converter are cooled in the 1st Stage Condenser (9101-E-02) by generating 5 barg steam, the condensed sulphur flows to the Sulphur Degassing Pit (9101-T-01/01B) through Sultraps. The gases from the Sulphur Condenser (9101-E-02) flow through a coalescer equipped with SS wire mesh pads for the removal of any entrained sulphur. The gases then passes through the 2nd Stage Auxiliary Burner (9101-F-03) where they are reheated by burning a split stream of acid gas (or fuel gas) with air, before entering the 2nd Stage Converter (9101-V-02), loaded with a more active catalyst CRS 31 and a layer of AM 4/8 mm catalyst on the top of the bed.

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TITLE: OPERATION AND MAINTENANCE MANUAL

The Last Condenser (9101-E-04) ensures cooling of the process gases by preheating the Boiler Feed Water which is used in the Reaction Furnace Boiler (9101-E-07) and the two LP steam producing Reaction Furnace Condenser (9101-E-01) & 1st Stage Condenser (9101-E-02). The process gases from Last Condenser passes through a Final Separator (9101-V-05) to achieve complete removal of liquid sulphur drops from the process gases. A coalescer is provided in Final Separator (9101-V-05). From final separator, the process gas is routed to Tail Gas Treatment Unit, where the hydrogen sulphide concentration in the tail gas is reduced to a level corresponding to >99.5% total sulphur recovery. The sulphur produced in the process is extracted from all sulphur condensers through sultraps and is routed to the Sulphur Degassing Pits (9101-T-01/9101-T-01B). The sulphur is degassed through AQUISULF sulphur degassing process. The degassed sulphur is then transferred to the Sulphur Storage Tank 9101-T-02 by Sulphur Product Pumps (9101-P-04A/B & 9101-P-10A/B). 4.2.4

Sulphur Recovery Unit Process Control

4.2.4.1

Pipe Separator Level Control

The acid gas stream from NGL-3 AGRU-1 & 2 enters the pipe separator where the acid gas is routed to the top of the separator to AGEU acid gas coolers and the bottom liquid is drained to amine drain distribution header. Level in the vessel is maintained by regulating the control valve 91-LV-1053, in the pipe separator bottom to amine drain distribution header through 91-LIC-1053. Control Loops: Controller Tag 91-LIC-1053

Alarm

Control Description

Unit

Operating Set Point

Low

High

Pipe separator level control

%

50

14

98

•

Low low level alarm (91-LALL-1054) set at 33% in the pipe separator closes the liquid outlet block valve 91-XV-1109.

•

Pipe separator level control valve 91-LV-1503 to amine drain distribution header closes on instrument air failure.

4.2.4.2

BFW Pre-heater Temperature Control

Temperature of the heated water outlet from the BFW pre heater is monitored by 91-TT-1091 and controlled by 91-TIC-1091. Temperature control is achieved by regulating the LP steam flow control valve 91-FV-1057 to BFW Preheater by 91-FIC-1057. The MASTER temperature controller 91-TIC-1091 is cascaded with SLAVE steam flow controller 91-FIC-1057.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Tag

Control Description

Alarm

Unit

Operating Set Point

Low

High

91-TIC-1091

BFW Preheater outlet temperature

°C

120

115

125

91-FIC-1057

LP steam flow to BFW Preheater

Kg/hr

860

775

947

LP steam control valve 91-FV-1057 closes on instrument air failure. 4.2.4.3

Last Condenser Outlet Tail Gas Control

Tail gas from the Last Condenser is routed to the Incinerator through 91-XV-1097 during start-up and during normal operation tail gas is routed to TGTU through 91-XV1098. This diversion is achieved by activating the selector switch 91-HS-1052A. This opens the valve 91-XV-1098, when 91-XV-1098 is fully open the valve 91-XV-1097 closes. This ensures that at least one path is fully open for the tail gas to pass through without pressuring the upstream reaction furnace. •

High high pressure alarm 91-PAHH-1055 set at 0.73 barg opens the valve 91-XV1097 to Incinerator and closes the valve 91-XV-1098 to RGG

•

ESD valve 91-XV-1097 opens on instrument air failure

•

ESD valve 91-XV-1098 closes on instrument air failure

4.2.4.4

New Sulphur Degassing Pit Level Control

New Sulphur Degassing Pit (9101-T-01B) level is measured by 91-LT-1051 which sends the signal to the level controller 91-LIC-1051. Level control is achieved by regulating the control valve 91-LV-1051 to the sulphur storage tank (9101-T-02). Controller Tag 91-LIC-1051

Alarm

Control Description

Unit

Operating Set Point

Low

High

Sulphur Degassing Pit level

%

50

17

80

•

Low low level alarm 91-LALL-1052 set at 10% trips the Sulphur Degassing Pumps (9101-P-09A/B) and Sulphur Product Pumps (9101-P-10A/B)

•

Sulphur Degassing Pit level control valve 91-LV-1051 closes on instrument air failure.

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.2.4.5

Combustion Control for 1st Stage Auxiliary Burner

During normal operation the Air/Acid Gas ratio controller maintains the temperature of the process gas and when the acid gas flow decreases, the temperature of the process gas is maintained by the Air to Fuel gas ratio controller. Selection of this controller can be either manual through 91-HS-1028A or automatically when the temperature 91-TICA-1007 of the 1st stage burner outlet reduces below the desired set point (210°C). This reduction in temperature stops the acid gas flow in the 1st stage auxiliary burner. Acid gas flow to 1st stage auxiliary burner is controlled by 91-FIC-1019 and fuel gas flow is controlled by 91-FIC-1020, set point for both the controllers is provided by 91-TICA1007 via selector switch 91-HS-1028A. 91-FIC-1019 commands the acid gas flow valve 91-FV-1019 and 91-FIC-1020 commands the fuel gas control valve 91-FV-1020. Ratio set point (air/fuel gas) and (air/acid gas) is provided via 91-HIC-1018A and 91-HIC-1018B, respectively. Combustion air flow is controlled by 91-FIC-1018. Set point for the controller is provided by air/acid gas or air/fuel gas ratio calculation as per selection through 91-HS-1028B and output of the combustion air flow controller 91-FIC-1018 directly commands the air damper valve 91-FV-1018. Controller Tag

Control Description

Alarm

Unit

Operating Set Point

Low

High

°C

230

210

250

st

91-TICA-1007

1 Stage Auxiliary Burner temperature

91-FIC-1019

acid gas flow

Sm3/hr

281.939

111

332

comb air flow

3

Sm /hr

908.768

NA

981

3

159.635

8

170

91-FIC-1018 91-FIC-1020

fuel gas flow

Sm /hr

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TITLE: OPERATION AND MAINTENANCE MANUAL

The schematic diagram for 1st stage auxiliary burner temperature control is shown below: Fig. 17 – 1st Stage Auxiliary Burner Temperature Control

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TITLE: OPERATION AND MAINTENANCE MANUAL

1st Stage Auxiliary Burner combustion air flow (91-FI-1133) low low alarm set at 253 Sm3/hr, acid gas flow (91-FI-1134) low low alarm set at 105 Sm3/hr and Fuel gas Flow (91-FI-1135) low low alarm set at 7 Sm3/hr activates the following:

•

4.2.4.6

•

Closure of Fuel gas block valves 91-XV-1028 and 91-XV-1031.

•

Opening of fuel gas vent valve 91-XV-1132

•

Closure of fuel gas control valve 91-FV-1020

•

Closure of acid gas control valve 91-FV-1019

•

Closure of combustion air control valve 91-FV-1018

•

1st stage combustion air damper/control valve 91-FV-1018 opens on instrument air failure

•

1st stage acid gas control valve 91-FV-1019 closes on instrument air failure

•

1st stage fuel gas control valve 91-FV-1020 closes on instrument air failure. Combustion Control for 2nd Stage Auxiliary Burner

During normal operation the Air/Acid Gas ratio control maintains the temperature of the process gas flowing through the catalytic converter and then to sulphur condenser. When the Acid gas flow decreases, the temperature of the process gas is maintained by the Air to Fuel gas ratio controller. The selection of this controller can be either manual through 91-HS-1029A or automatically when the temperature 91-TIC-1019 reduces below the desired set point (210°C). This reduction in temperature stops acid gas flow and introduce fuel gas flow in the 2nd stage Auxiliary burner. Acid gas flow to 2nd Stage Auxiliary Burner is controlled by 91-FIC-1026 and the fuel gas flow is controlled by 91-FIC-1027. Set point for both the controllers is provided by 2nd Stage Auxiliary Burner temperature controller 91-TIC-1019 via selector switch 91-HS-1029A. Output of the controller 91-FIC-1026 commands the acid gas flow control valve 91-FV-1026 and Output of the controller 91-FIC-1027 commands the fuel gas control valve 91-FV-1027. Ratio set point (air/fuel gas) and (air/acid gas) is provided by operator via 91-HIC1025A and 91-HIC-1025B, respectively. Combustion air flow is controlled by 91-FIC-1025. Set point for the controller is provided by air/acid gas or air/fuel gas ratio calculation as per selection through 91-HS-1029B. Output of the combustion air flow controller 91-FIC-1025 commands the air damper valve 91-FV-1025. Controller Tag

Control Description

Alarm

Unit

Operating Set Point

Low

High

°C

210

190

230

nd

91-TICA-1019

2 stage auxiliary burner temperature

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Controller Tag 91-FIC-1026 91-FIC-1025 91-FIC-1027 •

Control Description Acid gas flow combustion air flow fuel gas flow

Alarm

Operating Set Point

Low

High

3

Sm /hr

155.382

80

175

3

Sm /hr

519.541

NA

523

3

159.635

8

170

Unit

Sm /hr

2nd stage burner combustion air flow (91-FI-1136) low low alarm set 180 Sm3/hr, acid gas flow (91-FI-1137) low low alarm set at 76 Sm3/hr and Fuel gas Flow (91-FI1138) low low alarm set at 7 Sm3/hr activates the following: •

closure of Fuel gas block valves 91-XV-1031 and 91-XV-1133

•

opening of fuel gas vent valve 91-XV-1134

•

closure of fuel gas control valve 91-FV-1027

•

closure of acid gas control valve 91-FV-1026

•

closure of combustion air control valve 91-FV-1025

•

2nd stage combustion air damper/control valve 91-FV-1025 closes on instrument air failure.

•

2nd stage acid gas control valve 91-FV-1026 closes on instrument air failure

•

2nd stage fuel gas control valve 91-FV-1027 closes on instrument air failure

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TITLE: OPERATION AND MAINTENANCE MANUAL

The schematic diagram for 2nd stage auxiliary burner temperature control is shown below: Fig. 18 - 2nd Stage Auxiliary Burner Temperature Control

9101-V-02 2

X

Air Ratio HIC 1025B Acid Gas

SP

FY 1025B PV

FIC PV 1026

nd

Stage Converter

Selector MV

HS 1029A

TICA 1019

FT 1026 Acid Gas to 2nd Stage Burner

FV-1026

SP FIC PV 1027

MV

FT 1027 Fuel Gas to 2nd Stage Burner

FV-1027

PV Air Ratio HIC Fuel Gas 1025A

X

FY 1025A

HS 1029B Selector

FT 1025 Combustion Air to 2nd Stage Burner

PV

Comp PT 1002

TT 1004

SP

FY 1025

FIC 1025

MV

FV-1025

9101-F-03 2nd Stage Auxiliary Burner

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.2.4.7

Combustion Control for Reaction Furnace

Combustion temperature in the Reaction Furnace is maintained by controlling the ratio of fuel gas, combustion air flow rates during start-up and by acid gas, combustion air flow rates during normal operations. Fuel gas flow to reaction furnace is controlled by 91-FIC-1009 which commands the fuel gas control valve 91-FV-1009. Secondary combustion air flow to reaction furnace is controlled by 91-FIC-1002B; Set point for the controller is calculated in the block 91-FY-1009 by multiplying fuel gas flow with AIR/FG ratio, which is manually provided via 91-HIC-1009. Secondary air flow is regulated by 91-FV-1002B. Trim air (make-up) flow is controlled by 91-FIC-1003; set point for the controller is provided by analyzer controller 91-AIC-1001 which measures the H2S/SO2 ratio (4:1). 91-FIC-1003 throttles the damper 91-FV-1003. Air selection to the reaction furnace is done by 91-HS-1142 (Secondary air during start-up and trim air during normal operations). Acid gas flow to the reaction furnace is measured by 91-FT-1001 which determines the quantity of combustion air to the reaction furnace. Pressure, temperature Compensated acid gas flow to reaction furnace is indicated by 91-FI-1001A. Acid gas analyzer value in the reflux drum is measured by 91-AI-1502. 91-HIC-1001 bias range (80%-120%) is manually provided as (Main air flow)/(total air flow) * 100. Main combustion air flow is controlled by 91-FIC-1002, and set point for the main combustion air flow controller is calculated in the block 91-FFY-1001A as: 2.38*(91-AI1502/100)* (91-FI-1001A)*(91-HIC-1001)/100. 91-FFY-1001B a bias block receives the remote set point from 91-FFY-1001A, which adds or subtracts the bias value received from the selector/auto trigger switch 91-HS-1142. When the manipulated variable received by 91-HS-1142 is >=80%, then it adds 1.25% of 91-FIC-1002 set point at each 30sec to the bias block 91-FFY-1001B and when the manipulated variable received by 91-HS-1142 is 99.5% total sulphur recovery. All residual hydrogen sulphide is oxidised to sulphur dioxide before it is released to the atmosphere. The BSR/Amine process consists of a Reducing Gas Generator section, Hydrogenation section, Desuperheater/Contactor section and a selective amine absorption section. The process uses the BSR technology to reduce all sulphur compounds in the SRU tail gas to hydrogen sulphide. This section includes water condensation and separation upstream of the amine section with a caustic circulation system to protect against SO2 breakthrough, which degrades the amine and causes severe corrosion.

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The amine section uses an amine solution to remove most of the hydrogen sulphide from the treated sulphur plant tail gas while minimising the co-absorption of carbon dioxide. The Claus tail gas from the Final Separator 9101-V-05 is fed to the Reducing Gas Generator (RGG) 9102-F-11. The purpose of the Reducing Gas Generator is to generate reducing gases (H2 and CO). This is achieved by the combustion of fuel gas with a substoichiometric quantity of air. The production of reducing gases is regulated by controlling the flow of the fuel gas and air. Air flow is set by the outlet temperature of the Reducing Gas Generator 9102-F-11 while the fuel gas flow rate is set to be a fixed proportion of the air flow. LP steam is fed to the Reducing Gas Generator to suppress the formation of carbon. The flow rate of the steam is ratio-controlled according to the fuel gas flow rate. The tail gas from the Final Separator 9101-V-05 is mixed with the hot combustion products in the Reducing Gas Generator to ensure a temperature that will favour the desired reactions in the Hydrogenation Reactor (9102-V-11). The Hydrogenation Reactor contains a fixed bed Cobalt/Molybdenum (CoMo) catalyst. The reactions are exothermic resulting in a temperature rise across the reactor. The gas is cooled by the generation of LP steam in the Reactor Effluent Cooler 9102-E-11. The tail gas is then desuperheated and the excess water removed in the Desuperheater/Contact Condenser (9102-C-11). This tower contains an upper packed section, a chimney tray and a lower section containing packing and bubble cap trays. In the lower packed section of the tower (Desuperheater section), tail gas is contacted with a circulating stream of a mildly caustic water solution. This removes sulphur dioxide and cools the tail gas down. The Desuperheater Circulation Pump (9102-P11A/B) pumps the caustic water solution from the bottom of the tower to the top of the packing. Water make up is provided to the lower (Desuperheater) section, under level control, from the top (Contact Condenser) section circulation. The solution is maintained at an alkaline pH of around 9.0 to protect against SO2 breakthrough from the reactor. SO2 causes corrosive conditions in the Desuperheater Contact Condenser and the Amine Absorber, and degrades the amine. The pH of the circulating liquid is monitored by a continuous analyser and controlled by periodic, manual addition of fresh caustic solution. An intermittent bleed from this section removes accumulated contaminants from the circuit. The desuperheated gas and water vapour then passes through the (wash) bubble cap trays and the chimney tray into the upper (Contact Condenser) packed section. Here the gas is cooled by direct contact with a circulating water stream. The water is pumped by the Cooling Water Circulation Pump from the chimney tray, through the Contact Condenser Cooler 9102-E-12 and Contact Condenser Trim Cooler 9102-E-13A/B where it is cooled, and back to the top of the tower. The water that is condensed in this section is slightly sour. Some is used as make up on demand to the lower Desuperheater section and the remainder is taken off under level control and sent to

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TITLE: OPERATION AND MAINTENANCE MANUAL

effluent treatment. The condensed water loop is kept separate from the water in the Desuperheater circulation loop to avoid contamination with salt products that may be formed in the Desuperheater section. The tail gas leaves the Desuperheater Contact Condenser (9102-C-11) at a temperature of approximately 40°C and is sent to the Tail Gas Amine Absorber (9102-C-12) which uses a lean amine solution to remove the hydrogen sulphide from the tail gas, while minimising the co-absorption of carbon dioxide. The gas enters at the bottom of the absorber and passes through a trayed section counter current to the lean amine solution that preferentially absorbs H2S. The lean amine solution is supplied from the Lean Amine Pumps 9103-P-13A/B. The Tail Gas Rich Amine Pump (9102-P-16 A/B) pumps the rich solvent solution from the bottom of the Tail Gas Amine Absorber (9102-C-12) to the Acid Gas Amine Absorber (9103-C-11) before it is regenerated in the Amine regenerator (9103-C-12). The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas Treatment Units are shared with the use of a common solvent. The H2S that is stripped from the rich amine solution in the Amine Regenerator is fed to the Sulphur Recovery section, thus closing the recycle loop around the SRU and TGTU sections. Treated gas from the Tail Gas Amine Absorber passes to the Incinerator along with that from the Acid Gas Amine Absorber and from the Sulphur Pit. 4.3.3

Tail Gas Treatment Unit Control Description

4.3.3.1

Controls for RGG Combustion Air Blower (9102-K-11A/B)

4.3.3.1.1

Surge Protection

The basic objectives of the surge protection system are: •

To prevent surge-induced compressor damage and process upsets without sacrificing energy efficiency

•

To maintain selected process-limiting variables within safe or acceptable range

•

To achieve these objectives, the anti surge controller manipulates the position of a blow-off valve and IGV (inlet pressure control)

4.3.3.1.2

Anti surge Protection

The regulation of the combustion air blower valves is implemented on the CCC Antisurge controller.

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TITLE: OPERATION AND MAINTENANCE MANUAL

CCC receives the following signals from the compressor skid (9102-K-11A/B) to perform the pressure and anti-surge regulation: Sl. #

9102-K-11A Tag No.

9102-K-11B Tag No.

Service

1.

91-PT-1452

91-PT-1712

Discharge air pressure

2.

91-TT-1454

91-TT-1714

Discharge air temperature

3.

91-FT-1452

91-FT-1712

Discharge air flow

4.

91-PT-1454

91-PT-1714

Compressor inlet air pressure

5.

91-TT-1455

91-TT-1715

Compressor inlet air temperature

6.

91-PT-1456

91-PT-1716

Discharge air pressure after check valve

7.

91-ZT-1453

91-ZT-1713

IGV valve position transmitter

8.

91-ZT-1451

91-ZT-1711

Blow-off valve position transmitter

9.

91-II-1470

91-II-1730

Main motor current signal

Note: 9102-K-11A controls are discussed in the following section. After processing all the above signals, CCC controls the IGV 91-PCV-1453 and blow-off valve 91-FCV-1451. CCC also provides trip signal 91-XS-1464 for excessive surge to ESD to stop the compressor. When the blower is started IGV 91-PCV-1453 receives a minimum opening signal from CCC which is a pre-set value on CCC and the blow-off valve 91-FCV-1451 remains open. When the compressor is loaded, CCC modulates the IGV 91-PCV-1453 and blow-off valve 91-FCV-1451 to maintain the discharge air pressure constant. 4.3.3.1.3

IGV 91-PCV-1453

The regulation system of compressor IGV valve 91-PCV-1453 is of the constant pressure type. After the loading of compressor the pressure regulation loop stabilizes and the IGV 91-PCV-1453 opens or closes only when the air required by the machine varies, so as to maintain the discharge pressure of the blower within the set-point defined. 4.3.3.1.4

Blow-off Valve 91-FCV-1451

The anti-surge regulation loop provides to regulate the blow-off valve 91-FCV-1451 by a continuous calculation of the discharge pressure 91-PT-1452 and discharge flow 91-FT-1452. When the flow is higher than the pressure the result of the calculation closes the blow-off valve. When the pressure is higher than the flow the result of the calculation opens the blow-off valve.

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4.3.3.2

Reducing Gas Generator Controls

4.3.3.2.1

Hydrogenation Reactor I/L Temperature Control

The Hydrogenation Reactor inlet temperature is controlled through 91-TIC-1307 by adjusting the air and the fuel Gas flow rates to the Reducing Gas Generator. The Hydrogenation Reactor inlet temperature is controlled by 91-TIC-1307, output of the controller 91-TIC-1307 is directly fed to the combustion air flow controller 91-FIC1304 as a set point and output of the controller 91-FIC-1304 regulates the air flow damper 91-FV-1304. Fuel gas flow is controlled by 91-FIC-1311; set point for the fuel gas controller is derived in the block 91-UY-1304 by multiplying the air flow with AIR/FG ratio set value provided from 91-HIC-1304 (Range: 0.09 to 0.15). Output of the controller 91-FIC-1311commands the fuel gas control valve 91-FV-1311. If the Hydrogenation Reactor inlet temperature increases, then controller 91-TIC-1307 shall first decrease the Set point of combustion air flow controller 91-FIC-1304, which in turn decrease the set point of fuel gas controller 91-FIC-1311 and vice versa. 4.3.3.2.2

Steam Flow Control

LP steam is injected directly in to the RGG burner in a ratio of steam to fuel gas to suppress the formation of soot. Steam flow to RGG is measured by 91-FT-1310 which is fed as a process variable to the steam flow controller 91-FIC-1310, set point for the controller is calculated by multiplying the process variable from 91-FIC-1311(FG flow) with the STEAM/FG ratio manually provided via 91-HIC-1311(2.0:1.0). Output (0-100%) of the controller 91-FIC-1310 directly commands the control valve 91-FV-1310. Alarm

Control Loop

Unit

Operating Set Point

Low

High

91-TIC-1307

Hydrogenation reactor I/L temperature

°C

290

285

295

91-FIC-1304

RGG comb air flow

Sm3/hr

2371.6

2134

2609

3

Sm /hr

263.7

237

290

kg/hr

400

360

440

Controller

91-FIC-1311

RGG fuel gas flow

91-FIC-1310

RGG quench steam flow

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Fig. 20 - Reducing Gas Generator Temperature Control

9102-V-11 SP PV

X

Hydrogenation Reactor

FIC 1304 MV

Comp FY 1304

FT 1304

TIC 1307

PT 1304

FV-1304

PV Fuel Gas Ratio HIC Air 1304

MV

X

UY 1304

FIC SP 1311 PV

FT 1311 Fuel Gas to RGG

FV-1311 X

HIC 1311

SP

UY 1311

PV

SP FIC PV 1310

MV

FT 1310 Steam to RGG

Tail Gas

TT 1304

Combustion Air to RGG

Steam Ratio Fuel Gas

TT 1307

FV-1310

9102-F-11 Reducing Gas Generator

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4.3.3.3

Reactor Effluent Cooler Controls

4.3.3.3.1

Reactor Effluent Cooler Level Control

Hydrogenated process gases from the Hydrogenation Reactor are cooled in the Reactor Effluent Cooler (9102-E-11) and generates LP steam in the shell side of the cooler. The water level in the Reactor Effluent Cooler is maintained by level controller 91-LIC1302 by monitoring the level through 91-LT-1302, level control is achieved by controlling the boiler feed water inlet to the Reactor Effluent Cooler through the control valve 91-LV-1302. Controller Tag

Control Description

91-LIC-1302

Reactor Effluent Cooler level Control

Alarm

Unit

Operating Set Point

Low

High

%

85

81

92

•

Low low level alarm (91-LALL-1309) set at 76% in reactor effluent activates the RGG (9102-F-11), TGTU and SRU shutdown

•

BFW inlet to reactor effluent control valve 91-LV-1302 opens on instrument air failure.

4.3.3.3.2

Reactor Effluent Cooler Outlet Tail Gas Control

In normal operation tail gas from the Reactor Effluent Cooler will be routed to Contact Condenser but during start-up tail gas is diverted to the Incinerator. This diversion of tail gas is accomplished by activating the selector switch 91-HS1303A. This opens the valve 91-XV-1332 (tail gas going to the Contact Condenser) and when it is fully open the valve 91-XV-1331 will close (tail gas going to the incinerator). This ensures that at least one path is fully open for the tail gas to pass through without pressuring the upstream reducing gas generator RGG. 4.3.3.4 4.3.3.4.1

Desuperheater/Contact Condenser Controls Desuperheater/Contact Condenser Column Bottom Level Control

The Desuperheater Circulation Pump (9102-P-11A/B) takes suction from the Desuperheater/Contact Condenser (9102-C-11) bottom and circulates water to the column through Wash Water Filter (9102-S-15). The Desuperheater/Contact Condenser column bottom level is maintained by the level controller 91-LIC-1307, regulating the level control valve 91-LV-1307, which controls slip stream of water flow from the Cooling Water Circulation Pumps (9101-P-12A/B) to the bottom section of the column as top up water.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Tag 91-LIC-1307

Control Description Desuperheater/Contact Condenser column bottom level

Alarm

Unit

Operating Set Point

Low

High

%

50

22

93

•

Low low level alarm (91-LALL-1306) in Desuperheater/Contact Condenser column bottom trips the Desuperheater Circulation Pumps 9102-P-11A/B

•

Desuperheater/Contact Condenser column bottom level control valve 91-LV-1307 opens on instrument air failure.

4.3.3.4.2

Circulating Water Return Flow to Desuperheater Control

The Desuperheater Circulation Pump (9102-P-11A/B) takes suction from the column (9102-C-11) bottom and circulates water to the column through Wash Water Filter (9102-S-15). Flow from the Wash Water Filter to the column bottom is maintained by the flow controller 91-FIC-1314 which regulates the flow control valve 91-FV-1314. Controller Tag 91-FIC-1314

Alarm

Control Description

Unit

Operating Set Point

Low

High

Circulating water return to Desuperheater

m3/hr

199

179

219

•

Low low flow alarm (91-FALL-1306) set at 30 m3/hr in circulating water return to de super heater trips the de super heater circulation pumps 9102-P-11A/B

•

Circulating water return to de super heater flow control valve 91-FV-1314 opens on instrument air failure.

4.3.3.4.3

Desuperheater/Contact Condenser Top Level Control

The cooling water circulation in the Contact Condenser top section is carried out by Cooling Water Circulation Pump (9101-P-12A/B). The Contact Condenser (9102-C-11) top level is maintained by the level controller 91-LIC-1305 through the level control valve 91-LV-1305, which controls the excess water flow from the Cooling Water Circulation Pumps discharge to the Waste Water Degasser (6922-V-07). Controller Tag

Control Description

91-LIC-1305

Desuperheater/Contact Condenser top level

Alarm

Unit

Operating Set Point

Low

High

%

50

32

90

•

Low low level alarm (91-LALL-1304) in Desuperheater/Contact Condenser column top trips the Cooling Water Circulation Pump 9102-P-12 A/B

•

Desuperheater/Contact Condenser column top level control valve 91-LV-1305 closes on instrument air failure

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4.3.3.4.4

Desuperheater/Contact Condenser Top Circulating Water Flow Control

Cooled circulating water return from the Contact Condenser Trim Cooler (9102-E13A/B) flows to top of the de-super heater/contact condenser column (9102-C-11) is measured by 91-FT-1307 and controlled by the flow controller 91-FIC-1307 which regulates the flow control valve 91-FV-1307. Controller Tag

Control Description

91-FIC-1307

Desuperheater/ Contact Condenser top CW

• 4.3.3.4.5

Alarm

Unit

Operating Set Point

Low

High

m3/hr

197

177.3

216.7

Desuperheater/Contact Condenser column top cooling water control valve 91-FV1307 opens on instrument air failure Desuperheater/Contact Condenser Top Pressure Control

In normal operation Desuperheater/Contact Condenser column (9102-C-11) tail gas flows to the Tail Gas Amine Absorber 9102-C-12 but during start-up, flow will be diverted to the Incinerator and the tail gas pressure is maintained by the pressure controller 91-PIC-1308 by monitoring the pressure transmitter 91-PT-1308 located in the start-up bypass line to Incinerator. If the pressure increases then the control valve 91-PV-1308 opening will increase to pass more gas to the Incinerator (9101-F-14). Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

91-PIC-1308

Desuperheater/ Contact Condenser column top pressure

bara

1.19

NA

NA

• 4.3.3.4.6

Desuperheater/Contact Condenser column top pressure control valve 91-PV-1308 to incinerator opens on instrument air failure Contact Condenser Cooler Temperature Control

Temperature of the circulating water from the Cooling Water Circulation Pumps (9102-P-12-A/B) is controlled by cooling the fluid to 54°C (maximum temperature) in summer and not less than 40°C (minimum temperature) in winter using three fans: one fixed speed fan (on/off) control (column 1), and another two VSD controlled fans working simultaneously (in column 2 & 3). The contact condenser cooler outlet temperature is measured at outlet of Contact Condenser Trim Cooler by 91-TT-1301 and received by the temperature controller 91-TIC-1301. The output of this controller sends the control signal to control the three fans and also to control the bypass control valve 91-TV-1301 of Contact Condenser Trim Cooler.

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In auto mode, the temperature controller shall follow up the cooler outlet temperature changes by changing the VSD (9102-EM-12AB/AC/BB/BC) rates to maintain the temperature set point-1 = (54°C + 40°C)/2=47°C. The fixed speed fan (9102-EM-12AA/BA) will operate on gap control set point between the values Tmax=54°C & Tmin=42°C. The temperature control valve will be used only in case the cooler outlet temperature goes to pre-determined temperature T=42°C, then the control valve shall open gradually to maintain the cooler temperature and keep it around the set point-2 (42°C). 4.3.3.5

Tail Gas Amine Absorber Controls

4.3.3.5.1

Tail Gas Absorber Level Control

The tail gas from the Desuperheater/Contact Condenser (9102-C-11) enters at the bottom of Tail Gas Amine Absorber 9102-C-12. Bottom level in the Tail Gas Amine Absorber (9102-C-12) is maintained by controlling the rich amine flow from the bottom of the column to Acid Gas Amine Absorber (9103-C-11) through 9103-P-16A/B. Tail gas absorber bottom level is controlled by 91-LIC-1308; Tail Gas Rich Amine Pumps 9102-P-16A/B discharge flow to Acid Gas Amine Absorber is measured by 91-FT-1325 and controlled by the flow controller 91-FIC-1325; set point for the SLAVE flow controller 91-FIC-1325 is received from the tail gas absorber MASTER level controller 91-LIC-1308. Output of the flow controller 91-FIC-1325 directly controls the control valve 91-FV-1325 in the Tail Gas Rich Amine Pumps 9102-P-16A/B discharge flow to the acid gas amine absorber. Controller Tag

Control Description

91-LIC-1308

Tail Gas Amine Absorber bottom level

91-FIC-1325

Rich amine flow to 9103-C11

Alarm

Unit

Operating Set Point

Low

High

%

50

11

82

m3/hr

136

NA

NA

•

High high level alarm (91-LAHH-1310) in Tail Gas Amine Absorber bottom closes the lean amine inlet valve 91-XV-1310 to Tail Gas Amine Absorber

•

Low low level alarm (91-LALL-1301) in Tail Gas Amine Absorber bottom trips the Tail Gas Rich Amine Pumps (9102-P-16A/B) and closes tail gas rich amine valve 91-XV-1309.

•

Rich amine flow control valve 91-FV-1325 to Acid Gas Amine Absorber closes on instrument air failure.

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4.3.3.5.2

Lean Amine to Tail Gas Amine Absorber Flow Control

Lean amine solution from Lean Amine Pumps (9103-P-13A/B) and tail gas from Desuperheater/Contact Condenser (9102-C-11) enters the Tail Gas Amine Absorber (9102-C-12). Lean amine flow to the absorber is measured by 91-FT-1301 and controlled by 91-FIC-1301. Output of the flow controller directly regulates the lean amine flow control valve 91-FV-1301. Controller Tag 91-FIC-1301

Alarm

Control Description

Unit

Operating Set Point

Low

High

Lean amine flow to Tail Gas Amine Absorber

m3/hr

135

110

148.5

•

High high level alarm (91-LAHH-1310) in Tail Gas Amine Absorber bottom closes the lean amine inlet valve 91-XV-1310 to Tail Gas Amine Absorber located on the downstream of 91-FV-1301.

•

Lean amine inlet valve 91-XV-1310 closes on activation of ESD-0, ESD-1 and ESD-2 shutdown.

4.3.3.5.3

Tail Gas Rich Amine Pumps Minimum Flow Control

Tail Gas Rich Amine Pumps (9102-P-16A/B) minimum flow to Tail Gas Amine Absorber bottom is controlled by 91-FIC-1303. Output of the controller 91-FIC-1303 controls the fail open control valve 91-FV-1303. Controller Tag 91-FIC-1303 • 4.4 4.4.1

Control Description Tail Gas Rich Amine Pump min flow

Alarm

Unit

Operating Set Point

Low

High

m3/hr

31.25

27.5

NA

Tail Gas Rich Amine Pump discharge flow Low low alarm (91-FALL-1305) set at 25 m3/hr trips the Tail Gas Rich Amine pumps (9102-P-16A/B).

INCINERATOR Equipment Specification Incinerator Air Blowers Equipment Tag No. Process Medium Rated Capacity, ACMH

9101-K-12A/B Air 63,402

Design Temperature, (Min./Max.), °C

0/52

Drive Type

Motor

Driver Power, kW Material of Construction, Impeller

94 Corten Steel

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Incinerator Equipment Tag No.

9101-F-14

Size, (OD/L), m

3.886/17.374

Process Medium

Tail Gas/Air/Fuel Gas

Design Temperature, shell, °C

343

Design Pressure, barg

3.8

Burner Model Size Quantity Duty

GSLF-24J 82” 1 32.2 MW-H

Turndown

5:1

Pilot Type

AR/GS-1

Design Temperature, shell, °C

343

Design Pressure, barg

3.8

Incinerator Stack Equipment Tag No. Process Medium

9101-X-11 Flue Gas

Shell OD/Height, m

2.438/110

Design Temperature, (Shell/Refractory), °C

343/1538

Design Pressure, barg Internal Lining 4.4.2

Process Description and Control

4.4.2.1

Tail Gas Incinerator Process Description

ATM. YES, L.W. Castable

An Incinerator 9101-F-14 is provided to thermally oxidise all possible sulphur compounds to SO2 in off gas effluents from the Acid Gas Amine Absorber 9103-C-11, Tail Gas Amine Absorber 9102-C-12, SRU tail gases and vent gases from the Sulphur Degassing Pit 9101-T-01/01B. Moreover all BTEX content of off gas effluent is also destructed. To ensure complete combustion of these sulphur compounds the Incinerator's combustion chamber temperature is maintained at a temperature of about 800°C by burning fuel gas supplied with combustion air in the unit's burner. Combustion air is supplied from 2 x 100% Incinerator Air Blowers (9101-K-12 A/B, One Operating and One Standby). The Blowers are driven by VFD motors. Each Blower is provided with an Air Intake Stack with Bird Screen, Sand Filter and Rain Hood.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Fuel gas to the Incinerator is supplied from the existing Fuel Gas network. A tapping is taken from the existing fuel gas line 6”-6536-FG-101-C12P and fuel gas is supplied to the Incinerator 9101-F-14 and Reducing Gas Generator 9102-F-11. The flows of fuel gas and combustion air are each measured by flow and then ratio controlled to ensure the correct amount of excess air is always maintained in the Incinerator combustion chamber to allow the oxidation of the sulphur compounds in the tail and vent gases to take place. An Oxygen Analyser 91-AE-1051 located in the Incinerator outlet combustion gases Stack 9101-X-11 monitors the excess O2 in the Incinerator combustion gases. Adjustments may be made to the fuel gas to air ratio controller to ensure the correct excess of O2 (3% by Mol) is seen in the stack gases. A sulphur dioxide analyser AE-1052, located at the Incinerator Stack (9101-X-11), monitors the Incinerator stack gases for SO2 content. A NOX analyser 91-AE-1053, located at the Incinerator Stack (9101-X-11), monitors the Incinerator stack gases for NOX content. 4.4.2.2 4.4.2.2.1

Tail Gas Incinerator Process Control Incinerator Temperature control (91-TIC-1155)

Normal operating temperature of the Incinerator is 817⁰C; the temperature in the Incinerator is controlled by modulating the flow of fuel gas and combustion air. Temperature in the Incinerator is measured by 91-TT-1155 and controlled by 91-TIC1155. The output of the controller 91-TIC-1155 is fed to a splitter 91-TY-1155A where the output is splitted into 0-50% which is fed to 91-TY-1155C for regulating the combustion air flow and 50-100% which is fed to 91-TY-1155B for regulating the fuel gas flow. 0-50% output of 91-TIC-1155 is scaled to 0-100% and is reversed in 91-TY-1155C (This is for regulating the temperature of Incinerator during normal operation by varying the speed of the air blower). This value is then fed to a high selector function block 91-FY1156C. The other input of 91-FY-1156C is received from 91-FY-1155A (This determines the quantity of combustion air required based on fuel gas flow). The combustion air flow rate from Air Blowers is measured in the common discharge line by 91-FT-1156. 91-FIC-1156 receives the PV from 91-FT-1156 and set point (SP) from 91-FY-1156C. The output (MV) of 91-FIC-1156 is then scaled to 4-20 mA. The scaled current signal is sent to VSD panel of Duty Air Blower for controlling its speed. The speed of the Air Blower determines the quantity of combustion air required. The main fuel gas flowing to the burner is measured by 91-FT-1155 and the PV is sent to 91-FIC-1155.

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

The set point for 91-FIC-1155 is derived from the temperature controller 91-TIC-1155. i.e. The output (MV) of 50-100% is scaled to 0-100% and is fed as SP through 91-TY1155B to 91-FIC-1155. The ratio set point is manually entered by operator via 91-HIC-1155A. The fuel gas flow value (PV) of 91-FIC-1155 is multiplied by ratio set point in function block 91-FY1155A. The ratio set point gives the correct ratio of air to fuel gas based on a manually determined composition. The multiplication factor is a manual entry and is based on the design composition of the feed gas. The output value of 91-FY-1155A is given to the selector function block 91-FY-1156C. The actual ratio of combustion air to fuel gas is displayed in function block 91-FY-1155A. Fuel gas flow control is achieved via 91-FIC-1155 by controlling 91-FV-1155 This reversed output and air/fuel ratio provided via 91-HIC-1155A is allowed to pass through the high demand selector 91-FY-1156C which provides the set point to combustion air flow controller 91-FIC-1156. Output of the controller modulates the combustion air flow by changing the Combustion air fan 9101-K-12A/B VFD set point. 50-100% output of 91-TIC-1155 is scaled to 0-100% in 91-TY-1155B, which provides the set point to the fuel gas controller 91-FIC-1155 and output of the controller 91-FIC1155 commands the fuel gas control valve 91-FV-1155. Controller Tag

Control Description

Unit

91-TIC-1155 91-FIC-1155

Operating Set Point

Alarm Low NA NA

High 850 NA

Incinerator stack temp °C 800 3 Incinerator Fuel gas flow Sm /hr 2256.9 Incinerator combustion air 91-FIC-1156 Sm3/hr 46938.7 NA NA flow • High high temperature alarm (91-TAHH-1160) set at 900°C, low low combustion air flow alarm (91-FALL-1156B/C) set at 8383 Sm3/hr, low low fuel gas pressure alarm (91-PALL-1156) set at 0 barg and high high fuel gas pressure alarm (91-PAHH-1156) set at 4 barg at Incinerator •

Closes the following valves: •

Fuel gas block valve 91-XV-1555 to burner

•

Fuel gas block valve 91-XV-1557 to burner

•

Pilot gas block valve 91-XV-1558 to burner

•

Pilot gas block valve 91-XV-1560 to burner

•

Instrument air block valve 91-XV-1161

•

Pilot air block valve 91-XV-1162

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

•

•

Opens the following valves: •

Fuel gas vent valve 91-XV-1158

•

Pilot gas vent valve 91-XV-1159

Fuel gas supply control valve 91-FV-1155 to Incinerator furnace closes on instrument air failure.

The schematic diagram for Incinerator temperature control is shown below: Fig. 21 - Incinerator Temperature Control

Master TE 1155

TT 1155

TIC 1155

Incinerator 9101-F-14 X

TY 1155B Slave MV

SP

50-100%

TY 1155A

Split

X

0-50%

FY PV 1155A

FIC 1155 PV

X

Burner

TY 1155C FT 1155

HIC Fuel Ratio 1155A Air

Combustion Air Fuel Gas to Incinerator

FV 1155 Slave FT 1156A

Combustion Air Fan

PV

FIC 1156 MV

VFD

FY-1156A

9101-K-12A

Combustion Air Fan

VFD 9101-K-12B

FY-1156B

>

SP

FY 1156C High Selector

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.5

INSTRUMENT AIR PACKAGE

4.5.1

Instrument Air Compressor Package

4.5.1.1

Equipment Specification

Screw Compressors Tag No.

6837-K-02A/B Rotary, Dry Screw, 2 stage, Air-cooled

Type No. of units

Two (1 Working + 1 Standby) 3

Capacity, Nm /hr (Total) @52°C & 100% RH

900

Design Pressure, barg

8.6

Design Temperature, °C

52/0

Compressor Inlet Pressure, barg

ATM

Compressor Inlet Temperature, °C

AMB (0-52)

Compressor Outlet Pressure, barg

8

Driver Driver Power, kW

Motor 200

Pre-cooler Tag No.

6837-E-03A

Design Pressure, barg

11

Design Temperature, °C

260

Inter-cooler Tag No.

6837-E-03A

Design Pressure, barg

3.7

Design Temperature, °C

180

After-cooler Tag No.

6837-E-03A

Design Pressure, barg

13.7

Design Temperature, °C

200

After-cooler Tag No.

6837-E-04A

Design Pressure, barg

10.5

Design Temperature, °C

160

Max. Capacity, L/S

650

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

Discharge Air Receiver Tag No.

6837-V-10

Size, mm, (Dia x T/T)

2400 x 7200

Design Pressure, barg

9.7

Design Temperature, °C

85

Operating Pressure, barg

7

Operating Temperature, °C

60

Material of Construction

CS

4.5.2

Instrument Air Dryer Package

4.5.2.1

Equipment Specification

Air Dryer Tag No. Dryer Type

6837-A-03/04 Twin Tower, pressure swing absorption with heatless regeneration

Capacity, Nm3/hr

300

Design Pressure, barg

9.7

Design Temperature, °C

85/0

Operating Pressure, barg

8

Operating Temperature, °C

60

Desiccant Type

Activated Alumina/Molecular Sieve

Pre-Filter Tag No. Size (Dia x L), mm

6837-S-07A/B & 6837-S-09A/B 190 x 621

Design Pressure, barg

9.7

Design Temperature, °C

85

Material of Construction

Cast Aluminium

Dryer Vessels Tag No.

6837-V-14A/B & 6837-V-15A/B

Size (Dia x T/T), mm

550 x 1500

Design Pressure, barg

9.7

Design Temperature, °C

85

Material of Construction

CS

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TITLE: OPERATION AND MAINTENANCE MANUAL

After-Filters Tag No.

6837-S-08A/B & 6837-S-10A/B

Size (Dia x L), mm

190 x 621

Design Pressure, barg

9.7

Design Temperature, °C

85

Material of Construction

Cast Aluminium

Instrument Air Receiver Tag No.

4.5.3

6837-V-11

Size mm, (Dia x T/T)

3700 x 7400

Design Pressure, barg

9.7

Design Temperature, °C

85/0

Operating Pressure, barg

7.1

Operating Temperature, °C

60

Material of Construction

CS

Instrument Air Package Description The new air compressor package consists of the following: 1. Two (2x100%) single base frames mounted Air Compressors (6837-K-02A/B), each having a capacity of 900 Nm3/hr (dry basis). 2. Each Compressor is supplied with an individual After Cooler. 3. One air compressor discharge drum, (6837-V-10) is provided. 4. Two Instrument air dryer packages, (6837-A-03/04) running at 2X50%, each dryer capacity is 300 Nm3/hr (dry basis). 5. Pre and After Filters for each dryer. 6. One instrument air receiver (6837-V-11) with storage capacity to provide instrument air for a period of 20 minutes following a compressor trip. 7. Dew point analyzers are provided for individual dryer package. The compressors are air-cooled, oil free, rotary screw type and are sized 100% of duty. Both Compressors operate in Duty/Standby configuration (with automatic changeover of the standby unit compressor). The dryer consists of two 50% heater-less desiccant dryers each consisting of two vessels (one drying, one regenerating), a set of duplex pre and after filters. Each dryer is 50% of design capacity (Single Compressor supply). Compressors and Dryers have locally mounted instruments and junction boxes and operate from the UCP, with DCS and ESD remote monitoring, through TCP/IP.

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

Based on air demand only one compressor under normal conditions will be loaded, the second unit can start but will have load inhibitors to ensure only one unit is loaded. Each dryer has a sonic nozzle at the discharge header to ensure the protection against the greater flow. Each compressor is monitored and controlled by the Package Controller (UCP) which provides information to the ICSS. There is only a push button station available at each equipment station in the field (LCP). However this LCP still only communicates with the UCP which then sends signals to the DCS. All the signals are hardwired to UCP. The subsystems MCC, ESD and ICSS are hardwired to the UCP and linked also through a redundant modbus TCP/IP communication link. Compressor instrumentation and solenoids are all wired to junction boxes, the UCP system receives an external net air pressure signal and then starts, loads/unloads and stops the available compressor based on its own selecton routine. The ICSS supervises the system status via the UCP connected to the junction boxes shown in the Electrical Service Diagram. The new Air System will supply instrument and plant air with the following supply battery limit conditions for both instrument and plant air: Design

Operating

Pressure bar (g)

9.7

7.0

Temperature (°C)

85

55/60

The new instrument and plant air headers are connected to the existing NGL-3 instrument and plant air headers respectively through cross over connection lines with (manual isolation valves) for operation flexibility. 4.5.4

Instrument Air Package Control Description A. Loading/Unloading The compressor always starts to run in unloaded condition, up to first 20 seconds known as the load delay, this is to ensure the oil pressure is stabilised. After the load delay compressor will load unless either the operator manually selects to unload or there is no air demand. If there is no air demand the compressor runs unloaded and is said to be idle. To load the compressor the solenoid valve 68-XY-1401 shall be energized, similarly to unload the compressor solenoid valve 68-XY-1401 shall be de-energised and solenoid valve 68-XY-1403 shall be energised. When the compressor is in remote mode, loading/unloading of every compressor is based on the net air pressure signal 68-PT-1311.

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TITLE: OPERATION AND MAINTENANCE MANUAL

When the compressor is in local mode loading/unloading of every compressor is based on the compressor O/L pressure signal transmitter 68-PT-1406. If the air demand is low, i.e. when the pressure transmitter signal is above the load set point then UCP unloads the compressor and if the air demand is high, i.e. when the pressure transmitter signal is below the load set point then UCP loads the compressor. The loading/unloading set pressure in barg is given below: Compressor

Control

Loading

Unloading

Status

Compressor A

lead

XX

XX

running

Compressor B

lag

XX

XX

standby

Note: XX – Loading and Unloading set points will be set at site while commissioning the Air Compressor. B. Lead/Lag Control in Remote Mode Only in Remote-Auto mode the compressors shall follow the Lead, Lag logic. The purpose of Lead/Lag control is to allow two compressors to operate at once, with one operating as LEAD and maintaining system pressure, and the other operating as LAG and loading only as necessary when system pressure drops. When air demand is lower or equal to the air generation from one compressor, only the Lead compressor gets loaded. When the air demand increases above the capacity of one compressor, the lag Compressors gets loaded in sequence as per demand requirements. C. Compressor Auto changeover Compressor auto change over occurs on the 2 following conditions: 1. If the stand-by compressor was selected in remote mode then after 24 hours of duty compressor usage stand-by compressor will start automatically. 2. Duty compressor failure will start the standby compressor immediately. If the failed compressor was loaded and the air demand is still required, the unit will go in to loaded mode straight away after the starting delay (20 seconds). D. Dry Air Purge When the compressor is in “standby mode”, solenoid 68-XY-1407 is activated and this opens the purge air line allowing a small flow of dry air protecting the compressor during stand-by, also immediately when the status stand-by is changed to duty, solenoid 68-XY-1407 is de-energised.

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TITLE: OPERATION AND MAINTENANCE MANUAL

E. Water Separators Level Control Inter cooler and after cooler water Separators level is maintained by level indicators (68-XI-1402 and 68-XI-1406) via opening or closing of valves 68-XY-1402 and 68-XY-1406 respectively. F. Instrument Air Header Pressure Control The pressure on the discharge line from the instrument air receiver is monitored by a transmitter 68-PT-1310; pressure on the discharge line of the plant air header is controlled by 68-PIC-1310. Decrease in the instrument pressure signal will tends to close the control valve 68-PCV-1310 in the plant air line. Controller Tag 68-PIC-1310

4.6 4.6.1

Inst air header pressure control

Alarm

Unit

Operating Set Point

Low

High

bar(g)

6

5.5

NA

Control Description

•

Instrument Air pressure 68-PI-1312A/B/C/low low alarm set at 5 barg activates ESD Level-2 shutdown.

•

Instrument air pressure control valve 68-PCV-1310 closes on instrument air failure.

EFFLUENT & WASTE WATER TREATMENT Equipment Specification Waste Water Degasser Equipment Tag No. Process Medium Size (ID/T/T), mm

6922-V-07 Waste/Sour Water 1500/4500

Design Temperature, °C

165/0

Design Pressure, barg

3.5/FV

Operating Temperature, °C

73

Operating Pressure, barg

1

Material of Construction

CS

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

Waste Water Degasser Pumps Equipment Tag No.

6922-P-08A/B

Pump Type

Horizontal, Centrifugal

Process Medium

Waste/Sour Water 3

Capacity, Normal/Rated, m /hr Shut off Pressure, bar(g) Suction Pressure, bar(a), Normal/Rated Discharge Pressure, bar(a) Design Temperature, °C Operating Temperature, °C Driver Type Rated Power, kW Material of Construction, Casing/Internals

8.62/9.48 14.6 0.99/4.66 8.8 95/0 73 Motor 15 Duplex SS/Duplex SS

Sour Water Filter Equipment Tag No.

6922-S-06

Process Medium

Sour Water

Size (ID/T/T), mm

1500/4500

Design Throughput, m3/hr

9.48

Design Temperature, °C

95/0

Design Pressure, barg

14.6

Operating Temperature, °C

73

Operating Pressure, barg

7

Material of Construction

CS

Sour/Stripped Water Exchanger Equipment Tag No. Process Medium Design Pressure Shell Side (Stripped Water), barg Design Pressure Tube Side (Sour Water), barg Design Temperature Shell Side (Stripped Water), °C Design Temperature Tube Side (Sour Water), °C Operating Pressure Shell Side (Stripped Water), bar(a) Operating Pressure Tube Side (Sour Water), bar(a) Operating Temperature, Shell Side (Stripped Water), (In/Out) °C Operating Temperature, Tube Side (Sour Water), (In/Out) °C Design Duty, kW Material of Construction, Shell/Tube

6922-E-01 Sour/Stripped Water 11.3 14.6 160/0 160/0 6.80 7.4 126/104 73/96 276 CS/SS

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Sour Water Stripper Equipment Tag No.

6922-C-01

Design Pressure, barg (Max./Min.)

3.5/FV

Design Temperature, °C (Max./Min.)

165/0

Process Medium

Sour Water

Max. Liquid Level, Top Section, mm

700

Max. Liquid Level, Bottom Section, mm

1200

Tray Nos.

38

Tower Diameter, mm

1000

Tower Height, mm

25000

Operating Pressure, bar(a)

1.20

Operating Temperature, °C, Top/Bottom Material of Construction, Top section Material of Construction, Bottom section Material of Construction, Internals

82.2/126.1 CS+SS316L CLAD CS SS316L

Stripped Water Pumps Equipment Tag No.

6922-P-10A/B

Pump Type

Horizontal, Centrifugal

Process Medium

Stripped Water 3

Capacity, Normal/Rated, m /hr Shut off Pressure, bar(g) Suction Pressure, bar(a), Rated/Design Discharge Pressure, bar(a) Design Temperature, °C Operating Temperature, °C Driver Type Rated Power, kW Material of Construction, Casing/Internals

9.31/13.03 11.2 2.81/5.11 8.6 160/0 126 Motor 11 Duplex SS/Duplex SS

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TITLE: OPERATION AND MAINTENANCE MANUAL

Stripper Overhead Circulation Pumps Equipment Tag No.

6922-P-11A/B

Pump Type

Horizontal, Centrifugal

Process Medium

Water 3

Capacity, Normal/Rated, m /hr Suction Pressure, bar(a), Rated/Max. Discharge Pressure, bar(a) Design Temperature, °C Operating Temperature, °C Driver Type

13.23/19.85 3.9/7 8.0 150/0 121 Motor

Rated Power, kW

7.5

Material of Construction, Casing/Internals

Duplex SS/Duplex SS

Sour Water Stripper Reboiler Equipment Tag No.

6922-E-04

Process Medium

Sour Water

Design Pressure, Shell Side barg

7.0/FV

Design Pressure, Tube Side barg

7.0/FV

Design Temperature, Shell side °C

165/0

Design Temperature, Tube side °C

185/0

Operating Pressure, Shell, Side barg

1.40

Operating Pressure, Tube Side barg

3.5

Operating Temperature, Shell side °C

126.1

Operating Temperature, Tube side °C

147.7

Design Duty, kW

1803 kW

Material of Construction, Shell side

CS

Material of Construction, Tube side

SS316L

Re boiler Condensate Drum Equipment Tag No.

6922-V-09

Process Medium

Steam Condensate

Size (ID/T/T), mm

800/2400 3

Design Throughput, m /hr

9.48

Design Temperature, °C

185/0

Design Pressure, barg

7/FV

Operating Temperature, °C

155

Operating Pressure, barg

4.5

Material of Construction

CS

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TITLE: OPERATION AND MAINTENANCE MANUAL

Stripper Overhead Cooler Equipment Tag No. Type Process Medium

6922-E-03 Forced Draft Stripper Overhead Vapours

Design Pressure, barg

11.1

Design Temperature, °C

150/0

Operating Pressure, barg

2.7

Operating Temperature, °C

121/55

Design Duty, kW

998

Material of Construction

CS

Number of Fans

2

Driver Type

Motor

Rated Power, kW

15

Stripped Water Cooler Equipment Tag No. Type Process Medium

6922-E-02 Forced Draft Stripped Water

Design Pressure, barg Design Temperature, °C

130/0

Operating Pressure, bar(g)

5.7

Operating Temperature, °C

104/52

Design Duty, kW

630

Material of Construction

CS

Number of Fans

2

Driver Type Rated Power, kW 4.6.2

11.2

Motor 11

Effluent and Waste Water Treatment Process Description Sour water from various sources is collected in the Waste Water Degasser 6922-V-07, which provides over 20 minutes of hold-up for the waste water. The flow of waste water from TGTU Cooling Water Circulation Pumps 9102-P-12A/B is continuous at a rate of 8.7 m3/hr. The pressurised drain from Cooling Water Circulation Pumps 9102-P12A/B and the flow from Regenerator Reflux Drum Pumps 9103-P-11A/B are intermittent. The sour water from the Waste Water Degasser 6922-V-07 is continuously pumped under flow control by Waste Water Degasser Pumps (6922-P-08A/B) to the Sour Water Stripper 6922-C-01 for treatment.

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In the event the Sour Water Treatment System is unavailable due to a process upset, provision exists for manually routing the Waste Water Degasser liquids directly to the Observation Sump (6922-X-04). A balance line between Waste Water Degasser 6922-V-07 and Sour Water Stripper 6922-C-01 means that the pressure in the Waste Water Degasser 6922-V-07 floats on the Sour Water Stripper 6922-C-01 operating pressure (i.e. 1.0 barg). A nitrogen supply line is provided to maintain pressure in the Waste Water Degasser 6922-V-07 if it falls below a certain minimum as liquids are pumped out. The sour water from Waste Water Degasser 6922-V-07 is filtered in Sour Water Filter (6922-S-06) to remove particle size of 10 micron e.g. sand, pipe scale and salts and then preheated in Sour/Stripped Water Exchanger (6922-E-01) before feeding to Sour Water Stripper. The Sour Water Stripper operates at 1.0 barg and has an upper section and a lower tray section. The upper section is provided with temperature indication locally as well as in DCS. A differential pressure transmitter is also provided across trays 33 to 38 with indication in DCS. The middle section of the column is also provided with a temperature indication locally as well as in DCS. A differential pressure transmitter is also provided across trays 1 to 32 with indication in DCS. The bottom section of the column is provided with temperature and level indications locally as well as in DCS. The sour water is stripped by the vapours generated from the Sour Water Stripper Reboiler 6922-E-04. The Reboiler utilises LP steam to heat the sour water that comes from the bottom of the Sour Water Stripper to 126⁰C. The condensed steam from the Reboiler is sent to the LP Condensate system through level control. Reflux for the column is provided by a pump-around system. Water is taken from below tray 33 pumped by Stripper Overheads Circulation Pumps (6922-P-11A/B) under flow control, cooled in Stripper Overheads Cooler (6922-E-03) and then returned to the top tray. The stripper overhead acid gases are routed to the TGTU (upstream of Desuperheater/Contact Condenser, 9102-C-11). In the event of high column pressure, excess gases are diverted to LP Acid Gas Flare. The stripped water from the stripper is pumped under level control cascaded to a flow controller via Stripper Water Pump (6922-P-10A/B) to the Sour/Stripped Water Exchanger (6922-E-01) to preheat the feed to the stripper. The water is then routed to the Stripped Water Cooler (6922-E-02) where it is cooled to 55°C before discharge to the Observation Sump. An analyser is provided in the line to the Observation Sump to monitor the sulphide content of the stripped water stream.

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4.6.3

Effluent & Waste Water Treatment Control Description

4.6.3.1

Waste Water Degasser Pressure Control

Waste Water Degasser (6922-V-07) pressure is maintained by the pressure controller 69-PIC-1307 by monitoring the pressure through 69-PT-1307 located at the top of the vessel. The pressure is maintained by regulating the pressure control valve 69-PV-1307 in the nitrogen line to the Waste Water Degasser. 69-PIC-1307 opens the nitrogen control valve 69-PV-1307 on falling pressure in the Waste Water Degasser. Controller Tag 69-PIC-1307

Control Description Waste Water Degasser top pressure

Alarm

Unit

Operating Set Point

Low

High

barg

1

0.8

1.2

•

High high pressure alarm (69-PAHH-1311) set at 1.3 barg in Waste Water Degasser closes the nitrogen inlet valve 69-XV-1315

•

High high level alarm (69-LAHH-1311) set at 77% in Degasser closes the nitrogen inlet valve 69-XV-1315

•

Waste Water Degasser 6922-V-07 nitrogen pressure control valve 69-PV-1307 closes on instrument air failure.

4.6.3.2

Waste Water Degasser Level Control

Waste Water Degasser (6922-V-07) level is monitored by 69-LT-1301 and controlled by 69-LIC-1301. Level in the Degasser is controlled by controlling the sour water outlet from Sour/Stripped Water Exchanger (6922-E-01). Master controller 69-LIC-1301 acts in cascade and provides the set point to sour water flow Slave controller 69-FIC-1314 which regulates the control valve 69-FV-1314 in the outlet of Sour/Stripped Water Exchanger 6922-E-01. Controller Tag

Alarm

Control Description

Unit

Operating Set Point

Low

High

69-LIC-1301

Waste Water Degasser level

%

50

33

53

69-FIC-1314

Sour water to Stripper column

m3/hr

8.2

7.4

9

•

High high level alarm (69-LAHH-1311) set at 77% in Degasser closes the nitrogen inlet valve 69-XV-1315 and waste water valve 69-XV-1312 from the Cooling Water Circulation Pumps 9102-P-12A/B

•

Low low level alarm (69-LALL-1311) set at 20% in Degasser 6922-V-07 trips the Waste Water Degasser Pumps 6922-P-08A/B

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• 4.6.3.3

Sour water to Stripper column control valve 69-FV-1314 closes on instrument air failure. Sour Water Stripper Pressure Control

A split range pressure controller 69-PIC-1315 is provided to maintain the top pressure of Sour Water Stripper (6922-C-01) by throttling the sour gas to TGTU control valve 69-PV-1315A (0-50%) and sour gas to LP acid gas flare drum control valve 69-PV-1315B (50-100%). On rising pressure 69-PIC-1315 first opens the sour gas to TGTU control valve 69-PV1315A; further increase in pressure causes the pressure controller to open the vent valve 69-PV-1315B to release gases to the LP Acid Gas Flare. Fig. 22 – 69-PIC-1315 Controller Output

The above drawing shows the split range operation of 69-PV-1315A & 69-PV-1315B. •

69-XV-1313 located at the downstream of sour water stripper top pressure control valve 69-PV-1315A to TGTU closes on activation on ESD-0 and ESD-1 shutdown

•

Sour Water Stripper Column 6922-C-01 control valve 69-PV-1315A to TGTU closes on instrument air failure

•

Sour Water Stripper Column 6922-C-01 control valve 69-PV-1315B to LP flare opens on instrument air failure. Controller Tag

Control Description

69-PIC-1315

Sour Water Stripper top pressure

Alarm

Unit

Operating Set Point

Low

High

bar(g)

1

0.8

1.2

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4.6.3.4

Sour Water Stripper Bottom Level Control

Stripped water from the bottom of the Sour Water Stripper 6922-C-01 is pumped via Stripped Water Pumps (6922-P-10A/B) to the Sour/Stripped Water Exchanger (6922-E01). Outlet from the Sour/Stripped Water Exchanger 6922-E-01 enters in to the Stripped Water Cooler (6922-E-02) and the cooled stripped water is sent to Observation and Buffer Sump. Sour Water Stripper (6922-C-01) bottom level is controlled by regulating the stripped water cooler outlet to the Observation and Buffer Sump. Sour Water Stripper ‘MASTER’ level controller 69-LIC-1306 acts in cascade and provides the set point to the Stripped Water Cooler outlet ‘SLAVE’ flow controller 69-FIC-1317 which regulates the flow control valve 69-FV-1317. Controller Tag

4.6.3.5

Alarm

Control Description

Unit

Operating Set Point

Low

High

69-LIC-1306

Sour Water Stripper bottom level

%

50

21

73

69-FIC-1317

Stripped Water Cooler outlet flow

m3/hr

8

6

10

•

Low low level alarm (69-LALL-1316) in Sour Water Stripper 6922-C-01 bottom trips the Stripped Water Pumps 6922-P-10A/B and closes the stripper outlet valve 69-XV-1339.

•

High high level alarm (69-LAHH-1316) Sour Water Stripper 6922-C-01 bottom trips the Waste Water Degasser Pumps 6922-P-08A/B and closes the Waste Water Degasser 6922-V-07 outlet valve 69-XV-1316.

•

Stripped Water Cooler 6922-E-02 outlet valve 69-FV-1317 to buffer sump closes on instrument air failure. Sour Water Stripper 6922-C-01 Top Level Control

Water from the Stripper Overheads Cooler (6922-E-03) is circulated to the top of the Stripper through the Stripper Overhead Circulation Pumps (6922-P-11A/B). Stripper top level is maintained by controlling the start-up-water which is mixed with the circulated water from the Sour Water Stripper column at the suction of the Stripper Overheads Circulation Pumps (6922-P-11A/B). Stripper top level is monitored and controlled by 69-LIC-1325 which directly controls the control valve 6922-LV-1325 in the start-up-water line. Controller Tag

Control Description

69-LIC-1325

Sour Water Stripper top level

Alarm

Unit

Operating Set Point

Low

High

%

50

30

74

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•

Low low level alarm (69-LALL-1315) in Sour Water Stripper top trips the Stripper Overhead Circulation Pump 6922-P-11A/B

•

Start-up water control valve 69-LV-1325 closes on instrument air failure.

4.6.3.6

Circulating Water Flow to Stripper Overhead Cooler Control

Circulated water from the Sour Water Stripper (6922-C-01) top is pumped by Striper Overhead Circulation Pumps (6922-P-11A/B) to Stripper Overhead Cooler (6922-E-03). Circulated water flow to stripper overheads is measured by 69-FT-1316 and controlled by the flow controller 69-FIC-1316 which directly controls the flow control valve 69-FV-1316 located in the common discharge of 6922-P-11A/B.

• 4.6.3.7

Controller Tag

Control Description

69-FIC-1316

CW to Stripper Overhead Cooler

Alarm

Unit

Operating Set Point

Low

High

m3/hr

13.6

12.2

15

Circulating water flow control valve 69-FV-1316 to Stripper Overhead Condenser opens on instrument air failure Sour Water Stripper Reboiler Temperature Control

Temperature control is achieved by controlling the steam flow to the stripper reboiler. LP steam flow to the Sour Water Stripper Reboiler 6922-E-04 is controlled by 69-FIC1315 which regulates the LP steam flow control valve 69-FV-1315. Set point for the steam flow control is received from the calculation block 69-UY-1315, where the sour water flow from 91-FIC-1314 is multiplied with manually set ratio (193) between LP steam and sour water which is provided via 69-HIC-1315. Controller Tag 69-FIC-1315

Control Description LP steam flow to the Stripper Reboiler

Alarm

Unit

Operating Set Point

Low

High

kg/hr

2154

1725

3015

•

LP steam valve 69-XV-1314 located on the upstream of the control valve 69-FV1315 closes on activation of Waste Water Degasser pressure high high alarm set at 1.3 barg.

•

LP steam flow control valve 69-FV-1315 to reboiler closes on instrument air failure.

4.6.3.8

Stripper Reboiler Steam Temperature Control

Temperature control of LP steam is achieved by passing the LP steam to Desuperheater (6922-X-01), where the temperature is maintained by injecting Boiler Feed Water.

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LP steam outlet temperature from the Desuperheater is monitored by 69-TT-1327 and controlled by 69-TIC-1327. Temperature Controller 69-TIC-1327 directly regulates the boiler feed water flow via 69-TV-1327 located at the inlet of De-super heater. Controller Tag 69-TIC-1327

• 4.6.3.9

Control Description LP steam temperature to the Stripper Reboiler

Alarm

Unit

Operating Set Point

Low

High

°C

148

NA

153

BFW control valve 69-TV-1327 to LP steam closes on instrument air failure Re-boiler Condensate Level Control

LP condensate from the Sour Water Stripper Reboiler 6922-E-04 is collected in Reboiler Condensate Drum (6922-V-09). Condensate level is monitored by 69-LT-1327 and controlled by 69-LIC-1327. Condensate level is maintained by throttling the control valve 69-LV-1327 which regulates the condensate flow to the LP condensate header. Controller Tag 69-LIC-1327 •

Alarm

Control Description

Unit

Operating Set Point

Low

High

Re-boiler Condensate Drum level

%

50

17

75

Re boiler condensate control valve 69-LV-1327 to LP condensate header closes on instrument air failure

4.6.3.10 Stripper Overheads Cooler Temperature Control Circulating water from the Stripper Overheads Circulation Pumps (6922-P-11A/B) enters in to the Stripper Overheads Cooler (6922-E-03) where the water is cooled and passes to the Sour Water Stripper. Temperature of the circulating water to the Sour Water Stripper (6922-C-01) is monitored at the outlet of the Stripper Overheads Cooler by 91-TT-1315 and controlled by 69-TIC-1315. Temperature controller 69-TIC-1315 output controls the speed of the stripper overhead cooler fans VSDs at the same time. The temperature controller, 69-TIC-1315 regulates the speed of the sour water Stripper Overheads Cooler VSDs (6922-EM-03AA, 6922-EM-03AB) to maintain the temperature of circulation water to Sour Water Stripper.

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Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

69-TIC-1315

Stripper overheads cooler to sour water stripper

°C

55

50

60

Details of control tags for VSD’s are tabulated below: S No.

Motor-no

Control Tag

Remarks

1.

6922-EM-03AA

69-SY-1324

VSD

2.

6922-EM-03AB

69-SY-1329

VSD

High high vibration alarm of each fan trips the respective fan motors 4.7

LP FUEL GAS

4.7.1

Equipment Specification LP Fuel Gas KO Drum Tag No.

6236-V-05

Size, mm, (Dia x T/T)

1100 x 2400

Design Pressure, barg

9.0

Design Temperature, °C Operating Pressure, (Normal/Max), barg Operating Temperature, °C Material of Construction 4.7.2

Fuel Gas System Process Description

4.7.2.1

Introduction

100/0 6/7 25-50 CS

LP Fuel Gas is required for New Steam Generation Boiler Packages 6848-A-02A/B/C. 4.7.2.2

Process Description

The new Fuel Gas requirements under the SRU upgrade project will be secured from two separate sources as follows. Source 1 Supply The main normal LP Fuel Gas supply for the new MP Steam Boiler Package (6848-A02A/B/C) is supplied from the first stage suction of the existing Booster Compressors (6701-K-10/20/30) in NGL-3. In addition, two back up sources are provided; the first is the fuel gas from 6103-K-01A/B with a second backup from existing 30” line (T-10). The new fuel gas supply system will consist of a letdown station, Fuel Gas KO Drum (6236-V-05) and a supply header to the steam boilers. The source pressure from the take-off point will be let down to 7 barg through the pressure control valve 62-PV-

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1301A before entering the LP Fuel Gas KO Drum. The source pressure of the fuel gas from 6103-K-01 A/B is 20 barg whilst that of feed gas from the 30” line is 45 barg. The former is let down to 7 barg through the pressure control valve 62-PV-1301B and the latter via 62-PV-1302. Source 2 Supply LP fuel gas for SRU upgrade new users (Reducing Gas Generator 9102-F-11 and new Incinerator, 9101-F-14) will be sourced from the existing LP fuel gas header at NGL-3 as there is sufficient spare capacity available for there. 4.7.2.3

Operating and Control System

The fuel gas for the LP fuel gas system is taken from the first stage suction of the Lean Gas Booster Compressors (6701-K-10/20/30), through 62-PV-1301A via pressure controller 62-PIC-1301 located in the top of the LP Fuel Gas KO Drum (6236-V-05). In the event of loss of lean gas supply from the Booster Compressors, the pressure controller 62-PIC-1301 signal is routed to 62-PV-1301B via soft valve selector 62-PY1301. In addition if there is an emergency shutdown of NGL Extraction unit (from where fuel gas is ultimately supplied) valve selector 62-PY-1301 is overridden and the signal from 62-PIC-1301 is automatically routed to 62-PV-1301B. This allows back up fuel gas taken from 6103-K-01A/B. The takeoff for the second back up supply is from 30" existing line (T-10) routed through 62-PV-1302 via pressure controller 62-PIC-1302. A fast acting pressure control valve 62-PV-1303 controlled by pressure controller 62-PC-1303 is provided on the overhead line from 6236-V-05 to route fuel gas to LP flare in the event the pressure in the KO drum continues to increase beyond the normal operating range. Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

62-PIC-1301

LP fuel gas from existing Booster compressors

bar g

7

5.3

7.8

62-PIC-1302

LP fuel gas to new SRU

bar g

7

5.3

7.8

62-PIC-1303

Fuel gas to LP flare

bar g

7

NA

7.8

•

High high pressure alarm (62-PAHH-1304) set at 8.2 barg in LP fuel gas trips the boiler packages and closes the fuel gas inlet on/off valves 62-XV-1301, 62-XV-1302 and 62-XV-1303.

•

LP fuel gas inlet pressure control valves 62-PV-1301A, 62-PV-1301B and 62-PV-1302 close on instrument air failure.

•

Fuel Gas vent to LP flare pressure control valve 62-PV-1303 opens on instrument air failure.

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4.8 4.8.1

SEA COOLING WATER SYSTEM Equipment Specification Sea Cooling Water Pumps Equipment Tag No. Pump Type Process Medium Capacity, m3/hr Suction Pressure, barg, Normal/Max. Discharge Pressure, barg Design Pressure, bar(g) Design Temperature, °C Operating Temperature, °C Driver Type Rated Power, kW Material of Construction, Casing/Internals

6932-P-04A/B Vertical, Centrifugal Sea Water 1600 0.07/0.25 5.0 8.0 85/0 35 Motor 340 Duplex SS/Duplex SS

Sea Cooling Water Filters Equipment Tag No. Process Medium Size (ID/T/T), mm Design Throughput, m3/hr Design Temperature, °C Design Pressure, barg Operating Temperature, °C Operating Pressure, barg Material of Construction

6932-S-02A/B Sea Water 610/1016 1600 85/0 8 15-40 5 Duplex SS

Local Biocide Drain Pit Equipment Tag No.

6932-T-06

Size (L/W/H), mm

1000/1000/1000

Design Temperature, °C Design Pressure, barg Material of Construction

85/0 0 Concrete

Local Chemical Drain Pit Equipment Tag No.

6932-T-01

Size (L/W/H), mm

1000/1000/1000

Design Temperature, °C Design Pressure, barg Material of Construction

85/0 0 Concrete

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4.8.2

Sea Cooling Water System Process Description Sea Cooling Water system is required to supply cooling water for the coolers in the SRU upgrade facilities. A part of sea cooling water is also supplied to existing sea water supply system. The Sea Cooling Water system includes two Sea Cooling Water Pumps (6932-P-04A/B, one operating and one standby), one Electro Chlorination Package (6932-A-05), one Biocide Injection Package (6932-A-06) and one Scale Inhibitor Injection Package (6932-A-07). Two Sea cooling Water Pumps 6932-P-04A/B are installed on a new jetty and take suction from the sea. The pumps are vertical-shaft, constant speed centrifugal pumps and are electric motor driven. The sea water cooling pumps have a design capacity of 1600 m3/h (each) at a discharge pressure of 5.0 barg. To meet the design flow requirements, one pump will be normally running, whilst the other is on standby. Each pump is capable of supplying a normal flow of 1200 m3/h to the users for SRU upgrade. The water enters the pump body through a suction pipe (stilling tube) shaped to reduce turbulence. A coarse mesh bar suction screen is installed at each pump to prevent seaweed and other debris from entering the sea water system. From the common discharge of seawater cooling pumps, seawater stream flows via a new dedicated 24” main supply header to the new filtration package unit (6932-S02A/B). The self cleaning rotary type Sea Water Filters (one in operation and one on standby) are capable of removing particle sizes greater than 1000 microns from seawater and each unit is designed for a flow of 1600 m3/h. The filtered water from filters is routed to the heat exchangers located in AGEU/TGTU another users. A small portion of the main seawater (cooling water) flow is diverted downstream of the filters to provide seawater supply for the Electro Chlorination Unit (6932-A-05). The Electro Chlorination unit generates sodium hypochlorite solution. The sodium hypochlorite solution is injected into Sea Cooling Water system. There is one dedicated new Electro Chlorination Unit. In addition, a dedicated Biocide Injection Unit (6932-A-06) for effective control of growth of marine organisms and a dedicated Scale Inhibitor Injection Unit (6932-A-07) to prevent formation of mineral scales in the Sea Cooling Water system are also provided for existing as well as new sea cooling water systems. The new cooling water system is a once through system and the sea water returned from the SRU upgrade facilities is discharged into existing Seawater Observation Sump (6932-X-01) which has a retention capacity of 60 m3. From the sump the seawater overflows to the sea. To prevent fouling the temperature of cooling water from each exchanger outlet should not exceed the maximum allowable temperature limit of 45°C.

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A tie in to the existing NGL-3/4 seawater supply system is also provided to supply seawater from the new seawater pumps. 4.8.3

Sea Cooling Water Control

4.8.3.1

Sea Cooling Water Pumps (6932-P-04A/B)

The cooling water pumps can be started and stopped from the DCS by means of one of the hand switches 69-HS-1311/1322. The running status indication of the pumps is provided in the DCS. In addition, pump discharge low pressure alarms with indication in the DCS (69-PIA-1301/1303), a pressure transmitter (69-PT-1301/1303), and a sample connection (69-SC-013/014) are provided for each pump. The chlorination, biocide and scale inhibitor lines to the pumps are provided with flow indicators to monitor injection of these chemicals into the pump suction. The cooling water flow through each heat exchanger may be manually regulated by butterfly valves located upstream/downstream of the exchanger. The valves are within view of the respective process side temperature indicator locations. For operational flexibility a 18” crossover connection between sea cooling water pump discharge line 24”-6932-SW-259-A7A2 is provided to supply sea cooling water to NGL3/4. The crossover line contains two 18” butterfly valves which are normally closed. 4.8.3.2

Filtration System

The Sea Cooling Water Filtration system comprises of two self cleaning rotary type Cooling Water Filters (6932-S-02A/B), one operating and one standby. Each filter is designed for a flow of 1600 m3/hr and is capable of removing particle sizes greater than 1000 microns. In addition each filter is equipped with an automatic back flushing mechanism which operates on an intermittent basis when filter cleaning is required. Across a cleaner seawater filter the normal pressure drop is 0.2 bar. During normal operation the filter will become dirty over a period of time and the pressure drop across it will increase. To ensure periodic cleaning of the online filter, a timer facility within the filter control panel automatically initiates the cleaning cycle after a preset interval and terminates it after a preset duration. The cleaning sequence involves the start of the cleaning gear and opening of the drain ON/OFF valve 69-XV-1340/1341. The former causes the debris trapped across the filter mesh to be loosened as the mesh rotates against static scrapers whilst the latter allows the loosened debris to be discharged back to the sea. The cleaning cycle lasts for approximately 90 seconds after which the drain ON/OFF valve closes and the cleaning gear stops by de-energising the contactor. In addition to the timer, a differential pressure transmitter (PDT-1309/1310) can also initiate the cleaning cycle when the filter pressure drop reaches a specified value (0.5 barg). After the completion of the cleaning sequence the timer is also reset.

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The cleaning sequence may be stopped via hand switch (69-HS-1309/1310). In the event the cleaning gear is stuck, a common alarm 69-XA-1309/1310 is initiated. In addition a high high pressure drop alarm (69-PDAH-1309/1310) is also provided to alert the operator in the event of problems with the cleaning of the filter. The downstream isolation valves of both (operating and standby) filters are kept open at all the times during normal operation. The inlet isolation valve (MOV-1303/1304) of the standby filter is kept in closed position during normal operation. The selection of the operating filter must be made from the DCS via hand switches (HS-1309/1310). 4.8.3.3

Sea Cooling Water Outlet Pressure Control

Sea Cooling Water Pumps (6932-P-04A/B) outlet is routed to Sea Cooling Water Filters (6932-S-02A/B) and the outlet pressure is maintained by the pressure controller 69-PIC-1306 by monitoring the pressure through 69-PT-1306 located in the common discharge of the Sea Cooling Water Pumps. The pressure is maintained by regulating the pressure control valve 69-PV-1306 in the cooling water drain line connected to the sea. 69-PIC-1306 opens the drain line control valve 69-PV-1306 on rising pressure in the outlet of Sea Cooling Water Pumps common discharge. Controller Tag 69-PIC-1306 • 4.9 4.9.1

Control Description Sea Cooling Water Pumps outlet pressure

Alarm

Unit

Operating Set Point

Low

High

barg

6

NA

6.5

Sea cooling water drain control valve 69-PV-1306 opens on instrument air failure

ELECTROCHLORINATION PACKAGE Equipment Specification Electro Chlorination Package Equipment Tag No.

6932-A-05

Process Medium

Sea Water

Design Throughput, kg/hr Design Temperature, °C Design Pressure, barg

10 85/0 8

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TITLE: OPERATION AND MAINTENANCE MANUAL

Auto Backwash Filter Equipment Tag No. Process Medium Type Design Throughput, m3/hr Design Temperature, °C Design Pressure, barg

6932-S-03A/B Sea Water Auto Self Cleaning, Backwash type 14 85/0 6

Filtration Rate, Microns

500

Pressure Drop, Clean, bar

0.1

Pressure Drop, Dry, bar

0.22

Material of Construction, Body/Internal

GRP/Monel

Transformer Rectifier Equipment Tag No. Rating, kVA Power Supply

6932-RC-101A/B 52.7 415 V, 3ph, 50 Hz

Output Voltage

44V DC

Output Current

922 Amps DC

Cooling Design Temperature, °C

Air Natural Air Forced 85/0

Electrolyser Equipment Tag No. Type Capacity Per Cell, kg/hr Design Pressure, barg Design Temperature, °C Orientation Casing Anode Cathode

6932-G-01A/B Panchlor (Bi Polar) 10 6.0 85/0 Horizontal GRP with uPVC Lining Titanium Coated with Coating of Platinum group Mixed oxide Titanium

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Degassing Tank Equipment Tag No. Process Medium Capacity, m3/hr Design Temperature, °C Design Pressure, barg Residence Time, mins. Material of Construction

6932-T-02 Sea Water 5.0 80/0 Atmospheric + Fully Filled Liquid 15 Glass Reinforced Vinyl Ester

Hydrogen Dilution Blowers Equipment Tag No. Process Medium

6932-K-01A/B Air

3

Capacity, m /hr

362

Design Temperature, °C

85/0

Design Pressure, mmWG

150

Motor Rating, kW

1.1

Material of Construction

SS316L

Dosing Pumps Equipment Tag No. Type

6932-P-05A/B Centrifugal

3

7.0/14.0

Design Temperature, °C

85/0

Capacity, m /hr, Continuous/Shock Dosing Design Pressure, barg

7.5

Motor Rating, kW

5.5

Material of Construction

Titanium

Acid Wash Tank Equipment Tag No. Type

6932-T-03 Vertical

Process Medium

HCl

3

2.0

Design Temperature, °C

80/0

Capacity, m

Design Pressure, barg Working Pressure Material of Construction

Atmospheric + Fully Filled Liquid ATM. Glass Reinforced Vinyl Ester

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TITLE: OPERATION AND MAINTENANCE MANUAL

Acid Wash Pump Equipment Tag No.

6932-P-06

Type

Magnetic Drive

Process Medium

HCl

3

5.0

Design Temperature, °C

85/0

Capacity, m /hr, Continuous/Shock Dosing Design Pressure, barg

6.0

Motor Rating, kW

2.2

Material of Construction

Poly Propylene

Acid Bund Material of Construction

4.9.2

GRP

Electro Chlorination System Description During normal operation the Electro Chlorination Unit supplies Sodium Hypochlorite that is injected into the suction lines of the Seawater Supply Pumps (6932-P-04A/B). The hypochlorite controls the growth of marine organisms in sea cooling water system. A small portion of the main sea cooling water flow to the new units of SRU is diverted downstream of the filters 6932-S-02A/B and this provides the sea water supply for the Electro Chlorination Unit 6932-A-05. The required flow of sea water is fed to each electrolyser module designed to produce 10kg/h of active chlorine. Direct current is passed through the sea water producing a sodium hypochlorite solution and hydrogen. The amount of active chlorine (sodium hypochlorite) produced, is directly proportional to the current passed through the cells. Hence, sea water is not normally varied. Any required reduction in active chlorine demand can be achieved by manually adjusting electrical current to the electrolysers at the local control panel.

4.9.2.1

Biocide and Scale Inhibitor Injection Packages

During normal operation, the biocide from the Biocide Injection Package is directly injected into the hypochlorite injection line from Electro Chlorination Package just before the injection point into the Sea Cooling Water Pump Suction of existing (P-3001A/B/C & P-1618AR/BR/CR) and new 6932-P-04A/B sea cooling water systems. The injection is to be carried out at a concentration of 6.6 ppm three times daily for a 15 minute period. The biocide filling into the Biocide Storage Tank inside the package is a manual operation using flexible hose. During normal operation the scale inhibitor from the Scale Inhibitor Injection Package is injected into Sea Cooling Water Pump suction of existing (P-3001A/B/C &

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P-1618AR/BR/CR) and new 6932-P-04A/B Sea Cooling Water Pumps. The injection is carried out continuously at a concentration of 1.5 ppm. The scale inhibitor filling into the storage tank inside the package is a manual operation using flexible hose. 4.9.3

Electro chlorination Package Control

4.9.3.1

Changeover of Auto Back Wash Filter

Sea water is supplied to the skid at a rate of 14 m3/hr. 69-PCV-1463 maintains the system sea water pressure at 3.5 bar g from the inlet pressure of 5 bar (g). Sea water is filtered to 500 microns to supply to the electrolyser. An auto back wash filter (6932-S03A/6932-S-03B) is installed which operates on a duty/stand by basis, During the initiation of changeover/backwash the actuated discharge valve (69-XV1453/69-XV-1456) of duty filter will close, the actuated backwash valve of duty filter (69-XV-1452/69-XV-1455) will open and the actuated discharge valve (69-XV-1453/ 69-XV-1456) of stand by filter will open which ensures the filter changeover was happened. Following are the causes for filter change over to occur: Sl. #

Tag No.

1.

69-PDI-1452

2. 3. 4. 4.9.3.2

Limit

Unit

Value

DP across 6932-S-03A

High-high

barg

0.2

69-PDI-1453

DP across 6932-S-03B

High-high

barg

0.2

69-PI-1455

Filter common discharge

Low-low

barg

2.75

69-FI-1456

Service

Electrolyser common I/L

Low-low

3

m /hr

8.0

Changeover of Electrolyser

Electrolyser stream (6932-G-01A/6932-G-01B) operates on duty/standby basis. Following are the causes for electrolyser changeover to occur: Sl. # I.

Tag No. 69-FI-1451

Service Inlet flow to 6932-G01A

Limit Low-low

Unit

Value

3

10

3

m /hr

II.

69-FI-1452

Inlet flow to 6932-G01B

Low-low

m /hr

10

III.

69-PI-1455

Filter common discharge

High-high

barg

4.5

Also if the temperature difference between electrolyser upstream temperature (69TT-1451) and downstream of the individual electrolyser temperature (69-TT-1452/69TT-1453) is 5°C then controlled shutdown is initiated and the standby electrolyser unit is started.

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4.9.3.3

Dosing Pumps Discharge Flow Control

Dosing pumps (6932-P-05A/B) discharge flow is controlled via flow controller 69-FIC-1453. Dosing pump discharge flow rate is measured by magnetic flow transmitter 69-FT-1453 and controlled by 69-FIC-1453, set point is locally provided on the HMI. Output of 69-FIC-1453 directly commands the control valve 69-FV-1453. Controller Tag

Control Description

68-FIC-1453

Dosing pumps discharge flow control

Alarm

Unit

Operating Set Point

Low

High

m3/hr

2 & 11

1.8

13.0

Note: The controller 68-FIC-1453 has 2 Set Points based on the Continuous Dosing and Shock Dosing. When continuously dosed, set point is 2m3/hr whereas for Shock Dosing, set point is 11m3/hr. 4.9.3.4

Acid Pumps Control

The acid wash system is a manual system. To maintain the efficiency of the electrolyser streams, regular washing with dilute HCL is required to remove the hydroxide deposits. Following are the causes for tripping of Acid Wash Pump 6932-P-06: Sl. #

4.10 4.10.1

Tag No.

Service

Limit

Unit

Value

1.

69-LI-1454

Acid Wash Tank level

Low-low

mm

370

2.

69-AI-1451

Conductivity of acid wash solution

High-high

µS/cm

77000

NGL-4 SEA WATER FILTERS Equipment Specification Sea Water Filters Equipment Tag No.

S-8840A/B

Process Medium

Sea Water

Capacity, kg/hr, Min./Max. Design Temperature, °C Design Pressure, barg

138240/309760 85/0 7.0

Operating Temperature

40/15

Operating Pressure, barg

4

Material of Construction, Casing/Elements

SA240UNS S31803/Duplex SS

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4.10.2

NGL-4 Sea Water Filters S-8840A/B Description Two Sea Water Filters S-8840A/B are installed in the existing sea water from cooling water supply line 8”-88-32-WR-0066-001W. The filter consists of a pressure containment body with inlet, outlet, drain/backwash outlet, PSV and vent connections. Filter Basket has been sized for the design flow conditions. Access to the filter basket is via the bolted cover at the top of the assembly. Sealing of the cover to the body is via a spiral wound gasket and stud bolts. A simple devit arm is provided to allow removal and support of the cover during maintenance operations. Across a clean Seawater Filter S-8840A/B the normal pressure drop is 0.2 bar. During normal operation the filter will become dirty over a period of time and the pressure drop across it will increase. The differential pressure transmitter (88-PDT-801) raises an alarm when the filter pressure drop reaches a specified value (0.4 bar). This means the filter needs cleaning and the clean filter is brought on line.

4.11 4.11.1

DEMINERALISED WATER SYSTEM Equipment specification DM Water Package Equipment Tag No.

6834-A-07

Process Medium

DM Water

3

8.0

Design Temperature, °C

85/0

Design Pressure, barg

12.3

Capacity, m /hr

Cationic Exchangers Bed Equipment Tag No. Process Medium ID, mm

6834-S-21A/B Fresh Water 600

3

Capacity, m /hr 3

Flow Rate, m /hr

10.5 7.0

Design Temperature, °C

85/0

Design Pressure, barg

12.3

Operating Temperature, °C

49

Operating Pressure, bar

4.0

Material of Construction, Casing/Elements

CS

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TITLE: OPERATION AND MAINTENANCE MANUAL

Anionic Exchangers Bed Equipment Tag No. Process Medium

6834-S-22A/B Fresh Water

ID, mm

950 3

Capacity, m /hr

10.5

3

Flow Rate, m /hr

7.0

Design Temperature, °C

85/0

Design Pressure, barg

12.3

Operating Temperature, °C

49

Operating Pressure, bar

4.5

Material of Construction, Casing/Elements

CS

DM Water Recycle Pumps Equipment Tag No. Process Medium

6834-P-37A/B DM Water

3

Capacity, m /hr, Normal/Rated 3

10.5/10.5

Minimum flow, m /hr

1.11

Design Pressure, barg

12.3

Design Temperature, °C

85/0

Suction Pressure, bara, Rated

2

Operating Temperature, °C

43

Operating Pressure, bara

6

Driver Type Driver Power, kW Material of Construction, Casing/Elements

Motor 5.5 SS316L

Resin Trap Equipment Tag No.

6834-SP-11A/B/C/D

Diameter, mm

60.3

Length, mm

300

Design Temperature, °C

85/0

Design Pressure, barg

12.3

Material of Construction, Casing/Elements

SS316L

Mesh Size, mm

0.202

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TITLE: OPERATION AND MAINTENANCE MANUAL

DM Water Feed Pumps Equipment Tag No.

6834-P-24A/B

Process Medium

DM Water

3

Capacity, m /hr

12.0

Design Pressure, barg

5.1

Design Temperature, °C Suction Pressure, bara, Design/Rated

85/0 1.57/0.96

Operating Temperature, °C

43

Operating Pressure, bara

4.7

Material of Construction, Casing/Elements

A743CF3M/SS316L

DM Water Regeneration Pump Equipment Tag No. Process Medium

6834-P-36A/B DM Water

3

Capacity, m /hr

3.0

Suction Pressure, bara

1

Operating Temperature, °C

30

Operating Pressure, bara

5

Drive Type

Motor

Driver Power, kW

5.5

Material of Construction, Casing/Elements

SS

DM Water Neutralization Pumps Equipment Tag No. Process Medium

6834-P-38A/B DM Water

3

Capacity, m /hr, Normal/Rated 3

10.0/10.0

Minimum flow, m /hr

1.0

Design Pressure, barg

2.2

Design Temperature, °C Suction Pressure, kg/cm2(a), Design/Rated

85/0 0.8/0.78

Operating Temperature, °C

30

Operating Pressure, bara

2.6

Drive Type Drive Power, kW Material of Construction, Casing/Impeller

Motor 4.0 PP/PP

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TITLE: OPERATION AND MAINTENANCE MANUAL

HCl Dosing Pumps Equipment Tag No. Process Medium

6834-P-35A/B HCl Double Hydraulic Diaphragm Metering Pump

Type Capacity, Lit/hr

180

Design Pressure, barg

3.7

Design Temperature, °C

85/0

Operating Temperature, °C

30

Operating Pressure, bara

3.0

Driver Type

Motor

Driver Power, kW

1.1

Material of Construction

PP

HCl Storage Tank Equipment Tag No.

6834-T-16

Process Medium

HCl

ID/Height, mm

1400/2730

3

Capacity, m

4

Design Pressure, barg

ATM

Design Temperature, °C

85/0

Material of Construction

GRP

HCl Unloading Pump Equipment Tag No.

6834-P-38

Process Medium

HCl

Capacity, L/hr

150

Design Pressure, barg

3.5

Design Temperature, °C

85/0

Material of Construction

PTFE/PVDF

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

NaOH Dosing Pumps Equipment Tag No.

6834-P-34A/B/C

Process Medium

NaOH Double Hydraulic Diaphragm Metering Pump

Type Capacity, Lit/hr

301

Design Pressure, barg

3.7

Design Temperature, °C

85/0

Suction Pressure, bara

1

Discharge Pressure, bara

3

Operating Temperature, °C

30

Driver Type

Motor

Driver Power, kW Material of Construction

2.2 SS316L/PTFE

NaOH Storage Tank Equipment Tag No.

6834-T-15

Process Medium

HCl

ID/Height, mm

1400/2730

3

Capacity, m

4

Design Pressure, barg

ATM

Design Temperature, °C

85/0

Material of Construction

SS

NaOH Unloading Pump Equipment Tag No. Process Medium Capacity, L/hr Design Pressure, barg Design Temperature, °C Material of Construction 4.11.2

6834-P-39 NaOH 150 3.5 85/0 PTFE/PVDF

Demineralised Water System Process Description Demineralised Water Package Unit 6834-A-07 (one operating, one standby/ regenerating), is designed to produce flow of 7 m3/h of demineralised water. The Demineralised water is supplied to the new heating system and connectivity to the existing DMW header is also provided to allow operation flexibility. Demineralised water unit will provide DMW to the following users: •

Make up water to Steam Condensate Flash Drum (6834-V-05)

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TITLE: OPERATION AND MAINTENANCE MANUAL

•

Amine Surge Tank (9103-T-11)

•

Make up water to Cooling Water Circulation Pump (9102-P-12A/B)

•

Start-up water to Stripped Overhead Circulation Pump (9102-P-11A/B)

•

Make up water to Amine Regenerator Reflux Drum (9103-V-12)

•

Existing DMW network system (for operational flexibility, normally no flow)

4.11.2.1 Demineralised Water Package The Demineralised Water Package is based on ion exchange technology (similar to the existing DMW package) and consists of two identical trains. The DMW package operates continuously and automatically and thus requires minimum intervention. The package includes the necessary control and safety devices. The Demineralised Water from the DMW package is routed to Demineralised Water Storage Tank (6834-T-08). Capacity of Demineralised Water Storage Tank is 83 m3. Fresh water is sent to the new users (DMW package & utility) continuously by means of the Drinking Water Feed Pumps (6834-P-23A/B, one operating, one standby) each having a design capacity of 10 m3/h. The duty/standby is selected via a selector switch in the DCS. The pumps are manually started and stopped through hand switches 68-HS1305/1306 and operated continuously. A minimum continuous flow recycle line with a restriction orifice (6834-RO-1303) ensures that there is always a minimum flow through the pump. Low low level alarms (68-LALL-006/007, via existing manual selector 68-HS-008) will shutdown the operating pump in the event of low-low level in Drinking Water Storage Tanks. The control ensures a safe and continuous operation and is summarized below: A. Flow Totaliser A flow totaliser placed in the main fresh inlet line to each ion exchange train sums the total water passing through the DMW unit. In normal operation, the end of a treatment cycle is determined on a volumetric basis by the totaliser which generates the order to switch from the online train to standby train. Following the switch over the regeneration sequence is commenced for the offline train. B. Conductivity Meter If high conductivity is reached before the end of the volumetric cycle, then the respective conductivity meter initiates the same automatic switch over order as generated by the volumetric cycle. If, in spite of this order, the conductivity continues to increase, then a separate high-high conductivity meter initiates a complete shutdown.

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C. Differential Pressure A differential pressure transmitter switch installed across the ion exchangers, also initiates the same switchover as the above volumetric cycle. D. Regeneration Demineralised water is used as service water for regeneration. From the storage tank (6834-T-08), regeneration DMW is delivered by means of the Regeneration Water Pumps 6834-P-36A/B. A solution of Caustic Soda is used to regenerate the anion resins. Concentrated Caustic Soda is stored in a storage tank. Before injection into the exchanger bed, the caustic soda is diluted by means of an in-line mixer. A solution of Hydrochloric Acid is used for cation resin regeneration. It is stored in the HCl storage Tank. The required dilution before injection into the exchanger bed is made by means of an in-line mixer. The regeneration effluents are collected in the concrete Neutralisation Pit where they are neutralised before being pumped out for disposal to effluent treatment plant. The pit is fitted with a pH-meter controller which controls acid dosing or caustic dosing to achieve neutralisation. Neutralisation Pit Pump re-circulates the effluent mixture for homogenisation. Plant air diffusion is also provided to enhance mixing. E. DMW Storage Tank (6834-T-08) The DMW package outlet line includes an automatic ON/OFF valve which is actuated by means of a signal coming from low/high level signal (68-LT-1305) on the DMW Storage Tank (6834-T-08). De-mineralized water from the DMW storage tank is directed, at a pressure and temperature of 3.7 barg and ambient temperature respectively by means of DMW Feed Pumps (6834-P-24A/B) to condensate flash drum (6834-V-05). The DMW storage tank is equipped with level alarms, High-High/Low-Low liquid level (LAHH-1306/LALL-1307). The former generates a High-High liquid level alarm in the control room, whilst the latter initiates Low low liquid level trip which shuts down the Regeneration Pumps 6834-P-36A/B in the DMW Package and DMW Feed Pumps. F. Demineralised Water Feed Pumps (6834-P-24A/B) Centrifugal type, DMW feed pumps (one running, one standby) are used to supply demineralised water at 3.7 barg pressure and ambient temperature, from DMW storage tank. Each pump is designed for a flow of 12 m3/hr based in heating system start-up (Filling inventory vessels such as condensates flash drum, De-aerator and Boilers in one shift).

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TITLE: OPERATION AND MAINTENANCE MANUAL

A minimum flow recycle line with a restriction orifice (6834-RO-1301) ensures that there is always a minimum flow through the pump. These pumps can be stopped automatically, by the low low alarm (68-LALL-1307) or manually, from the central control room using hand switch (68-HS-1307B/1308B) or local panel (68-HS-1307A/1308A). In the event of non ESD trip of operating pump, standby pumps will start automatically. 4.11.3

Demineralised Water System Control description

4.11.3.1 Demineralised Water Flow Control 68-FIC1828 Demineralised water outlet to the DM water storage tank (6834-T-08) is controlled by 68-FIC-1828. Fresh water flow to the Train-1 & 2 is measured by 68-FT-1825 and 68-FT-1827 respectively and final treated DM water to the DM water storage tank is measured by 68-FT-1828. Flow controller 68-FIC-1828 takes any of the above transmitter’s value as per the train selection, for calculating the output which directly commands the DM water storage tank control valve 68-LCV-1827. DM water storage tank MASTER level controller 68-LIC-1305 cascaded with SLAVE 68-FIC-1828 for allowing a maximum flow rate equal to the inlet flow rate available to DM package in order to guarantee a minimum recirculation flow rate. Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

68-LIC-1305

DM Water Storage Tank level

%

XX

XX

XX

68-FIC-1828

DM Water package O/L flow

m3/hr

XX

XX

XX

•

DM Water Package flow low low alarm 68-FALL-1830 set at XXXX trips the Recirculation Pump 6834-P-37A/B

•

DM Water Storage Tank level control valve 68-LCV-1827 closes on instrument air failure.

4.11.3.2 Recirculation Water Flow Control 68-FIC-1826/68-FIC1829 Recycling fresh water flow controller 68-FIC-1826 (Train-A), 68-FIC-1829 (Train-B) determines the amount of recirculation flow passes through the control valve 68-FV1826 (Train-A), 68-FV-1829 (Train-B) to the cationic exchangers bed during phase no 1 (Service) and phase no 6 (Final rinse with recirculation).

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Recycle water pumped from 6834-P-37A is measured by a vortex type flow meter 68-FT-1826 (Train-A) and 68-FT-1829 (Train-B). Set points for the above controllers are provided locally. Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

68-FIC-1826

Train-A recirculation flow control

m3/hr

XX

XX

XX

68-FIC-1829

Train-B recirculation flow control

m3/hr

XX

XX

XX

•

Recirculation Pump 6834-P-37A discharge flow low low alarm 68-FALL-1837 trips the Recirculation Pump 6834-P-37A in MCC.

•

Recirculation Pump 6834-P-37B discharge flow low low alarm 68-FALL-1838 trips the Recirculation Pump 6834-P-37B in MCC.

•

Recirculation flow control valve 68-FV-1826 (Train-A) and 68-FV-1829 (Train-B) closes on instrument air failure.

4.11.3.3 Regeneration Water Flow Control Regeneration water from the DM Water Storage Tank (6834-T-08) to static mixers 6834-M-02A and 6834-M-02B is controlled by the flow controller 68-FIC-1835 and 68-FIC-1836 respectively. Regeneration water to static mixer 6834-M-02A and 6834-M-02B is measured by 68-FT1835 and 68-FT-1836. Set points for both the controllers are provided locally. Output of the controllers 68-FIC-1835 and 68-FIC-1836 directly commands the control valve 68-FV-1835 and 68-FV-1836, respectively. Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

68-FIC-1835

Regeneration Pump discharge to Static Mixer 6834-M-02A

m3/hr

XX

XX

XX

68-FIC-1836

Regenerated Pump discharge to Static Mixer 6834-M-02B

m3/hr

XX

XX

XX

•

Regeneration Pump 6834-P-36A/B discharge flow low low alarm 68-FALL-1839 trips the Regeneration Pump 6834-P-36A/B, HCl Dosing Pumps 6834-P-35A/B and Caustic Dosing Pump 6834-P-34A/B.

•

Regeneration water flow control valves 68-FV-1835 and 68-FV-1836 closes on instrument air failure.

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.11.3.4 Pump ON/OFF Controls 1. Acid Dosing Pumps Tag/Alarm 68-PI-1825 68-PI-1826 68-PI-1827 68-LI-1825 68-FI-1839 68-LI-1307 68-AI-1831 68-LI-1830

Description Pump diaphragm failure Pump diaphragm failure Pump diaphragm failure HCL storage tank level low Regeneration Pump discharge flow low low DMW Storage Tank level low Neutralisation Pump discharge Neutralisation Pit low level

Pump Tag No. 6834-P-35A 6834-P-35B 6834-P-35C

Action Trips the pump and start the stand by pump Trips the pump and start the stand by pump Trips the pump and start the stand by pump

6834-P-35A, B & C

Trips the running pumps

6834-P-35A, B & C

Trips all the running pumps

6834-P-35A, B & C

Trips all the running pumps

6834-P-35A, B & C

Starts the duty pump

6834-P-35 B & C

Trips the pump

2. Caustic Dosing Pumps Tag/Alarm 68-PI-1828 68-PI-1829 68-PI-1830 68-LI-1827 68-FI-1839 68-LI-1307 68-AI-1831 68-LI-1830

Description pump diaphragm failure pump diaphragm failure pump diaphragm failure NaOH Storage Tank level low low Regeneration Pump discharge DMW storage tank level low Neutralisation Pump discharge Neutralisation Pit low level

Pump Tag No. 6834-P-34A 6834-P-34B 6834-P-34C 6834-P-34A, B & C 6834-P-34A, B & C 6834-P-34A, B & C

Action Trips the pump and start the stand by pump Trips the pump and start the stand by pump Trips the pump and start the stand by pump Trips the running pumps Trips all the running pumps Trips all the running pumps

6834-P-34A, B & C

Starts the duty pump

6834-P-34 B & C

Trips the pump

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3. Regeneration Pumps Tag/Alarm

Description

Pump Tag No.

Action

68-LI-1307

DMW storage tank level low-low

6834-P-36A & B

Trips both the pump

68-FI-1839

Regeneration Pump flow low-low

6834-P-36A & B

Trips both the pump

68-FI-1835

Static Mixer 6834-M02A inlet DM Water flow low

6834-P-36A & B

Starts the stand-by pump

68-FI-1836

Static Mixer 6834-M02B inlet DM Water flow low

6834-P-36A & B

Starts the stand-by pump

4. Recirculation Pumps Tag/Alarm

Description

Pump Tag No.

Action

68-FI-1837

Recirculation pump flow low low

6834-P-37A

Trips the pump

68-FI-1838

Recirculation pump flow low low

6834-P-37B

Trips the pump

5. Neutralization Pumps Tag/Alarm

4.12 4.12.1

Description

Pump Tag No.

Action

68-LI-1831

Neutralisation tank level high

6834-P-38A/B

Starts the duty pump

68-LI-1830

Neutralisation tank level low

6834-P-38A/B

Trips both the pump

BOILER FEED WATER DEAERATOR SYSTEM Equipment specification Steam Condensate Flash Drum Equipment Tag No.

6834-V-05

Size, (ID X T/T), mm

2600/7800

Design Pressure, barg

3.5/FV

Design Temperature, °C, Min./Max.

0/150

Operating Pressure, barg

0.1

Operating Temperature, °C,

102

Material of Construction

CS + 1.5mm CA

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De-aerator Feed Pumps Equipment Tag No.

6834-P-20A/B

Type

Horizontal Centrifugal 3

Design Capacity, m /hr

221

Design Pressure, barg

8.5

Design Temperature, °C, Min./Max. Suction Pressure, bara, Normal/Rated

0/150 1.82/5.54

Discharge Pressure, bara

4.51

Operating Temperature, °C

102

Driver Type

Motor

Driver Rating, kW

30

Material of Construction, Casing/Impeller

CS/SS316

Steam Condensate Cooler Equipment Tag No.

6834-E-02

Type

Forced Draft

Design Duty, kW

5422

Design Pressure, barg Design Temperature, °C, Min./Max. Inlet Pressure, barg Operating Temperature, °C, In/Out No. of Fans

8.5 0/150 1.75 102/59 3

Fan Driver Type

Motor

Driver Rating, kW

15

Material of Construction, Casing/Impeller

CS

BFW De-aerator Package Equipment Tag No.

6834-A-08 3

Design Capacity, m /hr

110

Design Pressure, barg

3.5/FV

Design Temperature, °C, Min./Max.

0/185

Operating Pressure, barg

0.2

Operating Temperature, °C

105

Material of Construction, Casing/Impeller

CS + 3mm CA

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Boiler Feed Water Pumps Equipment Tag No. Type

Centrifugal 3

Flow Rate, m /hr

55

Design Pressure, barg

31

Design Temperature, °C, Min./Max.

0/185

Suction Pressure, barg, Max./Rated

5.55/1.92

Discharge Pressure, bara

21.8

Operating Temperature, °C

105

Driver Type Driver Rating, kW Material of Construction, Casing/Impeller 4.12.2

6834-P-22A/B/C

Motor 110 CS/SS316

Boiler Feed Water De-aerator Description

4.12.2.1 Steam Condensate Flash Drum (6834-V-05) The LP steam condensates mixtures are collected in the Steam Condensate Flash Drum. The purpose of this vessel is to stabilise the steam condensate entering the drum and to cool down the inventory to 102°C to prevent cavitations in De-aerator Feed Pumps. The Flash Drum receives fluids from two phase steam condensates from condensate distribution header and DMW from DMW Feed Pumps 6834-P-24A/B. The operating pressure in the Flash Drum is 0.1 barg. During normal operation, minimum or no flow across 68-RO-1302 is expected and which is sized for steam condensate cooler failure case. Pressure relief valves (68-RV-1091A/B, one operating and one spare) protect the drum against overpressure. The RVs relieve to the atmosphere and are set at 3.5 barg. 4.12.2.2 Steam Condensate Cooler (6834-E-02) The relatively cool (43°C) DMW feed make-up entering the mixing compartment of the Steam Condensate Flash Drum picks up heat from the incoming hot condensate stream. To maintain its liquid state, the demineralised water/condensate mixture in the drum is continuously circulated through the Seam Condensate Cooler by the De-aerator Feed Pump 6834-P-20A/B. The temperature is controlled at 102°C by using temperature control valve (68-TV-1301) prior to forwarding the water to the Boiler Feed Water De-aerator unit for further treatment. 4.12.2.3 De aerator Feed Pumps (6834-P-20A/B) Centrifugal type, De-aerator Feed Pumps (6834-P-20A/B, one running, one standby) has a dual purpose: first to recycle approximately 49.8 % of the total normal discharge

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flow back to the flash drum via the Steam Condensate Cooler. The second is to feed the balance of the pump discharge flow to the Boiler Feed De-aerator package (6834-A-08) for further treatment. These pumps will be stopped automatically, by the low-low alarm (68-LALL-1309) or manually, from the central control room using hand switch (68-HS-1309/1310) or local panel (68-HS-1309). In the event of a non ESD trip of the operating pump, the standby pump will start automatically. 4.12.2.4 Boiler Feed Water De-aerator Package (6834-A-08) The boiler feed water stream enters the BFW De-aerator Package (6834-A-08) at the top of the De-aerator column. It is contacted counter-currently with stripping steam, which heats and scrubs the incoming feed, forcing the water to give up its CO2 and most of its O2 content. Oxygen Scavenger is added to the water in the hold up section of the De-aerator to further reduce the O2 content. The De-aerator pressure is controlled at 0.2 barg by means of a pressure controller (68-PIC-1304) which acts on pressure control valve (68-PV-1304) located in the LP stripping steam line. The De-aerator is protected from over pressure by a set of pressure relief valves (68-PSV-1337A/B), set at 3.5 barg. The De-aerator package is designed for FV. The liquid level in the De-aerator drum is maintained by 68-LIC-1302 through 68-LV-1302 in the BFW feed inlet line. The Boiler Feed Water pumps (6834-P-22 A/B/C) take suction from a common manifold. The discharge pressure of Boiler Feed Water Pump is 20.8 barg. The minimum flow is controlled by 68-FIC-1305 using 68-FV-1305 and discharged liquid back to De-aerator drum. 4.12.2.5 Chemical Injection Package (6834-A-09) The BFW Chemical injection Package is used to inject Boiler Feed water with O2 Scavenger and a Complex Product. The Complex Product is administrated to increase pH value of the boiler feed water from 7 to between 9.0 and 10.5 to protect the internal walls of the steam drums against corrosion and scaling. The amount of complex product solution is proportional to the boiler feed water flow and is injected at the discharge of Boiler Feed Water pumps. The package includes for each chemical, a set of Chemical Storage Tank, Chemical Injections Pumps and Chemical Unloading Pump. Chemical Injection Pumps are of reciprocating, positive displacement, automatic metering type i.e. the amount of chemical injected is proportional to the boiler feed water flow as measured by the dedicated chemical pumps speed variation controllers.

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There are two sets of Chemical Injection Pumps (each comprising two electric motor driven gear pumps) provided for each chemical as follows; •

Two Oxygen Scavenger Injection Pumps 6834-P-39A/B for De-aerator (6834-A08) treatment

•

Two Complex Product Injection Pumps 6834-P-41A/B for Steam Boiler (6834-A02A/B/C) Feed Water treatment

4.12.2.6 Boiler Feed Water Pumps (6834-P-22A/B/C) Centrifugal type Boiler Feed Water Pumps (two running, one standby) have dual purpose; the first is to supply Boiler Feed Water at 18.5 barg and 105°C to Steam Generation Package and the second is to supply BFW to the TGTU. A small stream is also connected to Sour Water Stripper Reboiler 6922-E-04 for desuperheating purpose. The pumps are designed to supply a normal continuous flow of oxygen free and pH controlled Boiler Feed Water to the Steam Boilers 6834-A-02 A/B/C and Reactor Effluent Cooler (9102-E-11). The minimum flow is controlled by flow controller 68-FIC-1305 by acting on flow control valve 68-FV-1305 which returns part of the pump discharge flow back to the Deaerator. In the event of a non ESD trip of the operating pump, the standby pump will start automatically. 4.12.3

Boiler Feed Water Deaerator Control Description

4.12.3.1 Steam Condensate Flash Drum Level Control Level in the Steam Condensate Flash Drum 6834-V-05 is maintained by 68-LIC-1301 by monitoring the level through the transmitter 68-LT-1301. Level is controlled by regulating the makeup DMW through the control valve 68-LV-1301. Controller Tag 68-LIC-1301

Alarm

Control Description

Unit

Operating Set Point

Low

High

Steam Condensate Flash Drum level

%

50

18

79

•

High high level alarm 68-LAHH-1308 in Steam Condensate Flash Drum trips the DM Water Feed Pumps 6834-P-24A/B.

•

Low low level alarm 68-LALL-1309 in Steam Condensate Flash Drum trips the Deaerator Feed Pumps 6834-P-20A/B.

•

Steam Condensate Flash Drum level control valve 68-LV-1301 closes on instrument air failure.

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4.12.3.2 Steam Condensate Flash Drum Outlet Temperature Control Steam Condensate Flash Drum 6834-V-05 outlet temperature is monitored by 68-TT1301 and controlled by 68-TIC-1301 located in the suction of Deaerator Feed Pumps 6834/P-20A/B. Temperature control is achieved by regulating the steam condensate from the cooler 6834-E-02 through the control valve 68-TV-1301 located in the Steam Condensate Cooler outlet line entering in to the Steam Condensate Flash Drum. Controller Tag 68-TIC-1301

•

Alarm

Control Description

Unit

Operating Set Point

Low

High

Steam Condensate Flash Drum temperature

°C

102

97

107

Steam Condensate Flash Drum temperature control valve 68-TV-1301 opens on instrument air failure

4.12.3.3 Deaerator Feed Pumps Minimum Flow Control Deaerator feed pumps 6834-P-20A/B discharge one stream is routed to BFW Deaerator package and other stream is routed to Steam Condensate Cooler for maintaining temperature in the flash drum. Deaerator Feed Pumps 6834-P-20A/B minimum flow control is achieved by regulating the control valve 68-FV-1301 (located in the bypass of 68-TV-1301) which allows the minimum flow to pass even when the 68-TV-1301 is fully closed. Controller Tag

Control Description

68-FIC-1301

Deaerator Feed Pumps flow control

•

Alarm

Unit

Operating Set Point

Low

High

m3/hr

83

66.6

NA

De-aerator feed pumps minimum flow control valve 68-FV-1301 opens on instrument air failure

4.12.3.4 Deaerator Level Control Level in the Deaerator is monitored by the level transmitter 68-LT-1302 and controlled by the level controller 68-LIC-1302. Level control is achieved by regulating the control valve 68-LV-1302 located in the Deaerator Feed Pumps flow to the Deaerator. Controller Tag

Control Description

68-LIC-1302

Deaerator level control

Alarm

Unit

Operating Set Point

Low

High

%

50

16

86

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•

High high Level alarm 68-LAHH-1312 in Deaerator closes the Deaerator inlet ON/OFF valve 68-XV-1301.

•

Low low level alarm 68-LALL-1310 in Deaerator executes the following actions:

•

•

Boiler 6848-A-02A fuel gas inlet ON/OFF valve 68-XV-1302 close

•

Boiler 6848-A-02B fuel gas inlet ON/OFF valve 68-XV-1303 close

•

Boiler 6848-A-02C fuel gas inlet ON/OFF valve 68-XV-1304 close

•

BFW Pumps 6834-P-22A/B/C trip

•

De-aerator Feed Pumps 6834-P-20A/B trip

•

Steam Condensate Cooler Fans 6834-EM-2A1/2A2/2B1/2B2/2C1/2C2 trip

•

Boilers 6848-A-02A/B/C shutdown

68-LV-1302 closes on instrument air failure.

4.12.3.5 Boiler Feed Water Pumps Minimum Flow Control Boiler Feed Water Pumps 6834-P-22A/B/C discharge flow to the Steam Generation units is measured by 68-FT-1305 and minimum recirculation flow to Deaerator is controlled by 68-FIC-1305. The controller 68-FIC-1305 throttles the fail open control valve 68-FV-1305. Controller Tag 68-FIC-1305

Control Description BFW Pumps minimum flow

Alarm

Unit

Operating Set Point

Low

High

m3/hr

35

30

NA

4.12.3.6 Deaerator Pressure Control Deaerator 6834-A-08 pressure is monitored by 68-PT-1304 and controlled by the pressure controller 68-PIC-1304. The pressure is maintained through the pressure control valve 68-PV-1304 in the LP stripping steam inlet to the top of the Deaerator tank. 68-PIC-1304 opens the steam control valve 68-PV-1304 on falling pressure in the Deaerator. Controller Tag 68-PIC-1304

Control Description De-aerator top pressure control

Alarm

Unit

Operating Set Point

Low

High

barg

0.2

NA

0.3

Steam control valve 68-PV-1304 closes on instrument air failure.

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4.13 4.13.1

STEAM GENERATION PACKAGE Equipment Specifications Equipment Tag No.

6848-A-02A/B/C Water Tube Steam Generator

Type Capacity, T/hr (Each Boiler)

45

Design Pressure, barg

22

Design Temperature, °C

220

Steam Outlet Temperature at LP Header, °C

163

Feed Water Temperature, °C, Min./Normal

43/105

Saturated Steam Outlet Pressure at LP Header, barg

5

Steam Pressure at Drum, barg

16.4

Feed Water Pressure, barg

18.5

Feed Water Flow, T/hr

45.409

Desuperheater Water Flow, kg/hr

541

Type of Fuel

Natural Gas 3

Fuel Flow, Nm /hr

3296

Fuel Temperature, °C, (Operating/Design) Fuel Pressure, barg, (Operating/Design) Excess Air, %

25-50/100 6-7/9 10

3

Air Flow, Nm /hr

33860

Air Temperature at Air Heater Inlet, °C

25

Flue Gas Temperature at Furnace Outlet, °C

1037

Flue Gas Temperature at Economizer Inlet, °C

278

Flue Gas Temperature at Economizer Outlet, °C

157

Flue Gas Temperature at Stack, °C

157

Pressure Drop in Air Duct, mmWC

110

Air Pressure Drop in Burners, mmWC

160

Flue Gas Pressure Drop in Convection Coil, mmWC

67

Flue Gas Pressure Drop in Economizer, mmWC

42

Air Pressure at Fan Outlet, mmWC

364

Radiant Loss, %LHV

0.55

Unburned Loss, %LHV

0

Heat Loss in Flue Gas Stack, %LHV

4.72

Efficiency Calculated, (With Economizer), %LHV

93.49

Efficiency Calculated Without Drain, %LHV

93

Heat Introduced in Furnace, Kcal/h

27.2E6

2

269306

Heat Density in Furnace, Kcal/h.m

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Drums Drum Outside Diameter, mm Cylindrical Length, mm Thickness, mm Material Type of Head

Upper 1326 9550 28 SA 515 Gr 70 Elliptical

Lower 908 9550 22 SA 515 Gr 70 Elliptical

Combustion Chamber Size, L X W X H, m Type of Screen Tubes Outer Diameter and Thickness, mm Tube Fixation Type Projected Surface, m2 Screen Header Numbers Header Outer Diameter x Thickness, mm

8.787 X 2.727 X 3.778 Membrane Water Tube Type 76.1 x 4 Expanded/Welded 98.74 4 219.1 x 12.7

Desuperheater Type Location

Multi Nozzle Spray Steam Pressure Reducing and Desuperheating Station

Convection Coil Surface, m2 Location Type Tubes Outer Diameter x Length, mm Pitch Trans. x Length, mm Material

729 Furnace Side/Parallel to Drums Expanded Tubes 51 x 3400 96 x 95 ASTM A 210 Gr A1

Economizer Surface, m2 Location Type

724 In the Flue Gas Duct Finned Tube Type

Tubes Outer Diameter x Length, mm

48 x 2220

Pitch Trans. x Length, mm

114.3 x 90

Material

SA210GrA1

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Casing Boiler Material/Thickness, mm Insulation

CS Mineral Wool with Cladding

Type

Expanded Tubes

Refractory, Combustion Chamber, Front Wall

Refractory Cement Bricks

Refractory, Combustion Chamber, Other Walls

Refractory Cement Bricks

Material

ASTM A 210 Gr A1

Burners Number

1

Type

Low NOx

Location/Arrangement

Front Wall

Pilots or Igniters

1

Flame Failure Detector

2

Fan Number

1

Type

Centrifugal 3

Air Flow Normal, Nm /hr Static Pressure, mmWC Driver

51000 500 Electric Motor

Driver Power, kW

110

Speed, RPM

1550

Coupling Air Regulating Material

Flexible Coupling Inlet Damper CS

Air Duct Material

CS

Thickness, mm

4

Flue Gas Discharge Flow Rate, kg/hr

46112.4

Discharge Temperature, °C

155

Molecular Weight

27.59

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Flue Gas Duct Material Thickness, mm

CS (Rated for High Temperature Service) 6

Stack Type Height/Top Dia/Bottom Dia, m Material Thickness, mm, (min.)

Self Supporting 30/1/2 CS (Rated for High Temp. Service) 5

Boiler Blow Down Pit Tag No. Dimension Design Pressure, barg

6848-T-02 2200 x 1800 x 1000 0

Design Temperature, °C

220

Material of Construction

Concrete

4.13.2

Steam Generation Package Process Description Auxiliary Steam Boiler Package is essentially constituted by: Three water tube – Clajtub type saturated steam boilers.

4.13.2.1 Steam Generation Package 6848-A-02A The main purpose of Steam Generation Package 6848-A-02A is to generate steam and supply steam to the Customer steam network grid at the required pressure and temperature. 4.13.2.1.1 Water/Steam Circuit The Water/Steam circuit of the Steam Generator is realised in the following way: •

Boiler Feed Water enters into the external Economiser (6848-E-01A), which is a heat exchanger (water/flue gas) constituted by finned tubes. In this section, the feed water temperature is increased by absorption of the flue gas thermal heat.

•

When Sour fuel gas is used, the Boiler Feed Water is first sent to a preheating water circuit installed inside the water drum, before entering the Economiser (6848-E-01A). This preheating circuit prevents acid condensation inside the flue gas system (including the Economiser [6848-E-01A] outer surface) by keeping the temperature of the flue gas above the dew point of the acid gas.

•

From the Economiser (6848-E-01A) outlet, the feed water enters into steam drum 6848-V-02A.

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•

Boiler functions on the basis of “steam/water natural circulation”, with evaporating rising circuits formed by the hottest tubes of boiler. Remaining tubes act as down comers, which feed the rising circuits. All the evaporating tubes are (except, where indicated in the boiler pressure parts drawings) expanded on both steam drum and water drum.

•

In the boiler evaporating tubes, a mixture of saturated water & steam is produced. Then the saturated steam is separated from the water droplets in the Steam Drum 6848-V-02A Separators.

•

The saturated steam from the steam drum is then sent to a temperature and pressure controlling section;

•

Pressure of the saturated steam is controlled by the Pressure Control Valve 68-PV1524 which gets the input from the Pressure Indicator Controller 68-PIC-1819. A pressure transmitter 68-PT-1819 senses the pressure in the steam header and provides the input to the 68-PIC-1819.

•

The temperature of the saturated steam is controlled by the Desuperheater (6848X-03A). Boiler Feed Water from the Boiler Feed Water Pumps 6834-P-22A/B/C discharge is injected into the Desuperheater 6848-X-03A. The flow of the Boiler Feed Water is controlled by a Temperature control valve 68-TV-1522. The temperature control valve gets the temperature input from 68-TIC-1522 which in turn gets the input from the Temperature Transmitter 68-TT-1522 which measures the temperature of the saturated steam.

•

The steam from the Desuperheater 6848-X-03A is then routed to the Main LP steam header.

4.13.2.1.2 Air/Flue Gas Circuit •

The air/flue gas ducts of each of the three steam generator is arranged in the following way:

•

Combustion air is taken from the atmosphere by means of a Forced Draft Fan (6848-K02A), driven by an electric motor (6848-KM-02A). At the suction the combustion air passes through a Grid Filter 6848-S-03A, Sand Filter (6848-S-02A) and vertical air Silencer (6848-X-06A) and then a goose type vertical duct designed to have multiple stage inertial filtration of the entering combustion air. The inlet Sand Filter 6848-S-02A does not need any kind of maintenance or cleaning (self discharging type), goose neck type duct is advisable to be inspected through its lower manhole at least once in 6 months

•

Downstream of the Silencer 6848-X-06A, the air passes through the modulating inlet control damper (68-FV-1626) (pneumatically actuated); downstream of the Forced Draft Fan 6848-K-02A, the combustion air passes through a duct that delivers air to the wind-box

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•

Combustion air measuring device 68-FE-1526 (AIR-FOIL type) is installed downstream of the Forced Draft Fan 6848-K-02A

•

In the wind box the air is evenly distributed to the burner in order to optimise the combustion

•

Once the combustion takes place in the burner, the high temperature flue gases pass through the boiler furnace, enclosed by water cooled tubes. The water tubes assure a perfect tightness for the flue gases. At the end of combustion chamber, the flue gases turn to 180° entering through the evaporating convective section. The convective section is located on the right side of the furnace. At boiler outlet, the flue gases go through a connection duct and then pass through the external Economiser 6848-E-01A, where the flue gas temperature decreases by means of a heat transfer to Boiler Feed Water

•

Downstream of the Economiser 6848-E-01A, the flue gases pass through flue gas duct that connects the Economiser 6848-E-01A to the stack

•

Then the flue gases are discharged through the stack into the atmosphere

•

Air/flue gas circuit is provided also with a recirculation flue gas duct, that re circulates flue gas from Economiser outlet to AIR FOIL 68-FE-1526 and subsequently to burner wind-box inlet. The flue gas recirculation fan (FGRF) 6848-K-03A is installed in the Flue Gas Recirculation duct

4.13.2.1.3 Steam Generator Design & Process Main Data The Steam Generator data are summarised in the following table. These data are applicable to the Maximum operating Continuous Rate (MCR): Operating Data @ MCR Sl. #

Data

Unit

Value

Operating Data 1.

Steam flow at boiler outlet

t/h

44.96

2.

Steam flow at battery limit (net to Customer)

t/h

45

3.

Steam temperature at battery limit

°C

163

4.

Steam pressure at battery limit

barg

5

5.

Feed water temperature

°C

105

Design Data 1.

Design pressure (boiler - economiser)

barg

22

2.

Hydraulic test pressure (boiler economiser)

barg

33

3.

Design Code

ASME I EDITION 2007 ADDENDA 2009

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4.13.2.1.4 Boiler Drums •

The Water Drum 6848-V-03A and steam drum 6848-V-02A are symmetrically located on right side of the boiler when viewed from the burner side

•

The drums are manufactured with high quality steel according to ASME Code with submerged arc automatic welding

•

The drums are provided with manholes at both ends allowing a full inspection of the boiler and accessibility to all tubes for easy maintenance

•

From the upper part of water drum all water tubes converge into the lower part of the steam drum, ensuring the natural circulation

•

The Steam Drum 6848-V-02A is provided with internal Separators/Dryers, that ensure a very high steam purity, flanged nozzles for continuous blow down (CBD) outlet, Boiler Feed Water inlet, saturated steam outlet to common header, safety valves, level indicators and transmitters, pressure gauges and pressure transmitter, chemical injection inlet nozzle, nitrogen inlet and some spare connections (provided with blind flanges)

•

The water drum is provided with two nozzles to drain the boiler (to be opened only when the water inside the boiler is at ambient temperature)

4.13.2.1.5 Steam Drum Sl. #

Data

Unit

Value

Steam Drum 1.

Internal diameter

mm

1270

2.

Shell thickness

mm

28

3.

Material

SA516 Gr.70 Water Drum

1.

Internal diameter

mm

864

2.

Shell thickness

mm

28

3.

Material

SA516 Gr.70

Note: Before closing the steam drum manholes, Operator must verify that demisters are correctly installed inside the steam drum as shown in the following figure. That is with the perforated plate positioned above the wire mesh filters.

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Fig. 23 - Steam Drum

4.13.2.1.6 Boiler Furnace •

All the furnace walls are constituted by water-cooled membraned tubes. These tubes are seamless type

•

The tubes constituting the “D” shape are directly connected to the drums by mechanical expansion and seal welding. The front and rear wall tubes are welded to dedicated lower and upper headers

•

The front tubes are bent to create the burners throats, while the rear tubes are bent to allocate an inspection access door and two peep holes

•

The furnace dimensions are designed to assure an adequate cooling of the combustion gases

•

All tubes of the furnace are equally shaped and its membranes are welded each other to assure very high flue gas tightness and an equilibrated circulation of boiling water

•

Lower and upper headers of front and rear wall tubes are connected to both drums by external suppliers and risers tubes

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Sl. #

Data

Unit

Value

Furnace Tubes 1.

Outer diameter

mm

76.1

2.

Thickness

mm

4

3.

Material

ASTM A210 Gr.A1 Furnace Headers

1.

Outer diameter

mm

219.1

2.

Thickness

mm

12.7

3.

Material

ASTM A106 Gr.B

4.13.2.1.7 Evaporating Tube Bank The evaporating tube bundle is located in the convective section, which is formed by adequately spaced tubes, heated by the cross flow of flue gas. The outer tubes, forming the external enveloping walls, are welded over the whole length thus providing a continuous tight gas enclosure membraned wall. A few tubes, in the enveloping external wall, have been bent in order to create the free area to locate two inspection doors (one in SH bank and the other in the middle of the convective section) for access and/or maintenance purposes. Sl. #

Data

Unit

Value

Convective Bank Tubes 1.

Outer diameter

mm

51

2.

Thickness

mm

3.2

3.

Material

ASTM A210 Gr.A1 Enclosure Tubes

1.

Outer diameter

mm

76.1

2.

Thickness

mm

4

3.

Material

ASTM A210 Gr.A1

4.13.2.1.8 Economiser •

At the outlet of the flue gas from the steam generator, an external Economiser 6848-E-01A is located

•

This thermal heat exchanger consists of seamless tubes adequately finned and spaced so as to increase heat transfer coefficient

•

The flue gas heats the economizer tubes in cross flow

•

All the tubes are welded to the inlet and outlet horizontal headers. In order to separate the feed water circuitry, some baffles are installed inside the inlet and outlet headers

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

•

A carbon steel casing, externally insulated, constitutes the enveloping economizer enclosure

•

The Economiser 6848-E-01A is provided with adequate drain and vent valves. The Economiser 6848-E-01A cannot be by-passed, so it is not necessary to provide a dedicated pressure safety valve. Sl. #

Data

Unit

Value

Economiser Tubes 1.

Outer diameter

mm

48.3

2.

Thickness

mm

3.2

3.

Material

ASTM A210 Gr.A1 Economiser Fins

1.

Height

mm

19

2.

Thickness

mm

1.5

3.

Number of fins per meter

4.

Material

200 Fe P04 UNI EN 10130

Economiser Headers 1.

Outer diameter

mm

114.3

2.

Thickness

mm

11.13

3.

Material

ASTM A106 Gr.B

4.13.2.1.9 Refractory •

Refractory tiles are used to cover the furnace floor of the steam generator, both to reduce the absorbed thermal heat (increasing the natural circulation) and to allow future accessibility for any maintenance and/or inspection reasons

•

Refractory tiles are also used to protect the burner throats where combustion takes place

•

These refractory tiles are manufactured with high Alumina content and are suitable for high temperature operation.

4.13.2.1.10

External Insulation and Cladding

The steam generator is insulated with high-density mineral wool panels of suitable thickness entirely applied to all external walls. Sl. #

Data

Unit

Value

Boiler Thermal Insulation 1.

Material

2.

Thickness

3.

Density

Mineral wool mm

140 (2 layers, 70 mm each)

kg/m3

120

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The external insulation panels are enclosed in a cladding, made of painted aluminium, properly spaced and fixed through screws to allow an easy removal. 4.13.2.1.11 Air and Flue Gas Ducts •

The steam generator is provided with combustion air ducts, located at the suction and at the delivery of the Forced Draft Fan 6848-K-02A that convey the combustion air from ambient to boiler wind-box

•

The steam generator is provided also with flue gas ducts that convey the flue gas from boiler outlet to Economiser 6848-E-01A inlet and from Economiser 6848-E01A outlet to steel stack

•

The steam generator is provided also with recirculation flue gas ducts, located at the suction and at the delivery of the Flue Gas Recirculation Fan 6848-6848-K-03A that re-circulates the required flow rate of flue gas from Economiser 6848-E-01A outlet to Boiler wind-box inlet through a dedicated entrance in Air-Foil 68-FE-1526 duct Sl. #

Data

Unit

Value

Combustion Air Ducts 1.

Material

S275 JR EN 10025

2.

Thickness (all air ducts except intake air duct)

mm

4

3.

Thickness (intake air duct)

mm

7

Flue Gas and Flue Gas Recirculation Ducts 1.

Material

2.

Thickness

S275 JR EN 10025 mm

5

Boiler Base Frame The steam generator body is mounted on a steel base-frame, which supports it with a uniform load distribution. Ladders, Platforms and Stairways The Boiler, the Deaerator, the Stack and the air intake duct are provided with stairs, platforms and ladders in order to allow an easy access to the equipment and/or to the instruments installed on the equipments. Platforms area is completed with open grating, guards and handrails. Burners •

One burner 6848-X-05A is installed in the Steam Generator, designed to burn both Sour type and Sweet type (FG2 and FG1) of fuel gas

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•

Burner is designed to have a turndown of 10:1

•

Burner is provided with a pilot (Class 3 type) that can be fed by FG2 and FG1

•

The pilot ignitor is of high energy type

•

During pilot operation, the combustion air to pilot is provided by the Forced Draft Fan 6848-K-02A, providing the minimum combustion air flow rate

•

In order to meet the specified low emissions target, at high boiler load, the burners can be operated in flue gas recirculation mode. The combustion air is mixed with a proper flue gas flow rate (about 15% of nominal flow rate), upstream of the boiler wind-box. The recirculation flue gas flow rate is provided by the Flue Gas Recirculation Fan 6848-K-03A

The burner is mainly composed of the following equipment: •

Air swirler adjustable manually by Operator from external burner front, by means of proper handle. The air register deliver the combustion air at the desired velocity and rotation into the burner throat

•

Burner front plate assembly complete with one viewing port and two openings for flame detectors (complete with ball swivels)

•

FG distribution system, complete with multiple gas lances and relevant nozzles

•

Central gas gun, complete with diffuser

•

One pilot complete with high energy ignitor, relevant transformer (installed in a dedicated junction box) and cable

•

Two flame detectors both to sense the burner main flame and the pilot flame

•

One observation peep hole

•

Burner refractory throat made of several pre formed bricks

•

Flexible hoses for FG both for pilot, distribution system to gas lances and central gas gun

During boiler operation, in order to optimise the combustion, the FG flow rate is fed both to distribution system to multiple gas lances and to central gas gun. Forced Draft Air Fan (6848-K-02A) The Steam Generator is provided with one Forced Draft Air Fan (6848-K-02A) and its electric motor 6848-KM-02A. The combustion air flow rate is controlled by means of a modulating inlet control damper (pneumatically actuated) installed upstream of the Forced Draft Air Fan (6848-K-02A) suction.

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The unit basically includes: •

Grid Filter 6848-S-03A at inlet duct (installed at inlet section of the air intake duct)

•

Sand Filter 6848-S-02A at inlet duct (installed at inlet section of the air intake duct)

•

Combustion air Silencer 6848-X-06A (installed after Sand Filter 6848-S-02A)

•

Split housing (for rotor removal) provided with one inspection door and one plugged drain

•

Impeller (wheel and hub) statically and dynamically balanced in the manufacturer workshop to reduce vibration and noise

•

Shaft and relevant guard

•

Shaft seal

•

Flexible coupling and relevant guard

•

Anti-friction bearings

•

Electric motor 6848-KM-02A

•

Inlet vane control damper 6848-FV-1626 complete with pneumatic actuator

•

Thermal insulation on fan casing

•

flexible connections at suction and discharge sections

•

basement common for fan and electric motor

Flue Gas Recirculation Fan The Steam Generator is provided with one Flue Gas Recirculation Fan (FGRF) 6848-K03A, coupled with its electric motor 6848-KM-03A. The flue gas recirculation flow rate is controlled by means of a modulating inlet control damper 6848-FV-1524 (pneumatically actuated), installed upstream of the Flue Gas Recirculation Fan 6848-K-03A suction connection. The unit basically includes: •

Housing, provided with one inspection door and one drain

•

Impeller (wheel and hub), statically and dynamically balanced in the manufacturer workshop to reduce vibration and noise

•

Shaft and relevant guard

•

Shaft seal

•

Transmission belts and pulley and relevant guard

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•

Anti-friction bearings

•

Electric motor 6848-KM-03A

•

Inlet vane control damper 6848-FV-1524, complete with pneumatic actuator

•

Outlet non return damper

•

Flexible connections, at suction and discharge sections

•

Thermal insulation on fan casing

•

Basement, common for fan and electric motor

Chemical Dosing Units Each Steam Generator is provided with one Phosphate chemical dosing unit, whose purpose is to inject Phosphate into boiler Steam Drum 6848-V-02A. Each unit basically includes: •

One Phosphate Storage Tank 6848-T-03A

•

Two Phosphate Dosing Pumps 6848-P-01A/02A, one working and the other stand-by and respective electric motors 6848-PM-01A/02A, piping, valves and instruments

•

One tank mixer 6848-M-01A and its electric motor 6848-MM-01A

•

One steel catch basin

Sampling System •

Each Steam Generator is provided with one sampling system for two samples: one for boiler feed water at Economiser 6848-E-01A inlet, one for saturated steam

•

The sampling system consists of sample conditioning bench, relevant piping, measurement and safety instruments, all mounted on a common panel

•

All samplings are manual type sample

•

All the samples of the sampling system are cooled by Demineralised Water. The required cooling water flow rate is taken from raw water line supply.

Stack •

Each Steam Generator is provided with a double dedicated steel stack 6848-X-01A, that discharges the flue gas from boiler to the atmosphere

•

The stack is cylindrical self-supporting type, manufactured into three sections for shipping reasons

•

Each section is connected to the other by means of coupling flanges

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The stack has the following characteristics: Sl. #

Data

Unit

Value

Steel Stack 6848-X-01A 1.

Material

S275 JR

2.

Internal Diameter

Mm

1240

3.

Outer Diameter

Mm

1700 till 11.45m 1500 up to top

4.

Thickness (Inner Duct)

Mm

8

5.

Thickness (Outer Duct)

Mm

8

6.

Total Height

M

30

•

The Stack 6848-X-01A is provided with proper insulation between the two jackets

•

Platform is provided at 6 m and 12 m elevation and ladders are provided for approaching the platforms

•

A manhole is provided at the bottom of the Stack for internal inspection

•

The Stack 6848-X-01A is also provided with nozzles necessary for instruments installation including CEMS installation

•

A drain is provided at the bottom of the Stack

•

An internal plate conveys the possible condensate (from flue gas condensation or external atmospheric events) to the drain system

•

This drain must be periodically opened to empty the stack of any condensate accumulation

Steam Silencer Each Steam Generator is provided with one Steam Silencer 6848-X-02A for start-up vent in order to respect the required noise limit. 4.13.3

Control Description The Steam Generator is provided with a Boiler Control Panel containing the Burner Management System (BMS) and the Boiler Control System (BCS). The Steam Generator is provided with its own Local Panel (LP) connected to the Boiler Control Panel. Boiler control system (BCS) is responsible for the continuous control of the boilers and all the below mentioned controls are implemented in BCS (PLC).

4.13.3.1 Boiler Level Control The boiler level control is performed with single or three elements philosophy.

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If the steam flow (68-FT-1524) is greater than the settable threshold then the boiler level control is allowed to work in three element controls. If the steam flow (68-FT-1524) is less than the settable threshold then the boiler level control is allowed to work in single element behaviour. But there is also a provision to select three element controls at any time. Single Element Control When the single element philosophy is active the Inverse acting level controller 68-LIC1522 regulates the feed water flow control valve 68-LV-1522 to maintain the boiler level. The boiler drum level is measured by 68-LIT-1522 and controlled by 68-LIC-1522; set point is set locally and 0-100% output of 68-LIC-1522 directly controls the level control valve 68-LV-1522. Three Element Control Three elements used in this controls are Feed water flow (68-FT-1522), boiler level (68-LT-1522) and steam flow (68-FT-1524). When the three element philosophy is active the Inverse acting feed water flow controller 68-FIC-1522 regulates the feed water flow control valve 68-LV-1522 to maintain the boiler drum level. The main compensated steam flow 68-FT-1524 is applied to the output of the level controller 68-LIC-1522 to adjust the set point to the feed water control 68-FIC-1522 proportional to varying steam demands. 0-100% output of 68-FIC-1522 directly commands the level control valve 68-LV-1522. Controller 68-LIC-1522 68-FIC-1522

Alarm

Unit

Operating Set point

Low

High

Boiler drum level

%

50

34

62

Boiler Feed Water flow

3

XX

NA

NA

Control Loop

m /hr

High high level alarm (68-LAHH-1523A/B/C) set at 72% and low low level alarm (68-LALL-1523A/B/C) set at 23% in boiler drum. 1. Closes the following valves:

2.

•

Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529

•

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532

Opens the following valves: •

Main fuel gas vent valve 68-XV-1530

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• 3.

Pilot gas venting valve 68-XV-1533

Trips the following: •

FD fan 6848-K-01A

•

Re-circulation Glue Gas Fan 6848-K-02A

•

Boiler feed water level control valve 68-LV-1522 closes on instrument air failure.

Schematic diagram of level control is shown below.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 24 – Schematic of Boiler 1 Element/3 Element Drum Level

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4.13.3.2 SH Steam Temperature Control Super heated steam temperature control is achieved by direct acting temperature controller 68-TIC-1552 which regulates the water flow to the Desuperheater. SH steam temperature is controlled by 68-TIC-1522. Set point of 68-TIC-1522 set by operator on the HMI and is corrected by output of LP steam header direct acting temperature controller 68-TIC-1820 and commands the Desuperheater control valve 68-TV-1522. Controller Tag.

Control Loop

Alarm

Unit

Operating Set Point

Low

High

68-TIC-1522

SH steam temperature

°C

163

158

168

68-TIC-1820

Steam header

°C

XX

158

168

•

Desuperheater control valve 68-TV-1522 closes on instrument air failure

4.13.3.3 Boiler Steam Pressure Control The Steam Drum 6848-V-02A pressure is maintained by inverse acting pressure controller 68-PIC-1523A which determines the burner load to maintain the drum pressure. Boiler drum steam pressure is measured by 68-PT-1523 which is fed as a Process variable to 68-PIC-1523A and the set point is set by operator on the HMI. 0-100% CV of the controller 68-PIC-1523A is the power that burner should produce to maintain the steam pressure to the set point value. The required power is expressed as MWreq=CV*Pmax [MW] Where Pmax–maximum power that can be produced with the burner lighted at the maximum load (set by the supplier). Controller 68-PIC-1523A •

Alarm

Control Loop

Unit

Operating Set Point

Low

High

Boiler drum pressure

bar

16.4

19

20

High high steam pressure alarm (68-PAHH-1522A/B/C) in Boiler Drum 1.

Closes the following valves: •

Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529

•

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532

2. Opens the following valves: •

Main fuel gas vent valve 68-XV-1530

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•

Pilot gas venting valve 68-XV-1533

3. Trips the following: •

FD Fan 6848-K-01A

•

Re-circulation Flue Gas Fan 6848-K-02A

4.13.3.4 Fuel Gas Flow Control Fuel gas flow to produce the required power MWreq is determined by the Inverse acting flow controller 68-FIC-1525. Fuel gas flow is measured by the transmitter 68-FT-1525A and controlled by 68-FIC1525. Set point is the required FG flow, which is calculated from the formula QNG REQ =min {3.6 *106 * MWREQ/HVFG, QFG STOICH} [kg/h], Where HVFG [kJ/kg] - Fuel gas heat value QFG STOICH - stoichiometric fuel gas flow required for actual combustion air flow. MWREQ- Required power for the burner is calculated from steam pressure controller 68-PIC-1523A. Output (0-100%) of 68-FIC-1525 directly commands the fuel gas control valve 68-FV-1525. 68-FIC-1525 is turned on to manual mode after 5 seconds the 68-FIC-1526 (combustion air flow controller) has been turned on manual mode. Controller 68-FIC-1525

Control Loop Fuel gas flow to boiler

Alarm

Unit

Operating Set Point

High 1

High 2

kg/hr

XX

2800

2900

High high-1 flow alarm (68-FAHH-1525B/C/D) set at 2900 Kg/hr and high high-2 flow alarm (68-FAHH-1525 B/C/D) set at 3020 Kg/hr in boiler 1.

2.

Closes the following valves: •

Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529.

•

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532.

Opens the following valves: •

Main fuel gas vent valve 68-XV-1530.

•

Pilot gas venting valve 68-XV-1533.

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3.

Trips the following: •

FD fan 6848-K-01A.

•

Re-circulation Flue Gas Fan 6848-K-02A

Fuel gas flow control valve 68-FV-1525 to boiler closes on instrument air failure. 4.13.3.5 Combustion Air Flow Control Combustion air flow required to burn the amount of fuel gas is determined by the Inverse acting air flow controller 68-FIC-1526. Combustion air flow is measured from the transmitter 68-FT-1526A and controlled by 68-FIC-1526; the set point is determined by the formula QAIR REQ = (QFG * STOICH) [kg/h], Where QFG =max {QFG req, QFG meas} [kg/h], STOICH [KG/KG]-Air/FG stoichiometric ratio. QFG req is calculated from the fuel gas controller set point 68-FIC-1525 and QFG mean value is taken from the fuel gas flow transmitter 68-FIT-1525. O2 correction calculated from 68-AIC-1522 is also applied for adjusting airflow set point. Output (0-100%) of 68-FIC-1526B directly commands the air control damper 68-FV-1526. 68-FIC-1526 is turned on to manual mode after 5 seconds the 68-FIC-1525A (fuel gas flow controller) has been turned on manual mode. Controller 68-FIC-1526

Control Loop Combustion air flow to boiler

Alarm

Unit

Operating Set Point

Low

High

kg/hr

XX

NA

NA

•

Low low combustion air flow alarm (68-FALL-1525 B/C/D) set at 38,500 Kg/hr in boiler

1.

Closes the following valves:

2.

•

Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529.

•

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532.

Opens the following valves: •

Main fuel gas vent valve 68-XV-1530.

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• 3.

•

Pilot gas venting valve 68-XV-1533.

Trips the following: •

FD Fan 6848-K-01A

•

Re-circulation Flue Gas Fan 6848-K-02A

combustion air flow control valve 68-FV-1525 to boiler locks at the position on instrument air failure

4.13.3.6 Oxygen Control Oxygen concentration in the stack flue gas is maintained by the Inverse acting oxygen controller 68-AIC-1522 which determines the increase/decrease factor of the excess air which is used in the set point determination of 68- FIC-1526B (combustion air flow). Set point is determined by the expected oxygen for the required load MW REQ and is obtained by linear interpolation on the oxygen curve (provided by BONO). Output (0-100%) of 68-AIC-1522 is scaled to the range 1.3 – 0.7 which is the correction factor applied to the air excess in the calculation of the combustion air flow set point (68-FIC-1526B). Above control can be disabled/enabled from the HMI as required. Controller 68-AIC-1522

Alarm

Control Loop

Unit

Operating Set Point

Low

High

Oxygen analyzer controller

%

XX

2.2

6.7

4.13.3.7 Flue Gas Recirculation Control The position of the flue gas recirculation damper 68-FV-1524 is measured by 68-FZT1524 and controlled by controller 68-ZIC-1524. Set point is the desired position of the flue gas damper for the required load and is obtained by linear interpolation on the flue gas recirculation curve (provided by BONO). Output (0-100%) of 68-ZIC-1524 directly commands the flue gas recirculation damper 68-FV-1524. Flue gas control can be enabled/disabled by operator by means of software selector on local HMI and on remote DCS. Controller 68-ZIC-1524

Control Loop Flue gas damper position controller

Alarm

Unit

Operating Set Point

Low

High

%

XX

NA

NA

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Flue gas flow control valve 68-FV-1524 to boiler locks at the position on instrument air failure. 4.13.3.8 Boiler Steam Pressure (VENT) Control Saturated steam flow through the vent valve to maintain the boiler steam pressure is controlled by a direct acting pressure controller 68-PIC-1523B. Steam drum pressure transmitter 68-PIT-1523; Set point is provided by the operator on the HMI and output (0-100%) directly commands the vent control valve 68-PV-1523. If the boiler steam pressure increases then the controller 68-PIC-1523B increases the output to open the vent control valve 68-PV-1523, which maintains the steam pressure nearer to the set value.

68-PIC-1523B

Alarm

Control Loop

Unit

Operating Set Point

Low

High

Steam pressure vent

bar

17.4

NA

NA

Controller

•

High high steam pressure alarm (68-PAHH-1522A/B/C) set at 20barg in boiler drum

1.

Closes the following valves:

2.

3.

•

Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529.

•

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532.

Opens the following valves: •

Main fuel gas vent valve 68-XV-1530.

•

Pilot gas venting valve 68-XV-1533.

Trips the following: •

FD Fan 6848-K-01A

•

Re-circulation Flue Gases Fan 6848-K-02A

•

Steam pressure vent control valve 68-PV-1523 closes on instrument air failure.

4.13.3.9 Header Steam Pressure Control The three boilers supplied by BONO are connected via an Ethernet link and exchange the data themselves to co-operate on MASTER/SLAVE logic to maintain the desired pressure in the steam header. As per design only two boilers can feed the steam to the header continuously. Each boiler generates a signal named “consent to modulation for header PIC” and this signal is set when the following conditions are verified: •

Burner is lighted

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•

68-MOV-1522 located in super heated steam to LP steam header is not closed

•

The boiler pressure has reached the opening threshold for the 68-MOV-1522

•

At least one of the other two boiler control systems has not set the signal “consent to modulation for header PIC”.

Header steam pressure direct acting controller 68-PIC-1819 purpose is to maintain the steam header pressure and management is performed by the control system of the “MASTER” boiler (first boiler which starts to feed the header through its 68-MOV-1522). Steam header pressure is measured by 68-PIT-1819 and controlled by 68-PIC-1819, set point is provided by the operator on the HMI of the “MASTER” boiler. Output of the controller (0-100%) pass through the split range function 68-PY-1819, where the two outputs of the split range function commands directly the header pressure control valve 68-PV-1524 of the “MASTER”, “SLAVE” boilers (second boiler which starts to feed the header through its 68-MOV-1522 is known as slave boiler) and the commands of 68-PV-1523 to the third boiler is forced to 0%. 4.13.3.10

Fan Controls

Forced Draft Fan (6848-K-02A) The FD Fan motor can be started only if all the following conditions are verified: •

Presence of motor available signal (68-ZL-1548)

•

Absence of motor fault signal (68-ZA-1548)

•

Presence of close limit switch of combustion air damper 68-FV-1526 (68-ZSC-1526)

Fan motor can be started and stopped manually from the HMI. Flue Gas Recirculation Fan (6848-K-03A) The flue gas recirculation fan motor can be started only if all the following conditions are verified: •

Presence of motor available signal (68-ZL-1549)

•

Absence of motor fault signal (68-ZA-1549)

•

Presence of close limit switch of the flue air damper 68-FV-1524 (68-ZSC-1524)

Fan motor can be started and stopped manually from the HMI. Start/stop tag details for Forced draft and recirculation fans are as follows: Sl. #

Tag No.

Description

1.

68-HSOA-1548

Forced draft fan start

2.

68-HSCA-1548

Forced draft fan stop

3.

68-HSOA-1549

Recirculation air fan start

4.

68-HSCA-1549

Recirculation air fan stop

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4.13.3.11

Valve Management

ON/OFF MOV1522 Each boiler contains a MOV which feeds the steam to the header Valve can be operated in Local/Remote by changing the selecting switch (68-HSR1522C) located in the local panel. If the valve fault status signal (68-XA-1522) is active then the valve cannot be controlled from BCS. Automatic Mode Automatic mode of the MOV can be selected from the HMI and if the valve is not in fault mode then the valve will open automatically on the following conditions: •

Burner is ON

•

Steam Drum pressure 68-PT-1523 is higher than threshold (68-PSH-1523C)

•

other two boilers have not yet set the consent to modulation for header PIC signal

If any of the above condition is not satisfied then the valve will close automatically. Manual Mode When the manual mode of MOV is selected from HMI then the valve can only be operated from the HMI open/close commands (68-HSO-1522A/68-HSC-1522B). On/Off Valve Controls Boiler Blow Down Valve (68-XV-1525) The valve is opened automatically if at least any one of the following conditions is satisfied: •

The burner is ON

•

Hot standby mode is active (enabled manually) and the boiler level is higher than a opening threshold value

The valve is closed automatically if at least any one of the following conditions is satisfied: •

The burner is off

•

Hot standby mode is not active

•

Hot standby mode is active and the boiler level is lower than a closure threshold value

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Hot Stand-by Boiler Pressure Valve (68-XV-1523) The valve is opened automatically when all the following conditions are satisfied: •

Hot standby mode is active

•

The Steam Drum pressure 68-PT-1523 is lower than an opening threshold (PSL-1523)

The valve is closed automatically if at least any one of the following conditions is satisfied: •

Hot standby mode is not active

•

Hot standby mode is active and the upper drum boiler pressure 68-PT-1523 is higher than a closure threshold (PSH-1523)

Pre heating Feed Water Valves (68-XV-1523, 68- XV-1524) For commanding the above valves to permit feed water to boiler lower drum, following conditions needs to be satisfied: •

Burner is OFF

•

Operator has selected FG2 (H2S) from the HMI

4.13.3.12

LP Steam Header Pressure Control

Saturated steam from all the three boiler packages are connected in to the LP steam header and the pressure in the header is measured by 68-PT-1306 and controlled by the pressure controller 68-PIC-1306. Pressure in the header is maintained by the control valve 68-PV-1306 located in the steam vent line to atmosphere. Increase of pressure above the operating range will route the steam to the vent through the control valve 68-PV-1306.

•

Alarm

Controller Tag

Control Description

Unit

Operating Set Point

Low

High

68-PIC-1306

LP steam header pressure

barg

5

4.5

5.5

LP steam header pressure low low pressure 2oo3 (68-PALL-1303A/B/C) alarm set at 4 barg initiates the following: •

Fuel gas on/off valve 68-XV-1302 to the boiler 6848-A-02A close

•

Fuel gas on/off valve 68-XV-1303 to the boiler 6848-A-02B close

•

Fuel gas on/off valve 68-XV-1304 to the boiler 6848-A-02C close

•

Deaerator Feed Pumps 6834-P-20A/B trip

•

BFW Pumps 6834-22A/B/C trip

•

Steam Condensate Cooler Fans trip

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• • 4.14 4.14.1

Boiler Packages 6848-A-02A/B/C shutdown

Steam to vent valve 68-PV-1306 opens on instrument air failure

CHEMICAL INJECTION SYSTEMS Antifoam Injection Package 9103-A-11

4.14.1.1 Equipment Specification Antifoam Storage Tank Equipment Tag No.

9103-T-12

Size, ID/Height, mm

1550/1600

Chemical

Antifoam

Design Pressure bar(a)

1.01

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM.

Operating Temperature, °C Material of Construction

52 AISI 316L

Antifoam Injection Pumps Equipment Tag No. Pump Type Chemical

9103-P-16A/B Double Diaphragm Antifoam

Capacity, L/hr

55

Design Pressure, bar(g)

12

Discharge Pressure, bar(g)

8.5

Design Temperature, °C

120/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.37 SS316TI/PTFE

Antifoam Unloading Pump Equipment Tag No. Pump Type Chemical Capacity, L/hr

9103-P-19 Air Operated Pump Antifoam 2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

AISI 316L

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Antifoam Tank Agitator Equipment Tag No.

9103-M-12

Speed, RPM

155

Driver Rating, kW

0.37

Material of Construction

AISI 316L6

4.14.1.2 Antifoam Package 9103-A-11 Description Antifoam Package consists of an Antifoam Storage Tank 9103-T-12 and two numbers of Antifoam Injection Pumps 9103-P-16A/B. The Antifoam Storage Tank 9103-T-12 is having an agitator 9103-M-12. Antifoam from drums are transferred to the tank through an unloading pump 9103-P-19. The Antifoam Injection Pumps 9103-P-16A/B are having discharge pulsation dampner and calibration pots at the suction line. 4.14.1.3 Antifoam Injection Package Control Description The Antifoam Storage Tank (9103-T-12) level is monitored by 91-LI-1521 and antifoam from the storage tanks is injected to the following areas via the injection pumps (9103-P-16A/B): •

Acid Gas Amine Absorber 9103-C-11

•

Lean/Rich Amine Exchangers 9103-E-11A/B

•

Amine Regenerator 9103-C-12

•

Tail Gas Amine Absorber 9102-C-12

Following parameters are to be monitored: Tag No.

Description

Unit

91-FI-1533

9103-P-16A/B common discharge flow

91-PI-1559

Alarm High

Low

LPH

40

70

9103-P-16A discharge pressure

barg

NA

9.5

91-PI-1560

9103-P-16B discharge pressure

barg

NA

9.5

91-LI-1521

antifoam storage tank level (9103-T12)

%

6

NA

Following are the details of the switches & alarm related to motor controls: Tag No.

Description

91-HSOA-1582

Remote “ START” for the Pump 9103-P-16A

91-HSOA-1583

Remote “ START” for the Pump 9103-P-16B

91-HSCA-1582

Remote “ STOP” for the Pump 9103-P-16A

91-HSCA-1583

Remote “ STOP” for the Pump 9103-P-16B

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Tag No.

4.14.2

Description

91-ZL-1582

9103-P-16A Pump Available signal

91-ZL-1583

9103-P-16B Pump Available signal

91-XS-1582

9103-P-16A Pump ESD trip signal

91-XS-1583

9103-P-16B Pump ESD trip signal

91-ZI-1582

9103-P-16A Pump running indication

91-ZI-1583

9103-P-16B Pump running indication

•

Low low level alarm (91-LALL-1520) set at 3% in Antifoam Storage Tank 9103-T-12 trips the Antifoam Injection Pumps (9103-P-16A/B)

•

High high diaphragm pressure alarm (91-PAHH-1565) set at 8.5 barg in Antifoam Injection Pump 9103-P-16A initiates the pump changeover

•

High high diaphragm pressure alarm (91-PAHH-1566) set at 8.5 barg in Antifoam Injection Pump 9103-P-16B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Antifoam Injection Pumps (9103-P-16A/B). Caustic Injection Package 9103-A-13

4.14.2.1 Equipment Specification Caustic Storage Tank Equipment Tag No. Size, ID/Height, mm Chemical Design Pressure bar(a) Design Temperature °C Operating Pressure bar(g) Operating Temperature, °C Material of Construction

9103-T-14 1550/1600 Caustic 1.01 85/0 ATM. 52/0 AISI 316L

Caustic Injection Pumps Equipment Tag No. Pump Type Chemical Capacity, L/hr Design Pressure, bar(g) Discharge Pressure, bar(g) Design Temperature, °C Driver Type Rated Power, kW Material of Construction

9103-P-103A/B Double Diaphragm Caustic 55 11.5 5 120/0 Motor 0.37 SS316TI/PTFE

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Caustic Unloading Pump Equipment Tag No.

9103-P-104

Pump Type

Air Operated Pump

Chemical

Caustic

Capacity, L/hr

2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

AISI 316L

Caustic Tank Agitator Equipment Tag No.

9103-M-14

Chemical

Caustic

Speed, RPM

155

Material of Construction

AISI 316L

4.14.2.2 Caustic Package 9103-A-13 Description Caustic is injected to the suction of Desuperheater Circulation Pumps 9102-P-11. Caustic Package consists of a Caustic Storage Tank 9103-T-14 and two numbers of Caustic Injection Pumps 9103-P-103A/B. The Caustic Storage Tank 9103-T-14 is having an agitator 9103-M-14. Caustic from drums are transferred to the tank through an unloading pump 9103-P-104. The Caustic Pumps 9103-P-103A/B are having discharge pulsation dampner and calibration pots at the suction line. 4.14.2.3 Caustic Injection Package Control Description Following parameters are to be monitored: Tag No.

Description

Unit

91-FI-1535

9103-P-103A/B common discharge flow

91-PI-1563

Alarm Low

High

LPH

40

70

9103-P-103A discharge pressure

barg

NA

7.5

91-PI-1564

9103-P-103B discharge pressure

barg

NA

7.5

91-LI-1525

caustic storage tank level (9103-T14)

%

6

NA

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Following are the details of the switches & alarm related to motor controls: Tag No.

4.14.3

Description

91-HSOA-1586

Remote “ START” for the Pump 9103-P-103A

91-HSOA-1587

Remote “ START” for the Pump 9103-P-103B

91-HSCA-1586

Remote “ STOP” for the Pump 9103-P-103A

91-HSCA-1587

Remote “ STOP” for the Pump 9103-P-103B

91-ZL-1586

9103-P-103A Pump Available signal

91-ZL-1587

9103-P-103B Pump Available signal

91-XS-1586

9103-P-103A Pump ESD trip signal

91-XS-1587

9103-P-103B Pump ESD trip signal

91-ZI-1586

9103-P-103A Pump running indication

91-ZI-1587

9103-P-103B Pump running indication

•

Low low level alarm (91-LALL-1524) Set at 3% in caustic storage tank 9103-T-14 trips the Caustic Injection Pumps (9103-P-103A/B)

•

High high diaphragm pressure alarm (91-PAHH-1569) set at 5 barg in Caustic Injection Pump 9103-P-103A initiates the pump changeover

•

High high diaphragm pressure alarm (91-PAHH-1570) set at 5 barg in Caustic Injection Pump 9103-P-103B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Caustic Injection Pumps (9103-P-103A/B)

Corrosion Inhibitor Injection Package 9103-A-12

4.14.3.1 Equipment Specification Corrosion Inhibitor Storage Tank Equipment Tag No.

9103-T-13

Size, ID/Height, mm 3

Storage Capacity m Chemical

1550/1600 3 Corrosion Inhibitor

Design Pressure bar(a)

1.2

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM.

Operating Temperature, °C

52/0

Material of Construction

SS 316L

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Corrosion Inhibitor Injection Pumps Equipment Tag No.

9103-P-101A/B

Pump Type

Double Diaphragm

Chemical

Corrosion Inhibitor

Capacity, L/hr

55

Design Pressure, bar(g)

12

Discharge Pressure, bar(g)

8.5

Design Temperature, °C

85/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.37 SS 316TI/PTFE

Corrosion Inhibitor Unloading Pump Equipment Tag No.

9103-P-102

Pump Type

Air Operated Pump

Chemical

Corrosion Inhibitor

Capacity, L/hr

2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

AISI 316L

Corrosion Inhibitor Tank Agitator Equipment Tag No.

9103-M-13

Speed, RPM

155

Rated Power, kW

0.37

Material of Construction

AISI 316L

4.14.3.2 Corrosion Inhibitor Package 9103-A-12 Description Corrosion Inhibitor Package consists of a Corrosion Inhibitor Storage Tank 9103-T-13 and two numbers of Corrosion Inhibitor Injection Pumps 9103-P-101A/B. The Corrosion Inhibitor Storage Tank 9103-T-13 is having an agitator 9103-M-13. Corrosion Inhibitor from drums is transferred to the tank through an unloading pump 9103-P-102. The Corrosion Inhibitor Pumps 9103-P-101A/B are having discharge pulsation dampner and calibration pots at the suction line.

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4.14.3.3 Corrosion Inhibitor Injection Package Control Description Following parameters are to be monitored: Tag No.

Description

Unit

Alarm Low

High

91-FI-1534

9103-P-101A/B common discharge flow

LPH

40

70

91-PI-1561

9103-P-101A discharge pressure

barg

NA

9.5

91-PI-1562

9103-P-101B discharge pressure

barg

NA

9.5

91-LT-1523

corrosion inhibitor storage tank

%

6

NA

Following are the details of the switches & alarm related to motor controls: Tag No.

Description

91-HSOA-1584

Remote “ START” for the Pump 9103-P-101A

91-HSOA-1585

Remote “ START” for the Pump 9103-P-101B

91-HSCA-1584

Remote “ STOP” for the Pump 9103-P-101A

91-HSCA-1585

Remote “ STOP” for the Pump 9103-P-101B

91-ZL-1584

9103-P-101A Pump Available signal

91-ZL-1585

9103-P-101B Pump Available signal

91-XS-1584

9103-P-101A Pump ESD trip signal

91-XS-1585

9103-P-101B Pump ESD trip signal

91-ZI-1584

9103-P-101A Pump running indication

91-ZI-1585

9103-P-101B Pump running indication

•

Low low level alarm 91-LALL-1523 set at 3 % in Corrosion Inhibitor Storage Tank 9103-T-13 trips the Corrosion Inhibitor Injection Pumps (9103-P-101A/B)

•

High high diaphragm pressure alarm 91-PAHH-1567 set at 8.5 barg in Corrosion Inhibitor Injection Pump 9103-P-101A initiates the pump changeover

•

High high diaphragm pressure alarm 91-PAHH-1568 set at 8.5 barg in Corrosion Inhibitor Injection Pump 9103-P-101B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Corrosion Inhibitor Injection Pumps 9103-P-101A/B.

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4.14.4

Complex Product Injection Package 6834-A-09

4.14.4.1 Equipment Specification Complex Product Storage Tank Equipment Tag No.

6834-T-18

Size, ID/Height, mm 3

Storage Capacity m Chemical

950/1500 1 Complex Product

Design Pressure bar(a)

1.01

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM.

Operating Temperature, °C

52/0

Material of Construction

AISI 316L

Complex Product Injection Pumps Equipment Tag No.

6834-P-41A/B

Pump Type

Double Diaphragm

Chemical

Complex Product

Capacity, L/hr

1.87

Design Pressure, bar(g)

31

Discharge Pressure, bar(g)

25

Design Temperature, °C

120/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.18 SS 316TI/PTFE

Complex Product Unloading Pump Equipment Tag No. Pump Type Chemical Capacity, L/hr

6834-P-42 Air Operated Pump Complex Product 2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

AISI 316L

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Complex Product Tank Agitator Equipment Tag No.

6834-M-04

Speed, RPM

243

Rated Power, kW

0.25

Material of Construction

AISI 316L

4.14.4.2 Complex Product Injection Package Description Complex Product Injection Package consists of a Complex Product Storage Tank 6834-T-18 and two numbers of Complex Product Injection Pumps 6834-P-41A/B. The Complex Product Storage Tank 6834-T-18 is having an agitator 6834-M-04. Complex Product from drums is transferred to the tank through an unloading pump 6834-P-42. The Complex Product Injection Pumps 6834-P-41A/B are having discharge pulsation dampner and calibration pots at the suction line. 4.14.4.3 Complex Product Injection Process control Description The complex product is injected to the boiler feed water going to the steam generation package and to the boiler feed water going to TGTU. The control is achieved by maintaining the ratio between the total Boiler Feed Water flow and Complex Product flow. The Boiler Feed Water flow rate to Steam Generation Boiler A/B/C is measured by 68FT 1522, 68-FT-1622, 68-FT-1722 respectively and 68-FT-1304 measures the boiler feed water flow rate to TGTU. The Complex Product Pumps (6834-P-41A/B) common discharge flow rate is measured by 68-FT-1311. Total summation of all the above BFW flow is summated in the calculation block 68-FY-1304 and multiplied with the fixed ratio X (X=complex product/total BFW) in the multiplication block 68-FFY-1311. The output from 68-FFY-1311 is fed as a set point to the MASTER complex product flow controller 68-FIC-1311. The complex product pumps 6834-P-41A/B stroke length (0-15 mm) is measured by the stroke indicators 68-ZI-1303/1304 and the strokes are controlled by the position controllers 68-ZIC-1303, 68-ZIC-1304. Complex product flow controller 68-FIC-1311 is cascaded with the position controllers 68-ZIC-1303 and 68-ZIC-1304 and provides set point to the position controllers.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Tag

Control Description

Alarm

Unit

Operating Set Point

Low

High

L/hr

1.78

0.2

1.78

68-FIC-1311

Complex product flow control

68-ZIC-1303

6834-P-41A position control

%

100

NA

NA

68-ZIC-1304

6834-P-41B position control

%

100

NA

NA

The complex product injection pumps can be operated from the DCS when the Pumps are selected to “Remote” at its local panel. Following are the details of the switches & alarm related to motor controls: Tag No.

Description

68-HSOA-1324

Remote “ START” for the Pump 6834-P-41A

68-HSOA-1332

Remote “ START” for the Pump 6834-P-41B

68-HSCA-1324

Remote “ STOP” for the Pump 6834-P-41A

68-HSCA-1332

Remote “ STOP” for the Pump 6834-P-41B

68-ZL-1324

6834-P-41A Pump Available signal

68-ZL-1332

6834-P-41B Pump Available signal

68-XS-1324

6834-P-41A Pump ESD trip signal

68-XS-1332

6834-P-41B Pump ESD trip signal

68-ZI-1324

6834-P-41A Pump running indication

68-ZI-1332

6834-P-41B Pump running indication

Following parameters are to be monitored Tag No.

Description

Unit

Alarm Low

High

68-PI-1318

6834-P-41A Pump discharge pressure

barg

NA

26.5

68-PI-1316

6834-P-41B Pump discharge pressure

barg

NA

26.5

68-LI-1317

Complex product storage tank 6834-T18 level

%

6

NA

•

Low low level alarm 68-LALL-1316 set at 3% in Complex Product Storage Tank trips the Complex Product Injection Pumps 6834-P-41A/B

•

High high diaphragm pressure alarm 68-PAHH-1326 set at 25.0 barg in Complex Product Injection Pump 6834-P-41A initiates the pump changeover

•

High high diaphragm pressure alarm 68-PAHH-1327 set at 25.0 barg in Complex Product Injection Pump 6834-P-41B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Complex Product Injection Pumps 6834-P-41A/B.

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.5

Oxygen Scavenger Injection Package 6834-A-09

4.14.5.1 Equipment Specification Oxygen Scavenger Storage Tank Equipment Tag No.

6834-T-17

Size, ID/Height, mm 3

Storage Capacity m Chemical

950/1500 1 Oxygen Scavenger

Design Pressure bar(a)

1.01

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM.

Operating Temperature, °C

52/0

Material of Construction

AISI 316L

Oxygen Scavenging Injection Pumps Equipment Tag No.

6834-P-39A/B

Pump Type

Double Diaphragm

Chemical

Oxygen Scavenger

Capacity, L/H

0.55

Design Pressure, bar(g)

10.5

Discharge Pressure, bar(g)

6.5

Design Temperature, °C

120/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.18 SS 316TI

Oxygen Scavenger Unloading Pump Equipment Tag No.

6834-P-40

Pump Type

Air Operated Pump

Chemical

Oxygen Scavenger

Capacity, L/h

2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

AISI 316L

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TITLE: OPERATION AND MAINTENANCE MANUAL

Oxygen Scavenger Tank Agitator Equipment Tag No.

6834-M-03

Speed, RPM

243

Rated Power, kW

0.25

Material of Construction

AISI 316L

4.14.5.2 Oxygen Scavenger Injection Package Description Oxygen Scavenger Injection Package consists of a Oxygen Scavenger Storage Tank 6834-T-17 and two numbers of Oxygen Scavenger Injection Pumps 6834-P-39A/B. The Oxygen Scavenger Storage Tank 6834-T-17 is having an agitator 6834-M-03. Oxygen Scavenger from drums is transferred to the tank through an unloading pump 6834-P-40 The Oxygen Scavenger Injection Pumps 6834-P-39A/B is provided with discharge pulsation dampener and calibration pots at the suction line. 4.14.5.3 Oxygen Scavenging Injection Process control Description The oxygen scavenger is injected directly in to the De-aerator package (6834-A-08) and the flow rate of Oxygen Scavenger is measured by 68-FT-1310. Oxygen Scavenger Injection Pumps 6834-P-39A, 6834-P-39B stroke length is measured by 68-ZT-1301 and 68-ZT-1302 respectively. Stroke length of 6834-P-39A, 6834-P-39B is manually adjusted by the controllers 68-HIC-1301 and 68-HIC-1302, respectively. The Oxygen Scavenger Injection Pumps can be operated from the DCS when the Pumps are selected to “Remote” at its local panel Following are the details of the switches & alarm related to motor controls: Tag No.

Description

68-HSOA-1323

Remote “ START” for the Pump 6834-P-39A

68-HSOA-1331

Remote “ START” for the Pump 6834-P-39B

68-HSCA-1323

Remote “ STOP” for the Pump 6834-P-39A

68-HSCA-1331

Remote “ STOP” for the Pump 6834-P-39B

68-ZL-1322

6834-P-39A Pump Available signal

68-ZL-1331

6834-P-39B Pump Available signal

68-XS-1322

6834-P-39A Pump ESD trip signal

68-XS-1331

6834-P-39B Pump ESD trip signal

68-ZI-1322

6834-P-39A Pump running indication

68-ZI-1331

6834-P-39B Pump running indication

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TITLE: OPERATION AND MAINTENANCE MANUAL

Following parameters are to be monitored: Tag No.

4.14.6

Description

Alarm

Unit

Low

High

68-PI-1317

6834-P-39A Pump discharge pressure

barg

NA

8

68-PI-1315

6834-P-39B Pump discharge pressure

barg

NA

8

68-LI-1315

Oxygen Scavenger Storage Tank 6834-T-17 level

%

6

80

68-FI-1310

Oxygen Scavenger Injection flow rate

LPH

0.2

0.7

•

Low low level alarm 68-LALL-1314 set at 3 % in oxygen scavenger tank 6834-T-17 trips the Oxygen Scavenger Injection Pumps 6834-P-39A/B

•

High high diaphragm pressure alarm 68-PAHH-1324 set at 6.5 barg in Oxygen Scavenger Injection Pump 6834-P-39A initiates the pump changeover

•

High high diaphragm pressure alarm 68-PAHH-1325 set at 6.5 barg in oxygen scavenger Injection Pump 6834-P-39B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Oxygen Scavenger Pumps 6834-P-39A/B. Biocide Injection Package 6932-A-06

4.14.6.1 Equipment Specification Biocide Storage Tank Equipment Tag No.

6932-T-04

Size, ID/Height, mm 3

Storage Capacity m Chemical

1300/2300 3 Biocide

Design Pressure bar(a)

1.01

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM.

Operating Temperature, °C

52/0

Material of Construction

AISI 316L

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TITLE: OPERATION AND MAINTENANCE MANUAL

Biocide Injection Pumps Equipment Tag No. Pump Type Chemical Capacity, L/H

6932-P-07A/B Double Diaphragm Biocide 12/65/110

Design Pressure, bar(g)

10

Discharge Pressure, bar(g)

5.5

Design Temperature, °C

120/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.75 SS 316TI/PTFE

Biocide Unloading Pump Equipment Tag No. Pump Type Chemical Capacity, L/h

6932-P-08 Air Operated Pump Biocide 2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

AISI 316L

4.14.6.2 Biocide Injection Package Description Biocide Injection Package consists of a Biocide Storage Tank 6932-T-04 and two numbers of Biocide Injection Pumps 6932-P-07A/B. Biocide from drums is transferred to the tank through an unloading pump 6932-P-08. The Biocide Injection Pumps 6932-P-07A/B is provided with discharge pulsation dampener and calibration pots at the suction line. 4.14.6.3 Biocide Injection Process control Description The biocide storage tank 6932-T-04 level is measured by 69-LI-1328. Biocide from the storage tank is injected to Sea Cooling Water through remote stroke adjusting pumps (6932-P-07A/6932-P-07B). Stroke lengths of 3 stage 6932-P-07A are measured by 69-ZT-1301, 69-ZT-1326 and 69-ZT-1328. Manual adjustment of stroke is done via the controllers 69-HIC-1301, 69-HIC-1326 and 69-HIC-1328.

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TITLE: OPERATION AND MAINTENANCE MANUAL

Stroke lengths of 3 stage 6932-P-07B are measured by 69-ZT-1302, 69-ZT-1327 and 69-ZT-1329. Manual adjustment of stroke is done via the controllers 69-HIC-1302, 69-HIC-1327 and 69-HIC-1329. Following parameters are to be monitored: Tag No.

Description

Unit

Alarm Low

High

st

69-FI-1319

6932-P-07A/B 1 stage common discharge flow

LPH

80

130

69-FI-1323

6932-P-07A/B 2nd stage common discharge flow

LPH

80

130

69-FI-1324

6932-P-07A/B 3rd stage common discharge flow

LPH

80

130

69-PI-1330

6932-P-07A 1st stage discharge pressure

barg

NA

6.5

69-PI-1340

stage discharge pressure

barg

NA

6.5

rd

6932-P-07A 3 stage discharge pressure

barg

NA

6.5

st

barg

NA

6.5

stage discharge pressure

barg

NA

6.5

69-PI-1343

6932-P-07B 3 stage discharge pressure

barg

NA

6.5

69-LI-1328

Biocide Storage Tank (6932-T-04) level

%

6

NA

69-PI-1342 69-PI-1331 69-PI-1341

6932-P-07A 2

nd

6932-P-07B 1 stage discharge pressure 6932-P-07B 2

nd rd

The Biocide injection pumps can be operated from the DCS when the Pumps are selected to “Remote” at its local panel. Following are the details of the switches & alarm related to motor controls: Tag No.

Description

69-HSOA-1352

Remote “ START” for the Pump 6932-P-07A

69-HSOA-1353

Remote “ START” for the Pump 6932-P-07B

69-HSCA-1352

Remote “ STOP” for the Pump 6932-P-07A

69-HSCA-1353

Remote “ STOP” for the Pump 6932-P-07B

69-ZL-1352

6932-P-39A Pump Available signal

69-ZL-1353

6932-P-39B Pump Available signal

69-XS-1352

6932-P-07A Pump ESD trip signal

69-XS-1353

6932-P-07B Pump ESD trip signal

69-ZI-1352

6932-P-07A Pump running indication

69-ZI-1353

6932-P-07B Pump running indication

•

Low low level alarm 69-LALL-1329 set at 10 % in biocide storage tank 6932-T-04 trips the Biocide Injection Pumps 6932-P-07A/B

•

High high diaphragm pressure alarm 69-PAHH-1344 set at 5.5 barg in 1st stage Biocide Injection Pump 6932-P-07A initiates the pump changeover

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.7

•

High high diaphragm pressure alarm 69-PAHH-1346 set at 5.5 barg in 2nd stage Biocide Injection Pump 6932-P-07A initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1328 set at 5.5 barg in 3rd stage Biocide Injection Pump 6932-P-07A initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1345 set at 5.5 barg in 1st stage Biocide Injection Pump 6932-P-07B initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1347 set at 5.5 barg in 2nd stage Biocide Injection Pump 6932-P-07B initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1329 set at 5.5 barg in 3rd stage Biocide Injection Pump 6932-P-07B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Biocide Injection Pumps 6932-P-07A/B. Scale Inhibitor Injection Package 6932-A-07

4.14.7.1 Equipment Specification Scale Inhibitor Storage Tank Equipment Tag No.

6932-T-05

Size, ID/Height, mm 3

Storage Capacity m Chemical

2480/4900 24 Scale Inhibitor

Design Pressure bar(a)

1.2

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM

Operating Temperature, °C

52/0

Material of Construction

AISI 316L

Scale Inhibitor Injection Pumps Equipment Tag No. Pump Type Chemical Capacity, L/H

6932-P-09A/B Double Diaphragm Scale Inhibitor 26/41/4

Design Pressure, bar(g)

10

Discharge Pressure, bar(g)

5.5

Design Temperature, °C

120/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.37 SS 316TI/PTFE

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

Scale Inhibitor Unloading Pump Equipment Tag No.

6932-P-10

Pump Type

Air Operated Pump

Chemical

Scale Inhibitor

Capacity, L/h

5000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

SS 316TI

4.14.7.2 Scale Inhibitor Injection Package Description Scale Inhibitor Injection Package consists of a Scale Inhibitor Storage Tank 6932-T-05 and two numbers of Scale Inhibitor Injection Pumps 6932-P-09A/B. Scale Inhibitor from drums is transferred to the tank through an unloading pump 6932-P-10. The Scale Inhibitor Injection Pumps 6932-P-09A/B are having discharge pulsation dampner and calibration pots at the suction line. 4.14.7.3 Scale Inhibitor Injection Process control Description The Scale Inhibitor Storage Tank 6932-T-05 level is measured by 69-LI-1330. Scale Inhibitor from the storage tank is injected to sea cooling water through Injection Pumps 6932-P-09A/6932-P-09B. Following parameters are to be monitored: Tag No. 69-FI-1322 69-FI-1321 69-FI-1320 69-PI-1332 69-PI-1333 69-PI-1334 69-PI-1335 69-PI-1336 69-PI-1337 69-LI-1330

Description 6932-P-09A/B 1st stage common discharge flow 6932-P-09A/B 2nd stage common discharge flow 6932-P-09A/B 3rd stage common discharge flow 6932-P-09A 1st stage discharge pressure 6932-P-09A 2nd stage discharge pressure 6932-P-09A 3rd stage discharge pressure 6932-P-09B 1st stage discharge pressure 6932-P-09B 2nd stage discharge pressure 6932-P-09B 3rd stage discharge pressure Scale Inhibitor Storage Tank (6932-T05) level

Unit

Alarm Low High

LPH

2

8

LPH

35

45

LPH

20

30

barg barg barg barg barg barg

NA NA NA NA NA NA

6.5 6.5 6.5 6.5 6.5 6.5

%

6

80

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

The scale inhibitor injection pumps can be operated from the DCS when the Pumps are selected to “Remote” at its local panel. Following are the details of the switches & alarm related to motor controls: Tag No.

Description

69-HSOA-1354

Remote “ START” for the Pump 6932-P-09A

69-HSOA-1355

Remote “ START” for the Pump 6932-P-09B

69-HSCA-1354

Remote “ STOP” for the Pump 6932-P-09A

69-HSCA-1355

Remote “ STOP” for the Pump 6932-P-09B

69-ZL-1354

6932-P-09A Pump Available signal

69-ZL-1355

6932-P-09B Pump Available signal

69-XS-1354

6932-P-09A Pump ESD trip signal

69-XS-1355

6932-P-09B Pump ESD trip signal

69-ZI-1354

6932-P-09A Pump running indication

69-ZI-1355

6932-P-09B Pump running indication

•

Low low level alarm 69-LALL-1331 set at 3% in Scale Inhibitor Storage Tank 6932-T05 trips the Scale Inhibitor Injection Pumps (6932-P-09A/B)

•

High high diaphragm pressure alarm 69-PAHH-1338 set at 5.5 barg in 1st stage Scale Inhibitor Injection Pump 6932-P-09A initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1348 set at 5.5 barg in 2nd stage Scale Inhibitor Injection Pump 6932-P-09A initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1350 set at 5.5 barg in 3rd stage Scale Inhibitor Injection Pump 6932-P-09A initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1339 set at 5.5 barg in 1st stage Scale Inhibitor Injection Pump 6932-P-09B initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1349 set at 5.5 barg in 2nd stage Scale Inhibitor Injection Pump 6932-P-09B initiates the pump changeover

•

High high diaphragm pressure alarm 69-PAHH-1351 in 3rd stage Scale Inhibitor Injection Pump 6932-P-09B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Scale Inhibitor Injection Pumps 6934-P-09A/B.

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.8

Catalyst Injection Package 9101-A-01

4.14.8.1 Equipment Specification Catalyst Storage Tank Equipment Tag No.

9101-T-01

Size, ID/Height, mm 3

Storage Capacity m Chemical

950/1500 1 Catalyst

Design Pressure bar(a)

1.01

Design Temperature °C

85/0

Operating Pressure bar(g)

ATM

Operating Temperature, °C

52/0

Material of Construction

AISI 316L

Catalyst Injection Pumps Equipment Tag No. Pump Type Chemical Capacity, L/H

9101-P-11A/B Double Diaphragm Catalyst 0.55

Design Pressure, bar(g)

8

Discharge Pressure, bar(g)

5

Design Temperature, °C

85/0

Driver Type

Motor

Rated Power, kW Material of Construction

0.37 SS 316TI/PTFE

Catalyst Unloading Pumps Equipment Tag No. Pump Type Chemical Capacity, L/h

9101-P-12 Air Operated Pump Catalyst 2000

Design Pressure, bar(g)

8.7

Discharge Pressure, bar(g)

1.2

Design Temperature, °C

85/0

Material of Construction

SS 316TI

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.8.2 Catalyst Injection Package Description Catalyst Injection Package consists of a Catalyst Storage Tank 9101-T-01 and two numbers of Catalyst Injection Pumps 9101-P-11A/B. Catalyst from drums is transferred to the tank through an unloading pump 9101-P-12. The Catalyst Injection Pumps 9101-P-11A/B are having calibration pots at the suction line. 4.14.8.3 Catalyst Injection Process control Description The Catalyst Storage Tank level 9101-T-01 is monitored by 91-LI-1127 and Catalyst Injection Pumps 9101-P-11A/B common discharge flow is measured by 91-FI-1128. Following parameters are to be monitored: Tag No.

Description

Unit

Alarm Low

High

91-FI-1128

9101-P-11A/B common discharge flow

LPH

0.2

0.7

91-PI-1127

9101-P-11A discharge pressure

barg

NA

6

91-PI-1129

9101-P-11B discharge pressure

barg

NA

6

91-LI-1127

catalyst storage tank 9101-T01 level

%

6

NA

Following are the details of the switches & Alarm related to motor controls: Tag No.

Description

91-HSOA-1129

Remote “ START” for the Pump 9101-P-11A

91-HSOA-1130

Remote “ START” for the Pump 9101-P-11B

91-HSCA-1129

Remote “ STOP” for the Pump 9101-P-11A

91-HSCA-1130

Remote “ STOP” for the Pump 9101-P-11B

91-ZL-1129

9101-P-11A Pump Available signal

91-ZL-1130

9101-P-11B Pump Available signal

91-XS-1129

9101-P-11A Pump ESD trip signal

91-XS-1130

9101-P-11B Pump ESD trip signal

91-ZI-1129

9101-P-11A Pump running indication

91-ZI-1130

9101-P-11B Pump running indication

•

Low low level alarm 91-LALL-1128 set at 3% in Catalyst Storage Tank 9101-T-01 trips the Catalyst Injection Pumps 9101-P-11A/B

•

High high diaphragm pressure alarm 91-PAHH-1128 set at 5 barg in Catalyst Injection Pump 9101-P-11A initiates the pump changeover

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

•

High high diaphragm pressure alarm 91-PAHH-1130 set at 5 barg in Catalyst Injection Pump 9101-P-11B initiates the pump changeover

•

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Catalyst Injection Pumps 9101-P-11A/B.

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION V PRE-REQUISITE FOR START-UP

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TITLE: OPERATION AND MAINTENANCE MANUAL

5.1

GENERAL For Start-up of the SRU Upgrade Facilities the pre-requisites are given below: •

All vent and drain valves position are as per P&ID

•

All spectacle spacers and spectacle blinds are as per P&ID

•

Acid gas from AGRU 1 & 2 to the Acid Gas Enrichment Unit isolation valve 91-BV1881 is in closed condition

•

Electrical power is available

•

Fire & gas system of process unit is tested and in normal operation

•

Ensure that DCS, F&G and ESD systems are available

•

Acid gas flare system is in operation

•

LP Flare is in operation

•

All process line isolating valves are in closed condition

•

Ensure all ‘Lock Open’ and ‘Lock Closed’ valves are in their normal operating positions as per P&ID

•

Ensure that all safety devices have been set to the appropriate set-point as per P&ID

•

Ensure all mechanical equipment have been installed properly

•

All instrument root valves are open

•

All instrument vent/drain valves are closed

•

Ensure that no shutdown conditions are present (ESD)

•

Confirm availability of all tools, consumables, and spare parts that are required for start-up

•

Confirm that the required valid “Permit to Work” has been issued prior to the commencement of start-up activities

•

Ensure that fire protection system is ready for operation

•

Ensure that the AGRU 1 & 2 are running and ready to provide acid gas to the AGEU

Prior to the starting up of the plant there are several operations that must be conducted to prepare the plant for the actual start-up. This section covers the work required in preparing the unit for initial start-up. The jobs can be categorized as follows: •

Plant inspection

•

Final inspection of vessels and equipments

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

•

Line and Equipment leak test

It is important that these above procedures to be carried out thoroughly and at earliest possible to achieve a smooth, trouble free and steady normal operation. 5.2

INTERFACE ACTIVITIES The following tie-ins between the NGL 1, 2, 3 & 4 and the SRU Upgrade Facilities are to be completed before the start-up of the new facilities. Process •

Acid Gas from NGL-3 AGRU 1 & 2

•

Acid Gas from NGL 1 & 2 Blowers

•

Acid Gas from NGL-4 K-8201A/B

•

Acid Gas from AGEU Regenerator Reflux Drum 9103-V-12 to SRU

•

Sour Water from Acid Gas KO Drum Return Pump 9103-P-14A/B to SRU

•

Acid Water from SRU to Amine Sump 9103-V-10

Utilities •

Sea Cooling Water from new Sea Cooling Water system to the existing Sea Cooling Water system

•

Sea Cooling Water Return from AGEU/TGTU to existing Sea Water Observation Sump 6932-X-01

•

20” LP Flare header interconnection from new units to the existing units

•

NGL-4 Sea Cooling Water system new Sea Water Filters S-8840A/B

•

Line from existing Drinking Water Storage Tank 6834-T-01A/B to the new Drinking Water Pumps 6834-P-23A/B

•

Interconnection between existing Drinking Water Pumps 6834-P-01A/B and new Drinking Water Pumps 6834-P-23A/B

•

Interconnection between new DM Water network to the existing DM Water network

•

Interconnection between the new plant air header to the old plant air header

•

Interconnection between the existing 6”-GI-82-0357-C01A nitrogen header to the new nitrogen header

•

Interconnection between the existing Lean Gas from Booster Compressor suction to the LP Fuel Gas KO Drum 6236-V-05

•

Interconnection between the lean gas from 6103-K-01A/B and the LP Fuel Gas KO Drum 6236-V-05

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

•

Interconnection between the existing fuel gas line upstream of 65-XV-001 and the LP Fuel Gas KO Drum 6236-V-05

•

Interconnection from existing fuel gas header 6”-6536-FG-101-C12P to Incinerator 9101-F-14 and Reducing Gas Generator 9102-F-11

•

Interconnection of the following new flare lines to the existing LP Flare Header 10”-6922-FL-013-C14P: •

From LP Fuel Gas KO Drum 6236-V-05 drain line

•

LP Fuel Gas KO Drum 6236-V-05 PSVs 62-PSV-176/176S outlet lines

•

Fuel gas from steam generation package 6848-A-02A/B/C

•

From LP Fuel Gas KO Drum 6236-V-05 vent 62-PV-1303

•

From LP Fuel Gas KO Drum 6236-V-05 inlet pressure control valves 62-PV1301A/62-PV-1301B/62-PV-1302

•

Interconnection from existing fuel gas line 2”-6536-FG-011-C12P to LP Acid Gas flare header as purge gas

•

Interconnection from the existing Service Water Pump P-3103 discharge to the Electro Chlorination Package 6932-A-05

•

Interconnection between the existing Instrument Air supply to the new Sea Cooling Water Filters 6932-S-02A/B

•

Interconnection between the existing Plant Air supply to the Sea Cooling Water Filters 6932-S-02A/B

•

Interconnection between the existing nitrogen supply system to the new Electro Chlorination system

•

Interconnection between the existing Spent Caustic system and the new Spent Caustic form Desuperheater Circulation Pumps 9102-P-11A/B

•

Oily Waste Water from SRU Upgrade new Utilities/Process area to the existing Oily Waste Water Sump 6922-X-01

•

From new Stripped Water Cooler 6922-E-02/Cooling water return from AGEU/TGTU to Sea Water Observation Sump 6932-X-01 analyzer 69-AT-1301 outlet to the existing Observation & Buffer Sump 6922-X-04

•

Interconnection between the existing instrument air header and the new instrument air header

•

Interconnection between the new Biocide Injection Package 6932-A-06 and the existing Sea Cooling Water Pumps P-1618 AR/BR/CR suction

•

Interconnection between the new Scale Inhibitor Injection Package 6932-A-07 and the existing Sea Cooling Water Pumps P-1618 AR/BR/CR discharge.

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5.3

START-UP OF UTILITIES

5.3.1

Start-up Sequence Utilities are started in the following sequence:

5.4 5.4.1

1.

Instrument Air/Plant Air System

2.

Nitrogen System

3.

Drinking Water System

4.

Oily Water Drain System

5.

Effluent and Waste Water Treatment System

6.

Flare System

7.

Fuel Gas System

8.

Sea Cooling Water System

9.

Chemical Injection System

10.

DM Water System

11.

Boiler Feed Water Deaerator System

12.

Steam Generation System

INSTRUMENT AIR/PLANT AIR SYSTEM Pre Start-up Checks Ensure the following pre start-up checks are completed before the start-up: 1. Ensure the Readiness of Instrument Air Compressor, Instrument Air Dryer and all its auxiliary equipments. 2. Ensure all the instruments are lined up. 3. Ensure that the Air Compressor Discharge Drum 6837-V-10 & Instrument Air Receiver 6837-V-11 are clean. Ensure the following PSVs are calibrated, reinstated and lined-up as shown in P&ID: PSV Tag No.

Description

68-PSV-1401

PSV after intercooler

68-PSV-1402

PSV after intercooler

68-PSV-1106/1106S

Air compressor Discharge drum PSV

68-PSV-1107/1107S

Instrument air receiver PSV

68-PSV-1408

Adsorber 6837-V-14A

68-PSV-1409

Adsorber 6837-V-14A

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PSV Tag No.

5.4.2

Description

68-PSV-1458

Adsorber 6837-V-15A

68-PSV-1459

Adsorber 6837-V-15B

Instrument Air compressor Start-up There are two Instrument Air Compressors (2 x 100% capacity). The compressors operate on Duty/Standby configuration. Each compressor is monitored and controlled by the package controller (UCP) which contains Siemens S7-400H series PLC and provides information to the DCS through redundant modbus TCP/IP communication link. Air Compressors LCP details are tabulated below: Sl. #

Tag No. 6837-K-02A

Service

6837-K-02B

1.

68-HS-1403

68-HS-1453

Local/Remote Selector Switch

2.

68-HS-1402

68-HS-1452

Load/Unload Selector switch

3.

68-HSOA-1414

68-HSOA-1464

Start Push Button

4.

68-HSCA-1415

68-HSOA-1465

Stop Push Button

5.

68-HS-1404

68-HS-1454

Lamp Test Push Button

6.

68-HS-1401

68-HS-1451

Emergency Stop Push Button

7.

68-HS-1405

68-HS-1455

Reset Push Button

8.

68-XL-1408

68-XL-1458

Voltage ON lamp (white)

9.

68-XL-1409

68-XL-1459

Compressor loaded lamp

10.

68-XL-1410

68-XL-1460

Automatic operation lamp

11.

68-XL-1411

68-XL-1461

General warning lamp

12.

68-XL-1412

68-XL-1462

General shutdown lamp

Details of DCS tags for Air Compressors are tabulated below: Sl. #

Tag No. 6837-K-02A

6837-K-02B

Service

1.

68-HSOA-1428

68-HSOA-1478

Remote Start Button

2.

68-HSCA-1428

68-HSOC-1478

Remote Stop Button

3.

68-UA-1401

68-UA-1451

Compressor common alarm

Note: Press lamp test push button in local control panel and ensure all the lamps are in working normal. The procedure for start-up of one unit (6837-K-02A) of IA Compressor is covered in this section. The same procedure is applicable for other unit (6837-K-02B).

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TITLE: OPERATION AND MAINTENANCE MANUAL

Instrument air compressor can be started in two modes. I.

Local Mode

In local mode, the start/stop of the compressor is done from the local control station (LCS). For operating the Compressor in local mode, the selectors switch 68-HS-1403 in Local Control Station to be selected to local position. The loading/unloading is done by the operator using the loading/unloading switch 68-HS-1402 in the LCS. During Local mode loading and unloading of the compressor is based on the compressor outlet pressure transmitter signal 68-PT-1406. Local mode is used for service or maintenance purposes. II. Remote Mode Remote-Auto and Remote-Manual modes are possible under remote mode of operation. In Remote mode, start and stop of the individual compressors are initiated from UCP/DCS operating stations. In Remote-Auto mode, the UCP sequence control has total control over selection, start & stop and pressure control of both the compressors. All local controls are disabled in this mode except emergency stop from field. In Remote mode, the loading/unloading of compressors is based on the air receiver pressure transmitter signal 68-PT-1311. 5.4.3

Start-up permissive conditions: •

Availability of instruments and in healthy condition

•

Motor available signal (68-XU-1428) from MCC

•

Ensure the below mentioned interlocks in UCP of I/A Compressor are normal: Tag No.

Description

68-PAHH-1406

Compressor outlet pressure high-high

68-PDALL-1401

Compressor air inlet pressure low-low

68-PALL-1402

Compressor oil pressure low-low

68-PDAHH-1403

Compressor oil filter DP high-high

68-TAHH-1401

LP stage outlet temperature high-high

68-TAHH-1402

Compressor oil temperature high-high

68-TAHH-1403

LP stage inlet temperature high-high

68-TAHH-1405

Compressor outlet temperature high-high

68-TAHH-1406

Main motor (U1) winding temperature high-high

68-TAHH-1407

Main motor (V1) winding temperature high-high

68-TAHH-1408

Main motor (W1) winding temperature high-high

68-TAHH-1412

Main motor(U2) winding temperature high-high

68-TAHH-1413

Main motor (V2) winding temperature high-high

68-TAHH-1414

Main motor (W2) winding temperature high-high

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TITLE: OPERATION AND MAINTENANCE MANUAL

Tag No.

Description

68-TAHH-1410

Main motor bearing (DE) temperature high-high

68-TAHH-1411

Main motor bearing (NDE) temperature high-high

68-HS-1401

Emergency stop button at LCP

68-XS-1424

ESD signal to UCP

Following interlocks are bypassed automatically during start-up of compressor: •

68-PT-1402 (Lube oil pressure) low low alarm

•

Compressor trip (68-XZA-1428) and stop (68-XI-1428) feedback

Both the above interlocks are bypassed for 20 seconds. The local start-up procedure for 6837-K-02A is given below: 1.

Select both the compressors to “Local” from the Local Control panel through selector switch

2.

Open 6837-K-02A discharge isolation valve

3.

Close the Plant air header pressure control valve 68-PV-1310 and the upstream block valve

4.

Close the Air Dryer Package pre-filter upstream isolation valves

5.

Confirm ‘Motor available’ signal (68-XU-1428) exists

6.

Before starting the Compressor main motor, Set loading & unloading Pressure set point at XX barg in UCP HMI

7.

Start Compressor 6837-K-02A through Local Start Push Button and ensure that compressor is started and running

8.

Ensure that the Cooling Air Fans (6837-EFM-03AA/AB) and External After Cooler Fan Motor (6837-EFM-04A) is running and its running indication in DCS/HMI

9.

Ensure that oil pump is running and the oil pressure is 2.3 barg

10. Ensure compressor runs in unloaded condition for 20 seconds 11. Load the Air Compressor by Pressing Push button 68-HS-1402 in the local panel 12. Ensure that the compressor is loaded by checking the pressure 68-PT-1406 located in the HP Stage compressor outlet 13. Confirm ‘Loaded’ indication (68-XL-1409) in local control station 14. Confirm the Compressor loads up to XX barg, based on the value taken from 68PT-1406 located on the compressor outlet

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15. Check the performance of the Compressor by monitoring the following parameters: •

Discharge Pressure (68-PI-1406)

•

Discharge Temperature (68-TI-1405)

•

Motor Amperage

•

Oil Temperature (68-TI-1402)

•

Oil Pressure (68-PI-1402)

•

Motor Winding Temperatures

•

Compressor vibration

•

Motor vibration

•

Compressor and motor bearing temperatures

Note: Instrument air compressors can also be started from DCS by selecting the “Remote” in LCP and Auto/manual button to “Auto” in UCP-HMI.

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Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 25 - IA Compressor Start-up D

Instrument Air Compressor Start Sequence

Y

20 sec load delay, oil pressure trip (68-PT-1402) needs to be bypassed up to this time

Manual Unload N

Take corrective action

N

Interlocks & start-up permissive healthy

Ready to load/unload

Note-A

Set pressure 24H Y

Main motor, cooling fan motor and after cooler fan motor starts

20 sec load delay, Oil pressure trip (68-PT-1402) needs to be bypassed up to this time

Auto change over-Running compressor stop & reset the loading hour counter and start the standby

Compressor oil temperature high-high (68-TT-1402) LP stage I/L temperature high-high (68-TT-1403) Compressor O/L temperature high-high (68-TT1405) Overload relays of main motor, inter external after cooler motors Main motor winding temperatures high-high

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TITLE: OPERATION AND MAINTENANCE MANUAL

5.4.4

Instrument Air Dryer start-up The dryer package consists of two trains of dryers (6837-A-03 & 6837-A-04) which are to be operated (2 X 50%) together and this repetitive operation is controlled from UCP panel. ON/OFF valve details in the dryer package are tabulated below: Sl. #

Tag No. 6837-A-03

Service

6837-A-04

1.

68-XV-1416

68-XV-1466

Purge on/off valve

2.

68-XV-1417

68-XV-1467

Purge on/off valve

3.

68-XV-1418

68-XV-1468

Air inlet on/off valve

4.

68-XV-1419

68-XV-1469

Air inlet on/off valve

Details of tags for Air dryers are tabulated below: Sl. #

5.4.5

5.4.6

Tag No.

Service

6837-A-03

6837-A-04

1.

68-HSOA-1408

68-HSOA-1458

Remote start Button

2.

68-HSCA-1409

68-HSOC-1459

Remote stop Button

3.

68-UA-1402

68-UA-1452

Dryer common alarm

4.

68-UA-1403

68-UA-1453

Dryer changeover failure alarm

Instrument Air Dryer Start-up Checks 1.

Ensure the UCP for air dryers is powered up and ensure that all controls are in place.

2.

Close air supply towards the dew point analyzer AI-1401 & AI-1451 and by-pass its alarm on both units 6837-A-03 & 6837-A-04.

3.

Start the air compressor and wait for pressure to develop in the compressor discharge drum.

4.

Slowly open the pre-filters inlet manual isolation valve.

5.

Check the connections of the air dryer for air leaks and repair if necessary. Dryer Start

There are two Nos. Instrument Air Dryer Package (6837-A-03/04) consisting of heaterless desiccant dryers of 2 X 50% capacity. Each Dryer Package consists of two vessels (one drying, one regenerating), a set of duplex pre-filter and after-filter. Unit start/stop of the package can be done either from UCP or from DCS. No local mode of operation available for dryer package.

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TITLE: OPERATION AND MAINTENANCE MANUAL

At the initial start for the availability of the dryer, the position of valves is as follows: •

68-XV-1418/68-XV-1468-open (tower - A in drying)

•

68-XV-1419/68-XV-1469-closed

•

68-XV-1416/68-XV-1466-Closed

•

68-XV-1417/68-XV-1467-open (tower - B in regeneration mode)

Also after opening the manual valves following are required to be checked to start the dryer •

Tower pressures 68-PT-1408/68-PT-1409

•

Tower pressures 68-PT-1458/68-PT-1459

•

Dryer available status has to be selected by the operator from HMI

•

All the alarm conditions for healthy status to be checked before start-up

Start the dryer by activating the following commands: •

68-HSOA-1408 for Dryer-6837-A-03

•

68-HSOA-1458 for Dryer-6837-A-04

When drying is started, as a first step (step-0), ensure Adsorber-A (6837-V-14A) is initialised into drying and Adsorber-B (6837-V-14B) is initialised into depressurizing for 5 seconds. Ensure the following valves’ condition: •

68-XV-1418 & 68-XV-1417 are in OPEN condition

•

68-XV-1419 & 68-XV-1416 are in CLOSE condition

In step-1, ensure that Adsorber-A (6837-V-14A) is in the drying mode and Adsorber-B (6837-V-14B) is being pressurised for 55 seconds. Ensure the following valves’ condition: •

68-XV-1418 & 68-XV-1419 are in OPEN Condition

•

68-XV-1417 & 68-XV-1416 are in CLOSE condition

Tower B will pressurize up to the running pressure (7.8 bar), after pressure is reached both the towers will be operational for a brief period (5 seconds) together. In step-2, ensure that Adsorber-A (6837-V-14A) is in the drying mode and Adsorber-B (6837-V-14B) is in purge saving mode (this mode manually selected, when dew point is more than -30°C) until the dryer outlet dew point value is greater than the set point for the dew point or for a maximum duration of 24 hours. Ensure the following valves condition: •

68-XV-1418 & 68-XV-1419 are in OPEN Condition

•

68-XV-1417 & 68-XV-1416 are in CLOSE condition

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In step-3, ensure that Adsorber-A (6837-V-14A) is in the regenerating mode and Adsorber-B (6837-V-14B) is in drying mode for 195 seconds. Ensure the following valves’ condition: •

68-XV-1419 & 68-XV-1416 are in OPEN condition

•

68-XV-1418 & 68-XV-1417 are in CLOSE Condition

In step-4, ensure that Adsorber-A (6837-V-14A) is in the pressurizing mode and Adsorber-B (6837-V-14B) is in drying mode for 55 seconds. Ensure the following Valves’ condition: •

68-XV-1419 & 68-XV-1418 are in OPEN condition

•

68-XV-1417 & 68-XV-1416 are in CLOSE Condition

In step-5, ensure that Adsorber-A (6837-V-14A) is in the purge saving mode (this mode Manually Selected, when dew point is more than -30°C) and Adsorber-B (6837-V-14B) is in drying mode until the dryer outlet dew point value is greater than the set point for the dew point or for a maximum duration of 24 hours. Ensure the following Valves’ condition: •

68-XV-1419 is in OPEN condition

•

68-XV-1418,68-XV-1417 & 68-XV-1416 are in CLOSE Condition

In step-6, ensure that Adsorber-A (6837-V-14A) is in the drying mode and Adsorber-B (6837-V-14B) is in regenerating mode for 195 seconds. Ensure the following valves’ condition: •

68-XV-1418 & 68-XV-1417 are in OPEN condition

•

68-XV-1419 & 68-XV-1416 are in CLOSE condition

Repeat the above test for TRAIN B (6837-V-15A & 6837-V-15B) dryers. Steps 2 and 5 will be valid only when the purge saving is requested from UCP. Following table shows the valve positions of Tower A, B with respect to the above mentioned phase sequence. Valve Status

Sl. #

Operational Phase

Period

1.

A: Drying B:Depressurising

5 sec

XV-1418

XV-1417

XV-1416

XV-1419

2.

A: Drying B: pressurising

55 sec

XV-1418

XV-1419

XV-1416

XV-1417

3.

A: Drying B:Purge saving

DEW>set Max-24 hrs

XV-1418

XV-1419

XV-1416

XV-1417

Open

Close

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Sl. #

Operational Phase

Valve Status

Period

Open

Close

4.

A: Regenerating B: Drying

195 sec

XV-1419

XV-1416

XV-1417

XV-1418

5.

A: Pressurising B: Drying

55 sec

XV-1419

XV-1418

XV-1416

XV-1417

6.

A: Purge saving B: Drying

DEW>set Max-24 hrs

XV-1419

XV-1418

XV-1416

XV-1417

7.

A:Drying B:Regenerating

195 sec

XV-1418

XV-1417

XV-1416

XV-1419

Note: In the above table only train-A dryer is considered. 5.5

NITROGEN SYSTEM

5.5.1

Lining up of Nitrogen from existing system to the New Distribution Header Ensure that the following end user isolation valves are closed: •

Nitrogen line to the Reaction Furnace 9101-F-01

•

Nitrogen line to the Antifoam Storage Tank 9103-T-12

•

Nitrogen line to the Reducing Gas Generator 9102-F-11

•

Nitrogen line to the Incinerator Package 9101-F-14

•

Utility stations in AGEU area

•

Nitrogen line to the Amine Sump 9103-V-10

•

Nitrogen line to the Amine Regenerator 9103-C-12

•

Nitrogen line to the Waste Water Degasser 6922-V-07

•

Nitrogen line to the Amine Surge Tank 9103-T-11

•

Nitrogen line to the Utility Station in Effluent & Waste Water Treatment area

•

Nitrogen line to Utility Station in TGTU area

•

Nitrogen line to the Steam Generation Package 6848-A-02A/B/C

•

Nitrogen line to the Utility station in Heating Medium system area

•

Nitrogen line to the Utility station in Fuel Gas area

Lining up of Nitrogen •

Ensure that the vent and drain valves are closed in the header.

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5.6 5.6.1

•

Open the 3” isolation valve 68-GV-1953 from the existing 6”-GI-88-0357-C01A Nitrogen header to the new distribution header slowly and pressurise the header with Nitrogen.

•

Verify from the pressure gauge 68-PT-1309 that the pressure in the Nitrogen header is increasing slowly.

•

After pressurising the main header, slowly open the isolation valves for the sub headers 3”-9138-IG-312-C12M, 3”-6838-IG-126-C12M & 3”-6838-IG-123-C12M to process/utility area at battery limit and pressurise the lines.

•

Check that the headers are pressurised by checking the pressure gauges 68-PG1329/1331/1351.

•

Open the 2” isolation valves from the header for the utility stations of heating medium system and the fuel gas system.

•

Open the end user isolation valves and purge the lines to remove oxygen content.

•

Check for any leak in the system.

DRINKING WATER SYSTEM Lining up of Drinking Water to existing network 1. Ensure that the Drinking Water Storage Tank 6834-T-01A/B level is more than 50%. 3. Ensure that the isolation valve at the tie-in point (T-002) of the new and old drinking water network is closed. 4. Ensure that the vent and drain valves near the tie-in point is closed. 5. Ensure that the new drinking water line to existing network is cleaned by flushing and the leak test has been completed. 6. Open the Drinking Water isolation valves from the Tanks 6834-T-01A/B and slowly fill up the new drinking water lines. 7. Prime the Drinking Water Pumps 6834-P-23A/B. 8. Start the Drinking Water Pump 6834-P-23A on minimum circulation. 9. Ensure that the line connecting the existing network is filled by opening the vent and bleeding air near the tie-in point. 10. Check for any leaks in the line.

5.6.2

Lining up of Drinking Water to DMW Package 1. Ensure that the isolation valve at the inlet of the DMW Unit is closed. 2. Ensure that the drain valve upstream of the DMW Unit is closed. 3. Ensure that the new drinking water line to DMW Unit is cleaned by flushing and the leak test has been completed.

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4. Start the Drinking water pump 6834-P-23A and slowly open the discharge isolation valve and fill the line connecting the DMW Unit by opening the drain line upstream of the isolation valve. 5. Check for any leaks in the line. 6. After filling the line up to DMW Unit with Drinking water, it can be lined up to DMW Unit whenever required. 5.7

EFFLUENT & WASTE WATER TREATMENT SYSTEM

5.7.1

Lining up of Waste Water Degasser 6922-V-07 1.

Ensure that the Degasser and pipelines are flushed and cleaned and ready for lining up.

2.

Confirm that the drain and vent valves are closed.

3.

Ensure that waste water from Tail Gas Treatment Unit is available and Cooling Water Circulation Pumps 9102-P-12A/B are running.

4.

Ensure that high high level alarm 69-LAHH-1311 and high high pressure 69-PAHH1311 of the Degasser is not active in the ICSS.

5.

Reset ESD. Ensure that the waste water from Cooling Water Circulation Pumps 9102-P-12A/B inlet ON-OFF valve 69-XV-1312 is opened.

6.

Ensure water level starts rising in the Degasser by monitoring 69-LT-1311 & 1301 and cross checked through 69-LG-1302.

7.

Ensure that the low low level trip 69-LALL-1311 is cancelled after the level reaches 300 mm and also ensure that the Waste Water Degasser Pumps 6922-P08A/B suction ON-OFF valve 69-XV-1316 is open.

8.

Ensure that low level alarm 69-LAL-1301 is cancelled after the level reaches 450 mm.

9.

Open the suction isolation valves of the Waste Water Degasser Pumps 6922-P08A/B.

10. Prime the Waste Water Degasser Pumps 6922-P-08A/B by opening the casing vents. 11. Energize Waste Water Degasser Pumps 6922-P-08A/B from MCC. 12. Put Waste Water Degasser Pumps 6922-P-08A/B LOR switch to ‘Remote’ at Local Control Station. 13. Select Waste Water Degasser Pump 6922-P-08A as “DUTY” and 6922-P-08B as “STANDBY” from the ICSS. 14. Ensure the minimum flow recycle line 2″ isolation valve is opened for the pump 6922-P-08A. 15. Start the “DUTY” pump 6922-P-08A from the ICSS. 16. Ensure that the pump is running without any abnormal noise and vibration.

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5.7.2

Lining up of Sour Water Stripper 6922-C-01 1.

Slowly open the 2″ discharge valve of the pump 6922-P-08A and line up sour water to the Sour Water Filter 6922-S-06.

2.

Ensure that the sour water from 6922-P-08A discharge to the observation sump 2″ isolation valve is closed.

3.

Slowly open the sour water filter 2″ inlet isolation valve and fill the filter with the sour water.

4.

Open the 2″ vent valve of the sour water filter and release air. Close the vent isolation valve after filling the filter.

5.

Slowly open the filter outlet 2″ isolation valve and the Sour/Stripped Water Exchanger 6922-E-01 tube side inlet 2″ isolation valve.

6.

Open the Sour/Stripped Water Exchanger 6922-E-01 tube side outlet 2″ isolation valve and the 69-FV-1314 upstream and downstream isolation valves.

7.

Put 69-FV-1314 in manual and open the control valve slowly and allow the waste water to flow through to the Sour Water Stripper.

8.

Now put 69-LIC-1301 in auto mode with a set point of 50% and 69-FV-1314 in remote mode.

9.

Ensure that the level starts to build at the bottom of the Sour Water Stripper by checking the level gauge 69-LG-1306.

10. Ensure low low level 69-LALL-1316 is cancelled in the Sour Water Stripper when the level rises. 11. Ensure that the low level alarm 69-LAL-1306 is also cancelled as the level goes up. 12. Now open the 3″ suction isolation valve of the Stripped Water Pumps 6922-P-10A/B and prime the pumps. 13. Energize Stripped Water Pumps 6922-P-10A/B from MCC. 14. Put Stripped Water Pumps 6922-P-10A/B LOR switch to ‘Remote’ at field control panel. 15. Select Stripped Water Pumps 6922-P-10A as “DUTY” and 6922-P-10B as “STANDBY” from the ICSS. 16. Ensure the minimum flow recycle line 2″ isolation valve is opened for the pump 6922-P-10A. 17. Start the “DUTY” pump 6922-P-10A from the ICSS. 18. Ensure that the pump rated discharge pressure 8.6 bara is reached by checking the discharge pressure gauge 69-PG-1322. 19. Open the Sour/Stripped Water Exchanger 6922-E-01 shell inlet and outlet 2″ isolation valves.

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20. Open the Stripped Water Cooler 6922-E-02 inlet and outlet 2″ isolation valves. 21. Start the Stripped Water Cooler fan motors 6922-EM-02 AA/6922-EM-02 AB. 22. Line up 69-FV-1317 upstream and downstream isolation valves. 23. Slowly open 69-FV-1317 manually and line up the stripped water to the Observation & Buffer Sump 6922-X-04. 24. Line up the analyser 69-AT-1302 in the stripped water line. 5.7.3

Lining up of Stripper Overhead Circulation Pump 6922-P-11A/B 1.

Line up start-up water through 69-LV-1325.

2.

Prime the Stripper Overhead Circulation Pump 6922-P-11A/B.

3.

Select the Pump 6922-P-11A as ‘DUTY’ and 6922-P-11B as ‘STANDBY’ from ICSS.

4.

Start the Stripper Overhead Circulation Pump 6922-P-11A.

5.

Take level controller 69-LIC-1325 in ‘AUTO’ with a set point of 50% and ensure the control valve 69-LV-1325 is controlling the level at 50%.

6.

Take flow control valve 69-FV-1316 in ‘AUTO’ with a set point 13.2 m3/hr.

7.

Open the inlet and outlet isolation valves of the Stripper Overheads Cooler 6922-E-03.

8.

Start Stripper Overheads Cooler 6922-E-03AA/6922-E-03AB fans.

9.

Take 69-TIC-1315 in AUTO with a set point of 55°C.

5.7.4

Lining up of Sour Water Stripper overhead Sour Gas 1.

Ensure that 69-PV-1315A upstream and downstream isolation valves are closed.

2.

Reset ESD and ensure that the ON-OFF valve 69-XV-1313 is open.

3.

Ensure that the upstream and downstream isolation valves of 69-PSV-1303A are lock open and the bypass valve is closed.

4.

Ensure that the upstream isolation valves of 69-PSV-1303B are lock closed and the downstream isolation valves are open.

5.

Take 69-PIC-1315 in manual and close 69-PV-1315A fully.

6.

Ensure that 69-PV-1315B upstream and downstream isolation valves are open and close 69-PV-1615 fully.

7.

Now put 69-PIC-1315 in Auto with a set point of 1.0 barg and take 69-PV-1315A/B in Remote.

5.7.5

Pressurising Waste Water Degasser 6922-V-07 with Nitrogen 1.

Ensure that the Nitrogen inlet shut down valve 69-XV-1315 is opened after resetting the ESD.

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2.

Close 69-PV-1307 fully on manual. Open the 69-PV-1307 upstream and downstream isolation valves.

3.

Slowly open 69-PV-1307 in manual till the pressure in the Degasser and Stripper reaches 1.0 barg and indicated by 69-PT-1307/1311/1315. Now put the controller 69-PIC-1307 in auto with a set point of 1.0 barg.

4.

Take 69-PIC-1315 in AUTO. Since the isolation valves of 69-PV-1315A are closed, ensure that 69-PV-1315B opens when the pressure goes above 1.0 barg. Line up 69-PV-1315A upstream and downstream isolation valves and line up sour gas to TGTU.

5.7.6

Lining up of Sour Water Stripper Reboiler 1. Ensure that Sour Water Stripper Reboiler 6922-E-04 shell side is filled with sour water by checking 69-LT-1317/69-LG-1307. 2. Ensure that the 2” isolation valves of the Steam line from the Reboiler Steam inlet to the Reboiler vapour outlet line 2”-6848-LS-138-C12W-HC are closed. 3. Put steam inlet control valve 69-FV-1315 in manual and close it fully. 4. Ensure that after resetting ESD, steam inlet line ON/OFF valve 69-XV-1314 is open. 5. Open the 2″ vent valve in the steam inlet line to the reboiler and the condensate outlet line from the reboiler. 6. Open the vents and drains in the Reboiler Condensate Drum 6922-V-09. 7. Open the 69-LV-1327 upstream drain and close the bypass valve. 8. Ensure that the steam inlet line is warmed up upstream of the 8” isolation valve 68-GV-1928 and steam is charged. 9. Open the 2” bypass valves of the flow control valve 69-FV-1315. 10. Open the steam inlet 2″ warm up valve upstream of 68-XV-1314 slowly and admit steam into the Reboiler. 11. The Reboiler and the Reboiler Condensate Drum are warmed up by the steam and the condensed steam starts to come out of the drains and vents. 12. When full flow of steam comes out of the drains and vents, close all the vents and drains. 13. Close the 2″ steam inlet warm up bypass valve and open the steam inlet 8″ main isolation valve slowly. 14. Open 69-FV-1315 manually by 10%. 15. Close the bypass valves of the 69-FV-1315. 16. Ensure the temperature of the vapour line from the Reboiler increases as the steam flow is increased.

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17. When the temperature of the vapour line measured by 69-TT-1314 is increased to 120°C, put the steam flow controller 69-FIC-1315 in ratio control with the sour water flow 69-FIC-1314. 18. Line up Boiler Feed Water to the Desuperheater 6922-X-01. Take the temperature controller 69-TIC-1327 in AUTO with a set point of 148°C. 19. Ensure that the condensate level starts to increase in the Reboiler Condensate Drum 6922-V-09 through 69-LG-1308/69-LT-1327. 20. Ensure that the low level alarm 69-LAL-1327 (set at 400 mm) is cancelled when the level is rising in the Reboiler Condensate Drum 6922-V-09. 21. When the level in the drum reaches 50%, line up the level control valve 69-LV1327, put it on AUTO with a set point of 50%. 5.8

FLARE SYSTEM Reference: P&ID No. 2970-6-51-0033

5.8.1

Start-up of LP Flare System 1.

Ensure that the isolation valve 62-BV-2211 is closed near the tie-in point T-18.

2.

Ensure that the following new LP Flare lines are purged with Nitrogen and are under Nitrogen pressure: •

10”-6236-FL-033-D14M from 62-PSV-176/176S

•

8”-6848-FL-036-C12P from Steam Generation Package 6848-A-02A/B/C

•

2”-6236-FL-053-D14M from 62-PV-1301A/B vents

•

6”-6236-FL-052-D14M from 62-PV-1303

•

2”-6236-BD-005-C14P-HI from LP Fuel Gas KO Drum 6236-V-05

3.

Ensure that the vent and drain valves in the new flare header is closed.

4.

Ensure that the spectacle blind in the new LP Flare header 10”-6236-FL-033-D14M connecting with the existing header at tie-in point T-18 is in open position.

5.

Slowly open the 10” isolation valve in the new LP Flare header 10”-6236-FL-033D14M connecting with the existing header at tie-in point T-18.

6.

Line up 62-PV-1303 upstream and downstream isolation valves to LP Flare as shown in P&ID.

7.

Line up 62-PSV-176/176S upstream and downstream isolation valves from LP Fuel Gas KO Drum 6236-V-05 to LP Flare header as per requirement.

8.

Line up Steam Generation Package 6848-A-02A/B/C relief header 8”-6848-FL-036C12P to LP Flare header as per requirement.

9.

Line up the vent lines 2”-6236-FL-053-D14M from 62-PV-1301A/B to the new LP flare header as per requirement.

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10. Line up the drain line 2”-6236-BD-005-C14P from new LP Fuel Gas KOD 6236-V-05 to the new LP flare header as per requirement. 11. Line up the drains and vents from the fuel gas system to LP Flare whenever required by reversing the spectacle blind to open position and opening the drain/ vent valve as per requirement. 5.8.2

LP ACID GAS FLARE SYSTEM Reference: P&ID No. 2970-6-50-0039 Start-up of LP Acid Gas Flare System 1.

Ensure that the LP Flare header isolation valve is closed near the tie-in point T-69.

2.

Ensure that the following new LP Acid Gas Flare lines are purged with Nitrogen and are under Nitrogen pressure: a. 2”-6236-FG-131-C12P purge fuel gas line to the Acid Gas Flare header b. 20”-9103-AG-104-C14P from AGRU 1 & 2 c. 6”-6922-AL-064-C14P from 69-PSV-1303A/1303B d. 2”-6922-AL-065-C14P from Sour Water Stripper 6922-C-01 e. 16”-9103-AL-117-C14P from Regenerator Reflux Drum 9103-V-12 f. 2”-9102-AG-116-A1C1 from sulphiding line of Hydrogenation Reactor 9102-V-11 g. 6”-9103-AL-110-C14P from Regenerator Reflux Drum 9103-V-12 PSV-1505/1506 h. 6”-9103-AL-101-C14P from Lean Acid Gas KO Drum 9103-V-14 i. 6”-9103-AL-104-C14P from Acid Gas Amine Absorber 9103-C-11 PSV-1503/1504 j. 14”-9101-AL-565-C14P from Acid Gas Pre-heater 9101-E-06 PSV-1071A/B k. 2”-9136-FG-056-C12P from Incinerator Fuel Gas Skid 9101-E-06 l. 12”-9103-AL-107-C14P from Regenerator 9103-C-12 PSV-1508/1509 m. 6”-9102-AL-102-C14P PSV-1303/1304.

from

Desuperheater/Contact

Condenser

9102-C-11

n. 8”-9102-AL-110-C14P from Tail Gas Amine Absorber 9102-C-12 PSV-1334/1346 o. 2”-9136-FG-202-C12P from Fuel Gas distribution p. 20”-9103-AL-113-C14P Acid Gas flare header 3.

Slowly open the 20” isolation valve in the new LP Flare header 20”-9103-AL-113C14P connecting with the existing header at tie-in point T-069.

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4.

Reverse the 2”-6236-FG-131-C12P purge fuel gas line spectacle blind to open position. Line up purge fuel gas to the Acid Gas Flare header as per requirement.

5.

Line up AGRU 1 & 2, 20”-9103-AG-104-C14P to Acid Gas flare as per requirement.

6.

Line up 69-PSV-1303A/1303B from the Sour Water Stripper 6922-C-01 to the new LP Acid Gas flare header as per requirement.

7.

Line up 2”-6922-AL-065-C14P from Sour Water Stripper 6922-C-01 69-PV-1315B to the new LP Acid Gas flare header as per requirement.

8.

Line up 16”-9103-AL-117-C14P from Regenerator Reflux Drum 9103-V-12 to the new LP Acid Gas flare header as per requirement.

9.

Line up PSV-1505/1506 from Regenerator Reflux Drum 9103-V-12 to the new LP Acid Gas flare header as per requirement.

10. Line up 6”-9103-AL-101-C14P from Lean Acid Gas KO Drum 9103-V-14 to the new LP Acid Gas flare header as per requirement. 11. Line up 91-PSV-1503/1504 from Acid Gas Amine Absorber 9103-C-11 to the new LP Acid Gas flare header as per requirement. 12. Line up 91-PSV-1071A/B from Acid Gas Pre-heater 9101-E-06 to the new LP Acid Gas flare header as per requirement. 13. Line up 2”-9136-FG-056-C12P from Incinerator Fuel Gas skid 9101-E-06 to the new LP Acid Gas flare header as per requirement. 14. Line up 91-PSV-1508/1509 from Regenerator 9103-C-12 to the new LP Acid Gas flare header as per requirement. 15. Line up 91-PSV-1303/1304 from Desuperheater/Contact Condenser 9102-C-11 to the new LP Acid Gas flare header as per requirement. 16. Line up 91-PSV-1334/1346 from Tail Gas Amine Absorber 9102-C-12 to the new LP Acid Gas flare header as per requirement. 17. Line up 2”-9136-FG-202-C12P from fuel gas distribution to the new LP Acid Gas flare header as per requirement. 18. Line up 20”-9103-AL-113-C14P Acid Gas flare header to the new LP Acid Gas flare header as per requirement. 5.9

FUEL GAS SYSTEM Line-up Fuel Gas from the Existing 1st Stage Booster Compressor 6701-K-10/ 20/30 in NGL-3

5.9.1 1.

Ensure that the fuel gas inlet isolation valves to the new Steam Boiler Package 6848-A-02A/B/C are in closed position and the lines are under Nitrogen pressure of 0.5 barg.

2.

Ensure LP Fuel Gas KO Drum 6236-V-05 drain line isolation valve is closed.

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3.

Ensure Booster Compressor 6701-K-10/20/30 in NGL-3 is running.

4.

Ensure 62-PV-1301A/B & 62-PV-1302 control valves are closed manually and the upstream and downstream isolation valves are closed.

5.

Ensure 62-XV-1301 in the fuel gas supply line from Booster Compressor 6701-K-10/ 20/30 is open and the upstream isolation valve is closed.

6.

Ensure 62-XV-1302 in the back-up supply fuel gas from 6103-K-01 A/B is open and the upstream isolation valve is closed.

7.

Ensure 62-XV-1303 in the back-up supply fuel gas from 30” existing line is open and the upstream isolation valve is closed.

8.

Ensure 62-PV-1303 is closed in auto with a set point of 7.8 barg and its upstream and downstream isolation valves are open.

9.

Ensure 62-PSV-176 inlet and outlet isolation valves are open and the bypass is closed.

10. Ensure 62-PSV-176S inlet isolation valve is closed and outlet isolation valve is open. 11. Ensure that the spectacle blind on fuel gas supply line from Booster Compressor 6701-K-10/20/30 is in open position. 12. Open the 6” isolation valve slowly from the Booster Compressor 6701-K-10/20/30 and pressurise the line up to 62-XV-1301 upstream isolation valve. 13. Open 62-XV-1301 upstream isolation valve slowly and gradually pressurise the line up to 62-PV-1301A upstream isolation valve. 14. Open 62-PV-1301A bypass 3” isolation valves slowly and pressurise the fuel gas KO Drum 6236-V-05 gradually up to 7.0 barg. 15. Close the 62-PV-1301A bypass 3” isolation valves. 16. Open the 62-PV-1301A downstream isolation valve. 17. Put 62-PIC-1301 in auto with a set point of 7.0 barg. 18. Open 62-PV-1303 upstream and downstream isolation valves. 19. Open the upstream and downstream isolation valves of 62-PV-1301B/1302. 5.10

SEA COOLING WATER SYSTEM The start-up procedure for the Sea Cooling Water Pumps 6932-P-04A/B is given below:

5.10.1

Pre-start up checks Before starting the pump the following checks should be made 1. Rotate the pump shaft by hand to make sure that the pump rotates freely and the impellers are correctly positioned

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2.

The electric motor is properly lubricated

3.

Direction of Rotation of the motor is checked and marked

4.

Ensure all the piping connections are tight

5.

Check for foundation bolts tightness

6.

Check all bolting connections for tightness (coupling bolts, mechanical seal gland bolts, driver bolts)

7.

Ensure the coupling guard is in place

5.10.2

5.11

Initial Starting and Lining Up of Sea Cooling Water 1.

Open the Sea Cooling Water Pump 6932-P-04A discharge MOV 69-MOV-1301 by 10%

2.

Start pre-lubrication liquid flow for the pump

3.

Start the pump and open the discharge MOV 69-MOV-1301 immediately within 30 seconds

4.

Observe the operation of the pump for any abnormal noise and vibration.

5.

Measure the pump shaft vibration and lube oil temperature at regular intervals.

6.

Line up sea cooling water to the header.

7.

Start Biocide Injection and Scale Inhibitor Injection as per section 5.12.3 and 5.12.4 and start injection of the chemicals.

8.

Line up sea cooling water to the following heat exchangers one by one by opening the high point vents and releasing air. •

Lean Amine Trim Cooler 9103-E-15

•

Regenerator Condenser Trim Cooler 9103-E-16

•

Contact Condenser Trim Cooler 9102-E-13A/B

•

Acid Gas Cooler 9103-E-101A/B

ELECTRO CHLORINATION PACKAGE START-UP Control of the package is via Allen Bradley compact logix PLC located in the control panel which also contains an HMI which provides facility for the operator to input selections of duty and stand-by equipments and adjustments of system parameters in addition to providing system of status, indications and alarms. Both automatic and manual operation of the package is possible, but manual operation is recommended only for maintenance purpose.

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Electro chlorination package switch details are listed below: Sl. #

Tag No.

Service

1.

69-HSR-1480L

Local selector switch

2.

69-HSR-1480R

Remote selector switch

3.

69-HSOA-1451

Package start command from DCS

4.

69-HSCA-1451

Package stop command from DCS

5.

69-HS-1451

Package trip from UCP

6.

69-HS-1452

Package trip from field

7.

69-HS-1453

Package trip from field

8.

69-HSR-1470

Manual selected at transformer rectifier

9.

69-HSOA-1470

Transformer unit start

10.

69-HSCA-1470

Transformer unit stop

Control valve and ON-OFF valve details are tabulated below: Sl. #

5.11.1

Tag No.

Description

1.

69-XV-1451

Auto back wash filter 69-S-03A valve

2.

69-XV-1454

Auto back wash filter 69-S-03B valve

3.

69-XV-1452

Auto back wash filter drain valve

4.

69-XV-1455

Auto back wash filter drain valve

5.

69-XV-1456

Auto back wash filter 69-S-03A discharge valve

6.

69-XV-1456

Auto back wash filter 69-S-03B discharge valve

7.

69-XV-1457

Electrolyser – A inlet valve

8.

69-XV-1458

Electrolyser – B inlet valve

Normal start-up of Electro Chlorination Plant: Before starting the package, ensure the following emergency shutdown causes are normal/healthy: Sl. #

Tag No.

Description

1

69-HS-1451

Emergency stop in UCP

2

69-HS-1452

Emergency stop in ECP skid

3

69-HS-1453

Emergency stop in ECP skid

4

69-XS-1336

Sea cooling water pump (6932-P-04A/B) trip

5

66-GF-02-1801

Hydrogen gas high-high alarm

6

66-GF-02-1801

Hydrogen gas high-high alarm

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1.

Open the Electro chlorination I/L PCV 69-PCV-1463 upstream and downstream isolation valves.

2.

Open Auto Backwash Filters 6932-S-03A/B inlet and outlet isolation valves.

3.

Open Electrolyser 6932-G-01A/B inlet and outlet isolation valves.

4.

Open Hydrogen Dilution Blowers 6932-K-01A/B discharge isolation valves.

5.

Ensure that Sea Cooling Water Pumps 6932-P-04A/B is started and running.

6.

Open Auto Backwash Filter inlet PCV 69-PCV-1463, manually and slowly fill up the Sea Water Filter 6932-S-03A. Put 69-PCV-1463 in auto with a set point of 3.5 barg.

7.

Select ‘LOCAL’ for the unit start-up from UCP.

8.

Select Auto Backwash Filter 6932-S-03A as duty Filter from UCP.

9.

Select Electrolyser Stream 6932-G-01A as duty form UCP.

10. Select Dilution Blower 6932-K-01A as duty blower from UCP. 11. Select Dosing Pump 6932-P-05A as duty pump from UCP. 12. Press ‘start’ from UCP. 13. Ensure that system status indication changes to ‘starting’. Ensure that Start lamp is flashing. 14. Ensure Auto Backwash Filter outlet XV, XV-1453 opens and sea water flow is established through the filters. 15. Ensure that the duty dilution blower 6932-K-01A is started. 16. After a 30 second delay, Ensure that the Electrolyser inlet XV, XV-1457 is opened and sea water flows through the Electrolyser. 17. Ensure that the Transformer/Rectifier 6932-TA-08A is energised after confirming the flow through the Electrolyser with the help of Magnetic flow meter 69-FT-1451. 18. Ensure that the ‘system running’ indication is illuminated. 19. Ensure that the Sodium Hypochlorite generated is sent to the Degassing Tank 6932-T-02. 20. Ensure that the level in Degassing Tank 6932-T-02 starts rising. 21. Fill the Dosing Pump 6932-P-05A by opening the suction isolation valve and releasing air through the casing vent valve. 22. Ensure that the Dosing Pump 6932-P-05A starts after the level reaches the low alarm level of 924 mm measured by 69-LT-1452. 23. Ensure that Sodium Hypochlorite is continuously dosed at a rate of 7 m3/hr and 1.25 ppm concentration to the Sea Cooling Water by dosing pumps (6932-P05A/05B).

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24. Ensure that Sodium Hypochlorite is shock dosed at a rate of 11 m3/hr and 6 ppm concentration for 15 minutes in every 6 hours by dosing pumps (6932-P-05A/05B). 25. Ensure that the following indications are healthy a. Autoback wash Filter Outlet Pressure Status Healthy b. Autoback wash Filter 6932-S-03A/B Status Healthy c. Electrolyser 6932-G-01A/B inlet flow healthy d. Electrolyser Inlet Temperature Healthy e. Hydrogen Blower Outlet Pressure Status Healthy f. Transformer/Rectifier 6932-RC-101A/B Healthy. 26. Ensure that the time for START-UP is 5 minutes. Manual start-up of electro chlorination package: 1. Manual operation is provided for maintenance and commissioning purposes only. 2. Select the Auto/Manual switch to manual mode in UCP HMI for manual start of ECP. 3. Following manual controls are available:

5.12 5.12.1

•

Manual operation of each actuated on/off valve (69-XV-1457/69-XV-1458), (69XV-1453/69-XV-1456), (69-XV-1452/69-XV-1455) via a manual override facility, mounted on the valve

•

Flow control valve (69-FV-1453) which regulates the flow of sodium hypochlorite dosing to sea water can be operated by flow controller in UCP manually

•

Dilution blowers, dosing pumps and transformer rectifiers can be operated manually by selecting local mode at RCU in the field

•

Manual operation of each Transformer/Rectifier (6932-RC-101A/6932-RC-101B) can be done via local start/stop push buttons (69-HSOA-1470/69-HSCA-1470), by selecting manual button (69-HSR-1470) mounted on the front panel of each T/R.

CHEMICAL INJECTION SYSTEM Complex Product Injection Package (6834-A-09) Fill the Complex Product Tank, 68-T-18 with Complex Product Chemical. WARNING: REVIEW THE COMPLEX PRODUCT MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING THE CHEMICAL.

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1. Ensure that the Complex Product Inhibitor Tank, 68-T-18 is clean and dry for charging chemicals. 2. Line up the Complex Product Unloading Pump (6834-P-42) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Complex Product Unloading Pump (6834-P-42) and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level, 68-LALL-1316 and the low-level alarm, 68-LAL-1317 are reset at their respective set point. 7. Fill the tank up to its maximum operating level, stop the chemical unloading pump (6834-P-42) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Complex Product Injection Pump, 68-P-41A/B manual suction valve and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Complex Product Injection Pump, 68-P-41A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points. 5.12.2

Oxygen Scavenger Injection Package (6834-A-09) Fill the Oxygen Scavenger Storage Tank, 6834-T-17 with Oxygen Scavenger Chemical. WARNING: REVIEW THE OXYGEN SCAVENGER MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING THE CHEMICAL. 1. Ensure that the Oxygen Scavenger Storage Tank, 6834-T-17 is clean and dry for charging chemicals. 2. Line up the Oxygen Scavenger Unloading Pump (6834-P-40) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line.

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3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Oxygen Scavenger Transfer Pump (6834-P-40) and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 68-LALL-1314 and the low-level alarm, 68-LAL-1315 are reset at their respective set point. 7. Fill the tank up to its maximum operating level, stop the chemical unloading pump (6834-P-42) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Oxygen Scavenger Injection Pump, 68-P-39A/B manual suction valve and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Oxygen Scavenger Injection Pump, 68-P-39A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points. 5.12.3

Biocide Injection Package (6932-A-06) Filling the Biocide Tank, 6932-T-04 with Biocide Chemical WARNING: REVIEW THE BIOCIDE MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY CHEMICAL. 1. Ensure that the Biocide Tank, 6932-T-04 is clean and dry for charging chemicals. 2. Line up the Biocide Unloading Pump (6932-P-08) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Biocide Unloading Pump (6932-P-08) by opening the plant air isolation valve to the pump and start filling the tank. Check all connections and confirm that there is no leakage. 5. Line up instruments for operation.

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6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 69-LALL-1329 and the low-level alarm, 69-LAL-1328 are reset at their respective set point. 7. Fill the tank up to its maximum operating level, stop the Biocide Unloading Pump (6932-P-08) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Biocide Injection Pump, 6932-P-07A/B manual suction valves and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Biocide Injection Pump, 6932-P-07A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points. 5.12.4

Scale Inhibitor Injection Package (6932-A-07) Filling the Scale Inhibitor Tank 6932-T-05 with Scale Inhibitor Chemical WARNING: REVIEW THE SCALE INHIBITOR MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY CHEMICAL. 1. Ensure that the Scale Inhibitor Tank, 6932-T-05 is clean and dry for charging chemicals. 2. Line up the Scale Inhibitor Unloading Pump (6932-P-10) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Scale Inhibitor Transfer Pump (6932-P-10) by opening the plant air isolation valve to the pump and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 69-LALL-1331 and the low-level alarm, 69-LAL-1330 are reset at their respective set points.

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7. Fill the tank up to its maximum operating level, stop the Scale Inhibitor Unloading Pump (6932-P-10) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Scale Inhibitor Injection Pump, 6932-P-09A/B manual suction valves and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Scale Inhibitor Injection Pump, 6932-P-09A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points. 5.12.5

Catalyst Injection Package (9101-A-01) Filling the Catalyst Tank 9101-T-09 with Aquisulf Catalyst Chemical WARNING: REVIEW THE CATALYST MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY CHEMICAL. 1. Ensure that the Catalyst Tank, 9101-T-01 is clean and dry for charging chemicals. 2. Line up the Catalyst Unloading Pump (9101-P-12) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Catalyst Unloading Pump (9101-P-12) by opening the plant air isolation valve to the pump and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 91-LALL-1128 and the low-level alarm, 91-LAL-1127 are reset at their respective set points. 7. Fill the tank up to its maximum operating level, stop the chemical transfer pump (9101-P-12) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Catalyst Injection Pump, 9101-P-11A/B suction isolation valves and fill the pumps.

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9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Catalyst Injection Pump, 9101-P-11A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points. 5.12.6

Antifoam Injection Package (9103-A-11) Fill the Antifoam Tank, 9103-T-12 with Antifoam Chemical WARNING: REVIEW THE ANTIFOAM MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY CHEMICAL. 1. Ensure that the Antifoam Tank, 9103-T-12 is clean and dry for charging chemicals. 2. Line up the Antifoam Unloading Pump (9103-P-19) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Antifoam Unloading Pump (9103-P-19) by opening the plant air isolation valve to the pump and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 91-LALL-1520 and the low-level alarm, 91-LAL-1521 are reset at their respective set points. 7. Fill the tank up to its maximum operating level, stop the Antifoam Unloading Pump (9103-P-19) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Antifoam Injection Pump, 9103-P-16A/B suction valves and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Antifoam Injection Pump, 9103-P-16A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump.

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12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points. 5.12.7

Corrosion Inhibitor Injection Package (9103-A-12) Filling the Corrosion Inhibitor Tank, 9103-T-13 with Corrosion Inhibitor Chemical. WARNING: REVIEW THE CORROSION INHIBITOR MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY CHEMICAL. 1. Ensure that the Corrosion Inhibitor Tank, 9103-T-13 is clean and dry for charging chemicals. 2. Line up the Corrosion Inhibitor Unloading Pump (9103-P-102) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Corrosion Inhibitor Unloading Pump (9103-P-102) by opening the plant air isolation valve to the pump and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 91-LALL-1522 and the low-level alarm, 91-LAL-1523 are reset at their respective set points. 7. Fill the tank up to its maximum operating level, stop the Corrosion Inhibitor Unloading Pump (9103-P-102) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Corrosion Inhibitor Injection Pump, 9103-P-101A/B suction valves and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Corrosion Inhibitor Injection Pump, 9103-P-101A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points.

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5.12.8

Caustic Injection Package (9103-A-13) Filling the Caustic Storage Tank, 9103-T-14 with Caustic WARNING: REVIEW THE CAUSTIC MSDS AND ENSURE THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY CHEMICAL. 1. Ensure that the Caustic Storage Tank, 9103-T-14 is clean and dry for charging chemicals. 2. Line up the Caustic Unloading Pump (9103-P-104) (Pneumatic driven) with chemical Tote Tank through the pump suction line and open isolation valve on the suction line. 3. Check plant air pressure and line up air to the unloading pump. 4. Open the isolation valve on the tank fill line and start Caustic Unloading Pump (9103-P-104) by opening the plant air isolation valve to the pump and start filling the tank. Check all connections and confirm that there is no leakage. 5. Vent the instruments and line up for operation. 6. Monitor the level from the ICSS as the level increases. Ensure that the low low level trip, 91-LALL-1524 and the low-level alarm, 91-LAL-1525 are reset at their respective set points. 7. Fill the tank up to its maximum operating level, stop the Caustic Unloading Pump (9103-P-104) by closing the plant air isolation valve and close the isolation valve on the fill line. Close the isolation valve on the pump suction line. 8. Open the Caustic Injection Pump, 9103-P-103A/B manual suction valves and fill the pumps. 9. Open pump discharge valve and close valve at injection point and upstream drain valve. 10. Set the stroke adjuster of the Caustic Injection Pump, 9103-P-103A/B to 10%. 11. Start the pump and check for flow at the injection point drain valve. Then stop the pump. 12. The system is now ready for start-up. The manual stroke is later adjusted to the desired injection rate based on the actual chemical requirement at the injection points.

5.13 5.13.1

DEMINERALIZED WATER SYSTEM Demineralized Water Unit Start-up Demineralized Water Unit (2 trains) is designed for automatic operation via unit control panel which contains Siemens S7-400 PLC. All the alarms, indications and

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status signals generated within the package are transmitted from package UCP to DCS through serial link (modbus through TCP/IP). The list of switches used in the operation of DM water package is tabulated below: Sl. #

Tag No. Train-A

Train-B

Service

1.

68-HS-1840 A

68-HS-1840 B

Auto/Man/Off selector-Auto

2.

68-HS-1841 A

68-HS-1841 B

Auto/Man/Off selector-Manual

3.

68-HS-1843 A

68-HS-1843 B

Auto/Man/Off selector-off

4.

68-HS-1842 A

68-HS-1842 B

Step advance push button

5.

68-HSOA-1845 A

68-HSOA-1845B

Remote start from DCS

6.

68-HSCA-1845 A

68-HSCA-1845B

Remote stop from DCS

The list of ON/OFF valves is tabulated below: Sl. #

Tag No. Train-A

Train-B

Service

1.

68-XV-1825

68-XV-1840

Cation Exchanger Inlet

2.

68- XV-1831

68-XV-1846

Cation Exchanger outlet

3.

68-XV-1833

68-XV-1848

Anion Exchanger inlet

4.

68-XV-1838

68-XV-1852

Anion Exchanger outlet

5.

68- XV-1856

68-XV-1855

DM Water common header inlet

6.

68-XV-1832

68-XV-1847

AE-1825 pH Analyzer inlet

7.

68-XV-1839

68-XV-1853

AE-1826 Conductivity Analyzer inlet

8.

68-XV-1830

68-XV-1844

HCL drain to pit

9.

68-XV-1837

68-XV-1851

NaOH drain to pit

10.

68-XV-1828

68-XV-1843

DM+HCL inlet to cationic exchanger

11.

68-XV-1835

68-XV-1854

DM+ NaOH inlet to anionic exchanger

12.

68-XV-1829

68-XV-1845

Regeneration inlet to cationic exchanger

13.

68-XV-1836

68-XV-1850

Regeneration inlet to anionic exchanger

14.

68-XV-1826

68-XV-1841

Recycle water to cation exchanger

15.

68-XV-1827

68-XV-1842

Cation exchanger to neutralization pit

16.

68-XV-1834

68-XV-1849

Anion exchanger to neutralization pit

17.

68-XV-1857

Neutralization pump discharge

18.

68-XV-1858

Neutralization pump recycle

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The list of Pumps is tabulated below: Sl. # 1.

Tag No. Train-A 6834-P-37A

Service

Train-B 6834-P-37B

Recycling pump

2.

6834-P-34A/B/C

NaOH dosing pump

3.

6834-P-35A/B/C

HCL dosing pump

4.

6834-P-36A/B

Regeneration pump

5.

6834-P-38A/B

Neutralization pump

The operational status of the package is indicated by the following signals: Sl. #

Tag No. Train-A

Service

Train-B

1.

68-XL-1840A

68-XL-1840B

Package working in auto mode

2.

68-XL-1841A

68-XL-1841B

Package working in manual mode

3.

68-XL-1843A

68-XL-1843B

Package is in offline

4.

68-XL-1850A

68-XL-1850B

service phase

5.

68-XL-1851A

68-XL-1851B

waiting regeneration phase

6.

68-XL-1852A

68-XL-1852B

Acid regeneration/caustic regeneration

7.

68-XL-1853A

68-XL-1853B

Acid slow rinse/caustic slow rinse

8.

68-XL-1854A

68-XL-1854B

caustic slow rinse

9.

68-XL-1855A

68-XL-1855B

Final rinse with recirculation

10.

68-XL-1856A

68-XL-1856B

Waiting ready phase

11.

68-XL-1857A

68-XL-1857B

Pre-service phase

12.

68-UA-1844

Irregular valves/pumps position

13.

68-XL-1858

Neutralization

14.

68-XL-1859

Effluent discharge

15.

68-XL-1860

Neutralization recirculation

16.

68-XL-1861

Neutralization standby

Startup of the Demineralized Water System 1.

Put the AUTO/MANUAL/OFF selector in UCP in MANUAL position for Train-A (68-HS-1841A).

2.

Put the AUTO/MANUAL/OFF selector in UCP in MANUAL position for Train-B (68-HS-1841B).

3.

Put the LOR selector of all the pumps in ‘Remote’ and select the duty and standby pumps in UCP and put them in auto.

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4.

Put the Train-A in ‘SERVICE’ mode (Phase No. 1) by pressing the Step Advance push button 68-HS-1842A in the UCP once.

5.

Ensure that the following valves are open in Train–A: a.

68-XV-1825

b.

68-XV-1831

c.

68-XV-1833

d.

68-XV-1854

e.

68-XV-1830

f.

68-XV-1837

g.

68-XV-1832

6. Now Train A is on line. 7. Put Train B in ‘WAITING READY’ mode (Phase No. 7) by pressing the Step Advance push button 68-HS-1842B in the UCP. 8. Ensure that the following valves in Train-B are open: a.

68-XV-1844

b.

68-XV-1851

9. Ensure that drinking water is available in the existing Drinking Water Storage Tanks 6834-T-01A/B. 10. Open the isolation valve from the existing Drinking water storage tank 6834-T-01A to the new Drinking Water Pumps 6834-P-23A/B slowly and fill up the suction lines of the pumps. 11. Prime the Drinking Water Pumps 6834-P-23A/B by opening the casing vents and releasing air. 12. Put the LOR switch of the Drinking Water Pump 6834-P-23A in ‘LOCAL’ position. 13. Start the Drinking Water Pump 6834-P-23A on recirculation, gradually open the discharge valve and slowly pressurize the Demineralized Water Unit Train A. 14. Ensure 68-LCV-1827 is lined up and it is fully open on manual. 15. Ensure the Demineralized Water Storage Tank 6834-T-08 water level is raising. 16. When the level is 30% in the storage tank, take 68-LCV-1827 in auto with a set point of 70%. 17. After stabilising the unit, put the AUTO/MANUAL/OFF selector in UCP in AUTO for both A & B trains. 18. Prime the Recycling and Regeneration pumps. 19. Prepare HCl (33%) and Caustic solutions (50%).

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5.13.2

Demineralized Water Unit Sequence A. Phase No. 1: Service 1.

Ensure that when put in service the following XVs of Train-A are open: a.

68-XV-1825: Cation Exchanger I/L

b.

68-XV-1831: Cation Exchanger O/L

c.

68-XV-1833: Anion Exchanger I/L

d.

68-XV-1838: Anion Exchanger O/L

e.

68-XV-1856: Demin. Water common header I/L

f.

68-XV-1832: AE-1825 pH Analyzer I/L

g.

68-XV-1839: AE-1826 Conductivity Analyzer I/L

h.

68-XV-1830: HCl drain line

i.

68-XV-1837: NaOH drain line

2. Ensure that 68-FIC-1825 is on line and the flow rate through the train is 7 m3/hr. 3. Ensure that Train A is in line for a through put of 168 m3 (=24 hours @ 7 m3/hr) measured by the flow totaliser 68-FQI-1825 or until the high conductivity 68-AAH1829 measured by the Analyzer 68-AI-1829. 4. Ensure that Train A is transferred to Phase No. 2 ‘Waiting Regeneration’ mode after step 3. 5. Ensure that the high conductivity alarm is ON if 68-AAH-1829 is ON for 5 minutes. 6. Ensure that this service phase is terminated if 68-AAH-1829 is ON for additional 30 minutes. B. 1.

Phase No. 2: Waiting Regeneration Ensure that the following XVs are open in this phase: a.

68-XV-1830

b.

68-XV-1837

2. Ensure that the following conditions do not exist: a.

Acid Level Low (68-LAL-1825)

b.

Caustic Level Low (68-LAL-1827)

3. Ensure that the following alarms are not present: a.

Irregular valve position alarm 68-UA-1844

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b.

Both Regeneration Pumps unavailable

c.

Dosing Pumps unavailable

4. Ensure that this phase duration is 2 minutes. C. 1.

Phase No. 3: Acid Regeneration/Caustic Regeneration Ensure that the following XVs are open: a.

68-XV-1829

b.

68-XV-1828

c.

68-XV-1827

d.

68-XV-1836

e.

68-XV-1835

f.

68-XV-1834

2. Ensure that Acid Dosing Pump 6834-P-35A/B/C is started and dosing 174 litres/ hour of acid for regeneration. 3. Ensure that Caustic Dosing Pump 6834-P-34A/B/C is started and dosing 126 litres/ hour of caustic for regeneration. 4. Ensure that Regeneration Pump 6834-P-36 A/B is started and supplies 1173 litres/ hour of dilution water for acid regeneration and 2300 litres/hour of dilution water for caustic regeneration. 5. Ensure that the following control valves are in line to control the dilution water to the acid and caustic dosing systems: a.

68-FIC-1835 in auto with a set point of 2175 litres/hour

b.

68-FIC-1836 in auto with a set point of 1000 litres/hour

6. Ensure that the Neutralisation Pit Pump 6834-P-38 A/B starts when the level in the Neutralisation Pit rises to high level 68-LAH-1831. 7. Ensure that the duration of this regeneration phase is 25 minutes. D. 1.

Phase No. 4: Acid Slow Rinse/Caustic Slow Rinse Ensure that the following XVs are open: a.

68-XV-1830

b.

68-XV-1837

c.

68-XV-1827

d.

68-XV-1836

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e.

68-XV-1835

f.

68-XV-1834

g.

68-XV-1828

h.

68-XV-1829

2. Ensure that the Regeneration Pump 6834-P-36 A/B is started and supplies 1000 litres/hour to the Cationic Exchanger 6834-S-21A and 2175 litres/hour to the Anionic Exchanger 6834-S-22A for rinsing. 3. Ensure that the controllers 68-FIC-1835 and 68-FIC-1836 are inline. 4. Ensure that the rinsing duration is 54 minutes. E. 1.

Phase No. 5: Caustic Slow Rinse Ensure that the following XVs are open: a.

68-XV-1837

b.

68-XV-1836

c.

68-XV-1835

d.

68-XV-1834

2. Ensure that the Regeneration Pump 6834-P-36 A/B is started and supplies 2175 litres/hour to the Anionic Exchanger 6834-S-22A for rinsing. 3. Ensure that the controller 68-FIC-1835 is online. 4. Ensure that the rinsing duration is 29 minutes. F. 1.

Phase No. 6: Final Rinse with Recirculation Ensure that the following XVs are open: a.

68-XV-1831

b.

68-XV-1833

c.

68-XV-1826

d.

68-XV-1839

2. Ensure that the Recirculation Pump 6834-P-37 A is started and recirculates 10 m3/hour water through the cationic and anionic exchangers 3. Ensure that the rinsing duration is 30 minutes. 4. Ensure that after 30 minutes of rinsing, 68-AAH-826 alarm is OFF.

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5. Ensure that if the alarm 68-AAH-826 is ON after 30 minutes of recirculation, the Regeneration Failure alarm starts and the final rinse with recirculation phase continues until 68-AAH-826 is OFF. G.

Phase No. 7: Waiting Ready

Ensure that the following XVs are open: a.

68-XV-1830

b.

68-XV-1837

H. 1.

Phase No. 8: Pre-service Recirculation Ensure that the following XVs are open: a.

68-XV-1831

b.

68-XV-1833

c.

68-XV-1826

d.

68-XV-1839

e.

68-XV-1838

f.

68-XV-1830

g.

68-XV-1837

2. Ensure that the Recirculation Pump 6834-P-37 A is started and circulates 10 m3/hr water through the system. 3. Ensure that the duration of this phase is 10 minutes. 4. Ensure that the high conductivity 68-AAH-1826 alarm is not present at the end of the duration of this phase. 5. Ensure that if the alarm 68-AAH-1826 is present, then the Pre-service circulation continues till the alarm is cancelled. 5.13.3

Neutralization Pit The waste water generated during regeneration of the Demineralized Plant is collected in the Neutralization Pit (6834-T-014). Once the level reaches the required level, ensure the following 4 Phases to pump out the effluent. A. Phase No. P1: Waiting Ready 1.

Check of conditions for recirculation.

2.

Check the level 68-LT-1831/68-LT-1830 in Neutralization Pit 6834-A-01.

3.

Ensure duration of this phase is 1 minute.

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4.

Activation of level alarm 68-LAH-1831 in pit leads to phase No. P2. Recirculation

B. Phase No. P2: Recirculation 1.

Ensure that the Neutralization Pit Pump 6834-P-38 A/B starts at 68-LAH-1831.

2.

Ensure that 68-XV-1858 is open.

3.

Ensure that 68-XV-1857 is closed.

4.

Ensure the duration of this phase is 15 minutes.

5.

At the end of re-circulation time if pH is within range, then discharge phase 4 starts.

C. Phase No. P3: Neutralization 1.

Ensure that the Neutralization Pit Pump 6834-P-38 A/B starts at LAH-1831.

2.

Ensure that 68-XV-1858 is open.

3.

Ensure that 68-AAH-1831 (pH is more than 9) starts Acid Dosing Pumps 6834-P-35C.

4.

Ensure that 68-AAL-1831 (pH is less than 6) starts Caustic Dosing Pumps 6834-P34C.

5.

Activation of low low alarm 68-LALL-1830 in neutralization pit trips the neutralization, acid and caustic dosing pumps.

D. Phase No. P4: Effluents Discharge 1.

Ensure that the Neutralization Pit Pump 6834-P-38 A/B starts discharging effluents when pH analyzer 68-AI-1831 is in the range (pH: 6-9) for more than 5 minutes.

2.

Ensure that 68-XV-1857 is open.

3.

Ensure that the Neutralization Pit Pump 6834-P-38 A/B stops at low level alarm level of the pit 68-LAL-1831.

4.

By simulating 68-LALL-1830 check the trip signal of Neutralization Pit Pump 6834P-38 A/B in MCC.

Operator can abort Manual Step-by-Step mode and continue operating in Automatic Mode by simply putting the AUTO/MAN/OFF selectors in AUTO position. The sequence will continue operating from last selected phase during Step-by-Step mode. Details of ON/OFF valve positions against the respective phase are tabulated below: Tag No.

Demineralization - Phase Number

Neutralization Phase Number 1

Train “A”

Train “B”

1

2

3

4

5

6

7

8

68-XV-1825

68-XV-1840

O

C

C

C

C

C

C

C

68- XV-1831 68-XV-1846

O

C

C

C

C

O

C

O

68-XV-1833

O

C

C

C

C

O

C

O

68-XV-1848

2

3

4

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Tag No.

Demineralization - Phase Number

Neutralization Phase Number 1

2

3

4

Train “A”

Train “B”

1

2

3

4

5

6

7

8

68-XV-1838

68-XV-1852

O

C

C

C

C

O

C

O

68- XV-1856 68-XV-1855

O

C

C

C

C

C

C

C

68-XV-1832

68-XV-1847

O

C

C

C

C

C

C

C

68-XV-1839

68-XV-1853

O

C

C

C

C

O

C

O

68-XV-1830

68-XV-1844

O

O

C

O

O

O

O

O

68-XV-1837

68-XV-1851

O

O

C

O

O

O

O

O

68-XV-1828

68-XV-1843

C

C

O

O

C

C

C

C

68-XV-1835

68-XV-1854

C

C

O

O

O

C

C

C

68-XV-1829

68-XV-1845

C

C

O

O

C

C

C

C

68-XV-1836

68-XV-1850

C

C

O

O

O

C

C

C

68-XV-1826

68-XV-1841

C

C

C

C

C

O

C

O

68-XV-1827

68-XV-1842

C

C

O

O

O

C

C

C

68-XV-1834

68-XV-1849

C

C

O

O

O

C

C

C

68-XV-1857

C

C

C

C

C

C

C

C

C

C

C

O

68-XV-1858

C

C

C

C

C

C

C

C

C

O

O

C

Details of pump status against the respective phase are tabulated below: Pump Tag No. Train “A” 6834-P-37A

Train “B”

Demineralization - Phase Number 1

2

3

4

5

6834-P-37B ON

6834-P-34A 6834-P-34B

ON

6834-P-35B

6834-P-36B 6834-P-38A 6834-P-38B

8

1

2

3

4

ON

ON ON ON

6834-P-35C 6834-P-36A

7

ON

6834-P-34C 6834-P-35A

6

Neutralization Phase Number

ON ON ON ON ON ON

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5.14

BOILER FEED WATER DEAERATOR SYSTEM

5.14.1

Lining up of Steam Condensate Flash Drum 6834-V-05 1.

Open the 2” drum vent isolation valve to atmosphere.

2.

Open the 2” drain valve from the Steam Condensate Flash Drum 6834-V-05.

3.

Open the 12” Condensate Distribution Header isolation valves at battery limit and near the Steam Condensate Flash Drum 6834-V-05 slowly and introduce condensate from condensate distribution header and warm up the Steam Condensate Flash Drum 6834-V-05.

4.

Ensure enough time is given for the warming up of the drum and then open the condensate header isolation valves fully.

5.

Close the 2” drain valve from the Steam Condensate Flash Drum 6834-V-05.

6.

Ensure that low low level trip 68-LALL-1309 is cancelled when the water level is rising.

7.

Ensure that low level alarm 68-LAL-1301 is cancelled when the level is rising in the drum.

8.

Ensure that the level in the drum is rising by checking the level transmitter 68-LT1301/1308/68-LG-1303.

9.

When the level is around 50%, close the condensate inlet isolation valve near the drum.

10. Open the Deaerator Feed Pumps 6834-P-20A/B suction isolation valves and the common suction line isolation valve and warm up the pumps by opening the casing vent isolation valves. 11. Prime the pumps by opening the casing vent isolation valves and releasing air. 12. Ensure that the Deaerator Package 6834-A-08 inlet isolation valves from the Deaerator Feed Pumps 6834-P-20A/B discharge is closed. 13. Open the Steam Condensate Coolers fans 6834-E-02A/B/C inlet and outlet isolation valves. 14. Line up condensate from Steam Condensate Cooler 6834-E-02 to Steam Condensate Flash Drum 6834-V-05 isolation valve. 15. Open the discharge valve of Deaerator Feed Pump 6834-P-20A. 16. Open the minimum flow control valve 68-FV-1301 in manual by 50% and the upstream and downstream isolation valves. 17. Ensure that the temperature control valve 68-TV-1301 is manually closed. 18. Start Deaerator Feed Pump 6834-P-20A from the local panel.

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19. Now the Deaerator Feed Pump 6834-P-20A is circulating water back to the Steam Condensate Flash Drum 6834-V-05 through the Steam Condensate Cooler 6834-E-02. 20. Line up temperature control valve 68-TV-1301 upstream and downstream isolation valves and take 68-TV-1301 in AUTO with a set point of 102°C. 21. Line up Demineralised Water from Demineralised Water Feed Pumps 6834-P-24A/B by opening the upstream and downstream isolation valves of 68-LV-1301. 22. Take 68-LV-1301 in AUTO with a set point of 50%. 5.14.2

Lining up of BFW Deaerator Package 6834-A-08 1.

Open the 2” Deaerator Column vent isolation valve to atmosphere.

2.

Open the 3” drain valve from the Deaerator Storage Vessel 6834-A-08.

3.

Reset ESD and ensure the Deaerator inlet ON-OFF valve 68-XV-1301 opens.

4.

Line up 68-LV-1302 upstream and downstream isolation valve.

5.

Open 68-LV-1302 manually by 10%.

6.

Warm up the Deaerator Storage Vessel and the Deaerator Column with the condensate from Deaerator Feed Pumps.

7.

After allowing sufficient time for the warming up of Deaerator, close the 3” drain valve from the drum.

8.

Now the level in the drum starts to rise.

9.

Ensure that the low low level trip 68-LALL-1310 in the drum is cancelled when the level rises.

10. Ensure that the low level alarm 68-LAL-1310 is cancelled when the level rises. 11. When the level reaches 50%, put 68-LIC-1302 in AUTO with a set point of 50%. 12. Line up LP saturated steam by opening the upstream and downstream isolation valves of 68-PV-1304. 13. Put 68-PV-1304 in AUTO with a set point of 1.21 bara. 14. Drain condensate from the Deaerator if required to maintain the level at 50%. 15. Start Boiler Feed Water Pump 6834-P-22A and recirculate the condensate to the Deaerator through the minimum flow line. 16. Start O2 Scavenging Injection from the Chemical Injection Package 6834-A-09 as per section 5.12.2 and line up to the Deaerator at a rate of 0.55 l/hr. 17. Take a sample from the Sample cooler 68-SC-1004 at the suction of the Boiler Feed Water Pump 6834-P-22A and analyse for dissolved Oxygen. 18. If O2 and CO2 in the sample are less than 5 parts per billion then the Boiler Feed Water is ready for lining up to the steam generation units.

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5.15

STEAM GENERATION PACKAGE START-UP

5.15.1

Checks for Start-up •

First of all it is necessary to be sure that all lines up to boiler package battery limit (including water, steam, compressed air, fuel gas etc.) have been completely and properly cleaned to eliminate from internal side of lines, any possible presence of impurities/oxides, debris, rust and scales. This is very important for the first time start-up of the Boiler subsequent to a long shutdown and there is a reasonable doubt about possible accumulation of deposits on line internal parts

•

In the case boiler start-up is subsequent to a long boiler shutdown (for instance: for maintenance, inspection or repair purposes), the Operator visual inspection should be extended to internal and external parts and it should cover at least the following essential points: •

Check of cleaning of all involved piping by means of appropriate fluids so that piping is internally free from scale and impurities. Operator must always take care to achieve an ideal clean tube condition, in order to avoid any obstruction to the instruments, valves and fittings that could seriously jeopardize the boiler/plant functionality and operation. This visual inspection should be extended till to check the drains and to see if the fluid is discharged without any obstruction and free from scales or other impurities;

•

Water gauge passages and other boiler mounting openings are clear

•

Manhole doors are in position with good gaskets and satisfactorily tightened

•

All Boiler and Economizer valves and fittings are operated and checked

•

Combustion chamber and flue gas circuits are checked for cleanliness with refractory brickwork in good condition and expansion allowances are clear

•

All valves and fittings installed on remaining lines (such as instrument air, cooling water, fuel lines and so on) are proven clear and in working order

•

All installed instrumentation are in good and working conditions

•

Before start-up of the steam generator, it should be verified that all the auxiliary equipments are in proper working condition and all the control devices have been positively tested

Critical checks for start-up of Boiler: •

Verify the proper functioning of the level gauge (Boiler). If necessary level gauge drains are to be operated and the level gauge is checked. Ensure that water comes out of the level gauge drains and that upstream piping is not blocked by impurities. In case of doubt and if necessary remove the drain valves and clear the upstream piping of blockages

•

Verify that all the Boiler and Economizer drains are closed

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5.15.2

•

Verify that main steam stop valve and relevant by-pass valves are completely closed

•

Verify the proper operation of all the control and block valves

•

Verify that all equipment inspection doors are properly closed

•

Verify that feed water is available with proper quality

Water Filling •

Before the Boiler start-up operation, boiler has to be filled with water up to the operating level

•

Feed water must always be introduced slowly into the boiler. The filling water flow rate depends on the water temperature.

•

In general 20°C is the minimum recommended value of the feed water temperature. If this value is higher than 40°C, the steam generator should be filled very slowly in order to prevent stress on the boiler components (particularly on drums)

•

Before starting boiler filling, all vent valves (both manual and actuated) shall be fully opened

•

Ensure that the manual start-up vent valves GV-5045 & GV-5046 are fully open

•

Boiler and Economizer drains shall be opened (in order to check their proper operation). Boiler and Economizer drain valves shall be closed after few minutes

•

All the vent valves are to be kept open. This is to vent out air pockets inside steam generator tubes to atmosphere

•

When water exits from the Economizer vent, the relevant Economizer vent manual valve has to be closed.

•

Keep 68-PIC-1819 in Manual Mode and Open 68-PV-1524 fully (MV=100%).

•

Open the start-up vent 68-PV-1523 fully in Manual Mode.

•

Confirm that the LP Steam Outlet 68-MOV-1522 is in closed position.

•

Ensure that the BFW Pumps 6834-P-22 A/B/C are running.

•

Ensure that the BFW inlet 68-XV-1522 & 68-XV-1524 are open.

•

Ensure that complex product Injection package is started as per section 5.12.1 and complex product is dosed at a rate of 1.87 l/hr to the BFW.

•

Gradually open the 68-LV-1522 in Manual Mode and fill the downstream line.

•

Gradually open the valve GV-5013 and fill the Boiler Steam Drum 6848-V-02A with DM water.

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•

Fill the Boiler gradually and open the drain lines one by one for flushing.

•

Close all the drain valves after ensuring sediment free water from Boiler.

•

Monitor the level in the Steam Drum.

•

Check for water leakages if any.

•

Raise the Steam Drum Water level up to normal level.

•

Confirm that the all drain valves are closed properly.

•

Water filling is completed when drum level is at about 50 mm below the normal water level (NWL) so that there is enough volume for expansion during subsequent water heating when burner is lighted.

Note: Achieving of drum level is a necessary and mandatory pre-condition for boiler start-up operation. Normal Water Level is located +50 mm above Steam Drum centre line. 5.15.3

Fuel Gas Line-up 1.

Ensure that the main fuel gas line and the pilot fuel gas line are purged with nitrogen and are under nitrogen pressure.

2.

Ensure that the fuel gas lines are leak tested.

3.

Ensure that the vent and drain valves in the fuel gas lines are closed.

4.

Ensure that fuel gas inlet filter 6848-S-01A elements are available and boxed up.

5.

Ensure that the fuel gas inlet 68-XV-1302 is open.

6.

Slowly open the isolation valve upstream of 68-XV-1302 and pressurise the line. Check the pressure increase through 68-PG-1314.

7.

Open the isolation valve BV-5167 and slowly pressurise the downstream lines.

8.

Open 68-PCV-1522 in Manual Mode slowly and pressurise the Main Fuel Gas Line.

9.

Open the Block valve BV-5190 and slowly pressurise the Pilot Fuel Gas line.

10. Check for any gas leakages. 5.15.4

FD Fan Start-up 1.

Confirm that necessary lubricants/grease is filled as per specifications.

2.

Confirm that the Cooling water is lined-up and the water flows through the Sight Flow Glass (SFG).

3.

Ensure that the Inlet damper is fully open.

4.

Keep the “LOR” selector Switch in ‘Local’ mode.

5.

Rotate the shaft, half turn, by hand to ensure free rotation of the Fan.

6.

Confirm that the FD Fan 6848-K-02A is ready to start.

7.

Inform to the substation.

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8.

Start the FD Fan by pressing START push button.

9.

Ensure that there is no abnormal noise and vibration

5.15.5

Burner Start-up Burner management system (BMS): The burner operation is performed in fully automatic through Burner management system (BMS). The BMS performs the following basic functions: 1.

Continuous check of all valves and dampers of combustion systems

2.

Pre-firing cycle.

3.

Light-off cycle of burner.

4.

Boiler Stop cycle.

5.

ESD-Master fuel trip.

6.

Post firing purge.

Steam generation unit-Burner start-up: Note: Tags considered in this document are all related to BOILER A. Steam generation unit Local panel details (6848A02A-LP-003) are tabulated below: Sl. #

Tag No.

Description

1.

68-HSO-1526

Burner start

2.

68-HSC-1527

Burner stop

3.

68-HS-1528

Reset button

4.

68-HS-1524

Emergency shutdown

5.

68-HSR-1529

Local/Remote selector

6.

68-HS-1530

Lamp test button

7.

68-XL-1541

Burner firing lamp

8.

68-XL-1542

Burner shutdown lamp

Control valve/ON-OFF valve details are tabulated below: Sl. #

Tag No.

Description

1.

68-XV-1528

Main gas shut off valve-1

2.

68-XV-1529

Main gas shut off valve-2

3.

68-XV-1530

Main gas vent valve

4.

68-XV-1531

Pilot gas shut off valve-1

5.

68-XV-1532

Pilot gas shut off valve-2

6.

68-XV-1533

Pilot gas vent valve

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Sl. #

Tag No.

Description

7.

68-FV-1525

Fuel gas control valve

8.

68-FV-1524

Flue gas recirculation damper

9.

68-FV-1526

Combustion air damper

Burner start can be done from HMI, Local panel and DCS. DCS start is active only in remote mode and start on HMI or local panel is active in local mode. Burner Consent to Start: The start of the burner is allowed only if all the following consents are set: •

Burner is OFF

•

Combustion Air fan (6848-K-02A) is running

•

Flue gas recirculation fan (6848-K-03A) is running (If enabled)

•

Below mentioned burner Shutdowns are not present Sl. #

1.

Tag No./Alarm

Description

1.

68-PAHH-1528A/B/C

Combustion chamber pressure high-high

2.

68-LALL-1523A/B/C

Boiler level low-low

3.

68-LAHH-1523A/B/C

Boiler level high-high

4.

68-PAHH-1522A/B/C

Saturated steam pressure high-high

5.

68-PALL-1525A/B/C

Upstream burner gas pressure low-low

6.

68-PAHH-1526A/B/C

Downstream burner gas pressure high-high

7.

68-FALL-1526B/C/D

Combustion air flow low-low

8.

68-FAHH-1525B/C/D

Natural gas flow High-High

9.

68-PALL-1527A/B/C

Instrument air pressure low-low

10.

68-HS-1523

ESD from boiler control panel

11.

68-HS-1524

ESD from boiler local control panel

12.

68-HS-1525

Emergency shutdown

13.

68-ZI-1548

Forced draft fan not running

14.

68-XS-1327

Emergency shutdown from ESD

15.

NA

Burner main, pilot shutoff and vent valves discrepancies

The burner can be started only manually by the operator from LCP or DCS. The following permissives for burner start-up are to be satisfied. a.

The burner is off. The burner is not already “STARTING” or “ON”.

b.

Burner shutdown alarms are not present.

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c.

Combustion Air Fan 6848-K-02A is running.

d.

Flue Gas Recirculation Fan 6848-K-03A is running. (If flue gas recirculation control is enabled).

2. Select “LOCAL” in the Local Burner Panel. 3. Press the “START” push button HSO-1526 from the Local Burner Panel. 4. Set the minimum opening for the air flow control damper 68-FV-1526 from the LBP for purge. 5. Ensure that the air purge is done for 5 minutes. 6. After air purge is done ensure that the damper FV-1526 opening is decreased to the burner light off threshold. 7. If flue gas recirculation controller is enabled, set the opening for the flue gas recirculation damper FV-1524. 8. Ensure that the flue gas recirculation damper 68-FV-1524 is open. 9. Ensure that the flue gas recirculation purge is done for 1 minute. 10. After flue gas purge is done ensure that the damper 68-FV-1524 is decreased to the burner light off threshold. 11. After 2 seconds of the PURGE VALID signal given by BMS, ensure that the burner ignition transformer is powered. 12. After 2 seconds of powering of the transformer, ensure the burner igniter vent valve 68-XV-1533 is closed and opens the burner igniter shut-off valves 68-XV-1531 and 68-XV-1532. 13. Ensure that after 5 seconds, the burner ignition transformer is powered off. 14. Ensure that the flame is detected by the flame scanner 68-BE-1523. 15. If flame is detected, ensure ‘Pilot On’ indication is available in LBP. 16. If the flame scanner 68-BE-1523 does not detect the flame, ensure that the burner restart is attempted automatically after 1 minute without purging the combustion chamber again. Note: The system can try the restart for 3 times. If flame is not detected again, the shutdown of the burner is started and purge valid signal is reset. 17. When the pilot ignition is successful, ensure that the main burner vent valve 68-XV1530 is closed and the main shut-off valves 68-XV-1528 and 68-XV-1529 are opened. 18. After 5 seconds for flame stabilization, the pilot vent valve 68-XV-1533 is opened and the pilot shut off valves 68-XV-1531 and 68-XV-1532 are closed. 19. Ensure that the flame scanners 68-BE-1522A & 68-BE-1522B detect flame.

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 26 - Burner Management Sequence for Steam Generation Package

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TITLE: OPERATION AND MAINTENANCE MANUAL /212

5.15.6

Boiler Normal Start-up 1.

Raise the furnace Temperature gradually as per the Vendor IOM.

2.

Operate the Boiler as per the Vendor IOM.

3.

When the Drum Pressure reaches 1.5 barg (Hot) tighten the Drums bolts/nuts.

4.

Steam Trap line-up: •

Ensure that the steam flow through the trap bypass line.

•

Open the steam trap down steam valve.

•

Open the steam trap upstream valve.

•

Close the bypass valve.

5. Observe and monitor the parameters: •

Fuel Gas Flow/Pressure

•

Combustion Air flow

•

Furnace Pressure

•

FD Fan Discharge Pressure

•

Drum Level/Pressure

•

Main Steam line Pressure

6. Check for Boilers expansions, if any. 7. Ensure that the Main Steam line distribution headers, all vents and drains are opened. 8. Check the furnace for flue gas leakages, if any. 9. Gradually increase the Drum pressure by throttling the start-up vent valve 68-PV-1523. 10. Ensure that the Drum level is maintained. 11. Gradually raise the air flow and fuel gas flow to increase the Drum pressure. 12. Check and confirm that the expansion of the Boiler at various locations is as per the design values. 13. Collect the Boiler water sample periodically and analyse the sample in lab for oil traces. 14. When the Drum Pressure reaches 5 barg, gradually open the Main Steam line MOV-1522 and crack open the downstream isolation valve to warm up the main steam line Header. 15. Line up all the steam traps along the main header and open the drain valves fully in the steam traps and drain all the condensate from the header. /

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16. Keep open the traps drain valves till superheated steam comes out of the drain lines. 17. When the superheated steam is noticed close the steam trap drain valves one by one and line up the steam traps to the condensate header. 18. Ensure that the condensate header is already warmed up. 19. When the steam header is warmed up, close all the drains and vents and open the MOV-1522 downstream isolation valve fully and charge the header. 20. Gradually increase the header pressure to the normal operating pressure. 21. Take all the controls in auto. 22. Open the continuous blow down valve and give blow down as necessary. 23. Line up Complex Product Injection pump 6834-P-41A/B and start dosing the chemical as per requirement. 5.15.7

Start-up from Cold Condition (Manual Mode) “Start-up from cold condition” refers to the boiler that is being started at atmospheric pressure and ambient temperature. While starting the Boiler on Cold conditions, the following also has to be verified: •

Economizer manual vent valves are closed

•

Boiler and Economizer manual drain valves are closed

•

Desuperheater 6848-X-03A Boiler Feed water control valve 68-TV-1522 is closed as it is not necessary to use the Desuperheater 6848-X-03A during initial start-up as the first steam produced is still “cold”

•

Motorized main steam stop valve and relevant motorized by-pass valve are completely closed.

Before lighting any burner the Forced Draft Fan 6848-K-02A and the Flue Gas Recirculation Fan 6848-K-03A are to be started in order to allow the system to be ready to initiate the boiler purging and also the fuel gas lines leakage test. Provided that all detailed sequences and controls as described in BMS Controls are satisfied, it is necessary to wait for a sufficient time to completely purge all boiler flue gas passages. Light up the first burner according to the operating sequence described on BMS controls. The boiler thermal heat input introduced through the burner must be maintained at boiler minimum load.

/

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When saturated steam starts to exit from vents installed on the saturated steam line (this means that boiler pressure is slightly higher than atmospheric pressure) the vent valve installed on the saturated steam line to be closed to increase the Boiler pressure. During start-up, the boiler pressurisation curve (that is, saturated pressure and saturated temperature vs. time) shown in the following figure “Boiler start-up curve” to be followed for pressurisation. To follow the burner should be operated at minimum allowable firing rate and if necessary the burner should be shut down and subsequently (after purging time) started up. Note: Faster start-up can cause serious damages to boiler. In order to comply with boiler pressurisation limit curve shown on following figure the burner can be lighted off/lighted on, as long as necessary. During boiler pressurisation, do not exceed the following limitations: •

30°C/h: from ambient temperature up to about 130°C (2 barg steam pressure)

•

55°C/h: from 2 barg steam pressure till to MCR operating pressure

During the boiler heating ramp, when adequate steam pressure is reached the burner load/fuel heat input can be increased from its minimum, but in any case the boiler pressurisation curve shall be correctly followed. When adequate steam flow rate is reached, the Boiler Feed Water to Desuperheater 6848-X-03A is lined up.

/

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Fig. 27 - Burner Management Sequence for Steam Generation Package

/

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5.15.8

Start-up from Hot Condition If the steam generator is in “hot" condition (that is, the boiler is close to the value of operating pressure/temperature, condition that practically occurs immediately after or a few hours after a boiler trip) the following conditions often exist: •

Main steam stop valve 68-MOV-1522 and its by-pass valve are closed

•

Actuated start-up vent valve 68-PV-1523 is closed

Before starting the boiler again, Operator shall check the existing differential pressure between Steam Drum 6848-V-02A pressure and steam header downstream of main steam stop valve pressure. When the two pressures are equalised then steam from Steam Drum can be lined up to the header. After opening the actuated start-up steam vent valve the burner is started at minimum firing conditions. The Boiler pressure slowly increases. When the pressure increases above the header pressure, the produced steam from Steam Drum can be lined up to the steam network through the motorised main steam shut off valve 68-MOV-1522. If the steam network grid pressure is higher than the boiler pressure, the motorised steam shut off valve 68-MOV-1522 should remain closed. In case steam network grid pressure is lower than the Boiler pressure and main stop valve is closed, then the bypass valve is crack opened to pressurise the network grid. At the end of this pressurisation activity, when the network grid pressure is equal or a little bit lower than boiler pressure (approx 0,5 bar), the motorised main steam stop valve shall be fully opened by Operator. After that, the actuated start-up vent valve shall be gradually closed. During this transfer, the firing rate shall be maintained constant. Then the firing ramp can be started. It is strongly recommended during boiler ramping, do not exceed the following limitations: • 5.15.9

/

55°C/h: from 2 barg steam pressure to MCR operating pressure Going On Line

•

Once the Boiler has reached the operating pressure, the main shut off steam valve can be opened completely (provided that downstream steam network grid is warmed up and ready to take the boiler steam). The start-up vent valve can now be closed.

•

When this transfer is completed and the alignment between Steam Generator and steam network grid line has been stabilised, the Boiler load can be increased from minimum load.

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5.16

•

When the Boiler is stabilized, the Steam Pressure Controller 68-PIC-1819 can be put in AUTO.

•

The Steam Pressure Controller 68-PIC-1819 varies the firing rate of the fuel gas according to the pressure set point.

•

The entire system should be kept under close surveillance until full load operating conditions are achieved. There is always the possibility of a defect in the safety cut outs.

•

The operation of burner and the flame pattern shall be closely monitored during start-up phase.

•

Two scanners are installed on each burner so to reveal the flame presence. The flame pattern must be checked directly on field by Operator through the peepholes installed on each burner and in the rear furnace wall.

•

The flame pattern shall be set in order to have a good flame, without furnace tube impingement and achieving minimum unburned emissions (basically CO content on flue gases).

•

Operator shall verify that the combustion takes place correctly, monitoring the flame pattern.

LEAK CHECKING OF SYSTEMS Leak checking of process systems to be done after maintenance of equipment or break open of piping flanges for repair/maintenance works. Preparation: Ensure that the following activities are completed: •

Relevant Work Permit have been filled up and signed

•

The system is reinstated as per P&IDs

•

Pressurising manifold with suitable PSV and pressure gauge will be used.

Leak Check: Leak check shall be done as below:

/

•

Isolate the process system, using the available block valves

•

Close all vent and drains

•

Prepare a list of flanges and other critical locations to be checked.

•

Connect an air hose preferably from the plant air header or otherwise from a temporary compressor discharge manifold through temporary hoses.

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5.17

•

Pressurise the system step by step and hold the pressure at 25%, 50%, 75% and operating pressure and carry out a thorough leak check of all the listed flanges and other systems using tape and soap solution. Attend to leaks, if any after depressurisation.

•

Repeat the above procedure till there is no leak identified

•

Hold the pressure for 30 minutes and record the pressure loss. If the pressure loss is less than 0.05 bar/hr, the system will be considered to be leak free.

PURGING Purging of process lines and equipments with Nitrogen is to be carried out prior to introduction of acid gases into the process system. Process System and piping which contains acid gases are Nitrogen purged using an approved inerting procedure. A.

Pre-requisite for Nitrogen Purging

1.

Verify portable radios are available for communication.

2.

Verify that all-loose materials and tools have been cleaned up prior to nitrogen purging.

3.

Obtain Oxygen monitors for testing Oxygen concentration during purging.

4.

Verify that all personnel are appropriately equipped with required PPEs including hard hats, goggles, earplugs and gas monitoring equipment.

5.

Prior to initiating purge, a toolbox talk shall be held for the personnel regarding the purging and the hazards of Nitrogen gas.

B.

Preparation

1.

Risk assessment shall be done prior to purging of each system.

2.

System shall be marked and identified in the P&ID. Also the point used for purging will be marked in P&ID.

3.

The PI and PGs in the system will be used for monitoring the system pressure.

4.

Pressure test with nitrogen is carried along with the nitrogen purging.

5.

Depressurisation points shall be chosen such that the whole system is depressurised and no pressure is trapped downstream of check valves.

C.

Purging Procedure for Vessels & Equipment

1. Purging of Process Systems is critical for a safe start-up of the facility.

/

2.

Purging is accomplished by using Nitrogen.

3.

While carrying out the vessels and equipment purging ensure vents and pressure taps such as gauge glass, level control bridles, spare pumps, etc., are properly purged. Purging and testing should be continued until Oxygen content is less than 2%. A sample is taken in each case from the system being purged at the purge

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pressure and passed through an Oxygen monitor, which reads directly in percent Oxygen.

/

4.

Consider each line and piece of equipment to assure complete purging of air. Purge interconnecting piping systematically to avoid leaving air pockets in these systems. Ensure that all appropriate valves are open or closed as required. Particular attention should be given to block the valves located at the upstream of relief valves.

5.

If proper tapings are not available, arrange necessary flanged nipples to fix Nitrogen hose or to make purge outlet.

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SECTION VI

START-UP OF PLANT

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6.1

GENERAL The start-up procedure of the SRU depends on the exact situation of the unit at any particular point of time. The various cases are: •

Start-up after a major turnaround shutdown

•

Start-up after an emergency shutdown, where the unit is ready to be taken on stream immediately

When starting the unit after a shutdown, only the relevant procedures are followed depending on the status of the various sections of the unit and nature of jobs carried out. All safety precautions as per the safety rules and regulations are followed while taking over and starting up of any equipment or section of the unit. There are standard procedures to be followed as per the QP safety manuals for inspection, followed by accepting/deblinding any equipment before taking in line. Smooth start-up will depend to a larger degree on how well the unit is checked prior to start-up. In a major turnaround shutdown, all vessel internals are inspected, and if there are any modifications to be carried out, it is completed and the vessels boxed up. All safety items should be checked before, during and after start-up to ensure safe and stable operation. During start-up, the operating conditions of each unit must be adjusted to bring the product specifications in line with the design values. During the period of off-spec product it should be vented to flare system as far as possible to meet the required specification. Prior planning of various start-up activities can eliminate delay and improve the safety of personnel and equipment. 6.2

START-UP SEQUENCE It will be necessary to start-up all or section of the plant after shutting down plant for various reasons viz.; mechanical repair, repair of critical equipments/pipeline leaks, utilities failure or any operating problem. The process plants are to be started in the following sequence: 1. Incinerator 2. Acid Gas Enrichment Unit 3. Sulphur Recovery Unit 4. Tail Gas Treatment Unit

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6.3

START-UP OF PROCESS

6.3.1

Start-up of Incinerator 9101-F-14 Start-up of the Incinerator involves the following activities: 1.

Purging of the system and pilot ignition

2.

Main burner ignition, heat-up and introduction of Tail gases.

6.3.1.1

Purging Of the System and Pilot Ignition

a.

Pre-requisites

1.

Air inlets, burner and incinerator/stack passages are in good condition and free of foreign material.

2.

All personnel have been evacuated from the Incinerator, duct work, associated equipment and all access and inspection doors closed and sealed.

3.

Blower VFD’s are operated through full range to check the blower response.

4.

All safety shut off valves in fuel gas lines are closed.

5.

Fuel system vents are open and venting properly to atmosphere. Lines are properly drained and cleared of condensate.

6.

A complete functional check of the safety interlocks has been made after any overhaul or other significant maintenance.

7.

The area is clear of obvious safety hazards and flammable gases are not present in the area.

8.

All lines have been blown down with plant air to ensure they are free of debris that might plug metering orifices and burner tips.

9.

Utilities (fuel gas, instrument air and plant air) are established and initial operational checks performed on the elements in each line.

10. Burner elements and pilot are in their proper position in accordance with specifications shown in the burner assembly and pilot drawings. 11. Power has been supplied to control systems and to safety interlocks. 12. Meters or gauges indicating fuel header pressure to the unit are functional. 13. Ensure that the following Pressure self regulating valves are set according to the instrument data sheets. •

Pilot gas supply PCV-1155 set at 0.7 barg

•

Pilot air supply PCV-1164 set at 0.7 barg

14. Isolation valves for all pressure gauges and pressure transmitters are open and their respective bleed valves are closed.

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15. Purge air has been established for the sight ports and flame scanners. Flame scanners have clear lenses and the scanner isolation ball valves are open. b. Local Control Panel Incinerator is equipped with a Local Control Panel 9101-F-14-LP-001. This panel is used for the start-up of the Incinerator System. The LCP is supplied with the following indications: Tag No.

Description

Colour

91-XL-1173

System Ready for Purge

Green

91-XL-1174

Purge in Progress

Green

91-XL-1175

Purge Complete

Green

91-XL-1176

Pilot Flame On

Green

91-XL-1177

Main Burner On

Green

91-XA-1178

Common Alarm

Red

91-XL-1180

BE-1155A Flame Detected

Green

91-XL-1181

BE-1155B Flame Detected

Green

91-XL-1182

BE-1155C Flame Detected

Green

91-HS-1162

Reset

Black

91-HS-1163

Start Purge

Black

91-HS-1164

Start Pilot

Black

91-HS-1165

Start Burner

Black

91-HS-1166

Normal Stop

Black

91-HS-1167

Emergency Shutdown

Red – Mushroom Head

91-HS-1168

Lamp Test

Black

Control valve and ON-OFF valve details are tabulated below: Sl. #

Tag No.

Description

1.

91-XV-1155

Fuel gas upstream block valve

2.

91-XV-1156

Fuel gas vent valve

3.

91-XV-1157

Fuel gas downstream block valve

4.

91-XV-1158

Pilot gas upstream block valve

5.

91-XV-1159

Pilot gas vent valve

6.

91-XV-1160

Pilot gas downstream block valve

7.

91-XV-1161

Instrument air block valve

8.

91-XV-1162

Pilot air block valve

9.

91-FV-1155

Fuel gas control valve

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Prior to the start-up of the Incinerator ensure the following: •

BMS (PLC-UCP) is powered up

•

Signal 91-XS-1170 to force fuel gas flow rate controller 91-FIC-1155 to 0% output is present.

•

Signal 91-XS-1171 to force combustion air flow rate controller 91-FIC-1156 to 100% output is absent.

•

Fuel gas control valve 91-FV-1155 at minimum stop position.

•

Fuel gas upstream (91-XV-1155) and downstream (91-XV-1157) is closed.

•

Fuel gas vent valve (91-XV-1156) is opened.

•

Pilot gas upstream (91-XV-1158) and downstream (91-XV-1160) is closed.

•

Pilot gas vent valve (91-XV-1159) is opened.

•

Instrument air block valve (91-XV-1161) is closed.

•

Pilot air block valve (91-XV-1162) is closed.

Note: Press lamp test switch 91-HS-1168 on the local panel and ensure all the lamps are working. c.

Purge Cycle

Prior to the ignition of any burner it is important to purge the Incinerator with fresh air which will sweep away any combustible that may have accumulated in the system. Start-up of Blowers: •

Select Local on the local/remote selector switch 9101-RCU-KM-12A/B

•

Force VFD (9101-K-12A/B) to minimum speed from the DCS

•

Press motor start switch in 9101-RCU-KM-12A/B

•

Open the O/L damper

1.

Ensure the following BMS Shutdown alarm conditions in Incinerator are normal: Tag No.

Description

91-XS-1185

Remote ESD signal

91-HS-1167

Local ESD (PB on LCP)

91-FALL-1156B

Combustion Air flow low low alarm

91-PALL-1155

Fuel gas pressure low low alarm

91-PALL-1156

Fuel gas pressure low low alarm

91-PAHH-1156

Fuel gas pressure high high alarm

91-BSLL-1155

Flame fail (2oo3) alarm

91-TAHH-1160

Incinerator Temperature high high alarm

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Note: During start-up, the discrepancy alarms of BMS ON/OFF valves trips the Incinerator. 2.

Ensure that the following permissives to start the purge are available: Tag No.

Description

Position/Status

91-BSL-1155A

Flame Scanner Switch

Not energized (No flame)

91-BSL-1155B

Flame Scanner Switch

Not energized (No flame)

91-BSL-1155C

Flame Scanner Switch

Not energized (No flame)

91-BSL-1156

Flame Rod Switch

Not energized (No flame)

91-ZSL-1155

Fuel Gas Control valve

Valve at low-fire position

91-ZSC-1155

Fuel Gas upstream block valve

Valve closed

91-ZSO-1156

Fuel Gas vent valve

Valve open

91-ZSC-1157

Fuel Gas downstream block valve

Valve closed

91-ZSC-1158

Pilot Fuel Gas upstream block valve

Valve closed

91-ZSO-1159

Pilot Fuel Gas vent valve

Valve open

91-ZSC-1160

Pilot Fuel Gas downstream block valve

Valve closed

3. If purge permissives are met, ensure that the System Ready for Purge lamp 91-XL1173 on LCP is lit. 4. Press ‘START PURGE’ pushbutton 91-HS-1163 from LCP 9101-F14-LP-001. 5. Ensure that the force signal (91-XS-1171) to FIC-1156 is energized and forces the flow controller FIC-1156 to manual mode with 100% output. 6. Ensure that the shut off valves 91-XV-1161 & 91-XV-1162 are opened and air is supplied to the pilot and purge air to the flame scanners. 7. Ensure that the combustion air flow measured by 91-FT-1156C indicates a flow of >45500 Sm3/hr. 8. Ensure that the ‘PURGE IN PROGRESS’ lamp 91-XL-1174 on LCP is lit. 9. Ensure purging is completed in 5 minutes. 10. Ensure that ‘PURGE COMPLETE’ lamp 91-XL-1175 on the LCP is lit. 11. At the end of 5 minutes, the forcing signal 91-XS-1171 is de-energised allowing FIC-1156 to return to automatic mode, since no fuel gas is flowing to the burner at this point the output to the VFD is at its minimum, 11106 Sm3/hr. 12. Ensure that this condition exists for another 5 minutes.

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d.

Pilot Ignition

1.

Ensure that there are no alarms present in the UCP (BMS).

2.

Ensure that the above listed permissives are met.

3.

Press ‘START PILOT’ push button 91-HS-1164 from LCP.

4.

Ensure that ‘PURGE COMPLETE’ indication is no more present.

5.

Ensure that the pilot vent valve 91-XV-1159 is closed.

6.

Ensure that the pilot block valves 91-XV-1158 & 91-XV-1160 are opened after receiving the CLOSE feedback 91-ZSC-1159 of the vent valve 91-XV-1159.

7.

Ensure that the ignition transformer 91-XS-1183 is energised.

8.

Ensure that after 10 seconds, ignition transformer 91-XS-1183 is de-energised.

9.

Ensure that after 10 seconds, if pilot is ON, the flame is detected by the Pilot Flame Rod 91-BE-1156.

10. Ensure that the ‘PILOT FLAME ON’ lamp 91-XL-1176 on the LCP is lit. 11. Ensure that pilot stabilisation timer of 60 seconds is completed from UCP HMI. 12. If no pilot flame is detected by the flame rod, ensure that after 10 seconds, SRU tail gas Incinerator is tripped. 13. Ensure that the COMMON ALARM lamp 91-XA-1178 is lit. 14. Check the DCS/UCP for the first out alarm condition. 15. Clear the alarm condition. 16. RESET the system by pressing the RESET push button 91-HS-1162 from LCP. 17. Restart the system from the beginning. 18. If a flame is detected by 91-BE-1156 at the end of the 10 second trial period, then the second pilot flame stabilization timer will be started. 6.3.1.2

Main Burner Ignition, Heat-up and Introduction of Tail Gases

1.

After pilot stabilisation timer of 60 seconds is completed, press ‘START BURNER’ pushbutton 91-HS-1165 on LCP 9101-F14-LP-001.

2.

Ensure that fuel gas vent valve 91-XV-1156 is closed.

3.

Ensure that the vent valve closing feedback is received from the limit switch 91-ZSC-1156.

4.

Ensure that the fuel gas block valves 91-XV-1155 & 91-XV-1157 are opened.

5.

Ensure that the burner fuel gas control valve 91-FV-1155 is at its minimum stop position.

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6.

Ensure that in a 10 second trial for ignition period, the burner main flame is detected by 2oo3 voting of flame scanners 91-BE-1155A, 91-BE-1155B & 91-BE1155C.

7.

Ensure that the ‘MAIN BURNER ON’ lamp 91-XA-1178 is lit in LCP.

8.

If no pilot flame is detected by the flame scanners, ensure that after 10 seconds, SRU tail gas Incinerator is tripped.

9.

Ensure that the COMMON ALARM lamp 91-XA-1178 is lit.

10. Check the DCS/UCP for the first out alarm condition. 11. Clear the alarm condition. 12. RESET the system by pressing the RESET push button 91-HS-1162 from LCP. 13. Restart the system from the beginning. 14. Ensure that if the main flame is confirmed at the end of the main burner trial-forignition period, then a 60 second low fire timer in the BMS is automatically started. 15. Ensure at the end of the 60 second low fire period, the BMS stops sending the forcing signal 91-XS-1170 to the DCS. 16. Increase slowly the set point of 91-TIC-1155 so that the temperature of the incinerator does not rise faster than 50°C per hour, until the normal operating temperature of 817°C is reached. 17. Ensure that at 817°C the pilot is turned off. 18. Ensure that 91-XV-1158 & 91-XV-1160 are closed. 19. Ensure that 91-XV-1159 is opened. 20. Ensure that 91-XV-1162 is closed. 21. Ensure that there is a flow of 4.6 Sm3/hr. of purge cooling air through a restriction orifice RO-1155 to the pilot around 91-XV-1162. 22. To introduce tail gases ensure that the system is in operation with no alarm condition. 23. Ensure that the Incinerator temperature at 91-TE-1156 is greater than or equal to 817°C. 24. Now the system is ready for introduction of tail gases. 25. The flow of waste gases can be started and stopped in any order. However the waste gases should be introduced one at a time to the Incinerator.

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Fig. 28 - Incinerator Burner Start-up Flow Chart

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6.3.2

Start-Up of Acid Gas Enrichment Unit Pre-requisites •

Preparation of Antifoam

•

Preparation of Corrosion Inhibitor

•

Preparation of Amine Solution

6.3.2.1

Preparation of Antifoam

1.

Ensure that the Antifoam Injection Pumps 9103-P-16A/B and the Agitator 9103-M12 are energised in MCC.

2.

Ensure that the Antifoam Storage Tank 9103-T-12 is cleaned internally.

3.

Ensure that all the drain and vent valves in the package are closed.

4.

Introduce minimum flow of Nitrogen to the Antifoam Storage Tank and read the flow through the flow indicator 91-FI-1537.

5.

Procure the Antifoam drums to the site and place it near the unloading pumps 9103-P-19A/B.

6.

Connect the drums to the unloading pumps through flexible hose.

7.

Start the unloading pumps and transfer antifoam to the tank.

8.

Ensure that the low low level trip 91-LALL-1520 & low level alarm 91-LAL-1521 are cancelled while making up the solution.

9.

Ensure the level in the tank from 91-LG-1510 and 91-LT-1521 and ensure the tank does not overflow.

10. Start agitator 9103-M-12 from the local panel to mix the solution thoroughly. 6.3.2.2

Lining up of Antifoam Injection Pumps 9103-P-16A/B

1.

Ensure that the Antifoam Injection pumps 9103-P-16A/B suction strainer elements are fixed and boxed up.

2.

Ensure that the Antifoam Injection Pumps 9103-P-16A/B discharge PSVs 91-PSV1602/1603 are lined up.

3.

Open the Antifoam Storage Tank outlet isolation valve to the injection pumps and fill the lines with the antifoam solution.

4.

Open the discharge isolation valve of the Antifoam Injection Pump 9103-P-16A.

5.

Open the common discharge isolation valve of the Antifoam Injection Pumps 9103P-16A/B.

6.

Select the LOR switch of the Antifoam Injection Pump 9103-P-16A in Local.

7.

Start the Antifoam Injection Pump 9103-P-16A from local control station.

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8.

Ensure that the Antifoam Injection Pump 9103-P-16A is developing pressure by checking the discharge pressure transmitter 91-PT-1559.

9.

Stop the pump and keep the Antifoam Injection Pump 9103-P-16A ready for dosing.

10. Repeat the above procedure for Antifoam Injection Pump 9103-P-16B and keep it ready. 11. Line up Antifoam to the Acid Gas Amine Absorber 9103-C-11 or Amine Regenerator 9103-C-12 as required. 6.3.2.3

Preparation of Corrosion Inhibitor

1.

Ensure that the Corrosion Inhibitor Injection Pumps 9103-P-101A/B and the Agitator 9103-M-13 are energised in MCC.

2.

Ensure that the Corrosion Inhibitor Storage Tank 9103-T-13 is cleaned internally.

3.

Ensure that all the drain and vent valves in the package are closed.

4.

Transport the Corrosion Inhibitor drums to the site and place it near the unloading pumps 9103-P-102.

5.

Connect the drums to the unloading pumps through unloading hose.

6.

Start the unloading pumps and transfer Corrosion Inhibitor to the tank.

7.

Ensure that the low low level trip 91-LALL-1522 is cancelled while making up the solution.

8.

Ensure the level in the tank from 91-LG-1511 and 91-LT-1523 and ensure the tank does not overflow.

9.

Start agitator 9103-M-13 from the local panel to mix the solution thoroughly.

10. Keep the Corrosion Inhibitor Injection Pumps 9103-P-101A/B ready for dosing. 6.3.2.4

Lining up of Corrosion Inhibitor Injection Pumps 9103-P-101A/B

1.

Ensure that the Corrosion Inhibitor Injection pumps 9103-P-101A/B suction strainer elements are fixed and boxed up.

2.

Ensure that the Corrosion Inhibitor Injection Pumps 9103-P-101A/B discharge PSVs PSV-1504/1505 are lined up.

3.

Open the Corrosion Inhibitor Storage Tank outlet isolation valve to the injection pumps and fill the lines with the Corrosion Inhibitor solution.

4.

Open the discharge isolation valve of the Corrosion Inhibitor Injection Pump 9103P-101A.

5.

Open the common discharge isolation valve of the Corrosion Inhibitor Injection Pumps 9103-P-101A/B.

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6.

Put the stroke length of the Corrosion Inhibitor Injection Pump 9103-P-101A at minimum position.

7.

Keep the LOR switch of the Corrosion Inhibitor Injection Pump 9103-P-101A in ‘Local’.

8.

Start the Corrosion Inhibitor Injection Pump 9103-P-101A from local control station.

9.

Ensure that the Corrosion Inhibitor Injection Pump 9103-P-101A is developing pressure by checking the discharge pressure transmitter 91-PT-1561.

10. Stop the pump and keep the Corrosion Inhibitor Injection Pump 9103-P-101A ready for dosing. 11. Repeat the above procedure for Corrosion Inhibitor Injection Pump 9103-P-101B and keep it ready. 12. Line up Corrosion Inhibitor to the Acid Gas Amine Absorber 9103-C-11 or Amine Regenerator 9103-C-12 as required. 6.3.2.5

Filling Amine Surge Tank 9103-T-11 with Dow Ucarsol HS-103 (Amine Solution)

1.

Ensure that the Amine Surge Tank 9103-T-11 internals are clean and the man ways are boxed up.

2.

Ensure that the following valves are closed. a.

Lean Amine from Lean Amine Trim Cooler 9103-E-15 to the Tank 9103-T-11.

b.

Amine from Amine Filters 9103-S-11/12/13 to the Tank 9103-T-11.

c.

DM Water line to the Tank 9103-T-11.

d.

Lean Amine Pump 9103-P-13A/B minimum flow line isolation valves to the Tank 9103-T-11.

e.

Lean Amine from Tank 9103-T-11 to Lean Amine Pump 9103-P-13A/B isolation valve.

f.

Hydrocarbon skimming facility isolation valves.

g.

PSV-1513/1517/1518 outlet header isolation valve to the Tank 9103-T-11.

3. Ensure that the drain and vent valves of the Tank 9103-T-11 are isolated. 4. Ensure that the Tank PVRV-1521/PVRV-1522 upstream isolation valves are lined up. 5. Ensure that the Amine Surge Tank 9103-T-11 is purged with Nitrogen. 6. Line up tank vent valve 91-PV-1526B upstream isolation valve and take the control valve in Remote. 7. Take the pressure controller 91-PIC-1526 in Auto with a set point of 0.02 barg.

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8. Line up the Nitrogen supply line to the tank isolation valves and take the control valve 91-PV-1526A in Remote. 9. Ensure that all the instruments in the Amine Surge Tank 9103-T-11 are lined up. 10. Receive the road tanker containing amine solution and place it near the Amine Surge Tank 9103-T-11 filling station. 11. Connect a 2” flexible metallic hose to the road tanker unloading line. 12. Connect the other end of the flexible metallic hose to the suction of the Amine Unloading Pump 9103-P-18. 13. Ensure that the amine unloading pump suction strainer element is in place. 14. Connect the discharge of the amine unloading pump 9103-P-18 to the loading line 2”-9103-M-141-A189 of the Amine Surge Tank 9103-T-11 with a flexible metallic hose. 15. Connect plant air to the pneumatic amine unloading pump 9103-P-18. 16. Ensure that the air vent valve (if any) of the pneumatic pump is open. 17. Open the amine loading line isolation valves of the Amine Surge Tank 9103-T-11. 18. Open the road tanker unloading line isolation valve slowly and fill the metallic hose. 19. Start the Amine Unloading Pump 9103-P-18 by supplying plant air, and start to load the amine into the Amine Surge Tank 9103-T-11. 20. Ensure that low low level trip 91-LT-1511 (1000 mm) is cancelled in ICSS. 21. Ensure that the low level alarm 91-LAL-1512 (1150 mm) is cancelled as the level rises. 22. Monitor 91-LT-1512 and build the level up to 40% in the Amine Surge Tank 9103-T-11. 23. Stop pumping amine into the Amine Surge Tank 9103-T-11. 24. Close the tanker outlet valve and the Amine Surge Tank 9103-T-11 amine make up line isolation valves. 25. Drain amine from all the transfer lines and the metallic hoses and remove the metallic hoses. 26. Find the quantity of amine pumped into the Amine Surge Tank 9103-T-11. 27. If the added amine is 100% in concentration then DM water is to be added to dilute the solution to 50%. 28. Open DM water make up to the Tank and fill DM water by observing the flow through the flow gauge 91-FI-1529 in the DM water line equivalent to the Amine quantity. 29. The concentration of the solution in the Tank now is 50%.

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30. Collect a sample of the Amine solution and send it to laboratory for analysing the concentration. 31. When the sample concentration is given by the lab, necessary correction may be carried out to make the concentration of 50% amine. 32. Now the amine solution at 50% concentration is ready to be transferred to the AGEU and TGTU. 33. Ensure that the tank is blanketed by Nitrogen by checking through the pressure transmitter 91-PT-1526. 6.3.2.6

Transfer of Amine from Amine Surge Tank 9103-T-11 to Acid Gas Amine Absorber 9103-C-11

1.

Ensure that the Amine absorption section is under nitrogen pressure.

2.

Ensure that the drain and vent isolation valves are closed in the Lean Amine Pumps 9103-P-13A/B suction and discharge lines.

3.

Ensure that the H2S Analyzer 91-AI-1506 from Lean Amine Cooler 9103-E-14 outlet line joining the suction of the Lean Amine Pump 9103-P-13A/B isolation valve is closed.

4.

Open the Amine Surge Tank 9103-T-11 outlet line to Lean Amine Pump 9103-P13A/B isolation valve and fill up the line with amine.

5.

Open the suction isolation valves of the Lean Amine Pumps 9103-P-13A/B and fill the pumps by opening the casing vent valves.

6.

Ensure that the Lean Amine from the Lean Amine Pumps 9103-P-13A/B discharge to the Tail Gas Amine Absorber 9103-C-12 is closed.

7.

Ensure that the Lean Amine from the Lean Amine Pumps 9103-P-13A/B discharge to the Lean Amine Filter 9103-S-11/12/13 isolation valve is closed.

8.

Put the LOR switch position to “Local” position.

9.

Ensure that the Lean Amine Pumps 9103-P-13A/B are energized.

10. Reset PSD (Process Shut Down) from ICSS. 11. Ensure that Lean amine to Acid Gas Amine Absorber 9103-C-11 inlet ON-OFF valve 91-XV-1504 is opened. 12. Line up Lean Amine to Acid Gas Amine Absorber 9103-C-11 flow controller 91-FV-1501 isolation valves and close the bypass valve. Close the control valve 91-FV-1501 fully in manual. 13. Ensure that all the drain valves in the lean amine line to the Acid Gas Amine Absorber 9103-C-11 are closed. 14. Start the Lean Amine Pump 9103-P-13A on minimum flow from local control station.

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15. Ensure that the minimum flow line isolation valves are opened and the control valve 91-FV-1511 is lined up and the controller 91-FIC-1511 is in AUTO with a set point of 300 m3/hr. 16. Check the discharge pressure is normal at 6.50 barg from the pressure gauge 91-PG-1522. 17. Slowly open the discharge valve of the pump and fill the discharge line. 18. Open the Lean amine to Acid Gas Amine Absorber 9103-C-11 isolation valve and fill the downstream lines. 19. Open the flow control valve 91-FV-1501 slowly and start filling up the Acid Gas Amine Absorber 9103-C-11 with the amine. 20. Ensure that the Acid Gas Rich Amine Pumps 9103-P-12 A/B suction isolation valves are closed. 21. Ensure that the level is increasing in the Acid Gas Amine Absorber 9103-C-11 by checking the level transmitter 91-LT-1505 & level gauge 91-LG-1505A/B/C/D. 22. Ensure that the low low level alarm 91-LALL-1516 is cancelled as the level rises. 23. Ensure that the low level alarm 91-LAL-1506 is cancelled is cancelled as the level rises. 24. When the level reaches 100%, close the flow control valve 91-FV-1501 fully and close the isolation valve at pump discharge which is going to the Acid Gas Amine Absorber 9103-C-11. 6.3.2.7

Filling Lean Amine Filters 9103-S-11/12/13 with Lean Amine Solution

1.

Ensure that the Lean Amine Pump 9103-P-13A is running on minimum flow.

2.

Ensure that the drain and vent valves in the Lean Amine Filters 9103-S-11/12/13 are closed.

3.

Ensure that Lean Amine Filter 9103-S-11 and Fines Filter 9103-S-13 elements are fixed in the respective filter elements.

4.

Ensure that the Activated carbon Filter 9103-S-12 is loaded with the media and boxed up.

5.

Ensure that the amine from Amine Sump Pump isolation valve is isolated near the filters.

6.

Ensure that the upstream and downstream isolation valves of the 91-PSV-1512 are opened, the upstream isolation valve is closed for 91-PSV-1513 and the bypass valve is closed for Lean Amine Filter 9103-S-11.

7.

Ensure that the upstream and downstream isolation valves of the 91-PSV-1515 are opened, the upstream isolation valve is closed for 91-PSV-1514 and the bypass valve is closed for Activated Carbon Filter 9103-S-12.

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8.

Ensure that the upstream and downstream isolation valves of the 91-PSV-1517 are opened, the upstream isolation valve is closed for 91-PSV-1516 and the bypass valve is closed for Fines Filter 9103-S-13.

9.

Ensure all the instruments in the Lean Amine Filters are lined up.

10. Ensure that the bypass for the Activated Carbon Filter and Fines Filter is closed. 11. Open slowly the Lean Amine Pump 9103-P-13A/B discharge isolation valve to the filters and fill up the lines. 12. Crack open the Lean Amine Filter 9103-S-11 vent valve at the top. 13. Line up the flow control valve 91-FV-1507 and slowly open 91-FV-1507 on manual. 14. Slowly fill up the Lean Amine Filter 9103-S-11 until all the nitrogen is displaced through the vent and the amine just starts to overflow through the vent. 15. Close the vent valve at the top of the Lean Amine Filter 9103-S-11. 16. Crack open the vent valve at the top of the Activated Carbon Filter 9103-S-12. 17. Crack open the inlet isolation valve for the Activated Carbon Filter 9103-S-12 from the Lean Amine Filter 9103-S-11. 18. Fill the vessel with amine by displacing nitrogen through the vent valve at the top. 19. When the amine just starts to overflow through the vent valve, close the valve immediately. 20. Crack open the vent valve of the Fines Filter 9103-S-13 at the top. 21. Crack open the inlet isolation valve for the Fines Filter 9103-S-13 and start filling the vessel with amine. 22. The nitrogen inside the vessel is displaced through the vent and when the amine just starts to overflow through the vent immediately close the vent valve. 23. Open the outlet valve of the Fines Filter 9103-S-13 and fill the line up to the Amine Surge Tank 9103-T-11. 6.3.2.8

Lining up of Lean Amine Filters 9103-S-11/12/13

1.

Ensure that the Lean Amine Filter 9103-S-11, Activated Carbon Filter 9103-S-12 and Fines Filter 9103-S-13 are filled with the amine.

2.

Open the Lean amine Filters outlet isolation valves and line up the amine to the Amine Surge Tank 9103-T-11.

3.

Take Lean Amine Filters inlet control valve 91-FV-1507 in manual and slowly open the control valve so that the amine starts to flow through the amine filters.

4.

Slowly open the control valve till the flow measured by 91-FT-1507 reaches 155.6 m3/hr.

5.

Put the flow control valve 91-FV-1507 in auto with a set point of 155.6 m3/hr.

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6.

Check the pressure drop across the Lean Amine Filter 9103-S-11 and ensure that it is less than 0.7 barg from 91-PDT-1517.

7.

Check the pressure drop across the Activated Carbon Filter 9103-S-12 and ensure that it is less than 0.7 barg from 91-PDT-1518.

8.

Check the pressure drop across the Fines Filter 9103-S-13 and ensure that it is less than 0.7 barg from 91-PDT-1519.

6.3.2.9

Transfer of Amine from Acid Gas Amine Absorber 9103-C-11 to the Amine Regenerator 9103-C-12

1.

Ensure that all the drain valves in the Rich amine line to the Lean/Rich Amine Exchanger 9103-E-11A/B and to the Regenerator 9103-C-12 are closed.

2.

Open the suction isolation valves of Acid Gas Rich Amine Pumps 9103-P-12A/B and fill the suction lines.

3.

Prime the pumps by opening the casing vent valves of the pumps and releasing Nitrogen.

4.

Put the switch position of the Acid Gas Rich Amine Pumps 9103-P-12A/B to ‘LOCAL’ position.

5.

Ensure that the Acid Gas Rich Amine Pumps 9103-P-12A/B are energized.

6.

Line up the Rich Amine Pump 9103-P-12A minimum flow control valve 91-FV-1508 and open it manually by 50%.

7.

Start the Acid Gas Rich Amine Pump 9103-P-12A from local control station on minimum flow.

8.

Check the discharge pressure is normal at 7.50 barg from the pressure gauge 91-PG-1536.

9.

Ensure that the pump is running without any abnormal noise and vibration.

10. Open the discharge valves of the pump slowly and fill the discharge line and circulate the Rich Amine back to the Acid Gas Amine Absorber 9103-C-11 through the minimum flow line control valve 91-FV-1508. 11. Open the Rich amine to Lean/Rich Exchanger inlet isolation valves 9103-E-11A/B and fill the downstream lines and the exchanger. 12. Open the Lean Rich Exchanger outlet isolation valve and fill the downstream lines up to 91-FV-1520. 13. Take the flow control valve 91-FV-1520 in manual and open the control valve slowly and start taking level in Amine Regenerator 9103-C-12. 14. Ensure that the level is increasing in the Amine Regenerator 9103-C-12 by checking the level transmitter 91-LT-1510 and level gauge 91-1506A/B.

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15. Ensure that the Amine Regenerator 9103-C-12 low low level alarm 91-LALL-1517 is cancelled as the level rises. 16. Ensure that the Amine Regenerator 9103-C-12 low level alarm 91-LAL-1510 is cancelled as level increases. 17. When the level reaches 50%, close the flow control valve 91-FV-1520 fully and stop the Rich Amine Pump 9103-P-12A from the local control station. 18. Check the level in the Acid Gas Amine Absorber 9103-C-11 and ensure that it does not drop below 50%. 19. If the level drops below 50% in the Acid Gas Amine Absorber 9103-C-11, stop the Acid Gas Rich Amine Pump 9103-P-12A immediately. 20. Start the Lean Amine Pump 9103-P-13A and fill the Acid Gas Amine Absorber 9103-C-11 as mentioned previously. 6.3.2.10 Filling up of Lean Amine Section with Amine 1.

Ensure that the drain and vent valves of the Hot Lean Amine Pumps 9103-P-17A/B, lean amine side of the Lean/Rich Exchanger 9103-E-11A/B, Lean Amine Cooler 9103-E-14 and Lean Amine Trim Cooler 9103-E-15 are closed.

2.

Ensure that the Amine Regenerator 9103-C-12 is filled with amine upto 50% level. Check the level in 91-LT-1510 and also cross check with 91-LG-1506A/B.

3.

Open the Hot Lean Amine Pumps 9103-P-17A/B suction isolation valves slowly and fill the lines and the pumps with amine by opening the casing vent valves of the pumps and by releasing Nitrogen.

4.

Ensure that the Hot Lean Amine Pumps 9103-P-17A/B are energized in MCC.

5.

Put the LOR switch of the Hot Lean Amine Pumps 9103-P-17A/B to “LOCAL” at local control station.

6.

Ensure that the minimum flow line of the Hot Lean Amine Pumps 9103-P-17A/B is lined up and the flow control valve 91-FV-1512 is opened by 20% on manual.

7.

Start the Hot Lean Amine Pump 9103-P-17A from local control station.

8.

Ensure that the Hot Lean Amine Pump 9103-P-17A discharge pressure is normal at 6.80 barg.

9.

Ensure that the Hot Lean Amine Pump 9103-P-17A is pumping amine back to the Amine Regenerator 9103-C-12 through the minimum flow control valve 91-FV-1512.

10. Put the minimum flow control valve 91-FV-1512 in ‘Auto’ with a set point of 250 m3/hr. 11. Ensure that the Hot Lean Amine Pumps 9103-P-17A/B discharge ON-OFF valve 91-XV-1507 is opened.

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12. Open the Hot Lean Amine Pump 9103-P-17A discharge isolation valve slowly and fill the Lean/Rich Exchanger 9103-E-11A/B inlet strainer and the lean amine side of the Lean/Rich Exchanger 9103-E-11A/B. 13. Open the Lean/Rich Amine Exchanger 9103-E-11A/B outlet isolation valve and fill the outlet lines. 14. Open the Lean Amine Cooler 9103-E-14 inlet isolation valves and start filling the Exchanger. 15. Open the high point vent in the Lean Amine Cooler 9103-E-14 and release Nitrogen. 16. Close the vent valve when the amine just starts to come out of the vent valve. 17. Open the outlet isolation valve of the Lean Amine Cooler 9103-E-14 and fill the outlet lines. 18. Ensure that the Amine line from the Lean Amine Cooler 9103-E-14 outlet to the Analyzer AT-1506 isolation valve is closed. 19. Open the Lean Amine Trim Cooler 9103-E-15 inlet isolation valve and fill the Cooler with amine. 20. Ensure that the Lean Amine Trim Cooler 9103-E-15 bypass control valve 91-TV1509 is closed. 21. Open the high point vent in the Lean Amine Trim Cooler 9103-E-15 and release Nitrogen. 22. Close the high point vent isolation valve when the amine just starts to overflow. 23. Open the outlet isolation valve of the Lean Amine Trim Cooler 9103-E-15 and fill the outlet lines. 24. Check the level in the Amine Regenerator 9103-C-12 through the 91-LT-1510. If the level is less than 30%, make up the level as previously mentioned to 50%. 25. Put 91-FV-1530 in ‘Manual’ and open the control valve by 10% and line up the amine to Amine Surge Tank 9103-T-11. 26. Open the Amine Surge Tank inlet isolation valve and line up lean amine to Amine Surge Tank 9103-T-11. 27. Stop the Hot Lean Amine Pump 9103-P-17A from the local control station. 6.3.2.11 Establishing Amine Circulation in the System 1.

Ensure that Amine Surge Tank 9103-T-11 is having more than 50% level. If not then make up the tank from road tankers as mentioned previously.

2.

Ensure that the Lean Amine Pump 9103-P-13A/B suction, discharge and minimum flow lines are lined up.

3.

Put the LOR switch of the Lean Amine Pump in ‘Remote’.

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4.

Start the Lean Amine Pump 9103-P-13A from ICSS and put 9103-P-13B in AUTO.

5.

Open the minimum flow control valve 91-FV-1511 in manual and adjust the valve opening to ensure a minimum flow of 375 m3/Hr.

6.

Now put the minimum flow control valve in auto with a set point of 375 m3/hr.

7.

Reset Process Shutdown and ensure that the Acid Gas Amine Absorber 9103-C-11 inlet ON-OFF valve 91-XV-1504 is opened.

8.

Open the Lean Amine Pump 9103-P-13A/B discharge valve to the Acid Gas Amine Absorber 9103-C-11.

9.

Open the Acid Gas Amine Absorber 9103-C-11 inlet flow control valve 91-FV-1501 in manual by 10%.

10. Ensure that the level in Acid Gas Amine Absorber 9103-C-11 is rising by checking the level transmitter 91-LT-1505. 11. Ensure that the Acid Gas Rich Amine Pumps 9103-P-12A/B suction, discharge and minimum flow isolation valves are lined up and the pumps are primed. 12. Put the Acid Gas Rich Amine Pumps 9103-P-12A/B LOR switch in ‘Remote’ and start the pump 9103-P-12A from ICSS and put the pump 9103-P-12B in AUTO. 13. Open the minimum flow control valve 91-FV-1508 in manual and adjust the valve opening to get a flow of 375 m3/hr. 14. Take the minimum flow control valve 91-FV-1508 in Auto with a set point of 375 m3/hr. 15. Ensure that the Rich Amine to the Amine Regenerator 9103-C-12 isolation valves are lined up. 16. Open the Amine Regenerator inlet control valve 91-FV-1520 to 10% in manual. 17. Ensure that the level in the Amine Regenerator started to rise through 91-LT-1510. 18. Ensure that the suction, discharge and the minimum flow lines are lined up. 19. Put the LOR switch of the Hot Lean Amine Pumps 9103-P-17A/B in ‘Remote’ and start the pump 9103-P-17A from ICSS and put the pump 9103-P-17B in AUTO. 20. Open the minimum flow control valve 91-FV-1512 in manual and adjust the control valve opening to get a minimum flow of 250 m3/hr. 21. Put the control valve 91-FV-1512 in auto with a set point of 250 m3/hr. 22. Ensure that the Hot Lean Amine Pumps 9103-P-17A/B discharge ON-OFF valve 91-XV-1507 is open. 23. Line up the Hot Lean Amine Pumps discharge to the Lean/Rich Amine Exchanger 9103-E-11, Lean Amine Cooler 9103-E-14, Lean Amine Trim Cooler 9103-E-15 and the Amine Surge Tank 9103-T-11.

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24. Slowly increase the flow rate from the Lean Amine Surge Tank 9103-T-11 to the Acid Gas Amine Absorber 9103-C-11 by opening the control valve 91-FV-1501 to 487 m3/hr. 25. Ensure that the minimum flow control valve of the Lean Amine Pumps 9103-P13A/B is closed. 26. Correspondingly to maintain level in the Acid Gas Amine Absorber, open the flow Control valve 91-FV-1520 manually till the level is maintaining. Now put the flow control valve in auto with a set point of 487 m3/hr. 27. Ensure that the minimum flow control valve 91-FV-1508 of the Acid Gas Rich Amine Pumps 9103-P-12A/B is closed. 28. To maintain the level in the Amine Regenerator 9103-C-12, open the flow control valve 91-FV-1530 slowly till the level in the Regenerator is maintaining. 29. Put flow control valve 91-FV-1530 in auto with a set point of 487 m3/hr. 30. Ensure that the minimum flow control valve 91-FV-1512 of the Hot Lean Amine Pumps 9103-P-17A/B is closed. 31. Open the Sea Cooling water inlet isolation valve of the Lean Amine Trim Cooler 9103-E-15 and fill the cooler. 32. Open the Sea Cooling water outlet isolation valve and establish the cooling water flow. 33. Ensure that the temperature control valve 91-TV-1509 of the lean amine in the Lean Amine Trim Cooler 9103-E-15 is closed. 34. Ensure that the temperature control valve 91-TV-1513 of the lean amine in the Lean/Rich Exchanger 9103-E-11A/B is closed. 6.3.2.12 Lining up of Regenerator Overhead System 1.

Ensure that the drain and vent isolation valves in the Regenerator overhead system are closed.

2.

Ensure that the Regenerator overhead 91-PSV-1508 isolation valves are lined up, 91-PSV-1509 upstream isolation valve is closed and the bypass valves are closed.

3.

Ensure that the Regenerator Condenser Cooler 9103-E-12 inlet and outlet isolation valves are lined up and the vent and drain valves are closed.

4.

Ensure that the Regenerator Condenser Trim Cooler 9103-E-16 inlet and outlet isolation valves are lined up and the vent and drain valves are closed.

5.

Ensure that the Regenerator Reflux Drum 9103-V-12 drain and vent valves are closed.

6.

Ensure that the Regenerator Reflux Drum 9103-V-12 pressure control valves 91-PV1503A/B are lined up and they are in closed condition.

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7.

Ensure that the Regenerator Reflux Drum 9103-V-12 acid gas to Acid Gas KO Drum 9101-V-04 line ON-OFF valve XV-1516 is open.

8.

Put the Regenerator Reflux Drum 9103-V-12 pressure controller 91-PIC-1503 in Auto with a set point of 1.0 barg and the pressure control valves 91-PV-1503A/B in Remote.

9.

Line up DM water to the Regenerator Reflux Drum 9103-V-12 by opening the flow control valve 91-FV-1521 manually.

10. Check that the level in the Regenerator Reflux Drum 9103-V-12 is increasing by checking the level gauge 91-LG-1502 and 91-LT-1506. 11. When the level in the Regenerator Reflux Drum 9103-V-12 is around 40% close the DM water make up and the flow control valve 91-FV-1521. 12. Start the Regenerator Condenser Cooler fans 9103-EM-12AA/AB/AC/BA/BB/BC/ CA/CB/CC/DA/DB/DC. 13. Line up sea cooling water to the Regenerator Condenser Trim Cooler 9103-E-16 by opening the inlet and outlet isolation valves. 14. Line up the Regenerator Condenser Trim Cooler 9103-E-16 temperature control valve 91-TV-1509 and put it on Auto with a set point of 49°C. 6.3.2.13 Lining up of Regenerator Reboiler 9103-E-13 System 1.

Ensure that the Regenerator Reboiler 9103-E-13 is filled with amine solution by checking the level gauge 91-LG-1503.

2.

Open the drain valve upstream of Reboiler steam inlet ON-OFF valve 91-XV-1505 and drain all the condensate.

3.

Warm up the steam line upstream of Reboiler steam inlet ON-OFF valve 91-XV1505 till there is full fledged steam coming out from the drain valve.

4.

Close the drain valve. Open the drain valve downstream of the Reboiler steam inlet ON-OFF valve 91-XV-1505 and drain all the condensate.

5.

Reset Process shutdown and ensure that Reboiler steam inlet ON-OFF valve 91-XV1505 is open.

6.

Open the bypass valves of the Reboiler Steam inlet flow control valve 91-FV-1503 and start warming up the steam lines and Reboiler tubes.

7.

Ensure that Regenerator Reboiler Condensate Pot 9103-V-13 is also being warmed up through the equalisation line.

8.

Open the drain valve in the condensate outlet line of the Regenerator Reboiler Condensate Pot 9103-V-13.

9.

When all the condensate is drained and steam is coming out of the drain, close the drain valve.

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10. Open the Reboiler condensate outlet line drain valve and drain all the condensate. 11. Warm up the Reboiler tubes till hot condensate comes out of the drain line. 12. Open the Reboiler steam inlet flow control valve 91-FV-1503 by 5% and heat the Reboiler amine solution. 13. Close the drain line valve and allow the condensate level to be built up in the Regenerator Reboiler Condensate Pot 9103-V-13. 14. Ensure that the level is building up in the Regenerator Reboiler Condensate Pot 9103-V-13 by checking the level gauge 91-LG-1504A/B. 15. Ensure that low level alarm 91-LAL-1508 is cancelled in the Pot. 16. Line up Regenerator Reboiler Condensate Pot 9103-V-13 condensate outlet line level control valve 91-LV-1508 and put the controller in auto with a set point of 50%. 17. Ensure that the level in Regenerator Reboiler Condensate Pot 9103-V-13 is maintained at 50%. 18. Gradually increase the opening of the steam inlet control valve 91-FV-1503 and heat the amine solution at a rate of 25°C/hr till the Regenerator bottom temperature reaches 130°C. 19. Put the Reboiler steam inlet flow controller 91-FIC-1503 in “Remote” and enter the ratio of steam to rich amine at 118.5 in the ratio controller 91-HIC-1503 and take the ratio controller in Auto. 20. Put the Regenerator top temperature controller 91-TIC-1510 in Auto with a set point of 118°C. 21. Line up the Regenerator Reflux Drum Pumps 9103-P-11A/B by opening the suction and discharge valves and priming the pumps by opening the casing vent and releasing Nitrogen. 22. Ensure that the Regenerator Reflux Drum Pumps 9103-P-11A/B discharge to the Waste Water Degasser is isolated. 23. Ensure that the Regenerator Reflux Drum Pumps 9103-P-11A/B minimum flow line control valve FV-1505 is lined up. 24. Put the minimum flow controller 91-FIC-1505 in Auto with a set point of 20 m3/hr. 25. Put the LOR switch of the Regenerator Reflux Drum Pumps 9103-P-11A/B in ‘Remote’ position. 26. Start the Regenerator Reflux Drum Pumps 9103-P-11A from the ICSS and put 9103-P-11B in AUTO. 27. Line up the reflux from the Regenerator Reflux Drum Pumps 9103-P-11A to the Regenerator 9103-C-12 by lining up the control valve 91-FV-1531.

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28. Put the level controller 91-LIC-1506 of the Regenerator Reflux Drum 9103-V-12 in Auto with a set point of 50%. 29. Put the reflux flow control valve 91-FV-1531 in remote mode. 30. Ensure that the top temperature of the Regenerator is being maintained at around 118°C. 6.3.2.14 Lining up of Acid Gas to the Acid Gas Amine Absorber 1.

Ensure that the vent and drain valves in the Acid Gas Coolers 9103-E-101A/B, Lean Acid Gas KO Drum 9103-V-14, Acid Gas KO Drum Return Pumps 9103-P-14A/B are closed.

2.

Ensure that the sea cooling water to Acid Gas Coolers 9103-E-101A/B inlet filter elements are fixed and boxed up.

3.

Open the Sea Cooling water inlet and outlet isolation valves and line up sea cooling water to Acid Gas Coolers 9103-E-101A/B.

4.

Ensure that the 91-VRV-1577 upstream isolation valve is lined up in the sea cooling water inlet of Acid Gas Coolers 9103-E-101A/B.

5.

Ensure that the 91-VRV-1578 upstream isolation valve is lined up in the sea cooling water outlet of Acid Gas Coolers 9103-E-101A/B.

6.

Ensure that the 91-TSV-1501 upstream isolation valve is opened & 91-TSV-1502 upstream isolation valve is closed in the sea cooling water outlet of Acid Gas Coolers 9103-E-101A/B.

7.

Ensure that the 91-PSV-1501 in Lean Acid Gas KO Drum 9103-V-14 isolation valves is opened, 91-PSV-1502 upstream isolation valves are closed and the bypass valves are closed.

8.

Reset Process shutdown from ICSS.

9.

Ensure that Acid Gas inlet ON-OFF valve 91-XV-1501 is opened to the Acid Gas Cooler 9103-E-101A/B and the ON-OFF valve 91-XV-1502 to the Acid Gas Flare Header is closed.

10. Open the isolation valves downstream of ON-OFF valve 91-XV-1502 and lock the valves in open position. 11. Open the isolation valve upstream of ON-OFF valve 91-XV-1501 and lock the valve in open position. 12. Line up pressure control valve 91-PV-1502 of the Acid Gas Amine Absorber 9103-C11 and take the pressure controller 91-PIC-1502 in Auto with a set point of 0.2 barg. 13. Ensure that the 91-PSV-1503 in Acid Gas Amine Absorber 9103-C-11 isolation valves are lined up and the PSV-1504 upstream isolation valves are closed and the bypass valves are closed.

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14. Inform AGRU 1 & 2 (Existing units) to line up Acid Gas to AGEU. 15. Open the isolation valves of the Acid Gas line to AGEU in the battery limit slowly and admit acid gas into the Acid Gas Coolers 9103-E-101A/B. 16. Ensure that the temperature of the acid gas at the outlet of the acid gas coolers is 53°C by checking the temperature indicator 91-TI-1501. 17. When there is an increase in the level of the Lean Acid Gas KO Drum which is read from the LG-1501A/B & LT-1501, Line up Acid Gas KO Drum Return Pumps 9103-P14A/B. 18. Open the suction isolation valves of the Acid Gas KO Drum Return Pumps 9103-P14A/B and prime the pumps by opening the casing vents and releasing Nitrogen. 19. Reset process shutdown and ensure that the ON-OFF valve 91-XV-1503 in the pump discharge is open. 20. Ensure that the pumps 9103-P-14A/B discharge to the Sour Water Stripper 6922-C01 is isolated. 21. Put the LOR switch of the pumps in ‘Remote’ and start the pump 9103-P-14A from ICSS and put pump 9103-P-14B in AUTO. 22. Open the pump discharge valves and then open LV-1501 gradually. 23. Put the Lean Acid Gas KO Drum level controller 91-LIC-1501in auto with a set point of 50%. 24. Put the lean amine flow control valve 91-FV-1501 to the Acid Gas Amine Absorber 9103-C-11 in ratio control with the acid gas feed. 25. Check the Incinerator 9101-F-14 performance as acid gas is routed to it from the Acid Gas Amine Absorber. 26. Open 91-PV-1503A in manual and route acid gases from Regenerator Reflux Drum 9103-V-12 to flare. Keep 91-PV-1503B closed in manual. 27. When the acid gases produced from Regenerator is stabilized, put the pressure controller 91-PIC-1503 in Auto with a set point of 1.0 barg. 28. Check the differential pressure 91-PDT-1522 in the Acid Gas Amine Absorber and 91-PDT-1523 in the Amine Regenerator 9103-C-12. If the differential pressures shows increasing trend then antifoam has to be dosed to amine feed to that tower. 29. After stabilising the plant, inform NGL-1/2/4 to line up acid gases one by one.

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6.3.3

Start-Up of Sulphur Recovery Unit The first start-up of the SRU following a major overhaul may be carried out independent of the TGTU BSR Section. In this case the SRU tail gases will be routed to the Incinerator and closed to the TGTU. The start-up of sulphur recovery unit involves the following activities: 1.

Confirm LP heating steam is in service to all sulphur lines, Sulphur Degassing Pit 9101-T-01/01B heating coils and trace heating lines.

2.

Confirm acid gas shutdown valve 9103-XV-1516 from the upstream amine Regenerator Reflux Drum 9103-V-12 to the Acid Gas KO Drum 9101-V-04 is closed.

3.

Confirm that the SRU tail gas ON/OFF valve 91-XV-1097 from the Final Separator 9101-V-05 to the Incinerator 9101-F-14 is open.

4.

Confirm that the SRU tail gas ON/OFF valve 9101-XV-1098 from Final Separator 9101-V-05 to the Tail Gas Treatment Unit is closed.

5.

Introduce BFW to the SRU Reaction Furnace Boiler 9101-E-07 Steam Drum 9101-V07 and establish a normal operating water level in the vessel.

6.

Introduce BFW through the BFW Preheater and establish normal operating levels in the Last Condenser, Reaction Furnace Condenser 9101-E-01 and 1st Stage Condenser 9101-E-02.

7.

Now Reaction Furnace burner to be started to heat up the system.

6.3.3.1

Start-up of Reaction Furnace (9101-F-01) Burner

Reaction Furnace-BMS sequence The burner management system of Reaction Furnace is incorporated in ESD system. Reaction furnace LCP 9101-F-01–LP-005 hand switches detail is tabulated below: Sl. #

Tag No.

Description

1.

91-HS-1211

Start purge

2.

91-HS-1212

Start ignition

3.

91-HS-1213

Emergency shutdown

4.

91-HS-1214

Lamp test

Reaction Furnace 9101-F-01 hardwired auxiliary console hand switches detail is tabulated below: Sl. #

Tag No.

Description

1.

91-HS-1217

Acid gas ON/OFF

2.

91-HS-1218

Fuel gas ON/OFF

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Reaction furnace LCP 9101-F-01–LP-005 lamp indication detail is tabulated below: Sl. #

Tag No.

Description

1.

91-XA-1211

Reaction furnace burner shutdown

2.

91-XL-1212

Ready for purge

3.

91-XL-1213

Purge ON

4.

91-XL-1214

Ready for ignition

5.

91-XL-1215

Ignition ON

6.

91-XL-1216

Fuel gas ON

7.

91-XL-1217

Acid gas ON

8.

91-BAL-1055A

Flame-1 ON

9.

91-BAL-1055B

Flame-2 ON

Reaction Furnace 9101-F-01 soft pushbutton details in DCS is tabulated below: Sl. #

Tag No.

Description

1.

91-HS-1216

Quench steam valve 91-XV-1078 ON/OFF

2.

91-HS-1040

Quench steam valve 91-XV-1079 ON/OFF

3.

91-HS-1219

Nitrogen valve ON/OFF switch

4.

91-HS-1220

System reset

5.

91-HS-1017

Start-up bypass for 91-PALL-1025

Control valve/ON-OFF valve details are tabulated below: Sl. #

Tag No.

Description

1.

91-XV-1048

Fuel gas shut-off valve-1

2.

91-XV-1099

Fuel gas shut-off valve-2

3.

91-XV-1100

Fuel gas vent valve

4.

91-FV-1009

Fuel gas flow control valve

5.

91-XV-1001

Acid gas shut-off valve

6.

91-XV-1102

Acid gas shut-off valve

7.

91-XV-1110

Nitrogen shut-off valve

8.

91-XV-1127

Nitrogen shut-off valve

9.

91-XV-1101

Main combustion air shut-off valve

10.

91-FV-1002

Combustion air control valve

11.

91-FV-1002B

Secondary air control valve

12.

91-FV-1003

Make-up air control valve

13.

91-XV-1078

Quench steam ON/OFF valve

14.

91-XV-1079

Quench steam ON/OFF valve

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The burner light-on is carried out in three steps: i.

System reset

ii.

Pre-ignition purge

iii.

Fuel gas burner light-on

i.

System Reset

1.

Check the following shutdown interlocks are absent in the ICSS:

Sl. #

Tag No.

Description

1.

91-HS-1012A

Reaction furnace ESD pushbutton (CCR)

2.

91-HS-1213

Reaction furnace ESD pushbutton (LCP)

3.

65-XS-1008

AGR shutdown

4.

91-BSL-1055A/B

Flame failure of reaction furnace (2oo2)

5.

65-HS-001

General plant shutdown activation (existing)

6.

65-XA-1001

Existing SRU shutdown

7.

91-TT-1050

Rupture pin failure

8.

65-XS-1024

Total power Shutdown

9.

65-PT-1003A/B/C

Instrument air pressure low-low

10.

65-XS-1015

Steam pressure failure (low low pressure)

11.

91-HS-1011

Unit-91 general shutdown button

12.

91-XS-1901

Confirmed gas detection

13.

65-XS-1020

Fuel gas low-low pressure

14.

91-LT-1003

Acid gas KOD (9101-V-04) high-high level

15.

91-LT-1006

Steam drum (9101-V-07) low-low level

16.

91-LT-1009

RF condenser (9101-E-01) low-low level

17.

91-LT-1012

1st condenser (9101-E-02) low-low level

18.

91-PT-1025

Acid gas inlet low-low pressure

19.

91-XS-1063/1064

Blowers (9101-K-01A/B) are not running

20.

91-PT-1054A/B/C

Air for acid gas burner high-high pressure

21.

91-FT-1140

Acid gas to reaction furnace low-low flow

22.

91-FT-1129

Process air to acid gas burner flow low-low

23.

91-FT-1130

Fuel gas to reaction furnace flow low-low

If the above conditions do not exist, the Reaction furnace BMS system can be reset. When the BMS reset is pressed, following shutdown causes are automatically bypassed during start-up: a.

91-FT-1129 (Combustion Air low-low flow)

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b.

91-FT-1130 (Fuel gas to reaction furnace low-low)

c.

91-FT-1140 (Acid gas to reaction furnace low-low)

d.

91-BSL-1055A/B (Flame detector signal)

e.

91-PT-1025 (Acid gas I/L pressure low-low)

2. Start any one of Process Air Blower 9101-K-01A & 9101-K-01B. 3. The following conditions are to be satisfied for the pre-ignition purge: a.

No flame present – 91-BSL-1055A/91-BSL-1055B.

b.

Fuel Gas cut-in valve XV-1048 is in close position – 91-ZSC-1048.

c.

Fuel Gas cut in valve XV-1099 is in close position - 91-ZSC-1099.

d.

Fuel Gas vent valve XV-1100 is in open position - 91-ZSO-1100.

e.

Ensure “READY FOR RESET” (91-XL-1218) is lit in ICSS.

4. RESET the system by pressing the Soft switch 91-HS-1220 from DCS and ensure the following: a.

Energizing of combustion air control valve SOV 91-FY-1002B and 91-FY-1002.

b.

Process air flow controller 91-FIC-1002, 91-FIC-1002B to manual mode and output at start position.

c.

Fuel gas flow controller 91-FRC-1009 to manual mode and output at start position.

d.

“READY FOR PURGE” lamp (91-XL-1212) is lit on the local panel and also in ICSS.

e.

“SYSTEM IN SHUTDOWN” lamp 91-XA-1211 will extinguish on the LCP and ICSS.

ii. Pre-ignition Purge 1.

Ensure the control valves for combustion air 91-FV-1002, fuel gas control valve 91-FV-1009 and steam valves are in start position at the ICSS and in field.

2.

Press the start purge button 91-HS-1211 at the local control panel.

3.

Ensure the “SYSTEM READY FOR PURGE” is unlit.

4.

Ensure that the Nitrogen shutdown valve 91-XV-1127 for furnace purging and 91XV-1110 for flame scanner, sight glass purging are opened.

5.

Ensure that main Process air shutdown valve 91-XV-1101 is closed.

6.

Verify whether the ‘PURGE ON’ lamp 91-XL-1213 is lit for 20 minutes (purge timer) in the Local Control Panel.

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7.

After the purge time is over, ensure that the ‘PURGE ON’ lamp 91-XL-1213 is unlit in the Local Control Panel.

8.

Ensure that ‘PURGE COMPLETE’ lamp 91-XL-1219 is lit on the ICSS.

9.

Ensure the “READY FOR IGNITION” lamp 91-XL-1214 is lit on local panel.

10. Ensure that the Nitrogen cut-in valve 91-XV-1127 is closed. iii. Fuel Gas Burner Light On 1.

Ensure that the air inlets, burner and outlet passages are boxed up and free of foreign material.

2.

Ensure that all personnel have been evacuated from the reaction furnace area, ductwork and associated equipment and all access and inspecting doors closed and sealed.

3.

Ensure that the Process Air Blower 9101-K-01A/B is running.

4.

Ensure that all safety shut off valves are closed.

5.

Ensure that the Fuel System vents are open and venting to atmosphere. Lines are properly drained and cleared of condensate.

6.

Ensure that a complete functional check of the safety interlocks has been made.

7.

Ensure that the area is clear of obvious safety hazards and flammable gases are not present in the area.

8.

Ensure that all lines have been blown down with plant air to insure they are free of debris that might plug metering orifices and burner tips.

9.

Ensure that utilities like fuel gas, instrument air, nitrogen and plant air are available and initial operational checks performed on the elements in each line.

10. Ensure that the burner elements are in their proper position. 11. Ensure that power has been supplied to control systems and to safety interlocks. 12. Ensure that the gauges indicating fuel header pressure to the unit are functional. 13. Ensure that the pressure self regulating valves are set according to the instrument data sheets. 14. Ensure that the isolation valves for all the pressure gauges and pressure transmitters are open and their respective bleed valves are closed. Valves are sealed in position as indicated on P&IDs. 15. Ensure that the minimum purge period is satisfactorily completed. 16. Ensure that the control valves of the fuel gas 91-FV-1009, quench steam 91-XV1078, 91-XV-1079 and Combustion Air 91-FV-1002 are closed. 17. Ensure that the igniter is in the correct position and that the fuel gas gun is ready for operation with fuel gas.

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18. Open the fuel gas control valve 91-FV-1009 and combustion air control valve 91-FV-1002B to the pre-determined position. 19. Press the ‘START IGNITION’ push button 91-HS-1212 from the local control panel. 20. Ensure that ‘READY FOR IGNITION’ lamp 91-XL-1214 is unlit. 21. Ensure that the igniters insert SOV 91-XY-1103 is energised. 22. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1103. 23. Ensure the Process air shutdown valve 91-XV-1101 is opened. 24. Ensure fuel gas bleed valve 91-XV-1100 is closed and fuel gas shutdown valves 91-XV-1048 and 91-XV-1099 are opened. 25. Ensure that the igniter transformer is energised for 10 seconds and sparking begins. 26. Ensure that the igniter transformer is de-energised and igniter retracts automatically (91-ZSO-1103) after 10 seconds of ignition timer. 27. If flame is detected then ensure that the ‘FLAME ON’ lamps (91-BAL-1055A, 91-BAL-1055B) are lit on the local control panel. 28. Permit is provided to open the steam quench shutdown valve 91-XV-1078 and 91-XV-1079 from ICSS soft switches. 29. Permit is provided to open the acid gas shutdown valve 91-XV-1102. 30. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1216, 91-XL-1216A is lit in the Local Control Panel and ICSS respectively. 31. Open the instrument air purge valve to sight glasses, flame scanners and nozzles. 32. Ensure that the Nitrogen purge valve to sight glasses, flame scanners and nozzles is closed.

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Fig. 29 – Reaction Furnace Start-up Start

A &

Note A

B

Note B Ready for Reset XL-1218 ON

Y

Purge completed

Acid gas cut-off valves XV-1102, XV1001 and XV-1516 opens

Purge complete XL-1219

System Reset HS-1220

Acid gas XL-1217 ON Nitrogen SDV-XV-1127 close

Automatic bypass of combustion air flow (FT-1129), fuel gas flow (FT-1130), acid gas flow (FT-1128) low low alarm and acid gas inlet pressure (PT-1025) low low alarm

Ready for ignition XL-1214 Start Ignition-HS1212

Furnace is fully operational

Burner light on timer 10 min starts

Force combustion air FIC1002 and fuel gas FIC-1009 controllers to manual mode and output to minimum 10% System ready for purge XL1401 Purge start-HS1211

Common alarm XL1405

Nitrogen SDV-XV-1127, XV-1110 open

· Igniter insert SOV XY-1103 energized · combustion air XV-1101 opens · Fuel gas vent valve XV-1100 closes · Fuel gas block valves XV-1048 and XBV-1099 opens · Igniter transformer energized for 10 seconds

Purge timer 20min starts Purge ON XL-1213 Nitrogen flow alarm FAL-1131 Should be healthy within 15 sec

Flame detected on 1oo2 logic

N

N Y

BAL-1055A, BAL-1055B ON Fuel Gas XL-1216 ON Quench Steam StartHS-1216, HS-1040

Y

XV-1078, XV-1079 open Purge interlocks are healthy till purge timer completes

N

Following causes should be healthy: · ESD push button in CCR-HS-1012A · ESD push button HS-1213 in LCP · General plant shutdown activation 65-HS-001 · Existing SRU shutdown 65-XA-1001 · Total power shutdown 65-XS-1024 · Instrument air LL pressure 65-PT-1003A/B/C · BFW/steam failure 65-XS-1015 · Unit 91 General shutdown 91-HS-1011 · Confirmed gas detection 91-XS-1901 · Fuel gas LL pressure 65-XS-1020 · Acid gas KOD HH level 91-LT-1003 · Steam drum level low low 91-LT-1006 · Furnace condenser level low low 91-LT-1009 · 1st Condenser level low low 91-LT-1012 · Both blowers (9101-K-01A/B) are not running (91-XS-1063/1064) · Air pressure Hi Hi 91-PT-1054A/B/C · Process air flow low low 91-FT-1129 · Acid gas inlet pressure low low 91-PT-1025 · Fuel gas flow low low 91-FT-1130 · Acid gas flow low low 91-FT-1128 · AGR Shutdown 65-XS-1008

Acid Gas Start-HS1217 Light ON timer out XL-1406

Y B A

Gradually open acid gas control valve 91-FV-1503B and close fuel gas control valve 91-FV-1009 close

Following are the permissives for purging: · No flame detection by BSL-1055A/B · FG Block valve XV-1048 in close position · FG Block valve XV-1099 in close position · FG Vent valve XV-1100 in open position

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6.3.3.2

Heating Up the System

1. Take fuel gas controller 91-FIC-1009 in manual and slowly increase the fuel gas to Reaction Furnace. 2. Take the combustion air controller 91-FIC-1002/91-FIC-1002B in manual and increase the combustion air to the Reaction Furnace. 3. Proceed to heat up the Reaction Furnace at 50°C/hr Note 1) If the converters have been filled with catalyst following the unit’s precommissioning refractory dry out phase, then for the first start-up of the unit, the rate of temperature increase of the process air must be initially controlled to slowly heat up the converters at 10-15°C/hr to 90°C to ensure any free water and moisture is removed in the converters catalyst beds. In this case the introduction of BFW to the steam generators will be delayed until the converters catalyst beds are first heated through to 90°C. 2) As the SRU process gas system and the SRU converters does not contain sulphur compounds at this time, firing of fuel gas in the Reaction Furnace burner may be carried out in excess air conditions. 4. Open LP steam shutdown valve 91-XV-1079 to the Reaction Furnace. 5. To suppress the formation of carbon and soot at stoichiometric firing conditions, introduce LP steam to the SRU Reaction Furnace burner fuel gas line when a temperature of >300°C is seen in the Reaction Furnace and the SRU converters are heated through to >120°C. Set the steam flow in the ratio of 1:1 (by wt.) of fuel gas. Note that the furnace temperature will dictate the amount of steam used. Too much steam could result in interference of the burners flame detectors resulting in a burner trip. Before opening steam valves ensure steam lines are fully drained of condensate. 6. Continue to heat up the Reaction Furnace at 50°C/hr 7. When steam blows from the SRU Reaction Furnace Boiler 9101-E-07 atmospheric vent, set Reaction Furnace Boiler pressure controller 91-PV-1003 in automatic mode at 24.0 barg and route excess steam to the LP steam system. 8. Using the MS steam produced in the SRU Reaction Furnace Boiler, heat the Process Air Pre-heater 9101-E-05 outlet process air temperature at 50°C/hr to 210°C 9. When steam emits from each LP Steam Generator 9101-E-01/9101-E-02 atmospheric vents, close vents and route excess steam to the LP steam system. 10. Open LP steam to 9101-E-08 and start heating the BFW to 120°C. 11. Now the 1st Stage Auxiliary Burner 9101-F-02 and the 2nd Stage Auxiliary Burner 9101-F-03 to be started to heat up the converters up to their normal operating temperatures.

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TITLE: OPERATION AND MAINTENANCE MANUAL

6.3.3.3

1st Stage Auxiliary Burner 9101-F-02 Start-up

1st Stage Auxiliary Burner - BMS Sequence The burner management system of 1st Stage Auxiliary Burner is incorporated in ESD system. 1st stage auxiliary burner LCP 9101-F-102 –LP-006 hand switches detail is tabulated below: Sl. #

Tag No.

Description

1.

91-HS-1226

Start burner

2.

91-HS-1227

Stop burner

3.

91-HS-1228

Lamp test

1st stage auxiliary burner 9101-F-02 hardwired aux console hand switches detail is tabulated below: Sl. #

Tag No.

Description

1.

91-HS-1223

Acid gas ON/OFF

2.

91-HS-1224

Fuel gas ON/OFF

1st stage auxiliary burner LCP 9101-F-102–LP-006 lamp indication detail is tabulated below: Sl. #

Tag No.

Description st

1.

91-XA-1226

1 stage burner shutdown

2.

91-XL-1227

Ready for ignition

3.

91-XL-1228

Ignition ON

4.

91-XL-1229

Fuel gas ON

5.

91-XL-1230

Acid gas ON

6.

91-BAL-1003A

Flame-1 ON

7.

91-BAL-1003B

Flame-2 ON

System Reset to be done by activating the soft push button 91-HS-1225 in DCS. Control valve/ON-OFF valve details are tabulated below: Tag No.

Sl. #

Description

1.

91-XV-1028

Fuel gas block valve-1

2.

91-XV-1131

Fuel gas block valve-2

3.

91-XV-1132

Fuel gas vent valve

4.

91-FV-1018

Process air control valve

5.

91-FV-1019

Acid gas control valve

6.

91-FV-1020

Fuel gas control valve

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TITLE: OPERATION AND MAINTENANCE MANUAL

The burner light-on is carried out in below steps: i.

System Reset

ii.

Fuel Gas Burner Light-On

iii.

Acid Gas Introduction

i.

System Reset

1.

Check the following shutdown interlocks are absent in the ICSS: •

Reaction furnace shutdown

•

1st stage auxiliary burner flame failure (91-BALL-1003A/B)

•

Acid gas flow low-low (91-FT-1134)

•

Fuel gas flow low-low (91-FT-1135)

•

Combustion air flow low-low (91-FT-1133)

If the above conditions do not exist, the 1st stage auxiliary burner BMS system can be reset. 2. When the BMS reset is pressed, following shutdown causes are automatically bypassed during start-up (start-up override) a.

91-FT-1133 (Combustion Air low-low flow)

b.

91-FT-1135 (Fuel gas flow low-low)

c.

91-FT-1134 (Acid gas flow low-low)

3. Ensure that any one of Process Air Blower 9101-K-01A & 9101-K-01B is started and running. 4. If the above conditions are satisfied then ensure “1st STAGE BURNER READY FOR RESET” (91-XL-1232) is lit in ICSS. 5. RESET the system by pressing the Soft switch 91-HS-1225 from ICSS and ensure the following: a.

Energizing of fuel gas control valve SOV 91-FY-1020.

b.

Combustion air flow controller 91-FIC-1018 to manual mode and output at start position.

c.

Fuel gas flow controller 91-FIC-1020 to manual mode and output at start position.

d.

“READY FOR IGNITION” lamp 91-XL-1227 and 91-XL-1227A is lit on the local panel and also in ICSS respectively.

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e.

“SYSTEM IN SHUTDOWN” lamp 91-XA-1226 and 91-XA-1226A will extinguish on the LCP and ICSS, respectively.

ii. Fuel Gas Burner Light On 1.

Ensure that the air inlets, burner and outlet passages are boxed up and free of foreign material.

2.

Ensure that all safety shut off valves are closed.

3.

Ensure that the Fuel System vents are open and venting to atmosphere. Lines are properly drained and cleared of condensate.

4.

Ensure that a complete functional check of the safety interlocks has been made.

5.

Ensure that the area is clear of obvious safety hazards and flammable gases are not present in the area.

6.

Ensure that all lines have been blown down with plant air to insure they are free of debris that might plug metering orifices and burner tips.

7.

Ensure that utilities like fuel gas, instrument air, plant air and nitrogen are available and initial operational checks performed on the elements in each line.

8.

Ensure that the burner elements are in their proper position.

9.

Ensure that power has been supplied to control systems and to safety interlocks.

10. Ensure that the gauges indicating fuel header pressure to the unit are functional. 11. Ensure that the pressure self regulating valves are set according to the instrument data sheets. 12. Ensure that the isolation valves for all the pressure gauges and pressure transmitters are open and their respective bleed valves are closed. Valves are sealed in position as indicated on P&IDs. 13. Ensure that the minimum purge period is satisfactorily completed. 14. Ensure that the control valves of the fuel gas 91-FV-1020, quench steam and Combustion Air 91-FV-1018 are closed. 15. Ensure that the igniter is in the correct position and that the fuel gas gun is ready for operation with fuel gas. 16. Open the fuel gas control valve 91-FV-1020 and Process air control valve 91-FV1018 to the pre-determined position. 17. Press the ‘START IGNITION’ push button 91-HS-1226 from the local control panel. 18. Ensure that ‘READY FOR IGNITION’ lamp 91-XL-1227 is unlit on the local control panel and 91-XL-1227A is unlit on the ICSS. 19. Ensure “IGNITION ON” 91-XL-1288A lamp lit in ICSS and 91-XL-1228 lamp in Local panel.

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TITLE: OPERATION AND MAINTENANCE MANUAL

20. Ensure “Ist STAGE BURNER IN SHUTDOWN” 91-XA-1126 lamp extinguished in Local panel and 91-XA-1126A lamp extinguished in ICSS. 21. Ensure combustion air control valve SOV 91-FY-1018 energized. 22. Ensure Combustion air flow controller 91-FIC-1018 and fuel gas controller 91-FIC1020 to manual mode and output forced to start position at 10% 23. Ensure that the igniters insert SOV 91-XY-1234 is energised. 24. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1234. 25. Ensure fuel gas bleed valve 91-XV-1132 is closed and fuel gas shutdown valves 91-XV-1028 and 91-XV-1131 are opened. 26. Ensure that the igniter transformer is energised for 10 seconds and sparking begins. 27. Ensure that the igniter transformer is de-energised and Igniter retracts automatically (91-ZSO-1234) after 10 seconds ignition timer. 28. If flame is detected then ensure that the ‘FLAME ON’ lamp 91-BAL-1003A, 91-BAL1003B) are lit on the local control panel. 29. Permit is provided to open the steam quench valve. 30. Permit is provided to open the acid gas control valve 91-FV-1019. 31. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1229 is lit in the Local Control Panel. 32. Ensure combustion air controller 91-FIC-1018 and fuel gas controller 91-FIC-1020 force signal removed. 33. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1229A is lit in ICSS. 34. Open the instrument air purge valve to sight glasses, flame scanners and nozzles is opened. 35. Ensure that the Nitrogen purge valve to sight glasses, flame scanners and nozzles is closed. 36. Take the fuel gas controller 91-FIC-1020 in manual and slowly increase the fuel gas to the burner. 37. Take the combustion air controller 91-FIC-1018 in manual and increase the air to the burner. 38. Slowly open the fuel gas and combustion air and increase the 1st Stage Converter inlet temperature to 230°C.

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 30 - 1st Stage Auxiliary Burner Management Sequence

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TITLE: OPERATION AND MAINTENANCE MANUAL

6.3.3.4

2nd Stage Auxiliary Burner 9101-F-03 Start-up

2nd Stage Auxiliary Burner-BMS Sequence The burner management system of 2nd Stage Auxiliary Burner is incorporated in ESD system. 2nd Stage Auxiliary Burner LCP 9101-F103–LP-007 hand switches detail is tabulated below: Sl. #.

Tag No.

Description

1.

91-HS-1195

Start burner

2.

91-HS-1196

Stop burner

3.

91-HS-1197

Lamp test

2nd Stage Auxiliary Burner hardwired aux console hand switches detail is tabulated below: Sl. #

Tag No.

Description

1.

91-HS-1192

Acid gas ON/OFF

2.

91-HS-1193

Fuel gas ON/OFF

2nd Stage Auxiliary Burner LCP 9101 F103–LP-007 lamp indication detail is tabulated below: Sl. #

Tag No.

Description

1.

91-XA-1191

2nd stage burner shutdown

2.

91-XL-1192

Ready for ignition

3.

91-XL-1193

Ignition ON

4.

91-XL-1194

Fuel gas ON

5.

91-XL-1195

Acid gas ON

6.

91-BAL-1003A

Flame -1 ON

7.

91-BAL-1003B

Flame-2 ON

System Reset to be done by activating 91-HS-1194 in DCS. Control valve/ON-OFF valve details are tabulated below: Sl. #

Tag No.

Description

1.

91-XV-1031

Fuel gas block valve-1

2.

91-XV-1133

Fuel gas block valve-2

3.

91-XV-1134

Fuel gas vent valve

4.

91-FV-1025

Process air control valve

5.

91-FV-1026

Acid gas control valve

6.

91-FV-1027

Fuel gas control valve

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TITLE: OPERATION AND MAINTENANCE MANUAL

The burner light-on is carried out in below steps: i.

System reset

ii.

Fuel gas burner light-on

iii.

Acid gas introduction

i.

System Reset

1.

Check the following shutdown interlocks are absent in the ICSS: •

Reaction Furnace shutdown

•

2nd Stage Auxiliary Burner flame failure (91-BALL-1004A/B).

•

Acid gas flow low-low (91-FT-1137)

•

Fuel gas flow low-low (91-FT-1138)

•

Combustion air flow low-low (91-FT-1136)

If the above conditions do not do not exist “2nd Stage Auxiliary Burner” BMS system can be reset. 2. When the BMS reset is pressed, following shutdown causes are automatically bypassed during start-up (start-up override) a.

91-FT-1136 (Combustion Air low-low flow)

b.

91-FT-1138 (Fuel gas flow low-low)

c.

91-FT-1137 (Acid gas flow low-low)

3. Ensure that any one of Process Air Blower 9101-K-01A & 9101-K-01B is running. 4. If the above conditions are satisfied then Ensure “2nd STAGE BURNER READY FOR RESET” (91-XL-1197) is lit in ICSS. 5. “RESET” the system by pressing the Soft switch 91-HS-1194 from ICSS and ensure the following: a. Energizing of fuel gas control valve SOV 91-FY-1027. b. Combustion air flow controller 91-FIC-1025 to manual mode and output at start position. c. Fuel gas flow controller 91-FIC-1027 to manual mode and output at start position. d. “READY FOR IGNITION” lamp 91-XL-1192 and 91-XL-1192A is lit on the local panel and ICSS respectively. e. “SYSTEM IN SHUTDOWN” lamp 91-XA-1191 and 91-XA-1191A will extinguish on the LCP and ICSS, respectively.

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TITLE: OPERATION AND MAINTENANCE MANUAL

ii. Fuel Gas Burner Light On 1.

Ensure that the air inlets, burner and outlet passages are boxed up and free of foreign material.

2.

Ensure that all safety shut off valves are closed.

3.

Ensure that the Fuel System vents are open and venting to atmosphere. Lines are properly drained and cleared of condensate.

4.

Ensure that a complete functional check of the safety interlocks has been made.

5.

Ensure that the area is clear of obvious safety hazards and flammable gases are not present in the area.

6.

Ensure that all lines have been blown down with plant air to insure they are free of debris that might plug metering orifices and burner tips.

7.

Ensure that utilities like fuel gas, instrument air, nitrogen and plant air are available and initial operational checks performed on the elements in each line.

8.

Ensure that the burner elements are in their proper position.

9.

Ensure that power has been supplied to control systems and to safety interlocks.

10. Ensure that the gauges indicating fuel header pressure to the unit are functional. 11. Ensure that the pressure self regulating valves are set according to the instrument data sheets. 12. Ensure that the isolation valves for all the pressure gauges and pressure transmitters are open and their respective bleed valves are closed. Valves are sealed in position as indicated on P&IDs. 13. Ensure that the control valves of the fuel gas 91-FV-1027, quench steam and Combustion air 91-FV-1025 are closed. 14. Ensure that the igniter is in the correct position and that the fuel gas gun is ready for operation with fuel gas. 15. Open the fuel gas control valve 91-FV-1027 and combustion air control valve 91FV-1025 to the pre-determined position. 16. Press the ‘START IGNITION’ push button 91-HS-1195 from the local control panel. 17. Ensure that ‘READY FOR IGNITION’ lamp 91-XL-1192, 91-XL-1192A is unlit on the local control panel and ICSS respectively. 18. Ensure “IGNITION ON” lamp 91-XL-1193A, 91-XL-1193 lamp lit in ICSS and Local panel respectively. 19. Ensure “2nd STAGE BURNER IN SHUTDOWN” lamp 91-XA-1191 and 91-XA-1191A extinguished in Local panel and ICSS respectively. 20. Ensure combustion air control valve SOV 91-FY-1025 energized.

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TITLE: OPERATION AND MAINTENANCE MANUAL

21. Ensure Combustion air flow controller 91-FIC-1025 and fuel gas controller 91-FIC1027 forced to manual mode and output forced to start position at 10%. 22. Ensure that the igniters insert SOV 91-XY-1199 is energised. 23. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1199. 24. Ensure fuel gas bleed valve 91-XV-1134 is closed and fuel gas shutdown valves 91XV-1031 and 91-XV-1133 are opened. 25. Ensure that the igniter transformer is energised for 10 seconds and sparking begins. 26. Ensure that the igniter transformer is de-energised and Igniter retracts automatically (91-ZSO-1199) after 10 seconds ignition timer. 27. If flame is detected then ensure that the ‘FLAME ON’ lamps (91-BAL-1004A, 91BAL-1004B) are lit on the LCP and ICSS. 28. Permit is provided to open the steam quench valve. 29. Permit is provided to open the acid gas control valve 91-FV-1026. 30. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1194 is lit in the Local Control Panel. 31. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1194A is lit in ICSS. 32. Ensure combustion air controller 91-FIC1025 and fuel gas controller 91-FIC-1027 force signals removed. 33. Open the instrument air purge valve to sight glasses, flame scanners and nozzles. 34. Ensure that the Nitrogen purge valve to sight glasses, flame scanners and nozzles is closed. 35. Slowly increase the fuel gas to the burner by keeping the Fuel gas flow controller 91-FIC-1027 in manual. 36. Slowly increase the combustion air to the burner by keeping the Combustion air flow controller 91-FIC-1025 in manual. 37. Slowly open the fuel gas and combustion air and increase the 2nd Stage Converter inlet temperature to 230°C.

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001 TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 31 - 2nd Stage Auxiliary Burner Management Sequence

Rev.: 0 Date: 03/09/2012 Page: 300 of 517

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TITLE: OPERATION AND MAINTENANCE MANUAL

6.3.3.5

Lining up Of Acid Gas to Reaction Furnace

1. When the Reaction Furnace temperature is >1250°C set the Reaction Furnace burner control system to slightly sub-stoichiometric firing conditions with steam being injected as noted above to prevent the formation of carbon. 2. Acid gas may now be introduced to the SRU Reaction Furnace burner provided the following points are first confirmed: •

The SRU converters catalyst beds are at their normal operating temperatures of 230 and 210°C, respectively

•

The SRU Reaction Furnace burner is operating on fuel gas in slightly substoichiometric firing conditions with steam injection to fuel gas and process air lines

•

There is sufficient acid gas available from the upstream Amine Regenerator, at a stable flow rate of and at/or above the minimum design flow required for the SRU to operate satisfactorily.

3. Confirm that the acid gas system has been purged with nitrogen. 4. Using a utility water hose connected to the Acid Gas KO Drum utility connection, introduce water to establish a low level of water in the Acid Gas KO Drum 9101-V-04. 5. Using MS steam from the SRU Reaction Furnace Boiler 9101-E-07, continue increasing the Acid Gas Pre-heater 9101-E-06 outlet temperature at 50°C/hr to 210°C. 6. Confirm available acid gas flow is at or above the minimum turndown required of 5935 kg/hr, (2349 m3/hr) for the SRU to operate. 6.3.3.6

Reaction Furnace Acid Gas Burner Light-On

1.

Ensure the acid gas control valves 91-PV-1503A/91-PV-1503B from AGEU Regenerator Reflux Drum 9103-V-12 is closed.

2.

Ensure the 1st Stage and 2nd Stage Auxiliary Burner “FLAME ON” indication is available.

3.

Ensure Acid Gas KOD 9101-V-04 level 91-LAHH-1003 and acid gas feed pressure 91-PALL-1025 is healthy.

4.

Activate the “ACID GAS ON SWITCH” 91-HS-1217 on hardwired console.

5.

Ensure acid gas cut-off valve 91-XV-1102, 91-XV-1001 and 91-XV-1516 is open.

6.

After 30 seconds “ACID GAS ON” lamp 91-XL-1217, 91-XL-1217A is lit on the local panel and ICSS respectively.

7.

Gradually open the acid gas valve 91-PV-1503B and close the fuel gas control valve 91-FV-1009 and combustion air controller 91-FIC-1018 to be adjusted accordingly to provide the process air requirement for the acid gas.

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8.

Ensure the minimum air flow rate while switching between fuel gas and acid gas.

9. As soon as a flow of acid gas is introduced to the Reaction Furnace burner, commence reducing fuel gas flow to the burner. 10. When fuel gas flow has stopped, isolate fuel gas line by closing fuel gas shutdown valves. 11. Stop steam injection to the fuel gas and process air lines to the Reaction Furnace burner. 12. Set all controllers in automatic mode. 13. Remove the override from the acid gas low flow trip. 14. Acid Gas is now to be introduced to the 1st and 2nd Stage Auxiliary Burners 6.3.3.7

1st Stage Auxiliary Burner Acid Gas Burner Light-On

1.

Ensure the acid gas control valve 91-FV-1019 is closed.

2.

Activate the acid gas on switch 91-HS-1223 on hardwired console.

3.

Ensure acid gas control valve SOV 91-FY-1019 energized.

4.

Acid gas controller is forced at the start-up position to ensure acid gas flow is above low-low flow trip setting

5.

“1ST STAGE ACID GAS ON” lamp 91-XL-1230, 91-XL-1230A is lit on the local panel and ICSS respectively.

6.

Gradually open the acid gas valve 91-FV-1019 and close the fuel gas control valve 91-FV-1020 and combustion air controller 91-FIC-1018 to be adjusted accordingly to provide the process air requirement for the acid gas.

7.

Ensure the minimum air flow rate while switching between fuel gas and acid gas.

6.3.3.8

2nd State Auxiliary Burner Acid Gas Burner Light-On

1.

Ensure the acid gas control valve 91-FV-1026 is closed.

2.

Activate the acid gas on switch 91-HS-1192 on hardwired console.

3.

Ensure acid gas control valve SOV 91-FY-1026 energized.

4.

Acid gas controller is forced at the start-up position to ensure acid gas flow is above low-low flow trip setting.

5.

Ensure “2nd STAGE ACID GAS ON” lamp 91-XL-1195, 91-XL-1195A is lit on the local panel and ICSS respectively.

6.

Gradually open the acid gas valve 91-FV-1026 and close the fuel gas control valve 91-FV-1027, Combustion air controller 91-FIC-1025 to be adjusted accordingly to provide the process air requirement for the acid gas.

7.

Ensure the minimum air flow rate while switching between fuel gas and acid gas.

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TITLE: OPERATION AND MAINTENANCE MANUAL

6.3.3.9

Sulphur Production

1. When the SRU operation has stabilised, commission the tail gas analyser and set in automatic with the trim air control valve to maintain a H2S:SO2 of 2.0:1.0. 2. Following a period of approximately 30-60 minutes after the introduction of acid gases to the SRU Reaction Furnace Burner, commence checking of the SRU condensers, sultraps for liquid sulphur. 3. If the sultraps have not been pre-filled with flake or powdered sulphur then the following procedure should be adopted to fill the sultraps with liquid sulphur. Note: It is necessary to use a respirator or fresh air breathing apparatus to ensure complete operator safety during this operation. •

Slowly open each of the condensers sulphur outlet drain valves and observe through the open sultrap inspection door

•

When opening a sultrap if acid gas vapour appears, usually as a white smoky gas, this will indicate that no liquid sulphur has collected behind the isolation valve. The sultrap should be closed immediately in this case and only opened again after about 10 minutes. If only a bluish haze with little pressure behind it shows from the sultrap, this indicates that the sultrap is filling with liquid sulphur and the condensers sulphur outlet valve can be left open.

•

Check the sultrap inspection door at regular intervals until sulphur is seen to flow from each seal

•

When sulphur is seen at the condensers sulphur outlet valve may now be left open to allow the sulphur to flow freely

•

Repeat this exercise until sulphur is seen to flow from all three seals

Note: It may take a considerable period of time, possibly several hours before sulphur is seen to flow from the third condenser. •

Check the Sulphur Degassing Pit 9101-T-01/01B is showing an increase in level

•

When there is sufficient level in Sulphur Degassing Pit 9101-T-01/01B, start Sulphur Degassing Pumps 9103-P-03A/B/09A/B recirculating the liquid sulphur back to the pit

•

Start steam ejector and line up the vent gases to Incinerator

•

Ensure that the air flow 91-FI-1056 from safe location shows the normal value.

•

Start AQUISULF catalyst injection to the Degassing pit

•

Start Sulphur Product Pumps 9101-P-04A/B/10A/B and line up liquid sulphur to the Sulphur Storage Tank 9101-T-02 via the level control valve 91-LV-1014/1051.

•

When sufficient level is there in the Sulphur Storage Tank 9101-T-02 start the Sulphur Tank Pumps 9101-P-15A/B and transfer liquid sulphur to QAPCO.

The start-up of the SRU is now complete.

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6.3.4

Start-up of Tail Gas Treatment Unit

6.3.4.1

Pre-requisites

I.

Preparation of Caustic Solution

1.

Ensure that the Caustic Storage Tank 9103-T-14 is cleaned internally.

2.

Ensure that the Caustic Injection Pumps 9103-P-103A/B and the Agitator 9103-M-14 are energised in MCC.

3.

Ensure that all the drain and vent valves in the package are closed.

4.

Procure the Caustic Solution drums/tanks to the site and place it near the unloading pump 9103-P-104.

5.

Connect the drums/tanks to the unloading pump.

6.

Start the unloading pump and transfer the required amount of Caustic Solution to the tank.

7.

Make up the required concentration of the Caustic Solution by adding DM water to the tank.

8.

Ensure that the low low level trip 91-LALL-1524 is cancelled while making up the solution.

9.

Ensure the level in the tank from 91-LG-1512 and 91-LT-1525 and ensure the tank is filled upto the required level.

10. Start agitator 9103-M-14 from the local panel to mix the solution thoroughly. II.

Establishing Desuperheater/Contact Condenser 9102-C-11 circulation

1.

Ensure that the suction and discharge isolation valves of the Cooling Water Circulation Pumps 9102-P-12A/B are closed.

2.

Ensure that the Cooling Water Circulation Pumps 9102-P-12A/B suction to the Waste Water Degasser 6922-V-07 isolation valves are closed.

3.

Open the DM water make up to the suction of the Cooling Water Circulation Pumps 9102-P-12A/B and increase level in the top section of the Desuperheater/Contact Condenser 9102-C-11.

4.

When the level in the Desuperheater/Contact Condenser 9102-C-11 top section reaches 50% which is noted through the 91-LG-1302/91-LT-1305, close the DM water make up to the pumps suction.

5.

Take the flow control valve 91-FV-1307 in auto with a set point of 197 m3/hr.

6.

Ensure that the flow control valve 91-FV-1305 is closed fully on manual and the upstream and downstream isolation valves are closed.

7.

Start Cooling Water Circulation Pump 9102-P-12A from ICSS and circulate the water in the Desuperheater/Contact Condenser 9102-C-11 top chimney tray.

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8.

Select Cooling Water Circulation Pump 9102-P-12B in AUTO from ICSS and open the suction and discharge isolation valves and prime the pump.

9.

Line up 91-LV-1307 to top up Desuperheater/Contact Condenser 9102-C-11 bottom section.

10. Open 91-LV-1307 manually and top up Desuperheater/Contact Condenser 9102-C-11 bottom section. 11. Open the DM water make up to the suction of the Cooling Water Circulation Pumps 9102-P-12A/B to maintain the level at 50% at top section. 12. Check the level in the Desuperheater/Contact Condenser 9102-C-11 bottom by checking 91-LG-1303A/B & 91-LT-1307. 13. When the level in the Desuperheater/Contact Condenser 9102-C-11 bottom reaches 50%, close the DM water make up to the pump suction and put the level control valve 91-LV-1307 in auto with a set point of 50%. 14. Take the flow control valve FV-1314 in auto with a set point of 199 m3/hr. 15. Start Desuperheater Circulation Pump 9102-P-11A from ICSS and start circulating the water. 16. Ensure that the Desuperheater Circulation Pump 9102-P-11B is taken in AUTO from ICSS and the suction and discharge isolation valves are opened and primed. 17. Line up pH analyzer 91-AT-1302 in the suction of the Desuperheater Circulation Pumps 9102-P-11A/B. III.

Lining up of Caustic Solution Injection Pumps 9103-P-103A/B

1.

Ensure that the Caustic Solution Injection pumps 9103-P-103A/B suction strainer elements are fixed and boxed up.

2.

Ensure that the Caustic Solution Injection Pumps 9103-P-103A/B discharge PSVs PSV-1606/1607 are lined up.

3.

Open the Caustic Storage Tank outlet isolation valve to the injection pumps and fill the lines with the Caustic Solution.

4.

Open the suction isolation valves of the injection pumps.

5.

Open the discharge isolation valve of the Caustic Injection Pump 9103-P-103A.

6.

Put the LOR switch of the Caustic Injection Pump 9103-P-103A in ‘Local’.

7.

Start the Caustic Solution Injection Pump 9103-P-103A from LCP.

8.

Put the stroke length of the Caustic Solution Injection Pump 9103-P-103A at 10%.

9.

Ensure that the Caustic Solution Injection Pump 9103-P-103A is developing pressure by checking the discharge pressure transmitter 91-PT-1563.

10. Open the drain valve near the dosing point and ensure that the line is clear.

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11. Line up Caustic Solution to the Desuperheater Circulation Pump suction till a pH of 9.0 to 10.0 is achieved in the circulating solution. IV.

Calibration of Caustic Injection Pumps

1.

Stop the Caustic Injection Pumps 9103-P-103A/B from ICSS.

2.

Slowly open the calibration pot inlet isolation valves and fill up the pot up to the full level.

3.

Close the suction isolation valves of the Pumps upstream of the calibration pot.

4.

Open the Caustic Injection Pump 9103-P-103A discharge isolation valve.

5.

Set the Caustic Injection Pump 9103-P-103A stroke to 10%.

6.

Start the Caustic Injection Pump 9103-P-103A from ICSS.

7.

Note down the time taken to pump out the liquid from the calibration pot.

8.

Calculate the pumping rate from the volume of the calibration pot and time taken to pump the liquid from the pot.

9.

Repeat the above procedures for stroke length of 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90% and 100%.

10. List all the values and find out the pumping rate at different stroke lengths. 6.3.4.2

Preparation for Start-up

1.

Ensure that the instrument air from instrument air header to the Reducing Gas Generator 9102-F-11 isolation valve is closed.

2.

Ensure that the spectacle blind is in open position downstream of the isolation valve of the instrument air from instrument air header to the Reducing Gas Generator 9102-F-11.

3.

Ensure that the fuel gas from fuel gas distribution to Reducing Gas Generator 9102-F-11 isolation valve is closed.

4.

Ensure that the spectacle blind is in open position downstream of the isolation valve of the fuel gas from fuel gas distribution to Reducing Gas Generator 9102-F-11.

5.

Ensure that the steam from steam distribution to Reducing Gas Generator 9102-F-11 isolation valve is closed.

6.

Ensure that the spectacle blind is in open position downstream of the isolation valve of the steam from steam distribution to Reducing Gas Generator 9102-F-11.

7.

Ensure that the combustion air from combustion air blower 9102-K-11A/B to Reducing Gas Generator 9102-F-11 isolation valve is closed.

8.

Ensure that the spectacle blind is in open position downstream of the isolation valve of the combustion air from combustion air blower 9102-K-11A/B to Reducing Gas Generator 9102-F-11.

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9.

Ensure that the Nitrogen from Nitrogen distribution header to Reducing Gas Generator 9102-F-11 isolation valve is closed.

10. Ensure that the spectacle blind is in open position downstream of the isolation valve of the Nitrogen from Nitrogen distribution header to Reducing Gas Generator 9102-F-11. 11. Ensure that the drain and vent valves in the Reducing Gas Generator 9102-F-11 section is closed. 12. Ensure that all the instruments in Reducing Gas Generator 9102-F-11, Hydrogenation Reactor 9102-V-11, Reactor Effluent Cooler 9102-E-11 are lined up. 13. Ensure that the Reactor Effluent Cooler 9102-E-11 atmospheric steam vent isolation valves are open. 14. Ensure that the Reactor Effluent Cooler 9102-E-11 vents and drains isolation valves are closed. 15. Ensure that the SRU tail gas valve to the TGTU 91-XV-1098 is closed at SRU. 6.3.4.3

Lining up of Reactor Effluent Cooler 9102-E-11

1.

Open Reactor Effluent Cooler 9102-E-11 tail gas outlet to Desuperheater/Contact Condenser 9102-C-11 ON-OFF valve 91-XV-1332 from ICSS by selecting open position in HS-1303A.

2.

Close the Reactor Effluent Cooler 9102-E-11 tail gas outlet to Incinerator 9101-F-14 bypass ON-OFF valve 91-XV-1331 from ICSS by selecting close position in HS-1303A.

3.

Ensure that the steam outlet isolation valve from Reactor Effluent Cooler 9102-E-11 is closed.

4.

Ensure that the Boiler Feed Water from distribution header to the Reactor Effluent Cooler isolation valves are closed and the level control valve 91-LV-1302 is closed fully on manual.

5.

Ensure that the Boiler Feed Water is available from utility plant.

6.

Ensure that the process gas from the Desuperheater/Contact Condenser 9102-C-11 to the Tail Gas Amine Absorber 9102-C-12 isolation valve is closed.

7.

Open the process gas recycle isolation valve from the Desuperheater/Contact Condenser 9102-C-11 top to the Reducing Gas Generator 9102-F-11.

8.

Ensure that the process gas start-up bypass from the Desuperheater/Contact Condenser 9102-C-11 to the Incinerator 9101-F-14 is lined up and take the pressure controller 91-PIC-1308 in Auto with a set point of 0.25 barg.

9.

Connect a Nitrogen hose to the vent line of the start-up bypass line from the Desuperheater/Contact Condenser 9102-C-11 to the Reducing Gas Generator 9102-F-11.

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10. Open the isolation valve of the start-up bypass line near the Reducing Gas Generator 9102-F-11. 11. Introduce Nitrogen through the hose to the Reducing Gas Generator via the process gas inlet line. 12. Ensure that the start-up pressure control valve PIC-1308 opening to control the excess Nitrogen gases to the Incinerator from Desuperheater/Contact Condenser 9102-C-11. Close the nitrogen valve. 13. Open the Start-up Gas Steam Ejector 9102-X-11 process gas inlet and outlet isolation valves. 14. Open the Boiler Feed Water to Reactor Effluent Cooler 9102-E-11 isolation valves. 15. Open the level control valve 91-LV-1302 in manual and introduce Boiler Feed Water to the Reactor Effluent Cooler 9102-E-11. 16. Slowly increase the level in the Reactor Effluent Cooler 9102-E-11. 17. When the level in the Reactor Effluent Cooler 9102-E-11 is around 85%, take the level control valve LV-1302 in Auto with a set point of 80%. 6.3.4.4

Circulating Nitrogen through TGTU

1.

Ensure that RGG, Hydrogenation Reactor, Reactor Effluent Desuperheater/Contact Condenser is pressurised with nitrogen.

Cooler

and

2.

Open LP Steam drain valve and slowly open the upstream isolation valve to the Start-Up Gas Steam Ejector 9102-X-11.

3.

Drain the condensate from the LP steam line and slowly warm up the line.

4.

Open the steam ejector outlet isolation valve and then open the steam inlet isolation valve to the steam ejector 9102-X-11.

5.

Open the process gas inlet line to the steam ejector and start circulating Nitrogen around the TGTU BSR Section. Nitrogen gases will flow through and around the RGG, Hydrogenation Reactor, Reactor Effluent Cooler and DCC Desuperheater/Contact Condenser 9102-C-11 with excess gases being vented to the Incinerator through 91-PV-1308.

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Fig. 32 - Burner Management Sequence for RGG Start

A Note A

Note B

& Y

Fuel gas vent valve XV-1308 close, Fuel gas XV-1303, XV-1304 and air shutdown valve XV-1306 open, igniter insertion, activation of 10 sec timer for ignition transformer

System Reset HS-1400 Automatic bypass of combustion air (FT-1309), fuel gas (PT-1305) low low alarm Confirm FG, combustion air, quench steam control valve closed

System ready for purge-XL-1401

Burner ignition timer completed

N

Flame Detected on 2oo3 logic

Purge start HS-1401

Nitrogen SDV-XV-1307, XV-1301 open

Y BAL-1301, BAL-1302, BAL-1303 ON Fuel Gas ON-XL-1404

Nitrogen flow alarm FAL-1308

Y Quench steam start-HS-1406

N XV-1305 open, XL-1407 ON Common Alarm XL-1405 Purge timer – 7.5 minutes completed

N

Tail gas Start-HS-1052A from DCS Light ON timer out XL-1406

Y Purge Complete XL-1403

Nitrogen SDV-XV-1307 close, 10 min light on cycle initiated

XV-1098 open Instrument air purge valve XV-1032 open and close nitrogen purge valve XV-1301

Furnace is fully operational Burner start HS-1402

A

Note A Following causes should be healthy for system reset: 1. RGG DCS soft push button HS-1336 2. RGG ESD push button HS-1337 in LCP 3. ESD total plant shutdown XS-1101 4. ESD level-1 shutdown XS-1102 5. ESD level-2 shutdown XS-1103 6. FG to RGG burner HI HI pressure PAHH-1303 7. Combustion air high high pressure PT-1341 8. Reactor effluent cooler low low level LT-1309 9. RGG process gas Outlet temperature high high TT1305

Note B Following are the interlocks for purging: 1. No flame detection by BSL-1301/1302/1303 2. Nitrogen flow low should be absent 3. FG control valve at low fire position 4. FG Block valve XV-1303 in close position 5. FG Block valve XV01304 in close position 6. FG vent valve XV-1308 in open position

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6.3.4.5

Lighting up of Burner in Reducing Gas Generator 9102-F-11

Burner Light On The burner light-on is carried out in three steps. i.

System reset

ii.

Pre-ignition purge

iii.

Direct fuel gas light-on

i.

System Reset

1.

Check the following shutdown interlocks are absent in the ICSS: a.

RGG Shutdown soft push button from DCS – 91-HS-1336

b.

RGG ESD push button (Local Panel) – 91-HS-1337

c.

ESD Level 0 Total Plant Shutdown – 65-XS-1101

d.

ESD Level 1 Shutdown – 65-XS-1102

e.

ESD Level 2 Shutdown – 65-XS-1103

f.

Fuel Gas to RGG burner high high pressure – 91-PT-1303

g.

Combustion air high high pressure – 91-PT-1341

h.

Reactor Effluent Cooler low low level – 91-LT-1309

i.

RGC Process gas outlet high high temperature – 91-TT-1305

If the above conditions are not exists, then the RGG BMS system can be reset. 2. The following shutdown causes are automatically bypassed during start-up a.

91-PT-1305 (Fuel Gas low low pressure)

b.

91-FT-1309 (Combustion Air low low flow)

3. Start Combustion Air Blower 9102-K-11A To start the Blower 9102-K-11A, the following permissives are to be satisfied: a.

Instrument air must be available and the seal air low low pressure 91-PALL1460 is reset.

b.

The lube oil tank level 91-LT-1451 is more than 30%.

c.

Lube oil temperature in the tank 91-TT-1473 is greater than 15°C.

d.

The auxiliary lube oil pump 91-P-13A is started and running and the low low lube oil pressure 91-PI-1459 is reset.

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e.

All trip functions must be healthy.

f.

Three minute restart timer is completed.

g.

The Blower is not running

h.

IGV valve 91-PCV-1453 is closed

i.

Blow off valve 91-FV-1451 is open

j.

Blower ready to start indication is ON

k.

Blower running indication is OFF.

l.

Blower common trip alarm is OFF.

Blower Start-up a.

Ensure that blower ready to start indication is available in the Local Control Panel.

b.

Switch ON the electrical heater for the Lube Oil tank 91-E-15AA.

c.

Ensure that the temperature of the Lube oil is increasing by checking 91-TI-1463.

d.

When the temperature reaches 45°C ensure that the heater is cut off automatically.

e.

Ensure that when the temperature reaches 40°C, the heater is cut in automatically.

f.

Start the Auxiliary Oil Pump 91-P-13A.

g.

Ensure that the Auxiliary Oil Pump 91-P-13A develops a discharge pressure of 5.50 barg.

h.

Line up the instrument air to the seal system of the blower and ensure that the low low seal air pressure 91-PALL-1460 is reset by 91-HS-1471.

i.

Select “Local” from the Local Control Panel 9102K11A-LP-003 selector switch 91-HS-1452.

j.

Start the Blower by pushing the start push button 91-HS-1454.

k.

Ensure that the Blower is started and running.

l.

Ensure that the Lube Oil Cooler duty fan is started and running.

m. Ensure that the air filter inlet inertial fan is started and running. n.

Ensure that the IGV valve opens in unloaded condition.

o.

Ensure that the blow off valve 91-FV-1451 is open.

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p.

After 17 minutes ensure that the Auxiliary Oil Pump 91-P-13A is stopped and the Blower load function is enabled.

q.

Load the Blower from the Local Control Panel selector switch 91-HS-1455.

r.

Ensure the discharge pressure of the blower is 1.57 bara.

s.

The following conditions are to be satisfied for the pre-ignition purge: i. No flame present – 91-BSL-1301/1302/1303 ii. Sufficient purge Nitrogen flow rate – 91-FAL-1308 iii. FG Control valve at low fire position – 91-FZSL-1311 iv. Fuel Gas cut-in valve XV-1303 is in close position – 91-ZSC-1303 v. Fuel Gas cut in valve XV-1304 is in close position - 91-ZSC-1304 vi. Fuel Gas vent valve XV-1308 is in open position - 91-ZSO-1308 Ensure the above conditions are satisfied.

t.

Ensure that the combustion air flow control valve 91-FV-1304, Fuel Gas flow control valve FV-1311 and quench steam flow control valve FV-1310 are closed.

u.

RESET the system by pressing the pushbutton 91-HS-1400 from the local control panel.

ii. Pre-ignition Purge 1.

Verify whether the ‘System ready for purge’ lamp 91-XL-1401 is lit after RESET at Local Control Panel.

2.

Ensure that the Nitrogen shutdown valve 91-XV-1307 for furnace purging and 91-XV-1301 for flame scanner, sight glass purging are opened.

3.

Ensure that main combustion air shutdown valve 91-XV-1306 & instrument air valve 91-XV-1302 (for flame scanner, sight glass purging) are closed.

4.

Open the Nitrogen line isolation valve slowly and set a flow rate of 125 m3/hr read by 91-FT-1308.

5.

Press ‘Purge Start’ Pushbutton 91-HS-1401 from the Local Control Panel.

6.

Ensure that the ‘Purge On’ lamp 91-XL-1402 is lit in the Local Control Panel.

7.

Set the purge timer at 7.5 minutes.

8.

Verify whether the ‘Purge On’ lamp 91-XL-1402 is lit for 7.5 minutes in the Local Control Panel.

9.

After the purge time is over, ensure that the ‘Purge On’ lamp 91-XL-1402 is unlit in the Local Control Panel.

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10. Ensure that ‘Purge Complete’ lamp 91-XL-1403 is lit on the Local Control Panel. 11. Ensure that the Nitrogen cut-in valve 91-XV-1307 is closed. iii. Fuel Gas Burner Light On 1.

Ensure that the air inlets, burner and outlet passages are boxed up and free of foreign material.

2.

Ensure that all personnel have been evacuated from the RGG area, ductwork and associated equipment and all access and inspecting doors closed and sealed.

3.

Ensure that the Combustion Air Blower 9102-K-11A/B is running.

4.

Ensure that all safety shut off valves are closed.

5.

Ensure that the Fuel System vents are open and venting to atmosphere. Lines are properly drained and cleared of condensate.

6.

Ensure that a complete functional check of the safety interlocks has been made.

7.

Ensure that the area is clear of obvious safety hazards and flammable gases are not present in the area.

8.

Ensure that all lines have been blown down with plant air to insure they are free of debris that might plug metering orifices and burner tips.

9.

Ensure that utilities like fuel gas, instrument air, Nitrogen and plant air are available and initial operational checks performed on the elements in each line.

10. Ensure that the burner elements are in their proper position. 11. Ensure that power has been supplied to control systems and to safety interlocks. 12. Ensure that the gauges indicating fuel header pressure to the unit are functional. 13. Ensure that the pressure self regulating valves are set according to the instrument data sheets. 14. Ensure that the isolation valves for all the pressure gauges and pressure transmitters are open and their respective bleed valves are closed. Valves are sealed in position as indicated on P&IDs. 15. Ensure that the 2” steam drum vent isolation valves of the reactor effluent cooler are open. 16. Ensure that the Reactor Effluent Cooler is filled with boiler feed water and the level is being maintained at 80%. 17. Ensure that the minimum purge period is satisfactorily completed. 18. Ensure that the control valves of the fuel gas - 91-FV-1311, quench steam – 91-FV1310 and Combustion Air – 91-FV-1304 are closed. 19. Ensure that the igniter is in the correct position and that the fuel gas gun is ready for operation with fuel gas.

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20. Ensure that the ‘Purge Complete’ lamp 91-XL-1403 is lit in the local control panel. 21. Open the fuel gas control valve 91-FV-1311 from ICSS to the pre-determined position signalled by the lamp 91-FZAL-1311 at the local control panel. 22. Open the combustion air control valve 91-FV-1304. 23. Press the ‘Burner Start’ push button 91-HS-1402 from the local control panel. 24. Ensure that ‘Purge Complete’ lamp 91-XL-1403 is unlit. 25. Ensure that the igniter insert SOV is energised. 26. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1400. 27. Ensure that the igniter transformer is energised for 10 seconds and sparking begins. 28. Ensure that the combustion air shutdown valve 91-XV-1306 is opened. 29. Ensure that the fuel gas bleed valve 91-XV-1308 is closed. 30. Ensure that the fuel gas shutdown valves 91-XV-1303 and 1304 are opened. 31. Ensure that the igniter transformer is de-energised and Igniter retracts automatically (91-ZSO-1400) after 10 seconds ignition timer. 32. If flame is detected then ensure that the ‘FLAME ON’ lamps (91-BAL-1301, 91-BAL1302, 91-BAL-1303) are lit. 33. Ensure that the fuel gas control valve correct start-up position lamp 91-FZSL-1311 is unlit. Note: Permit is provided to open the steam quench shutdown valve 91-XV-1305 from ICSS soft switch 91-HS-1406 34. Permit is provided to open the tail gas shutdown valve 91-XV-1098 from ICSS soft switch 91-HS-1052A. 35. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1404 is lit in the Local Control Panel. 36. Ensure that the ‘FUEL GAS ON’ lamp 91-XL-1410 is lit in ICSS. 37. Ensure that the instrument air purge valve 91-XV-1302 to sight glasses, flame scanners and nozzles is opened. 38. Ensure that the Nitrogen purge valve 91-XV-1301 to sight glasses, flame scanners and nozzles is closed. 6.3.4.6

Hydrogenation Reactor Catalyst Sulphiding

1.

Warm up the Hydrogenation Reactor 9102-V-11 at 50°C/hr by opening the combustion air and the fuel gas to the RGG.

2.

Open the LP steam shutdown valve 91-XV-1305 to the RGG by manual reset of the soft push button 91-HS-1406 from ICSS.

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3.

When RGG outlet and Hydrogenation Reactor inlet temperature is 200°C and the Hydrogenation Reactor is heated through to >120°C, introduce LP steam to the RGG by opening the steam inlet control valve 91-FV-1310.

4.

Set the steam flow in a ratio of 2:1 by weight to fuel gas in 91-HIC-1311.

5.

Boiler feed water in the Reactor Effluent Cooler 9102-E-11 are heated by the effluent gases from the Hydrogenation Reactor 9102-V-11 and steam will start coming out of the drum vent.

6.

Slowly close the drum vent and increase the pressure in the drum to the LP steam header pressure of 5.0 barg which is read by the drum pressure gauge 91-PT-1309.

7.

When the drum pressure reaches 5.0 barg, open the steam outlet isolation valve connecting to the header and close the drum vent fully at the same time.

8.

When the Hydrogenation Reactor has heated through to 200°C the sulphiding of the catalyst should be started.

9.

Check the temperature transmitters in the catalyst bed 91-TT-1303/1306/1308/ 1309/1318/1319/1320/1321/1322 from ICSS.

10. All the temperature points should be around 200°C. 11. Line up the isolation valves of the Acid Gas sulphiding line from Regenerator Reflux Drum 9103-V-12 to the Hydrogenation Reactor 9102-V-11. 12. Open the Acid Gas sulphiding line control valve 91-HV-1301 slowly and introduce acid gases to the Hydrogenation Reactor 9102-V-11. 13. Introduce acid gases for 1% - 2% volume of H2S initially in the process gases. Note: The reaction of H2S in the Hydrogenation Reactor catalyst is exothermic. For every 1% volume of H2S entering the reactor a catalyst temperature increase of approximately 15°C can be expected. 14. Slowly increase Hydrogenation Reactor inlet temperature at a rate of approximately 15°C/hr to 315°C whilst keeping the catalyst bed delta temperature 25°C then reduce the flow of H2S acid gas into the Hydrogenation Reactor. Note: Under no circumstances should catalyst temperature be allowed to exceed 425°C as damage to the catalyst and equipment will occur. 16. As soon as amine acid gas is introduced into the Hydrogenation Reactor inlet line start sampling the reactors inlet and outlet process gas. 17. A hand held Drager tube type sampling system is suggested where an immediate read out of H2S in % or ppm can be seen. 18. Continue sampling reactor outlet gas at one hour intervals.

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19. When the Hydrogenation Reactor has been fully sulphided, the reactor outlet gas H2S concentration will equal the inlet gas H2S concentration. 20. Maintain the reactor catalyst bed temperature at 390°C with the H2S rich amine acid gas flow to the reactor for a minimum of 4 hours to ensure the catalyst is fully sulphided. 21. Stop the flow of the H2S rich amine acid gas to the inlet of the Hydrogenation Reactor by closing the isolation valves near the Hydrogenation Reactor inlet line and the Regenerator Reflux Drum. 22. Depressurise the line through the drain line given upstream of the check valve. 23. Connect a Nitrogen hose to the acid gas line and purge the line through the drain line to acid gas flare. 24. Close the control valve 91-HV-1301 in the acid gas line. 25. Reverse the spectacle blinds to close position at both the ends of the acid gas line. 26. Reduce the reactor inlet temperature to 290°C by slowly reducing the firing. 27. Sulphiding of the reactor catalyst is now complete and the TGTU is now ready to receive and process SRU tail gases. 6.3.4.7

Lining up of Tail Gases to the TGTU

1.

Confirm that the SRU is operating at near to its minimum design acid gas feed rate.

2.

When the SRU operation has stabilised commission the tail gas analyzer 91-AT-1001.

3.

Set a H2S:SO2 ratio of 4.0:1.0 in the controller 91-ARC-1001.

4.

Open the Reactor Effluent Cooler 9102-E-11 outlet ON-OFF valve 91-XV-1331 to the Incinerator 9101-F-14.

5.

Close the Reactor Effluent Cooler 9102-E-11 outlet ON-OFF valve 91-XV-1332 to the Desuperheater/Contact Condenser 9102-C-11.

6.

Open the manual isolation valve in the Desuperheater/Contact Condenser 9102-C-11 gas outlet to the Tail Gas Amine Absorber 9102-C-12.

7.

Simultaneously open the SRU tail gas ON-OFF valve 91-XV-1098 to the TGTU and close the ON-OFF valve 91-XV-1097 to the Incinerator 9101-F-14.

8.

Slowly open the downstream isolation valve of the ON-OFF valve 91-XV-1098 and start the tail gas flow to the Reducing Gas Generator.

9.

Close the LP steam supply isolation valve to the Start-up Gas Steam Ejector 9102-X-11.

10. Close the process gas inlet isolation valve to the Start-up Gas Steam Ejector 9102-X-11 and outlet valve from the Start-up Gas Steam Ejector 9102-X-11.

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11. Close BSR section start-up vent gas pressure control valve 91-PV-1308 and manual isolation valves. 12. Close Nitrogen supply to the RGG process gas inlet line. 13. Observe Hydrogenation Reactor operation, catalyst temperature will increase as exothermic reactions take place in the reactors catalyst. 6.3.4.8

Lining up of TGTU Wet Section

1.

Ensure that the DCC 9102-C-11 process outlet gas isolation valve to the Tail Gas Amine Absorber 9102-C-11 is open.

2.

Ensure that DCC top chimney tray level is made up and the Cooling Water Circulation Pump 9102-P-12A/B is running circulating water back to the DCC top section.

3.

Ensure that sea cooling water is lined up to the Contact Condenser Trim Cooler 9102-E-13A/B.

4.

Ensure that the Contact Condenser Cooler 9102-E-12 fans are started and running.

5.

Ensure that the DCC bottom Desuperheater section water level is made up and the Desuperheater Circulation Pump 9102-P-11A/B is started and circulating water to the Desuperheater bottom 9102-C-11.

6.

Ensure that the desuperheater circulating water pH is maintained in the range of 9.0-10.0.

7.

Line up lean amine to the Tail Gas Amine Absorber 9102-C-12 by opening all the isolation valves from the Lean Amine Pumps 9103-P-13A/B discharge.

8.

Reset process shutdown and ensure that lean amine to Tail Gas Amine Absorber 9102-C-12 inlet ON-OFF valve 91-XV-1310 is opened.

9.

Open the lean amine flow control valve 91-FV-1301 slowly and establish a flow of lean amine to the Tail Gas Amine Absorber 9102-C-12. Put the control valve 91-FV1301 in auto with a set point of 110 m3/hr.

10. Ensure that the low low level alarm 91-LALL-1301 in the Tail Gas Amine Absorber 9102-C-12 is cancelled. 11. Check the level transmitter 91-LT-1308 and ensure that the level is increasing in the Tail Gas Amine Absorber 9102-C-12. 12. When the level reaches to about 50% in the Tail Gas Amine Absorber 9102-C-12, line up the Tail Gas Rich Amine Pumps 9102-P-16A/B by opening the suction and discharge isolation valves. 13. Keep the Tail Gas Rich Amine Pumps 9102-P-16A/B discharge control valves 91-FV1325 & 91-FV-1303 in closed condition. 14. Fill up the Tail Gas Rich Amine Pumps 9102-P-16A/B casing, by opening the casing vent valve and releasing Nitrogen.

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15. Put the LOR switch of the Tail Gas Rich Amine Pumps 9102-P-16A/B in ‘Remote’. 16. Reset the process shutdown and ensure that the Tail Gas Rich Amine Pumps 9102-P-16A/B discharge ON-OFF valve 91-XV-1309 is opened. 17. Start the Tail Gas Rich Amine Pump 9102-P-16A from ICSS. Put the Tail Gas Rich Amine Pump 9102-P-16B in AUTO from ICSS. 18. Open the minimum flow control valve 91-FV-1303 in manual and establish a flow rate of 31.25 m3/hr. Put the controller 91-FIC-1303 in AUTO with a set point of 31.25 m3/hr. 19. Take the level controller 91-LIC-1308 in AUTO with a set point of 50%. 20. Take the flow controller 91-FIC-1325 in REMOTE and ensure the level of the Tail Gas Amine Absorber is maintained at 50%. 21. Ensure that the level in the Acid Gas Amine Absorber 9103-C-11 is maintained due to the lining up of the rich amine from Tail Gas Amine Absorber 9102-C-12. 22. Ensure that the SRU is in stable operation and the acid gas feed to the SRU at or above the minimum design flow rate. 23. Ensure that the TGTU Hydrogenation Reactor is in a stable operation. 24. Open the Reactor Effluent Cooler process gas outlet valve 91-XV-1322 to the DCC and the close the process gas outlet valve 91-XV-1331 to the Incinerator 9101-F-14 through the hand switch 91-HS-1303A from the ICSS. 25. Check the Tail Gas Amine Absorber 9102-C-12 outlet vent gas line H2 and H2S analysers 91-AI-1301 in ICSS. The H2 analyser should show a minimum of 1.5% excess H2 in the vent gases. 26. Closely observe the Incinerator’s operation as the unit stops incineration of the H2S rich process gases from the Reactor Effluent Cooler and commences incineration of the very dilute in H2S rich vent gases from the Tail Gas Amine Absorber. 27. Ensure that the DCC cooling water circulation level control valve 91-LV-1305 is taken in auto with a set point of 50%. 28. Ensure that the DCC Desuperheater top up water control valve 91-LV-1307 is taken in auto with a set point of 50%. 29. Ensure that the level in the Contact Condenser is always maintained at 50% by making up with DM water if needed.

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6.4

RAMP UP OF PLANT LOAD 1.

Check the flow of acid gases from Regenerator Reflux Drum 9103-V-12 to Acid Gas KO Drum 9101-V-04 of SRU is above the minimum turndown required of 5935 kg/hr, for the SRU to operate.

2.

Gradually increase the flow from Regenerator Reflux Drum 9103-V-12 to Acid Gas KO Drum 9101-V-04 of SRU.

3.

Ensure the Acid Gas Pre-heater 9101-E-06 outlet temperature is maintained at 200°C.

4.

Adjust the process air flow to the Reaction furnace accordingly.

5.

Ensure that the Process Air pre-heater 9101-E-05 outlet temperature is maintained at 200°C.

6.

Ensure that steam drum 9101-V-07 level is maintained.

7.

Ensure that 1st Stage Converter 9101-V-01 inlet temperature is maintained at 230°C.

8.

Ensure that 2nd Stage Converter 9101-V-02 inlet temperature is maintained at 210°C.

9.

Ensure that the level in the Sulphur Degassing Pit 9101-T-01 is maintained.

10. Ensure that the tail gases from the SRU to the TGTU have gradually increased due to the load increase in the SRU. 11. Ensure that the combustion air flow to the Reducing gas Generator has increased accordingly. 12. Ensure that the Hydrogenation Reactor 9102-V-11 inlet temperature and outlet temperature are maintained at 290°C and 320°C. 13. Ensure that the BFW level is maintained in the Reactor Effluent Cooler 9102-E-11. 14. Ensure that the Tail Gas Amine Absorber level, pressure and temperature parameters are maintained. 15. Ensure that the Incinerator is at its normal operating temperature of 817°C.

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SECTION VII

OPERATION & MONITORING

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7.1

PROCESS PLANT OPERATION AND MONITORING

7.1.1

Acid Gas Enrichment Unit The absorption of H2S by the Methyl Di Ethanol Amine (MDEA) in the Acid Gas Amine Absorber 9103-C-11 is a function of the following: •

The flow and distribution of MDEA falling down the Acid Gas Amine Absorber tower through the upward flow of process gases

•

The temperature of the lean MDEA entering the Acid Gas Amine Absorber 9103-C-11.

•

The concentration and condition of the lean MDEA entering the Acid Gas Amine Absorber 9103-C-11

Monitoring of the amine unit will include the following: •

Regularly check the following vessels and towers level gauges and compare with DCS indicated levels: Sl. # 1.

•

Vessel Lean Acid Gas KO Drum

Vessel Tag No.

Level Gauge Tag No.

9103-V-14

9103-LG-1501A 9103-LG-1501B

2.

Acid Gas Amine Absorber

9103-C-11

9103-LG-1505A 9103-LG-1505B 9103-LG-1505C 9103-LG-1505D

3.

Amine Regenerator

9103-C-12

9103-LG-1506A 9103-LG-1506B

4.

Regenerator Reflux Drum

9103-V-12

9103-LG-1502

5.

Regenerator Reboiler Condensate Pot

9103-V-13

9103-LG-1504A 9103-LG-1504B

6.

Regenerator Reboiler

9103-E-13

9103-LG-1503

Regularly check the function of the following level transmitters and alarms to confirm correct operation: Sl. #

1.

2.

Vessel

Lean Acid Gas KO Drum

Acid Gas Amine Absorber

Vessel Tag No.

Level Transmitter Tag No.

9103-V-14

9103-LT-1501 9103-LT-1502 9103-LT-1503

9103-C-11

9103-LT-1505 9103-LT-1504 9103-LT-1516

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Sl. #

•

Vessel Tag No.

Level Transmitter Tag No.

3.

Amine Regenerator

9103-C-12

9103-LT-1509 9103-LT-1510 9103-LT-1517

4.

Regenerator Reflux Drum

9103-V-12

9103-LT-1506 9103-LT-1518

5.

Regenerator Reboiler Condensate Pot

9103-V-13

9103-LT-1508

Confirm that the following pumps are operating satisfactorily. Periodically run each spare pump and check the operation: Sl. #

•

Vessel

Pump

Pump Tag No.

1.

Acid Gas KO Drum Return Pump

9103-P-14A/B

2.

Acid Gas Rich Amine Pumps

9103-P-12A/B

3.

Hot Lean Amine Pumps

9103-P-17A/B

4.

Regenerator Reflux Drum Pumps

9103-P-11A/B

5.

Lean Amine Pumps

9103-P-13A/B

6.

Amine Sump Pump

9103-P-15

Confirm that the following air cooler fans are operating satisfactorily. Periodically run each spare fan and check the operation: Sl. #

1.

2.

Fan

Fan Tag No

Regenerator Condenser Cooler

9103-E-12AA 9103-E-12AB 9103-E-12AC 9103-E-12BA 9103-E-12BB 9103-E-12BC 9103-E-12CA 9103-E-12CB 9103-E-12CC 9103-E-12DA 9103-E-12DB 9103-E-12DC

Lean Amine Cooler

9103-E-14AA 9103-E-14AB 9103-E-14AC 9103-E-14BA 9103-E-14BB 9103-E-14BC

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Sl. #

Fan

Fan Tag No 9103-E-14CA 9103-E-14CB 9103-E-14CC 9103-E-14DA 9103-E-14DB 9103-E-14DC 9103-E-14EA 9103-E-14EB 9103-E-14EC 9103-E-14FA 9103-E-14FB 9103-E-14FC 9103-E-14GA 9103-E-14GB 9103-E-14GC 9103-E-14HA 9103-E-14HB 9103-E-14HC 9103-E-14IA 9103-E-14IB 9103-E-14IC 9103-E-14JA 9103-E-14JB 9103-E-14JC

•

Maintain lean amine flows to the amine absorbers at the correct flows for efficient absorption of H2S in the towers.

•

Maintain amine and gas temperatures as given below: Flow

•

Pressure, bar(a)

Temp. °C

Amine flow to Acid Gas Amine Absorber 9103-C-11

4.69

45

Process gas flow to Acid Gas Amine Absorber 9103-C-11

1.38

49

Regularly test the concentration of the lean amine. Add fresh amine if the strength is 1250°C to maximise thermal sulphur production in the Reaction Furnace 9101-F-01.

•

If Reaction Furnace 9101-F-01 temperatures appear excessive, check air and acid gas or fuel gas meters, and the Tail Gas Analyser 91-ARC-1001, to be sure the air to acid gas ratio is correct.

•

Be alert for hot spots on the outside of the shell of the Reaction Furnace 9101-F01 that would indicate refractory trouble.

•

Observe Reaction Furnace 9101-F-01 inlet pressure, an increase above normal will indicate a possible partial blockage in downstream converters and condensers and/or in the TGTU Hydrogenation Reactor and wet section towers.

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e. SRU Converters (9101-V-01 & 9101-V-02) The following points will help ensure efficient converter operation: •

Keep close surveillance of the temperatures at the inlet of SRU 1st Stage Converter 9101-V-01 and 2nd Stage Converter 9101-V-02. Keep these temperatures at 230/210ºC to avoid liquid sulphur deposition on the catalyst.

•

Sulphur deposition in a SRU 1st Stage Converter 9101-V-01 and 2nd Stage Converter 9101-V-02 catalysts is indicated by a progressive catalyst bed temperature drop starting at the top and continuing downward. If this is noted, increase the corresponding converter inlet temperature by adjusting the upstream auxiliary burner outlet temperature to carry out a rejuvenation of the converters catalyst.

•

Over long periods of operation a decrease in the activity of a SRU 1st Stage Converter 9101-V-01 and 2nd Stage Converter 9101-V-02 catalysts will be seen. The reaction of the H2S and SO2 in the process gas combining to form sulphur vapour is seen by the exothermic reaction in the converters. As the converters catalysts age this exothermic temperature rise reaction will be seen to move further down the converters catalyst bed. The temperature rise across the first converter will decrease whilst the temperature increase across the second converter will increase.

•

An increased pressure drop across the SRU, seen by an increased pressure on the Reaction Furnace 9101-F-01 process air inlet line pressure indicator 91-PI-1054 A/B/C, could indicate the deposition of soot/carbon deposits on the converters catalysts. Soot and carbon deposits are the result of operating the SRU at start-up or during a hot inert gas sweep with insufficient process air or steam injection to the fuel gas in the Reaction Furnace 9101-F-01 burner or the result of excess hydrocarbons in the acid feed gases to the SRU.

•

SRU converters 1st Stage Converter 9101-V-01 and 2nd Stage Converter 9101-V-02 catalyst deterioration can be partially reversed by carrying out a catalyst rejuvenation exercise. Failure of signs of improved catalyst activity following a series of rejuvenations will require the catalyst to be sulphur stripped.

Note that soot/carbon deactivation can only be corrected by removal of the contaminated top layers of catalyst from the reactors and replenishment with new. f. SRU Steam Generators & Condensers The following points should be carried out to ensure good operation of the Steam Generators: •

Regularly check the levels (as given below) of the SRU Reaction Furnace Boiler 9101-E-07 Steam Drum 9101-V-07, Reaction Furnace Condenser 9101-E-01, 1st Stage Condenser 9101-E-02 and Last Condenser 9101-E-04. These levels can vary on load change, especially during start-up, but will normally present no problem

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unless there is evidence of water carryover in the steam systems. In that case, gradually lower the steam generators level by operating the intermittent blow down. Blowing down too quickly could result in the start of a cycling level in the steam generator by an over compensating level controller. Sl. #

Column/Vessel

Level Gauges

Level Transmitters

1.

Reaction Furnace Boiler 9101-E-07 Steam Drum 9101-V-07

91-LG-1003 91-LG-1008

91-LT-1005

2.

Reaction Furnace Condenser 9101-E-01

91-LG-1004

91-LT-1008

3.

1st Stage Condenser 9101-E-02

91-LG-1005

91-LT-1011

•

Keep a record of the analysis of the treated Boiler Feed Water that enters the unit. Also maintain a record of the analysis of each Steam Generator Boiler Feed Water. These samples are drawn from the vessels continuous blow down lines through the sample coolers.

•

Maintain total dissolved solids, TDS, in the boiler water to below 3000 ppm for the LP Steam Generators and 1500 ppm for the SRU Reaction Furnace Boiler 9101-E-07. Control the TDS in each Steam Generator by the setting of the continuous blow down valve.

•

Carry out an intermittent blow down of each Steam Generator periodically to remove any accumulated sludge in the bottoms of the vessels. The frequency of this blow down will depend upon the quality of the Boiler Feed Water; a Boiler Feed Water containing a high TDS content will require more frequent intermittent blow downs than a demineralised or condensate based Boiler Feed Water that has a lower TDS content. Not using these blow downs will result in solids carry over from the Steam Generators into the steam systems. The long term result will be is the failure of the Steam Generators tubes due to overheating and or water side corrosion.

•

Maintain the Reaction Furnace Boiler 9101-E-07 at its operating pressure of 24.0 barg and the Reaction Furnace condenser 9101-E-01 and 1st Stage Condenser 9101-E-02 at 5.0 barg. Operating the LP steam system pressure higher than advised will result in viscous sulphur leaving the condensers and high temperatures in the sulphur pit.

•

Normal Operating Parameters - SRU Tag. No.

Description

Value

Unit

91-FI-1001

Acid gas flow to Reaction Furnace burner

>10912

Sm3/hr

91-TI-1003

Acid gas from Acid Gas Preheater temperature

200

°C

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Tag. No.

Description

Value

Unit

91-FIC-1002

Main Combustion Air flow to Reaction Furnace burner

21124.6

Sm3/hr

91-FIC-1002B

Secondary Air flow to Reaction Furnace burner

5744.1

Sm3/hr

91-FIC-1003

Trim Air flow to Reaction Furnace burner

2057.59

Sm3/hr

91-TI-1004

Air Temperature from Air Preheater

200

°C

91-TI-1055/ 1056

Reaction Furnace temperature

>1250

°C

91-TI-1005

Reaction Furnace Boiler oultlet process gas temperature

303

°C

91-TI-1006

Reaction Furnace Condenser outlet process gas temperature

185

°C

91-TICA-1007

1st stage auxiliary burner temperature

230

°C

st

91-FIC-1019

acid gas flow to 1 stage auxiliary burner

282

Sm3/hr

91-FIC-1018

Combustion Air flow to 1st Stage Auxiliary burner

909

Sm3/hr

91-HIC-1018A

air to fuel gas ratio in 1st stage auxiliary burner

8.35

91-HIC-1018B

air to acid gas ratio in 1st stage auxiliary burner

3.23

91-TI-1017

1st Stage Converter outlet process gas temperature

315

°C

91-TI-1018

1st Stage Condenser outlet process gas temperature

182

°C

91-TICA-1019

2nd Stage Auxiliary burner temperature

210

°C

nd

91-FIC-1026

acid gas flow to 2

stage auxiliary burner

156

Sm3/hr

91-FIC-1025

combustion air flow to 2nd stage auxiliary burner

520

Sm3/hr

91-HIC-1025A

air to fuel gas ratio in 2nd stage auxiliary burner

8.35

91-HIC-1025B

air to acid gas ratio in 2nd stage auxiliary burner

3.23

91-ARC-1001

H2S/SO2 analyzer ratio at Final Separator outlet, if TGTU is not in line

2:1

91-ARC-1001

H2S/SO2 analyzer ratio at Final Separator outlet, if TGTU is in line

4:1

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7.1.3

Tail Gas Treatment Unit The operation and monitoring of the TGTU includes the following activities: a. Hydrogenation Reactor 9102-V-11 Operation To maintain good operation of the Hydrogenation Reactor 9102-V-11 the following points should be noted: •

Maintain the RGG outlet temperature at 290⁰C

•

Maintain the RGG process air to fuel gas at a sub-stoichiometric ratio of approximately 14.0:1.0 (by weight)

•

Maintain the RGG steam to fuel gas at a ratio of approximately 2.0:1.0 (by weight)

•

The chemical conversion of SO2 to H2S in the Hydrogenation Reactor 9102-V-11 is exothermic. Changes in the H2S and SO2 concentrations in the SRU tail gases will be seen by a temperature change across the Hydrogenation Reactor 9102-V-11. A change in the H2 content, normally 2.0-4.0%, in the Tail Gas Amine Absorber 9102-C-12 outlet vent gases will also be seen. An increase in ∆T across the reactor indicates an increase in SO2 and a decrease in H2S in the SRU tail gases, whilst an increase of H2S and decrease of SO2 in the SRU tail gases will results in a decrease in ∆T across the reactor. When a change in the H2 content of the Tail Gas Amine Absorber 9102-C-12 vent gases is seen, check the upstream amine unit operation and the SRU Reaction Furnace 9101-F-01 controllers operation.

•

Observe the Hydrogenation Reactor 9102-V-11 catalyst ∆T 91-TDI-1307; it should normally be approximately 32°C.

•

Reactor inlet (91-TIC-1307) and outlet (91-TI-1310) temperatures are to be maintained around 290°C and 322°C respectively, Provided the unit is operated correctly the reactor catalyst should last for several years.

•

Over long periods of operation a decrease in the activity of the Hydrogenation Reactor 9101-V-11 catalyst will be seen. In the Hydrogenation Reactor 9101-V-11 deterioration in catalyst activity is seen by the point of reaction temperature moving down the catalyst bed and/or the ∆T (91-TDI-1307) increase falling below the 32°C expected across the reactor and possibly by an increase in the concentration of hydrogen seen by the Hydrogen Analyser 91-AI-1301 in the Tail Gas Amine Absorber 9102-C-12 outlet vent gas line.

•

If the Hydrogenation Reactor 9102-V-11 catalyst activity has declined then an increase in reactor inlet temperature may temporarily restore some activity, however a catalyst regeneration exercise will be eventually be required followed by sulphiding the catalyst to fully restore catalyst activity.

•

Periodically, e.g. every 3 months, sample the reactor outlet process gas and analyse for SO2.

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b. De superheater Contact Condenser 9102-C-11 Operation The following points should be carried out to ensure good operation of the De superheater Contact Condenser 9102-C-11 tower: •

Maintain the Desuperheater Contact Condenser 9102-C-11 tower top temperature (91-TI-1317) at 42°C.

•

Maintain the top (91-FIC-1307), bottom (91-FIC-1314) circulating water flows at 197 m3/hr and 199 m3/hr, respectively.

•

Control the Desuperheater circulating water pH between 9.0 and 10.0 by monitoring 91-AI-1302. Regularly check pH analyser probe for cleanliness and flow of sample to ensure it gives accurate readings. Daily samples to check the water pH using a portable pH meter or litmus paper should be used to verify the pH analyser accuracy. Failure of the analyser over a period of time could result in low pH circulation water and corrosion of equipment. Adjust Desuperheater circulating water pH by small injections, 1 - 2 litres of liquid caustic injection at a time. Over injection of caustic will result in free caustic in the circulating water with the potential for caustic deposition and possible fouling of equipment.

•

Note the times that caustic has to be injected. An increase in the frequency of caustic additon has to be added to the Desuperheater circulating water suggest that the Hydrogenation Reactor 9102-V-11 catalyst is not fully converting SO2 to H2S.

•

Regularly check the Desuperheater circulating water for colour. The water colour will change from brown to dark brown to black over time as it becomes contaminated by traces of SO2 which pass out of the Hydrogenation Reactor 9102-V-11 into the Desuperheater Contact Condenser 9102-C-11. Should a sudden breakthrough of SO2 from the Hydrogenation Reactor 9102-V-11 occur then a rapid change of the circulating water colour will take place, accompanied by a low pH. Should a sudden breakthrough of SO2 occur due to an upset in the SRU, and if the upset condition is likely to take some time to correct, then it is advised that the Desuperheater Contact Condenser 9102-C-11/Tail Gas Amine Absorber 9102-C-12, i.e. the TGTU wet section, are temporarily taken off line to minimise any low pH corrosion of the Desuperheater Contact Condenser 9102-C-11 and possible degradation to the Tail Gas Amine Absorber 9102-C-12 circulating amine.

•

Periodically change out the Desuperheater circulating water by manually bleeding off to the spent caustic system. Water from the top cooling section of the Desuperheater Contact Condenser 9102-C-11 automatically replenish the tower’s bottom Desuperheater section level.

•

Monitor the Desuperheater Contact Condenser 9102-C-11 tower packed sections differential pressure indicators 91-PDI-1323/1324. An increase in differential pressure >0.04 barg could indicate packing fouling or flooding whilst a decrease in

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

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TITLE: OPERATION AND MAINTENANCE MANUAL

pressure could indicate low circulation water flow and/or poor distribution across the packing. c. Tail Gas Amine Absorber 9102-C-12 The absorption of H2S by the Methyl Di Ethanol Amine (MDEA) in the Tail Gas Amine Absorber 9102-C-12 is a function of the following: •

The flow and distribution of MDEA falling down the Tail Gas Amine Absorber 9102-C-12 tower through the upward flow of process gases

•

The temperature of the lean MDEA entering the Tail Gas Amine Absorber 9102-C-12

•

The concentration and condition of the lean MDEA entering the Tail Gas Amine Absorber 9102-C-12

Monitoring of the amine unit will include the following: •

Regularly check the following Tail Gas Amine Absorber 9102-C-12 level gauges and compare with DCS indicated levels: Vessel

Vessel Tag No.

Tail Gas Amine Absorber

•

9102-C-12

Level Gauge Tag No. 9102-LG-1304A 9102-LG-1304B 9102-LG-1304C 9102-LG-1304D

Regularly check the function of the following level transmitters and alarms as given below to confirm correct operation: Vessel

Vessel Tag No.

Tail Gas Amine Absorber

9102-C-12

Level Transmitter Tag No. 9102-LT-1308 9102-LT-1301 9102-LT-1310

•

Maintain lean amine flow (91-FIC-1301) to the amine absorber at the correct flow for efficient absorption of H2S in the towers.

•

Maintain amine and gas temperatures as given below. Flow

Pressure, bar(a)

Temp. °C

Amine flow to Tail Gas Amine Absorber 9102-C-12

4.69

45

Process gas flow to Acid Gas Amine Absorber 9102-C-12

1.19

41

EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan Part-1 SRU (Mesaieed) Doc. No.: 2970-0-22-0001

Rev.: 0 Date: 03/09/2012 Page: 334 of 517

TITLE: OPERATION AND MAINTENANCE MANUAL

•

Regularly test the concentration of the lean amine. Add fresh amine if the strength is