CONTROL & SHUTDOWN PHI R.B - Comment PDF

PROJECT NO.
PROCESS 16-8612
DOCUMENT NO.
GRPU-KRW-00-PROS-PH-001 14 Pages
JASA PERANCANGAN, PENGADAAN, DAN KONSTRUKSI

PEMBANGUNAN PIPA GAS GRISSIK - PUSRI
PROCESS OPERATING, CONTROL & SHUTDOWN

PHILOSOPHY
B 06-Jul-17 Issued for Approval SHD MZQ/IM MR/ASB

A 13-Mar-17 Issued for Review SHD MZQ/IM MR/ASB
PREPD CHKD APVD CHKD APVD
REV. DATE DESCRIPTION
REKIND PERTAGAS
samakan dengan
cover
PEMBANGUNAN PIPA GAS GRISSIK PUSRI
Date:
Doc. No. PROCESS OPERATING, CONTROL & 06-Jul-17
Rev. B
GRPU-KRW-00-PROS-PH-001 SHUTDOWN PHILOSOPHY Page 2 of 14
REVISION TABLE
REVISION NUMBER REVISION NUMBER REVISION NUMBER

PAGE PAGE ATTACHMENT
A B
1 x
2 x
3 x
4 x
5 x
6 x x
7 x x
8 x x
9 x x
10 x x
11 x x
12 x
13 x
14 x x
Date:
Rev. B
RECORD OF REVISION
NO. PAGE SUBJECT DESCRIPTION OF CHANGE REV.

1 6 Wording Add word shutdown B
2 8 Flowrate Change from 126 MMscfd to 149.19 MMscfd B
3 7-11 Process control narrative More detail in process control narrative B
4 11 Wording Add word commissioning procedure B
5 14 Wording Add LBCV area B
Date:
Rev. B
TABLE OF CONTENT
REVISION TABLE .............................................................................................................. 2

RECORD OF REVISION .................................................................................................... 3
TABLE OF CONTENT ......................................................................................................... 4
1. PROJECT OVERVIEW ............................................................................................... 5
2. OBJECTIVES.............................................................................................................. 5
3. REFERENCE ............................................................................................................... 6
4. SCOPE ........................................................................................................................ 6
5. DEFINITIONS ........................................................................................................... 6
6. ABBREVIATIONS...................................................................................................... 7
7. PROCESS CONTROL AND MONITORING NARRATIVE ....................................... 7
7.1 GRISSIK FACILITY .................................................................................................................. 7
7.2 PIPELINE ............................................................................................................................. 8
7.3 PUSRI RECEIVING FACILITY EQUIPMENT....................................................................................... 8
8. OPERATION MODE ................................................................................................ 11
8.1 GAS PIPELINE START UP ..................................................................................................... 11
8.2 GAS PIPELINE NORMAL OPERATION ....................................................................................... 11
8.3 PIGGING OPERATION ............................................................................................................ 11
9. SHUTDOWN PHILOSOPHY ................................................................................... 12
9.1 SHUTDOWN ....................................................................................................................... 12
9.2 OVERPRESSURE PROTECTION DOUBLE SDV IN PUSRI .................................................................... 13
9.3 PIPELINE RUPTURE .............................................................................................................. 14
9.4 FIRE AND GAS DETECTION SYSTEM .......................................................................................... 14
Date:
Rev. B
1. PROJECT OVERVIEW
PT Pertamina Gas (Pertagas) plans to build new pipeline to support the plan of gas distribution for
fertilizer, by delivering gas sourced from Grissik Processing Plant heading to Pusri Plant at Palembang.
A pig launcher will be installed in Conoco Phillips area and power source especially for RTU will be
provided via solar cell. This pig launcher will be designed for intelligent pig. Liquid drain from pig
launcher will be collected using dedicated portable drum. Gas driven system will be provided to
operate SDV and fusible plug for fire detection.
The project location is the construction site of the new gas pipeline. Pictures of these locations can be
seen on the following map. Pipeline planned through 3 (three) route, i.e. Right of Way (ROW)
ConocoPhillips, ROW Pertagas and ROW Jalan Raya Palembang-Jambi. About 70 MMSCFD (Future 126
MMSCFD) gas will be transfered 176 km via 20 pipeline and LBCV will be installed along this
pipeline.
The pipeline will be protected from corrosion with cathodic protection.
Instrument air will be used for SDV and control valve at Pusri area. Out of the fence of Pusri area
there are receiving facilities that consists of Pig Receiver, Slug Catcher, Air Instrument Receiver, Fire
B
Fighting devices and Gas Metering (ultrasonic type) will be constructed. Drain from the receiving
facility will be disposed periodically by vacuum truck. Venting from the facility will be routed to safe
area. The required electrical power, fire water and instrument air will be supplied from PT Pusri
fertilizer plant.
2. OBJECTIVES
The intents this document is to provide the Process Operating, Control and Shutdown Philosophy for
Pipe Gas Grissik-Pusri Project. This philosophy is to be read in conjunction with the Process Flow
Date:
Rev. B instrumentation
GRPU-KRW-00-PROS-PH-001
diagram SHUTDOWN PHILOSOPHY Page 6 of 14
Diagrams, Piping and Instrument Diagrams, and other referenced documents listed in Table 3.1 which
were prepared as part of this project.
3. REFERENCE
Table 3.1 References Document
No. Document Number Description

1 GRPU-KRW-00-PROS-DB-001 Process Design Basis
2 GRPU-KRW-00-PROS-PID-001 P&ID Metering Area Conoco Phillips Grissik
3 GRPU-KRW-00-PROS-PID-002 P&ID Pig Launcher
4 GRPU-KRW-00-PROS-PID-003 P&ID LBCV Sectional Block Valve
5 GRPU-KRW-00-PROS-PID-004 P&ID Pig Receiver Area Pusri
6 GRPU-KRW-00-PROS-PID-005 P&ID Slug Catcher Area Pusri
7 GRPU-KRW-00-PROS-PID-006 P&ID Metering Area Pusri
8 GRPU-KRW-00-PROS-PID-007 P&ID Instrument Air System Area Pusri
B
4. SCOPE
This document describes the process operating, control and shutdown philosophy of the following:
1. Gas Pipeline-Start up.
2. Gas Pipeline-Normal Operation.
3. Pigging Operation.
For the purposes of clarity, this document should be read with reference to the project PFD and
P&IDs.
5. DEFINITION
In this specification, the following words and terms shall have the meanings as stated below, unless
as noted differently.
PROJECT JASA PERANCANGAN, PENGADAAN, DAN KONSTRUKSI PEMBANGUNAN
PIPA GAS GRISSIK PUSRI
CLIENT PT PERTAMINA GAS (PERTAGAS) as a CLIENT of the PROJECT.
CONTRACTOR Consortium PT REKAYASA INDUSTRI and PT WAHANAKARSA SWANDIRI as
a CONTRACTOR of this PROJECT.
VENDOR/SUPPLIER A company providing specific materials of services required for the
construction of the facility.
DITJEN MIGAS Representatives from the Indonesia Government which is responsible for
issuing licences and permits of oil and gas facilities.
Date:
Rev. B
6. ABBREVIATIONS
DBB Double Block and Bleed
DCS Distributed Control System
ESD Emergency Shutdown
F&G Fire and Gas
FEED Front End Engineering Design
LBCV Line Break Control Valve
MMSCFD Million Standard Cubic Feet per Day
PCS Process Control System
PFD Process Flow Diagram
P&ID Piping and Instrumentation Diagram
7. PROCESS CONTROL AND MONITORING NARRATIVE difference

7.1 Grissik Facility
At Grissik, only a pig launcher and SDV installed there. There is no different pipeline rating between
Conoco Phillips and Pertagas Pipeline. Sales gas exported from Conoco Phillips Gas Processing
Facilities piping up to tie-in point in the outlet Sales Gas Metering has been designed with 600# rating
to withstand for the maximum pressure of 1120 psig at temperature 188F, meanwhile PERTAGAS 20"
pipeline designed for capacity of 149.19 MMSCFD total capacity (including 126 MMSCFD to Pusri) and
1060 psig. The process control and monitoring at Grissik facility is detailed as follows:
a) Pressure.
Pressure Switch High-High and Low-Low will detect overpressure or leak of gas incoming from
ConocoPhillips gas plant. The PL-PSHH-101 and PL-PSLL-101 will send pneumatic signal to close
the PL-SDV-101 at upstream the Pig Launcher. SDV and adjacent system are provided by vendor.
Set pressure of PL-PSHH-101 and PL-PSLL-101 refer to GRPU-KRW-00-PROS-PID-002 P&ID Pig
Launcher.
In case of fire, the fusible plug will melt down and the pressure inside the fusible loop will drop,
released to atmosphere, this will also trigger the PL-SDV-101 to close. When fusible plug melts,
gas supply from pipeline to PL-SDV-101 actuator will be blocked automatically by using PCV.
Venting is routed to safe location. A local control panel placed in this area.
Pressure inside Pig Launcher is monitored via PL-PG-102 and PL-PG-103 locally.
Pressure in pipeline is monitored from PL-PG-101 (locally) and PL-PI-101 that can be seen in
control room through Remote Terminal Unit (RTU).
The opening/closing of PL-SDV-101 is monitored in control room via PL-ZIC-101 and PL-ZIO-101,
transmitted from RTU.
Date:
Rev. B
b) Temperature.
PL-TG-101 is provided sales gas line so that operator can monitor temperature locally.
c) Pig Signal
Grissik facility is completed with two pig signals to alert if pig is already launched. Signal will be
given when pig travels through this pig signal, only for local indication. PL-XI-101 is installed in
pipeline and PL-XI-102 is installed in Pig Launcher.
7.2 Pipeline
Twelve (12) LBCV packages are installed along pipeline from Grissik to Pusri for overpressure and gas
leak/rupture protection. The process control and monitoring at pipeline is detailed as follows:
a) Pressure.
B Low-Low and High-High Pressure Switch (BV-PSHH-X01 & BV-PSLL-X01, with X = 01 to 12) will not
activate Emergency Shutdown (ESD), they will trigger only the consecutive LBCV to close (BV-
LBCV-X01). Set pressure of BV-PSHH-X01 and BV-PSLL-X01 (with X = 01 to 12) refer to GRPU-
KRW-00-PROS-PID-003 P&ID LBCV Sectional Block Valve. In addition in case of fire, pressure loss
at fusible loop BV-FL-X01 (X = 01 to 12) also will trigger consecutive LBCV to close. Fusible plug is
released to atmosphere. When fusible plug melts, gas supply from pipeline to BV-LBCV-X01
actuator will be blocked automatically by using PCV. Venting is routed to safe location.
BV-PG-X01 and BV-PG-X03 is provided adjacent to LBCV to monitor the pressure locally.
BV-PG-X02 is installed in vent line to monitor pressure during venting.
b) Pig Signal
BV-XI-X01 is installed adjacent to LBCV to alert if pig is already passes through. Signal will be given
when pig travels through this pig signal, only for local indication.
7.3 Pusri Receiving Facility Equipment
Pusri Receiving Facility has independent DCS. Double SDV installation is provided to protect Pusri area
facilities from incoming overpressure from ConocoPhillips. Process equipment can be monitored and
controlled locally or remotely from this DCS. All the supervisory signals from process equipment,
manual shutdown and F&G actions will be sent to DCS.
A stand-alone Emergency Shutdown System (ESS) will be provided.
7.3.1 Pig Receiver.

Pig Receiver is used to receive pig during pigging. The process control and monitoring at pig receiver
is detailed as follows:
a) Pressure.
PR-SDV-101 installed upstream pig receiver is provided to protect Pusri facility from over pressure.
PR-PT-101 will send command to close PR-SDV-101 when High-High or Low-Low pressure
Date:
Rev. B
condition occur. Set pressure of PR-PAHH-101 and PR-PALL-101 is shown in GRPU-KRW-00-PROS-

LIST-003 Instrument Set Point List. Pressure also can be monitored through DCS by PR-PI-101.
Open and close indication of PR-SDV-101 is also shown in DCS (PR-ZIO-101 and PR-ZIC-101).
Pressure in pipeline downstream PR-SDV-101 can be monitored in DCS from PR-PI-102 and also
locally via PR-PG-101.
Pig Receiver is equipped with PR-PG-102 and PR-PG-103 to monitor pressure inside Pig Receiver
locally during pigging activity.
B
b) Temperature.
Temperature in gas line from pig receiver to slug catcher can be monitored in DCS by PR-TI-101.
c) Pig Signal.
Pig Receiver is completed with two pig signals to alert if pig is already received. Signal will be given
when pig travels through this pig signal, only for local indication. PR-XI-101 is installed in pipeline
and PR-XI-102 is installed in Pig Receiver.
7.3.2 Slug Catcher

Slug catcher is used to collect slug at the outlet of pipelines. Process control and monitoring at slug
catcher is detailed as follow:
a) Pressure
Pressure to Slug Catcher is controlled from pressure control valve SC-PV-101A/B. Control valves is
2x100% service. SC-PV-101A (electric type) is controlled from SC-PIC-101A while SC-PV-101B
(pneumatic type) is controlled from SC-PIC-101B.
Slug catcher is protected from over pressure by SC-PT-102 installed upstream the vessel to close
B PR-SDV-101 and M-SDV-101AB when high-high or low-low alarm occurs. These alarms set point
are shown in GRPU-KRW-00-PROS-LIST-003 Instrument Set Point List.
Pressure inside Slug Catcher is monitored from SC-PI-103, high pressure alarm will alert operator
in control room.
Bypass line across Slug Catcher is completed with strainer. For monitoring pressure drop across
this strainer, SC-PDI-101 with high alarm can alert operator in control room.
The outlet liquid stream pressure indicator SC-PG-102 is provided to indicate the liquid pressure to
warn the operator before draining liquid from slug catcher.
b) Temperature
set point jangan dimunculkan. refer ke inst
Temperature can be observed locally through
set SC-TG-102.
point table. kalimatnya diganti saja.
c) Level
The level of liquid at slug catcher can be observed locally through SC-LG-101 and from SC-LI-101
which can be read in control room. If the liquid level is more than 30 inch high from bottom of
Date:
Rev. B
vessel then the transmitter SC-LT-101 will send the alarm signal to control room without any
automatic.
7.3.3 Metering System

The Gas Metering system shall contain all the necessary hardware and software functionality to
receive field inputs, perform flow and energy calculations to the required standards, provide
control/analogue and digital outputs and display sufficient information to enable the operator to
monitor the total package fully.
The system is 2 x 100% of integrated Gas Ultrasonic Metering System that will be installed at Pusri
Receiving Facility. Each stream shall consist of:
Multipath Ultrasonic Gas Flow Meter custody meter class complete with upstream and downstream
as compliance with AGA 9 complete with flow profiler at upstream spool to improve the flow
yang terbaca di DCS indikasinya, bukan
profile. transmitternya. contoh: M-FI-101A/B.
Pressure transmitter with pressure tap at meter body for Standard flow calculation
B
Temperature transmitter complete with temperature element PT 100 and bar stock thermowell
a) Analyzer
Indication of gas flowrate (M-FT-101A/B), Pressure (M-PT-101A/B), temperature (M-TT-101A/B),
composition (M-AT-101), Hydrocarbon (M-AT-102), Water content (M-AT-103) and H2S (M-AT-
104) can be monitored through DCS.
b) Pressure
Inlet pressure metering is controlled from control valve M-FV-101A (electric type) and M-FV-101B
(pneumatic type). Control valves is 2x100% service. Inlet pressure metering controlled by M-FV-
101A (electric type), it is triggered by M-PIC-102A which is cascade to M-FIC-101 to achieve 450
psig. Other options, M-FV-101A can also being controlled by selecting either M-PIC-102A or
M-FIC-101 to control, whichever is lower.
Metering is protected from over pressure by double shutdown valve, M-SDV-101A which is
triggered by M-PSHH-101A and M-SDV-101B which is triggered by M-PSHH-101B. At outlet
metering there is M-PT-103 which will close M-SDV-101A/B and PR-SDV-101 if it is triggered.
c) Temperature
Temperature at metering can be monitored in control room by M-TI-101A/B.
d) Valve Opening
Open and close position of valve in metering can be monitored in control room by M-ZSC-
102A/B/C and M-ZSO-102A/B/C.
Date:
Rev. B
7.3.4 Instrument Air System

Pusri receiving facility only installed new instrument air receiver 2-V-004. Instrument air downstream
distributed to gas metering and pig receiver area. The new instrument air receiver is tied in to
B
existing instrument air header.
a) Pressure
Pressure at instrument air receiver 2-V-004 can be monitored locally through IA-PG-401. Pressure
downstream of instrument air receiver is controlled by IA-PCV-401 which is set at 90 Psig.
b) Temperature
Temperature at instrument air receiver 2-V-004 can be monitored locally through IA-TG-401
B
8. OPERATION MODE
8.1 Gas Pipeline Start Up
B
8.1.1 Grissik-Pusri as Pipeline Start Up
Start up procedure will be detailed in the Commissioning Procedure (GRPU-KRW-00-PROS-PRO-004).
In this document will describe general for the start up:
1. Ensure the 16" isolation valve at downstream pipeline Pusri tie-in point in closed position.
2. Ensure the 16" sales gas from Grissik Conoco Philips isolated from PERTAGAS inlet line.
3. Override to open PL-SDV-101 in Departure line of Conoco Phillips in Grissik.
4. Open slowly the bypass globe valve of Conoco Phillips metering outlet control valve at metering
system to pressurize the piping and pipeline to Pusri. Pressurize this line until reaching the
pressure of Pusri pressure at 450 psig.
5. Open isolation valve at downstream pipeline Grissik-Pusri tie-in point and the gas.
8.2 Gas Pipeline Normal Operation
70 MMSCFD produced gas from Conoco Phillips will be transferred to Pusri processing plant. Pressure
for each departure pipeline can be monitored in the field and in the control room of Pertagas South
Sumatera Area (Master Station).
During normal operation, all manual valves to each new Pig Launcher shall be closed to prevent gas
flow to pig launcher.
8.3 Pigging Operation
Launcher and receiver are designed to launch intelligent pig.
A balancing line shall be provided on pig launcher to enable pressurizing of the barrel on both sides
of the pig at the same time. This is to prevent a pig which is ready to be launched from moving either
forward (and thereby hitting and possibly damaging the Pig Launchers valve) or backwards (and
losing the seal in the reducer). To ensure this, the balance line, branching off from the kicker line,
shall be connected to the minor barrel as close as possible to the Pig Launcher valve.
Date:
Rev. B
Pig launcher will be operated manually by operator intervention with the following procedure
that will be detailed in operating procedure:
1. Verify that the all Pig Launcher isolation valve is closed.

2. Verify that the kicker valve is closed.
3. Open the drain valves to drain the Pig Launcher of any residual product.
4. Open the vent valve to assist the Pig Launcher to drain and to verify that the Pig Launcher is
depressurized.
5. Check pressure on the Pig Launcher to verify the Pig Launchers is depressurized.
6. Purge the pig launcher with nitrogen via nitrogen purge connection and check the methane
concentration inside pig launcher and then stop nitrogen purging when minimum allowable
methane concentration achieved.
7. Open the pig launcher enclosure
8. Insert the pig.
9. Close the pig launcher enclosure.
10. Close the manual drain valve and manual vent valve.
11. Slowly open the 2" globe valve on the balance line to pressurize the pig launcher.
12. Leave the 2" globe valve on the balance line open until it has been verified that the pressure in
the pig launcher has equalized with the pipeline pressure, and then close it.
13. Fully open the pig Launcher isolation valve to the pipeline.
B 14. Make sure valve at line to Pusri Slug Catcher is open and the bypass line is closed.
15. Obtain permission to launch the pig from the pipeline control center.
16. Fully open the block valve in the kicker line.
17. Partially close the main line valve to create flow through the launching Pig Launcher. Monitor the
pig signaler and when pig has passed, immediately open the main line valve fully.
18. The Pig Launcher may be left in this condition or if it is to be left depressurized, repeat Step 1
through 6.
9. SHUTDOWN PHILOSOPHY
9.1 Shutdown
Emergency Shutdown (ESD) of the facility is triggered by pressure loss inside fusible loop or manually
activation of local ESD pull button from ESD panel. Both on Grissik and Pusri, shutdown valve can
only be reset from local i.e. field visit is required to clear the trip signal, once the cause of ESD trip is
found and the potential hazard is eliminated. At Grissik, pneumatic type shut-down signal will used to
close the SDV with pressure supplied by gas at pipeline. At Pusri area, electric type shut-down signal
will used to close the SDVs with pressure supplied from new instrument air receiver that connected to
Date:
Rev. B
existing instrument air header. Fire and Gas detectors also provided in this area and in case there is
gas leak or fire happened then the detector will send the shut-down (ESD) signal to close SDVs in this
area. Process Shutdown (PSD) initiated from PL-PSHH/PSLL-101, BV-PSHH/PSLL 0101-1201,
PSHH/PSLL PR-PT-101, PSHH/PSLL SC-PT-102, PSHH/PSLL M-PT-103 and manual push button PSD-
PB-001. Below is the shutdown hierarchy of Pusri receiving facility.
9.2 Overpressure Protection Double SDV in Pusri

There is a different pipe rating between metering Pusri and another receiving facility. Pusri sales gas
exported from Conoco Phillips Gas Processing Facilities has been designed with 600# rating and could
withstand maximum pressure of 1120 psig at temperature 188F, meanwhile metering Pusri with
capacity of 126 MMSCFD has been designed to withstand for the pressure of rating #300, 675 psig.
Hence, protection system needed to ensure that Pertagas facilities in safe manner. Double SDV as
protection system.
Date:
Rev. B
9.3 Pipeline Rupture

Pressure Switch High-High, Low-Low and SDV is installed on each LBCV (Line Break
Control Valve) each 16 km along the pipeline for gas leak/rupture protection. In the event of
low-low pressure or high-high pressure, the pressure switch will close the consecutive SDV
respectively. Rupture is noticed by PSLL in each LBCV (BV-PSLL-X01).
Low-Low and High-High Pressure Switch (BV-PSHH-X01 & BV-PSLL-X01,with X= 01 to 12)

will not activate Emergency Shutdown (ESD), they will trigger only the consecutive LBCV to
close (BV-LCBV-X01).
The LBCV will close in consecutive if there is a pipeline rupture in the middle of pipeline. In
case of fire around LBCV, pressure loss at adjacent fusible loop BV-FL-X01 (X= 01 to 12) will trigger
consecutive LCBV (BV-LBCV-00X, with X= 01 to 12) to close.
9.4 Fire and Gas Detection System
At Grissik area and LBCV area, fusible plug will be installed as fire detection system that will activate
B
Emergency Shutdown (ESD) of launching facility. Since there is no fire water system available at
Grissik, then portable fire extinguisher will be provided as Fire Fighting system. Different system
takes place in Pusri area, fire gas detector will trigger Emergency Shutdown System to take action to
isolate the service fluid.

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PROJECT NO.

JASA PERANCANGAN, PENGADAAN, DAN KONSTRUKSI

PROCESS OPERATING, CONTROL & SHUTDOWN

B 06-Jul-17 Issued for Approval SHD MZQ/IM MR/ASB

PEMBANGUNAN PIPA GAS GRISSIK PUSRI

REVISION NUMBER REVISION NUMBER REVISION NUMBER

NO. PAGE SUBJECT DESCRIPTION OF CHANGE REV.

REVISION TABLE .............................................................................................................. 2

No. Document Number Description

7. PROCESS CONTROL AND MONITORING NARRATIVE difference

7.3.1 Pig Receiver.

condition occur. Set pressure of PR-PAHH-101 and PR-PALL-101 is shown in GRPU-KRW-00-PROS-

7.3.2 Slug Catcher

7.3.3 Metering System

7.3.4 Instrument Air System

1. Verify that the all Pig Launcher isolation valve is closed.

9.2 Overpressure Protection Double SDV in Pusri

9.3 Pipeline Rupture

Low-Low and High-High Pressure Switch (BV-PSHH-X01 & BV-PSLL-X01,with X= 01 to 12)

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