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REGASIFICATION TERMINAL
Doc. No. : H-FALR-23-1230-001-A
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PT PERTAMINA (PERSERO)
PROJECT TITLE :
LOCATIONS
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31-May-11
FE
IRA
ADN/AB
27-May-11
FE
IRA
ADN
20-May-11
FE
IRA
ADN
09-May-11
FE
IRA
ADN
REV
DATE
DESCRIPTION
PREPARED
CHECKED
APPROVED
TABLE OF CONTENT
SEC. TITLE
PAGE
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1.
2.
3.
4.
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INTRODUCTION.........................................................................................................................3
PROCESS DESCRIPTION...........................................................................................................3
REFERENCE DOCUMENT.........................................................................................................4
OVERALL DESCRIPTION..........................................................................................................4
4.1 SHIP BERTHING/ARM CONNECTION............................................................................4
4.2 SHIP UNLOADING.............................................................................................................4
4.3 LNG STORAGE TANK.......................................................................................................6
4.4 BOIL-OFF HANDLING......................................................................................................9
4.5 VAPORIZER AND SEND OUT SYSTEM........................................................................11
4.6 HOLDING MODE (NO LOADING/UNLOADING)........................................................12
5. BLACK START-UP PROCEDURE............................................................................................13
5.1 PURPOSE...........................................................................................................................13
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1. INTRODUCTION
This document presents the black Start UP Scenario for the ARUN LNG RECEIVING HUB &
REGASIFICATION TERMINAL. This philosophy base on availability of existing Arun facilities
especially power management which one will be used for Arun LNG Receiving Hub and
Regasification Terminal .
2. PROCESS DESCRIPTION
The Arun LNG Receiving -Hub & Regasification Terminal is designed to receive LNG
from Tangguh & Badak. The normal production rate is 280 MMSCFD of Send out gas
and expandable to 400 MMSCFD.
LNG from LNG ship is transferred to LNG Storage Tank (F-6001/F-6002/ F-6003/F-
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6005) by Cargo Pump. The unloading flow rate is 10,000 m 3/hr and 5,000 m3/hr
with discharge pressure cargo pump is 10 barg.
significantly when unloading due to heat in leak a long pipe, heat loss in motor
Cargo Pump, and LNG Tank. BOG will be out from top of LNG Tank (F-6001/F-6002/
F-6003/F-6005), BOG will be split become two stream, one stream as BOG Return to
ship and another stream flow to BOG Compressor (K-6801A/BC/D). Discharge BOG
Compressor flows to BOG Cooler (E-7501A) to get outlet temperature 33 0C. It is
used as HP Fuel Gas for Power Generator and PDPA (Local Company of Aceh
Province) and PT. PLN. If there is excess HP Fuel Gas, it is will be recompressed by
BOG Booster Compressor (K-2501A) to 52 kg/cm 2g. Discharge BOG Booster
Compressor will be combined with the outlet LNG Vaporizer to reduce load of LNG
Vaporizer and will be sent to customer.
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LNG is pumped by Primary LNG Transfer Pumps (G-2306 A/B) or LNG Transfer Pump
(G-2304A/B/C) to LNG Vaporizer (E-2302A/B/C) with discharge pressure 52 kg/cm 2g.
LNG will be vaporized until 50C by Sea Water Supply from Sea Water Pumps. Then
vapor LNG will be sent to customer and for fuel gas make up if consumption of HP
Fuel Gas is increasing. It is heated by electric heater to get the temperature of fuel
gas is appropriate with specification of HP fuel gas.
The existing equipment will be reused are including:
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4. OVERALL DESCRIPTION
4.1
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Once the ship has been securely moored to the mooring hooks and communications have
been established, the liquid unloading and vapor return arms can be connected. The ship's
transfer piping and the liquid arms will then be cooled down.
4.2
SHIP LOADING/UNLOADING
The Arun LNG Receiving -Hub & Regasification Terminal is designed to loading /
unloading operation.
SHIP UNLOADING
LNG from the LNG Cargo is pumped into the LNG storage tanks F-6001/6002/
6003/6005 using the Cargo Pumps. In support of the target pilot to pilot port turn-
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directed to the storage tanks via 24 two parallel lines, then through 30 headers
serving the LNG storage tanks.
The actual unloading rates are established on level indications in the onshore
storage tanks. 20 storage tanks valves allow balancing the flow into each tank. The
quality of LNG being unloaded is monitored on-line via an analyzer located on the
jetty, whilst additional manual sampling always remains open to further spot-check
the LNG qualities in the plant laboratory. The analysis of incoming LNG is done to
supplement the cargo certificates provided with the incoming CIF (Carriage,
Insurance & Freight) LNG to ensure LNG is placed appropriately into the LNG
storage tanks via top or bottom fill nozzles to avoid roll-over risks.
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Fiscal metering of the quantity of LNG unloaded per LNGC will be done based on
tank-dip surveys of the LNGC.
SHIP LOADING
As Hub Terminal, loading operation is required. Loading operation is
performed by LNG Loading Pumps (Pumps G-6801 A~D/L/M) located in
pump station of each tank group. LNG is pumped from LNG Storage Tanks F6001/2 to Berths 2 by LNG Loading Pumps G-6801 A~D/L/M. Each Loading
Pump has a capacity 2,724 m3/hr and the design loading rate of 10,900
m3/hr is achieved by four loading pumps. The LNG flows to the pumps
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through a 48" header that splits into a 30" branch to each pump. The
discharge from each pump flows through a 20" branch into a 36" header.
Two 30" loading lines connect the Loading Berths to the header.
Three 16" identical arms, each with an Emergency Release Coupling (ERC), are provided
for ship loading/unloading, for LNG transfer from/to the storage tanks. A loading arm V6801C, identical 16" arm, is provided to route displaced gas back from/to the ship. The
maximum loading/unloading rates will be limited to 5,000 m3/h per arm.
Due to the length of the loading/unloading lines and the difference in elevation between the
ship deck and the top of the tank, hydraulic pressure drops through piping systems
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(inclusive of its auxiliaries such as valves, elbows, and strainers) have been reduced as
much as feasible.
At the end of the ship loading/unloading, the LNG will be purged out of the unloading
arms with nitrogen connected at the top of the arm. The LNG is thus driven back into the
ship and into the 24" unloading header from the arm apex and the arm flanges are
disconnected.
Between LNG tanker arrivals, the heat ingress into the loading/unloading lines is removed
continuously by circulating a part of the send-out LNG through the unloading system. The
circulated LNG is preferably sent to the send-out system to avoid extra BOG generation in
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the LNG storage tanks, which would trigger extra duty cycles on the BOG compressors and
thus increase the terminal electricity consumption. The line-up allows also the return of
circulated LNG to the storage tanks. Between two ships unloading, the 16" vapor return line
is also connected to the tank vapor space via the boil-off gas header line.
4.3
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head limit (NPSH limit), and first high level alarm. There is sufficient land area available
to meet the sitting requirements of NFPA 59A.
The storage tanks are of the single containment type. The tanks have a maximum heat
leakage rate of 0.05 % wt per day of the tank contents based on a full tank of LNG.
All fill and withdrawal connections, and all other instrumentation nozzles are top entry
through the tank roof (and suspended deck where relevant). LNG tanks will be equipped
with a top splash plate for distributing the liquid during top-filling operations and an
internally vented standpipe to accomplish bottom filling.
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The tanks F-6001/6002 are connected to 24 boil-off header. This boil-off header is
connected to the boil-off gas compressors K-6801A/B. The tank F-6003/6005 are
connected to 24 boil-off header ant the through the boil-off gas compressor K-6801C/D.
Two boil-off header connected with 30 common header, but normally connection of them
isolation by manual valve. When unloading partly of boil-off gas from F-6003/6005 split to
the vapor return line to the ship via the vapor return blower K-2302A/B, and to the flare
system if overpressure in BOG line.
The boil-off compressors are two-stage, labyrinth piston type electrically driven
compressors. The maximum duty expected from them is for 2 machines running.
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The boil-off gas blowers are single stage dry centrifugal machines driven by electrical
motors. This blower operates during LNG unloading to keep pressure of ship LNG storage.
The tanks have a design pressure of 0.14 kg/cm 2g. The normal vapor space operating
pressures of the LNG storage tanks will range between 0.04 and 0.1 kg/cm 2g, and this
pressure will generally be controlled by selective operations of the BOG compressors.
During LNGC unloading, the tank pressures are assumed steady at a relatively high level
of 0.12 kg/cm2g, whilst the LNG transfer pumps are designed for a steady low vapor
pressure of 40 mbarg. The boil-off gas compressors are designed for the LNGC unloading
operating mode at highest unloading rate of 10,000m3/h with four storage tanks available in
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the Terminal at a relatively high constant pressure, without taking any credit for added
vapor suppression by gradual increase in vapor pressure.
LNG storage tanks are provided with protection systems in order to prevent:
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safety valves (PSVs) at set point 1.173 kg/cm 2A on each tank roof. The overpressure
protection covers a combination of atmospheric pressure drop tank rollover (events
such as which is the design case of the PSV's), etc.
LNG stratification in the tanks. Several precaution have been taken in the design
in order to reduce the possibility of rollover considerably, such as the choice to top and
bottom-fill mode together with an extensive temperature / density measuring, a regular
renewal of tank contents, and the option to circulate LNG within the storage tanks (via
local circulation).
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Vacuum conditions in the storage tanks are prevented initially by tripping the
on-line boil-off gas blowers and BOG compressors, followed by a small injection of
high pressure gas in the common boil-off gas header. The ultimate protection of the
tanks against vacuum is effected by recycling the LNG pumps on their kickback and
finally by a minimum of (4) air vacuum breakers at - 50 mmH2O.
Pump and piping configurations allow for individual tank mixing. Nitrogen injections
arrangements in the tank as well as vent lines are provided for tank drying, purging and
inerting. A cool-down spray ring is provided to initially cool-down the tank to put in
service or to precondition the tank prior to tanker unloading.
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BOIL-OFF HANDLING
SHIP UNLOADING
Filling of LNG into tank, each tank has a capacity of 127,000m 3 (800,000 bbl) is to be top
filling to cool down boil off gas regardless of tank liquid level, loading or no-loading
operation. During filling operation necessary to control the filling rates to each tank by
adjusting valves on laterals to each tank, observing increase rate of tank level.
During ship unloading, the level in the on-shore storage tanks increases causing a vapor
displacement. Simultaneously, the level in the ship cargo tanks decreases at the same rate,
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causing a negative displacement effect and therefore a pressure drop into the ship's cargo
tank.
To prevent vacuum in the ship's cargo tank, a part of the vapor displaced in the storage tanks
is sent back to the ship by means of vapor return blowers K-2302A/B through the boil-off
header and MBOG Quenching Vessel D-6804, the 16 vapor return line and the vapor return
arm V-6801C.
A LNG atomizer is incorporated in the vapor return line. This facilitates is used to cooldown of temperature vapors at start of return gas flow. When the main steady state return
flows are established, this atomizer ensures that gas returned to the ship can be maintained
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at a temperature not warmer than -130C. Excess injected liquid is trapped in the jetty
Blowdown drum D-6802, which can also be used for quick draining of one transfer arm in
case of leakage problems.
BOG production increase significantly when unloading due to heat in leak a long pipe, heat
loss in motor Cargo Pump, pressure drop of control valve and from LNG Tank. BOG will be
generated and released to top of LNG Tank. The maximum BOG produced is 65 MMSCFD
(54.3 ton/hr), it will be split in two streams, one stream as BOG return to ship (25
MMSCFD) and another stream sent to BOG Compressor (K-6801 A/B/C/D) which is
condition 2 (two) BOG Compressor running parallel to handle BOG. Discharge BOG
Compressor flows to BOG Cooler (E-7501 A) to get outlet temperature of 33 0C. it is used
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as HP Fuel Gas for Power Generator (PG) and PDPA (Local Company of Aceh Province)
and PT. PLN. If there is excess HP Fuel Gas, it will be recompressed by BBOG Compressor
will be combined with the outlet of LNG Vaporizer to reduce load of LNG Vaporizer Excess
boil-off gas in the LNG tanks is handled by the boil-off compressors K-6801A/B/C/D and
will be sent to fuel gas system.
NORMAL OPERATION
During normal operation (no ship unloading), boil-off from the storage tank (F6001/6002/6004/6003/6005) is compressed by one of boil-off gas compressor K6801A/B/C/D because total production BOG maximum 12 MMSCFD (9.8 ton/hr). Then
compressed gas is sent to the high pressure fuel gas system. This gives the terminal operator
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the freedom to run a single compressor continuous in part-load condition, or to lower vapor
pressures at times of cheaper electricity and minimize running the compressors at day time.
The pressure in the storage tank is controlled by operations of the boil-off compressors.
Compressed excess vapors are sent to fuel gas system.
MINIMUM SEND-OUT OPERATION
The minimum send-out will be 70 MMSCFD. This rate allows for boil-off recompression
and for running one of Primary LNG Transfer Pump (G-2306A/B).
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BOIL-OFF COMPRESSOR
Four boil-off compressors K-6801A/B/C/D are provided for the boil-off handling. During
LNG unloading two BOG compressors are to be operated to cope with the maximum boiloff gas amount 33.5 ton/hr and other for standby. If one of the compressors is trip, then the
standby compressor will be operates manually.
Each compressor with a rated flow rate of 20,820 kg/h is provide to compress LNG boil-off to 16.5
kg/cm2, to be necessary for delivered to the high fuel gas system. Actual amount of boil-off will be
depended on the operating mode.
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The compressor is provided with an anti surge control system which protects the machine
from surging by recycling vapor to the vapor space of the LNG storage tanks. This vapor is
quenched with LNG to be sprayed into the vapor recycle line upstream of the storage tanks
using a series of five LNG atomizing nozzles. Excess gas from the compressor is sent to the
high pressure fuel gas system through FV-6826C. Marine Flare pilot and purge gas is
supplied via 2" line from compressor discharge or from reverse flow from the high pressure
fuel gas system. Quenching LNG is supplied from discharge header of the loading pump or
the circulating pump which is on duty depending on the operation mode.
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group which is will be using for HUB terminal. G-2304A will be used if LNG stock from F6003/6005 was limited. A minimum flow bypass line is provided for each pump, the
discharges of which are tied into one common 16" intertank transfer line.
The small foot plinth also assists in minimizing the size of the noise shelter & crane
structure over the booster pump station. The suction header in the LNG transfer pump
station is prepared for a parallel operation of 2 LNG transfer pumps and 2 Primary LNG
Transfer Pump to achieve the maximum daily send-out rate of 400 MMSCFD.
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These pump sets are provided with individual vent pots to release the vapor from pump and
the vapor from the pots is sent back to the individual tank on level control. This line ties into
the boil-off gas recycle line, discharging into the top of the tank above the liquid level.
The gas produced by the vaporizers will split partly to fuel gas system/new costumer
(PDPA) and the fertilizer plants. The gas produced by vaporizers before sent to fuel gas
system and PDPA, it pass through a fuel gas heater E-2303 to maintain temperature as per
fuel gas specification. Then to the fertilizer plants pass through inlet facilities line and gas
metering system before being conveyed to the gas pipeline. There will be a back pressure
controller before the gas metering system to maintain a constant pressure to customer. The
gas metering system consists of three parallel metering lines (one in stand-by). An on-line
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gas chromatograph for analyzing the gas composition is included within the gas metering
system.
Send out gas that is used within for the terminal, will be taken downstream of the LNG
vaporizer. The gas pressure is reduced before supplying it to the LNG storage tanks for
intermittent make-up as required.
The Terminal is able to adjust its high pressure LNG send-out rate between minimum sendout and maximum send-out by increasing or decreasing as required the number of parallel
operational pumps and vaporizers, and use minimum flow re-circulation loops as required
to trim actual flows. All these send-out capacity changes will be controlled through the PCS
system.
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At times of zero send-out (except when suffering from a prolonged black-out) most
cryogenic line-work in the Terminal will be kept cold via circulation loops from the LNG
tanks to LNG jetty and process area with LNG circulation pumps.
4.6
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Normally, for the existing berth 2 loading line, cold circulation is performed by one
circulation pump out of two in the first tank group pump station, G-6802A or B. For the
loading line from F-6005 pump station, cold circulation is performed by one circulation
pump out of two in F-6005 pump station, G-6802C or D, and for the loading line from F6003 pump station to the loading lines from F-6005 pumps, one circulation pump will be
used installed in F-6003 pump station, G-6802E.
At zero send-out, no liquid is available for regasification of boil-off in the LNG vaporizers
and the compression system will not be able to accommodate the boil-off gas produced in
the terminal. This implies that vapor pressures within the Terminal will gradually rise, and if
this situation prevails for a longer period (of a few hours) the boil-off is then let-off to the
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vent system under pressure control. As this situation conflicts with the adopted no venting
philosophies zero send-out should normally be avoided, and only be accepted for
exceptional circumstances, such as a persistent pipeline problem, or a longer black-out.
5.
5.1
PURPOSE
The purpose of this document is to describe a general philosophy for the initial start-up
of the Arun LNG Receiving Hub Regasification terminal facilities. Detailed
commissioning and start up packages will be developed with the project team during
detailed design and upgraded during construction. It also describes the start up of
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the facilities following a total plant shutdown and blowdown with the facility
only on emergency power generation, which is referred to as "black start". The
black start procedure is usually completed just before start up. Training and
verification on the procedure takes place during final commissioning of the systems.
The sequence of activities and details of commissioning will be determined during
detailed design. The anticipated duration of each activity will also be defined during
this phase in conjunction with equipment vendors, operations and commissioning
personnel.
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02021 A
Conform diesel fuel available for Emergency Power Generator, Diesel Engine at
PG-9001A and Diesel fire Water Pump.
2.
Conform that Power always available for small LNG pump in order to run the
pump and Ambient vaporizer ready for operation.
3.
Confirm fire water pond filled by Well Water Pump with raw water
4.
Conform all safety equipment include PSV, emergency relieve valve, etc at
condition ready for operation if overpressure condition happen.
5.
Conform all ESD system at stand by condition and ready for operation, PSD will
action if deviation un control process happen caused and reach limit high-high or limit
low-low signal activated the process shut down. ESD will activated if un control
process happen and to avoid hazard condition caused of overpressure, badly leakage,
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02021 A
environmental problem, etc by isolate inlet and outlet hydrocarbon, isolate heat
sources (Electric heater, evaporizer , etc), stop critical equipment by activated ESD
from push button in the control room. Detail explanation about ESD refers to ESD
Philosophy.
6.
Conform that Marine flare stack ready for operation with fuel gas from LNG
Back-up pump G-2305 and LNG Back-up Vaporizer E-2304A/B
7.
Commissioning gas purge to flare header and make sure flare header in positive
pressure and ready for receive gas.
8.
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9.
02021 A
10.
Ensure that power available for supply power for LNG Back-up pump and get
fuel gas system from Ambient vaporizer.
11.
Line up the system ,and start to run LNG Back-up pump G-2305
12.
13.
Start LNG Circulation pump and BOG compressor for continuous fuel gas
supply to Power Generation A, then stop Emergency Power Generator.
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14.
02021 A
Conform Plant Fire Protection include Fire Water system and F&G detector are
in operation.
15.
16.
Utility Units include Air system, Fire Protection systems, Fuel gas conditioning
include fuel gas electric heater, Power generator, Diesel system, Sea Water Cooling
system and Flare system are in operation.
17.
Conform Sea Water line and pump available and ready for operation
18.
Start Sea Water Pump and circulating line to LNG Vaporizer until operating
condition
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19.
02021 A
Start LNG Circulating Pump to cooling down all LNG line gradually to
operating condition.
20.
Starts pressurize BOG Compressor System until reach suction operation pressure of
BOG compressor used manual by pass valve slowly (keep pressure stable by venting
to flare by pressure control if pressure increased suddenly)
21.
Start sealing gas for BOG compressor, lube oil pump, then make sure seal gas and
lube oil system on stable condition
22.
Start BOG Compressor with follow the step chart of BOG compressor start up and
make sure anti surging valve working well.
23.
Conform fuel gas supply to Main Power Generator A and to flare are in normal
condition and under control.
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24.
02021 A
Conform LNG Transfer pump and line ready to operation after cooling down to
normal operating condition.
25.
Start LNG Transfer Pump to LNG vaporizer to produce Gas for Client and ensure
continuous flow fuel gas to Power Generation.