ملف خاص بمعمل جنوب المنطقة الوسطى لأنه يعتمد النظام الحديث by Hasanen Mohammad

Any exploitation and/ or other utilization, including but not limited to reproduction, dissemination and/ or distribution of this document and its contents are strictly prohibited unless expressly authorized in writing by CAC. Offenders are liable for damages. All rights, including but not limited to all proprietary rights in relation to patents, utility models and/ or other industrial property rights, are reserved.

Index of Revisions Rev.

Prepared, changed Checked Name

Date

P. Torres

2.3.2007

Name

Approved Name

M. Nagel Niederstadt

Sheet Remarks, type of change

Date

Status

2.3.2007

INF

1 - 190 Draft for Information

Index of Relevant Documents Document No

Title

Summary of Revisions

0 1 2 3 X

12466-01 10001 Design Basis Memorandum

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

2 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Table of Contents 1

Design Basis ...........................................................................................................9

1.1

Introduction ................................................................................................................................9

1.2

Design Criteria ...........................................................................................................................9

1.3

Plant Capacity and Flexibility ...................................................................................................10

1.4

Feed Composition and Characteristics....................................................................................10

1.4.1

Gas from North Al Faid Field ...................................................................................................10

1.4.2

Gas from Abo Rabah Field ......................................................................................................11

1.4.3

Gas from Qomqom Field .........................................................................................................11

1.4.4

Mixture from Al Balass GGMS (for check up) .........................................................................12

1.4.5

Raw Water ...............................................................................................................................13

1.5

Products and By-Products .......................................................................................................14

1.5.1

Sales Gas ................................................................................................................................14

1.5.2

Liquefied Petrol Gas ................................................................................................................14

1.5.3

Gas Condensate......................................................................................................................14

1.5.4

Propane ...................................................................................................................................14

1.5.5

Fuel Gas ..................................................................................................................................15

1.5.6

Acid Gas ..................................................................................................................................16

1.5.7

Produced Water.......................................................................................................................16

1.5.8

Demineralized Water ...............................................................................................................16

1.5.9

Potable Water ..........................................................................................................................17

1.6

Utilities .....................................................................................................................................18

1.6.1

Quality and Conditions at Battery Limit....................................................................................18

1.6.1.1

Instrument Air ..........................................................................................................................18

1.6.1.2

Plant Air ...................................................................................................................................18

1.6.1.3

Nitrogen...................................................................................................................................19

1.6.1.4

Fuel Gas..................................................................................................................................19

1.6.1.5

Electrical Power.......................................................................................................................19

1.6.1.6

Potable Water .........................................................................................................................20

1.6.1.7

Service Water..........................................................................................................................20

1.6.2

Utility Block Flow Diagrams .....................................................................................................21

1.6.3

Utility Balance ..........................................................................................................................21

1.7

Chemicals ................................................................................................................................22

Description of the Plant........................................................................................23

2.1

Unit 100 Inlet Facilities.............................................................................................................23

2.1.1

Inlet Separation (Unit 100) .......................................................................................................23

2.1.2

Stabilization (Unit 110).............................................................................................................24

2.1.3

Methanol Injection (Unit 160) ...................................................................................................25

2.2

Unit 200 Gas Sweetening ........................................................................................................26

2.2.1

Amine Wash System (Unit 200) ..............................................................................................26

2.2.2

Amine Drain System (Unit 240) ...............................................................................................28

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

3 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.2.3

Acid Gas Incineration (Unit 260)..............................................................................................28

2.3

Unit 300 Hydrocarbon Recovery..............................................................................................29

2.3.1

Gas Dehydration and Glycol Regeneration Package (Unit 350)..............................................29

2.3.2

NGL Recovery (Unit 300).........................................................................................................30

2.3.3

Emulsion Breaker Unit (Unit 320) ............................................................................................31

2.3.4

Glycol Drain System (Unit 340)................................................................................................31

2.4

Unit 400 Fractionation..............................................................................................................32

2.4.1

Fractionation System (Unit 400) ..............................................................................................32

2.4.1.1

System Deethanizer Column GC-401 .....................................................................................32

2.4.1.2

System Debutanizer Column GC-402 .....................................................................................34

2.4.1.3

System Depropanizer Column GC-403...................................................................................35

2.4.2

Unit 440 HC Drain (Oily Slop) ..................................................................................................36

2.5

Unit 500 Gas Condensate Storage and Product Loading........................................................37

2.5.1

Condensate Storage & Loading (Unit 500) ..............................................................................37

2.5.2

LPG Storage & Loading (Unit 520) ..........................................................................................37

2.5.3

LPG Unloading (Unit 540)........................................................................................................39

2.5.4

Propane Storage (Unit 560) .....................................................................................................39

2.5.5

Weight Scale for Trucks ..........................................................................................................39

2.5.6

Chemicals Storage (Unit 580)..................................................................................................40

2.6

Unit 600 Utilities .......................................................................................................................41

2.6.1

Nitrogen System (Unit 600) .....................................................................................................41

2.6.2

Instrument Air System (Unit 630).............................................................................................41

2.6.3

Heat Medium System (Unit 650)..............................................................................................41

2.6.4

Propane Refrigeration System (Unit 670)................................................................................42

2.6.5

Flare System including Emergency Drain (Unit 690) ...............................................................43

2.6.5.1

Flare System ...........................................................................................................................43

2.6.5.2

Emergency Drain System........................................................................................................43

2.6.6

Fuel Gas System .....................................................................................................................44

2.7

Unit 700 Water Systems ..........................................................................................................45

2.7.1

Raw Water Treatment (Unit 700).............................................................................................45

2.7.2

Waste Water System (Unit 720)..............................................................................................45

2.7.3

Potable Water System (Unit 740) ............................................................................................46

2.7.4

Demineralized Water System (Unit 760) .................................................................................46

2.7.5

Fire Water System (Unit 780) ..................................................................................................46

2.8

Unit 800 Electrical Supply ........................................................................................................47

2.9

Summary of Operating Conditions of important Equipments ..................................................47

2.10

Process Simulation ..................................................................................................................48

Commissioning and Special Equipments Description.......................................49

3.1

Commissioning General ..........................................................................................................49

3.1.1

Commissioning Utilities............................................................................................................49

3.1.2

Commissioning Equipment......................................................................................................49

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

4 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

3.1.3

Commissioning Instruments, Computer, and Control..............................................................50

3.2

Special Equipments Description ..............................................................................................51

3.2.1

Mechanical Equipments or Units: ............................................................................................51

3.2.2

Instrumentation ........................................................................................................................51

3.2.2.1

Design Philosophy...................................................................................................................51

3.2.2.2

Design Criteria. Safeguarding Hierarchy:................................................................................52

3.2.2.3

ESD System and Relief System ..............................................................................................52

Start up ..................................................................................................................54

4.1

General ....................................................................................................................................54

4.2

Initial Start-up...........................................................................................................................54

4.2.1

Utilities Start-Up .......................................................................................................................55

4.2.1.1

Unit 800, Diesel Engine Generator (PU17) and Diesel Fuel Vessel .......................................55

4.2.1.2

Water Supply (Raw Water) Unit 700: ......................................................................................56

4.2.1.3

Safety and Fire Water System: ...............................................................................................57

4.2.1.4

Raw Water Treatment (PU-15; Unit 700) ................................................................................58

4.2.1.5

Instrument Air Generation Unit (PU-09): .................................................................................59

4.2.1.6

Nitrogen Generation Unit (PU10A):.........................................................................................59

4.2.1.7

Start up Flare Stack (PU-06) and Fuel Gas System with â&#x20AC;&#x153;Raw Wet Gasâ&#x20AC;? ..............................60

4.2.1.8

Start up with Fuel Gas from the Sales Gas Pipeline (Dry sweet gas) .....................................62

4.2.1.9

Service Generator (PU11).......................................................................................................63

4.2.1.10

Methanol Storage and Injection:............................................................................................63

4.2.1.11

Glycol Storage .......................................................................................................................65

4.2.1.12

Amine Storage.......................................................................................................................65

4.2.1.13

Corrosion Inhibitor .................................................................................................................66

4.2.1.14

Anti-Foam..............................................................................................................................67

4.2.1.15

Propane.................................................................................................................................67

4.2.1.16

Heat Media System (PU07)...................................................................................................68

4.2.2

Instruction for Purge and Inert .................................................................................................68

4.2.2.1

Circuit Nr 1, Unit 100. Sour Gas Inlet Separator (GV-101) .....................................................68

4.2.2.2

Circuit Nr 2. Unit 200. Gas Sweetening...................................................................................69

4.2.2.3

Circuit Nr 3. Unit 110. Stabilization Unit ..................................................................................70

4.2.2.4

Circuit Nr 4 Unit 100; Sweet Gas Inlet Separators (GV-102; GV-103)....................................71

4.2.2.5

Circuit Nr 5. Unit 300/350; Hydrocarbon Recovery .................................................................72

4.2.2.6

Circuit No 6. Unit 400; Fractionation. ......................................................................................73

4.2.2.7

Circuit No 7. Unit 500; Condensate and LPG Storage. Loading System ................................74

4.3

Gas Treatment Plant Start-Up .................................................................................................75

4.3.1

Start Up Procedures ................................................................................................................76

4.3.1.1

Sweet Gas Inlet Separator (GV-102) ......................................................................................76

4.3.1.2

Sweet Gas Inlet Separator (GV-103) ......................................................................................77

4.3.1.3

Dehydration Unit (PU-03) ........................................................................................................78

4.3.1.4

Unit 300 Hydrocarbon Recovery Process ...............................................................................80

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

5 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.3.1.5

Produced Water Flash Drum (GV-724); Produced Water Storage Tank (GT-722) ................82

4.3.1.6

Deethanizer Feed/Drum (GV-419) ..........................................................................................83

4.3.1.7

Deethanizer Column (GC-401) and Related Equipments .......................................................85

4.3.1.8

Debutanizer Column (GC-402) and Related Equipments .......................................................88

4.3.1.9

Gas Condensate Storage........................................................................................................90

4.3.1.10

LPG Storage..........................................................................................................................91

4.3.1.11

Depropanizer Column (GC-403) and Related Equipments ...................................................92

4.3.1.12

Propane Storage ...................................................................................................................93

4.3.1.13

Loading Station (PU-13) ........................................................................................................94

4.3.1.14

Sour Gas Inlet Separator (GV-101).......................................................................................95

4.3.1.15

Sour Gas/liquid Stabilization..................................................................................................96

4.3.1.16

Procedure to Clean Out Amine System: ...............................................................................98

4.3.1.17

Unit 200. Gas Sweetening Amine System (low pressure side) .............................................99

4.3.1.18

Unit 200. Gas Sweetening Amine System (Filter GF-208)..................................................101

4.3.1.19

Unit 200. Gas Sweetening, Amine System (high pressure side).........................................102

4.3.1.20

Unit 200. Gas Sweetening, Amine Drain System ................................................................104

4.3.1.21

Unit 200. Gas Sweetening, Amine Flash Drum (GV-220)...................................................104

4.3.1.22

Unit 200. Amine Filters (GF-209 A/B; GF-210; GF-211). ....................................................105

4.3.1.23

Unit 260. Acid Gas Separator (GV-261), Transfer Vessel (GV-262). .................................106

4.3.1.24

Unit 260. Acid Gas Incinerator Unit (PU02).........................................................................107

4.3.1.25

Unit 400/440. Oily Drain System. ........................................................................................108

4.3.1.26

Final Consideration before to Start Up Sales/Buyback Custody Metering ..........................108

4.3.1.27

Sales/Buyback Custody Metering........................................................................................109

4.3.2

Updating Start-Up Procedures...............................................................................................110

4.4

Start Up following process Shut Down (Intermediate Start Up).............................................111

4.5

Start Up following Emergency Shut Down (Restart) ..............................................................112

4.5.1

Sour Gas Inlet Separator (GV-101), Restart..........................................................................112

4.5.2

Sweet Gas Inlet Separator (GV-102), Restart .......................................................................114

4.5.3

Sweet Gas Inlet Separator (GV-103), Restart .......................................................................115

4.5.4

Unit 200. Gas Sweetening, Amine Contactor (GC-201), Restart ..........................................116

4.5.5

Dehydration Unit (PU-03), Restart .........................................................................................118

4.5.6

Hydrocarbon recovery, Restart ..............................................................................................119

Production Control â&#x20AC;&#x201C; Analysis ...........................................................................122

5.1

Analysis Plan .........................................................................................................................122

5.2

Description of Analysing Methods..........................................................................................122

Shut down ...........................................................................................................123

6.1

Normal Controlled Shut Down ...............................................................................................123

6.1.1

Sour Gas Inlet Separator (GV-101) .......................................................................................124

6.1.2

Sour Gas/liquid Stabilization, Unit 110...................................................................................125

6.1.3

Gas Sweetening, Unit 200 .....................................................................................................126

6.1.4

Acid Gas Incinerator, Unit 260...............................................................................................128

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

6 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.1.5

Sweet Gas Inlet Separator (GV-102).....................................................................................130

6.1.6

Sweet Gas Inlet Separator (GV-103).....................................................................................130

6.1.7

Dehydration Unit (PU-03), Unit 300 .......................................................................................131

6.1.8

Hydrocarbon Recovery Process, Unit 300.............................................................................132

6.1.9

Fractionation - Deethanizer, Unit 400 ....................................................................................133

6.1.10

Fractionation – Debutanizer, Unit 400 ...................................................................................135

6.1.11

Gas Condensate Storage ......................................................................................................136

6.1.12

LPG Storage. .........................................................................................................................136

6.1.12.1

LPG Off Spec Bullet (GV-528) ............................................................................................137

6.1.12.2

LPG Storage Bullet (GV-526A) ...........................................................................................137

6.1.12.3

LPG Storage Bullet (GV-526B) ...........................................................................................138

6.1.12.4

LPG Storage Bullet (GV-526C) ...........................................................................................138

6.1.13

Fractionation – Depropanizer, Unit 400 .................................................................................139

6.1.14

Propane Storage....................................................................................................................139

6.1.15

Produced Water Flash Drum (GV-724); Produced Water Storage Tank (GT-722) ..............140

6.2

Extended Shut Down .............................................................................................................141

6.3

Emergency Shut Down ..........................................................................................................141

6.3.1

General ..................................................................................................................................141

6.3.2

Classification of Safeguarding ...............................................................................................143

6.3.3

ESD Description ....................................................................................................................144

6.3.3.1

ESD- SD-2A: Unit 100/110 Sour Gas Inlet Separator/ Stabilization......................................144

6.3.3.2

ESD- SD-2B: Unit 100 Sweet Inlet Separators .....................................................................147

6.3.3.3

ESD- SD-2C: Unit 200/260 Gas Sweetening/ Acid Gas Incinerator......................................149

6.3.3.4

ESD- SD-2D: Unit 350 Dehydration Unit (PU03)...................................................................151

6.3.3.5

ESD- SD-2E: Unit 300 NGL Recovery ..................................................................................152

6.3.3.6

ESD- SD-2F to 2I: Unit 400 Fractionation .............................................................................153

6.3.3.7

ESD- SD-2F: Section Deethanizer Feed Drum GV-419........................................................153

6.3.3.8

ESD- SD-2G: Section Deethanizer Column GC-401 and Reflux Drum GV-420...................155

6.3.3.9

ESD- SD-2H: Section Debutanizer / Depropanizer Column GC-402/GC-403 ......................156

6.3.3.10

ESD- SD-2I: Section Deethanizer OVHD Compressor Unit (PU04) ...................................158

6.3.3.11 ESD-SD-2J to 2P: Unit 500/520/530/560 Condensate, LPG, Off Spec and Propane Storage ..................................................................................................................159 6.3.3.12

ESD- SD-2J to 2M and 2O: Unit 520 LPG Off Spec/LPG Bullets and Unit 560 Propane Storage Bullet ......................................................................................................................160

6.3.3.13

ESD- SD-2J: Unit 520 Off Spec Bullet GV-528 ...................................................................161

6.3.3.14

ESD- SD-2K: Unit 520 LPG Bullet GV-526A.......................................................................161

6.3.3.15

ESD- SD-2L: Unit 520 LPG Bullet GV-526B .......................................................................162

6.3.3.16

ESD- SD-2M: Unit 520 LPG Bullet GV-526C ......................................................................162

6.3.3.17

ESD- SD-2O: Unit 560 Propane Bullet GV-562 ..................................................................163

6.3.3.18

ESD- SD-2N: Unit 530 Sour Off Spec Bullet GV-530..........................................................163

6.3.3.19

ESD- SD-2P: Unit 500 Condensate Storage Tank GT-506 ................................................164

6.3.3.20

ESD- SD-2Q: Unit 670 Propane Refrigeration System .......................................................165

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

7 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.21

ESD- SD-2R: Loading Station (PU13).................................................................................166

6.3.3.22

ESD- SD-2S: Sales Gas to B.L. ..........................................................................................167

6.3.4

ESD General Functions .........................................................................................................168

6.3.4.1

ESD Level 0. Plant Shut Down..............................................................................................168

6.3.4.2

Plant Air to Pits ......................................................................................................................169

6.3.5

Gas detection at Heaters and Incinerator respectively ..........................................................170

6.3.6

Fire detection .........................................................................................................................170

6.3.7

Safeguarding Flow Schemes.................................................................................................170

Safety ...................................................................................................................171

7.1

Chemicals Properties and Hazards .......................................................................................171

7.1.1

H2S and CO2 Human Body Concentration Exposure ...........................................................171

7.1.2

Safety Precautions to Prevent exposure to hazardous Chemicals........................................171

7.1.3

Personal Protective Devices ..................................................................................................172

7.1.4

Protective Practices ...............................................................................................................173

7.1.5

Safety Data Sheets ................................................................................................................174

7.2

Emergency Procedures .........................................................................................................175

Appendices..........................................................................................................176

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

8 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Design Basis 1.1

Introduction Syrian Gas Company plans to further develop the South Middle Area gas Exploitation Project located about 70 km west of the City of Palmyra, Syria. The project involves the tie-in of the wells in three non-associated gas fields to a central location in each field, the central facilities in each field, main gathering pipelines from these central facilities to a gas treatment plant, and a gas treatment plant that removes H2S from the sour gas and produces specification sales gas, LPG, and condensate. The sales gas will be pipelined to the existing Palmyra pipeline in the area, and the condensate will be pumped to an oil pipeline in the area.

1.2

Design Criteria The design of the plant is based on the Document: “Design Basis Memorandum” (Doc.-No. 12466-01 10001). The following important principles were taken in consideration for designing the facilities of gas treatment and conditioning as well as for fractionation of natural gas liquids (NGL): Designing is carried out based on the Basic Design of TITAN Company with a view to achieve a high NGL yield. The complete facility is designed for achieving a capacity referred to raw gas of 7.560 Mm³/d (120% of 6.300 Mm³/d). The design has been made for three defined feedstock mixtures. A fourth has been checked for consequences in capacity of the facility and quality of the product. The whole facility is designed as a one-line unit with two separate inlet facilities, one for sour gas and one for H2S free gas. Main equipment is principally designed for a technologically required above mentioned capacity without additional reserve. Parallel apparatuses, which have to be operated continuously, have been considered as one equipment unit. Excepted from this are pumps and compressors, which mostly have a stand-by of 100 % (1 + R) or 50 % (2 + R). The stabilization facility of the Gas Treatment Plant is designed for achieving of a H2S content in the liquid HC of 3 mol-ppm maximum. The gas amine wash system has been designed for removal of H2S as well as of a portion of approx. 50 % of the CO2 content in the sour gas. For maintaining the required water dew point temperature a TEG Dehydration Unit has been included. The NGL Recovery System is designed to reach a product temperature of –37 °C at operation pressure. The propane production for make up purpose and for sales is designed for a capacity of 155 kg/hr and may be run discontinuously. The produced water can be pumped to a loading facility for disposal outside battery limit or to the evaporation pond.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

9 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.3

Plant Capacity and Flexibility Maximum plant capacity The maximum plant capacity is defined as the capacity referred to raw gas of 7.56 MMm³/d. This capacity consist in:

Case A 1.80 MMm³/d sour feed plus 5.76 MMm³/d sweet feed Case B 0.96 MMm³/d sour feed plus 6.60 MMm³/d sweet feed

Normal plant capacity Also called “100 % Case” is defined as the capacity referred to raw gas of 6.300 Mm³/d. This capacity consist of: 1.500 Mm³/d sour feed plus 4.800 Mm³/d sweet feed Minimum plant capacity Also called “60 % Case” is related to the 100 % Case and defined as the capacity referred to raw gas of 3.780 Mm³/d. This capacity consist of:

900 Mm³/d sour feed plus 2.880 Mm³/d sweet feed

At least the turn down ratio is 50 % related to total plant capacity (7.56 to 3.78 Mm³/d), 50 % related to sour feed (1.80 to 0.9 Mm³/d), 43,6 % related to sweet feed (6.60 to 2.88 Mm³/d). 1.4

Feed Composition and Characteristics 1.4.1

Gas from North Al Faid Field

Recombined Gas Analysis

Dimension

mol-%

2.09

CO2

mol-%

2.43

H2S

mol-%

0.24

CH4

mol-%

90.91

C2H6

mol-%

1.30

C3H8

mol-%

0.73

IC4H10

mol-%

0.28

NC4H10

mol-%

0.29

IC5H12

mol-%

0.23

NC5H12

mol-%

0.20

EDV-Ident-Nr.

Value

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

10 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Recombined Gas Analysis

Dimension

mol-%

0.39

mol-%

0.29

mol-%

0.24

mol-%

0.12

C10+

mol-%

0.26

Estimated Minimum Free Water

m続 per MMm続 gas

2.35

1.4.2

Value

Gas from Abo Rabah Field

Recombined Gas Analysis

Dimension

mol-%

1.21

CO2

mol-%

0.86

H2S

mol-%

CH4

mol-%

91.19

C2H6

mol-%

2.98

C3H8

mol-%

1.07

IC4H10

mol-%

0.35

NC4H10

mol-%

0.44

IC5H12

mol-%

0.26

NC5H12

mol-%

0.18

mol-%

0.29

mol-%

0.32

mol-%

0.26

mol-%

0.18

C10+

mol-%

0.41

Estimated Minimum Free Water

m続 per MMm続 gas

1.85

1.4.3

Value

Gas from Qomqom Field

Recombined Gas Analysis

Dimension

mol-%

2.09

CO2

mol-%

6.89

EDV-Ident-Nr.

Value

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

11 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Recombined Gas Analysis

Dimension

H2S

mol-%

0.0

CH4

mol-%

88.46

C2H6

mol-%

1.16

C3H8

mol-%

0.41

IC4H10

mol-%

0.15

NC4H10

mol-%

0.46

IC5H12

mol-%

0.05

NC5H12

mol-%

0.09

C6+

mol-%

0.24

mol-%

C10+

mol-%

Estimated Minimum Free Water

m続 per MMm続 gas

1.4.4

Value

2.12

Mixture from Al Balass GGMS (for check up)

Gas Analysis

Dimension

mol-%

2.14

CO2

mol-%

1.54

H2S

mol-%

0.0

CH4

mol-%

88.61

C2H6

mol-%

3.56

C3H8

mol-%

1.70

iC4H10

mol-%

0.37

nC4H10

mol-%

0.56

iC5H12

mol-%

0.27

nC5H12

mol-%

0.17

mol-%

0.22

mol-%

0.34

mol-%

0.27

mol-%

0.13

C10+

mol-%

0.10

Vapour Fraction

EDV-Ident-Nr.

Value

0.9847 Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

12 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Gas Analysis

Dimension

Temperature

°C

Pressure

bar (g)

Molar Flow

kgmole/h

Std Gas Flow

m³/d

2.509.120

Mass Flow

kg/h

85.558

Mass Density

kg/m³

81.13

Molecular Weight

kg/kgmole

19.35

Std Gas Flow (vapour)

m³/d

2.470.660

Std. Liqu. Volume Flow

m³/d

179.6

Std. Aqu. Volume Flow

m³/d

0.0

1.4.5

26.6

Dimension

Total hardness

mg/l

Organic Substances

mg/l

4421.6

Value

wt-ppm -

wt-ppm

NO3 NO2 PO4 SO4

wt-ppm

mg/l

NH4

mg/l

Fe.T

mg/l

Color

Odor

pH value

Temperature

°C

OCl Na

EDV-Ident-Nr.

83.14

Raw Water

Typical Water Analysis

Value

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

13 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.5

Products and By-Products 1.5.1

Sales Gas

The sales gas will be produced according the following parameters: Parameter

Value

Dimension

Water Dew Point

max 0

°C @ 75 bar(g)

Hydrocarbon Dew Point

max 0

°C @ 75 bar(g)

Gross Heating Value of sales gas

min 950 – max 1160

Btu/std cubic feet

CO2 Specification

Gas must meet lower heating value spec

H2S Content Total Sulphur

22 max 30 max

1.5.2

ppm vol ppm wt

Liquefied Petrol Gas

Liquefied Petrol Gas will be produced according the following parameters: Parameter

Value

Dimension

C3 Content

up to 25 max

wt-%

C4 Content

not less than 73

wt-%

Content of C5+

2 max

wt-%

Vapour Pressure

bar(g) @ 50°C

Max. temp. to evaporate 95 vol-%

2.2

°C

1.5.3

Gas Condensate

Gas Condensate will be produced according the following parameters: Parameter

Value

Dimension

Reid vapour pressure

0.8 max

bar(a)

The content of sulphur components (except H2S) is not adjustable and therefore complies with the amount in the raw material. 1.5.4

Propane

Propane will be produced according the following parameters:

EDV-Ident-Nr.

Parameter

Value

Dimension

C3 Content

not less than 98

mole-%

C4 Content

max 2

mole-%

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

14 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.5.5

Fuel Gas

Fuel gas will be produced only for internal use. Therefore, it is not necessary to obtain certain quality parameters. The expected typical composition of Fuel Gas is: Gas from suction side of GK-423A/B Typical Gas Analysis

Dimension

mol-%

0,3

CO2

mol-%

3,2

H2S

ppm

CH4

mol-%

78,3

C2H6

mol-%

11,2

C3H8

mol-%

4,1

C4H10

mol-%

2,2

C5+

mol-%

0,5

water

mol-%

0,2

Lower Heating Value

MJ/Stdm続

Value

42,7

Gas from Sales Gas header Typical Gas Analysis

Dimension

mol-%

1,5

CO2

mol-%

1,4

H2S

ppm

CH4

mol-%

93,2

C2H6

mol-%

2,5

C3H8

mol-%

0,8

C4H10

mol-%

0,4

C5+

mol-%

0,2

water

mol-ppm

Lower Heating Value

MJ/Stdm続

EDV-Ident-Nr.

Value

36,6

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

15 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.5.6

Acid Gas

The Acid Gas is a By-Product, which becomes incinerated internally in PU-02. The expected typical composition of Acid Gas is:

Typical Gas Analysis

Dimension

mol-%

0,03

CO2

mol-%

69,50

H2S

mol-%

13,60

CH4

mol-%

2,06

C2H6

mol-%

0,03

C3H8

mol-%

0,01

Water

mol-%

14,77

1.5.7

Value

Produced Water

The Produced Water is a By-Product, which is sent by truck to further handling. The expected typical composition is:

Typical Water Analysis

Dimension

Water

mol-%

98,9

CO2

mole-ppm

235

H2S

mole-ppm

CH4

mole-ppm

Chlorine (expected)

mole-ppm

10000

Dimension

Value

1.5.8

Value

Demineralized Water

Typical Water Analysis Total dissolved solids

100

Total hardness

Content of Chlorides

wt-ppm

Sodium Content

wt-ppm

Potassium Content

wt-ppm

Iron Content

wt-ppm

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

16 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.5.9

Potable Water

Typical Water Analysis

Dimension

Value

Total hardness

mg/l

max. 500

Organic Substances

mg/l

max. 2

wt-ppm

max. 1,5

wt-ppm

max. 250

wt-ppm

max. 45

wt-ppm

max. 0.033

mg/l

max. 0.5

mg/l

max. 250

mg/l

max. 0.5

mg/l

max. 200

NH4

mg/l

max. 0.05

Fe.T

mg/l

max. 0.3

Color

colorless

Odor

odorless

pH value

6.5 – 8.5

El. Conductivity

µS/cm

Temperature

°C

NO3 NO2 PO4 SO4 OCl Na

EDV-Ident-Nr.

1500 max. 25

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

17 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.6

Utilities 1.6.1

Quality and Conditions at Battery Limit

All Utilities used in the gas treatment plant are provided in the own plant. The quality parameters and conditions at B.L. are shown in the following tables: 1.6.1.1

Instrument Air Parameter

Value

Dimension

min

bar(g)

norm

bar(g)

max

bar(g)

min

-12

°C

norm

ambient

°C

max

°C

Dew point at operating pressure

-30

°C

Design Pressure

bar(g)

Design Temperature

°C

Value

Dimension

min

bar(g)

norm

bar(g)

max

bar(g)

min

-12

°C

norm

ambient

°C

max

°C

Dew point at operating pressure

-30

°C

Design Pressure

bar(g)

Design Temperature

°C

Operating Pressure

Operating Temperature

1.6.1.2

Plant Air Parameter

Operating Pressure

Operating Temperature

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

18 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.6.1.3

Nitrogen Parameter

Value

Dimension

Nitrogen Content

min 99

mole-%

Oxygen Content

max 1

mole-%

min

bar(g)

norm

bar(g)

max

bar(g)

min

-12

°C

norm

ambient

°C

max

°C

Dew point at operating pressure

-30

°C

Design Pressure

bar(g)

Design Temperature

°C

Value

Dimension

min

bar(g)

norm

bar(g)

max

bar(g)

min

-12

°C

norm

ambient

°C

max

°C

Dew point at operating pressure

-30

°C

Design Pressure

bar(g)

Design Temperature

°C

Value

Dimension

above 132 kW

3.3

up to 110 kW

400

Operating Pressure

Operating Temperature

1.6.1.4

Fuel Gas

Typical composition - see point 1.5.5 Parameter Operating Pressure

Operating Temperature

1.6.1.5

Electrical Power Parameter

Motor Drives

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

19 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Parameter

Value

Dimension

230

230 and 24

Switch Gears

110

Convenience Outlets

230

Value

Dimension

min

bar(g)

norm

bar(g)

max

bar(g)

min

°C

norm

°C

max

°C

Design Pressure

bar(g)

Design Temperature

°C

Lighting Systems Levels for Instruments

1.6.1.6

Potable Water

Quality parameter - see point 1.5.9 Parameter Operating Pressure

Operating Temperature

1.6.1.7

Service Water

Two different types of water can be charged to the Service Water System - Potable Water (quality - see point 1.5.9) or - Raw Water (quality - see point 1.4.5) Parameter

Value

Dimension

min

bar(g)

norm

bar(g)

max

bar(g)

min

°C

norm

°C

max

°C

Design Pressure

bar(g)

Design Temperature

°C

Operating Pressure

Operating Temperature

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

20 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

1.6.2

1.6.3

EDV-Ident-Nr.

Utility Block Flow Diagrams

The Utility Block Flow Diagrams (utilities with continuous consumption) are shown in Appendix 5. Utility Balance

The Utility Balance is shown in Appendix 6.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

21 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

Ausgabe: 02/05 Rev.:01

CFA 1500E

1.7

Chemicals For normal operation of the Gas Treatment Plant the following Chemicals and Auxiliary Aids are required: Chemicals Triethylene Glycol Heat Media (Shell Thermia B) Methyl Diethanol Amine (MDEA) Methanol Odorant Antifoam Agent (for Unit 200) Corrosion Inhibitor (water soluble for Unit 200) Corrosion Inhibitor (HC soluble for Unit 100) Emulsion Breaker Foaming agent (for fire fighting purpose) Chemicals of Package Units to be added Auxiliary Aids Activated Carbon (for Unit 200) Soda solution (for degreasing of amine system during start-up) Molecular sieve Auxiliary Aids of Package Units to be added. Detailed information about the use of the chemicals are introduced in the description of the plant and in the â&#x20AC;&#x153;Specification of Catalyst and Chemicalsâ&#x20AC;? (Document No 12466-01 10223), shown in Appendix 7. The Safety Data Sheets are also given in the above mentioned document.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

22 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Description of the Plant 2.1

Unit 100 Inlet Facilities 2.1.1

Inlet Separation (Unit 100)

See PFD:

12466-01 10102 12466-01 10103

In the Inlet Manifold two streams of gas/liquid mixtures are taken over into the plant. The sour gas stream from the North Al Faid Pipeline (Sour Feed) which contains up to 0.24 mole-% H2S is sent to the Sour Gas Inlet Separator GV-101 and the H2S free sweet gas stream from the Abo Rabah Pipeline, which contains also gas from Qomqom-Field, will be sent to the Sweet Gas Inlet Separators GV-102 and GV-103. In the Gas Inlet Separators the separation of the water phase and natural gas liquids from gas phase takes place. The water and natural gas liquids separation is based on difference of density. The settling conditions for water will be influenced mainly by the weir height in the separator, which causes a very low velocity of the liquid. The capacity of each Gas Inlet Separator is provided big enough to handle possible liquid slug of approximately 5 m続. In case of 5 m続 slug enters one separator, the liquid level increases to about 1.20 m and overflows the weir, which has a height of 1.00 m. At this time a very small amount of water may enter the hydrocarbon chamber because the velocity in the water chamber increases. The settling conditions for liquid droplets will be also influenced by the weir height in the separator, exactly by the free area above the liquid surface, by the distance between inlet and gas outlet nozzle and by the demister. The demister is provided as a vane type, which allows sending the separated liquid back behind the weir. Using this system removed water particles that do not fall into the hydrocarbon chamber. The pressure in the plant is controlled by means of pressure transducers in the gas lines downstream of the Inlet Gas Separators (one for both Sweet Gas Inlet Separators GV-102 and GV-103 and one for the Sour Inlet Gas Separator GV-101), that adjust the control valves upstream the Gas Inlet Separators. The (required) operating pressure will be influenced at least mainly by the pressure in the sales gas pipeline and the planned throughput. Considering, that the pressure drop of the plant is 3.5 to 5.5 bar (depended on the throughput) the performance of Gas Field Wells have to be provided in the required way. In case of High-High pressure or High-High Liquid Level in Sweet Gas Inlet Separators GV-102 and GV-103 or Sour Gas Separator GV-101, the Unit Shut Down valves in Inlet Facilities (UV-G101F in Sour Gas Feed and UV-G102F; UV-G103F in Sweet Gas Feed) are closed via interlock (PSD). The water phase is sent level controlled (two point interface level controller) to the Produced Water Flash Drum GV-724 for further handling. In case of Low-Low water level and/or Low-Low NG Liquids Level in inlet separators, the water level control valves are closed via interlock to prevent gas-break through to produced water system. Also, if liquid level is too high in Produced Water Flash Drum GV-724 and/or Produced Water Tank GT722, the water level control valves are closed via interlock to prevent liquid overflow in produced water system. The hydrocarbon liquids phase is sent level controlled to further handling. The sour natural gas liquids (Sour HC Liquids) from the Sour Gas Inlet Separator GV-101 are sent to stabilization (Unit 110). The sweet natural gas liquids (Sweet HC Liquids) from the Sweet

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

23 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Gas Inlet Separators GV-102 and GV-103 are lead to the Deethanizer Feed Drum GV-419 in the Fractionation Unit 400. In case of NG Liquid Level is too low in Sweet Gas Inlet Separators and/or Liquid Level is too high in Deethanizer Feed Drum GV-419, the NG Liquid level control valves in GV-102 and GV-103 are closed via interlock to prevent gasbreak through or liquid overflow in Deethanizer Feed Drum GV-419. The outlet streams from all inlet separators are measured for balancing of the whole plant. For effective measuring it is necessary during start up to provide characteristic property curves for different operating conditions which can be used in the computer system for balancing. For different reasons such like low ambient temperature, high water content in feed, high differential pressure between incoming pipeline and inlet separator freezing problems may occur at pressure controller water phase level controllers or NGL level controllers. At this exposed points the possibility of methanol injection is provided. A (typical) quantity between 5 and 15 l/hr at each injection point can be adjusted by hand. 2.1.2

Stabilization (Unit 110)

See PFD:

12466-01 10104

The sour natural gas liquids (Sour HC Liquids) from the Sour Gas Inlet Separator GV-101 are sent level controlled via Stabilizer Feed Preheater GE-112A/B, to the Stabilizer Column GC-111. If Sour Gas Liquid Level is too low in Sour Gas Inlet Separator GV-101 and/or Liquid Level is too high in Stabilizer Column GC-111, the Liquid Level Control valve in GV-101 is closed via interlock to prevent gas-break through or liquid overflow in Stabilizer Column GC-111. The operating pressure of column GC-111 is approx. 7.5 bar(g). Overhead vapors are partly condensed in Stabilizer Top Condenser GE-114 at 65째C, and separated in the Stabilizer Reflux Drum GV-116 in liquid hydrocarbons, water (if any) and gas. The stabilizer is running with total reflux. The reflux is given to the top of GC-111 by means of Stabilizer Reflux Pump GP-115A/B. The pressure in the Stabilizer Column GC-111 is controlled by means of the control valves in the bypass around the two stages of the compressor GK-117A/B (pressure at suction side constant). In case of high pressure at suction side of GK-117A/B gas can be sent partly or total to flare. The bottom temperature of the Stabilizer Column GC-111 (approx. 195 째C) is done by adjusting the heat medium flow (thermal oil) through the Stabilizer Reboiler GE-113. In case of High-High pressure in GC-111, the temperature control valve in GE-113 is closed via interlock. The gas condensate is sent level controlled via Stabilizer Feed Preheater GE-112A/B, where it will be cooled down below 40 째C (almost approx. 25 째C), to the Condensate Storage Tank GT-506. In case of disturbances or off spec product, the bottom product can be sent to the Sour Off Spec Bullet GV-530. The Liquid hydrocarbons separated in Stabilizer Reflux Drum GV-116 are sent via reflux to GC-111. The level is controlled by flow control valve located in discharge line of Stabilizer Reflux Pump GP-115A/B. In the same way, Pump Control is provided by throttling the flow control valve in the discharge piping of the pump. These pumps are shut down by LowLow level in GV-116 or by Low-Low flow in suction line. Collected water in GV-116 is sent to Produced Water Flash Drum GV-724 by use of a two point interface level controller. In case of Low-Low water phase level, the water level control valve is closed via interlock to prevent gas-break through to Produced Water System. Also, if liquid level is too high in Produced Water Flash Drum GV-724 and/or

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

24 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Produced Water Tank (GT-722), the water level control valve is closed via interlock to prevent liquid overflow in produced water system respective. The gas separated in Stabilizer Reflux Drum GV-116 is lead to the Stabilizer OVHD Compressor GK-117A/B that is compressing the gas in two stages to the level of the sour gas from GV-101. Both gas streams are lead together to the Gas Sweetening, Unit 200. The discharge stream of gas from compressor is not cooled down because it is mixed with the big quantity coming from Sour Gas Separator GV-101. The resulting temperature is below 35 °C and will be measured downstream the combination of both streams. In case of exceeding 80 °C the compressor GK-117A/B will be switched off by safety interlock. st Condensate from the 1 stage aftercooler of compressor GK-117A/B is sent back to the feed stream to GC-111 upstream GE-112A/B.

The quality parameters of the bottom product of the Stabilizer Column GC-111 (gas condensate) are the “Reid Vapor Pressure” (maximum 0.8 bar(a) ) as well as the H2Scontent (maximum 3 mole-ppm). The quality can be influenced mainly by the throughput of heat media i.e. the bottoms temperature of the column. A higher stream of heat media causes a higher bottoms temperature and at least a higher reflux rate. Up to the design load of the column a better quality of gas condensate is the result. To prevent corrosion, a corrosion inhibitor is dosed from Corrosion Inhibitor Vessel GV118 by Corrosion Inhibitor Injection Pump GP-119 into a split stream of the reflux stream of the Stabilizer GC-111, which is given to the top of the column. Using this system it is not necessary to provide a solution with water or hydrocarbons in the agitator vessel. In the inlet manifold is provided a connecting line with double block and bleed between the Sour Gas and the Sweet Feed Inlet lines upstream the inlet shut off valves / downstream the hand operated inlet block valves. It serves to conduct Sweet Feed via the Sour Inlet Gas Separator GV-101 to the Dehydration, for special reasons. Similar there is a connection for NGL downstream GV-101 to downstream GV-102/GV-103. A stream in opposite direction is not possible because of safety reasons (excess of design pressure at GE-112A/B and related piping). 2.1.3

Methanol Injection (Unit 160)

See PFD:

12466-01 10102

For prevention of formation of gas hydrate as well as for decomposing of existing gas hydrates there is the possibility of methanol injection at critical points in the plant, not only in Unit 100 but also in Units 300 and 400. Methanol is stored in the Methanol Day Tank GV-162 with a sufficient quantity for one operational day. From there methanol is forwarded by Methanol Injection Pump GP-161A/B with the required high pressure (up to more than 81 bar(g) ) at the critical points. Local flow meters register Methanol consumption with alarm by low flow. Also, Methanol Injection Pumps GP-161A/B are shutdown by Low level in Methanol Day Tank GV-162. Fresh methanol can be sent to GV-162 from the Chemical Storage Section 580.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

25 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.2

Unit 200 Gas Sweetening 2.2.1

Amine Wash System (Unit 200)

See PFD:

12466-01 10105 12466-01 10106 12466-01 10107

Sour natural gas from North Al Faid Field is sent from the Sour Gas Inlet Separator GV101 via Amine Contactor Gas Filter GF-208 Type Cartridge, to the bottom of Amine Contactor GC-201. The separated sour gas liquid filtered in GF-208 is sent level controlled via Stabilizer Feed Preheater GE-112A/B back to the Stabilizer Column GC-111. The operating pressure of GC-201 depends mainly on the pressure in the sales gas pipeline and on the operating conditions in the NGL Recovery section and must correspond with the pressure in the Inlet Separator GV-101. It can move between 55 and 81 bar(g). The gas, moving upward in the column, contacts an 11% mole MDEA solution. The regenerated Amine is constantly supplied to the top of the Amine Contactor GC-201 by means of the Amine Charge Pump GP-212A/B. The regenerated (lean) Amine can be charged into the Column above tray 1, 4 or 6 partly or with full flow. Pump Capacity is provided by throttling the flow control valve in the discharge piping of the pump. Final cooling of the regenerated amine to approx. 45 째C is provided by heat exchange with a sales gas stream from downstream of E-301A/B in the NGL Recovery unit in the Amine Contactor Feed Cooler GE-203. It is important to adjust a lean amine temperature which is higher than the gas temperature to prevent condensation of hydrocarbons. Otherwise foaming may occur. Hydrogen sulfide and a part of the carbon dioxide are absorbed from the sour inlet gas. The sweetened gas flows from the top of GC-201 via Sweet Gas Separator GV-219, equipped with a demister to eliminate the amine solution carry-over, to the Gas Dehydration, Unit 350 (PU-03). The rich amine flows level controlled from the bottom of Amine Contactor GC-201 to the Amine Flash Drum GV-220. The operating pressure of GV-220 is 4.5 bar(g). To prevent a gas break through from GC-201 to GV-220 an additional and safety related level switch is installed, which closes the UV-G201B in case of Low-Low Level. In GV-220 the separation of the dissolved gases (mainly light hydrocarbons) from the rich amine takes place. The pressure in the Amine Flash Drum GV-220 provides the rich amine flow via Amine Particle Filters GF-209A/B, Amine Charcoal Filter GF-210 and Amine Particle Filter GF-211 and a recuperative heat exchanger Lean/Rich Amine Exchanger GE-204A/B to Amine Regenerator GC-202. In case of High-High level in GV-220, the level control valve in GC201 is closed via interlock. Also, by a Low-Low level in GV-220, level control valve in GV220 is closed via interlock. The Amine Flash Drum GV-220 is also used for removal of liquid hydrocarbons. The liquid hydrocarbons will be collected in a special chamber which can be discontinuously level controlled drained to the closed hydrocarbon drain. The separated gas from the GV-220 is lead to the Acid Gas Separator GV-261. For start up and special operating conditions the pressure in GV-220 can be maintained by fuel gas supply. In the Amine Regenerator GC-202 the stripping of the acid gases (CO2 and H2S) from the rich amine solution takes place.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

26 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

The adjustment of the bottom temperature (about 120 째C) of the Amine Regenerator is done by adjusting the Heat Media flow through the Amine Regenerator Reboiler GE-207, which is provided as a cascade with the signal from lean amine flow to Amine Contactor GC-201. The pressure in the Reboiler GE-207 should not exceed 0.7-1.0 bar(g) to prevent thermal decomposition of the amine. The heat medium is supplied with maximum temperature of 200 째C. In case of High-High pressure in GC-202, the Media Flow control valve in GE-207 is closed via interlock. The lean amine is drawn level controlled by means of the Amine Regenerator Bottom Pump GP-213A/B and lead via the Lean/Rich Amine Exchanger GE-204 to the Amine Surge Vessel GV-221, that is operated at about 1.4 bar(g). These pumps are shut down by Low-Low level in GC-202 or by Low flow in suction line. The Amine Regenerator GC-202 is running at total reflux at an operating pressure of about 0.4 bar(g) and a top temperature of about 85 째C. In the Amine Regenerator Reflux Condenser GE-206 the overhead vapors are partly condensed at about 61째C. In the Reflux Drum GV-222 is integrated a skimming device for removal of liquid hydrocarbons. The acid gas separated in the Amine Reflux Drum GV-222 is lead via Acid Gas Separator GV-261 to the Acid Gas Incinerator Unit. The total liquid from GV-222 is given back to the top tray of GC-202 by means of the Amine Reflux Pump GP-214A/B. Pump Control is provided by throttling a level control valve located in the discharge piping of the pump. These pumps are shut down by Low-Low level in GV-222 or by Low flow in suction line. The Amine Surge Vessel GV-221 provides stable operation of Amine Charge Pump GP212A/B. Besides, the Surge Vessel GV-221 is used for preparation of a make-up MDEA solution and for maintaining the solution concentration at about 11 % mole. If the amine concentration in the absorbent decreases below 10 % mole, an appropriate portion of the MDEA concentrate is charged into Amine Surge Vessel GV-221. A balance quantity of demineralized water is also supplied to this vessel to compensate the water lost during treating and regeneration. To maintain the provided pressure level and to exclude contact of the amine solution with air, additional blanketing with fuel gas is performed in Amine Surge Vessel GV-221. The regenerated amine solution is pumped from GV-221 with Amine Charge Pump GP-212A/B via Amine Contactor Feed Cooler GE-203 to the Amine Contactor GC-201. In case of Low-Low level in GV-221, the Amine Charge Pumps GP212A/B are shutdown via interlock and Amine Flow control valve is closed to Amine Contactor Feed Cooler GE-203. Other condition to close Amine Flow control valve is by High-High level in GC-201. Also, In case of high-high level in GV-221, the demin water flow control valve to GV-221 is closed via interlock. Removal of products of thermal decomposition of amine and other impurities is carried out using a filtration system, consisting of Amine Particle Filters GF-209 A/B, Amine Charcoal Filter GF-210 and Amine Particle Filter GF-211. The filter system is installed on the rich amine solution line. Approximately 50% of the total stream of the rich solution with pressure of 4.5 - 3.9 bar(g) is passed through the filters. To prevent corrosion a continuous quantity of corrosion inhibitor will be added to the top vapor line of the Amine Regenerator by means of the Corrosion Inhibitor Vessel GV-218 and Corrosion Inhibitor Injection Pump GP-216. The corrosion inhibitor type is soluble in water and will be used as mixture with demin water. The mixture will be prepared in the agitator vessel GV-218. First the required quantity of inhibitor is to be filled by means of the Drum Pump GP-529 directly from a drum. After that the required quantity of demin water is filled to the vessel via steady pipe connection. Similar to the corrosion inhibitor system, a system for injection of antifoam agent is provided. In case of foaming presence (rising differential pressures) a certain (small) amount of anti foam agent can be added to the system using the Anti Foam Vessel GV217 and Anti Foam Injection Pump GP-215A/B. The Anti Foam Agent is used as pure

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

27 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Agent. It can be injected downstream of the amine filters (GF-211) and upstream of the Amine Charge Pump GP-212A/B. 2.2.2

Amine Drain System (Unit 240)

See PFD:

12466-01 10106

The Amine Drain System serves for the collection of all amine-containing liquids discharged in the area of the Amine Wash System in Amine Drain Vessel GV-242. In addition, the Amine Drain Vessel GV-242 collects the liquids separated in the Acid Gas Separator V-261 (and transferred by means of the Amine Transfer Vessel GV-262) and the rich amine solution from the Sweet Gas Separator GV-219. By means of the submerged Amine Drain Pump GP-241, the content of the Amine Drain Vessel GV-242 is lead into the pipe for the rich amine solution to the filtration system of the Amine Wash System. The pump will not start automatically at high level because the liquid, mainly coming from the Amine Wash System will be sent back to this system. High level in the Amine Drain Vessel GV-242 triggers an alarm. Only at HH level the Amine Drain Pump GP-241 start-up for a certain time to prevent liquid overflow. 2.2.3

Acid Gas Incineration (Unit 260)

See PFD:

12466-01 10123

In this Unit, the enriched H2S-containing gases from the Amine Wash System are incinerated. This includes the acid gas from the Amine Regenerator GC-202 and the sour gas from the Amine Flash Drum GV-220. The gases are lead via the Acid Gas Separator GV-261 to the Acid Gas Incinerator Unit (PU-02) and will be incinerated with natural gas and excess air. The gas with a remaining maximum H2S content of 3 mg/m³ is lead to atmosphere. Separated sour liquids from the GV-261 are lead to the Transfer Vessel GV-262. This Vessel is emptied discontinuous by blowing with fuel gas to the Amine Drain Vessel GV242. In case of High level in Transfer Vessel GV-262, following Unit Shut Down Valves are closed via interlock (PSD): •

UV-G262B (located in liquid drain stream from GV-261 to GV-262)

•

UV-G262C (located in acid gas stream from GV-262 to GV-261)

Also, in case of Low or Low-Low level in GV-262, Unit shut down valve UV-G262C (fuel gas stream to GV-262) is closed via interlock (PSD). In case of High-High level in Acid Gas Separator GV-261 the Unit Shut Down valve UVG260A (acid gas to PU-02) will be closed via safety interlock (ESD) and the pressure control valve (Acid gas to Flare) will be put in operation. If the mentioned control valve leaves the “closed” position the UV-G262B opens to give additional fuel gas to flare to ensure a good burning off of the acid gas. Remark: More detailed description will be added after receiving of related documents from vendor of PU.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

28 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.3

Unit 300 Hydrocarbon Recovery The Hydrocarbon Recovery includes the Dehydration System, the Glycol Regeneration Package, the NGL Recovery and systems for injection of emulsion breaker and for drains. 2.3.1

Gas Dehydration and Glycol Regeneration Package (Unit 350)

See PFD:

12466-01 10108 12466-01 10110

Dehydration Section This section serves to adjust a water vapor dew point to a value of maximum –50 °C at operating pressure, which is an adequate dew point as feed to the following Low NGL Recovery (Unit 300), and adjust at the same time the required water dew point of 0 °C at 75 bar(g) for the sales gas. The dehydration of the separated gases from the Sweet Inlet Separators GV-102/GV-103 and the sweetened gas from the Amine Wash System (Unit 200) is done by a TriethyleneGlycol contactor and Glycol regeneration with the “DRIZO” technology. Sweet Gas first flows through an inlet scrubber GV-351 to remove all liquid and solid impurities. Then gas flows into and upward through the Glycol Contactor GC-352 where it is contacted counter currently and dried by the glycol. Lean Glycol enters the top of the contactor where it flows downward from tray to tray and absorbs water from the rising natural gas. Finally the dried gas passes through a gas/glycol exchanger and enters the NGL Recovery Section. Glycol Regeneration Section The glycol from the bottom of Glycol Contactor GC-352 passes through the Glycol Flash Drum GV-361 where vapor is flaring. The glycol flows level controlled through the filter GF-362A/B and glycol/glycol heat exchanger GE-363 where is preheated by hot lean glycol. After the glycol/glycol heat exchanger, the rich glycol enters the Glycol Still Column GC-364 where the water and solvent (hydrocarbons) leaves the still as steam. The Glycol Reboiler GE-365 is a direct fired heater, which provides the heat (flue gas) necessary to boil the water and solvent out of the glycol. Different liquids – almost hydrocarbons – can be used as solvent for the DRIZO technology. Here gas condensate product is used, which will be taken over directly from the product line to storage. The DRIZO technology is a glycol based gas dehydration process. The process makes use of a solvent which is vaporized in the Solvent Electrical Superheater GE-568 and used as a stripping agent in the Glycol stripping column GC-366. The vapor from the glycol reboiler/still column is condensed in a unit together with the vapor from the stripping column. The solvent are condensed in this unit before the vapor is discharged to the flare. The hot re-concentrated glycol flows out the reboiler into the Glycol stripping Column GC366, and then is cooled by heat exchange with solvent in Solvent Vaporizer heat exchanger GE-367. Finally the lean glycol flows through the glycol/glycol heat exchanger GE-363 to the suction drum GV-369 and is pumped back into the Glycol Contactor. The Dehydration and Glycol Regeneration Unit (PU-03) is foreseen as a complete automatic package unit. In case of need (feared or expected formation of gas hydrates in the process) is possible to inject TEG to several points.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

29 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

The Glycol System has the necessary piping and fittings to inject the glycol, as required, into the separated Natural Gas Liquids downstream the Inlet Separators GV-101, GV-102 and GV-103 and the tube sheet of the Deethanizer Condenser GE-407. The glycol/water mixtures separated in the water boots of the Deethanizer Feed Drum GV419 and Deethanizer Reflux Drum GV-420 are drawn by means of two point interface level switch, and sent to the Glycol Regeneration via the Rich Glycol Separator GV-361, where very small amounts of light hydrocarbons are flashed to the flare. The regenerated Lean Glycol is pumped back by the Glycol Injection Pump to the injection points. To ensure the supply of make up glycol in case of need, TEG from the Ethylene Glycol Storage Tank GT-586 in the Unit 580, Chemicals Storage, is forwarded to the Glycol Regeneration by means of the Ethylene Glycol Transfer Pump GP-585. Remark: More detailed description will be added after receiving of related documents from vendor of PU. 2.3.2

NGL Recovery (Unit 300)

See PFD:

12466-01 10109

This Unit serves to achieve a high value of NGL recovery and at least to adjust the required hydrocarbon dew point of the sales gas to a value of less than 0 °C related to a pressure of 75 bar(g). This is done by separating liquid hydrocarbons as a result of cooling the gas down to a value of –37 °C. The temperature of up to –37 °C was chosen to prevent vacuum pressure at the inlet of the Compressors in Refrigeration Unit (PU-05). The gas from Dehydration Section (Unit 350) is heat exchanged to a temperature of about –30 °C in the Gas/Gas Heat Exchanger GE-301A/B with cold gas from Low Temperature Separator GV-304. Then the gas liquid mixture is cooled by the refrigeration chiller to a temperature of -37 °C and sent to the Low Temperature Separator GV-304 where natural gas liquids are separated. This low temperature is reached by means of a propane stream, coming from the Refrigeration Unit (PU-05), and pre-cooled to approx. –33 °C in the heat exchanger GE303A/B against LTS liquids. After depressurization of the propane to approx. 1.05 bar (a) the inlet temperature to chiller GE-302 of –41 °C is reached. With total vaporization of propane the heat exchange with incoming sweet gas takes place. The gas separated in Low Temperature Separator GV-304 is heated in the Gas/Gas Heat Exchanger GE-301A/B to a temperature of about 35 °C and sent via the Sales Gas Metering into the sales gas pipeline as natural gas that complies with the specifications. The separated HC liquids are drawn at the bottom of GV-304 level controlled, heated in the GE-303A/B LTS Liquids Propane Subcooler to approx. –10 °C, and enter the Deethanizer Feed Drum GV-419 in the Unit 400 “Fractionation” for further processing. In case of High-High level in Low Temperature Separator GV-304, the Unit Shut Down Valve UV-G301A (Sweet Gas from Dehydration Section (PU-03) to Gas/Gas Exchanger GE-301A/B) is closed via safety interlock (ESD). Also, in case of Low-Low level, the level control valve in GV-304 and the Unit Shut Down Valve UV-G304A are closed to prevent gas-break through from GV-304 to LTS Liquid Propane Subcooler GE-303A/B. In case of Low temperature in stream NG Liquids Sour to GV-419, caused by low flow of propane to GE-303A/B, the level control valve in GV-304 is closed via interlock to prevent undercut of minimum design temperature of downstream piping and equipment. Also in case of Low-Low temperature, the Unit Shut Down Valve UV-G304A is closed via safety interlock (ESD). To prevent a shut down situation, the normal propane flow to GE-303A/B

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

30 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

should be maintained or the LTS Liquids from GE-303A/B have to be warmed up by means of the LTS Liquids Preheater GE-305. To do this, the respective hand operated bypasses for the LTS Liquids as well as for the gas condensate have to be opened. This procedure can also be used in case of expected gas hydrate problems in GV-419. 2.3.3

Emulsion Breaker Unit (Unit 320)

See PFD:

12466-01 1009

From the Emulsion Breaker Vessel GV-322, by means of the Emulsion Breaker Pump GP321 a demulsificant can be added to the separated liquid hydrocarbons from the Low Temperature Separator GV-304 to prevent the formation of an emulsion. At normal operating conditions formation of emulsion is not expected, but during start up or during possible disturbances it may happen. Pump GP-321 is shut down via interlock by Low-Low level in GV-322. Emulsion breaker agent can be filled from a drum to the vessel GV-322 using the Drum Pump GV-529. 2.3.4

Glycol Drain System (Unit 340)

See PFD:

12466-01 1008

Because of amount of glycol used in dehydration unit a separate drain system for TEG is available. The volume of Drain Vessel GV-343 is designed to get all glycol liquids present in running cycle (40 m続). Drained TEG from PU-03 can be collected to GV-343. This vessel is equipped with submerged pump GP-342, which can discharge glycol through filter GF-341 to the Glycol Reboiler GEV-365. High level in the Glycol Drain Vessel GV-343 triggers an alarm. Only at HH level the Glycol Drain Pump GP-342 start-up for 1 minute to prevent liquid overflow.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

31 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.4

Unit 400 Fractionation 2.4.1

Fractionation System (Unit 400)

See PFD:

12466-01 10112 12466-01 10113 12466-01 10114 12466-01 10115

The Fractionation System serves to separate the liquid hydrocarbons from the Unit 100 and Unit 300 into the fractions Gas Condensate, LPG and Propane by means of distillation.

2.4.1.1

System Deethanizer Column GC-401

In the Deethanizer Feed Drum GV-419, which is running at operating pressure of 25 bar (g), the liquid hydrocarbons coming from the Sweet Inlet Separators GV-102 and GV-103 are collected together with the liquid hydrocarbons coming from the Low Temperature Separator GV-304. The 3-phase-separator GV-419 is equipped with a water boot, where water or water/ glycol mixtures can be separated. The Deethanizer Feed Drum GV-419 has a volume which is big enough for handling possible liquid slugs and for providing a very constant feed to fractionation system. Another task of GV-419 is to take over off spec product for further processing in the fractionation system. Because the off spec product is almost flashed to a low pressure the allowed quantity, which can be added to the normal feed is limited. This is realized by the capacity of the LPG Recycle Pump GP-525A/B (3.5 m³/h). The gas phase from the Deethanizer Feed Drum GV-419 is led in the gas stream upstream of the Deethanizer OVHD Propane Subcooler GE-409. A good removal of ethane is important for further fractionation. A (relative) high content of C2 in the bottom product may be the reason that the quality parameter C3 in propane product (> 98 wt-%) cannot be met. The liquid hydrocarbons leave the GV-419 level controlled and are preheated in the heat exchangers GE-404 (against LPG product), and GE-405 and GE-424 (against gas condensate product) to a temperature of approx. 68 °C. Afterwards, the hydrocarbons are given to the 13th of altogether 30 trays of Deethanizer GC-401 as feed stream. In case of Low-Low level in Deethanizer Feed Drum GV-419, the flow control valve in NG liquids outlet of GV-419 and Unit Shut Down Valve UV-G419D are closed via safety interlock (ESD). In case of High-High level in Deethanizer Feed Drum GV-419, the level control valve in GV-304 and the following Unit Shut Down Valves are closed via safety interlock (ESD): •

UV-G304A (NG Liquids from GV-304 to GV-419);

•

UV-G420C (gas from GE-409 to compressor GK-423A/B (PU-04))

•

UV-G423A (total gas to compressor GK-423A/B (PU-04)) and

•

UV-G102H (NG liquids sour from GV-102 to GV-419).

In case of Low-Low level in water/glycol boot, the level control valve is closed via interlock to prevent gas-break through or hydrocarbon break through to Glycol Regeneration Section (part of PU-03).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

32 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In the Deethanizer Column GC-401 non-condensable gases are removed at a head pressure of 23 bar(g) and a temperature of approx. 2°C. The overhead vapors are partly condensed in the Deethanizer Condenser GE-407 and separated in the Deethanizer Reflux Drum GV-420. The condensation temperature of approx. 2°C is adjusted by means of control valves in the bypass around GE-407 and in the line from GE-407 to GV-420. The proper function of the condenser is ensured by level control of the refrigerant in the shell side. The gas phase, mainly ethane, is discharged after pressure regulation and compressed in the compressor GK-423 A/B to pipeline pressure, before it is added to the sales gas. The reflux of all condensed hydrocarbons to column GC-401 is ensured by means of the Deethanizer Reflux Pumps GP-415 A/B and a LC-FC cascade control. In the same way, Pump Control is provided by throttling the reflux control valve in the discharge piping of the pump. The bottom product of the column are C3+ hydrocarbons with a temperature of approx. 210 °C, drawn level controlled from the bottom of Deethanizer Column GC-401 . The adjustment of the bottom temperature of the column is done by adjusting the Heat Media flow (TV-G408C) through the Deethanizer Reboiler GE-408. This bottom product is the feed stream for the 2nd stage of fractionation - the Debutanizer GC-402. The feed is given to the 11th of altogether 18 valve trays. In case of High-High pressure in Deethanizer Column, the temperature control valve in GE-408 is closed via interlock. In case of High-High Level in Deethanizer Column GC-401, the flow control valve FVG419A (liquid from GV-419) and Unit Shut Down Valve UV-G419D are closed via safety interlock (ESD). In case of Low-Low liquid level in Deethanizer Column GC-401, the level control valve in GC-401 and Unit Shut Down Valve UV-G402C (located in stream natural gas liquids from GC-401 to GC-402) are closed via interlock. In case of High-High Liquid level in Deethanizer Reflux Drum GV-420, the following valves are closed: •

Pressure control valve PV2-G699A, which is located in stream Sweet Gas to Fuel Gas Separator GV-699 via interlock.

•

Unit Shut Down Valve UV-G420C located in stream Sweet Gas from GV-420 to GE-409 via safety interlock (ESD)

•

Unit Shut Down Valve UV-G419D located in stream NG liquids from GV-419 to GE-405 and flow control valve in NG liquids outlet from GV-419 via safety interlock (ESD)

In case of Low-Low flow from Deethanizer Reflux Pumps GP-415A/B, after 15 seconds the active reflux pump will be switched off and the spare reflux pump will be switched on. If the Low-Low flow signal continues after another 15 seconds, the spare pump will be switched off and the Reflux control valve FV-G401A to GC-401 is closed via interlock. In case of Low-Low Liquid Level in Deethanizer Reflux Drum GV-420, via interlock is closed or shut down •

Interface level control valve LDV-G420H closes (located in stream Glycol Sour from GV-420 to Glycol Regeneration Section (part of PU-03))

•

Shut down Deethanizer Reflux Pumps GP-415A/B and close reflux control valve FV-G401A to GC-401.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

33 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In case of Low-Low level in water/glycol boot of GV-420, the level control valve is closed via interlock to prevent gas-break through or hydrocarbon break through to Glycol Regeneration Section (part of PU-03).

2.4.1.2

System Debutanizer Column GC-402

In the Debutanizer Column GC-402, at a head pressure of 11 bar(g) and a head temperature of 70 째C propane and butane (LPG), are separated from the C5+ fraction. In the Debutanizer Condenser GE-410 total condensation of overhead products takes place. The adjustment of system pressure is done at least by means of a control valve PV2G421B around condenser GE-410. Generally the temperature controller TC-G410D of the air cooler GE-410 should be adjusted so, that the outlet temperature is slightly below the total condensing temperature and the above mentioned control valve PV2-G421B opens 10 to 30 %. The liquid overhead product is drawn from the Debutanizer Reflux Drum GV-421 level controlled by means of Debutanizer Reflux Pumps GP-416 A/B. It is cooled in the GE-404 against the inlet stream to the Deethanizer to a temperature of 45 째C or less. Then it is stored in one of the LPG Storage Bullets GV-526A/B/C, ready for sale. The adjustment of reflux to column GC-402 is done by means of a plain flow control (FV1-G402A). In the same way, Pump Control is provided by throttling the flow control valve (FV1-G402A) in the discharge piping of the pump. In case of Low Flow from GP-416 A/B LPG reflux is forward to GV-421 through flow control valve (FV2-G402A) and close reflux control valve (FV1-G402A) to GC-402. The bottom product, gas condensate, is drawn off level controlled at the bottom of Debutanizer GC-402 with a temperature of about 202 째C. The adjustment of the bottom temperature of the column is done by adjusting the Heat Media flow (TV-G411C) through the Debutanizer Reboiler GE-411. Then it is cooled to approx. 40 째C in heat exchangers GE-405 and GE-424 against the feed stream to the Deethanizer, and in the Condensate Product Cooler GE-406 (air cooler). A basic adjustment will be done at the hand operated bypass valve around the exchanger GE-424. The final temperature control is done by adjusting the duty of air cooler GE-406 (speed control), which influences at least the heat transfer in GE-405. The gas condensate is stored in the Gas Condensate Storage Tank GT-506, ready for sale. In case of High-High pressure in Debutanizer Column GC-402, the Heat media Temperature Control valve in GE-411 is closed via interlock. In case of High-High liquid level in Debutanizer Column GC-402, the flow control valve in GC-401 and Unit Shut Down Valve UV-G402C are closed via safety interlock (ESD). In case of Low-Low liquid level in Debutanizer Column GC-402, the level control valve located in stream: Gas condensate to GT-506, is closed via interlock (DCS). In case of Low-Low Liquid Level in Debuthanizer Reflux Drum GV-421, the following valves are closed via interlock: Reflux control valve in GC-402 and Flow control Valve located in stream: LPG from GP-417A/B to GC-403. Also is shut down Debuthanizer Reflux Pumps GP-416A/B and Depropanizer Feed Pumps GP-417A/B. Debuthanizer Reflux Pumps GP-416A/B are shutdown in case of Low-Low flow. In case of shut down Debuthanizer Reflux Pumps GP-416A/B, the Reflux control valve in GC-402 and the level control valve located in stream: LPG from GE-404 to LPG off spec Bullet GV-528, are closed via interlock (DCS). In case of shut down Depropanizer Feed Pumps GP-417A/B, the Flow control Valve located in stream: LPG from GP-417 A/B to GC-403, is closed via interlock.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

34 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.4.1.3

System Depropanizer Column GC-403

The Depropanizer Column GC-403 is operated if required and serves for the supply of make-up propane for the Propane Refrigeration System in case of need, as well as to produce propane for sale. LPG is supplied by means of the Depropanizer Feed Pump GP-417A/B, from the th Debutanizer Reflux Drum GV-421, as feed on the 27 tray counted from the top of Depropanizer GC-403. Pump capacity is adjusted by the rotational speed of the pump with a Speed Controller according to the signal of Flow Meter type Turbine FE-G403A located in the inlet of GC-403. The Propane is generated as a result of total condensation in the Depropanizer Condenser GE-412 and collected in the Depropanizer Reflux Drum GV-422. The control of condenser pressure is done by means of control valve PV2-G422B around the condenser GE-412. Generally the temperature controller TC-G412B of the air cooler GE-412 should be adjusted so, that the outlet temperature is slightly below the total condensing temperature and the above mentioned control valve PV2-G422B opens 10 to 30 %. The Depropanizer Reflux Pumps GP-418 A/B with level control forward the propane to the Propane Storage Bullet GV-562. In case of start up or disturbances the propane can also be forwarded back to the Deethanizer Feed Drum GV-419. The control of reflux to the column is done by means of a plain flow control (FV-G403B). In the propane product line is provided a direct (hand operated) connection to the refrigeration system. The task of this connection is in case of medium quality propane in the storage and actual produced high quality propane, it can be sent to refrigeration unit. At the bottom of Depropanizer GC-403 LPG is drawn off by means of level control with a temperature of approx. 113 °C. After cooling to 65°C in the Depropanizer Bottom Cooler GE-414 the LPG is added to the LPG product stream to the LPG Storage Bullets GV-526 A/B/C. The adjustment of the bottom temperature of the column is done by adjusting the heating media (Gas condensate split flow from the Debutanizer) flow through the Depropanizer Reboiler GE-411 (TV-G413D). In case of High-High pressure in Depropanizer Column GC-403, the Three-Way temperature control valve located in stream: Gas Condensate from GC-402 to GE-424 is closed via interlock. In case of High-High Liquid Level in Depropanizer Column GC-403, via interlock is closed or shut down •

Block valve UV-G417A located in stream: LPG from GP-417A/B to GC-403

•

Shut down of GP-417A/B.

In case of Low-Low liquid level in Depropanizer Column GC-403, the level control valve LV-G403A located outlet of Depropanizer Bottom Cooler GE-414, is closed via interlock. In case of Low-Low flow in Depropanizer Reflux Pumps, these pumps are shut down via interlock. In case of High-High Liquid Level in Depropanizer Reflux Drum GV-422, via interlock is closed or shut down •

Block valve UV-G417A located in stream: LPG from GP-417A/B to GC-403 is closed

•

Shut down of GP-417A/B.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

35 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In case of Low-Low Liquid Level in Depropanizer Reflux Drum GV-422, via interlock is closed or shut down •

Level control valve LV-G422A located in stream propane to GV-562 is closed

•

Shut down Depropanizer Reflux Pumps GP-418A/B.

In case of shut down GP-418A/B, following control valves are closed via interlock: •

Level control valve LV-G422A located in stream: Propane to GV-562 from GP-418 A/B.

•

Reflux Flow control valve FV-G403B.

In case of Low-Low Reflux Flow, is shut down Depropanizer Reflux Pumps GP-418A/B via interlock. 2.4.2

Unit 440 HC Drain (Oily Slop)

See PFD:

12466-01 10122

The HC Drain (Oily Slop) serves to collect the hydrocarbon-containing residuals (C4+) from the overall plant area in the Oily Slop Vessel GV-443. Furthermore, in the Oily Slop Vessel GV-443 the liquids from the skimmer in the Produced Water Tank GT-722 as well as in the Amine Flash Drum GV-220 are collected. Liquids from the Flare Knock Out Drum GV-692 may also be collected in this drum (in case of small quantity) or send to Sour Off Spec Bullet GV-530. The Oily Slop Vessels GV-443 is emptied by means of the Oily Slop Pump GP-442 through the Oily Slop Filter GF-441and the Oily Slop Cooler GE-444 into the Sour Off Spec Bullet GV-530. The slop temperature after the air cooler is controlled by adjusting the fan speed. In case of high temperature downstream GE-444 an alarm is provided that the operator can respond by starting the second fan or open more the louvers. As required, slops could be pumped upstream of Stabilizer Feed Pre-heater GE-112A/B. In case of high differential pressure through Slop Filter GF-441, the filter must be blocked in by the hand-valves and its cartridge shall be cleaned manually. After cleaning it has to be checked that the hand valves are opened again, and the bypass valve is closed. The filter can be emptied via the hand valve into the closed drain. In urgent requirement for running the slop pump, the bypass valve around the filter GF441 can be opened.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

36 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.5

Unit 500 Gas Condensate Storage and Product Loading This Unit serves for the storage and loading of Gas Condensate, LPG and Propane and to tank trucks. The facility for loading of Produced Water is also located in this area. 2.5.1

Condensate Storage & Loading (Unit 500)

See PFD:

12466-01 10128

The Gas Condensate is stored in the Condensate Storage Tank GT-506. The Condensate Storage Tank has a nominal capacity of 6800 m続. The Gas Condensate can be supplied into the existing oil pipeline by means of the Condensate Pipeline Pump GP-504A/B via the Condensate Filter GF-502A/B, followed by a flow measurement. Alternatively, the Gas Condensate can be loaded on trucks by means of the Condensate Transfer Pump GP-503A/B. The amount of loaded condensate is recorded by the Weight Scale GWS-571. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of throttling a pressure control valve PV-503C in the discharge piping of the pump. At the bottom of the Condensate Storage Tank GT-506, accumulation of water and pollutions is possible. It can be pumped by means of the Water Pump GP-505A/B to the Produced Water Tank GT-722. In case of High-High liquid level in Condensate Storage Tank GT-506, the Unit Shut down UV-506A located in feed of the tank is closed via safety interlock (ESD). Also, in case of Low-Low level, the Condensate Transfer Pumps GP-503A/B and Condensate Pipeline Pumps GP-504A/B are shut down via interlock. In case of low flow in Condensate Pipeline Pumps GP-504A/B, these pumps are shut down via interlock. In case of shut down Condensate Pipeline Pumps GP-504A/B, the Unit Shut Down Valve UV-G594A located in condensate custody metering is closed via safety interlock (ESD). 2.5.2

LPG Storage & Loading (Unit 520)

See PFD:

12466-01 10120

For the storage of Liquefied Petrol Gas (LPG), the LPG Storage Bullets GV-526A/B/C with a capacity of 230 m続 each and the LPG Off Spec Bullet GV-528 with a capacity of 230 m続 are available. All bullets can be filled and discharged separately. The LPG Off Spec Bullet GV-528 is designed preferential to store material that is not in compliance with specifications, though any of the other bullets can serve for this purpose as well. As long as possible the GV-528 shall be kept serving as the Off-spec Bullet for all sweet Liquid Hydrocarbons to be recycled. This is to prevent difficulties with the pressure level and contamination of LPG-product in this bullet. One of the GV-526A/B/C shall serve as the dedicated LPG Off Spec Bullet preferential to store LPG that is not in compliance with specification, or that has to be pumped in recycle to remix its content. LPG and also off-spec material can be loaded on trucks by means of the LPG Loading Pump GP-524 A/B. The necessary odorization of LPG is done by means of the Odorant Injection System Package which is part of PU-13. For blending or in case of a disturbance, the content of the Bullets GV-528 and GV-526 A/B/C can be pumped to any of these bullets by means of the LPG Loading Pump GP524A/B via the bypass line.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

37 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

By means of the LPG Recycle Pump GP-525A/B is possible to pump the collected sweet off spec products into the Deethanizer Feed Drum GV-419 for reprocessing in the Fractionation Unit 400. The pump GP-525 is designed for a small throughput (approx. 3.5 m³/h) in order to avoid a disturbance of the Fractionation Unit 400. Pump capacity is adjusted by the rotational speed of the pump with a Speed Controller according to the signal of Orifice Flow Meter FE-G525C. Further there is a connection for hydrocarbon liquids (operated by hand valves) from downstream GV-419 via the control valve FV-419B into the GV-528 (or in special cases of necessity into GV-526A/B/C). This serves for collecting sweet HC Liquids in case of need from GV-419 in GV-528 for later recycling. The recycling is than carried out by pumping the HC Liquids from GV-528 back into GV-419 by means of the GP-525. In case of HHH liquid level and/or HH Pressure in LPG off spec Bullet GV-528, the following Unit Shut Down valves are closed: •

UV-G528A (located in inlet of bullet) via interlock (PSD)

•

UV-G528D (located in inlet of bullet) via safety interlock (ESD)

•

UV-G528C (located in stream: LPG from/to PU-13) via safety interlock (ESD)

Also, in case of LLL level, The Unit Shut down valve UV-G528B (located in stream: LPG to LPG Loading Pump GP-524 A/B and LPG Recycle Pump GP-525 A/B) is closed via safety interlock (ESD) and shut down GP-525 A/B. In case of HHH liquid level and/or HH Pressure in LPG Storage Bullet GV-526A, the following Unit Shut Down valves are closed: •

UV-G526A (located in inlet of bullet) via interlock (PSD)

•

UV-G526D (located in inlet of bullet) via safety interlock (ESD)

•

UV-G526C (located in stream: LPG from/to PU-13) via safety interlock (ESD)

Also, in case of LLL level, The Unit Shut down valve UV-G526B (located in stream: LPG to LPG Loading Pump GP-524 A/B and LPG Recycle Pump GP-525 A/B) is closed via safety interlock (ESD) and shut down GP-524 A/B. In case of HHH liquid level and/or HH Pressure in LPG Storage Bullet GV-526B, the following Unit Shut Down valves are closed: •

UV-G526G (located in inlet of bullet) via interlock (PSD)

•

UV-G526K (located in inlet of bullet) via safety interlock (ESD)

•

UV-G526J (located in stream: LPG from/to PU-13) via safety interlock (ESD)

Also, in case of LLL level, The Unit Shut down valve UV-G526H (located in stream: LPG to LPG Loading Pump GP-524 A/B and LPG Recycle Pump GP-525 A/B) is closed via safety interlock (ESD) and shut down GP-524 A/B. In case of HHH liquid level and/or HH Pressure in LPG Storage Bullet GV-526C, the following Unit Shut Down valves are closed: •

UV-G526N (located in inlet of bullet) via interlock (PSD)

•

UV-G526Q (located in inlet of bullet) via safety interlock (ESD)

•

UV-G526P (located in stream: LPG from/to PU-13) via safety interlock (ESD)

Also, in case of LLL level, The Unit Shut down valve UV-G526O (located in stream: LPG to LPG Loading Pump GP-524 A/B and LPG Recycle Pump GP-525 A/B) is closed via safety interlock (ESD) and shut down GP-524 A/B.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

38 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In case of Low Flow in suction line in LPG Loading Pump GP-524 A/B and LPG Recycle Pump GP-525 A/B or Low-Low flow at discharge line, these pumps are shut down via interlock. In case of shut down LPG Recycle Pump GP-525 A/B flow control valve located in stream: LPG from GP-525 A/B to GV-419 is closed via interlock. In case of shut down LPG Loading Pump GP-524 A/B, the Unit Shut Down Valve UVG524A located in stream: LPG from GP-524 A/B to PU-13, is closed via interlock (PSD). 2.5.3

LPG Unloading (Unit 540)

See PFD:

12466-01 10128

By means of the LPG Unloading Pump GP-543 it is possible to unload tank trucks and to fill the LPG Storage Bullets GV-526 A/B/C (and Off Spec Bullet GV-528) with LPG for start-up purposes. 2.5.4

Propane Storage (Unit 560)

See PFD:

12466-01 10120 12466-01 10128

In the Propane Storage Bullet GV-562 the propane generated in the Depropanizer GC-403 is stored. The Propane Storage Bullet GV-562 has a capacity of 110 m³. By means of the Propane Transfer Pump GP-561 the propane can be loaded on tank trucks in the product loading area. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the bullet by means of Pressure Control Valve PV-G561C. By means of the Odorant Injection System the propane can be odorized. In case of HHH liquid level and/or HH Pressure in Storage Bullet, via safety interlock (ESD) closed following Unit Shut down valves: •

UV-G562A (located in inlet of bullet)

•

UV-562C (located in stream: propane from/to PU-13).

Otherwise in case of LLL level, via safety interlock (ESD) closed following Unit Shut down valves: •

UV-G562B (located in stream Propane to Propane Transfer Pump GP-561)

•

UV-562D (located in stream: Propane from GP-561 to LPG Bullets) and shut down GP-561.

2.5.5

Weight Scale for Trucks

See PFD:

12466-01 10128

To record the received quantities of chemicals (in case of delivery by truck) such as amine solution, ethylene glycol and methanol and to record the quantities of products sent by truck, such as gas condensate, LPG and propane, a weight scale (GWS-571) is provided.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

39 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.5.6

Chemicals Storage (Unit 580)

See PFD:

12466-01 10111

The Chemical Storage Unit 580 serves to supply and store methanol, ethylene glycol and MDEA. For first filling large quantities of these chemicals are required. All chemicals are delivered in drums. The Methanol Storage Tank GT-582 has a capacity of 48 m続. By means of the Methanol Transfer Pump GP-581, the Methanol Day Tank GV-162 located in Unit 100 is filled. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting. In case of Low-Low liquid level in Methanol Storage Tank GT-582, shut down via interlock Methanol Transfer Pump GP-581. The Glycol Storage Tank GT-586 has a capacity of 15 m続. By means of the Glycol Transfer Pump GP-585 the Glycol System (Unit 350) is filled. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting In case of Low-Low liquid level in Glycol Storage Tank GT-586, shut down via interlock Glycol Transfer Pump GP-585. The Amine Storage Tank GT-584 is located in the area of unit 200 and has a capacity of 35 m続. By means of the Amine Transfer Pump GP-583 the Amine Surge Vessel GV-220 in the Amine Wash System is filled. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting. The Amine Storage Tank GT-584 has a connection for demineralized water to dilute the Amine solution. The addition of demineralized water is to be done always directly during or after filling of high concentrated amine. So the risk of explosion is prevented because the amine solution is not flammable. In case of Low-Low liquid level in Amine Storage Tank GT-584 and/or Low flow in suction line of Amine Transfer Pump GP-583, shut down via interlock GP-583.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

40 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.6

Unit 600 Utilities 2.6.1

Nitrogen System (Unit 600)

See PFD:

12466-01 10124

The Nitrogen System is directly connected with the Instrument Air System (PU-09). A Nitrogen Generation Unit, GA-601 (PU-10A), based on membrane technology is provided in the plant. Air from the Instrument Air Generation Unit will be separated in nitrogen (normally 99 mole % up to 99.5 mole %) and an oxygen rich stream, that is lead to atmosphere. The production capacity amounts to 200 Nm³/h. The nitrogen will be used mainly for purging and inertization purposes. Additional there is provided a small compression unit for nitrogen bottling (PU-10B), which may be used in case of excess-production of nitrogen. The capacity is 200 Nm³/h and the final pressure in the bottles is 200 bar(g). The Nitrogen Storage Bullet, GV-602 has a volume of 200 m3 and is used as a buffer for the Low Pressure Nitrogen Header of the plant. The Storage Bullet is operated at 18 bar(g). The normal operating pressure in the LP Nitrogen Header is 7 bar(g). Remark: More detailed description will be added after receiving of related documents from vendor of PU. 2.6.2

Instrument Air System (Unit 630)

See PFD:

12466-01 10119

In the Instrument Air Generation Unit (PU-09) the required quantity of dry air is generated for instrument air and nitrogen generation as well as for plant air supply. Four compressors (2 operating + 2 spare or 3 operating + 1 spare), with a maximum capacity of approx. 880 Nm³/hr each are provided. Instrument air is lead via Instrument Air Receiver GV-640 to the consumers. Instrument Air Supply has first priority of all air streams. Plant air is lead via Plant Air Receiver GV-641 to the consumers. The instrument air system is directly connected to the Nitrogen Generation Unit PU-10 and provides the required supply of compressed air. Remark: More detailed description will be added after receiving of related documents from vendor of PU.

2.6.3

Heat Medium System (Unit 650)

See PFD:

12466-01 10121

The Heat Medium System ensures the heat supply to the consumers of the plant. The System consists mainly of the Heat Medium supply and return header, and the Heat Medium Station with the necessary pumps, filters, vessels and heater. See Section 3.2.1. for detail description of this equipment The fuel to be used is fuel gas (natural gas). The heat medium to be used is “Shell Thermia B”.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

41 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In the 1st circuit of the circulation system, thermal oil is pumped by means of the HM Pump Circ.1 GP-652 A/B via the HM Filter GF-657 A/B and the Thermal Oil Heater GH651 with a supply temperature of 275 °C to the consumers - Stabilizer Reboiler GE-113, Deethanizer Reboiler GE-408 and Debutanizer Reboiler GE-411. The branched off stream nd to the 2 circuit is also supplied by this pump. The return from the consumers with a temperature of approx. 240°C is lead to the suction side of the HM Pump Circuit 1 GP-652 A/B. A second circuit with the dedicated HM Pump Circ.2 GP-653 A/B branches off the 1st heating circuit. The supply temperature to the consumers is only about 200 °C. This temperature is adjusted by means of a branched off stream from the circuit return to the suction side of the dedicated circulation pump. This heating circuit supplies the Amine Regenerator Reboiler GE-207 and the heating system for vessels and pipes. Its branched off return (return temperature approx. 160°C) is also lead to the suction side of the HM Pump Circuit 1 GP-652 A/B. The HM Expansion Drum GV-656 is connected to the suction side of the HM Pump Circuit 1 GP-652 A/B to allow the expansion of the Heat Media according to the temperature in the system. Into this drum for start up or compensation of losses Heat Medium is filled in by means of the HM Transfer Pump GP-654 from the HM Pop Tank GT-655. Remark: More detailed description will be added after receiving of related documents from vendor of PU.

2.6.4

Propane Refrigeration System (Unit 670)

See PFD:

12466-01 10116

The Propane Refrigeration System is carried out as a complete Package Unit (PU-05). It serves to deliver refrigeration energy for the Gas Chiller GE-302 and the Deethanizer Condenser GE-409. See Section 3.2.1. for detail description of this equipment The system basically consists of two refrigeration circuits. The high pressure circuit is led via the propane subcooler GE-409 (cooling by Sales Gas) to the Deethanizer Condenser GE-407. The low pressure circuit is led via the propane subcooler GE-303A/B (cooling by LTS liquids from GV-304) to the Chiller GE-302. In the Chiller the product has to be cooled to –37°C. This temperature is reached by evaporating the propane at a slight overpressure so that a propane temperature of about –41°C is provided. The refrigerant is propane (purity between 98 and 99,5 wt-% C3). It can be produced in the Depropanizer Column GC-403 and stored in the Propane Storage Bullet GV-562, or directly transferred to the Refrigeration Unit. The initial filling will be done by direct filling from a propane tank truck via hose connection. The compensation of losses can be provided by means of Propane Transfer Pump GP-561 from the Propane Storage Bullet GV-562, or by means of the Depropanizer Reflux Pump GP-418A/B directly from the Depropanizer GC-403. Remark: More detailed description will be added after receiving of related documents from vendor of PU.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

42 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.6.5

Flare System including Emergency Drain (Unit 690)

See PFD:

2.6.5.1

12466-01 10123 12466-01 10118

Flare System

The flare system serves to collect and disposing of combustible gases by burning in the open the gases that are continuously generated in the vessel for overpressure and the purge gas amounts in the normal operation. The most important task of the flare system is to collect and burn the gases from safety valves and from the emergency depressurizing valves in case of emergency. The Flare System consists in the main flare header and sub headers, the Flare Knock Out Drum GV-692, the Cold Knock Out Drum GV-689, the Flare Knock Out Drum Pumps GP691 A/B and the Flare Stack GS-693 (PU-06). The Flare Stack is designed as high flare. Fuel gas is used as pilot gas. In the headers, the flare gas is led to the Flare Knock Out Drum GV-692, which is designed to separate and collect the liquids. A heating coil is provided into the Flare Knock Out Drum for in case of deicing the liquid relieved. The liquids collected in the Flare Knock Out Drum GV-692 are pumped with GP-691 A/B to the Oily Slop Vessel GV-443 (small amounts) or via Oily Slop Filter GF-441 and Oily Slop Cooler GE 444 to Sour Off Spec Vessel GV-530. In case of High level in GV-692 the procedure is start one pump. If liquid level increases until High High level, procedure is start spare pump. Otherwise, in case of liquid decrease until Low level procedure is stop both pumps, and if level continues decreasing at Low Low level (independent measurement) procedure is stop complete pumping system. In case of HHH liquid level together with HH level (of an independent measurement) procedure is an Emergency Shut Down in the whole Plant (See Section 6.3.4.1) Relief gas that comes from the emergency depressuring valves in the Low Temperature Separation (at GE-301) or by the Liquid Relief valves from Low Temperature Separator GV-304 is led directly to the Cold Knock Out Drum GV-689. A heating coil is provided into the cold Knock Out Drum for deicing and evaporates the liquid relieved. It is expected, that all cold liquid can be evaporated. In case of remaining liquid that is not evaporated is drained via closed drain to the slop system. Relief products to the Cold Flare Knock Out Drum GV-689 will be mainly from ESD Depressurizing Valve UV-G301C and from relief valve 300-PSV-003A/B which is located downstream UV-G304A. During depressurizing less than 1 m³ liquid is expected, but in case of relief via 300-PSV-003A/B 11 m³/h liquids are expected. For this reason, in case of HH liquid level in GV-689, Unit Shut Down valve UV-G304A will be closed via safety interlock (ESD), in order to prevent liquid overflow in Cold Flare Knock Out Drum. Remark: More detailed description will be added after receiving of related documents from vendor of PU06.

2.6.5.2

Emergency Drain System

An Emergency Shut Down System (ESD) is installed in Gas Treatment Plant. In an emergency case the operator can block-in, shut down and relief the plant, total or in sections. For a detailed description of Emergency Shut Down System (ESD) refers to the document Nr. 12466-01 10250 “Description of ESD System”.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

43 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In the area of Unit 100 Emergency Drain Vessel GV-697 is installed. This vessel is used to collect drain product of GV-101, GV-102, GV-103 and GC-111, that can be released after depressuring of this equipment. By means of the Emergency Drain Pump GP-690 this product is pumped to the Sour Off Spec Bullet GV-530. In case of HHH level in GV-530 the pump does not start up automatically. Also, in case of HH Level in GV-697, pump starts up automatically. In the area of Unit 300/400 the Emergency Drain Vessel GV-694 is installed. This vessel is used to collect drain product of GV-304, GE-302; PU05; GV-421; GV-419, GC-401, GC402 and GC-403, that can be released after depressuring of this equipment. The Emergency Drain Vessel GV-694 is equipped with an Electrical Heater (GE-695). The Heater is used to vaporize light hydrocarbons to the flare. By means of the Emergency Drain Pump GP-696 this product is pumped to Off Spec Bullet GV-528. In case of HH Level in GV-697, pump starts up automatically. As cold (-29°C) Natural Gas Liquids (drain from GV-304) can be mixed with warm products in GV-528, light HC will evaporate and lead via the PCV to the flare. The PSV of GV-528 will not open in this case as it is set pressure (17,3 bar (g)) is much higher than the max. head of the pump GP-696 (rated approx. 12 bar (g)) . The same applies if warm products from GV-694 (in case of drained Fractionation) can be mixed with light HC in GV-528: light HC will vaporize and is lead via the PCV to the flare.

2.6.6

Fuel Gas System

The Fuel Gas System serves to provide fuel gas for the consumers in the overall plant except the Service Generators. The normal system pressure of the fuel gas is 7 bar(g). The gas is taken from the sales gas pipeline on the basis of pressure control. The fuel gas is supplied to the fuel gas net via the Fuel Gas Heater GE-698 (to compensate the temperature drop that results from the expansion from pipeline pressure to the fuel gas system pressure) and the Fuel Gas Separator GV-699 (to separate eventually hydrocarbons into the oily slop). The overall demand of the plant amounts to approx. 1200 Nm³/hr Main consumers are the Heat Medium Heater GH-651 and the Glycol Reboiler in the TEG Dehydration Unit. Fuel Gas is also used as purge gas in several vessels and tanks in the plant. Fuel Gas Heater GE-698 is shut down via safety interlock (PSD) in case of High High temperature in Fuel Gas Outlet from GV-699. In case of HH Level in GV-699 following valves are closed via interlock: •

Pressure Control Valve PV1-G699A: Sweet gas from Gas Header to GV-699 via GE-698.

•

Pressure Control Valve PV-G699C: Fuel gas raw from Inlet Facilities to GV-699 via GE-698.

•

Pressure Control Valve PV2-G699A: Sweet gas from GE-409 to GV-699.

In case of HHH liquid level in GV-699 procedure is an Emergency Shut Down in the whole Plant (See Section 5.3.4.1)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

44 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.7

Unit 700 Water Systems 2.7.1

Raw Water Treatment (Unit 700)

See PFD:

12466-01 10117

Raw water is provided from Battery Limit and stored in the Raw Water Storage Tank GT704. By means of the Service Water Pumps GP-703 A/B, raw water is pumped to the service stations in the plant. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting 3

The Raw Water Transfer Pumps GP-702 A/B (capacity 35 m /h) supply raw water for the Water Treatment Plant (PU-15) and fill the Fire Water Tank GT-784 in case of need. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting. The Water Treatment Plant has a capacity of 25 m続/h. It serves to provide potable water and demineralized water. In case of Low Liquid Level in Raw Water Storage Tank GT-704 and/or Low Flow in suction line of Service Water Pumps GP-703 A/B and Raw Water Transfer Pumps GP-702 A/B, these pumps are shut down via interlock. Remark: More detailed description will be added after receiving of related documents from vendor of PU15

2.7.2

Waste Water System (Unit 720)

See PFD:

12466-01 10122

The Waste Water System serves to collect the water that is separated in the water boots of the Inlet Separators GV-101, GV-102 and GV-103 and the Stabilizer Reflux Drum GV116, as well as small amounts from the Gas Condensate Storage Tank GT-506 (eventually separated small amounts, directly pumped by the Water Pump GP-505 to GT722). The Produced Water is led via the level controlled Produced Water Flash Drum GV-724 into the Produced Water Tank GT-722. In the Produced Water Flash Drum GV-724 dissolved gases are separated at a pressure of about 1.5 bar(g) and led to the flare. The (flashed) Produced Water is pumped by the Produced Water Transfer Pump GP-721 A/B to the Product Loading, Unit 500 where it is loaded on tank trucks for transportation to disposal or reprocessing. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting. The Produced Water Tank GT-722 is equipped with an oil skimmer to separate floating oil to the Oily Slop Vessel GV-443 in the HC Drain, Unit 440. In case of Low-Low liquid level in Produced Water Tank GT-722, the Produced Water Transfer Pumps GP-721A/B are shut down via interlock. Domestic waste water will be collected and forwarded to a 3 stage treating system. From there clean water is given via rain water system to Battery Limit. Remaining solids have to be disposed by an externally Company.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

45 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.7.3

Potable Water System (Unit 740)

See PFD:

12466-01 10117

Potable Water is supplied from the Water Treatment Plant (PU-15). It is stored in the Potable Water Storage Tank GT-742. By means of Potable Water Pumps GP-741 A/B the potable water is supplied to the Potable Water Day Tank GT-743 and to truck loading. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting. Potable Water can be loaded on trucks to supply the Gas Gathering Stations in the area. In case of Low-Low Water Level in Potable Water Storage Tank GT-742 and/or Low Flow in suction line of Potable Water Pumps GP-741 A/B, these pumps are shut down. In case of High-High Water Level in Potable Water Storage Tank GT-742 a signal is given to the treatment plant to stop the production. One part of the Water Treatment Plant (PU-15) consists of a pressure maintaining section, which supplies Potable Water to safety showers, to personal use and in case of necessity also to service water stations at a pressure of approx. 4 bar(g). 2.7.4

Demineralized Water System (Unit 760)

See PFD:

12466-01 10117

The Water Treatment Plant also supplies demineralized water. It is stored in the Demin Water Storage Tank GT-762 and pumped by means of the Demin Water Transfer Pumps GP-761 to the Amine Surge Vessel GV-221 and to the Amine Storage Tank GT-584 to dilute the amine solution and compensate water losses in the Amine Wash System (Unit 200). One additional connection is located near the Filter in the Unit 200 for special flushing purpose. Pump capacity will be controlled by recirculation a portion of the pumped fluid back to the tank by means of Orifice Fitting. In case of Low Flow in suction line of Demin Water Transfer Pumps GP-761, this pump is shut down. 2.7.5

Fire Water System (Unit 780)

See PFD:

12466-01 10127

The plant is equipped with an automatic fire fighting system. The system consists basically of the Fire Water Storage Tank GT-784 with a capacity of 2000 m続, the Fire Water Pump Station, which is carried out as a complete Package Unit (PU-08), and the fire lines with the necessary fittings, monitors and hydrants, carried out as a ring conduit with underground fire lines. The Fire Water Pump Station (PU-08) consists of two Fire Water Pumps GP-782 and GP783 with a capacity of 570 m続/h each. The Fire Water Pump GP-782 is electric driven. The Fire Water Pump GP-783 is driven by a diesel engine with its separate Diesel Fuel Tank GV-785. To maintain a constant pressure level in the fire lines, the Fire Water Jockey Pump GP-781 is provided. The fire lines supply fire fighting water to the fire fighting equipment installed in the individual units. In case of pressure drop in the fire lines, i.e. when fire fighting equipment is triggered or operated, first the Fire Water Jockey Pump GP-781 tries to maintain the pressure. Afterwards, the Fire Water Pump GP-782 starts to work.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

46 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In case of Low-Low Water Level in Fire Water Storage Tank GT-784 Alarm will be given. The shut down of running pumps shell be initiated by a member of the fire brigade. Remark: More detailed description will be added after receiving of related documents from vendor of PU08.

2.8

Unit 800 Electrical Supply See PFD:

12466-01 10125

The plant will have three electrical generators. Two generators will be driven by gas turbines (GG-811 and GG-841). Each will be capable of supplying the total plant demand plus 25 %. The electrical power of each generator will be 10 MW (at ISO conditions). The generators will be carried out as a complete Package Unit (PU-11). The fuel for the gas turbines will be Sales Gas (dried and sweetened natural gas). Raw sweet gas from the pipeline (sweet but water saturated natural gas) can be used as fuel gas for start-up operations, in case that no sales gas from the Sales Gas Pipeline is available. The third generator (GG-871) will be driven by diesel engine with the capacity to operate key equipment and provide the power for a cold plant start up. The electrical power is 750 kW. This generator will also be carried out as a complete Package Unit (PU-17). See Section 3.2.1 for detail description of this equipment. The diesel fuel is stored in the Diesel Fuel Vessel GV-863 (capacity about 6 m続), that is filled from drums. The drums are emptied by means of the Diesel Fuel Pump GP-864. This pump also transfers the diesel from the tank to the day tank of the diesel engine. Emergency generator has been arranged to start automatically on detection of mains power failure and to take over the supply of power on closing of the generator circuit breaker. It is expect Emergency Generator Start-Up in 10 sec. After receive signal from starters and automatic transfers switches. Facilities have been provided to permit periodic on-load testing of emergency generators by enabling the generator to be synchronized with the mains supply. The emergency lighting system consist of a number of standard luminaries of the normal lighting installation, which will be fed via circuits having a stand-by supply from the emergency generator. It will be provide in following areas: Electrical Sub-Station; Control Room; Emergency-Exit in Administrative Office; Elevators. In the case of luminaries in the control room and the basement of the control room, as well as field auxiliary rooms will have a stand-by supply from an independent source (UPS) with battery back-up to avoid complete darkness during start-up time of the diesel generator. Remark: More detailed description will be added after receiving of related documents from vendor of PU-11.

2.9

Summary of Operating Conditions of important Equipments In Appendix 8 a summary of Operating Conditions of important Equipments such as Columns, Inlet Separators is shown.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

47 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

2.10 Process Simulation The basis for the simulation of the process plant is the simulation program “ProVision” Version 7.0 of SIMSCI Company. The process was designed taking in consideration four (4) Scenarios: Case 100% (Normal Operation Mode) This scenario considers the following process parameters: Pressure at inlet plant:

64 bar (g)

Temperature at inlet plant: Sour Feed:

19.7 °C

Volume flow (norm.):

Sweet Feed:

35 °C

Sour Feed:

1.5 MMStdm³/d

Sweet Feed:

4.8 MMStdm³/d

Case 60% (Minimum Operation Mode) This scenario considers the following process parameters: Pressure at inlet plant:

64 bar (g)

Temperature at inlet plant: Sour Feed:

19.7 °C

Volume flow (norm.):

Sweet Feed:

35 °C

Sour Feed:

0.9 MMStdm³/d

Sweet Feed:

2.88 MMStdm³/d

Case 120% A (Maximum Operation Mode) This scenario considers the following process parameters: Pressure at inlet plant:

81 bar (g)

Temperature at inlet plant: Sour Feed:

19.7 °C

Volume flow (norm.):

Sweet Feed:

35 °C

Sour Feed:

1.8 MMStdm³/d

Sweet Feed:

5.76 MMStdm³/d

Case 120% B (Maximum Operation Mode) This scenario considers the following process parameters: Pressure at inlet plant:

55.5 bar (g)

Temperature at inlet plant: Sour Feed:

19.7 °C

Volume flow (norm.):

Sweet Feed:

35 °C

Sour Feed:

0.96 MMStdm³/d

Sweet Feed:

6.6 MMStdm³/d

Based on those scenarios, in the Appendix 9 “Material Balances of Gas Treatment Plant” are shown, which include the Process Conditions.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

48 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Commissioning and Special Equipments Description 3.1

Commissioning General The objective of commissioning equipment is to find out if it will perform as intended before process materials are introduced. The commissioning of utilities and equipment is the final step of the pre-startup plan. All inspections, testing, and commissioning should be performed according to established safety procedures. Before commissioning, all vessels, piping, and equipment should be inspected to verify that construction is complete and all items have been tagged or labeled. To ensure a complete inspection, detailed inspection checklists should be prepared for each item on the master list of all vessels, piping, and equipment. The specific inspection checklists should cover safety considerations such as the accessibility of valves, the generation of static electricity by free falling streams, sampling provisions, and the protection of sensors and sight glasses. Auxiliary items such as foundations, anchor bolts, pipe supports and hangers, insulation, and protective coatings should be covered in the detailed checklists. During the inspections, necessary baseline corrosion data of metal thickness should be recorded. Following the inspections, vessels, piping, and equipment should be pressure tested, cleaned, flushed, dried, and purged. Any deficiencies found during inspection, testing, and commissioning should be corrected. All changes made during this period should be documented and appropriate changes should be made to the process safety information and the operating and maintenance procedures. 3.1.1

Commissioning Utilities

Diesel Generator; Water Supply; Safety and Fire Water System; Instrument Air Package; Nitrogen Generation; Service Generator; Methanol Storage Injection; Glycol Storage Injection; Amine Storage; Corrosion Inhibitor; Anti-Foam; Odorant and Heat Media Unit, underground drains, and fuel gas should be commissioned. A detailed checklist should be prepared using vendor instructions for commissioning each of the plant utilities. In addition to cleaning, flushing, and purging the lines and headers, each utility should be, if possible, tested for its required delivery capacity. 3.1.2

Commissioning Equipment

Pumps; compressors; fired heaters; electric motor, gas-engine and gas-turbine drivers; and their instruments and controls should be commissioned before startup. Commissioning includes such tasks as drying out, checking the piping strain on equipment, checking the rotation of electrical motors, and checking the lubrication systems. In addition to commissioning individual pieces of equipment, as many process stage and operations as possible should be simulated with water, air, or other inert fluids. Closed loop dynamic testing with safe fluids permits the flow testing of equipment, indicates how the controls respond, and acquaints the operators with the equipment before process fluids are introduced. Dynamic testing can also be used to collect baseline data such as air flow rates, pressures, and tank flow verification. At the end of the simulation the equipment should be dried and purged.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

49 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

3.1.3

Commissioning Instruments, Computer, and Control

The numerous sensors, analyzers, interlocks, and alarms should be commissioned before startup. Instruments and controls designed as critical to safety should be commissioned before startup. Some of the checks that should be performed are: •

Instrument placement according to drawings

•

Specified instrument installed

•

Installation according to manufacturer's instructions

•

Instrument suitable for electrical classification area

•

Calibration

•

Continuity check

•

Loop check

•

Alarms check

•

Interlocks check

•

Analyzers check

Once the location, instrument, installation and tagging have been verified to be correct, the instruments should be put in operation. Scheduling of the inspection and testing should be made from the master list of instruments. For each type of instrument, a checklist should be prepared for testing and documentation purposes. Sensors should be tested by comparing at least two measurements over the control range at the sensor with the readings in the control room. Gas detectors should be calibrated with standard gas mixtures. The alarm settings and the response of alarms and interlocks to sensors should be verified. The controllers can be operated locally in the plant or remotely in the control room computer. Each control loop should be checked. In the Appendix 10 is presented a preliminary checklist for Plant Completion. Using the checklist, a detailed schedule should be developed to assign tasks for inspection and commissioning.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

50 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

3.2

Special Equipments Description 3.2.1

Mechanical Equipments or Units:

Mechanical Equipments and Units will be described in detail once defined Manufacturer during Detail Engineering. •

Propane Refrigeration Unit

•

Dehydration and Glycol Regeneration Unit

•

Acid Gas Incinerator

•

Nitrogen Generation Unit

•

Water Treatment Plant

•

Heat Media Unit

•

Emergency Generator

3.2.2

Instrumentation

The design functional control and protection is based in the CAC Good Engineering Practice and “Instrumented Safeguarding Systems” Schedule L-2, Rev 03 and “Distributed Control Systems” Schedule L-3, Rev. 12/97. 3.2.2.1

Design Philosophy

The following philosophies are applied: •

The SGS works independently from the DCS and every fault in the DCS shall not affect the availability and safety of SGS.

•

The SGS shall be designed capable of functioning under the conditions, which may be experienced when the system is required to operate. Loss of power or key input signals shall not compromise the integrity of the system or its capability to shutting down the facilities in a controlled manner.

•

The SGS shall be installed in designated climate controlled equipment / auxiliary room forming an integral part of the facilities infrastructure e.g. controls building.

•

To ensure a high degree of availability, provisions shall be made to allow for regular testing.

•

Suitable and sufficient alarms and visual indications shall be provided to the operator to indicate the status of the SGS.

•

Detailed safeguarding design documents and drawings shall be provided with the process design and SGS.

•

The SGS shall be functionally segregated to avoid total shut down on failure of a single component.

•

Cascade trips shall be avoided where practically possible.

•

‘Fail safe’ and ‘failure to safety’ design principles shall be applied.

•

All shut down systems shall react within the available time from the trip initiation to the plant becoming unsafe (the plant response time). In the context of this

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

51 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

specification however, this may be taken as a firm criteria for less than one second response time, unless less required. In principle the design objective for the SGS shall be for maximum integration (in a modular way) of all safeguarding functionality within 1 facility, i.e. all safeguarding logic’s, including specific equipment logic, should be part of 1 SGS instead of multiple SGS’s for individual pieces of equipment. Deviations to this principle require approval of SGC.

•

3.2.2.2

Design Criteria. Safeguarding Hierarchy:

Automatic shut downs shall be designed to operate automatically in case safety, environment, process or equipment is outside its design or allowable operating envelope. This to avoid hazardous or undesired situations from developing, to control escalation of the event and to bring the facilities to a safe state. If the operation of one process system or subsystem is conditional upon the operation of another, reliance shall not be placed on the process to cascade the effects of trips. Simultaneous trips of all such systems shall be initiated without any time delay between detection of an upset condition and execution of the logic function. However, where sequencing is specifically required, e.g. rundown of equipment on loss off supply, then the machine protection logic shall ensure correct sequencing. Dependent on the cause of the shut down, a corrective action in accordance with one of the following categories, shall be taken: Emergency Shut Down – ESD:

•

An emergency shut down is defined as the isolation and de-activation of all process and non-essential utility systems together with depressurization (initiated by the operator) of the facility, where appropriate. Process Shut Down – PSD:

•

A process shut down is defined as the automatic isolation and de-activation of all or part of the process. During a PSD the process remains pressurized. Manual Shut down Initiation:

•

Manual initiation causing either an ESD or PSD of the entire plant or part of the plant, is provided remotely, at the station main operator interface as well as at strategic positions in the plant e.g. along escape routes and at selected equipment. At the main operator interface these are separate and of the ‘turn and push’ type (i.e. not part of DCS), while outside in the facility these shall be of the ‘mushroom’ type with covers to avoid accidental activation. The separate push-buttons at the stations main operator interface and in the facility shall be hardwired into the SGS and shall be designed fail safe, i.e. cable or push-button failure causes a shut down. Remote manual shut down initiation (e.g. via SCADA) shall be designed non-fail safe, i.e. loss of telemetry will not cause a shut down. 3.2.2.3

ESD System and Relief System

An Emergency Shut Down System (ESD) is installed in the Gas Treatment Plant. In an emergency case the operator can block-in, shut down and relief the plant, total and in sections.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

52 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Depending on the respective emergency situations that are appearing or expected, the whole plant or sections can be blocked in and the whole plant or sections can be relieved to the Flare System.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

53 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

Ausgabe: 02/05 Rev.:01

CFA 1500E

Start up 4.1

General There are Three (3) different phase level for Start Up the Gas Treatment Plant. a) Initial Start Up b) Start Up following process Shut Down (Intermediate Start Up) c) Start Up following Emergency Shut Down (Restart) Following is described each item

4.2

Initial Start-up The first Units to be started are the utilities. They must be functioning properly before the rest of the plant can be brought up to capacity. This section included instructions for start-up the following Systems: Diesel Generator; Water Supply; Safety and Fire Water System; Instrument Air Package; Nitrogen Generation; Fuel Gas Raw; Service Generator; Methanol Storage Injection; Glycol Storage Injection; Amine Storage; Corrosion Inhibitor; Anti-Foam; Odorant and Heat Media Unit. Include Guidelines for Training Personnel and Commissioning Requirements. Finally this section included instructions for purging / inerting the equipments to guarantee that facilities are in safety condition to receive gas production from wells. Before to Start-Up the Plant, is required a safety review. A pre-start-up safety review is conducted before the initiation of any start-up activities. Basic is review to find out how the recommendations were resolved from the previous hazard analyses (e.g. HAZOP). It allows verify that appropriate safety precautions have been taken before a plant goes onstream. The review is performed by a team composed of production, research and development, engineering, and safety department personnel. The start-up team should verify that all design safety and pre-start-up safety review recommendations have been satisfactorily addressed. The training of the operators, maintenance personnel, and laboratory technicians should be verified. All start-up personnel must know the emergency response plan and what action to take in an emergency. The spare parts inventory should be reviewed from the perspective of the maintenance department being able to make repairs quickly. Safety equipment should be inventoried and locations checked for accessibility. Following is presented Specific activities for Initial Start-Up. First is presented Utilities Start-Up and then Purge and Inert Procedure. For the purpose of the Operating Manual is assumed than all preliminary requirements for starting-up described in the Pre-Commissioning and Commissioning requirements have been completed. It includes the flushing of all lines using air or water to remove any foreign material that may have gotten into the lines. The General Schedule and sequence for Initial Star Up activities is presented in Appendix 11. The tasks are shown in boxes describing the tasks.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

54 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.2.1

Utilities Start-Up

Utilities are needed in many parts of the plant, and must be functioning properly before the rest of the plant can be brought up to capacity. The sequence to Start-Up Facilities Equipments is presented next. During initial start-up, operations and maintenance staff must ensure safe conditions for the transport and transfer of process materials from trucks. These materials include lubricants, process fluids, chemicals, and water treatment chemicals. The process fluids and chemicals will be transferred to a feed tank or to the process vessels. Detailed checklists and procedures will help ensure that the fluids are isolated in the correct feed tanks and process vessels. The basis is the functioning of the Instrument Air and Nitrogen System. Pressurized air and nitrogen are used for flushing and drying of equipment after pressure tests and water flushing. Nitrogen is also used as breathing gas. The most important Unit is the Diesel Engine Generator GG-871 (PU-17) including the filled Diesel Fuel Tank GV-863 as by means of the generator the minimum amount of electrical energy can be produced in case of disrupted energy supply from B.L., and the diesel tank ensures sufficient fuel capacity for the diesel generator as well as for the refilling of the diesel day tank of the Fire Water Pump Station (PU-08). The next units to be started are the water supply that means the raw water storage and treatment, to be able to fill and start up the Fire Water System. 4.2.1.1

Unit 800, Diesel Engine Generator (PU17) and Diesel Fuel Vessel

See PFD:

12466-01 10125

See PID:

12466-01 22277 12466-01 22278

In case of Pressure tests have been completed with water, verify that the Diesel Fuel Vessel GV-863 and the pipes have been dried out.

For the initial filling (and some reserve) of the Diesel Fuel Vessel GV-863 (storage capacity approx. 5,5 m3) order 30 drums of diesel fuel and fill the vessel by means of the Diesel Fuel Pump GP-864.

Also fill the day tanks of the Diesel Engine Generator GG-871 and the Fire Water Pump Station PU-08.

Open Diesel supply ball valve from Diesel Drums

Open suction and discharge ball valve in Diesel Fuel Pump (GP-864)

Close Diesel outlet ball valve in Diesel Fuel Vessel (GV-863)

Close ball valve of Diesel Fuel distribution to PU-08 (Fire Water Pump Station) and PU-17 (Diesel Engine Generator)

Open inlet ball valve (NC) to fill Diesel Fuel Vessel (GV-863)

Start Up Diesel Fuel Pump (GP-864). Check outlet pressure in local indicator (PIG864A)

10.

Check diesel level in local indicator (LI-G863A)

11.

After Diesel Fuel Vessel (GV-863) is full, close Diesel Fuel supply ball valve in Diesel drums.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

55 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

12.

Close inlet ball valve (NC) in Diesel Fuel Vessel (GV-863).

13.

Open ball valve of Diesel Fuel distribution to PU-08 (Fire Water Pump Station) and PU-17 (Diesel Engine Generator)

14.

Start Up PU-17 (Diesel Engine Generator) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

4.2.1.2

Water Supply (Raw Water) Unit 700:

See PFD:

12466-01 10117

See PID:

12466-01 22266 12466-01 22267 12466-01 22270

Basis: Raw Water Wells are prepared and ready for delivery; the inlet hand valves at B.L. are closed. 1.

Verify Raw Water Supply to the Plant from wells. Check Pressure at the local Indicator (PI-G704A) after opening the inlet hand valve upstream the a.m. pressure gauge. The water quality shall be checked visually by opening the 1”- hand valve. If no dirt/rust is visible this valve can be closed and the Raw Water Storage Tank GT704 can be filled up.

Open inlet valve of the Tank GT-704. Check water level at the local Indicator (LIG704B) and fill up the tank until water flows out of the tank overflow pipe. While doing this also communicate with the control room to check the functioning of the low level alarm (LAL-704C) and the level indication and high level alarm (LI-704A)

Open the bottom drain valve (at N5) slowly to check the water quality visually. If the quality is o.k. close the valve and fix its blind.

Open inlet and re-circulating gate valve of the Raw Water Transfer Pump GP-702 A/B and the Service Water Pump GP-703 A/B. Run-In pumps (at first the spare pumps “B” than the operating pumps “A”) and forward to the tank GT-704 to check pump operability. Verify that all gate valves to Water Service Network, the Raw Water Treatment Unit (PU-15) and the Fire Water Tank (GT-784) are closed during that. When everything is running smooth open the ways to the networks step by step.

Open outlet gate valves of Raw Water Transfer Pump GP-702 A/B to Distribution Network and its Utility Water Service Stations. Flush the system and check the water quality visually at the most distant valves of each Service Station. Now Service Water is available throughout the plant.

Open the outlet valves of the Service Water Pump GP-703 A/B and the valves to Raw Water Treatment Unit (PU-15) and Fire Water System.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

Maintain records, as required

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

56 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.2.1.3

Safety and Fire Water System:

See PFD:

12466-01 10127

See PID:

12466-01 22272 12466-01 22273 12466-01 22300

Basis: Raw Water supply from B.L., Raw Water Storage Tank GT-704 and Raw Water Transfer Pump are running smooth.

Open inlet gate valve of Fire Water Storage Tank GT-784. Check water level at the local Indicator (LI-G784B) and fill up the tank until water flows out of the tank overflow pipe. While doing this also communicate with the control room to check the functioning of the low level alarms (LAL-G784C; LALL-G784D) and the level indication and high/low level alarm (LI-G784A).

As filling of the tank (approx. 2100 m3) by means of the Raw Water Transfer Pump GP-702 (capacity 35 m3/h).

Open the bottom drain valve (at N7) slowly to check the water quality visually several times during filling. If the quality is o.k. close the valve and fix its blind when the tank is completely filled.

Close the inlet valve of the tank as its capacity is sufficient for the start up of the Fire Water Pump Station (PU-08) and the fire lines.

Open the gate valves to and from the Fire Water Pump Station (PU-08) at the tank.

Ensure that the Diesel Day Tank of the Fire Water Pump Station is filled.

Start Up Fire Water Pump Station (PU-08) according the Operation Manual of the supplier (see Appendix 12.: Standard Instructions) and re-circulated to the tank.

When the Unit is running smooth slowly open the valves to the fire lines to fill the system.

10.

Open step by step sprinklers, monitors and hydrants to flush and de-aerate the system. Close it after de-aerating and flushing.

11.

Now test the Foaming Systems according Suppliers Manual (see Appendix 12.: Standard Instructions)

12.

When the tests are successful, flush the systems with pure fire water.

13.

When all valves, sprinklers, monitors and hydrants are closed, the main Fire Water Pumps (GP-782, resp. GP-783 shall shut off automatically and only of the Jockey Pumps GP-781A/B shall run.

14.

Now the system is in the normal working mode.

15.

Now test the whole system by opening and after some minutes closing one hydrant. Immediately after opening the electrical driven Fire Water Pump shall start and shortly after closing this pump shall stop automatically. (If the system does not work that way check the function of the Fire Water Pump Station PU-08 according the Suppliers Manual.)

16.

If everything is running smooth fill up the Fire Water Storage Tank again. Now the system is safe and ready in case of need.

17.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

57 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

18.

Check all other necessary safety devices such as safety showers, eye wash fountains.

19.

Maintain records, as required

4.2.1.4

Raw Water Treatment (PU-15; Unit 700)

See PFD:

12466-01 10117

See PID:

12466-01 22267 12466-01 22270 12466-01 22271

Verify that inlet valve of Potable Water Storage Tank GT-742 and the Demin Water Storage Tank GT-762 are closed.

Start Up Raw Water Treatment Unit (PU-15) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions).

After successful start-up and smooth operation of the Water Treatment Unit (both potable water and Demin Water start to fill the Potable Water Storage Tank GT-742, the Potable Water Day Tank GT-743 and the Demin Water Storage Tank GT-762.

Open inlet valve of the Potable Water Storage Tank GT-742, Check water level at the local Indicator (LI-G742B) and fill up the tank until water flows out of the tank overflow pipe. While doing this also communicate with the control room to check the functioning of the low level alarms (LAL-742C; LALL-742D) and the level indication and high level alarm (LI-742A)

Open the bottom drain valve (at N3) slowly to check the water quality visually. If the quality is o.k. close the valve and fix its blind.

Open inlet and re-circulating valve of pumps GP-741 A/B. Run-in pumps and recirculated to tank GT-742 to check pump operability. Verify that all valves to Potable Water Network are close.

Open outlet valves of Pumps GP-741 A/B to Distribution Network and to the Potable Water Day Tank GT-742 and fill up the tank until water flows out of the tank overflow pipe. While doing this, also communicate with the control room to check the functioning of water level in Potable Water Day Tank GT-743 at LI-743A and LA743B.

Open the valve to the potable water distribution and flush and de-aerate the system at the most distant valves.

Check and ensure the proper function of the safety showers and the eye-wash fountains.

10.

Open inlet valve of the Demin Water Storage Tank GT-762, Check water level at the local Indicator (LI-G762B) and fill up the tank until water flows out of the tank overflow pipe. While doing this also communicate with the control room to check the functioning of the alarms (LI-762A) and the level indication.

11.

Open the bottom drain valve (at N3) slowly to check the water quality visually. If the quality is o.k. close the valve and fix its blind.

12.

Open inlet and re-circulating valve of Demin Water Transfer Pump GP-761. Run-In pump and re-circulated to tank GT-762 to check pump operability. Verify that the valve to Demin Water Network is closed during that. When everything is running

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

58 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

smooth, open the valve to Demin Water Network, so that the Amine System can be flushed and filled. 13.

Check status at control room of Monitored Functions (Process Conditions) and alarms.

14.

Maintain records, as required

4.2.1.5

Instrument Air Generation Unit (PU-09):

See PFD:

12466-01 10119

See PID:

12466-01 22257

Verify that the valves to the headers and in the headers are closed.

Start Start-Up Instrument Air Generation Unit (PU-09) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

After successful start up and the filling of the plant air and instrument air buffer vessels GV-640 and GV-641, pressurize the instrument air header by slowly opening the bypass valve around the pressure controller PV-630A.

When the header is pressurized to the operating pressure close the bypass valve, open the block valves of pressure controller PV-630A and flush the pipes at the most distant hand valves.

When the instrument air header is flushed and pressurized to operating pressure, pressurized the plant air header by slowly opening the bypass valve around the pressure controller PV-630C.

When the header is pressurized to the operating pressure, open the block valves of pressure controller PV-630C and flush the pipes at the most distant hand valves.

Check mechanical conditions like compressor oil level, motor temperature, vibration, mechanical seals, leak.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

Check air supply pressure to the system in local Pressure Indicator (PI-G630B) and (PI-G630D).

10.

Maintain records, as required

11.

When the plant air header is flushed and pressurized to operating pressure and the Unit is running smooth, the Nitrogen Generation Unit PU-10A can be started up.

4.2.1.6

Nitrogen Generation Unit (PU10A):

See PFD:

12466-01 10124

See PID:

12466-01 22254 12466-01 22255 12466-01 22256

EDV-Ident-Nr.

Open air supply valve (UV-G630A) from Instrument Air Generation Unit (PU-09). Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

59 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Start-Up Nitrogen Generation Unit (PU-10A) according to Manufacturer Manual Operation (see Appendix 12.: Standard Instructions)

After successful start up and filling up of the Nitrogen Storage Bullet GV-602 pressurize the nitrogen header by slowly opening of the bypass valve around the pressure controller PV-602C.

When the header is pressurized to the operating pressure, open the block valves of pressure controller PV-602C and flush the pipes at the most distant hand valves.

When the nitrogen header is flushed and pressurized to operating pressure and the Unit is running smooth, the basis for the start up of the other Utility Units and the plant is provided.

Open outlet valve of Nitrogen Storage Bullet (GV-602) to Nitrogen Bottles Filling Station (PU10B).

Open block valves of Safety valves (600-PSV-001A/B; 600-PSV-002A/B)

Close nitrogen supply ball valve to Nitrogen Distribution Network.

Check nitrogen supply pressure in Pressure Indicator (PI-G602B)

10.

Check mechanical conditions in Nitrogen Generation Unit (PU10A).

11.

Check status at control room of Monitored Functions (Process Conditions) and alarms.

12.

Maintain records, as required

4.2.1.7

Start up Flare Stack (PU-06) and Fuel Gas System with “Raw Wet Gas”

See PFD:

12466-01 10118 12466-01 10103

See PID:

12466-01 22200 12466-01 22263 12466-01 22275

When Instrument Air, Nitrogen and Fire Water Units are running smooth fuel gas is needed for further start up activities, as it is needed for flushing, as a purge gas and as energy source. It should be ensured that Sales Gas from the pipeline can be used for start up of the system. If this is not possible than wet sweet raw gas (Sweet Feed) from the plant inlet can be used. Basis is that the pipeline (“Sweet Feed”) is pressurized and ready for use, all valves are closed and the blinds are in operating position. Communicate with the Gas Fields before further activities and get the allowance to start up. 1.

Verify Unit Shut Down Valves from Inlet Manifold Distribution Plant are close: • UV-G101D and UV-G101E: Sour Gas/ liquid to Sour Gas Separator (GV-101) • UV-G102D and UV-G102E: Sour Gas/ liquid to Sweet Gas Separator (GV-102) • UV-G103D and UV-G103E: Sour Gas/ liquid to Sweet Gas Separator (GV-103)

EDV-Ident-Nr.

Verify Pipelines from Gas Field (Battery Limits) are pressured with gas Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

60 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

For initial Start-Up is recommendable use Sweet Gas from ABO Rabah Pipeline for Fuel Gas. In that case, verify that Ball Valve installed in line that connected North Al Faid Pipeline (Sour Feed) with ABO Rabah Pipeline (Sweet Feed) is close

It is assumed that pipelines are full of water from Pressure Tests. It is necessary to purge and inert Fuel Gas line before to supply Fuel Gas. General procedure following: • For pipelines and equipments purged with air. Use a compressor to supply air to displacing water until is drained out. • Use 1 inch ball valve connection in Inlet Manifold Distribution for air supply. • Verify that block valves of following equipments and instruments are close: Fuel Gas Header (GE-698) (use bypass ball valve); Pressure control valve (PV1G699A) which supply Sweet Gas from Header to Fuel gas Separator (GV-699). • Verify that block valves of Pressure Control Valve (PV-699C) are open and bypass is closed. • Verify that drain connection of Fuel Gas Separator (GV-699) is open. • Pressurized Fuel Gas Raw Pipeline with air from Inlet Manifold Distribution Plant until Pressure Fuel Gas Separator (GV-699) is 2 bar (g) to guarantee Water Drain out. • Close drain connection of Fuel Gas Separator (GV-699) and open Vent connections. • Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection in Inlet Manifold Distribution for nitrogen supply. • Inert with nitrogen pipelines (also Fuel Gas Header) and equipments using Nitrogen Generation Unit (PU10A). • Verify safety valves bypass are close. • Pressurized Fuel Gas Raw Pipeline with nitrogen from Inlet Manifold Distribution Plant to Fuel Gas Separator (GV-699) until 2 bar (g) to guarantee air displacing. • Open By-pass ball valve in (690-PSV-002 A/B) to inert Flare Gas Header. • Verify Nitrogen Out in Vent Connections. • Close vent connection when Nitrogen Out.

Slowly open the bypass valve around the inlet block valve upstream PI-102E. Check the pressure at the inlet pressure gauge PI-102E.

Slowly open the hand valves of the pipe for the raw fuel gas to pressurize the pipe down to the inlet of the Service Generators (PU-11) and the pressure control valve PCV-699C upstream the Fuel Gas System.

Keep the pipe via PCV-699C closed until the Fuel Gas Header GE-698 is switched on and ensured that its bypass is closed; if this is done, pressurize the fuel gas system

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

61 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

to 7 bar (g) (avoid higher pressure as the set pressure of the PSVâ&#x20AC;&#x2122;s of the Fuel Gas System is 10 bar (g)) by means of the bypass valve around the PCV-699C. 8.

When the system is filled, open the block valves of the PCV-699C so that the pressure controller is brought to function.

When the whole system is flushed and running smooth, opens the purge gas valves at the ends of the flare headers to purge the whole flare system and flush out the air/oxygen content through the stack.

10.

Drain liquids separated in GV-699 to the closed drain.

11.

Check liquid level in Flare Knock-Out Drum (GV-692). Check pressure and temperature. Start Up Flare Knock-Out Drum Pump (GP-691 A/B) if required.

12.

Start up Flare Stack (PU06) (Flare Pilots and Flare Ignition Control System) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

13.

Maintain records, as required

4.2.1.8

Start up with Fuel Gas from the Sales Gas Pipeline (Dry sweet gas)

See PFD:

12466-01 10118

See PID:

12466-01 22263 12466-01 22245

This fuel gas pipe is situated downstream the hand operated block valve at the B.L. to the Sales Gas Pipeline. 1. Basis is that the sales gas pipeline is pressurized from the main pipeline and ready for use, all valves are closed, the ESD-block valve UV-599A of this pipe and the hand operated block valve downstream this UV-599A are open, and the blinds are in operating position. 2.

Communicate with the Authorities responsible for that pipeline before further activities, and get the allowance to start up.

Slowly open the hand operated inlet block valve upstream the local pressure gauge PI-599A. Check the pressure at the inlet pressure gauge PI-599A, if it shows the actual pipeline pressure that is in the range of 50 bar (g) to 75 bar (g) open the second block valve (otherwise close inlet block valve and check the for the problem in the Sales Gas Pipeline before continuing).

Open the bypass valve UV-599C around the motor operated inlet valve UV-699B to pressurize the pipe down to the pressure control valve PCV-699A upstream the Fuel Gas Heater GE-698.

EDV-Ident-Nr.

Close the bypass valve UV-699C and open the motor operated inlet valve UV-699B. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

62 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Keep the pipe via PCV-699A closed until the Fuel Gas Heater GE-698 is switched on and ensured that its bypass is closed; if this is done, pressurize the fuel gas system to 7 bar (g) (avoid higher pressure, as the set pressure of the PSVâ&#x20AC;&#x2122;s of the Fuel Gas System is 10 bar (g)!) by means of the bypass valve around the PCV-699A.

When the system is filled, open the block valves of the PSV-699A so that the pressure controller is brought to function.

Flush the system by means of the most distant valves to the flare. Now the Fuel Gas System is ready for purging the flare system.

4.2.1.9

Service Generator (PU11)

See PFD:

12466-01 10125

See PID:

12466-01 22275

When Generator Fuel Gas (wet raw gas from the plant inlet) is provided one of the Service Generators can be started up to provide electrical energy. 1. Open inlet ball valves of Service Generator (PU11) to supply Fuel Gas Raw from Inlet Distribution Plant. 2.

Keep close ball valves supply of Fuel Gas from Header.

Start-Up Service Generator (PU11) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

Maintain records, as required

Note: After the whole Plant has been stabilized, switch to Fuel gas from Sweet Gas to metering.

4.2.1.10 Methanol Storage and Injection: See PFD:

12466-01 10111

See PID:

12466-01 22208 12466-01 22253

In case of Pressure tests have been complete with water, verify that pipeline have been drain out.

Open inlet ball valve of Methanol Storage Tank (GT-582)

Open ball valve from Fuel gas Header to Methanol Storage Tank (GT-582) . Check Fuel Gas Pressure in local indicator (PI-G582A).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

63 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open suction ball valve of Methanol Transfer Pump (GP-581)

Close re-circulating ball valves (∅= 3”) from Methanol Transfer Pump discharge (GP581) to Methanol Storage Tank (GT-582).

Open re-circulating ball valves (∅= 1“) from Methanol Transfer Pump discharge (GP581) to Methanol Storage Tank (GT-582) for flow control.

Open discharge ball valves of Transfer Pump (GP-581)

Open ball valve to Methanol Day Tank (GV-162)

Open ball valve from Fuel gas Header to Methanol Day Tank (GV-162). Check Fuel Gas Pressure in local indicator (PI-G162D).

10.

Open Outlet ball Valve in Methanol Day Tank (GV-162)

11.

Open suction ball valves in Methanol Injection Pumps (GP-161 A/B)

12.

Open Discharge ball valves in Methanol Injection Pumps (GP-161 A/B)

13.

Open inlet / outlet block valves of Safety valves (160-PSV-001A / B)

14.

Open ball valves installed in Methanol Header to Supply Methanol to following equipments: (GV-103; GV-101; GV-102; GE-407; GE-302; GE-301 A/B).

15.

Open ball valve to Supply Methanol from Truck Loading to Storage Tank (GT-582).

16.

Start to fill Methanol Storage Tank (GT-582). Check Methanol level in local indicator (LI-G582B)

17.

Start Up Methanol Transfer Pump (GP-581). Check outlet pressure in local indicator (PI-G581A)

18.

Check methanol level in local indicator (LI-G162A).

19.

Check suction pressure in Methanol Injection Pumps (GP-161 A/B).

20.

Start Up Methanol Injection Pumps (GP-161 A/B).

21.

Fill injection lines with Methanol until hand operated control valves in following equipments: (GV-103; GV-101; GV-102; GE-407; GE-302; GE-301 A/B). Keep hand operated control valves closed.

22.

Stop Methanol Transfer Pump (GP-581) and Methanol Injection Pumps (GP-161 A/B) until Start Up Plant.

23.

EDV-Ident-Nr.

Maintain records, as required

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

64 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.2.1.11 Glycol Storage See PFD:

12466-01 10111

See PID:

12466-01 22225 12466-01 22251

In case of Pressure tests have been complete with water, verify that pipeline have been drain out.

Open inlet ball valve of Glycol Storage Tank (GT-586)

Open ball valve from Fuel gas Header to Glycol Storage Tank (GT-586). Check Fuel Gas Pressure in local indicator (PI-G586A).

Open suction ball valve in Glycol Transfer Pump (GP-585)

Close re-circulating ball valves (∅= 3”) from Glycol Transfer Pump discharge (GP585) to Glycol Storage Tank (GT-586).

Open re-circulating ball valves (∅= 2”) from Glycol Transfer Pump discharge (GP585) to Glycol Storage Tank (GT-586) for flow control.

Open discharge ball valve in Glycol Transfer Pump (GP-585)

Close ball valve from Glycol Feed to Glycol Regeneration Unit (PU-03)

Open ball valve to supply Glycol from Truck Loading to Glycol Storage Tank (GT586).

10.

Start to fill Glycol Storage Tank (GT-586). Check Glycol level in local indicator (LIG586B)

11.

Start Up Glycol Transfer Pump (GP-585). Check outlet pressure in local indicator (PIG585A)

12.

Stop Glycol Transfer Pump (GP-585) when the injection line to Glycol Regeneration Unit (PU-03) has been filled.

13.

Maintain records, as required

4.2.1.12 Amine Storage See PFD:

12466-01 10111

See PID:

12466-01 22212 12466-01 22252

In case of Pressure tests have been complete with water, verify that pipeline have been drain out.

EDV-Ident-Nr.

Open inlet ball valve of Amine Storage Tank (GT-584)

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

65 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open ball valve from Fuel gas Header to Amine Storage Tank (GT-584) and Amine Surge Vessel (GV-221). Check Fuel Gas Pressure in local indicator (PI-G584A).

Open inlet ball valve to supply Demin Water from Demin Water Distribution Header to Amine Storage Tank (GT-584)

Open inlet ball valve to supply Demin Water from Demin Water Distribution Header to Amine Surge Vessel (GV-221)

Open suction and discharge ball valve in Amine Transfer Pump (GP-583)

Start to fill Amine Storage Tank (GT-584) with Mobil Pump (GP-532 A/B). Check Liquid level in local indicator (LI-G584B)

Start Up Amine Transfer Pump (GP-583). Check outlet pressure in local indicator (PIG583B)

Check amine level in local indicator (LI-G221B) in Amine Surge Vessel (GV-221).

10.

Check suction pressure in Amine Charge Pumps (GP-212 A/B).

11.

Maintain records, as required

4.2.1.13 Corrosion Inhibitor See PFD:

12466- 01 10107

See PID:

12466-01 22214

Open ball valve to supply Corrosion Inhibitor from Drum Pump Corrosion Inhibitor Vessel (GV-218)

Open hand operated valve to supply Demin Water from Demin Water Distribution Header to Corrosion Inhibitor Vessel (GV-218)

Check liquid level in local indicator (LI-G218A)

Start Up Mixer in Corrosion Inhibitor Vessel (GV-218) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

Open suction and discharge ball valve in Corrosion Inhibitor Injection Pump (GP-216)

Open block valves of Safety valve (200-PSV-004)

Keep close hand operated valve (â&#x2C6;&#x2026;= 1â&#x20AC;?) to supply Corrosion Inhibitor in Amine Regenerator (GC-202).

Start Up Corrosion Inhibitor Injection Pump (GP-216). Check outlet pressure in local indicator (PI-G216A)

Stop Corrosion Inhibitor Injection Pump (GP-216) when the injection line to Amine Regenerator (GC-202) has been filled.

10.

EDV-Ident-Nr.

Maintain records, as required

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

66 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.2.1.14 Anti-Foam See PFD:

12466-01 10106

See PID:

12466-01 22214

Open ball valve to supply Anti-Foam from Drum Pump to Anti-Foam Vessel (GV-217)

Check liquid level in local indicator (LI-G217A)

Open inlet / outlet ball valve in Anti-Foam Injection Pump (GP-215A)

Open block valves of Safety valve (200-PSV-005 A/B)

Keep close hand operated valve (∅= 1/2”) for supply Anti-Foam Agent in Lean/Rich Amine Exchangers (GE-204A).

Keep close hand operated valve (∅= 1/2”) to supply Anti-Foam Agent in Amine Surge Vessel (GV-221).

Start Up Anti-Foam Injection Pump (GP-215 A/B). Check outlet pressure in local indicator (PI-G215 A/B)

Stop Anti-Foam Injection Pump (GP-215 A/B) when the injection line to Lean/Rich Amine Exchangers (GE-204A) and Amine Surge Vessel (GV-221) have been filled.

Maintain records, as required

4.2.1.15 Propane See PFD:

12466-01 10120

See PID:

12466-01 22239 12466-01 22250 12466-01 22260

In case of Pressure tests have been complete with water, verify that pipeline have been drain out.

From Loading Station “PU13” pumped Propane to Propane Storage Bullet (GV-562)

Open Unit Shut Down Valve (UV-562C)

Close Unit Shut Down Valve (UV-562A)

Open block valves of Pressure Control Valve (PCV-G562C)

Open ball valve from Fuel gas Header to Propane Storage Bullet (GV-562).

Start to fill Propane Storage Bullet (GV-562). Check liquid level in local indicator (LIG562C/D)

Open Unit Shut Down Valve (UV-562B)

Open Inlet / outlet block valves of Propane Transfer Pump (GP-561)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

67 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.2.1.16 Heat Media System (PU07) See PFD:

12466-01 10121

See PID:

12466-01 22258

Verify Initial charge of Heat Medium from trucks to Heat Media System (PU07)

Open inlet gate valve Supply of Heat Media to Heat Media System (PU07)

Open inlet ball valve supply of Fuel gas From Header.

Start-Up Heat Media System (PU07) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

Maintain records, as required

4.2.2

Instruction for Purge and Inert

After Start-Up Utilities, is required to purge and inert flow lines and equipments to guarantee a safety operation for Initial Start Up. At this point, the fuel gas system and Flare Stack are operative with fuel Gas Raw from Manifold Inlet Distribution. The procedure to inert the plant is brought on stream piece by piece, starting with the feed preparation and following in sequence the steps on the process flow sheets. For that reason instructions for purge and inert will be described by Circuits.

4.2.2.1

Circuit Nr 1, Unit 100. Sour Gas Inlet Separator (GV-101)

See PFD:

12466-01 10103

See PID:

12466-01 22200 12466-01 22201

Instruction to Purge Sour Gas Inlet Separator (GV-101) with air. Use Compressor Package to supply air.

Use 1 inch ball valve connection in Inlet Manifold Distribution for air supply.

Open Unit Shut Down Valves (UV-G101D; UV-G101F). Keep close (UV-G101E).

Open Ball valve installed downstream of (UV-G101F).

Open Bypass valve of Pressure Control Valve (PV-G101C). Keep (PV-G101C) and block valves close.

Close Unit Shut Down Valves (UV-G101A; UV-G101C; UV-G101B)

Close Block and Bypass valves of (LV-G101A)

Close Block and Bypass valves of (LDV-G101E)

Close Unit Shut Down Valves (UV-G101H; UV-G102H)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

68 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

10.

The equipment is prepared to purge. Pressurized Sour Gas Inlet Separator (GV-101) with air from Inlet Manifold Distribution Plant until 2 Bar (g) to guarantee Water Drain out. Open ball valve to closed drain.

11.

Close drain valve connection of Sour Gas Inlet Separator (GV-101) after drain out..

12.

Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection in Inlet Manifold Distribution for nitrogen supply.

13.

Inert with nitrogen pipelines and equipments using Nitrogen Generation Unit (PU10A).

14.

Open vent Connections.

15.

Pressurized Sour Gas Inlet Separator (GV-101) with nitrogen from Inlet Manifold Distribution Plant until 2 Bar (g) to guarantee air displacing.

16.

Verify Nitrogen Out in Vent Connections.

17.

Close vent connection when Nitrogen Out.

4.2.2.2

Circuit Nr 2. Unit 200. Gas Sweetening.

See PFD:

12466-01 10105 12466-01 10106 12466-01 10107

See PID:

12466-01 22209 12466-01 22210 12466-01 22211 12466-01 22212 12466-01 22213 12466-01 22216 12466-01 22217 12466-01 22218 12466-01 22219 12466-01 22220

Instruction to Purge Equipments Unit 200. Use Compressor Package to supply air.

Use 1 inch ball valve connection installed upstream (GF-208) for air supply.

Open inlet Block valves of Amine Contactor Gas Filter (sour Gas) (GF-208). Close ball valve to Closed Drain

Open inlet Block valves in Amine Contactor (Amine Lean and Sour gas)(GC-201); Close ball valve to Closed Drain

Open inlet and outlet Block valves in Amine Contactor Feed Cooler (GE-203) in tube side and shell side.

Open inlet Block valves in Amine Regenerator (GC-202) and Amine Regenerator Reboiler (Shell Side) (GE-207).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

69 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open Outlet Amine Valve; Sour Gas Valve in Amine Flash drum (GV-220). Close Level control Valve (LV-G220C)

Open Inlet / outlet Valve in Amine Particle Filter (GF-290 A / B; GF-211) and Amine Charcoal filter (GF-210). Close Amine Drain valve

Open inlet and outlet Block valves in Lean/Rich Amine Exchangers (GE-204 A/B). Open block valves of PSV (200-PSV-007/8/9/10)

10.

Open Inlet / Outlet block valves of Amine Reflux Drum (GV-222). Keep close Pressure control valve (PV2-G222B). Open Pressure control valve (PV1-G222B).

11.

Open inlet / outlet block valves of Acid Gas Separator (GV-261). Open Pressure control valve (PV1-G261C) to PU02. Close Pressure control valve (PV2-G261C) to Flare Gas. Close valve from Fuel Gas.

12.

Open Inlet valve of Transfer Vessel (GV-262). Close Liquid Level (LV-G262A).

13.

Close Unit Shut Down Valve (UV-G260A) in Acid Gas Incinerator Unit (PU02)

14.

The circuit is prepared to purge. Pressurized with air inlet connection until 2 Bar (g) to guarantee Water Drain out. Open ball valve to opened drain in each equipment.

15.

Close drain valve in each equipment after drain out..

16.

Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection for nitrogen supply.

17.

Inert with nitrogen pipelines and equipments using Nitrogen Generation Unit (PU10A).

18.

Open vent Connections. Open Unit Shut Down Valve (UV-G260A) in Acid Gas Incinerator Unit (PU02).

19.

Pressurized equipments with nitrogen until 2 Bar (g) to guarantee air displacing.

20.

Verify Nitrogen Out in Vent Connections.

21.

Close vent connection when Nitrogen Out.

4.2.2.3

Circuit Nr 3. Unit 110. Stabilization Unit

See PFD:

12466-01 10104;

See PID:

12466-01 22204; 12466-01 22205; 12466-01 22206 12466-01 22207

Instruction to Purge Equipments in Unit 110. Use Compressor Package to supply air.

Use 1 inch ball downstream (UV-G101H; UV-G102H). for air supply.

Close ESD Valves (UV-G101H; UV-G102H; UV-G110B; UV-G110C)

Open ESD Valve (UV-G110A)

Close ESD Valves (UV-G111B; UV-G116B; UV-G110C)

Open inlet ball valve in (GE-112A/B)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

70 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open inlet and outlet block valves in Stabilizer Reboiler (GE-113) from Stabilizer Column (GC-111)

Close Ball Valve to (GE-112B) from (GC-111)

Close Level Control Valve (LV-G111A) in Stabilizer Feed Pre-Heater (GE-112 A/B).

10.

Close Flow Control valve (FV-G116A) installed in Stabilizer Reflux Pump (GP-115A/B) discharge

11.

Close Level control valve (LDV-G116C) and Pressure Control valve (PV1-G116C) installed in Stabilizer Reflux Drum (GV-116)

12.

The equipments are prepared to purge. Pressurized with air inlet connection until 2 Bar (g) to guarantee Water Drain out. Open ball valves to closed drain in each equipment.

13.

Close drain valves in each equipment after drain out.

14.

Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection for nitrogen supply.

15.

Inert with nitrogen pipelines and equipments using Nitrogen Generation Unit (PU10A).

16.

Open vent Connections.

17.

Pressurized equipments with nitrogen until 2 bar (g) to guarantee air displacing.

18.

Verify Nitrogen Out in Vent Connections.

19.

Close vent connection when Nitrogen Out.

4.2.2.4

Circuit Nr 4 Unit 100; Sweet Gas Inlet Separators (GV-102; GV-103)

See PFD:

12466-01 10103

See PID:

12466-01 22202; 12466-01 22203

Instruction to Purge Sweet Gas Inlet Separators (GV-102; GV-103) with air. Use Compressor Package to supply air.

Use 1 inch ball installed between block valves in line interconnection Sour Gas Feed with Sweet Gas Feed for air supply. Keep close following valves: Block valve upstream Connection air supply; Block valve installed upstream Fuel Gas Raw Connection.

Open Unit Shut Down Valves (UV-G102D; UV-G102F; UV-G-103D; UV-G103F). Keep close (UV-G102E; UV-G103E)

Open Ball valves installed downstream of (UV-G102F; UV-G103F).

Open Bypass valve of Pressure Control Valves (PV1-G102D; PV2-G102D). Keep (PV1-G102D; PV2-G102D) and block valves close.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

71 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Close Unit Shut Down Valve (UV-G102A; UV-G102C; UV-G103A; UV-G103C; UVG102B; UV-G103B)

Close Block and Bypass valves of (LV-G102A; LV-G103A)

Close Block and Bypass valves of (LDV-G102E; LDV-G103E )

The equipment is prepared to purge. Pressurized Sweet Gas Inlet Separators (GV102; GV-103) with until 2 bar (g) to guarantee Water Drain out. Open ball valve to closed drain.

10.

Close drain valve connection of Sweet Gas Inlet Separators (GV-102; GV-103) after drain out.

11.

Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection in Inlet Manifold Distribution for nitrogen supply.

12.

Inert with nitrogen pipelines and equipments using Nitrogen Generation Unit (PU10A).

13.

Open vent Connections.

14.

Pressurized Sweet Gas Inlet Separators (GV-102; GV-103) with nitrogen until 2 Bar (g) to guarantee air displacing.

15.

Verify Nitrogen Out in Vent Connections.

16.

Close vent connection when Nitrogen Out.

4.2.2.5

Circuit Nr 5. Unit 300/350; Hydrocarbon Recovery

See PFD:

12466-01 10108; 12466-01 10109

See PID:

12466-01 22221; 12466-01 22222; 12466-01 22223; 12466-01 22263; 12466-01 22245

Instruction to Purge Equipments in Unit 300/350. Use Compressor Package to supply air.

Use 1 inch connection downstream (UV-G102C) for air supply.

Open Unit Shut Down Valves (UV-G301A; UV-G301B; UV-G304A).

Close Unit Shut Down Valves (UV-G301C; UV-G597B; UV-597C; UV-599B; UV599C).

Open inlet and outlet block valves of Gas/Gas Exchanger (GE-301 A/B); Gas Chiller (only Tube Side) (Ge-302); Low Temperature Separator (GV-304); LTS Liquid Propane Subcooler (only Tube Side)(GE-303 A/B); LTS Liquid Preheater (only Tube Side) (GE-305)

EDV-Ident-Nr.

Open block valves of PSV in the circuit Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

72 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open Bypass valve of Level Control Valves (LV-G304A). Close (LV-G304A) and block valves.

The circuit is prepared to purge. Pressurized with air until 2 Bar (g) to guarantee Water Drain out. Open ball valve to closed drain in each equipment.

Close drain valve after drain out in each equipment.

10.

Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection for nitrogen supply.

11.

Inert with nitrogen pipelines and equipments using Nitrogen Generation Unit (PU10A).

12.

Open vent Connections.

13.

Pressurized equipments with nitrogen until 2 bar(g) to guarantee air displacing.

14.

Verify Nitrogen Out in Vent Connections.

15.

Close vent connection when Nitrogen Out.

4.2.2.6

Circuit No 6. Unit 400; Fractionation.

See PFD:

12466-01 10112 12466-01 10113 12466-01 10114 12466-01 10115

See PID:

12466-01 22226 12466-01 22227 12466-01 22228 12466-01 22229 12466-01 22230 12466-01 22231 12466-01 22232 12466-01 22233 12466-01 22234 12466-01 22235

Instruction to Purge Equipments in Unit 400. Use Compressor Package to supply air.

Use 1 inch connection downstream LV-G102A for air supply.

Open Unit Shut Down Valves (UV-G419A; UV-G419E; UV-G423A; UV-G419A; UV402C)

Close Unit Shut Down Valves (UV-G419C; UV-G419B; UV-G401A; UV-G401B; UVG420A; UV-G423C; UV-G423B; UV-G402A; UV-G402B; UV-G421A; UV-G403A; UVG403B; UV-G418A; UV-G422A; UV-G416A)

Open process inlet and outlet block valves of Equipments in Unit 400.

Open By-pass and Close level control Valve (LDV-G419H; LDV-G420H; LV-G407A; LV-G422A);

Close inlet/outlet Heat Media in Deethanizer Rebolier (GE-408); Debutanizer Condenser (GE-411)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

73 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open bypass and close block valves of Pressure Control Valve (PV-G419B; PV1G420B; PV2-G421B, PV2-G422B)

Open bypass and close block valves of Flow Control Valve (FV-G419A; FV-G401A; FV-G402A; FV-G403B; FV-G403A)

10.

Close Pressure Control Valve (PV2-G420B; PV-G423A; PV1-G421B; PV1-G422B)

11.

Open block valves of PSV in the circuit

12.

The circuit is prepared to purge. Pressurized with air until 2 bar (g) to guarantee Water Drain out. Open ball valve to closed drain in each equipment.

13.

Close drain valve in each equipment after drain out.

14.

Inert pipelines and equipments with nitrogen. Use 1 inch ball valve connection for nitrogen supply.

15.

Inert with nitrogen pipelines and equipments using Nitrogen Generation Unit (PU10A).

16.

Open vent Connections.

17.

Pressurized equipments with nitrogen until 2 bar (g) to guarantee air displacing.

18.

Verify Nitrogen Out in Vent Connections.

19.

Close vent connection when Nitrogen Out.

4.2.2.7

Circuit No 7. Unit 500; Condensate and LPG Storage. Loading System

See PFD:

12466-01 10115 12466-01 10116

See PID:

12466-01 22237 12466-01 22238 12466-01 22239 12466-01 22240 12466-01 22241 12466-01 22242 12466-01 22243 12466-01 22244 12466-01 22246 12466-01 22248 12466-01 22249 12466-01 22250

Instruction to Purge Equipments in Unit 500. Purged by water filling. Water is injected, displacing the residual vapor and liquid contents over the top into the adjacent vessel or closed drain.

Use 2 inch connection downstream (LV-G111A) for water supply to Purged Condensate Storage Tank (GT-506) and pipelines.

Use 2 inch connection downstream block outlet valve of Deeth. Feed/LPG Exchanger (GE-404) for water supply to Purged LPG Bullets.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

74 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open Unit Shut Down Valves (UV-506A; UV-506B; UV-G524A; UV-528A; UV-528B;

UV-528C; UV-528D; UV-526A; UV-526B; UV-526C; UV-526D; UV-526G; UV-526H; UV-526J; UV-526K; UV-526N; UV-526O; UV-526P; UV-526Q; UV-G524A; UVG562A; UV-G562B; UV-G562C; UV-G562D; UV-G594A) 5.

Close Unit Shut Down Valves (UV-594B; UV-594C; UV1-G594D; UV2-G594D; UV3G594D)

Open process inlet and outlet block valves of Equipments in Unit 500.

Open By-pass and Close level control Valve (LV-G421A; LV-G402A)

Open By-pass and Close flow control Valve (FV-G525C; FV-G594A)

Close by pass and block valves of Pressure Control Valves (PV-G503C; PV-G504E;

10.

Open By-pass and Close Pressure control Valve (PV-G524C)

11.

Close by pass and block valves of flow Control Valve (FV-G525C)

12.

Open block valves of PSV in the circuit

13.

The circuit is prepared to purge. Pressurized until 2 Bar (g) to guarantee displaced the residual vapor and liquid.

4.3

14.

Open vent Connections and closed after venting air or vapor

15.

Open ball valve to closed drain in each equipment.

Gas Treatment Plant Start-Up

The Start-Up procedures detail the step-by-step actions to be taken to bring the plant to full production. For the initial start-up, the first step will be to complete a pre-start-up checklist (Commissioning explained in section II) and introduce process fluid inventories into the units. The instructions include the specific opening and closing of valves, any assistance needed from maintenance for temporary piping, which alarm and safety interlocks must be bypassed, and which process parameters are used for the basis of adjusting flow and recycle rates. Any potential process safety hazards shall be explained. As the process parameters come into operating range, the procedures shall explain how to activate the alarms and safety interlocks. Following is step-by-step start up procedure for The Gas Treatment Plant Start-Up. It is assumed that inlet Manifold is pressured with gas from Gas Field. It is out of scope work to describe the procedure to Start-Up Gas Wells and main pipelines from Gas Field.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

75 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.3.1

Start Up Procedures

4.3.1.1

Sweet Gas Inlet Separator (GV-102)

See PFD:

12466-01 10103

See PID:

12466-01 22200; 12466-01 22202

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G102F); (PV1-G102D); (LV-G102A); (LDV-G102E).

Close block valves of Pressure Control Valve (PV1-G102D).

Close Unit Shutdown Valve (UV-G102C) and block ball valve located upstream.

Close block valves of level control valves (LV-G102A; LDV-G102E).

Open block valves of Unit Shutdown Valve (UV-G102A; UV-G102B)

Open block ball valve to closed drain in (GV-102).

Check ESD valves (UV-G102D; UV-G102E; UV-G102F) are closed in inlet manifold

10.

Reset ESD through Hand Switch (HS-G102G) located in control Room (just in case of Re-Start after an ESD)

11.

Open ESD valve (UV-G102F) and bleeding off the pressure captured in the volume between the ESD valve (UV-G102F) and the MOV (UV-G102D). On detection of ESD valve (UV-G102F) fully open, the by-pass valve (UV-G102E) across the MOV (UVG102D) is opened allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G102D) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G102D) is travelling to the open position, the by-pass valve (UV-G102E) is closed.

12.

Check pressure in local indicator (PI-G102K). Pressure should be approx. 64 bar (g).

13.

Slowly open inlet gas production by adjusting Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G102D).

14.

Slowly Open Hand Operated Control Valve (â&#x2C6;&#x2026;= 3â&#x20AC;?) to Flare Gas.

15.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen)

16.

Close block ball valve to closed drain in order to pressurizing separator.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

76 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

17.

Slowly increase feed pressure and flow to obtain design performance (Case 60% of Process Simulation Basis) by adjusting feed in Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G102D). Check pressure, temperature and level in local indicators. Pressure should be approx. 64 bar (g) and temperature 35 °C.

18.

Once obtained design performance, open block valves of Pressure Control Valve (PV1-G102D) and close Hand Operated Control Valve installed in bypass. Set base pressure control loop to auto.

19.

For Initial Start-Up Open Hand Operated Control Valve (∅= 3”) and Flaring Gas until Start Up (PU-03). Drain Liquid separated to the Closed Drain until Start-Up Deethanizer Feed/Drum GV-419 and Produced Water System.

20.

Start-Up Methanol Injection, if required

21.

Activate alarms and safety interlocks.

22.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

23.

Maintain records, as required.

4.3.1.2

Sweet Gas Inlet Separator (GV-103)

See PFD:

12466-01 10103

See PID:

12466-01 22200 12466-01 22203

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G103F); (PV1-G103D); (LV-G103A); (LDV-G103E).

Close block valves of Pressure Control Valve (PV2-G102D).

Close Unit Shutdown Valve (UV-G103C) and block ball valve located upstream.

Close block valves of level control valves (LV-G103A; LDV-G103E).

Open block valves of Unit Shutdown Valve (UV-G103A; UV-G103B)

Open block ball valve to closed drain.

Check ESD valves (UV-G103D; UV-G103E; UV-G103F) are closed in inlet manifold

10.

Reset ESD through Hand Switch (HS-G102G) located in control Room (just in case of Re-Start after an ESD)

11.

ESD valve (UV-G103F) is opened bleeding off the pressure captured in the volume between the ESD (UV-G103F) valve and the MOV (UV-G103D). On detection of ESD

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

77 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

valve (UV-G103F) fully open, the by-pass valve (UV-G103E) across the MOV (UVG103D) is opened allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G103D) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G103D) is travelling to the open position, the by-pass valve (UV-G103E) is closed. 12.

Check pressure in local indicator (PI-G103K). Pressure should be approx. 64 bar (g).

13.

Slowly open inlet gas production by adjusting Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV2-G102D).

14.

Slowly Open Hand Operated Control Valve (∅= 3”) to Flare Gas.

15.

Gas Flaring 30 minutes to guarantee flushing and displacing inert gas (nitrogen)

16.

Close block ball valve to closed drain in order to pressurizing separator.

17.

Slowly increase feed pressure and flow to obtain design performance (Case 60% of Process Simulation Basis) by adjusting feed in Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV2-G102D). Check pressure, temperature and level in local indicators of the vessel. Pressure should be approx. 64 bar (g) and temperature 35 °C.

18.

Once obtained design performance, open block valves of Pressure Control Valve (PV2-G102D) and close Hand Operated Control Valve installed in bypass. Set base pressure control loop to auto.

19.

20.

Drain Liquid separated to the Closed Drain until Start Up (PU-03) and Unit 400

21.

Start-Up Methanol Injection, if required

22.

Activate alarms and safety interlocks.

23.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

24.

Maintain records, as required.

4.3.1.3

Dehydration Unit (PU-03)

See PFD:

12466-01 10108

See PID:

12466-01 22202 12466-01 22203 12466-01 22223

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

78 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Bypass interlocks as required

Close ball valve and bypass located upstream UV-G301A

Bleed off the captured pressure between the ESD valve and the ball valve prior to open.

Open slowly hand control valve located in bypass of ball valve upstream of ESD (UVG102C; UV-G103C) to equalize pressure around ball valve.

Once equalized pressure around ball valve, open Unit Shutdown Valves (UV-G102C; UV-G103C) of Outlet Sweet gas from separators (GV-102; GV-103). Close hand control valve

It is assumed that gas separated in Sweet Gas Separator (GV-102; GV-103) is flared for Initial Start Up. Slowly close Hand Operated Control Valve (∅= 3”) to Flare Gas installed in (GV-102; GV-103) to feed PU-03.

Start-Up Dehydration Unit (PU-03 Part 1 and Part 2) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions). Outlet Pressure should be approx. 62 bar(g) and temperature 45 °C. Verify if %H2O (wt) in gas composition to (GE-301) is 0.

For Initial Start-Up Open Hand Operated Control Valve in (PU-03 Part 1) and Flaring Gas until Start Up Hydrocarbon Recovery Process.

10.

Activate safety interlocks

11.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

12.

EDV-Ident-Nr.

Maintain records, as required.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

79 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.3.1.4

Unit 300 Hydrocarbon Recovery Process

See PFD:

12466-01 10109

See PID:

12466-01 22221 12466-01 22222 12466-01 22260 12466-01 22263

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Bypass safety interlocks in following valves: (UV-G301A); (LV-G302A); (LV-G304A); (UV-G304A)

Close inlet/outlet block Valve in shell side of Gas/Gas Exchanger (GE-301A/B).

Close Unit Shut Down Valve (UV-G301B). Close ball valve and bypass located upstream UV-G301B.

Open Unit Shut Down Valve (UV-G301C). Close block ball valve located upstream.

Bleed off the captured pressure between the ESD valve and the ball valve located upstream prior to open ESD (UV-G301A).

Open hand control valve installed upstream ESD (UV-G301A) slowly to equalize pressure around ball valve.

Once equalized pressure around ball valve, open Unit Shut Down Valve (UV-G301A) to supply Sweet gas from (PU-03) to (GE-301A/B). Close hand control valve.

10.

It is assumed that gas in (PU-03) is flared for Initial Start Up. Close Hand Operated Control Valve to Flare Gas in (PU-03)

11.

Open slowly inlet/outlet Tube side Block valves in Gas/Gas Exchanger (GE-301A/B). Check inlet / outlet temperature and Pressure in local indicators. Pressure should be approx. 62 bar (g) and temperature 45 째C for initial start up in inlet/outlet tube side.

12.

Open slowly inlet/outlet Tube side Block valves in Gas Chiller (GE-302). Check inlet / outlet temperature and Pressure in local indicators. Pressure should be approx. 62 bar (g) and temperature 45 째C for initial start up in inlet/outlet tube side.

13.

Close block valves of level control valve (LV-G304A) in Low temperature Separator (GV-304)

14.

Open block valve to closed drain in Low temperature Separator (GV-304).

15.

Slowly open bypass Valve of Pressure Relief valves (300-PSV-002A/B) to Flare Gas.

16.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen).

17.

Close block ball valve to closed drain in order to pressuring Low temperature Separator (GV-304). Check pressure, temperature and level in local indicators of the

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

80 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

vessel. Open block valve to closed drain if required. Pressure should be approx. 62 bar (g) and temperature 45 °C for initial start up. 18.

Once obtained design performance, close bypass Valve of Pressure Relief valves (300-PSV-002A/B) to Flare Gas.

19.

Open inlet/outlet shell side block Valve of Gas/Gas Exchanger (GE-301A/B).

20.

Open Unit Shut Down Valve (UV-G301C) to Flare Gas. Flare Gas until Start Up Propane Unit (PU05).

21.

Start-Up Propane Transfer Pump (GP-561) to supply propane to Propane Refrigeration System (PU-05). Open Block valve in discharge line to (PU-05). Check discharge pressure in local indicator (PI-G561B).

22.

Start-Up Dehydration Unit (PU-05) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions).

23.

Close Inlet / Outlet Block valves in Shell Side of LTS Liquid Propane Subcooler (GE303 A/B) to Supply Propane Cold –45 from (PU05). Open slowly bypass block valve. Check inlet / outlet temperature in local indicator (TI-G303 H). Inlet Temperature should be 0 °C

24.

Open slowly Open Hand Operated Control Valve installed in bypass of Level control valve (LV-G302A) to supply Propane Cold to Gas Chiller (GE-302). Keep close block valves of (LV-G302A). Propane should be supplied in a quantity, which provides the product cooling rate until the steady Chiller condition is established.

25.

Open outlet block valve shell side in Gas Chiller (GE-302). Check, temperature and level in Gas Chiller in local indicators. Inlet Temperature should be 0 °C

26.

Open Inlet / Outlet Block valves in Shell Side of LTS Liquid Propane Subcooler (GE303 A/B) to Supply Propane Cold from (PU05). Close bypass block valve. Check inlet / outlet temperature in local indicator (TI-G303 H). Inlet Temperature should be –3,3 °C.

27.

Once obtained design performance in Gas Chiller (GE-302), close Hand Operated Control Valve of Level control valve (LV-G302A) and open block valves of (LVG302A). Open block valves of level control valve (LV-G304A) in Low temperature Separator (GV-304). Inlet and outlet gas temperature should be approx. –44 and -43 °C in gas Chiller respective.

28.

Open inlet/outlet block Valve in shell side of Gas/Gas Exchanger (GE-301A/B). Check inlet and outlet gas temperature. They should be approx. –-37 °C and 39 °C respective.

29.

Verify process condition in Low temperature Separator (GV-304). Pressure and temperature should be approx. 61 bar(g) and -37 °C.

30.

Once obtained design performance in Gas Outlet for sale, open Unit Shut Down Valve (UV-G301B) to Metering and close Unit Shut Down Valve (UV-G301C) to gas

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

81 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Flare. Gas Pressure and Temperature to metering should be approx. 60 Bar (g) and 40 째C. Before to open UV-G301B, Bleed off the captured pressure between the ESD valve and the ball valve located upstream. Open hand control valve installed upstream ESD (UV-G301B) slowly to equalize pressure around ball valve. Once equalized pressure around ball valve open ESD (UV-G301B). Close hand control valve. 31.

Open Block valve downstream Unit Shut Down Valve (UV-G301B)

32.

Start-Up Methanol Injection and Emulsion Breaker if required.

33.

For Initial Start Up, Open Unit Shut Down Valve (UV-G699B) and Flaring Gas until The Plant has reached design conditions and has stabilized in combination with Sweet Gas from Sour Gas Treatment.

34.

Activate alarms and safety interlocks.

35.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

36.

Maintain records, as required.

4.3.1.5

Produced Water Flash Drum (GV-724); Produced Water Storage Tank (GT-722)

See PFD:

12466-01 10122

See PID:

12466-01 22201 12466-01 22202 12466-01 22203 12466-01 22268 12466-01 22269

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in pump (GP-721 A/B)

Open Inlet / Outlet block valves in Produced Flash Water Drum (GV-724).

Close Block valve in Level control valve (LV-G724A)

Slowly Open hand operated control valves installed in bypass of Level Control valve (LDV-G101E) from (GV-101); Level Control valve (LDV-G102E) from (GV-102); Level Control valve (LDV-G103E) from (GV-103) to supply Produced to Water Flash Drum (GV-724). Keep block valves closed. Check pressure in Produced Flash Water Drum (GV-724). It should be approx. 1,5 bar (g).

Open bypass hand operated control valve of Pressure Control valve (PV2-G724B) from Fuel Gas header to pressurized (GV-724).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

82 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Slowly Open Hand Operated Control Valve (â&#x2C6;&#x2026;= 2â&#x20AC;?) installed in bypass of Pressure Control valve (PV1-G724A) to Flare Gas. Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Close the valve. Check pressure, level and temperature in local indicators of (GV-724).

Open Block valve of Level control valve (LV-G724A) to supply water to Produced Water tank (GT-722)

10.

Open inlet / outlet block valves in Produced Water tank (GT-722). Check level and temperature in local indicators.

11.

Open suction valves in Produced Water transfer Pump (GP-721 A/B) and Skimmed Oil Pump (GP-725)

12.

Start Up Produced Water transfer Pump (GP-721 A/B) and transfer water to (PU-13). Outlet pressure should be 2 bar (g).

13.

Start Up Skimmed Oil Pump (GP-725) to Closed Drain (If required)

14.

Slowly increase feed pressure and flow to obtain design performance by adjusting feed in Hand Operated Control Valve installed in bypass of Level Control valve (LDVG101E) from (GV-101); Level Control valve (LDV-G102E) from (GV-102); Level Control valve (LDV-G103E) from (GV-103).

15.

Once obtained design performance, open block valves in Level Control valve (LDVG101E; LDV-G102E; LDV-G103E). Close Hand Operated Control Valve installed in bypass. Set base level control loop to auto.

16.

Activated alarms and safety interlocks

17.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

18.

Maintain records, as required

4.3.1.6

Deethanizer Feed/Drum (GV-419)

See PFD:

12466-01 10112

See PID:

12466-01 22222 12466-01 22226

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G102H; FV-G419A; LDV-G419H; PV-G419B).

Close block and bypass valves in Pressure Control valve (PV-G419B).

Close block and bypass valves in Level Control valve (LDV-G419H).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

83 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Close block and bypass valves in Flow Control valve (FV-G419A).

Open Unit Shutdown Valve (UV-G102H)

Open block valve inlet of Deethanizer Feed/Drum (GV-419).

Open block ball valve to closed drain.

10.

Slowly open inlet natural gas liquids by adjusting Hand Operated Control Valve installed in bypass of Level Control Valves (LV-G102A; LV-G103A) in separators (GV102; GV-103) and (LV-G304A) in Low Temperature Separator (GV-304).

11.

Slowly Open bypass Valve (∅= 2”) of Pressure Relief valves (400-PSV-001A/B) to Flare Gas.

12.

Gas Flaring by 30 minutes to guarantee flushing.

13.

Close block ball valve to closed drain in order to pressurizing Deethanizer Feed/Drum (GV-419).

14.

Open block valves of Pressure Control valve PV-G419 B. Set base pressure control loop to auto.

15.

Slowly increase feed pressure and flow to obtain design performance by adjusting feed in Hand Operated Control Valve installed in bypass of Level Control Valves (LVG102A; LV-G103A) of separators (GV-102; GV-103) and (LV-G304A) in Low Temperature Separator (GV-304). Check pressure, temperature and level in local indicators in Deethanizer Feed drum (GV-419). Pressure should be approx. 25 bar (g) and temperature 13 °C.

16.

Once obtained design performance, open block valves of Level Control Valves (LVG102A; LV-G103A) of separators (GV-102; GV-103) and (LV-G304A) in Low Temperature Separator (GV-304). Close Hand Operated Control Valve installed in bypass of these valves. Set base level control loop to auto.

17.

Open Unit Shutdown Valve (UV-G419D)

18.

Close bypass Valve (∅= 2”) of Pressure Relief valves (400-PSV-001A/B) to Flare Gas.

19.

Open block valves of Level Control valve (LDV-G419H). Close bypass.

20.

Start-Up Methanol Injection and Emulsion Breaker if required.

21.

Activated alarm and safety interlocks

22.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

23.

EDV-Ident-Nr.

Maintain records, as required.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

84 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.3.1.7

Deethanizer Column (GC-401) and Related Equipments

See PFD:

12466-01 10112 12466-01 10113

See PID:

12466-01 22226 12466-01 22227 12466-01 22228 12466-01 22229 12466-01 22230

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves and equipments: (LV-G401A); (FVG401A); (GP-415A/B); (LDV-G420H)

Verify that ESD Valves (UV-G419D; UV-G402C; UV-G670C; UV-G423A) are closed.

Reset ESD through Hand Switch (HS-401E) located in control Room (just in case of Re-Start after an ESD)

Open inlet / outlet globe valves in Tube Side Inlet Heat media of Deethanizer Reboiler (GE-408)

Close block and bypass valves in Temperature Control valve (TV-G408C) of Deethanizer Reboiler (GE-408).

Open Inlet / Outlet block valves in Tube Side Deethanizer Feed/LPG Exchanger (GE404)

Open Inlet / Outlet block valves in Tube Side Deethanizer Feed/Gas Condensate Exchanger (GE-405)

10.

Open Inlet / Outlet block valves in Tube Side Deethanizer Feed/Gas Condensate Exchanger (GE-424)

11.

Open Inlet / Outlet block valves in Shell Side Deethanizer Reboiler (GE-408).

12.

Close block and bypass valves in Level Control valve (LV-G401A) of Deethanizer Column (GC-401).

13.

Open block ball valve to closed drain in Deethanizer Column (GC-401).

14.

Close block and bypass valves in flow Control valve (FV-G401A): NG Liquids Sour inlet (GC-401) from GP (415 A/B).

15.

Close Unit Shut Down Valve (UV-G401A; UV-G401B).

16.

Open Unit Shut Down Valve (UV-G419D)

17.

Close block and bypass valves of Level Control valve (LDV-G420H) in Deethanizer Reflux Drum (GV-420).

18.

EDV-Ident-Nr.

Close block valves suction in Deethanizer Reflux Pump (GP-415A/B) Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

85 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

19.

Slowly Open hand operated control valve installed in bypass of Flow Control valve (FV-G419A) to supply NG liquids to Deethanizer Column (GC-401). Introducing feed into the column sump until the liquid feed fills the plates below the feed tray and a certain liquid hold-up is achieved.

20.

Close hand operated control valve.

21.

Check inlet / outlet tube side temperature in local indicators of Heat Exchangers (GE404; GE-405; GE-424).

22.

Supply Heat Media to Deethanizer Reboiler (GE-408). Use bypass hand operated control valve installed in Temperature Control valve (TV-G408C). The heat medium should be supplied in a quantity, which provides the product heating rate adequate until the steady reboiler condition is established.

23.

Heat the reboiler section in the column with the reboiler on total recycle

24.

Adjust temperature in top and bottom of the column.

25.

After the reboiler has reached the operating temperature, feed is slowly introduced while the temperature is maintained in the lower section of the column. Set temperatures to auto control

26.

Pressurized Deethanizer Column (GC-401) until 23 bar (G).

27.

Open Inlet / Outlet block valves of Shell Side Deethanizer Overheads Propane Subcooler (GE-409).

28.

Use bypass hand operated control valve installed in Level Control valve (LV-G407A) to control propane feed from (PU05) to Deethanizer Overheads Propane Subcooler (GE-409) and Deethanizer Condenser (GE-407).

29.

Slowly increase Propane feed pressure and flow to obtain design performance by adjusting feed in Hand Operated Control Valve installed in Level Control valve (LVG407A). Check pressure, temperature and level in local indicators in Deethanizer Condenser (GE-407). Propane should be supplied in a quantity, which provides the product cooling rate until the steady conditions are established.

30.

Check inlet/outlet pressure and temperature in local indicators of Tube side Deethanizer Condenser (GE-407).

31.

Open block ball valve to closed drain in Deethanizer Reflux Drum (GV-420).

32.

Supply NG Liquids Sour to Deethanizer Reflux Drum (GV-420). Slowly Open hand operated control valve installed in bypass of Temperature Control Valves (TV1G420B; TV2-G420B) to supply NG liquids Sour to Deethanizer Reflux Drum (GV420). Check pressure, temperature and liquid level in local indicators.

33.

Once obtained design performance, open block valves of Level Control Valves (LDVG420H) to supply Glycol Sour to (PU-03); Open block valves of Temperature Control Valves (TV1-G420B; TV2-G420B) and close Hand Operated Control Valve installed in bypass. Open block valves of Pressure Control Valves (PV2-G420B to Flare gas;

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

86 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

PV1-G420B to supply Sweet Gas to GE-409) and close Hand Control Valve installed in bypass of Pressure Control valve (PV2-G420B). Set base level control loop to auto. Set temperatures to auto control. 34.

Open slowly hand control valve installed in bypass of Pressure Control Valve (PVG423A) to flare the gas separated in Deethanizer Reflux Drum (GV-420). Keep close Unit Shut Down Valve (UV-G423A) in Deethanizer OVHD Compressor Unit (PU04). Take a sample from gas composition to verify if composition is mainly ethane.

35.

Reset ESD through Hand Switch (HS-423D) located in control Room (just in case of Re-Start Deethanizer OVHD Compressor Unit (PU04) after an ESD)

36.

Open Unit Shut Down Valve (UV-G423A) in Deethanizer OVHD Compressor Unit (PU04) after verify gas composition.

37.

Start Up Deethanizer OVHD Compressor Unit (PU04) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions). Open Unit Shut Down (UV-G423B) to pipeline. Outlet pressure should be approx. 76,5 bar (g).

38.

Close hand operated control valve installed in Level Control valve (LV-G407A) and open block valves

39.

Open block valves and keep close bypass in flow Control valve (FV-G401A): NG Liquids Sour inlet (GC-401) from GP (415 A/B).

40.

Open block valves suction in Deethanizer Reflux Pump (GP-415A/B) and transfer NG Liquids Sour to Deethanizer Column (GC-401).

41.

Slowly increase feed pressure and flow to obtain design performance by adjusting feed in Hand Operated Control Valve installed in bypass of Flow Control Valves (FVG419A) of Deethanizer Feed Drum (GV-419) to Fractionation System. Adjust bottom temperature in Deethanizer Reboiler (GE-408) with hand control valve installed in bypass of Temperature Control valve of Heat Media (TV-G408C). Adjust the reflux flow with Flow Control Valves (FV-G401A) to reach design conditions. Keep the bottoms products in Deethanizer Column (GC-401) to closed drain. Take samples from products bottom to verify that composition is basis C3+.

42.

After the system has reached design conditions and has stabilized (Basis Composition of C3+ in bottoms products of Deethanizer Column (GC-401) and mainly ethane in gas composition to (PU-04)), check operating conditions and performance parameters.

43.

Open block valves of Temperature Control Valve of (TV-G408C) in Deethanizer Reboiler (GE-408). Close bypass valve.

44.

Open block valves and keep close bypass of Level Control valve (LV-G401A) in Deethanizer Column (GC-401). Close valve to closed drain. Supply Natural Gas Liquids to Debutanizer Column (GC-402). Set base level control loop to auto

45.

EDV-Ident-Nr.

Start-Up Methanol Injection if required. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

87 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

46.

Activate alarms and safety interlocks

47.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

48.

Maintain records, as required.

4.3.1.8

Debutanizer Column (GC-402) and Related Equipments

See PFD:

12466-01 10114

See PID:

12466-01 22231 12466-01 22232 12466-01 22226 12466-01 22227 12466-01 22228 12466-01 22240

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves and equipments: (FV-G402A); (GP-G417 A/B); (GP-416 A/B).

Verify that ESD Valves (UV-G402C; UV-G402E; UV-G402D; UV-G421B) are closed.

Reset ESD through Hand Switch (HS-402E) located in control Room (just in case of Re-Start after an ESD)

Open Unit Shut Down Valve (UV-G402C)

Slowly Open hand operated control valve installed in bypass of Level Control valve (LV-G401A) to supply NG liquids to Debutanizer Column (GC-402). Introducing feed into the column sump until the liquid feed fills the plates below the feed tray and a certain liquid hold-up is achieved. Close hand operated control valve.

Supply Heat Media to Debutanizer Reboiler (GE-411). Use bypass hand operated control valve installed in Temperature Control valve (TV-G411C). The heat medium should be supplied in a quantity, which provides the product heating rate adequate until the steady reboiler condition is established.

Heat the reboiler section in the column with the reboiler on total recycle

10.

Adjust temperature in top and bottom of the column.

11.

After the reboiler has reached the operating temperature, feed is slowly introduced while the temperature is maintained in the lower section of the column. Set temperatures to auto control.

12.

EDV-Ident-Nr.

Pressurized Debuthanizer Column (GC-402) until 11 bar (G).

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

88 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

13.

Start-Up Debutanizer Condenser (GE-410) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

14.

Close inlet Block valve suction of debutanizer Reflux Pump (GP-416AB) and depropanizer reflux pump (GP-417A/B)

15.

Open block ball valve in Debutanizer Reflux Drum (GV-421) to closed drain.

16.

Supply NG Liquids Sour to Debutanizer Reflux Drum (GV-421). Slowly Open hand operated control valve installed in bypass of Pressure Control Valves (PV2-G421B) to supply NG liquids to Debutanizer Reflux Drum (GV-421). Check pressure, temperature and liquid level in local indicators. Once obtained design performance, open block valves of Pressure Control Valves (PV2-G421B) and close bypass; Open Pressure Control valve (PV1-G421B) and close Hand Operated Control Valve installed in bypass.

17.

Open inlet Block valve suction of debutanizer Reflux Pump (GP-416 A/B) and Depropanizer Reflux Pump (GP-417A/B)

18.

Start Up Debutanizer Reflux Pump (GP-416AB) and transfer LPG to Debutanizer Column (GC-402) and (GE-404).

19.

Open block valves of Flow Control Valve (FV1-G402A) to supply LPG to Debutanizer Column (GC-402). Slowly Open hand operated control valve installed in bypass of Flow Control Valves (FV-G402A) to supply LPG to debutanizer Column (GV-402). Adjust the reflux flow to reach design conditions. Check pressure, temperature and liquid level in local indicators. Pressure should be approx. 11 bar (g) and Temperature should be: 70.3 째C (Top) and 191.5 째C (Bottom).

20.

Keep close ball valve installed upstream Level control Valve (LV-G402A) to break LPG into Shell side (GE-305)

21.

Open hand control valve installed in bypass of Level control Valve (LV-G402A) and close block valve installed upstream Unit Shut down Valve (UV-G506A). Open Unit Shut Down Valve (UV-G402D) to transfer Gas Condensate to (GV-528).

22.

Open Three Way valve (TV-G413D) to send LPG off spec to Heat Exchangers (GE424; GE-406; GE-405).

23.

Start-Up Condensate Product Cooler (GE-406) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

24.

Open hand control Valve installed in bypass of Level Control valve (LV-G421A).

25.

Open Block valve and Unit Shutdown valves (UV-G528A; UV-G528D) to supply LPG off Spec to (GV-528).

26.

Open Unit Shutdown valve (UV-G528B).

27.

Start Up LPG Recycle Pumps (GP-525 A/B) and transfer LPG off Specification to (V419) inlet for Re-Processing.

28.

EDV-Ident-Nr.

Keep re-circulating Gas condensate and LPG from (GV-528) to (V-419) inlet. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

89 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

29.

Take samples of Gas Condensate and LPG to verify Composition of fluids.

30.

After the system has reached design conditions and has stabilized (Basis Composition of C5+ in bottoms products and LPG in Overhead Products of Debutanizer Column (GC-402)), check operating conditions and performance parameters.

31.

Activate alarms and safety interlocks

32.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

33.

Maintain records, as required.

4.3.1.9

Gas Condensate Storage

See PFD:

12466-01 10128

See PID:

12466-01 22237 12466-01 22238

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Bypass safety interlocks in following valves and pumps: (LV-G402A); (GP-503 A/B); (GP-505 A/B); (GP-504 A/B).

Reset ESD through Hand Switch (HS-506C) located in control Room (just in case of Re-Start after an ESD)

Close hand control valve installed in bypass of Level control Valve (LV-G402A) and open block valve installed upstream Unit Shut down Valve (UV-G506A). Set base level control loop to auto

Open ball valve to supply Gas Condensate to Condensate Storage Tank (GT-506) from Bottoms Products in (GC-402).

Open ESD valve (UV-G506A)

Close Block valve to transfer Gas Condensate to (GV-528)

Open Fuel gas supply to Condensate Storage Tank (GT-506).

10.

Start to fill Condensate Storage Tank (GT-506). Check liquid level and temperature in local indicators.

11.

Open Unit shut Down Valve (UV-G506B) and suction block valve of: Condensate Transfer Pumps (GP-503 A/B); Condensate Pipeline Pumps (GP-504 A/B); Water Pumps (GP-505 A/B).

12.

Start Up (GP-503 A/B) if Condensate is pumped to Loading Station (PU-13). Discharge Pressure should be approx. 6.6 bar (g).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

90 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

13.

Start Up (GP-504 A/B) if Condensate is pumped to Condensate Pipeline. Discharge Pressure should be approx. 70 bar (g).

14.

Start Up (GP-505 A/B) to drain out water from (GT-506) to inlet (GT-722). Pressure should be approx. 1 bar (g).

15.

Activate alarms and safety interlocks

16.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

17.

Maintain records, as required.

4.3.1.10 LPG Storage See PFD:

12466-01 10120

See PID:

12466-01 22240 12466-01 22241 12466-01 22242 12466-01 22243 12466-01 22244

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves and pumps: (LV-G421A); (UV-G528A); (UV-G528D); (GP-525 A/B); (UV-G526A); (UV-G526B); (UV-G526G); (UV-G526K); (UV-G526N); (UV-G526Q).

Open block valve of Fuel gas Inlet to LPG Storage Bullets (GV-526 A/B/C)

Close Bypass Valve of Level Control valve (LV-G421A); Open Block valves

Close Unit Shutdown valves (UV-G528A; UV-G528D; UV-528B): LPG off Spec Inlet to (GV-528) and Shut down (GP-525 A/B)

Open ESD valve UV-G402E

Open Unit Shutdown valves (UV-G526A; UV-G526D; UV-526B): Start to fill (GV526A). Check liquid level and pressure in local indicators. Pressure should be approx. 12.4 bar (g)

And / Or if is necessary open Unit Shutdown valves (UV-G526G; UV-G526K; UVG526H): Start to fill (GV-526B). Check liquid level and pressure in local indicators. Pressure should be approx. 12.4 bar (g)

10.

And / Or If is necessary open Unit Shutdown valves (UV-G526N; UV-G526Q; UVG526O): Start to fill (GV-526C). Check liquid level and pressure in local indicators. Pressure should be approx. 12.4 bar (g)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

91 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

11.

Open suction block valve of: LPG Loading Pumps (GP-524 A/B); Open Unit shut Down Valve (UV-G524) in discharge stream.

12.

Start Up (GP-524 A/B) to transfer LPG to Loading Station (PU13).

13.

Activated alarms and safety interlocks

14.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

15.

Maintain records, as required

4.3.1.11 Depropanizer Column (GC-403) and Related Equipments See PFD:

12466-01 10115

See PID:

12466-01 22233 12466-01 22234

The Depropanizer Column (GC-403) is operated as required. Supply make-up propane for the Propane Refrigeration System as needed, as well as to produce propane for sale. Depropanizer Process will be Start Up only when conditions in the Debutanizer Column (GC402) have reached design conditions and have stabilized. 1.

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Bypass safety interlocks in following valves and pumps: (GP-418 A/B); (LV-G403A).

Verify that ESD Valves (UV-G403E; UV-G403B) are closed.

Reset ESD through Hand Switch (HS-402E) located in control Room (just in case of Re-Start after an ESD)

Open Inlet / Outlet block valves in Shell Side of Debutanizer Reboiler (GE-413)

Close block valves and bypass of Pressure Control valve (PV2-G422B); Flow Control valves (FV-G403B; FV-G403A) in Depropanizer Column (GC-403)

Start Up Depropanizer Feed Pump (GP-417 A/B) to transfer LPG to Depropanizer Column (GC-403).

Slowly Open hand operated control valve installed in bypass of Flow Control valves (FV-G403A) to supply LPG to Depropanizer Column (GC-403). Introducing feed into the column sump until the liquid feed fills the plates below the feed tray and a certain liquid hold-up is achieved. Close hand operated control valve.

10.

Open inlet / outlet globe valves in Tube Side of Depropanizer Reboiler (GE-413) to supply Gas Condensate.

11.

Heat the reboiler section in the column with the reboiler on total recycle

12.

Adjust temperature in top and bottom of column.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

92 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

13.

After the reboiler has reached the operating temperature, feed is slowly introduced while the temperature is maintained in the lower section of the column.

14.

Pressurized the Column until 22 bar (G).

15.

Start-Up Depropanizer Condenser (GE-412) according to Manufacturer Operating Manual (see Appendix 12: Standard Instructions). Inlet/Outlet temperature should be approx. 63.3 °C and 62,6 °C.

16.

Supply LPG to Depropanizer Reflux Drum (GV-422). Slowly Open hand operated control valve installed in bypass of Pressure Control Valves (PV2-G422B) to supply LPG to Depropanizer Reflux Drum (GV-422). Check pressure, temperature and liquid level in local indicators.

17.

Open inlet Block valve suction in depropanizer Reflux Pump (GP-418 A/B)

18.

Start Up depropanizer Reflux Pump (GP-418 A/B) and transfer Propane to Depropanizer Column (GC-403). Slowly Open hand operated control valve installed in bypass of Flow Control Valves (FV-G403B) to adjusting feed. Control the reflux flow to reach design conditions. Check pressure, temperature and liquid level in local indicators in the column. Pressure should be approx. 22 bar (g) and Temperature should be: 63.3 °C (Top) and 111.2 °C (Bottom).

19.

Start up Depropanizer Bottom Cooler (GE-414) according to Manufacturer Operating Manual (see Appendix 12: Standard Instructions). Open Block valve of Bottoms Products in Depropanizer Column (GC-403) to supply LPG to (GE-404). Inlet/Outlet temperature should be approx. 111.2 °C and 65 °C.

20.

Once obtained design performance in the column, open block valves of Pressure Control Valves (PV2-G422B) and close bypass; Open Flow Control valves (FVG403A; FV-G403B) and close Hand Operated Control Valve installed in bypass.

21.

Open ESD Valve (UV-G403E).

22.

Activate alarms and safety interlocks.

23.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

24.

Maintain records, as required

4.3.1.12 Propane Storage See PFD:

12466-01 10120

See PID:

12466-01 22250

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

93 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valve and pump: (UV-G562A); (GP-561).

Verify that ESD Valves (UV-G562A; UV-G562B; UV-G562C; UV-G562D) are closed.

Reset ESD through Hand Switch (HS-562B) located in control Room (just in case of Re-Start after an ESD)

Open Bypass Valve of Level Control valve (LV-G422A); Close Block valves

Open Unit Shutdown valves (UV-G418A) and block valves upstream.

Open block valve of Fuel gas to Propane Storage Bullets (GV-562)

Open Unit Shutdown valves (UV-G562A) and block valves upstream. Start to fill (GV562). Check liquid level and pressure in local indicators. Pressure should be approx. 23,5 bar (g) and temperature 63 째C.

10.

Open suction block valve of Propane Transfer Pump (GP-561); Open Unit shut Down Valve (UV-G562B)

11.

Start Up (GP-561) to transfer Propane to Loading Station (PU13) and/or (PU05).

12.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

13.

Maintain records, as required

4.3.1.13 Loading Station (PU-13) See PFD:

12466-01 10128

See PID:

12466-01 22239

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Reset ESD through Hand Switch (HS-500C) located in control Room (just in case of Re-Start after an ESD).

Open ESD Valves (UV-G560A; UV-G560B; UV-G520A; UV-G520B; UV-G520C; UVG500A).

Start-Up Loading Station (PU-13) according to Specific Operating Procedure (see Appendix 12: Standard Instructions)

Maintain records, as required

Once the processes related to the sweet gas have been stabilized, the procedure is start up the process of sour gas treatment. The feed to Sour Gas Inlet Separator (GV-101) For Initial Start Up should be Sweet Gas from Abo Rabah Pipeline.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

94 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.3.1.14 Sour Gas Inlet Separator (GV-101) See PFD:

12466-01 10102

See PID:

12466-01 22200 12466-01 22201

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G101F); (PV-G101C); (LV-G101A); (LDV-G101E).

Close block valves of Pressure Control Valve (PV1-G101C)

Close Unit Shutdown Valve (UV-G101E).

Close block valves of level control valves (LV-G101A; LDV-G101E).

Open block valves of Unit Shutdown Valve (UV-G101A; UV-G101B)

Close ball valves (∅= 10”) of inlet Sour Gas to Plant from gas Field.

Open Bypass ball valves to supply Sweet gas from Abo Rabah Pipeline to Sour gas Inlet Plant (only required for Initial Start Up).

10.

Open block ball valve to closed drain in Sour Gas Inlet Separator (GV-101)

11.

Checked ESD Valves (UV-G101D; UV-G101E; UV-G101F) are closed in inlet manifold

12.

Check ESD Valves (UV-101C; UV-111A; UV-G111C) are closed.

13.

Reset ESD through Hand Switch (HS-G101H) located in control Room (just in case of Re-Start after an ESD)

14.

Open ESD Valve (UV-111A)

15.

Open ESD valve (UV-G101F) and bleeding off the pressure captured in the volume between the ESD (UV-G101F) valve and the MOV (UV-G101D). On detection of ESD valve (UV-G101F) fully open, the by-pass valve (UV-G101E) across the MOV (UVG101D) is opened allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G101D) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G101D) is traveling to the open position, the by-pass valve (UV-G101E) is closed.

16.

Check pressure in local indicator (PI-G101K). Pressure should be approx. 64 bar (g).

17.

Slowly open inlet gas production by adjusting Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G101C).

18.

Slowly Open Hand Operated Control Valve (∅= 3”) to Flare Gas.

19.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen)

20.

Close block ball valve to closed drain in order to pressurizing separator.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

95 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

21.

Slowly increase feed pressure and flow to obtain design performance (Case 60% of Process Simulation Basis) by adjusting feed in Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G101C). Check pressure, temperature and level in local indicators in separator. Pressure should be approx. 64 bar (g) and temperature 35 °C. (In case of Start-Up with Sour Gas temperature should be 19,6 °C)

22.

Once obtained design performance, open block valves of Pressure Control Valve (PV1-G101C) and close Hand Operated Control Valve installed in bypass.

23.

For Initial Start-Up Open Hand Operated Control Valve in (∅= 3”) and Flaring Gas until Start Up Unit 200 Gas Sweetening.

24.

Open by pass and block valves of level control valves LV-G101A and LDV-G101E. Set base level control loops to auto.

25.

Start-Up Methanol Injection and Glycol Sour (If required).

26.

Activate alarms and safety interlocks

27.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

28.

Maintain records, as required

4.3.1.15 Sour Gas/liquid Stabilization See PFD:

12466-01 10104

See PID:

12466-01 22204 12466-01 22205 12466-01 22206 12466-01 22207

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Bypass safety interlocks in following valves and pumps: (LV-G111A); (FV-G116A); (GP-115 A/B); (LDV-G116C)

Reset ESD through Hand Switch (HS-G101H) located in control Room (just in case of Re-Start after an ESD)

Open ESD Valves (UV-G101H; UV-G111C)

Open Inlet / Outlet block valves in Stabilizer Feed Preheater (GE-112 A/B).

Close block valves of Level Control Valve (LV-G111A).

Open Inlet / Outlet block valves in Shell Side in Stabilizer Reboiler (GE-413)

Slowly Open hand operated control valve installed in bypass of Level Control valve (LV-G101A) to supply Sour/gas liquids to Stabilizer Feed Preheater (GE-112 A/B).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

96 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

10.

Check inlet / Outlet Temperature and Pressure in local indicators in Tube side of Stabilizer Feed Preheater (GE-112 A/B).

11.

Introducing feed into the column sump and fill Stabilizer Column (GC-111) with Sour/Gas Liquids until the liquid feed fills the plates below the feed tray and a certain liquid hold-up is achieved. Close hand operated control valve installed in bypass of Level Control valve (LV-G101A).

12.

Supply Heat Media to Stabilizer Reboiler (GE-113). Use bypass hand operated control valve installed in Temperature Control valve (TV-G113D). The heat medium should be supplied in a quantity, which provides the product heating rate adequate until the steady reboiler condition is established.

13.

Heat the reboiler section in the column with the reboiler on total recycle

14.

After the reboiler has reached the operating temperature, feed is slowly introduced while the temperature is maintained in the lower section of the column. Temperature should be approx. 195 °C in the bottom of the column.

15.

Pressurized Stabilizer Column (GC-111) and Stabilizer Reflux Drum (GV-116) until 7,6 bar (G).

16.

Start Up Stabilizer Top Condenser (GE-114) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions).

17.

Open block valves of Level Control Valve (LV-G111A) to supply Gas Cond. To Sour Off spec Bullet (GV-530).

18.

Reset ESD through Hand Switch (HS-530B) located in control Room (just in case of Re-Start after an ESD)

19.

To start Up Sour Off spec Bullet (GV-530) open unit Shut Down Valve (UV-G530A; UV-G530B); Open Pressure Control valve (PV2-G530A) from Fuel Gas header to pressurized the bullet; Open slowly bypass of Pressure Control valve (PV1-G530A) in order to flushing and displacing inert gas (nitrogen). Check liquid level, pressure and temperature in local indicators of the bullet and open block valves in the suction of Sour Off Spec Pumps (GP-531 A/B) to reprocessing NG liquids sour to the inlet tube side of (GE-112 A/B). Open block valves of level control valve (LDV-G116C): Produced Water to (GV-724).

20.

Check liquid level, pressure and temperature in Stabilizer Column (GC-111) and Stabilizer Reflux Drum (GV-116). In the column, Pressure should be approx. 7,6 bar (g) and Temperature should be: 142 °C (Top) and 194,6 °C (Bottom). In Stabilizer Reflux Drum (GV-116) Pressure should be approx. 7,5 bar (g) and Temperature 65 °C. The quality parameters of the bottom product of the Stabilizer Column GC-111 (gas condensate) are the “Reid Vapor Pressure” (maximum 0.8 bar(a) ) as well as the H2S-content (maximum 3 mole-ppm).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

97 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

21.

Open block valves inlet in Stabilizer Reflux Pumps (GP-115 A/B) and transfer Sour/Gas liquid to Stabilizer Column (GC-111). Discharge pressure should be approx. 8,2 bar (g). ). Adjust reflux flow with hand control valve installed in bypass of Flow control valve (FV-G116A).

22.

Slowly increase feed pressure and flow to obtain design performance by adjusting feed in Hand Operated Control Valve installed in bypass of Level Control valve (LVG101A) and hand operated control valve installed in Temperature Control valve (TVG113D) to supply heat media to Stabilizer reboiler (GE-113). Adjust reflux flow with hand control valve installed in bypass of Flow control valve (FV-G116A) until reach design conditions. Check pressure, temperature and level in local indicators.

23.

Once obtained design performance, open block valves of Level Control valve (LVG101A) and Temperature Control valve (TV-G113D). Close Hand Operated Control Valve installed in bypass for both valves. Close hand operated control valve in bypass of Flow control valve (FV-G116A).

24.

Close Hand Operated Control Valve (∅= 2”) installed in bypass of Pressure Control valve (PV1-G116C) to Flare Gas to feed Stabilizer OVHD Compressor Package (PU01)

25.

Start Up Compressor Package (PU-01) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions). Discharge pressure should be approx. 80,6 bar (g) and temperature 149,2 °C.

26.

For Initial Start-Up: Close Unit Shut Down Valve (UV-G110B) and open (UV-G110C) and Flaring Gas until Start Up Unit 200 Gas Sweetening.

27.

Start-Up Corrosion Inhibitor Injection (If required).

28.

Activate alarms and safety interlocks

29.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

30.

Maintain records, as required

4.3.1.16 Procedure to Clean Out Amine System: The first action to start up Amine Regenerator is Clean Out the Amine Units. Cleaning removes protective oil, valve grease, mill scale, rust and other contaminants which foul amine solutions. The wash out procedure is very similar to start up. New units require a soda ash or caustic wash and demineralized water rinse. Used units also need an acid wash to remove rust and sulfide scale. 1.

Charge the unit with 2% Na2CO3. Start the Amine Regenerator Reboiler GE-207 and heat to 93 °C

EDV-Ident-Nr.

Check the circulation Pump. Verify leak Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

98 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Start the Amine Regenerator Reflux Condenser GE-206. Increase heating in GE-207 to establish reflux

Pressurize contactor slowly. Bypass all filters. Start Lean/Rich amine Exchangers GE204 and Amine Charge Pumps GP-212 A/B

Vent trapped air from valves at high points

Establish an operating level in contactor

Circulate for six hours. Periodically, open vessel bottom and piping drains and flush for one minute. Add soda ash solution as required.

Shut of the reboiler and the pumps and fans when system has cooled to 82 째C

Drain the entire system. Use blanket gas to keep air out

10.

Refill the amine system with demineralized water

11.

Repeat the washout procedure. Circulate for about 8 hours, flushing low points every two hours and observe the cleanliness

12.

If clean, drain sufficient water to add enough amine to obtain the desired solution strength. If the rinse water appears dirty, drain completely and fill with proper strength amine solution.

13.

Circulate for two hours to mix thoroughly

14.

Open the block valves on filters, close bypass valves.

The amine plant is now ready for start up. Remove blinds to process, as required.

4.3.1.17 Unit 200. Gas Sweetening Amine System (low pressure side) See PFD:

12466-01 10107

See PID:

12466-01 22211 12466-01 22217 12466-01 22218

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Bypass safety interlocks in following valves and pumps: (LV-G220A); (GP-213 A/B); (GP-214 A/B).

Open Inlet / Outlet block valves in Lean Rich Amine Exchangers (GE-204 A/B)

Close block valves in Level control Valve (LV-G220A) in (GC-202)

Close block valves in Pressure Control Valve (PCV-G202C)

Open Inlet / Outlet block valves in Amine Regenerator Reboiler (GE-207)

Close block valve suction of Amine Regenerator Bottom Pump (GP-213 A/B)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

99 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Close block valves in Pressure Control valve (PV1-G222B; PV2-G222B) in (GV-222)

10.

Close block valve suction in Amine Reflux Pump (GP-214 A/B)

11.

Close block valve to closed drain in (GF-211) to supply Lean Rich in Amine Exchangers (GE-204 A/B)

12.

Slowly Open hand operated control valve installed in bypass of Level Control valve (LV-G220A) to supply Amine Rich to (GC-202). Introducing feed into the column sump and fill GC-202 until the liquid feed fills the plates below the feed tray and a certain liquid hold-up is achieved. Close hand operated control valve.

13.

Start Up Amine Regenerator Reflux Condenser (GE-206) according to Manufacturer Operating Manual (see Appendix 12: Standard Instructions). Inlet and Outlet temperature should be approx. 85, 1 °C and 61 °C.

14.

Supply Heat Media to Amine Regenerator Reboiler (GE-207). Use bypass hand operated control valve (∅= 4”) installed in Flow Control valve (FV-G207A). The heat medium should be supplied in a quantity, which provides the product heating rate adequate until the steady reboiler condition is established. The pressure in the Reboiler should not exceed 0.7-1.0 bar(g) to prevent thermal decomposition of the amine.

15.

Heats the reboiler section in the column with the reboiler on total recycles.

16.

Circulate until the still overhead temperature at the Amine Reflux Regenerator Condenser GE-206 inlet reaches the minimum operating temperature of 85 °C.

17.

After the reboiler has reached the operating temperature, feed is slowly introduced while the temperature is maintained in the lower section of the column. Temperature in the bottom of the Amine Regenerator should be approx. 120 °C.

18.

Slowly Open hand operated control valve installed in bypass of Pressure Control valve (PCV-G202C) to supply Fuel Gas to (GC-202) for pressuring.

19.

Slowly Open Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV2-G220B) to Flare Gas. Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Check pressure, level and temperature in local indicators of (GV-222) and (GC-202).

20.

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve (∅= 4”) in bypass of Level Control Valve (LV-G220A) and Heat Media Supply in hand operated control valve (∅= 4”) installed in Flow Control valve (FV-G207A). Open ball valve to closed drain in (GC-202) and (GV222). In the Amine Regenerator, Pressure should be approx. 0,4 bar (g) and Temperature should be: 85 °C (Top) and 120 °C (Bottom).

21.

Check liquid level and temperature in local indicators in Amine Regenerator Reboiler (GE-207). Pressure should be approx. 0.9 bar (g) and Temperature should be: 120 °C

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

100 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

in shell side outlet. Inlet and outlet tube side from Heat medium should be 200 °C and 175 °C respective. 22.

Once obtained design performance, open block valves of Level control Valve (LVG220A) and close Hand Operated Control Valve installed in bypass; Close hand operated valve in bypass of Flow control Valve (FV-G207A) and open block valves to supply heat media to Amine Regenerator Reboiler (GE-207); Close hand operated valve in bypass of Pressure control Valve (PCV-202C) and open block valves.

23.

Open block valve suction in Amine Regenerator Bottom Pump (GP-213 A/B) and transfer Amine Lean to (GE-204 A/B)

24.

Open block valve suction of Amine Reflux Pump (GP-214 A/B) and transfer Amine Rich to (GC-202). Discharge pressure should be approx. 2.4 bar (g).

25.

After the system has reached design conditions and has stabilized, check operating conditions and performance parameters.

26.

Keep Open Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV2-G222B). Gas Flaring until Start Up (GV-261).

27.

Activate alarms and safety interlocks

28.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

29.

Maintain records, as required

4.3.1.18 Unit 200. Gas Sweetening Amine System (Filter GF-208) See PFD:

12466-01 10105

See PID:

12466-01 22201 12466-01 22207 12466-01 22209 12466-01 00210

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valve: (LV-G208A)

Reset ESD through Hand Switch (HS-G200D) located in control Room (just in case of Re-Start after an ESD)

Open Inlet valves in Amine Contactor Filter (GF-208). Open Block valve to closed drain.

Close block valve in Level control Valve (LV-G208A).

Close Unit Shut down Valve (UV-G201A) to (GC-201)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

101 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open Unit Shut down Valve (UV-G101C) in (GV-101) and slowly close Hand Operated Control Valve (∅=2”) to Flare Gas

Open Unit Shut Down Valve (UV-G110B) installed in discharge of (PU01) and close (UV-G110C) to Flare. Start Up (PU01).

10.

Open slowly Hand Operated Control Valve (∅= 10”) in bypass of hand Control Valve (HV-G201A) to flare. Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Check pressure, level and temperature in local indicators of (GF208).

11.

Close block valve to closed drain in order to pressurizing (GF-208).

12.

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve (∅=2”) to Flare Gas in (GV-101) and (PU01). Check pressure, temperature and level in local indicators of separator. Open hand operated valve in bypass of Level control Valve (LV-G208A) to drain out. Pressure should be approx. 63,6 bar (g) and temperature 21 °C.

13.

Once obtained design performance, open block valves of Level control Valve (LVG208A) and close Hand Operated Control Valve installed in bypass.

14.

Open Hand Operated Control Valve (∅= 10”) in bypass of hand Control Valve (HVG201A). Flaring gas until Start Up Amine Contactor (GC-201).

15.

Activate alarms and safety interlocks

16.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

17.

Maintain records, as required

4.3.1.19 Unit 200. Gas Sweetening, Amine System (high pressure side) See PFD:

12466-01 10105

See PID:

12466-01 22202 12466-01 22210 12466-01 22215

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves and pumps: (UV-G201B); (LV-G201A)

Close block valve in Pressure Control Valve (PV-G219C) installed in (GV-219)

Close block valve in Level control Valve (LV-G201A).

Open Block valve to opened drain.

Close block valve in Amine Lean from (GE-203).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

102 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Open Unit Shut down Valve (UV-G201B) to (GV-220)

Bleed off the captured pressure between the ESD valve UV-G201A and the upstream ball valve.

10.

Open slowly hand control valve located in bypass of ball valve upstream of ESD (UVG201A). This is to equalize pressure around ball valve. Once equalized pressure around ball valve, open Unit Shut down Valve (UV-G201A). Close hand control valve

11.

Close slowly Hand Operated Control Valve (∅= 10”) in bypass of hand Control Valve (HV-G201A) to flare And Open slowly Hand Operated Control Valve (∅= 8”) in bypass of Pressure Control Valve (PV-G219C) to flare.

12.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Check pressure, level and temperature in (GC-201).

13.

Close block valve to opened drain in order to pressurizing (GC-201).

14.

Open block valve from Fuel Gas in order to pressurized (GC-201).

15.

Open inlet / outlet block valves in Amine Condenser Feed Cooler (GE-203).

16.

Close Block valve downstream Unit Shut Down Valve (UV-G301B) to force Gas Outlet from (GE-301 A/B) supply Gas to Amine Condenser Feed Cooler Tube Side (GE-203)

17.

Start Up Amine Charge Pumps (GP-212 A/B). Open block valve of Flow control valve (FV1-G212C). Outlet pressure should be approx. 82,2 bar (g).

18.

Check amine solution concentration.

19.

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve (∅= 10”) in bypass of hand Control Valve (HV-G201A) and Hand Operated Control Valve (∅= 8”) in bypass of Pressure Control Valve (PVG219C). Check pressure, temperature and level in local indicators of separator. Open hand operated valve in bypass in Level control Valve (LV-G201A) to drain out at (GV220). In the Amine Contactor, Pressure should be approx. 63,2 bar (g) and Temperature should be: 52 °C (Top) and 27,8 °C (Bottom).

20.

Once obtained design performance, open block valves in Level control Valve (LVG201A) and close Hand Operated Control Valve installed in bypass; Open block valve in hand Control Valve (HV-G201A) and Close Hand Operated Control Valve (∅=10”) in bypass.

21.

Keep Open Hand Operated Control Valve (∅= 8”) in bypass of Pressure Control Valve (PV-G219C). Gas flaring before use Sour Gas Feed.

22.

Start-Up Corrosion Inhibitor Injection (If required).

23.

Activate alarms and safety interlocks

24.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

25.

EDV-Ident-Nr.

Maintain records, as required Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

103 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.3.1.20 Unit 200. Gas Sweetening, Amine Drain System See PFD:

12466-01 10106

See PID:

12466-01 22213

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Open block valve of pressure control valve (PCV-G242C) to pressurized Amine Drain Vessel (GV-242). Open bypass valve of (240-PSV-001 A/B) to flushing and displacing inert gas (nitrogen).

Check liquid level, pressure and temperature in local indicators of GV-242. Close bypass valve of (240-PSV-001 A/B).

Start Up Amine Drain Pump (GP-241) to transfer Amine Rich at (GF-209). Discharge pressure should be approx. 4,5 bar (g).

Check status in control room of Monitored Functions (Process Conditions) and alarms.

Maintain records, as required

4.3.1.21 Unit 200. Gas Sweetening, Amine Flash Drum (GV-220). See PFD:

12466-01 10105

See PID:

12466-01 22210 12466-01 22216

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Close Block valve of Level control valve (LV-G220C).

Close Block valve of Pressure control valve (PV1-G220D; PV2-G220D).

Open valve to amine drain.

Slowly Open hand operated control valves installed in bypass of Level Control valve (LV-G201A) from (GC-101) to supply Amine Rich at (GV-220).

After flushing, close valve to amine drain.

Open bypass hand operated control valve of Pressure Control valve (PV3-G220D) from Fuel Gas header to pressurized (GV-220).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

104 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Slowly Open Hand Operated Control Valve (∅= 2”) installed in bypass of Pressure Control valve (PV1-G220D) to Flare Gas. Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Close the valve. Check pressure, level and temperature in local indicators of (GV-220).

10.

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve (∅= 3”) in bypass of Level Control Valve (LV-G201A). Open hand operated valve in bypass of Level control Valve (LV-G220C) to closed drain. Pressure and temperature should be approx. 4,5 bar (g) and 27,8 °C.

11.

Once obtained design performance, open block valves of Level control Valve (LVG220C) and close Hand Operated Control Valve installed in bypass; Close hand operated valve in bypass of Level control Valve (LV-G201A) and open block valves.

12.

Open Hand Operated Control Valve (∅= 2”) installed in bypass of Pressure Control valve (PV1-G220D). Gas Flaring until Start-UP Amine Filters.

13.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

14.

Maintain records, as required

4.3.1.22 Unit 200. Amine Filters (GF-209 A/B; GF-210; GF-211). See PFD:

12466-01 10106

See PID:

12466-01 22210 12466-01 22216 12466-01 22217

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Purge filters with Demin Water. Drain water to open drain.

Close ball valve to open drain.

Open Inlet / Outlet Block Valves in Amine Particle Filters (GF-209 A/B), Amine Charcoal Filters (GF-210); Amine Particle Filter (GF-210).

Open ball valve in Amine Rich outlet from (GV-202)

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve installed downstream (FI-G209A)

Check PDT in each filter.

Open block valve to closed drain in (GF-211) before supply Lean Rich to Amine Exchangers (GE-204 A/B)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

105 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

10.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

11.

Maintain records, as required

4.3.1.23 Unit 260. Acid Gas Separator (GV-261), Transfer Vessel (GV-262). See PFD:

12466-01 10123

See PID:

12466-01 22218 12466-01 22219

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Bypass safety interlocks to following valve: (LV-G262A).

Open Inlet / Outlet block valves in Acid Gas Separator (GV-261).

Close Block valve of Pressure control valves (PV1-G261C; PV2-G261C)

Close Unit Shut Down Valve (UV-262B)

Open block valve to closed Amine drain in (GV-261)

Close Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV2-G222B) and Slowly Open Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV1-G222B) to supply Acid Gas at (GV-261)

Slowly Open Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV2-261C) to Flare Gas. Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Close the valve. Check pressure, level and temperature in local indicators of (GV-261).

10.

Close block valve to closed Amine drain in order to pressurizing (GV-261).

11.

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV1-G222B). Check pressure, temperature and level in local indicators of separator (GV-261). Open block valve to closed Amine drain in order to drain out. Pressure should be approx. 0,4 bar (g) and temperature 60,7 °C.

12.

Open Unit Shut Down Valve (UV-262B) to supply amine to Transfer Vessel (GV-262)

13.

Open (PCV-G262C) and (UV-262A) to supply fuel gas at (GV-262)

14.

Slowly Open Hand Operated Control Valve installed in bypass of Pressure Relief Valves (260-PSV-002 A/B) to Flare Gas. Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Close the valve. Check pressure, level and temperature in local indicators of (GV-262).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

106 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

15.

Open block valve in Level Control valve (LV-G262A) to closed Amine drain in (GV262)

16.

Once obtained design performance, close Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV1-G222B) and open block valves.

17.

After the system has reached design conditions and has stabilized, check operating conditions and performance parameters.

18.

Keep Open Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV2-261C). Gas Flaring until Start Up Acid Gas Incinerator Unit (PU02).

19.

Activate alarms and safety interlocks

20.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

21.

Maintain records, as required

4.3.1.24 Unit 260. Acid Gas Incinerator Unit (PU02). See PFD:

12466-01 10123

See PID:

12466-01 22220

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open.

Checked ESD Valves (UV-G260A) is closed.

Reset ESD through Hand Switch (HS-G260C) located in control Room (just in case of Re-Start after an ESD)

Open Unit Shutdown Valve (UV-G260A) to Acid Gas from separator (GV-261)

Slowly Open Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV1-261C) and close Hand Operated Control Valve (∅= 6”) installed in bypass of Pressure Control valve (PV2-261C).

Open block ball valve supply fuel gas.

Start-Up Acid Gas Incinerator Unit (PU02) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

Close Hand Operated Control Valve installed in bypass of Pressure Control valve (PV1-261C) and open block valves.

10.

Close Hand Operated Control Valve installed in bypass of Pressure Control valve (PV2-261C) and open block valves.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

107 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

11.

After the system has reached design conditions and has stabilized, check operating conditions and performance parameters.

12.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

13.

Maintain records, as required

4.3.1.25 Unit 400/440. Oily Drain System. See PFD:

12466-01 10122

See PID:

12466-01 22236

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Open inlet/outlet block valve in Oily Slop Vessel (GV-443); Oily slop filter (GF-441).

Check liquid level, pressure and temperature in local indicators of the Vessel.

Start Up Oily slop Pump transfer slop to (GF-241)

Check PDT In (GF-441)

Start up Oily sloop Cooler (GE-444) according to Manufacturer Operating Manual (see Appendix 12: Standard Instructions).

After the system has reached design conditions and has stabilized, check operating conditions and performance parameters.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

10.

Maintain records, as required

4.3.1.26 Final Consideration before to Start Up Sales/Buyback Custody Metering 1.

Close slowly bypass in Inlet Manifold Facilities to feed with Sour gas at Sour Gas Separator (GV-101). Check performance in Stabilization system and amine Wash system. Take samples from gas from the top of (C-201) to verify if gas is free of H2S.

If Gas is free of H2S, Close Hand Operated Control Valve (â&#x2C6;&#x2026;= 8â&#x20AC;?) in bypass of Pressure Control Valve (PV-G219C) to flare and open block valves and Open Unit Shut Down (UV-G219A) to supply sweet gas to (PU-03)

Verify that Sweet Gas and Sour Gas Treated mixture is free of H2S before to Start Up Sales/Buyback Custody Metering.

After the plant have been stabilized with a feed of 60% flow, Increase feed pressure and flow to obtain design performance (Case 100% of Process Simulation Basis) by adjusting feed in Hand Operated Control Valve installed in bypass of Pressure Control

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

108 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Valve (PV1-G101C) in (GV-101); (PV1-G102D) in (GV-102) and (PV2-G102D) in (GV-103), or by Increase production in gas field wells. After the system has stabilized, check operating conditions and performance parameters.

4.3.1.27 Sales/Buyback Custody Metering. See PFD:

12466-01 10118

See PID:

12466-01 22245

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Checked ESD valves (UV-G597A; UV-G597B; UV-G597C) are closed in Gas Pipeline to B.L.

Check Block ball valve upstream ESD Valve (UV-G697A) is closed.

It is assumed that Unit Shut Down Valve (UV-G699B) is open to Flare. Close (UVG699B).

Open ESD valve (UV-G597A) and bleeding off the pressure captured in the volume between the ESD valve (UV-G597A) and the MOV (UV-G597B)

On detection of ESD valve (UV-G597A) fully open, open Block ball valve upstream ESD Valve (UV-G697A) and by-pass valve (UV-G597C) across the MOV (UV-G597B) allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G597B) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G597B) is traveling to the open position, the by-pass valve (UV-G597C) is closed.

Check pressure in local indicator of Gas Pipeline.

To supply with Sweet Gas to Fuel Gas Separator (GV-699) from Gas Custody Metering, Check ESD valves (UV-G599A; UV-G599B; UV-G599C) are closed.

Check Block ball valve downstream ESD Valve (UV-G599A) is closed.

10.

Open ESD valve (UV-G599A) and bleeding off the pressure captured in the volume between the ESD valve (UV-G599A) and the MOV (UV-G599B). On detection of ESD valve (UV-G599A) fully open, the by-pass valve (UV-G599C) across the MOV (UVG599B) is opened allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G599B) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G599B) is traveling to the open position, the by-pass valve (UV-G597C) is closed.

11.

Open Block ball valve downstream ESD Valve (UV-G599A).

12.

Check pressure in local indicator of stream to Fuel Gas Separator (GV-699).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

109 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

13.

Open block valves of Pressure control Valve (PV1-G699A) to supply sweet gas to Fuel gas Separator (GV-699). Close block valve of Raw Fuel Gas in Inlet Facilities, if required.

14.

After the system has reached design conditions and has stabilized, check operating conditions and performance parameters.

15.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

16. 4.3.2

Maintain records, as required. Updating Start-Up Procedures

As the process is being started up, documentation should cover any problems with or failure of: •

Equipment

•

The safety protective systems, particularly sensors, alarms and interlocks

•

Maintaining critical process parameters within design ranges

•

Controls; and

•

Procedures.

The startup procedures should be changed as soon as possible, either during a shutdown or after the process has stabilized at design rates and specifications. Changes that require only clarification of the startup and operating procedures may be made by revising the operating manual. All revisions should carry the date of the latest revision. Data obtained during the startup can be used to understand the process and may result in changes being made to the critical operating parameters. However, before revising any of the critical operating parameter limits, such as temperature, pressure, or fluid flow rates, operations supervisors should initiate a management of change review to evaluate the effect on process safety. Process, equipment, instrumentation and control changes should trigger management of change procedures that will include necessary revisions to the start-up, operating, and maintenance procedures.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

110 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.4

Start Up following process Shut Down (Intermediate Start Up)

An intermediate start up occurs after the plant has been shut down for required inspections, preventive maintenance, equipment repairs, or process modifications. The piping, vessels, and equipment disassembled during the turnaround will have to be inspected, tested, and commissioned. Critical safety systems related to the process piping, vessels, and equipment repaired during the turnaround should be recommissioned before start-up. Any process equipment idled during the turnaround should be inspected and tested. Problems that may exist for each type of process and equipment should be identified and a checklist should be developed for the time the unit is down. It is important that the commissioning of repaired equipment be as thorough as the commissioning for an initial startup. Process and equipment modifications require management of change procedures. Maintenance departments have the lead role initiating and executing management of change procedures during the turnaround. Operations personnel will be responsible for making necessary updates about any changes in the operating procedures to the operating procedures training, and documentation of the training. Maintenance staff should make any necessary changes to maintenance procedures, schedules, and the inventory of spare parts. Before a start-up after a turnaround, a pre-startup safety review should be performed if the modifications trigger management of change procedures. The pre-startup safety review should be applied to the parts of the plant affected by the turnaround modifications and management of change criteria. After the turnaround repairs have been completed, the piping, vessels; and equipment have been inspected and commissioned, and final preparations for start up have been completed, the start up sequence should follow the same sequence as the initial start-up. Although the process had been started up and run previously, the introduction of process fluids and the initial process monitoring should be given the same degree of attention as during the initial start up. In order to avoid mechanical damage in ESD valves during opening is recommendable that equipments have to be double block with manual valves and not using ESD valves for blocking.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

111 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

4.5

Start Up following Emergency Shut Down (Restart)

A restart is a startup after a sudden trip-out or emergency shutdown. The part of the process that was the source of the problem should be bypassed for maintenance or repair and the rest of the process is placed in an idling status until repairs can be completed and the process restarted. After the idled process has been stabilized according to the operating instructions, operations and maintenance personnel should consider several process safety issues either to prepare for restart or to complete the shutdown by reducing, isolating and decontaminating the inventory. First, operating staff should find the cause of the shutdown. Next, maintenance personnel should estimate the time needed to complete any necessary repairs. On the basis of the time of repair estimate, operations personnel should decide if the process can be safely held in an idling state during the repair period and if the process can be safely restarted. To safely hold the process in an idling state, supervisors should consider the adequacy of normal operation instrumentation to control the process. While repairs are being made, operations also should plan where in the startup sequence to begin and review the deviations in the startup sequence that will be required for the restart. After a shut down has been initiated and the cause of the shut down has been corrected, the operator is allowed to re-start the process. The operator first reset the SGS logics, which latches the SGS into the normal operational state, and subsequently open / close valves and re-start individual pieces of equipment in order to get the process running again. Individual resets have been supplied for each unit. Only after the initiation of the relevant reset, the operator is allowed to re-start the facility. Each individual ESD valve shall have a local push-button next to the valve (open in case of block valves / close in case of a depressurizing valve), which moves the valve via the SGS to the normal operating position. Refers to section 5.1.3 â&#x20AC;&#x153;Emergency Shut Downâ&#x20AC;? in this document, and Document 12466-01 10250 to review Emergency Shut Down Description. Following is presented instruction to restart a Process Unit after a Emergency Shut Down. The restart sequence is basically the same as the initial start-up for the plant except for the equipments described next. The main difference is the additional procedure to open ESD Valves after Emergency situation. It is required in order to avoid mechanical damage in ESD valve due high differential pressure exist across ESD valves after initiated ESD and depressurization. Mechanical Damage could occur if valve is opened without equalizing pressure across it.

4.5.1

Sour Gas Inlet Separator (GV-101), Restart

See PFD:

12466-01 10102

See PID:

12466-01 22200 12466-01 22201

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G101F); (PV-G101C); (LV-G101A); (LDV-G101E).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

112 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Close block valves of Pressure Control Valve (PV1-G101C)

Close Unit Shutdown Valve (UV-G101E).

Open block valves of level control valves (LV-G101A; LDV-G101E).

Open block valves of Unit Shutdown Valve (UV-G101A; UV-G101B)

Close ball valves (∅= 10”) of inlet Sour Gas to Plant from gas Field.

Open Bypass ball valves to supply Sweet gas from Abo Rabah Pipeline to Sour gas Inlet Plant (only required for Initial Start Up).

10.

Open block ball valve to closed drain in Sour Gas Inlet Separator (GV-101)

11.

Checked ESD Valves (UV-G101D; UV-G101E; UV-G101F) are closed in inlet manifold

12.

Check ESD Valves (UV-101C; UV-111A; UV-G111C) are closed.

13.

Reset ESD through Hand Switch (HS-G101H) located in control Room

14.

Open ESD Valve (UV-111A)

15.

16.

Check pressure in local indicator (PI-G101K). Pressure should be approx. 64 bar (g).

17.

Slowly open inlet gas production by adjusting Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G101C).

18.

Slowly Open Hand Operated Control Valve (∅= 3”) to Flare Gas.

19.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen)

20.

Close block ball valve to closed drain in order to pressurizing separator.

21.

Slowly increase feed pressure and flow to obtain design performance (Case 60% of Process Simulation Basis) by adjusting feed in Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G101C). Check pressure, temperature and level in local indicators in separator. Pressure should be approx. 64 bar (g) and temperature 19.6 °C

22.

Once obtained design performance, open block valves of Pressure Control Valve (PV1-G101C) and close Hand Operated Control Valve installed in bypass.

23.

Open hand control valve installed upstream ESD UV-G102C slowly to equalize pressure around ball valve (i.e. DP<15 bar). Once equalized pressure, open ball valve and ESD valve. Close hand control valve. As required, the operator should bleed off the captured pressure between the ESD valve and the ball valve prior to open.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

113 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

24.

Check if level control valves (LV-G101A; LDV-G101E) are operating correctly.

25.

Slowly close Hand Operated Control Valve (∅=3”) to Flare Gas

26.

Start-Up Methanol Injection and Glycol Sour (If required).

27.

Activate alarms and safety interlocks

28.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

29.

4.5.2

Maintain records, as required

Sweet Gas Inlet Separator (GV-102), Restart

See PFD:

12466-01 10103

See PID:

12466-01 22200 12466-01 22202

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G102F); (PV1-G102D); (LV-G102A); (LDV-G102E).

Close block valves of Pressure Control Valve (PV1-G102D).

Close Unit Shutdown Valve (UV-G102C).

Open block valves of level control valves (LV-G102A; LDV-G102E).

Open block valves of Unit Shutdown Valve (UV-G102A; UV-G102B)

Open block ball valve to closed drain in (GV-102).

Check ESD valves (UV-G102D; UV-G102E; UV-G102F) are closed in inlet manifold

10.

Reset ESD through Hand Switch (HS-G102G) located in control Room

11.

Open ESD valve (UV-G102F) and bleeding off the pressure captured in the volume between the ESD valve (UV-G102F) and the MOV (UV-G102D). On detection of ESD valve (UV-G102F) fully open, the by-pass valve (UV-G102E) across the MOV (UVG102D) is opened allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G102D) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G102D) is traveling to the open position, the by-pass valve (UV-G102E) is closed.

12.

Check pressure in local indicator (PI-G102K). Pressure should be approx. 64 bar (g).

13.

Slowly open inlet gas production by adjusting Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV1-G102D).

14.

EDV-Ident-Nr.

Slowly Open Hand Operated Control Valve (∅= 3”) to Flare Gas. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

114 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

15.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen), as required.

16.

Close block ball valve to closed drain in order to pressurizing separator.

17.

18.

Once obtained design performance, open block valves of Pressure Control Valve (PV1-G102D) and close Hand Operated Control Valve installed in bypass.

19.

20.

Check if level control valves (LV-G102A; LDV-G102E) are operating correctly.

21.

Slowly close Hand Operated Control Valve (∅=2”) to Flare Gas

22.

Start-Up Methanol Injection and Glycol, if required

23.

Activate alarms and safety interlocks.

24.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

25.

4.5.3

Maintain records, as required.

Sweet Gas Inlet Separator (GV-103), Restart

See PFD:

12466-01 10103

See PID:

12466-01 22200 12466-01 22203

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves: (UV-G103F); (PV1-G103D); (LV-G103A); (LDV-G103E).

Close block valves of Pressure Control Valve (PV2-G102D).

Close Unit Shutdown Valve (UV-G103C).

Open block valves of level control valves (LV-G103A; LDV-G103E).

Open block valves of Unit Shutdown Valve (UV-G103A; UV-G103B)

Open block ball valve to closed drain.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

115 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Check ESD valves (UV-G103D; UV-G103E; UV-G103F) are closed in inlet manifold

10.

Reset ESD through Hand Switch (HS-G102G) located in control Room

11.

ESD valve (UV-G103F) is opened bleeding off the pressure captured in the volume between the ESD (UV-G103F) valve and the MOV (UV-G103D). On detection of ESD valve (UV-G103F) fully open, the by-pass valve (UV-G103E) across the MOV (UVG103D) is opened allowing pressure equalization across the MOV. Upon detection of equalized pressure across the MOV (UV-G103D) (i.e. DP<15 bar) the MOV is opened. As soon as it is detected that the MOV (UV-G103D) is traveling to the open position, the by-pass valve (UV-G103E) is closed.

12.

Check pressure in local indicator (PI-G103K). Pressure should be approx. 64 bar (g).

13.

Slowly open inlet gas production by adjusting Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV2-G102D).

14.

Slowly Open Hand Operated Control Valve (∅= 3”) to Flare Gas.

15.

Gas Flaring 30 minutes to guarantee flushing and displacing inert gas (nitrogen)

16.

Close block ball valve to closed drain in order to pressurizing separator.

17.

Slowly increase feed pressure and flow to obtain design performance (Case 60% of Process Simulation Basis) by adjusting feed in Hand Operated Control Valve installed in bypass of Pressure Control Valve (PV2-G102D). Check pressure, temperature and level in local indicators of the vessel. Pressure should be approx. 64 bar (g) and temperature 35 °C.

18.

Once obtained design performance, open block valves of Pressure Control Valve (PV2-G102D) and close Hand Operated Control Valve installed in bypass.

19.

20.

Check if level control valves (LV-G103A; LDV-G103E) are operating correctly.

21.

Slowly close Hand Operated Control Valve (∅=3”) to Flare Gas

22.

Start-Up Methanol Injection and Glycol, if required

23.

Activate alarms and safety interlocks.

24.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

25.

4.5.4

Maintain records, as required.

Unit 200. Gas Sweetening, Amine Contactor (GC-201), Restart

See PFD:

EDV-Ident-Nr.

12466-01 10105 Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

116 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

See PID: 1.

12466-01 22210

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Recheck that all Pressure Relief Valves are set and block valves are open

Bypass safety interlocks in following valves and pumps: (UV-G201B); (LV-G201A)

Close block valve in Pressure Control Valve (PV-G219C) installed in (GV-219)

Close block valve in Level control Valve (LV-G201A).

Open Block valve to opened drain.

Close block valve in Amine Lean from (GE-203).

Open Unit Shut down Valve (UV-G201B) to (GV-220)

Open hand control valve installed upstream ESD UV-G201A slowly to equalize pressure around ball valve (i.e. DP<15 bar). Once equalized pressure, open ball valve and ESD valve. Close hand control valve. As required, the operator should bleed off the captured pressure between the ESD valve and the ball valve prior to open.

10.

11.

Gas Flaring by 30 minutes to guarantee flushing and displacing inert gas (nitrogen). Check pressure, level and temperature in (GC-201).

12.

Close block valve to opened drain in order to pressurizing (GC-201).

13.

Open inlet / outlet block valves in Amine Condenser Feed Cooler (GE-203).

14.

Close Block valve downstream Unit Shut Down Valve (UV-G301B) to force Gas Outlet from (GE-301 A/B) supply Gas to Amine Condenser Feed Cooler Tube Side (GE-203)

15.

Start Up Amine Charge Pumps (GP-212 A/B). Open block valve of Flow control valve (FV1-G212C). Outlet pressure should be approx. 82,2 bar (g).

16.

Slowly increase feed pressure and flow to obtain design performance by adjusting Hand Operated Control Valve (∅= 10”) in bypass of hand Control Valve (HV-G201A) and Hand Operated Control Valve (∅= 8”) in bypass of Pressure Control Valve (PVG219C). Check pressure, temperature and level in local indicators of separator. Open hand operated valve in bypass in Level control Valve (LV-G201A) to drain out at (GV220). In the Amine Contactor, Pressure should be approx. 63.2 bar (g) and Temperature should be: 52 °C (Top) and 27.8 °C (Bottom).

17.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

117 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

18.

Close Hand Operated Control Valve (∅= 8”) in bypass of Pressure Control Valve (PVG219C).

19.

Start-Up Corrosion Inhibitor Injection (If required).

20.

Activate alarms and safety interlocks

21.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

22.

4.5.5

Maintain records, as required

Dehydration Unit (PU-03), Restart

See PFD:

12466-01 10108

See PID:

12466-01 22202 12466-01 22203 12466-01 22223

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Purge equipment following steps mentioned in Section 4.2.1.2.

Verify that ESD Valves (UV-G219A; UV-G102C; UV-103C; UV-G301A) are closed

Open hand control valve installed upstream ESD valve UV-G219A slowly to equalize pressure around ball valve (i.e. DP<15 bar). Once equalized pressure, open ball valve and ESD valve. Close hand control valve. As required, the operator should bleed off the captured pressure between the ESD valve and the ball valve prior to open.

Reset ESD through Hand Switch (HS-G650D) located in control Room

Open Unit Shutdown Valves (UV-G102C; UV-G103C) in Outlet Sweet gas from separators (GV-102; GV-103)

Open unit Shut down valve (UV-G219A) Located in Sweet Gas Separator (GV-219): Sweet Gas From (GV-219) to Unit 300.

It is assumed that during an ESD in Level 2D, the gas separated in Sweet Gas inlet separators is flared through hand control valves located in each separator.

It is assumed that during an ESD in Level 2D, the feed gas to Sweet gas Separator (GV-219) is flared through hand control valves located in bypass of Pressure Control Valve (PV-G219C).

10.

Open block ball valves located upstream of ESD Valves (UV-G219A; UV-G102C; UV103C)

11.

Slowly close Hand Operated Control Valve (∅= 2”) to Flare Gas installed in (GV-102; GV-103)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

118 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

12.

Slowly close Hand Operated Control Valve (â&#x2C6;&#x2026;= 8â&#x20AC;?) in bypass of Pressure Control Valve (PV-G219C).

13.

Slowly Open Hand Operated Control Valve to Flare in Dehydration Unit (PU-03). Gas Flaring by 30 minutes to guarantee flushing. Close hand operated valve.

14.

Open ESD valve (UV-G301A): Sweet Gas from PU-03 to (NGL) recovery

15.

Open block ball valve supply fuel gas to (GH-356).

16.

Open block valve of produced water to (GV-724)

17.

Start-Up Dehydration Unit (PU-03) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

18.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

19.

4.5.6

Maintain records, as required.

Hydrocarbon recovery, Restart

See PFD:

12466-01 10109

See PID:

12466-01 22221 12466-01 22222 12466-01 22260 12466-01 22263

Start-Up instrument air Package. Recheck and test all in-line sensors, set points of interlocks, time delay and alarms.

Purge equipment following steps mentioned in Section 4.2.2

Recheck that all Pressure Relief Valves are set and block valves are open.

Verify that ESD Valves (UV-G301A; UV-G301B; UV-G304A; UV-G670A/B/E) are closed.

Open hand control valve installed upstream ESD UV-G301A; UV-G301B slowly to equalize pressure around ball valve (i.e. DP<15 bar). Once equalized pressure, open ball valve and ESD valve. Close hand control valve. As required, the operator should bleed off the captured pressure between the ESD valve and the ball valve prior to open.

Close block ball valve located upstream of ESD Valve (UV-G301A; UV-G301B)

Vent and draining the relative small stream volume between ESD valve (UV-G301A) and block valve to minimize the erosive effects while opening the ESD valve.

Reset ESD through Hand Switch (HS-G300E) located in control Room

It is assumed that during an ESD in Level 2E, gas flared in Dehydration Unit (PU-03).

10.

Close inlet/outlet block Valve in shell side of Gas/Gas Exchanger (GE-301A/B).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

119 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

11.

Open Unit Shut Down Valve (UV-G301A)

12.

Open block ball valve located upstream of ESD Valve (UV-G301A) to supply Sweet gas from (PU-03) to (GE-301A/B).

13.

Close Hand Operated Control Valve to Flare Gas in (PU-03)

14.

Open slowly inlet/outlet Tube side Block valves of Gas/Gas Exchanger (GE-301A/B). Check inlet / outlet temperature and Pressure in local indicators.

15.

Open slowly inlet/outlet Tube side Block valves of Gas Chiller (GE-302). Check inlet / outlet temperature and Pressure in local indicators.

16.

Close block valves of level control valve (LV-G304A) in Low temperature Separator (GV-304)

17.

Open block valve to closed drain in Low temperature Separator (GV-304).

18.

Open block Valve of Unit Shut Down valve (UV-G304B)

19.

Slowly open bypass Valve of Pressure Relief valves (300-PSV-002A/B) to Flare Gas.

20.

Gas Flaring by 30 minutes to guarantee flushing.

21.

Close block ball valve to closed drain in order to pressuring Low temperature Separator (GV-304). Check pressure, temperature and level in local indicators of vessel. Open block valve to closed drain if required.

22.

Once obtained design performance, close bypass Valve of Pressure Relief valves (300-PSV-002A/B) to Flare Gas.

23.

Open ESD valve (UV-G301B). Close block ball valve downstream ESD valve. Vent and draining the relative small stream volume between ESD valve (UV-G301A) and block valve to minimize the erosive effects while opening the ESD valve.

24.

Open inlet/outlet shell side block Valve of Gas/Gas Exchanger (GE-301A/B).

25.

Open Unit Shut Down Valve (UV-G301C) to Flare Gas.

26.

Start-Up Propane Transfer Pump (GP-561) to transfer propane to Propane Refrigeration System (PU-05). Open ESD valves (UV-G670A/B/E). Check discharge pressure in local indicator (PI-G561B).

27.

Verify that ESD Valves (UV-G670A; UV-G670B; UV-G670C; UV-G670D; UV-G670E; UV-GG670F) are closed in Propane Refrigeration Unit (PU-05).

28.

Reset ESD through Hand Switch (HS-G70E) located in control Room

29.

Open ESD Valves (UV-G670A; UV-G670B; UV-G670C; UV-G670D; UV-G670E; UVGG670F)

30.

Start-Up Dehydration Unit (PU-05) according to Manufacturer Operating Manual (see Appendix 12.: Standard Instructions)

31.

Close Inlet / Outlet Block valves in Shell Side of LTS Liquid Propane Subcooler (GE303 A/B) to Supply Propane Cold â&#x20AC;&#x201C;45 from (PU05). Open slowly bypass block valve. Check inlet / outlet temperature in local indicator (TI-G303 H)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

120 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

32.

Open slowly Open Hand Operated Control Valve installed in bypass of Level control valve (LV-G302A) to supply Propane Cold â&#x20AC;&#x201C;100 to Gas Chiller (GE-302). Keep close block valves of (LV-G302A).

33.

Open outlet block valve shell side of Gas Chiller (GE-302). Check, temperature and level in local indicators of Gas Chiller.

34.

Open Inlet / Outlet Block valves in Shell Side of LTS Liquid Propane Subcooler (GE303 A/B) to Supply Propane Cold â&#x20AC;&#x201C;45 from (PU05). Close bypass block valve. Check inlet / outlet temperature in local indicator (TI-G303 H)

35.

Once obtained design performance in Gas Chiller (GE-302), close Hand Operated Control Valve of Level control valve (LV-G302A) and open block valves of (LVG302A).

36.

Once obtained design performance in Gas Outlet for sale, Open Block valve downstream Unit Shut Down Valve (UV-G301B) to Metering and close Unit Shut Down Valve (UV-G301C) to gas Flare.

37.

Start-Up Methanol Injection and Emulsion Breaker if required.

38.

Check status in control room of Monitored Functions (Process Conditions) and alarms.

39.

EDV-Ident-Nr.

Maintain records, as required.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

121 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Production Control â&#x20AC;&#x201C; Analysis 5.1

Analysis Plan

(To be finalized in accordance to document 12466-01 10252)

5.2

Description of Analysing Methods

(To be finalized in accordance to document 12466-01 10251)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

122 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Shut down The purpose of a shutdown is to place the process in a stable non-operating state. Three categories of Shutdown: normal, extended, and emergency are defined below: •

Normal Shutdown: The facility is taken out of service in a scheduled routine way for maintenance, process modifications, inventory control, etc.

•

Extended or Mothball Shutdown: Extended shutdown is a special case of normal shutdown, caused by equipment damage, lack of product demand, or other business reasons; the intent is to restart the unit at some future date.

•

Sudden or Emergency Shutdown: An unplanned shutdown can be caused by a critical process parameter exceeding its preset limit, an unexpected equipment failure, or utilities failure.

6.1

Normal Controlled Shut Down

The operations and sequence for normal shutdown are described using a ordered way and safe for all the units. The purge after shutdown does not discuss, since the exact reason of the same one is not determined. Once shutdown has been complete is just required a final drainage and appropriate purge, and with this the equipment will be surely and could be opened for maintenance, repair or inspection. The General Shutdown Sequence Steps are: •

Chemical Inventory Reduction: The initial step of the shutdown procedure is to reduce the inventory of process chemicals or products to the lowest safe level. Reducing inventory decreases the amount of material that must be managed during decontamination.

•

Isolation of Equipment for Maintenance: It is necessary include procedures for isolating equipment scheduled for maintenance during the shutdown period. Lockout and Tagout refers to the requirement that workplace procedures must be used to prevent the unexpected energization of equipment that may cause damage or injury during maintenance activities. It covers any situation where operating a piece of equipment could cause injury, damage, or the release of a hazardous material. Lockout refers to the process of installing locks on circuit breakers and disconnecting switches, blind flanges, or block valves so that the equipment cannot be operated until the lock is removed. Tagout refers to the signs or warning labels attached to an isolating device to warn others not to operate the tagged equipment.

•

Decontamination of Equipment for Maintenance: Decontamination is important in planning the final steps of the shutdown sequence, before the process equipment, piping, or vessels are transferred to the maintenance staff. Decontamination includes removing toxic and /or flammable materials.

•

Maintenance. It included: Opened. Clean, inspection, Revamping. After maintenance the equipment is closed; hydrostatic and leakage test; removed Lockout/Tagout.

•

Unit Restart: After the maintenance department completes its various tasks on the shutdown equipment, operations staff can proceed with the restart procedures discussed in Start Up Section 4. The lockout/tagout practice would dictate that the operations staff not begins startup activities until all locks and tags are removed and inventoried.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

123 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Following the detailed step-by-step procedure to take the process from an operational to a safe non-operational state is described. The procedure describes the steps for safely performing the removal of inventory, isolation, and the decontamination of each piece of equipment or part of Process Unit. Shutdown Procedure will be described from Sour Gas Treatment to continue with Sweet Gas Treatment.

6.1.1

Sour Gas Inlet Separator (GV-101)

See PFD:

12466-01 10102

See PID:

12466-01 22200 12466-01 22201

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Start-Up Emergency Power Generator (Diesel) in case of Complete Shut Down in the Plant.

Keep communication with Gas fields Well Operators

Close simultaneously Unit Shut Down valves (UV-G101D; UV-G101E; UV-G101F) in Inlet Facilities.

Slowly Open hand control valve (∅= 3”) to Gas Flare in (GV-101)

Close block valve of Level Control Valves (LV-G101A; LDV-G101E)

Close block valve from gas outlet to (GF-208) installed upstream Unit Shut Down Valve (UV-G101C)

Close block valves of Pressure Control valve (PV-G101C)

10.

Close block valves of Unit Shut Down Valve (UV-G101A; UV-G101B)

11.

Close block valves from Methanol and Glycol Injection.

12.

Adjusting feed to gas Flare in hand control valve (∅= 3”) in order to depressurized flow lines and separator.

13.

Open block valve to drain/depressurized level controller in (GV-101)

14.

Open block valve to closed drain.

15.

Close hand control valve (∅= 3”) to Gas Flare and block valve to closed drain, after depressurized.

16.

Verify if pressure in the vessel and flow lines is 0 bar (g).

17.

If required, install temporary piping for draining and decontamination.

18.

Lockout and Tagout the equipment(s)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

124 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.1.2

Sour Gas/liquid Stabilization, Unit 110

See PFD:

12466-01 10104

See PID:

12466-01 22204 12466-01 22205 12466-01 22206 12466-01 22207 12466-01 22224

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Open block valves located downstream Level Control Valve (LV-G101A) in Sour Gas Inlet Separator to transfer Sour/Gas liquid to NG liquids Sour stream in Sweet Gas Inlet Separator (GV-102) (if required).

Close Unit Shut down valves UV-G101 H (Sour/gas liquid from GV-101); UV-G102H (NG liquids sour from GV-102); UV-G111 C (Gas condensate Sour to GV-530)

Close inlet / outlet block valves tube side in Stabilizer Reboiler (GE-113) from Heat Media Supply. Open bypass.

Shut down Stabilizer Top Condenser (GE-114)

Shut Down Corrosion Inhibitor Injection Pump (GP-119). Close suction/discharge block valves.

Close Unit Shut down Valves (UV-G110A; UV-G110B) in Stabilizer OVHD Compressor Package (PU-01)

Open Unit Shut Down Valve (UV-G110C) to Flare Gas in Stabilizer OVHD Compressor Package (PU-01) in order to depressurized.

10.

Open block valves in Compressor Package (PU-01) to closed drain.

11.

Shut Down Stabilizer Reflux Pumps (GP-115 A/B). Close suction/discharge block valves.

12.

Close block valves in Level Control valve (LDV-G116C) in Stabilizer Reflux Drum (GV-116): produced water from (GV-116) to (GV-724)

13.

Close block valve Gas Cond. Sour Outlet in Stabilizer Column (GC-111)

14.

Close inlet /outlet block valves in Shell side of Stabilizer Feed Preheater (GE-112 A/B): Sour gas liquid from (GC-111) to (GV-530)

15.

Close inlet /outlet block valves in Tube side of Stabilizer Feed Preheater (GE-112 A/B): Sour gas liquid from (GV-101) to (GC-111)

16.

Close block valves of Pressure Control valve (PV1-G116C) and open hand control valve (â&#x2C6;&#x2026;= 2â&#x20AC;?) located in bypass in order to depressurized (GC-111); (GE-113) and (GV-116)

17.

EDV-Ident-Nr.

Open block valve in each equipment to closed drain. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

125 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

18.

Open block valve to drain/depressurized level controller in (GE-113) and (GV-116); Standpipe in (GC-111)

19.

Close hand control valve (∅= 2”) located in bypass of Pressure Control valve (PV1G116C) after depressurized (GC-111); (GE-113) and (GV-116)

20.

Verify if pressure in equipments and flow lines is 0 bar (g).

21.

Close block valve to closed amine drain in each equipment

22.

If required, install temporary piping for draining and decontamination.

23.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GC-111

6.1.3

Gas Sweetening, Unit 200

See PFD:

12466-01 10105 12466-01 10106 12466-01 10107

See PID:

12466-01 22201 12466-01 22209 12466-01 22210 12466-01 22211 12466-01 22212 12466-01 22213 12466-01 22214 12466-01 22215 12466-01 22216 12466-01 22217 12466-01 22218 12466-01 22271

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Open hand control valve (∅= 2”) located in Sour gas Inlet Separator (GV-101) to Flare Gas (This action is required only for a Partial Shut Down in this section of the Plant)

Open Unit Shut Down Valve (UV-G110C) to Flare Gas : Discharge Stabilizer OVHD Compressor Package (PU-01)

Close inlet block valve in Amine Contactor Gas Filter (GF-208): Sour Gas from (PU01) and Sour Gas from (GV-101)

Close inlet / outlet block valves tube side in Amine Regenerator Reboiler (GE-207); Heat Media Supply

Continue MDEA circulation until H2S-concentration in the Rich Amine at the outlet of the Absorber (GC-201) becomes equal to Amine concentration in the regenerated amine.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

126 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Shut Down Demin Water Transfer Pump (GP-761). Close suction/discharge block valves.

Shut Down Amine Transfer Pump (GP-583). Close suction/discharge block valves.

10.

Shut Down Corrosion Inhibitor Injection Pump (GP-216). Close suction/discharge block valves.

11.

Shut Down Anti-Foam Injection Pump (GP-215 A/B). Close suction/discharge block valves.

12.

Close block valves located downstream Unit Shut Down Valve (UV-G219A) in Sweet gas Separator (GV-219)

13.

Close block valves of Pressure Control Valve (PV1-G222B) in Amine Reflux Drum (GV-222)

14.

Close block valves of Pressure Control Valve (PV2-G220D) in Amine Flash Drum (GV-222)

15.

Shut Down Amine Reflux Pump (GP-214 A/B). Close suction/discharge block valves.

16.

Shut Down Amine Regenerator Bottom Pump (GP-213 A/B). Close suction/discharge block valves.

17.

Shut Down Amine Charge Pump (GP-212 A/B). Close suction/discharge block valves.

18.

Close block valves of Level Control Valve (LV-G208A) in Amine Contactor Gas Filter (GF-208)

19.

Close outlet block valve in Amine Contactor Gas Filter (GF-208): Sour Gas from (GF208) to (GC-201)

20.

Close block valves of Level Control Valve (LV-G201B) in Amine Contactor (GC-201)

21.

Close block valves of Level Control Valve (LV-G220C) in Amine Flash Drum (GV-220)

22.

Close outlet block valve in Amine Flash Drum (GV-220): Amine Rich from (GV-220) to (GF-209 A/B)

23.

Shut Down Amine Drain Pump (GP-241) in Amine Drain Vessel (GV-242). Close discharge block valves.

24.

Close inlet/outlet block valve in tube side of Amine Contactor Feed Cooler (GE-203). Open block valve located downstream Unit Shut Down Valve (UV-G301B): Sweet gas to Metering.

25.

Open bypass valves located in Pressure Relief Valves (200-PSV-001 A/B) to Flare Gas Cold in order to depressurized Amine Contactor Gas Filter (GF-208)

26.

Close block valves of Pressure Control valve (PV-G219C) and open hand control valve (∅= 8”) located in bypass in order to depressurized (GC-201) and (GV-219)

27.

Close block valves of Pressure Control valve (PV1-G220D) and open hand control valve (∅= 2”) located in bypass in order to depressurized (GV-220).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

127 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

28.

Close block valves of Pressure Control valve (PV2-G222B) and open hand control valve (∅= 6”) located in bypass in order to depressurized (GV-222); (GC-202) and (GE-207)

29.

Close block valves of Pressure Control valve (PV1-G221A) and open hand control valve (∅= 2”) located in bypass in order to depressurized (GV-221)

30.

Open bypass valves located in Pressure Relief Valves (240-PSV-001 A/B) to Flare Gas Cold in order to depressurized Amine Drain Vessel (GV-242)

31.

Open block valve to drain/depressurized level controller in (GF-208); (GC-201); Standpipe in (GC-202); (GV-201; (GV-219); (GV-220); (GV-222)

32.

Open block valve in each equipment to closed amine drain.

33.

Close bypass valves located in Pressure Relief Valves (200-PSV-001 A/B) after depressurized Amine Contactor Gas Filter (GF-208)

34.

Close hand control valve (∅= 8”) located in bypass of Pressure Control valve (PVG219C) after depressurized (GC-201) and (GV-219)

35.

Close hand control valve (∅= 2”) located in bypass of Pressure Control valve (PV1G220D) after depressurized (GV-220).

36.

Close hand control valve (∅= 6”) located in bypass of Pressure Control valve (PV2G222B) after depressurized (GV-222); (GC-202) and (GE-207)

37.

Close hand control valve (∅= 2”) located in bypass of Pressure Control valve (PV1G221A) after depressurized (GV-221)

38.

Close bypass valves located in Pressure Relief Valves (240-PSV-001 A/B) after depressurized Amine Drain Vessel (GV-242)

39.

Verify if pressure in equipments and flow lines is 0 bar (g).

40.

Close block valve in each equipment to closed amine drain.

41.

If required, install temporary piping for draining and decontamination.

42.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GF-208; GC201; GC-202; GV-221; GV-242; GV-219; GV-220; GF-209 A/B; GF-210; GF-211; GV222.

6.1.4

Acid Gas Incinerator, Unit 260

See PFD:

12466-01 10123

See PID:

12466-01 22219 12466-01 22220

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

128 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Shut down Acid Gas Incinerator Unit (PU-02)

Close block valve from Fuel Gas Header to Acid Gas Incinerator Unit (PU-02)

Close block valves in Pressure Control Valve in (PV1-G222B). Acid Gas from (GV222) to (GV-261)

Open Hand control valve located in bypass of Pressure Control Valve in (PV1G222B): Acid Gas from (GV-222) to Flare Gas Cold.

Close block valves in Pressure Control Valve in (PV2-G220D). Sour Gas from (GV220) to (GV-261)

Open Hand control valve located in bypass of Pressure Control Valve in (PV1G220D): Sour Gas from (GV-220) to Flare Gas Cold.

Close block valves of Pressure Control valve (PV1-G261C): Acid Gas from (GV-261) to (PU-02)

10.

Close inlet block valve in Acid Gas Separator (GV-261): Acid Gas from (GV-222) and (Sour Gas from (GV-220)

11.

Close block valve located upstream Pressure Control Valve (PCV-G262C): Fuel Gas from Gas header to (GV-262)

12.

Close block valves of Pressure Control valve (PV1-G261C): Acid Gas from (GV-261) to (PU-02)

13.

Close block valves of Level Control valve (LV-262A): Amine Drain from (GV-262) to (GV-242)

14.

Close block valves of Pressure Control valve (PV2-G261C) and open hand control valve (∅= 6”) located in bypass in order to depressurized (GV-261)

15.

Open bypass valve located in Pressure Relief Valves (260-PSV-002 A/B) to Flare Gas Cold in order to depressurized Transfer Vessel (GV-262)

16.

Open block valve to drain/depressurized level controller in (GV-261); (GV-262)

17.

Open block valve in each equipment to amine closed drain.

18.

Close hand control valve (∅= 6”) located in bypass of Pressure Control valve (PV2G261C) after depressurized (GV-261)

19.

Close bypass valve located in Pressure Relief Valves (260-PSV-002 A/B) after depressurized Transfer Vessel (GV-262)

20.

Verify if pressure in equipments and flow lines is 0 bar (g).

21.

Close block valve in each equipment to amine closed drain.

22.

If required, install temporary piping for draining and decontamination.

23.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GV-261; GV262.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

129 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.1.5

Sweet Gas Inlet Separator (GV-102)

See PFD:

12466-01 10103

See PID:

12466-01 22202

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Start Up Emergency Power Generator (Diesel) in case of Complete Shut Down in the Plant.

Keep communication with Gas fields Well Operators

Closing Unit Shut Down valves (UV-G102D; UV-G102E; UV-G102F) in Inlet Facilities.

Slowly Open hand control valve (∅= 3”) to Gas Flare.

Close block valve of Level Control Valves (LV-G102A; LDV-G102E)

Close block valve from gas outlet to (GE-301) installed upstream Unit Shut Down Valve (UV-G102C)

Close block valves of Pressure Control valve (PV1-G102D)

10.

Close block valves of Unit Shut Down Valve (UV-G102A; UV-G102B)

11.

Close block valves from Methanol and Glycol Injection.

12.

Adjusting feed to gas Flare in hand control valve (∅= 3”) in order to depressurized flow lines and separator.

13.

Open block valve to drain/depressurized level controller in (GV-102)

14.

Open block valve to closed drain.

15.

Close hand control valve (∅= 3”) to Gas Flare and block valve to closed drain, after depressurized.

16.

Verify if pressure in the vessel and flowlines is 0 bar (g).

17.

If required, install temporary piping for draining and decontamination.

18.

Lockout and Tagout the equipment(s)

6.1.6

Sweet Gas Inlet Separator (GV-103)

See PFD:

12466-01 10103

See PID:

12466-01 22203

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Start up Emergency Power Generator (Diesel) in case of Complete Shut Down in the Plant.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

130 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Keep communication with Gas fields Well Operators

Closing Unit Shut Down valves (UV-G103D; UV-G103E; UV-G103F) in Inlet Facilities.

Slowly Open hand control valve (∅= 3”) to Gas Flare.

Close block valve of Level Control Valves (LV-G103A; LDV-G103E)

Close block valve from gas outlet to (GV-102) installed upstream Unit Shut Down Valve (UV-G103C)

Close block valves of Unit Shut Down Valve (UV-G103A; UV-G103B)

10.

Close block valves of Pressure Control valve (PV2-G102D)

11.

Close block valves from Methanol and Glycol Injection.

12.

Adjusting feed to gas Flare in hand control valve (∅= 3”) in order to depressurized flow lines and equipments.

13.

Open block valve to drain/depressurized level controller in (GV-103)

14.

Open block valve to closed drain.

15.

Close hand control valve (∅= 3”) to Gas Flare and block valve to closed drain, after depressurized.

16.

Verify if pressure in the vessel separator and flow lines is 0 bar (g).

17.

If required, install temporary piping for draining and decontamination.

18.

Lockout and Tagout the equipment(s)

6.1.7

Dehydration Unit (PU-03), Unit 300

See PFD:

12466-01 10108

See PID:

12466-01 22202 12466-01 22203 12466-01 22223

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Open Slowly hand control valve (∅= 2”) to Gas Flare in Dehydration Unit (PU-03)

Open slowly hand control valve to Gas Flare in (GV-102; GV-103; GV-219). Check liquid level, pressure and temperature in (GV-102; GV-103; GV-219). (This action is required only for a Partial Shut Down in this section of the Plant)

Shut Down Compressors (GK-357 A/B) according to Manufacturer Operating Manual.

Close block valve for fuel Gas supply to (GH-356)

Close block valve inlet to Dehydration Unit (PU-03).

Shutoff the heat to the reboiler and close burner manifold valves

Circulate glycol until rebolier temperature drops to 80 °C to prevent overheating the glycol.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

131 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

10.

Stop glycol pumps and appropriate valves

11.

Close block valve from Sweet gas outlet in (PU-03) to (GE-301)

12.

Close block valve of Level Control Valves in (GV-358) and (GV-359)

13.

Adjusting feed to gas Flare in hand control valve installed in (PU-03) in order to depressurize the dehydration Unit. Bleed off pressure in contactor slowly.

14.

Open block valve to drain/depressurized level controllers

15.

Open block valve to closed drain in each equipment.

16.

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

17.

Verify if pressure in equipments and flowlines is 0 bar (g).

18.

If required, install temporary piping for draining and decontamination.

19.

Lockout and Tagout the equipment(s)

6.1.8

Hydrocarbon Recovery Process, Unit 300

See PFD:

12466-01 10109

See PID:

12466-01 22221 12466-01 22222 12466-01 22260 12466-01 22263

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Slowly Open block valve located in bypass of Gas/Gas Exchangers (GE-301 A/B) to transfer Sweet gas from (PU-03) to Metering. (This action is required only for a Partial Shut Down in this section of the Plant)

Close Unit Shut Down (UV-G301B) to gas metering

Open Unit Shut Down (UV-G301C) to Flare Gas

Close block valves inlet/outlet shell side of LTS Liquid Propane Sub cooler (GE-303 A/B) from propane supply (PU-05)

Close block valves in Level Control Valve (LV-G302A) to supply Propane to Gas Chiller (GE-302) from (GE-303B). Close inlet/outlet block valve propane to/from (PU05). Open bypass to Flare Gas Cold in Pressure Relief Valves (300-PSV-001 A/B) in order to depressurized shell side in Gas Chiller (GE-302) and shell side (GE-303 A/B).

Close inlet block valves of LTS Liquids Preheater (GE-305) to supply Natural Gas liquids to (GV-419) and bypass

EDV-Ident-Nr.

Close inlet/outlet block valve shell side in LTS Liquids Preheater (GE-305) Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

132 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

10.

Close outlet block valves in shell side Gas/Gas Exchangers (GE-301 A/B)

11.

Close inlet block valve in tube side (GE-301 A)

12.

Open block valve from gas Condensate outlet in (GE-404) to Condensate Storage Tank (GT-506)

13.

Open bypass valves in Pressure Relief Valves (300-PSV-002 A/B) in order to depressurized (GE-301 A/B Tube side and shell side); (GE-302 Tube side); (GV-304); (GE-303 A/B Tube side)

14.

Open block valve to drain/depressurized level controllers

15.

Open block valve to closed drain in each equipment.

16.

Close bypass valves in Pressure Relief Valves (300-PSV-002 A/B) after depressurized.

17.

Close block valve to closed drain each equipment

18.

Close block valves of Level Control Valve (LV-G304A) in Low Temperature Separator (GV-304)

19.

Close outlet block valve in tube side (GE-301 A)

20.

Verify if pressure the vessels and flow lines is 0 bar (g).

21.

If required, install temporary piping for draining and decontamination.

22.

Lockout and Tagout the equipment(s)

6.1.9

Fractionation - Deethanizer, Unit 400

See PFD:

12466-01 10112 12466-01 10113

See PID:

12466-01 22226 12466-01 22227 12466-01 22228 12466-01 22229 12466-01 22230

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Shut down Deethanizer OVHD Compressor Unit (PU-04)

Close Unit Shut Down Valve (UV-G423A): Feed Deethanizer OVHD Compressor Unit (PU-04)

Close block valves in Pressure Control Valve (PV-G423A) and open Bypass to Flare Gas Cold

Close inlet / outlet block valves tube side in Deethanizer Reboiler (GE-408); Heat Media Supply

Close inlet block valves in Shell side of Deethanizer OVHD Propane Subcooler (GE409): Propane From (PU-05)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

133 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Close block valves in Level Control Valve (LV-GE407) in Deethanizer Condenser (GE-407): (Shell Side Propane Inlet)

Close outlet block valves shell side in Deethanizer Condenser (GE-407): Propane to (PU-05)

10.

Shut Down Deethanizer Reflux Pumps (GP-415 A/B).

11.

Close suction/discharge block valves in Deethanizer Reflux Pumps (GP-415 A/B).

12.

Close block valves from Methanol and Glycol Injection.

13.

Close block valves of Level Control Valve (LV-G401A): Natural Gas Liquids to (GC402)

14.

Close inlet block valve in Deethanizer Feed Drum (GV-419).

15.

Close block valves in Pressure Control Valve (PV1-G420B): Sweet gas from (GV420) to (GE-409)

16.

Close block valve in Level Control Valve (LDV-G420H): Glycol Sour from (GV-420) to (PU03)

17.

Close inlet block valve in shell side of Deethanizer Feed/Gas Condensate Exchanger (GE-424): Gas condensate from (GE-413)

18.

Close outlet block valve in shell side of Deethanizer Feed/Gas Condensate Exchanger (GE-405): Gas Condensate to (GE-305).

19.

Shut down Condensate Product Cooler (GE-406)

20.

Close inlet/outlet block valve in Shell side of Deethanizer Feed/LPG Exchanger (GE404)

21.

Close block valves in Pressure Control Valve (PV-G419B): Sweet gas from (GV-419) to (GE-409)

22.

Close block valve in Level Control Valve (LDV-G419H): Glycol Sour from (GV-419) to (PU03)

23.

Close Bypass in Pressure Control Valve (PV-G423A) to Flare Gas

24.

Open bypass valve (∅= 2”) located in Pressure Relief Valves (400-PSV-001 A/B) to Flare Gas Cold in order to depressurized Deethanizer Feed Drum (GV-419).

25.

Open bypass valve (∅= 4”) located in Pressure Relief Valves (400-PSV-002 A/B) to Flare Gas Cold in order to depressurized Deethanizer Feed Column (GC-401) and Deethanizer Rebolier (GE-408) in shell side.

26.

Open bypass valve located in Pressure Relief Valves (400-PSV-004 A/B) to Flare Gas Cold in order to depressurized Deethanizer Reflux Drum (GV-420)

27.

Open block valve to drain/depressurized stand-pipe in (GV-419); (GC-401) and (GV420)

28.

EDV-Ident-Nr.

Open block valve in each equipment to closed drain in order to drain out.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

134 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

29.

Close bypass valve (∅= 2”) located in Pressure Relief Valves (400-PSV-001 A/B) after depressurized.

30.

Close bypass valve (∅= 4”) located in Pressure Relief Valves (400-PSV-002 A/B) after depressurized.

31.

Close bypass valve located in Pressure Relief Valves (400-PSV-004 A/B) after depressurized.

32.

Verify if pressure in equipments and flowlines is 0 bar (g).

33.

Close block valve to closed drain

34.

If required, install temporary piping for draining and decontamination.

35.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GV-419; GC401; GV-420.

6.1.10 Fractionation – Debutanizer, Unit 400 See PFD:

12466-01 10114

See PID:

12466-01 22231 12466-01 22232 12466-01 22226 12466-01 22227 12466-01 22228 12466-01 22240

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Shut down Debutanizer Reflux Pump (GP-416 A/B)

Close suction/discharge block valves of Debutanizer Reflux Pump (GP-416 A/B)

Close block valves in tube side of Debutanizer Reboiler (GE-411) from Heat Media Supply.

Close Unit Shut Down Valve (UV-G402C)

Close bottom products valve in Debutanizer Column (GC-402)

Close block valves of Pressure Control Valve (PV1-G421B)

Open slowly hand control valve located in bypass of Pressure Control Valve (PV1G421B) to flare, in order to depressurized flow lines and equipments.

10.

Open block valve in each equipment to closed drain in order to drain out.

11.

Open block valve to drain/depressurized stand-pipe in (GC-402) and (GV-421)

12.

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

13.

Verify if pressure in the equipments and flow lines is 0 bar (g).

14.

If required, install temporary piping for draining and decontamination.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

135 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

15.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GC-402; GV421

6.1.11 Gas Condensate Storage See PFD:

12466-01 10120

See PID:

12466-01 22237 12466-01 22238

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Close block valve downstream Unit Shut Down Valve (UV-G506A)

Pumped Gas condensate from Condensate Storage Tank (GT-506) to (PU-13) with Condensate transfer Pump (GP-503 A/B) until liquid level in (GT-506) is low, and/or

Pumped Gas condensate from Condensate Storage Tank (GT-506) to Pipeline with Condensate transfer Pump (GP-503 A/B) until liquid level in (GT-506) is low

Pumped Water from Condensate Storage Tank (GT-506) to (GT-722) with Water Pump (GP-505 A/B), until water level in (GT-506) is low

Shut down Condensate transfer Pump (GP-503 A/B). Close suction/discharge block valves

Shut down Water Pump (GP-505 A/B). Close suction/discharge block valves

Open block valve to open drain in Condensate Storage Tank (GT-506)

10.

If required, install temporary piping for draining and decontamination.

11.

Lockout and Tagout the equipment(s)

6.1.12 LPG Storage. See PFD:

12466-01 10120

See PID:

12466-01 22240 12466-01 22241 12466-01 22242 12466-01 22243 12466-01 22244

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Close block valves of Level control valve (LV-G421A) if required shut down all bullets.

Shut down LPG Recycle Pump (GP-525 A/B)

Close suction/discharge block valves of LPG Recycle Pump (GP-525 A/B)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

136 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.1.12.1 LPG Off Spec Bullet (GV-528) 1.

Close block valve upstream Unit shut Down valve (UV-568D). LPG Inlet to (GV-528)

Pumped LPG from LPG Storage Bullet (GV-528) to (PU-13) with LPG Loading Pump (GP-524 A/B) until liquid level LPG Storage Bullets is low.

Shut down LPG Loading Pump (GP-524 A/B)

Close block valves downstream Unit shut Down valve (UV-568D). LPG to LPG Recycle Pump (GP-525 A/B) and LPG Loading Pump (GP-524 A/B).

Close block valves of Pressure Control Valve (PCV-G528C)

Open slowly hand control valve located in bypass of Pressure Control Valve (PCVG528C) to Flare, in order to depressurized flow lines and bullet.

Open block valve to closed drain.

Open block valve to drain/depressurized stand-pipe in (GV-528)

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

10.

Verify if pressure in the bullet is 0 bar (g).

11.

If required, install temporary piping for draining and decontamination.

12.

Lockout and Tagout the equipment(s)

6.1.12.2 LPG Storage Bullet (GV-526A) 1.

Close block valve upstream Unit shut Down valve (UV-526D). LPG Inlet to (GV-526A)

Pumped LPG from LPG Storage Bullet (GV-526A) to (PU-13) with LPG Loading Pump (GP-524 A/B) until liquid level LPG Storage Bullets is low.

Shut down LPG Loading Pump (GP-524 A/B)

Close block valve downstream Unit shut Down valve (UV-526B). LPG to LPG Recycle Pump (GP-525 A/B) and LPG Loading Pump (GP-524 A/B).

Close block valves of Pressure Control Valve (PCV-G526C)

Open slowly hand control valve located in bypass of Pressure Control Valve (PCVG526C) to Flare, in order to depressurized flow lines and bullet.

Open block valve to closed drain.

Open block valve to drain/depressurized stand-pipe in (GV-526A)

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

10.

Verify if pressure in the bullet is 0 bar (g).

11.

If required, install temporary piping for draining and decontamination.

12.

Lockout and Tagout the equipment(s)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

137 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.1.12.3 LPG Storage Bullet (GV-526B) 1.

Close block valve upstream Unit Shut Down valve (UV-526K). LPG Inlet to (GV-526B)

Pumped LPG from LPG Storage Bullet (GV-526B) to (PU-13) with LPG Loading Pump (GP-524 A/B) until liquid level LPG Storage Bullets is low.

Shut down LPG Loading Pump (GP-524 A/B)

Close block valve downstream Unit shut Down valve (UV-526H). LPG to LPG Recycle Pump (GP-525 A/B) and LPG Loading Pump (GP-524 A/B).

Close block valves of Pressure Control Valve (PCV-G526J)

Open slowly hand control valve located in bypass of Pressure Control Valve (PCVG526J) to flare, in order to depressurized flow lines and bullet.

Open block valve to closed drain.

Open block valve to drain/depressurized stand-pipe in (GV-526B)

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

10.

Verify if pressure in the bullet is 0 bar (g).

11.

If required, install temporary piping for draining and decontamination.

12.

Lockout and Tagout the equipment(s)

6.1.12.4 LPG Storage Bullet (GV-526C) 1.

Close block valve upstream Unit Shut Down valve (UV-526Q). LPG Inlet to (GV526C)

Pumped LPG from LPG Storage Bullet (GV-526C) to (PU-13) with LPG Loading Pump (GP-524 A/B) until liquid level LPG Storage Bullets is low.

Shut down LPG Loading Pump (GP-524 A/B)

Close block valve downstream Unit shut Down valve (UV-526O). LPG to LPG Recycle Pump (GP-525 A/B) and LPG Loading Pump (GP-524 A/B).

Close block valves of Pressure Control Valve (PCV-G526P)

Open slowly hand control valve located in bypass of Pressure Control Valve (PCVG526P) to Flare, in order to depressurized flow lines and bullet.

Open block valve to closed drain.

Open block valve to drain/depressurized stand-pipe in (GV-526B)

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

10.

Verify if pressure in the bullet is 0 bar (g).

11.

If required, install temporary piping for draining and decontamination.

12.

Lockout and Tagout the equipment(s)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

138 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.1.13 Fractionation â&#x20AC;&#x201C; Depropanizer, Unit 400 See PFD:

12466-01 10115

See PID:

12466-01 22233 12466-01 22234

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Shut down Depropanizer Reflux Pump (GP-418 A/B)

Close suction/discharge block valves of Depropanizer Reflux Pump (GP-418 A/B)

Shut down Depropanizer Feed Pump (GP-417 A/B)

Close suction/discharge block valves of Depropanizer Feed Pump (GP-417 A/B)

Close block valves of Flow Control Valve (FV-G403A)

Close inlet/outlet block valve in tube side of Depropanizer Reboiler (GE-413)

Close bottom products valve in Depropanizer Column (GC-401)

10.

Shut Down Depropanizer Condenser (GE-412)

11.

Close block valves of Pressure Control Valve (PV1-G422B)

12.

Open slowly hand control valve located in bypass of Pressure Control Valve (PV1G422B) to flare, in order to depressurized flow lines and equipments.

13.

Open block valve in each equipment to closed drain in order to drain out.

14.

Open block valve to drain/depressurized stand-pipe in (GC-403) and (GV-422)

15.

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

16.

Verify if pressure in equipments and flow lines is 0 bar (g).

17.

If required, install temporary piping for draining and decontamination.

18.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GC-403; GV422

6.1.14 Propane Storage See PFD:

12466-01 10120

See PID:

12466-01 22250

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Pumped propane from Propane Storage Bullet (GV-562) to (PU-13) and/or (PU-05) with Propane transfer Pump (GP-561) until liquid level in (GV-562) is low.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

139 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Shut down Propane transfer Pump (GP-561)

Close suction/discharge block valves of Propane transfer Pump (GP-561)

Close block valve upstream Unit shut Down valves (UV-562A; UV-G562C)

Close block valve of Pressure Control Valves (PV-G561C) and (PCV-G562C)

Open hand control valve (∅= 3”) located in bypass of Pressure Control Valve (PCVG562C) to Flare Gas , in order to depressurized Propane Storage Bullet (GV-562)

Open block valve to drain/depressurized stand-pipe

10.

Close hand control valve to Gas Flare and block valve to closed drain, after depressurized.

11.

Verify if pressure in the bullet and flow lines is 0 bar (g).

12.

If required, install temporary piping for draining and decontamination.

13.

Lockout and Tagout the equipment(s)

6.1.15 Produced Water Flash Drum (GV-724); Produced Water Storage Tank (GT-722) See PFD:

12466-01 10122

See PID:

12466-01 22201 12466-01 22202 12466-01 22203 12466-01 22268 12466-01 22269

Verify Control Valves and Block Valves Condition

Notify to Control Room activity to realize

Close inlet block valve in Produced Water Flash Drum (GV-724)

Close block valves of Pressure Control Valve (PV2-G724B): Fuel Gas from Gas header to (GV-724)

Close block valve located upstream Pressure Control Valve (PCV-G722C): Fuel Gas from Gas header to (GT-722)

Close block valves of Level Control Valve (LV-G724A) in Produced Water Flash Drum (GV-724)

Close inlet block valve in Produced Water Flash Tank (GT-722): Produced Water from (GV-724) and (GP-505 A/B) to Produced Water Flash Tank (GT-722)

Shut Down Produced Water Transfer Pumps (GP-721 A/B). Close suction/discharge block valves.

Shut Down Skimmed Oil Pump (GP-725). Close suction/discharge block valves.

10.

Close block valves of Pressure Control valve (PV1-G724B) and open hand control valve (∅= 2”) located in bypass in order to depressurized (GV-724)

11.

EDV-Ident-Nr.

Open block valve to drain/depressurized level controller in (GV-724) Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

140 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

12.

Open block valve to open drain in (GV-724) and .(GT-722)

13.

Close hand control valve (∅= 2”) to Gas Flare and block valve to open drain, after depressurized.

14.

Verify if pressure in equipments and flow lines is 0 bar (g).

15.

If required, install temporary piping for draining and decontamination.

16.

Lockout and Tagout the equipment(s). Use spectacles blind closed in GT-704; GV724; GT-722; GT-742; GT-743

6.2

Extended Shut Down Extended shutdown is a special case of the normal shutdown. Additional safety concerns relate specifically to extended shutdowns. Simply stated, the goal of the extended shutdown involves removing process materials from the system and keeping them out. Normal shutdown procedures may have to be changed to prepare the equipment for extended shutdown periods. Following present additional steps to Normal Shut down Procedure to take in consideration for Mothball Shutdown:

6.3

•

Removing a piping spool piece may be a desirable isolation technique during the extended shutdown of a process unit. It is recommended because, although a double block and bleed piping isolation is acceptable for normal shutdowns, even a tiny, undetectable valve leak may cause safety problems in a mothballed unit.

•

Physically remove critical electrical equipment, such as entire circuit breaker boxes or termination panels. Simply removing the fuses or circuit breakers may not adequately protect mothballed units from future accidental reactivation.

•

For long shutdown periods, special corrosion protection, both internal and external, may be needed, and a corrosion monitoring program may be required.

•

Freeze protection may be needed for instruments or special process units like Unit 300, to protect these equipments from undesirable or damaging temperature extremes.

•

In Dehydration and Regeneration Unit perform following actions: Flush Contactor and Still with water and drain; Clean Pumps; Remove packing from pumps and coat plungers with corrosion inhibitor.

Emergency Shut Down 6.3.1

General

The Gas Treatment Plants is designed with an emergency shutdown system that can automatically shut down specific Units and isolate parts of the plant or the whole plant, as appropriate. The ability to safely shut down a plant is critical to responding to most emergencies. The purpose of emergency shut down is the isolation and de-activation of all process and nonessential utility systems together with depressurization of the facility and displace inventory of

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

141 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

flammable products, where appropriate, to reduce the effect of Emergency on the plant and its surroundings. An emergency shut down of the plant is initiated automatically because of following reasons: •

Gas detection at suction side of instrument air compressors (PU-09)

•

High liquid level in Flare Knock Out Drum (GV-692)

•

High liquid level in Fuel Gas Separator (GV-699)

An emergency shut down of the plant respectively an unit primary is initiated manually because of following reasons: •

Fire and/or gas emission

•

Malfunction of utility units e.g. failure of instrument air supply or other important utilities

•

Malfunction of instrumentation or other important facilities

It leads to the following actions:

Isolate the facility from all hydrocarbon inventories within pipelines and reservoirs. Isolation valves are strategically installed in equipment and throughout the plant and are manually activated with a safety interlock shutdown by an operator pushbutton on a local control panel or in the process unit control room in response to Alarm. These valves will allow isolation of affected equipment or sections in order to limit the quantity of material feeding and increasing the size of the fire.

Control potential ignition sources such as fired units, engines and non-essential electrical equipment, i.e. shut down of all process equipment and non-essential utility systems.

Depressurization The Facility. The purpose of this system is to reduce, in a rapid and controlled manner, the pressure in equipment and operational systems to avoid breaks due to mechanical failures and prolonged releases. It is manually activated with safety interlock shutdown and can be initiated by an operator pushbutton in the control room.

Removing the inventory of flammable material from the equipment. This system is utilized to displace inventory of flammable products from equipment at high risk to reduce the duration of a fire, when no other normal means are available. It is manually activated with safety interlock shutdown and can be initiated by an operator pushbutton in the control room after depressurization.

Initiate actions in utility systems to mitigate hazardous events e.g. start-up of fire pumps, etc

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

142 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

The plant is separated in certain blockable sections. These sections are provided with blocking, depressurization and draining valves. The designated sections are divided into certain levels. Level 0: Total Process Shut Down in entire facility Level 1: Unit Shut Down e.g. Unit 100.Level 2: Partial Shut Down of process or

equipment located in certain plant sections e.g. Sweet Inlet Separators. The following table shows zoning (safeguarding groups).

6.3.2

Classification of Safeguarding Classification of Safeguarding

Emergency Shut Down System (ESD) SD group

SD group

(ESD Level 0)

(ESD Level 1)

(ESD Level 2)

100/110

100

200/260

350

Dehydration Unit

300

NGL Recovery

400 (A)

GV-419 Deethanizer Feed Drum

400 (B)

GC-401 Deethanizer Column

Unit (blockable)

Description

Sour Inlet Separator/ Stabilisation Sweet Inlet Separator Gas Sweetening/ Acid Gas Incinerator

GV-420 Deethanizer Reflux Drum 2H

400 (C)

GC-402 Debutanizer Column GC-403 Depropanizer Column

400 (D)

GK-423 (PU04) Deethanizer OVHD Compressor Unit

520 (A)

GV-528 Off Spec Bullet

520 (B)

GV-525 A LPG Bullet

520 (C)

GV-525 B LPG Bullet

520 (D)

GV-525 C LPG Bullet

530

GV-530 Sour Off Spec Bullet

560

GV-562 Propane Bullet

500

GT-506 Condensate Storage Tank

670

Propane Refrigeration System

PU13

EDV-Ident-Nr.

Loading Station (PU13) Sales Gas to B.L

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

143 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Following is presented a description of special features of units which can be blocked separately in case of an Emergency Situation. For more details about ESD System, refers to the Document 12466-01 10250 “Description of ESD System”

6.3.3

ESD Description

6.3.3.1

ESD- SD-2A: Unit 100/110 Sour Gas Inlet Separator/ Stabilization

See PFD: 1.

12466-01 10151

In case an Emergency Situation in Unit 100/110 Sour Gas Inlet Separator/ Stabilization is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G101A)

or • 3.

Control Room Operator using ESD Control Room Button (HS-G101B)

Once the ESD is activated, the 3 Sections GV-101, GC-101 (Stabilization) and GK117A/B (PU01) are blocked in for a later Depressurizing and following Draining.

Following valves are closed: •

UV-G101F: ESD Valve GV-101 inlet

•

UV-G101C: ESD Valve GV-101 outlet

•

UV-G101H: Isolation Valve Sour Liquid HC from GV-101

•

UV-G110A: ESD Valve inlet PU01

•

UV-G110B: ESD Valve outlet PU01

•

UV-G111C: ESD Valve Condensate from GC-111

Switch off following pumps. •

Corrosion Inhibitor Injection Pump (GP-119)

•

Sour Off Spec Pumps (GP-531 A/B)

•

Oily slop Pump (GP-442)

•

Stabilizer Reflux Pumps (GP-115 A/B) are not switched off because of Reflux to GC-111 (Cooling of Column). Switch off of GP-115A/B has to be done by operator manually.

•

Methanol Injection Pumps (GP-161 A/B) are not switched off because of its Methanol supply to other Units. The switch off of Methanol supply has to be done by operator manually.

EDV-Ident-Nr.

The activation of ESD performs following further actions: Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

144 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

Signal to Stabilizer OVHD Compressor Package (PU-01) (e.g. switch off Compressor GK-117A/B)

•

Signal to Glycol Regeneration Unit (PU03) (e.g. switch off Delivery Pumps in PU-03)

Automatic isolation and de-activation of following valves: •

LDV-G101E: Interface Level Controller GV-101

•

TV-G113D: Temperature Controller Reboiler Return GC-111

•

LDV-G116C: Interface Level Controller GV-116

ESD Depressurizing can occur for 3 Sections GV-101, GC-101/GV-116 (Stabilization) and GK-117A/B (PU01) from Control Room.

Section GV-101 (Sour Gas Inlet Separator) ESD Depressurizing Button (HS-G101C) causes opening Emergency Depression Valve GV101 (UV-G101A) and depressurizes Sour Gas Inlet Separator (GV-101). It will occur if • ESD Depressurizing Button (HS-G101C) was activated and •

UV-G101F, UV-G101C (ESD Valves) are closed and

•

UV-G101H (Isolation Valve) is closed and

•

ESD local Button (HS-G101A) or ESD Control Room Button (HS-G101B) activated (Signal "Shut Down 2A" of Sour Gas Inlet Separator / Stabilization exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G101A) or ESD Control Room Button (HS-G101B) is activated (Signal "Shut Down 2A" of Sour Gas Inlet Separator / Stabilization exists)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

145 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Section GC-111/GV-116 (Stabilization) ESD Depressurizing Button (HS-G101D) causes opening Emergency Depression Valve GV116 (UV-G116B) and depressurizes Stabilization (GC-111, GV-116). It will occur if •

ESD Depressurizing Button (HS-G101D) is activated and

•

UV-G101H (Isolation Valve) is closed and

•

UV-G110A, UV-G111C (ESD Valves) are closed and

•

ESD local Button (HS-G101A) or ESD Control Room Button (HS-G101B) is activated (Signal "Shut Down 2A" of Sour Gas Inlet Separator / Stabilization exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G101A) or ESD Control Room Button (HS-G101B) activated (Signal "Shut Down 2A" of Sour Gas Inlet Separator / Stabilization exists)

Section GK-117A/B (Stabilizer OVHD Compressor Package PU01) •

ESD Depressurizing Button (HS-G101E) performs a Signal to Stabilizer OVHD Compressor Package (PU-01) (e.g. for Opening internal Valves in PU01), causes opening Emergency Depression Valve PU01 (UV-G110C) and depressurizes Stabilizer OVHD Compressor Package PU01 (GK-117A/B). It will occur if ESD Depressurizing Button (HS-G101E) is activated and

•

UV-G110A, UV-G110B (ESD Valves) are closed and

•

ESD local Button (HS-G101A) or ESD Control Room Button (HS-G101B) is activated (Signal "Shut Down 2A" of Sour Gas Inlet Separator / Stabilization exists)

•

After a time delay (20 sec.) and

•

ESD local Button (HS-G101A) or ESD Control Room Button (HS-G101B) activated (Signal "Shut Down 2A" of Sour Gas Inlet Separator / Stabilization exists)

ESD Draining can occur after Depressurizing at very low pressure level for 2 Sections GV-101 and GC-111/GV-116 (Stabilization) from Control Room.

Section GV-101 (Sour Gas Inlet Separator) ESD Draining Button (HS-G101F) causes opening Emergency Drain Valve GV-101 (UVG101B) and liquid can leave Sour gas Inlet Separator (GV-101) to Drain Header. It will occur if •

EDV-Ident-Nr.

ESD Draining Button (HS-G101F) is activated and Sour Gas Inlet Separator (GV-101) is depressurized. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

146 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Section GC-111/GV-116 (Stabilization) ESD Draining Button (HS-G101G) causes opening Emergency Drain Valve GC-111 (UVG111B) and liquid can leave Stabilizer Column (GC-111) to Drain Header. It will occur if ESD Draining Button (HS-G101G) is activated and Stabilization (GC-111/GV116) is depressurized. For restart of this section the Reset Button has to be pressed

• 10.

6.3.3.2

ESD- SD-2B: Unit 100 Sweet Inlet Separators

See PFD: 1.

12466-01 10152

In case an Emergency Situation in Unit 100 Sweet Gas Inlet Separators is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G102A)

or 3.

• Control Room Operator using ESD Control Room Button (HS-G102B) Once the ESD is activated, the 2 Sections GV-102 and GV-103 are blocked in for a later Depressurizing and following Draining.

Following valves are closed: •

UV-G102F: ESD Valve GV-102 inlet

•

UV-G102C: ESD Valve GV-102 outlet

•

UV-G103F: ESD Valve GV-103 inlet

•

UV-G103C: ESD Valve GV-103 outlet

•

UV-G102H: Isolation Valve Sour NGL from GV-102/GV-103

Pumps: •

Methanol Injection Pumps (GP-161 A/B) will not be switched off, because of its Methanol supply to other Units. The switch off of Methanol supply has to be done by operator manually.

The activation of ESD performs following further actions: •

Signal to Glycol Regeneration Unit (PU03) (e.g. switch off Delivery Pumps in PU-03)

EDV-Ident-Nr.

Automatic isolation and de-activation of following valves: •

LV-G102A: Level Controller outlet chamber GV-102

•

LDV-G102E: Interface Level Controller GV-102

•

LV-G103A: Level Controller outlet chamber GV-103 Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

147 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

• 8.

LDV-G103E: Interface Level Controller GV-103

ESD Depressurizing can occur for 2 Sections GV-102 and GV-103 from Control Room.

Section GV-102 (Sweet Gas Inlet Separator) ESD Depressurizing Button (HS-G102C) causes opening Emergency Depression Valve GV102 (UV-G102A) and depressurizes Sweet Gas Inlet Separator (GV-102). It will occur if ESD Depressurizing Button (HS-G102C) was activated and •

UV-G102F, UV-G102C (ESD Valves) are closed and

•

UV-G102H (Isolation Valve) is closed and

•

ESD local Button (HS-G102A) or ESD Control Room Button (HS-G102B) activated (Signal "Shut Down 2B" of Sweet Gas Inlet Separators exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G102A) or ESD Control Room Button (HS-G102B) is activated (Signal "Shut Down 2B" of Sweet Gas Inlet Separators exists)

Section GV-103 (Sweet Gas Inlet Separator) ESD Depressurizing Button (HS-G102D) causes opening Emergency Depression Valve GV103 (UV-G103A) and depressurizes Sweet Gas Inlet Separator (GV-103). It will occur if •

ESD Depressurizing Button (HS-G102D) was activated and

•

UV-G103F, UV-G103C (ESD Valves) are closed and

•

UV-G102H (Isolation Valve) is closed and

•

ESD local Button (HS-G102A) or ESD Control Room Button (HS-G102B) activated (Signal "Shut Down 2B" of Sweet Gas Inlet Separators exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G102A) or ESD Control Room Button (HS-G102B) is activated (Signal "Shut Down 2B" of Sweet Gas Inlet Separators exists)

ESD Draining can occur after depressurizing at very low pressure level for 2 Sections GV-102 and GV-103 from Control Room.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

148 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Section GV-102 (Sweet Gas Inlet Separator) ESD Draining Button (HS-G102E) causes opening Emergency Drain Valve GV-102 (UVG102B) and liquid can leave Sweet Gas Inlet Separator (GV-102) to Drain Header. It will occur if ESD Draining Button (HS-G102E) is activated and Sweet Gas Inlet Separator (GV102) is depressurized. Section GV-103 (Sweet Gas Inlet Separator) ESD Draining Button (HS-G102F) causes opening Emergency Drain Valve GV-103 (UVG103B) and liquid can leave Sweet Gas Inlet Separator (GV-103) to Drain Header. It will occur if ESD Draining Button (HS-G102F) is activated and Sweet Gas Inlet Separator (GV103) is depressurized. 10.

For restart of this section the Reset Button has to be pressed

6.3.3.3

ESD- SD-2C: Unit 200/260 Gas Sweetening/ Acid Gas Incinerator

See PFD:

12466-01 10154

Unit 200 Gas Sweetening 1.

In case an Emergency Situation in Unit 200 Gas Sweetening is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G200A)

or • 3.

Control Room Operator using ESD Control Room Button (HS-G200B)

Once the ESD is activated Unit 200 Gas Sweetening is blocked in for a later ESD Depressurizing. ESD Draining for Unit 200 is not provided.

Following valves are closed: •

UV-G101C: ESD Valve GV-101 outlet

•

UV-G110B: ESD Valve outlet PU01

•

UV-G201B: Isolation Valve Rich Amine from GC-201to GV-220

•

UV-G219A: Isolation Valve Sweet Gas from GV-219

Switch off following pumps.

Amine Charge Pumps (GP-212 A/B)

Automatic isolation and de-activation of following valves: •

EDV-Ident-Nr.

PV-G219C: Pressure Controller Sweet Gas from GV-219 Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

149 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

LV-G219A: Level Controller GV-219

•

LV-G208A: Level Controller GF-208

•

FV1-G212C: Lean Amine from GV-221 to GE-203

ESD Depressurizing can occur for Unit 200 Gas Sweetening from Control Room.

ESD Depressurizing Button (HS-G200C) causes opening Emergency Depression Valve GV219 (UV-G219B) and depressurizes Unit 200 Gas Sweetening (GC-201, GV-208, GV-219). It will occur if •

ESD Depressurizing Button (HS-G200C) was activated and

•

UV-G101C, UV-G110B (ESD Valves) are closed and

•

UV-G201B, UV-G219A (Isolation Valves) are closed and

•

HV1-G201A (Manual Controller Sour Gas to Flare) is closed and

•

PV-G219C (Pressure Controller Sweet Gas from GV-219) is closed and

•

ESD local Button (HS-G200A) or ESD Control Room Button (HS-G200B) is activated (Signal "Shut Down 2C" of Gas Sweetening exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G200A) or ESD Control Room Button (HS-G200B) is activated (Signal "Shut Down 2C" of Gas Sweetening exists)

For restart of this section the Reset Button has to be pressed

Unit 260 Acid Gas Incinerator 1.

In case an Emergency Situation in Unit 260 Acid Gas Incinerator is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G260A)

or • 3.

Control Room Operator using ESD Control Room Button (HS-G260B)

Once the ESD is activated Unit 260 Acid Gas Incinerator is isolated. An ESD Depressurizing and ESD Draining for Unit 260 is not provided.

Following valve is closed: •

UV-G260A: Isolation Valve Acid Gas to PU02

The activation of ESD performs following further actions: •

Signal to Acid Gas Incinerator Unit (PU02) (e.g. switch off Air Blower in PU02; closing internal Fuel Gas Valves etc.)

EDV-Ident-Nr.

For restart of this section the Reset Button has to be pressed

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

150 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.4

ESD- SD-2D: Unit 350 Dehydration Unit (PU03)

See PFD: 1.

12466-01 10155

In case an Emergency Situation in Unit 350 Dehydration is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G350A)

or • 3.

Control Room Operator using ESD Control Room Button (HS-G350B)

Once the ESD is activated, Dehydration Unit (PU03) is blocked in for a later Depressurizing. ESD Draining for Dehydration Unit is not provided.

Following valves are closed: •

UV-G219A: Isolation Valve Sweet Gas from GV-219

•

UV-G102C: ESD Valve GV-102 outlet

•

UV-G103C: ESD Valve GV-103 outlet

•

UV-G301A: Isolation Valve Sour Gas to GE-301/GE-302

The activation of ESD performs following further actions: •

Signal to Dehydration Unit (PU-03) (e.g. Signal for internal block in valves, Fuel Gas to Heater etc.)

ESD Depressurizing can occur for Unit 350 Dehydration Unit (PU03) from Control Room.

ESD Depressurizing Button (HS-G350C) causes opening Emergency Depression Valves PU03 (UV-G350A and UV-G350B) and depressurizes Unit 350 Dehydration Unit (PU03). It will occur if •

ESD Depressurizing Button (HS-G350C) was activated and

•

UV-G219A, UV-G301A (Isolation Valves) are closed and

•

UV-G102C, UV-G103C (ESD Valves) are closed

•

ESD local Button (HS-G350A) or ESD Control Room Button (HS-G350B) activated (Signal "Shut Down 2D" of Dehydration Unit exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G350A) or ESD Control Room Button (HS-G350B) is activated (Signal "Shut Down 2D" of Dehydration Unit exists)

EDV-Ident-Nr.

For restart of this section the Reset Button has to be pressed

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

151 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.5

ESD- SD-2E: Unit 300 NGL Recovery

See PFD: 1.

12466-01 10155

In case an Emergency Situation in Unit 300 NGL Recovery is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G300A)

or • 3.

Control Room Operator using ESD Control Room Button (HS-G300B)

Once the ESD is activated, Unit 300 NGL Recovery is blocked in for a later Depressurizing and following Draining.

Following valves are closed: •

UV-G301A: Isolation Valve Sour Gas to GE-301/GE-302

•

UV-G301B: Isolation Valve Sweet Gas from GE-301

•

UV-G304A: Isolation Valve Sour NGL from GV-304 to GE-303

•

UV-G670A: ESD Valve Propane Supply to GE-303A/B

•

UV-G670E: ESD Valve Special Propane Supply to GE-302

•

UV-G670B: ESD Valve Propane Return from GE-302

Switch off following pumps. •

Emulsion Breaker Pump (GP-321)

•

Methanol Injection Pumps (GP-161 A/B) are not switched off, because of its Methanol supply to other Units. The switch off of Methanol supply has to be done by operator manually.

The activation of ESD performs following further actions: •

Signal to Propane Refrigeration System (PU-05) (e.g. switch off Propane Pump)

ESD Depressurizing can occur for Unit 300 NGL Recovery from Control Room.

ESD Depressurizing Button (HS-G300C) causes opening Emergency Depression Valve GE301/GE-302 (UV-G301C) and depressurizes Unit 300 NGL Recovery to the Cold Flare Knock Out Drum GV-689. It will occur if •

ESD Depressurizing Button (HS-G300C) was activated and

•

UV-G301A, UV-G301B, UV-G304A (Isolation Valves) are closed

•

ESD local Button (HS-G300A) or ESD Control Room Button (HS-G300B) activated (Signal "Shut Down 2E" Unit 300 NGL Recovery exists)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

152 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

After a time delay (20 sec.) and

•

ESD local Button (HS-G300A) or ESD Control Room Button (HS-G300B) is activated (Signal "Shut Down 2E" Unit 300 NGL Recovery exists)

ESD Draining can occur after Depressurizing at very low pressure level for Unit 300 NGL Recovery from Control Room. ESD Draining Button (HS-G300D) causes opening Emergency Drain Valve

•

GV-304 (UV-G304B) and liquid can leave Low Temperature Separator (GV304) to Drain Header. It will occur if ESD Draining Button (HS-G300D) is activated and Unit 300 NGL Recovery is depressurized. 9.

For restart of this section the Reset Button has to be pressed

10.

During Depressurizing via UV-G301C or Relieving via 300-PSV-003 A/B, Unit Shut Down valve UV-G304A will be closed in order to prevent liquid overflow in Cold Flare Knock Out Drum GV-689.

6.3.3.6

ESD- SD-2F to 2I: Unit 400 Fractionation

See PFD: 1.

12466-01 10156

Control Room Operator and Plant Operator have the feasibility of an Emergency Shut Down of 4 individual Sections in Unit 400 Fractionation.

•

Section Deethanizer Feed Drum GV-419

•

Section Deethanizer Column GC-401 and Reflux Drum GV-420

•

Section Debutanizer / Depropanizer Column GC-402/GC-403

•

Section Deethanizer OVHD Compressor Unit (PU04)

In case an Emergency Situation in Unit 400 Fractionation is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

Emergency Shut Down System for every of 4 individual Sections are described next

6.3.3.7 1.

ESD- SD-2F: Section Deethanizer Feed Drum GV-419 There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G419A)

or • 2.

Control Room Operator using ESD Control Room Button (HS-G419B)

Once the ESD is activated the Section Deethanizer Feed Drum GV-419 is blocked in for a later Depressurizing and following Draining.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

153 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Following valves are closed: •

UV-G102H: Isolation Valve Sour NGL from GV-102/GV-103

•

UV-G304A: Isolation Valve Sour NGL from GV-304 to GE-303

•

UV-G403E: ESD Valve Propane from GV-422

•

UV-G419D: Isolation Valve LPG from GV-419

•

UV-G420C: ESD Valve Sweet Gas from GV-420

•

UV-G423A: ESD Valve inlet PU04

Switch off following pumps. •

LPG Recycle Pumps (GP-525A/B)

•

Depropanizer Reflux Pumps (GP-418A/B) are not switched off because of Reflux to GC-403 (Cooling of Column). Switch off of GP-418A/B has to be done by operator manually.

The activation of ESD performs following further action: •

Signal to Deethanizer OVHD Compressor Unit (PU-04) (e.g. switch off Compressor GK-423A/B)

Automatic isolation and de-activation of following valves: •

FV-G525C: Liquefied Petrol Gas from GV-528 to GV-419

•

LDV-G419H: Interface Level Controller GV-419

ESD Depressurizing can occur for Section Deethanizer Feed Drum GV-419 from Control Room.

ESD Depressurizing Button (HS-G419C) causes opening Emergency Depression Valve GV419 (UV-G419B) and depressurizes Deethanizer Feed Drum GV-419 and Deethanizer Overhead Propane Subcooler GE-409 (Shell Side). It will occur if •

ESD Depressurizing Button (HS-G419C) was activated and

•

UV-G102H, UV-G304A (Isolation Valves) are closed and

•

UV-G403E, UV-G419D, UV-G420C, UV-G423A (ESD Valves) are closed and

•

ESD local Button (HS-G419A) or ESD Control Room Button (HS-G419B) activated (Signal "Shut Down 2F" of Deethanizer Feed Drum GV-419 exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G419A) or ESD Control Room Button (HS-G419B) is activated (Signal "Shut Down 2F" of Deethanizer Feed Drum GV-419 exists)

ESD Draining can occur after Depressurizing at very low pressure level for Section Deethanizer Feed Drum GV-419 from Control Room.

ESD Draining Button (HS-G419D) causes opening Emergency Drain Valve GV-419 (UVG419C) and liquid can leave Deethanizer Feed Drum GV-419 to Drain Header. It will occur if

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

154 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

ESD Draining Button (HS-G419D) is activated and Deethanizer Feed Drum

•

GV-419 is depressurized) 9.

For restart of this section the Reset Button has to be pressed

6.3.3.8

ESD- SD-2G: Section Deethanizer Column GC-401 and Reflux Drum GV-420

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G401A)

or • 2.

Control Room Operator using ESD Control Room Button (HS-G401B)

Once the ESD is activated the Section Deethanizer Column GC-401 and Reflux Drum GV-420 is blocked in for a later Depressurizing and following Draining.

Following valves are closed: •

UV-G419D: Isolation Valve LPG from GV-419

•

UV-G420C: ESD Valve Sweet Gas from GV-420

•

UV-G402C: Isolation Valve NGL to GC-402

•

UV-G670C: ESD Valve Propane Supply to GE-409

•

UV-G670D: ESD Valve Propane Return from GE-407

Pumps. •

Methanol Injection Pumps (GP-161 A/B) are not switched off, because of its Methanol supply to other Units. Switch off of Methanol supply has to be done by operator manually.

•

Deethanizer Reflux Pumps (GP-415A/B) are not switched off because of Reflux to GC-401 (Cooling of Column). Switch off of GP-415A/B has to be done by operator manually.

The activation of ESD performs following further actions •

Signal to Propane Refrigeration System (PU-05) (e.g. switch off Propane Pump)

•

Signal to Glycol Regeneration Unit (PU03) (e.g. switch off Delivery Pumps in PU-03)

Automatic isolation and de-activation of following valves: •

LDV-G420H: Interface Level Controller GV-420

•

TV-408C: Temperature Controller Reboiler Return to GC-401

Automatic opening of following valve •

EDV-Ident-Nr.

TV1-G420B: Temperature Controller Sweet Gas from GV-420 to PU04

ESD Depressurizing can occur for Section GC-401 / GV-420 from Control Room. Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

155 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

ESD Depressurizing Button (HS-G401C) causes opening Emergency Depression Valve GV420 (UV-G420B) and depressurizes GC-401 / GV-420. It will occur if •

ESD Depressurizing Button (HS-G401C) was activated and

•

UV-G419D, UV-G402C (Isolation Valves) are closed and

•

UV-G420C (ESD Valve) is closed and

•

ESD local Button (HS-G401A) or ESD Control Room Button (HS-G401B) activated (Signal "Shut Down 2G" of GC-401 / GV-420 exists)

or •

After a time delay (20 sec.) and

•

ESD local Button (HS-G401A) or ESD Control Room Button (HS-G401B) is activated (Signal "Shut Down 2G" of GC-401 / GV-420 exists)

ESD Draining can occur after Depressurizing at very low pressure level for Section GC-401 / GV-420 from Control Room.

ESD Draining Button (HS-G401D) causes opening Emergency Drain Valve GC-401 (UVG401B) and liquid can leave Deethanizer Column GC-401 to Drain Header. It will occur if ESD Draining Button (HS-G401D) is activated and GC-401 / GV-420 is

•

depressurized. 10.

For restart of this section the Reset Button has to be pressed

6.3.3.9 1.

ESD- SD-2H: Section Debutanizer / Depropanizer Column GC-402/GC-403 There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G402A)

or • 2.

Control Room Operator using ESD Control Room Button (HS-G402B)

Once the ESD is activated the Section Debutanizer Column GC-402 and Depropanizer Column GC-403 is blocked in for a later Depressurizing and following Draining.

EDV-Ident-Nr.

Following valves are closed: •

UV-G402C: Isolation Valve NGL to GC-402

•

UV-G403E: ESD Valve Propane from GV-422

•

UV-G402E: ESD Valve LPG from GV-421

•

UV-G402D: ESD Valve Condensate from GC-402

•

UV-G403D: ESD Valve LPG from GC-403

Switch off following pumps Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

156 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

Depropanizer Feed Pumps (GP-417A/B)

•

Debutanizer Reflux Pumps (GP-416A/B) are not switched off because of Reflux to GC-402 (Cooling of Column). Switch off of GP-416A/B has to be done by operator manually.

•

Depropanizer Reflux Pumps (GP-418A/B) are not switched off because of Reflux to GC-403 (Cooling of Column). Switch off of GP-418A/B has to be done by operator manually.

Automatic isolation and de-activation of following valves: •

TV-G411C: Temperature Controller Reboiler Return to GC-402

•

FV-403A: Liquefied Petrol Gas to GC-403

ESD Depressurizing can occur for Section GC-402/GC-403 from Control Room.

ESD Depressurizing Button (HS-G402C) causes opening Emergency Depression Valves on GV-421 (UV-G421B) and GV-422 (UV-G422B) and depressurizes Section GC-402/GV421/GC-403/GV-422. It will occur if •

ESD Depressurizing Button (HS-G402C) was activated and

•

UV-G402C (Isolation Valve) is closed and

•

UV-G402E, UV-G402D, UV-G403E, UV-G403D (ESD Valves) are closed and

•

ESD local Button (HS-G402A) or ESD Control Room Button (HS-G402B) is activated (Signal "Shut Down 2H" of GC-402/GC-403 exists)

•

After a time delay (20 sec.) and

•

ESD local Button (HS-G402A) or ESD Control Room Button (HS-G402B) is activated (Signal "Shut Down 2H" of GC-402/GC-403 exists)

ESD Draining can occur after depressurizing at very low pressure level for 3 Sections GC-402, GV-421 and GC-403 from Control Room.

Section GC-402 (Debutanizer Column) ESD Draining Button (HS-G402D) causes opening Emergency Drain Valve GC-402 (UVG402B) and liquid can leave Column GC-402 to Drain Header. It will occur if •

ESD Draining Button (HS-G402D) is activated and GC-402/GC-403 is depressurized.

Section GV-421 (Debutanizer Reflux Drum) ESD Draining Button (HS-G402E) causes opening Emergency Drain Valve GV-421 (UVG421A) and liquid can leave Drum GV-421 to Drain Header. It will occur if

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

157 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

ESD Draining Button (HS-G402E) is activated and GC-402/GC-403 is depressurized.

Section GC-403 (Depropanizer Column) ESD Draining Button (HS-G402F) causes opening Emergency Drain Valve GC-403 (UVG403B) and liquid can leave Column GC-403 to Drain Header. It will occur if •

ESD Draining Button (HS-G402F) is activated and GC-402/GC-403 is depressurized.

For restart of this section the Reset Button has to be pressed

6.3.3.10 ESD- SD-2I: Section Deethanizer OVHD Compressor Unit (PU04)

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G423A)

or • 2.

Control Room Operator using ESD Control Room Button (HS-G423B)

Once the ESD is activated the Section Deethanizer OVHD Compressor Unit (PU04) is blocked in for a later Depressurizing. ESD Draining for Section Deethanizer OVHD Compressor Unit (PU04) is not provided.

Following valves are closed: •

UV-G423A: ESD Valve inlet PU04

•

UV-G423B: ESD Valve outlet PU04

The activation of ESD performs following further actions •

Signal to Deethanizer OVHD Compressor Unit (PU04) (e.g. switch off Compressors GK-423A/B)

ESD Depressurizing can occur for Section Deethanizer OVHD Compressor Unit (PU04) from Control Room.

ESD Depressurizing Button (HS-G423C) causes opening Emergency Depression Valve PU04 (UV-G423C) and depressurizes Section Deethanizer OVHD Compressor Unit (PU04). It will occur if •

ESD Depressurizing Button (HS-G423C) was activated and

•

UV-G423A, UV-G423B (ESD Valves) are closed and

•

ESD local Button (HS-G423A) or ESD Control Room Button (HS-G423B) is activated (Signal "Shut Down 2I" of Deethanizer OVHD Compressor Unit (PU04) exists)

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

158 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

After a time delay (20 sec.) and

•

ESD local Button (HS-G423A) or ESD Control Room Button (HS-G423B) is activated (Signal "Shut Down 2I" of Deethanizer OVHD Compressor Unit (PU04) exists)

For restart of this section the Reset Button has to be pressed

6.3.3.11 ESD-SD-2J to 2P: Unit 500/520/530/560 Condensate, LPG, Off Spec and Propane Storage See PFD:

12466-01 10157

In case an Emergency Situation in Unit 500 Gas Condensate Storage, Unit 520 LPG and LPG Off Spec Bullets, Unit 530 Sour Off Spec Bullet and Unit 560 Propane Bullet is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

Control Room and Plant Operator have the feasibility of following Emergency Shut Downs: •

Unit 500 Gas Condensate Storage: ESD local and ESD Control Room

•

Unit 520 LPG Off Spec Bullet / LPG Bullets and Unit 560 Propane Storage Bullet:

•

ESD local and ESD Control Room for all Bullets and

ESD Control Room for every single Bullet

Unit 530 Sour Off Spec Bullet: ESD local and ESD Control Room

ESD System for Unit 520 / 560 / 530 and for Unit 500 is following described.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

159 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.12 ESD- SD-2J to 2M and 2O: Unit 520 LPG Off Spec/LPG Bullets and Unit 560 Propane Storage Bullet

There are two ways to activate the ESD for Unit 520/560 LPG Off Spec / LPG Bullets / Propane Storage Bullet for whole LPG and Propane Storage: •

Plant Operator using local ESD Button (HS-G520A) for whole LPG/Propane Storage

or •

Control Room Operator using ESD Control Room Button (HS-G520B) for whole LPG/Propane Storage

Once the ESD is activated all LPG / LPG Off Spec Bullets and Propane Bullet are blocked in. ESD Depressurizing and ESD Draining are not provided.

EDV-Ident-Nr.

Following valves are closed: •

UV-G526D: Isolation Valve Circulation Line GV-526A

•

UV-G526B: ESD Valve Liquefied Petrol Gas from GV-526A to PU13

•

UV-G526C: ESD Valve Gas Oscillation GV-526A from/to PU13

•

UV-G526K: Isolation Valve Circulation Line GV-526B

•

UV-G526H: ESD Valve Liquefied Petrol Gas from GV-526B to PU13

•

UV-G526J: ESD Valve Gas Oscillation GV-526B from/to PU13

•

UV-G526Q: Isolation Valve Circulation Line GV-526C

•

UV-G526O: ESD Valve Liquefied Petrol Gas from GV-526C to PU13

•

UV-G526P: ESD Valve Gas Oscillation GV-526C from/to PU13

•

UV-G528D: Isolation Valve Circulation Line GV-528

•

UV-G528B: ESD Valve Liquefied Petrol Gas from GV-528

•

UV-G528C: ESD Valve Gas Oscillation GV-528 from/to PU13

•

UV-G562A: Isolation Valve Propane to GV-562

•

UV-G562B: Isolation Valve Propane from GV-562 to PU05/PU13

•

UV-G562C: ESD Valve Gas Oscillation GV-562 from/to PU13

•

UV-G562D: Isolation Valve Circulation Line GV-562

Switch off following pumps. •

Propane Transfer Pumps (GP-561)

•

LPG Loading Pumps (GP-524A/B)

•

LPG Recycle Pumps (GP-525A/B) Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

160 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

If ESD was activated for whole LPG and Propane Storage by local (HS-520A) or Control Room Button (HS-520B) there is no possibility for draining of one bullet to another by pumps.

6.3.3.13 ESD- SD-2J: Unit 520 Off Spec Bullet GV-528

In case an Emergency Situation exists only for Unit 520 Off Spec Bullet GV-528 plant operator informs Control Room Operator for activation of ESD Control Room Button (HS-528A).

Once the ESD is activated LPG Off Spec Bullet GV-528 is blocked in. ESD Depressurizing and ESD Draining are not provided.

Following valves are closed: •

UV-G528D: Isolation Valve Circulation Line GV-528

•

UV-G528B: ESD Valve Liquefied Petrol Gas from GV-528

•

UV-G528C: ESD Valve Gas Oscillation GV-528 from/to PU13

Pumps. •

LPG Loading Pumps (GP-524A/B) and LPG Recycle Pumps (GP-525A/B) are not switched off because they may connect to another bullet.

In case of a leakage of the bullet GV-528 liquid can be pumped to another bullet by opening ESD valve UV-G528B manually.

6.3.3.14 ESD- SD-2K: Unit 520 LPG Bullet GV-526A

In case an Emergency Situation exists only for Unit 520 LPG Storage Bullet GV-526A plant operator informs Control Room Operator for activation of ESD Control Room Button (HS-526A).

Once the ESD is activated LPG Storage Bullet GV-526A is blocked in. ESD Depressurizing and ESD Draining are not provided.

Following valves are closed: •

UV-G526D: Isolation Valve Circulation Line GV-526A

•

UV-G526B: ESD Valve Liquefied Petrol Gas from GV-526A to PU13

•

UV-G526C: ESD Valve Gas Oscillation GV-526A from/to PU13

Pumps. •

LPG Loading Pumps (GP-524A/B) and LPG Recycle Pumps (GP-525A/B) are not switched off because they may connect to another bullet.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

161 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

In case of a leakage of the bullet GV-526A liquid can be pumped to another bullet by opening ESD valve UV-G526B manually.

6.3.3.15 ESD- SD-2L: Unit 520 LPG Bullet GV-526B

In case an Emergency Situation exists only for Unit 520 LPG Storage Bullet GV-526B plant operator informs Control Room Operator for activation of ESD Control Room Button (HS-526C).

Once the ESD is activated LPG Storage Bullet GV-526B is blocked in. ESD Depressurizing and ESD Draining are not provided.

Following valves are closed: •

UV-G526K: Isolation Valve Circulation Line GV-526B

•

UV-G526H: ESD Valve Liquefied Petrol Gas from GV-526B to PU13

•

UV-G526J: ESD Valve Gas Oscillation GV-526B from/to PU13

Pumps. •

LPG Loading Pumps (GP-524A/B) and LPG Recycle Pumps (GP-525A/B) are not switched off because they may connect to another bullet.

In case of a leakage of the bullet GV-526B liquid can be pumped to another bullet by opening ESD valve UV-G526H manually.

6.3.3.16 ESD- SD-2M: Unit 520 LPG Bullet GV-526C

In case an Emergency Situation exists only for Unit 520 LPG Storage Bullet GV-526C plant operator informs Control Room Operator for activation of ESD Control Room Button (HS-526E).

Once the ESD is activated LPG Storage Bullet GV-526C is blocked in. ESD Depressurizing and ESD Draining are not provided.

Following valves are closed: •

UV-G526Q: Isolation Valve Circulation Line GV-526C

•

UV-G526O: ESD Valve Liquefied Petrol Gas from GV-526C to PU13

•

UV-G526P: ESD Valve Gas Oscillation GV-526C from/to PU13

Pumps. •

LPG Loading Pumps (GP-524A/B) and LPG Recycle Pumps (GP-525A/B) are not switched off because they may connect to another bullet.

In case of a leakage of the bullet GV-526C liquid can be pumped to another bullet by opening ESD valve UV-G526O manually.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

162 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.17 ESD- SD-2O: Unit 560 Propane Bullet GV-562

In case an Emergency Situation exists only for Unit 560 Propane Storage Bullet GV562 plant operator informs Control Room Operator for activation of ESD Control Room Button (HS-562A).

Once the ESD is activated Propane Storage Bullet GV-562 is blocked in. ESD Depressurizing and ESD Draining are not provided.

Following valves are closed: •

UV-G562A: Isolation Valve Propane to GV-562

•

UV-G562B: Isolation Valve Propane from GV-562 to PU05/PU13

•

UV-G562C: ESD Valve Gas Oscillation GV-562 from/to PU13

•

UV-G562D: Isolation Valve Circulation Line GV-562

Switch off following pumps. •

Propane Transfer Pump (GP-561)

In case of a leakage of the bullet GV-562 liquid Propane can be pumped to another bullet by opening Isolation Valves UV-G562B, UV-G562D and starting of Propane Transfer Pump (GP-561) manually.

6.3.3.18 ESD- SD-2N: Unit 530 Sour Off Spec Bullet GV-530

Note: In case ESD for Unit 530 Sour Off Spec Bullet GV-530 is activated no draining of Flare Knock Out Drum GV-692 into GV-530 is possible. 1.

There are two ways to activate the ESD for Unit 530 Sour Off Spec Bullet GV-530: •

Plant Operator using local ESD Button (HS-G530A) for Sour Off Spec Bullet GV-530

or •

Control Room Operator using ESD Control Room Button (HS-G530B) for Sour Off Spec Bullet GV-530

Once the ESD is activated Sour Off Spec Bullet GV-530 is blocked in. ESD Depressurizing and ESD Draining are not provided.

EDV-Ident-Nr.

Following valves are closed: •

UV-G530A: Isolation Valve HC Drain to GV-530

•

UV-G530B: ESD Valve Sour NGL from GV-530 to GC-111 Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

163 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Switch off following pumps. •

Sour Off Spec Pumps (GP-531A/B)

In case of a leakage of the bullet GV-530 Sour Off Spec Liquid can be pumped to GC-111 by opening ESD Valve UV-G530B and starting Sour Off Spec Pumps (GP531A/B) manually).

6.3.3.19 ESD- SD-2P: Unit 500 Condensate Storage Tank GT-506

There are two ways to activate the ESD for Unit 500 Condensate Storage Tank GT506: •

Plant Operator using local ESD Button (HS-G506A)

or • 2.

Control Room Operator using ESD Control Room Button (HS-G506B)

Once the ESD is activated Condensate Storage Tank GT-506 is blocked in. ESD Depressurizing and ESD Draining are not provided.

Following valves are closed: •

UV-G506A: ESD Valve Gas Condensate to GT-506

•

UV-G506B: ESD Valve Gas Condensate from GT-506

•

UV-G594A: ESD Valve Gas Condensate to Pipeline

•

UV1-G594D: ESD Valve Gas Condensate Coupling 1

•

UV2-G594D: ESD Valve Gas Condensate Coupling 2

•

UV3-G594D: ESD Valve Gas Condensate Coupling 3

Switch off following pumps. •

Condensate Transfer Pumps (GP-503A/B)

•

Condensate Pipeline Pumps (GP-504 A/B)

•

Water Pumps (GP-505A/B):

In case of a leakage of the Condensate Storage Tank GT-506 Gas Condensate can be pumped •

to Pipeline by opening ESD Valve UV-G506B, UV-G594A and starting Condensate Pipeline Pumps (GP-504 A/B) manually

or •

to Loading Station by opening ESD Valve UV-506B, Loading Valves and starting Condensate Transfer Pumps (GP-503A/B) manually.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

164 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.20 ESD- SD-2Q: Unit 670 Propane Refrigeration System See PFD: 1.

12466-01 10161

In case an Emergency Situation in Unit 670 Propane Refrigeration System (PU05) is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD:

•

Plant Operator using local ESD Button (HS-G670A) or

•

Control Room Operator using ESD Control Room Button (HS-G670B)

Once the ESD is activated Unit 670 Propane Refrigeration System (PU05) is blocked in for a later Depressurizing and following Draining.

Following valves are closed:

•

UV-G670F: ESD Valve Propane Refill PU05

•

UV-G670A: ESD Valve Propane Supply to GE-303A/B

•

UV-G670B: ESD Valve Propane Return from GE-302

•

UV-G670C: ESD Valve Propane Supply to GE-409

•

UV-G670D: ESD Valve Propane Return from GE-407

•

UV-G670E: ESD Valve Special Propane Supply to GE-302

The activation of ESD performs following further actions: •

Signal to Unit 670 Propane Refrigeration System (PU05) (e.g. switch off Internal Pumps)

ESD Depressurizing can occur for Unit 670 Propane Refrigeration System (PU05) from Control Room. ESD Depressurizing Button (HS-G670C) causes opening Internal Emergency Depression Valve of Propane Refrigeration System (PU05) and depressurizes PU05. It will occur if •

ESD Depressurizing Button (HS-G670C) was activated and

•

UV-G670F, UV-G670A, UV-G670B, UV-G670C, UV-G670D, UV-G670E (ESD Valves) are closed and

•

ESD local Button (HS-G670A) or ESD Control Room Button (HS-G670B) is activated (Signal "Shut Down 2Q" of Unit 670 Propane Refrigeration System (PU05) exists)

or •

EDV-Ident-Nr.

After a time delay (20 sec.) and

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

165 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

ESD local Button (HS-G670A) or ESD Control Room Button (HS-G670B) is activated (Signal "Shut Down 2Q" of Unit 670 Propane Refrigeration System (PU05) exists)

ESD Draining can occur after Depressurizing at very low pressure level for Unit 670 Propane Refrigeration System (PU05) from Control Room. ESD Draining Button (HS-G670D) causes opening Internal Emergency Drain Valve of Unit 670 Propane Refrigeration System (PU05) and liquid can leave PU05 to Drain Header. It will occur if •

ESD Draining Button (HS-G670D) is activated and Unit 670 Propane Refrigeration System (PU05) is depressurized.

6.3.3.21 ESD- SD-2R: Loading Station (PU13) See PFD:

12466-01 10163

In case an Emergency Situation in Unit Loading Station (PU03) is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G500A) or

•

Control Room Operator using ESD Control Room Button (HS-G500B)

Once the ESD is activated Unit Loading Station (PU03) is blocked in. An ESD Depressurizing and Draining is not provided.

Following valves are closed: •

UV-G560A: ESD Valve Propane to Loading

•

UV-G560B: ESD Valve Propane Balancing Line

•

UV-G520A: ESD Valve LPG to Loading

•

UV-G520B: ESD Valve LPG Balancing Line

•

UV-G520C: ESD Valve LPG Unloading

•

UV-G500A: ESD Valve Gas Condensate to Loading

The activation of ESD performs following further actions: •

Signal to Unit Loading Station (PU-13) (e.g. Stop Loading, Closing Internal Valves, and Closing Odorisation).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

166 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.3.22 ESD- SD-2S: Sales Gas to B.L. See PFD:

12466-01 10163

In case an Emergency Situation in Section Sale Gas to B.L. is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There are two ways to activate the ESD: •

Plant Operator using local ESD Button (HS-G590A) or

•

Control Room Operator using ESD Control Room Button (HS-G590B)

Once the ESD is activated the Section Sales Gas to B.L. is blocked in for a later Depressurizing. An ESD Draining is not provided.

Following valves are closed: •

UV-G301B: Isolation Valve Sour Gas to GE-301/GE-302

•

UV-G423A: ESD Valve inlet PU04

•

UV-G423B: ESD Valve outlet

•

UV-G699A: Isolating Valve Flare Gas to PU06

•

UV-G597A: ESD Valve Sweet Gas to B.L. (UV-G599A is not closed because of Fuel Gas Supply to Flare etc.)

The activation of ESD performs following further actions: •

Signal to Deethanizer OVHD Compressor Package (PU-04) (e.g. switch off Compressor GK-423A/B)

•

Signal to Service Generators (PU11) (e.g. Closing Fuel Gas to Generator Valves)

ESD Depressurizing can occur for Section Sales Gas to B.L. from Control Room. ESD Depressurizing Button (HS-G590C) causes opening Emergency Depression Valve Sweet Gas to Metering (UV-G699B) and depressurizes Section Sales Gas to B.L.. It will occur if •

ESD Depressurizing Button (HS-G590C) was activated and

•

UV-G423A, UV-G423B (ESD Valves) are closed and

•

UV-G301B, UV-G699A (Isolation Valves) are closed and

•

UV-G597A (ESD Valve Sweet Gas to B.L.) is closed and

•

ESD local Button (HS-G590A) or ESD Control Room Button (HS-G590B) activated (Signal "Shut Down 2S" of Section Sales Gas to B.L. exists)

or •

EDV-Ident-Nr.

After a time delay (20 sec.) and Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

167 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

•

ESD local Button (HS-G590A) or ESD Control Room Button (HS-G590B) activated (Signal "Shut Down 2S" of Section Sales Gas to B.L. exists)

6.3.4

ESD General Functions

6.3.4.1 1.

ESD Level 0. Plant Shut Down In case an Emergency Situation in whole plant is indicated at Control Room Panel or is reported by Plant Operator, Control Room Operator and Plant Operator begin with execution of activities of an emergency response plan.

There is one way to activate the ESD Plant Shut Down manually: •

Control Room Operator using ESD Control Room Button (HS-G001A)

Once the ESD is activated the whole plant is blocked in. After blocking in Plant Operator with Control Room Operator decide further steps e.g. blocking in of individual unit or sections and later Depressurizing / Draining if necessary or switching off individual pumps.

Following valves are closed: •

UV-G101F: ESD Valve GV-101 inlet

•

UV-G102F: ESD Valve GV-102 inlet

•

UV-G103F: ESD Valve GV-103 inlet

•

UV-G560A: ESD Valve Propane to Loading

•

UV-G560B: ESD Valve Propane Balancing Line

•

UV-G520A: ESD Valve LPG to Loading

•

UV-G520B: ESD Valve LPG Balancing Line

•

UV-G520C: ESD Valve LPG Unloading

•

UV-G500A: ESD Valve Gas Condensate to Loading

•

UV-G699A: Isolating Valve Flare Gas to PU06

•

UV-G597A: ESD Valve Sweet Gas to B.L.

(UV-G599A is not closed because of Fuel Gas Supply to Flare etc.) 5.

The activation of ESD performs following further actions: •

Signal to Dehydration Unit (PU-03) (e.g. switch off Regeneration Heater)

•

Signal to Propane Refrigeration System (PU05) (e.g. switch off internal pumps, close internal valves)

•

Signal to Heat Media Unit (PU07) (e.g. switch off Heat Media Pumps and Heater)

•

Signal to Unit Loading Station (PU-13) (e.g. Stop Loading, Closing Internal Valves, and Closing Odorisation).

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

168 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Automatic isolation and de-activation of following valves: •

TV-G113D: Temperature Controller Reboiler Return GC-111

•

TV-G408C: Temperature Controller Reboiler Return to GC-401

•

TV-G411C: Temperature Controller Reboiler Return to GC-402

•

TV-G413D: Temperature Controller Reboiler Return to GC-403

•

FV-G207A: Heat Media from GE-207

Following further Measures activates an ESD Plant Shut Down and Actions according to point 4 to 6 above as well: a.

LG-692D: Level Switch GV-692 SHHH and LG-692E: Level Switch GV-692 SHH (2 of 2) Or

LG-699C: Level Switch GV-699 SHH and LG-699D: Level Switch GV-699 SHH (2 of 2) Or

Gas Alarm of Hydrocarbons (AHH 3 of 4) in Instrument Air System Gas Alarm in Instrument Air System performs a Signal to Instrument Air Generation Unit PU09 (e.g. Shut off Air Compressors)

6.3.4.2 1.

Plant Air to Pits In case hydrocarbons are detected in one of the pits, following Emergency Vent Valves will open for pit flushing with plant air:

•

Pit of GV-697: UV-G697A (Emergency Vent Valve Pit GV-697)

•

Pit of GV-694: UV-G694A (Emergency Vent Valve Pit GV-694)

•

Pit of GV-242: UV-G242A (Emergency Vent Valve Pit GV-242)

•

Pit of GV-443: UV-G443A (Emergency Vent Valve Pit GV-443)

Flushing with plant air does not absolve the Plant Operator from responsibility for an air analysis before entering the pit.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

169 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

6.3.5 1.

Gas detection at Heaters and Incinerator respectively In case hydrocarbon emissions are detected at Incinerator (PU02), direct fired regenerator of PU03 or the Heater of PU07 following actions will be caused by the relevant signals: •

Gas detection (2 detectors) at Incinerator of Acid Gas Incinerator Unit PU02 performs a Signal to shut down PU02 (e.g. closing Fuel Gas supply, closing Incinerator Gas supply, switch off Acid Gas Incinerator etc.)

•

Gas detection (2 detectors) at Heater of Dehydration Unit PU03 performs a Signal to shut down PU03 (e.g. closing Fuel Gas supply, switch off Regeneration Heater etc.)

•

Gas detection (2 detectors) at Heater of Heat Media System PU07 performs a Signal to shut down PU07 (e.g. closing Fuel Gas supply, switch off Heater and Heat Media Pumps etc.)

6.3.6 1.

Fire detection Fire detection at Condensate Storage Tank GT-506 performs a Signal to Stationary Fire Fighting System PU20. The decision to feed foam into Tank GT-506 will be taken by the operator.

Fire detection at LPG Off Spec Bullet GV-528, LPG Storage Bullets GV-526A to C Sour Off Spec Bullet GV-530 and Propane Storage Bullet GV-562 perform a Signal to Stationary Fire Fighting System PU20 for starting up sprinkler system of the respective Bullet.

6.3.7

Safeguarding Flow Schemes

Safeguarding Flow Schemes are shown in Appendix 14.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

170 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Safety 7.1

Chemicals Properties and Hazards For hazardous media in the plant safety data sheets are provided, showing physical and chemical identification, composition, properties, hazards identification, first aid and fire fighting as well as accidental release measures, exposure controls, notes for handling and storage. 7.1.1

H2S and CO2 Human Body Concentration Exposure

Hydrogen sulfide is a highly toxic gas. At very low concentrations irritation of the eyes, nose, and throat is possible. The human nose can detect hydrogen sulfide in concentrations as low as 0.02 ppmv. However, the human sense of smell cannot be relied on to detect hazardous concentrations of hydrogen sulfide. Higher concentrations and extended exposure to hydrogen sulfide will desensitize the sense of smell. The concentrations required for different reactions by the human body are: 1.

Threshold limit value (TLV) for prolonged exposure: 10 ppmv

Slight symptoms after several hours exposure: 10-100 ppmv

Maximum concentration that can be inhaled for one hour without serious effects, significant eye and respiratory irritation: 200-300 ppmv

Dangerous after exposure of 30 minutes to one hour: 500-700 ppmv

Fatal in less than 30 minutes: 700-900 ppmv and above.

Death in minutes: greater than 1000 ppmv

Hydrogen sulfide is a highly flammable gas and will support combustion in air at concentrations from 4.3 to 46.0 volume percent. Gaseous carbon dioxide is a naturally occurring gas that is 50% heavier than air and is colorless and odorless. CO2 is inactive and therefore non-flammable. CO2 will displace oxygen and can create an oxygen- efficient atmosphere resulting in suffocation. The principal hazard of CO2 is exposure to elevated concentrations. The atmospheric concentration immediately hazardous to life is 10% (volume). Because CO2 is heavier than air, its hazard potential is increased, especially when entering tanks and vessels. 7.1.2

Safety Precautions to Prevent exposure to hazardous Chemicals

The first step prevention injury is the identification of the hazardous chemicals. Although the precise nature of the hazard needs not to be known, this would assist in the choice of the preventive measure to be adopted. How the exposure takes place - inhaled, absorbed through the skin or ingested - is also important. There are several general principles to be employed in industrial hygiene and occupational health to decrease exposures. Education of workers is most vital. The most toxic compound can be put to use if the danger is known and sufficient precautions are taken. It is enough for a worker to know what work practices are recommended because unless the reasons are understood, the worker may intentionally deviate from these practices to save time or trouble.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

171 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

The first requirement of safety training is through the recognition of danger. Most chemicals are toxic to some degree and care in handling all types of chemicals should be a routine practice. Misrepresenting or underestimating a particular danger leads to carelessness accidents. Specific information in the safety training of employees includes methods of determining an exposure or release of a chemical. This determination may be the result of periodic monitoring done by the employer or the use of continuous monitoring systems. The employee must understand the physical and health hazards associated with the agent(s) in question. From a preventive viewpoint, employees must be trained to understand the elements of good hygiene to minimize exposure to, and therefore ill effects from, chemicals. Personal protective clothing, emergency procedures, containment systems, and other means of reducing contact with the chemical should be understood by the employee.

7.1.3

Personal Protective Devices

Chemical protective clothing is designed to protect the skin from exposure of gaseous, liquid and particulate chemical hazards. It includes gloves, boots, aprons and full body protection. Filtering systems are available for non-toxic dust, organic vapors, acid vapours, carbon monoxide, etc. In the selection of a system, it is essential to be certain that the particular contaminant will be effectively filtered by the device. Protection of the eyes and face is also necessary. The protection needed depends on the job operation being conducted, materials involved and the severity of the eye or face injury that could result. The most common types of eye and face protective devices include spectacles, spectacles with side shields, goggles and face shields. Workers wearing contact lenses should avoid chemical atmospheres. These lenses may trap and increase the duration of chemicals in the eyes. Workers should be instructed to remove contacts immediately if there is redness of the eye, blurring of vision, or pain in the eye. Protective footwear is also necessary.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

172 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

7.1.4

Protective Practices

No strict separation should be made between protective practices and devices. Either one or the other may be of predominant importance in a given situation. Protective practices according to Risk Exposure:

RISK

PROTECTIVE PRACTICES Maintenance Staff Have to be properly authorized to start up electrical equipments and operate or maintained it. During maintenance installing locks on circuit breakers and disconnecting switches so that the equipment cannot be operated until the lock is removed (Lockout) Install signs or warning labels attached to an isolating device to warn others not to operate the tagged equipment (Tagout) Maintenance personnel have to use head protection, eye shields, gloves, sleeves and dielectric boots.

Electricity

RISK

PROTECTIVE PRACTICES

Falls and/or Blows

Fire and/or Explosion

EDV-Ident-Nr.

Use chemical-resistant safety boots. Avoid to run in stairs and to jump from high parts. Verify that the floor is frees of oil or any slippery substance. Maintain cleared the areas of execution of the activity

Test the presence of gases in the area with explosive meter. Accept the indications of classification of dangerous areas. Avoid the use of matches, lighters or other devices that produce sparks Avoid sparks produced by metal rubbing

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

173 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

RISK

PROTECTIVE PRACTICES Avoid to open drainage valve before taking the necessary precautions Avoid touching any pipe or equipment, unless the certainty that is not warm.

Temperature

Use ear protection.

Noise

Chemicals

7.1.5

Avoid chemicals spill. Use the personal protective equipment according to the indications provided in the work area (e.g. Liquid splash-protective suit and chemical splash goggles)

Safety Data Sheets

The Material/Safety Data Sheets of the chemicals used in the plant are collected in Appendix 7: The following hazardous media are handled in the plant: Activated Charcoal: used for removal several impurities from rich amine solution in unit 200. Antifoam: Antifoam agent is added to the amine solution in Unit 200 to avoid foaming of the amine solution Corrosion Inhibitor: added for corrosion protection. Diesel: fuel for engines in the Fire Water Pump Station, PU-08, Unit 780 and the Diesel Engine Generator PU-17, Unit 800 Foaming agent: for producing fire fighting foam by mixing with Fire Water Glycol: Tri Ethylene Glycol or TEG for Hydrate-prevention

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

174 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Methanol: Methanol is added to unit 100 and 300 to avoid blockage of equipment or pipelines by formation of hydrates Odorant: Ethyl Mercaptan / Tetrahydrothiophane. To add an unpleasant odor as a safety measures to an odorless material such LPG Product. Heat Medium: Thermal Oil: Shell Thermia B, used in all reboilers except Depropanizer. Used for heat tracing where applicable. MDEA: Solution of MDEA, 44wt%, in Demin-Water. MDEA-solution, rich: Solution of MDEA, 44wt%, in Demin-Water, with absorbed H2S and CO2 MDEA-solution lean: used as aqueous solution (approx. 45 wt.%) in unit 200 for removal of H2S and CO2 from natural gas. Sour gas: Gas containing undesirable quantities of hydrogen sulphide and/or carbon dioxide. Containing approx. 0,5 wt%, 0,25 vol.% H2S. Sweet Gas: Gas which has no more than the maximum sulfur and/or CO2 content defined by the specifications for the sales gas from the plant. Acid Gas: The hydrogen sulfide and/or carbon dioxide contained in gas streams from: the top of the Amine Regenerator GC-202, incinerated to SO2 in the Incinerator, PU-02, Unit 260. It is mainly H2S/CO2 : 12/80 wt%; saturated with water. SO2: Occurring in the Incinerator, PU-02, Unit 260, transformed to gypsum in the Acid Gas Treatment, PU-19. Propane: produced in the Depropanizer GC-403 , Stored in the Propane Storage Bullet GV562; used as Refrigerant in the Refrigeration System PU-05, Unit 670 Triethylene Glycol: used for dehydration of the natural gas to the required water dew point Emulsion breaker: added to increase the separation of Hydrocarbons and TEG/Water LPG: Predominately butane which is maintained in a liquid state under pressure within the confining vessel. See section I to review quality of LPG. Sales Gas: Treated gas leaving the Plant under specification of H2S; CO2; water and hydrocarbon dew point and Gross Heating Value. See section I to review quality of Sales Gas. Fuel Gas Combustible used for engines, blanketing and purging. See section I to review quality Fuel Gas. 7.2

Emergency Procedures Emergency Response Plan will be defined and provided to the Operating Manual during Detail Engineering.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

175 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Appendices 1.

Process Block Diagram

Process Flow Diagrams

Piping & Instrumentation Diagrams

Process Data Sheets for Equipments and Package Units

Utility Block Diagrams

Utility Balance

Specification of Catalyst and Chemicals

Summary of Operating Conditions of important Equipments

Material Balances of Gas Treatment Plant

10.

Check list for Plant Completion

11.

General Schedule for Initial Start Up Activities

12.

Standard Instructions

13.

Troubleshooting

14.

Safeguarding Flow Schemes

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

176 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Code Project No

12466-01 10011

Document No

177 of 190

Sheet

Revision

Appendix 1: Process Block Diagram

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the Process Block Diagram of the Gas Treatment Plant.

EDV-Ident-Nr.

Code Project No

12466-01 10011

Document No

178 of 190

Sheet

Revision

Appendix 2: Process Flow Diagrams

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the Process Flow Diagrams of the Gas Treatment Plant.

EDV-Ident-Nr.

Appendix 3: Piping & Instrumentation Diagrams Please find below the Piping & Instrumentation Diagrams of the Gas Treatment Plant.

nd Remark: The Diagrams are included in Delivery Package of 2 of March 2007

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

179 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Appendix 4: Process Data Sheets for Equipments and Package Units Please find below the Process Data Sheets for Equipments and Package Units of the Gas Treatment Plant. Remark: The Data Sheets will be delivered later with next revision.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

180 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Appendix 5: Utility Block Diagrams

Please find below the Utility Block Diagrams of the Gas Treatment Plant.

Remark: The Block Diagrams will be delivered later with next revision of Utility Balance.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

181 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

Ausgabe: 02/05 Rev.:01

CFA 1500E

Project No Document No

182 of 190

Sheet

Revision

Appendix 6: Utility Balance

Code

12466-01 10011

Please find below the Utility Balance of the Gas Treatment Plant.

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Remark: The Document will be delivered later with next revision.

EDV-Ident-Nr.

Appendix 7: Specification of Catalyst and Chemicals Please find below the Specification of Catalyst and Chemicals of the Gas Treatment Plant. Remark: The Document will be delivered later again with an updated revision.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

183 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Code Project No

12466-01 10011

Document No

184 of 190

Sheet

Revision

Appendix 8: Summary of Operating Conditions of important Equipments

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the Summary of Operating Conditions of important Equipments of the Gas Treatment Plant.

EDV-Ident-Nr.

Appendix 9: Material Balances of Gas Treatment Plant Please find below the Material Balances of Gas Treatment Plant of the Gas Treatment Plant. The Document will be delivered later again with an updated revision.

EDV-Ident-Nr.

Code

Project No

Document No

Sheet

Revision

SMAGP

1.12466.01 92/2005

12466-01 10011

185 of 190

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Formblatt

CFA 1500E

Ausgabe: 02/05 Rev.:01

Code Project No

12466-01 10011

Document No

186 of 190

Sheet

Revision

Appendix 10: Check list for Plant Completion

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the Check list for Plant Completion.

EDV-Ident-Nr.

Code Project No

12466-01 10011

Document No

187 of 190

Sheet

Revision

Appendix 11: General Schedule for Initial Start Up Activities

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the General Schedule for Initial Start Up Activities of the Gas Treatment Plant.

EDV-Ident-Nr.

Project No Document No

188 of 190

Sheet

Revision

Appendix 12: Standard Instructions

Code

12466-01 10011

Please find below the Standard Instructions for the Gas Treatment Plant.

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Remark: The Document will be delivered later.

EDV-Ident-Nr.

Code Project No

12466-01 10011

Document No

189 of 190

Sheet

Revision

Appendix 13: Troubleshooting

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the Troubleshooting for the Gas Treatment Plant.

EDV-Ident-Nr.

Appendix 14:

Code Project No

12466-01 10011

Document No

190 of 190

Sheet

Revision

Safeguarding Flow Schemes

SMAGP

CFA 1500E

Ausgabe: 02/05 Rev.:01

Formblatt

1.12466.01 92/2005

X:\12466x01\VT\2007_Engineering\Operating Manual\Operating Manual_10011_Rev0.doc

Please find below the Safeguarding Flow Schemes for the Gas Treatment Plant.

EDV-Ident-Nr.