1

PROCESS SHUTDOWN PHILOSOPHY FOR

BALANCE OF PLANT

PT PUPUK INDONESIA ENERGI

GRESIK GAS COGENERATION PLANT PROJECT
CONTRACT NO : 010/SP/DIR/XI/2015
PROJECT CODE : P-6001
JOB NO

: 781502

DOC NO

: GGCP-00-P0-ES-009-PP

PURPOSE

: ISSUED FOR APPROVAL

CONTRACTOR

PT PP (Persero) Tbk DIVISI EPC

CONSULTANT

PT Rekayasa Engineering
REV.
NO.

DATE

DESCRIPTION

PREPARED

CHECKED

APPROVED

12/10/2016

Issued for Approval

ANG

SAW

GWN/FIA

FP

8/08/2016

Issued for Review

ANG

SAW

GWN/FIA

FP

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REVISION CONTROL SHEET

REV. NO.

DATE

DESCRIPTION

08/08/2016

Issued for Review

12/10/2016

Issued for Approval

DISTRIBUTION ORDER

EXTERNAL ISSUE

PT PP (Persero) Tbk - INTERNAL ISSUE

PT PUPUK INDONESIA ENERGI

PROJECT MANAGER

CHIEF ADMINISTRATION

TRACTEBEL / CONNUSA

ENGINEERING MANAGER

CHIEF SHE

CONSTRUCTION MANAGER
PROCUREMENT MANAGER
PROJECT CONTROL MANAGER
SHE MANAGER
QC MANAGER
CHIEF ENGINEERING
CHIEF PROJECT CONTROL

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TABLE OF CONTENT

1.

INTRODUCTION ....................................................................................................................................... 4
1.1. Scope ................................................................................................................................................ 4
1.2. Definition ........................................................................................................................................... 4
1.3. Project Reference Document ............................................................................................................. 4
1.4. Abbreviations ..................................................................................................................................... 4

2.

SHUTDOWN OBJECTIVE ........................................................................................................................ 5

3.

SHUTDOWN PHILOSOPHY ..................................................................................................................... 6

3.1. Natural Gas System ........................................................................................................................... 7
3.2. Steam Distribution System ................................................................................................................. 7
3.3. Water Treatment Plant (WTP) ............................................................................................................ 8
3.4. Waste Water Treatment System ........................................................................................................ 9
3.5. Fire Protection System ..................................................................................................................... 10
3.6. Compressed Air System .................................................................................................................. 10
3.7. Cooling Water System ..................................................................................................................... 11
3.8. Service Water & Potable Water System ........................................................................................... 11

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1. INTRODUCTION
1.1. Scope
This document provides the philosophy for process shutdown system for Balance of Plant (BOP)
system of the project scope of work defined in Gresik Gas Cogeneration Plant (GGCP) Project.
Shutdown system is safeguarding system which protects personnel and equipments from potential
hazards created by unexpected operating excursions or others causes.
1.2. Definition
The following words shall have the meaning indicated when used herein:
Owner

: PT. PUPUK INDONESIA ENERGI

Consultant PMC

: TRACTEBEL ENGINEERING S.A.& PT. CONNUSA ENERGINDO

Contractor

: PT. PP (Persero) Tbk DIVISI EPC

Engineering Consultant

: PT. REKAYASA ENGINEERING

Vendor/Subcontractor

: The party that manufactures or supplies equipment and services to

perform the duties specified by the Owner or Contractor

1.3. Project Reference Document

P&ID Water Treatment System, GGCP-04-PI-003-PP.

P&ID Fire Fighting & Protection System, GGCP-04-PI-004-PP.

P&ID Fire Water Distribution System, GGCP-04-PI-005-PP.

P&ID Compressed Air System, GGCP-04-PI-006-PP.

P&ID Natural Gas Feed System, GGCP-04-PI-004-PP.

P&ID Cooling Water System, GGCP-04-PI-007-PP.

P&ID Cooling Water Distribution System, GGCP-04-PI-008-PP.

P&ID Waste Water System, GGCP-04-PI-002-PP.

EPC Bid Document Gresik Gas Cogeneration Plant (GGCP) Project Addendum 1.

EPC Bid Document Gresik Gas Cogeneration Plant (GGCP) Project Addendum 2.

EPC Bid Document Gresik Gas Cogeneration Plant (GGCP) Project Addendum 3.

IFB Document for Engineering, Procurement, Construction and commissioning of Gresik Gas
Cogeneration Plant (GGCP) Project.
1
P&ID Interconnecting from GGCP PIE to PKG III, 34-P-11-00-2350-01

1.4. Abbreviations
The following abbreviations are used within this document:
ALARP

As Low As Reasonably Practicable

BOP

Balance of Plant

CW

Cooling Water
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CCR

Central Control Room

EPC

Engineering, Procurement, and Construction

ESD

Emergency Shut Down

GGCP

Gresik Gas Cogeneration Plant

GTG

Gas Turbine Generator

HRSG

Heat Recovery Steam Generation

HS

Hand Switch

IA

Instrument Air

IFB

Invitation for Bid

LCP

Local Control Panel

MB

Mixed Bed

PB

Package Boiler

PKG

Petrokimia Gresik

SDV

Shut Down Valve

SMBS

Sodium Metabisulfite

UF

Ultra Filtration

UV

Ultra Violet

WTP

Water Treatment Plant

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2. SHUTDOWN OBJECTIVE
Most of the risks to safety in the Gresik Gas Cogeneration Plant are from the production process by
release of hydrocarbons and steam. Hazards associated with the uncontrolled release of hydrocarbons
and steam are as follows:

Over pressure

Leak of flammables and toxic material

Liquid overflow

Gas blow by

Over temperature

Leak of Chemical

Power supply failure

Abnormal operation condition (noise of operation

Failure of emergency supply systems

Other hazards include equipment destruction due to high vibration, part failure, chemical reactions etc.
This document describes the philosophy that be used in shutdown systems for BOP system of Gresik
Gas Cogeneration Plant to provide a means to protect and reduce the risk associated with the hazards
to ALARP.

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The goals of the shutdown system is protect personnel, protect plant and equipment, and also prevent
pollution to the environment.
The shutdown system shall achieve its goals by:
Automatically sensing abnormal operation of process condition,
automatically shutting down plant and utilities to a safe state under a controlled manner on an
abnormal condition,
providing

process

isolation, venting, and under certain abnormal conditions,

3. SHUTDOWN PHILOSOPHY
To minimize the interruption to production caused by a shutdown condition, the shutdown system should
be divided into 4 levels. These levels of shutdown are as follows:
a) Level 1 Total Shutdown
The first level of safety system is the total pant shutdown both main facilities and utility facilities
(except fire fighting system) because of emergency condition, such as power failure and F&G system.
Plant is directed in a safe condition. Total plant shutdown can be initiated either automatically due to
Fire Alarm and Detection system or initiated manually from ESD hard-wired push button at strategic
locations in the plant area. A level reset will only be enabled when all the trip initiators have returned to
a safe condition.
Here are typical actions that shall taken from ESD:
Shutdown all of system and equipment
Isolate hydrocarbon inventories
Isolate electrical equipments
Prevent escalation of events

Stop hydrocarbon flow

Depressurize/blowdown
b) Level 2 Unit Shutdown
A Level 2 shutdown shall be initiated by major process or utility failure that may affect all systems within
a unit. A Level 2 shut down will shutdown equipments for the unit in which the abnormal condition give
the effect and initiate audible and visual alarms at the CCR. Example, PSLL at header IA supply will
shutdown Gas Turbine Generator Package, Package Boiler system, HRSG system and Water
Treatment Plant system.

Here are typical actions that shall taken from USD:

Shutdown the whole unit process/package
Depressurize/blowdown parts of the unit process, such as GTG, Package Boiler, HRSG and Gas
Metering System (main equipment detailed shutdown process will be determined by related vendor)
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c) Level 3 Equipment Shutdown

A Level 3 shutdown will shutdown individual equipment required to bring an abnormal situation under
control

and

initiate

audible

and visual alarms

at

the CCR, where the situation has a low

potential for escalation. A typical example is a low-low level in a storage tank, which shuts pump at
outlet tank to prevent pump cavitation.
d) Level 4 Normal Shutdown
A Level 4 shutdown is a planned shutdown. Normal shutdown will lead the equipment or unit into
minimum load and then complete shutdown manually.
3.1. Natural Gas System
Level 1

In case of emergency case (ESD), such as power failure or F&G system is activated, natural gas
flow shall be stopped. 12-SDV-701 installed at inlet scrubber will close automatically by human
action to stop the natural gas flow.

Level 2
In case of compressed air system is failure, SDV-701 will be closed automatically (Fail Close), in
this situation the operator shall be open vent valve-12728/12730 to release natural gas to safe
location (depressurize/ blowdown).
3.2. Steam Distribution System
Level 1
In case of emergency case (ESD), such as power failure , steam distribution system will be stopped.

Level 2
If pressure in IA supply header reaches low-low condition, low alarm in 10-PI-526 will active and
initiate steam distribution system to stop.
1
Level 4
In case of maintenance or turnaround period, 26-HV-950, 26-HV-951 from UBB plant, and
HV-001 can be closed by signal from CCR.

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3.3. Water Treatment Plant (WTP) System

Level 1

In case of emergency case (ESD), such as power failure or F&G system is activated, all
equipments in WTP will shutdown automatically.

Level 2
If pressure in IA supply header reaches low-low condition, low alarm in 10-PI-526 will active and
initiate WTP system to shutdown.

Level 3
Low liquid level Filtered at Water Tank, 07-LSLL-462 will initiate Filtered Water Pump (01-GA05373-A/B-M) to shutdown.
Low liquid level at Dual Media Filter Tank, 05-LAL-326 will initiate UF Feed Pump (01-GA05331-A/B-M) to shutdown.
Low liquid level at DMF Backwash Tank, 05-LAL-327 will initiate DMF Backwash Pump (01-GA05351-A/B-M) to shutdown.
Low liquid level at Ultra Filtration Tank, 05-LAL-328 will initiate UF Backwash Pump (01-GA05335-A/B-M) and RO Feed Pump (01-GA-05342-A/B-M) to shutdown.
Low-low liquid level at CIP Tank, 05-LALL-329 will initiate CIP Pump (01-GA-05353-A/B-M) to
shutdown.
Low-low liquid level at Degasser Tank, 05-LALL-330 will initiate Mixed Bed Feed Pump (01-GA05357-A/B-M) to shutdown.
Low liquid level at SMBS Tank, 05-LSL-331 will initiate SMBS Dosing Pump (01-CS-05344-A/BM) to shutdown.
Low liquid level at Antiscalant Tank, 05-LSL-332 will initiate Antiscalant Dosing Pump (01-CS05346-A/B-M) to shutdown.
Low liquid level at Coagulant Tank, 05-LSL-333 will initiate Coagulant Dosing Pump (01-CS05330-A/B-M) to shutdown.
Low liquid level at Acid Tank, 05-LSL-334 will initiate Acid Dosing Pump (01-CS-05341-A/B-M)
to shutdown.
Low liquid level at Caustic Tank, 05-LSL-335 will initiate Caustic Dosing Pump(01-CS-05339A/B-M) to shutdown.
Low liquid level at Hypo Tank, 05-LSL-336 will initiate Hypo Dosing Pump(01-CS-05337-A/B-M)
to shutdown.
Low liquid level at Acid Tank, 05-LSL-338 will initiate Acid Dosing Pump (01-CS-05363-A/B-M)to
shutdown.

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Low liquid level at Caustic Tank, 05-LSL-340 will initiate Caustic Dosing Pump (01-CS-05361A/B-M) to shutdown.
High liquid level at Acid Bulk Tank, 05-LAH-337 will initiate Acid Unloading Pump (01-CS-05368A/B-M) to shutdown.
High liquid level at Caustic Bulk Tank, 05-LAH-339 will initiate Caustic Unloading Pump (01-CS05366-A/B-M) to shutdown.
Low-low liquid level at Condensate Tank, 08-LALL-477 will initiate Backwash Pump (01-GA05359-A/B-M) to shutdown.
Low-low liquid level at Condensate Tank, 08-LALL-477 will initiate Demin Feed Package Boiler
Pump (01-GA-08477-A/B-M) to shutdown.
Low-low liquid level at Condensate Tank, 08-LALL-477 will initiate Demin Feed HRSG Pump
(01-GA-08478-A/B-M) to shutdown

Level 4
In case of maintenance or turnaround period, Water Treatment Package can be shutdown by
push bottom located in LCP Water Treatment Package.
All pumps in Water Treatment Package can be shutdown by each pump local hand switch.
3.4. Waste Water Treatment System
Level 1

In case of emergency case (ESD), such as power failure or F&G system is activated, Waste Water
1
System Package shall be shutdown.
Level 3
Low-low liquid level at Caustic Dosing Tank, 06-LSL-431 will initiate Caustic Dosing Pump (01CS-06437-A/B-M) to shutdown
Low-low liquid level at Acid Dosing Tank, 06-LSL-434 will initiate Acid Dosing Pump
1

(01-CS-06441-A/B-M) to shutdown

Low-low liquid level at Coagulant Dosing Tank, 06-LSL-433 will initiate Coagulant Dosing Pump
(01-CS-06439-A/B-M) to shutdown

1
Low-low liquid level at A-polymer Dosing Tank, 06-LSL-437 will initiate A-polymer Dosing Pump
(01-CS-06444-A/B-M) to shutdown
Low-low liquid level at C-polymer Dosing Tank, 06-LSL-442 will initiate C-polymer Dosing Pump
(01-CS-06452-A/B-M) to shutdown
1
Level 4
In case of maintenance or turnaround period, Waste Water Treatment System package can be
shutdown by push bottom located in LCP Waste Water Treatment System.
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All pumps in Waste Water Treatment System can be shutdown by each pump loca/remotel hand
switch.
3.5. Fire Protection System
Level 3
Low-low liquid level at Filtered Water Tank, 07-LSLLL-463 will initiate Fire Fighting Pump (01GA-11552-A-M &01-GA-11552-B-D) and Jockey Pump (01-GA-11551-M) to shutdown for
preventing pump cavitation.

Level 4

In fire condition Fire Water Pump (01-GA-11552-A-M &01-GA-11552-B-D) comes into operation
automatically through the impulse from pressure switch 11-PS-552 A/B. Fire Fighting Pump
1
shall be shut down manually from local/remote hand switch.

Jockey Pump (01-GA-11551-M) is intended to maintain pressure in a fire protection piping

system, Jockey pump will start at low pressure initiated by 11-PS-551. Jockey Pump (01-GA1
11551-M) shall be shut down manually from local/remote hand switch.

3.6. Compressed Air System

1

Level 1

In case of emergency case (ESD), such as power failure or F&G system is activated, Compressed
Air System Package shall be shutdown.
Level 2

If the pressure at Instrument Air supply header reaches low-low condition, low alarm in 10-PI526 will active and initiate Level 2 Shutdown for GTG, PB,HRSG, WTP system, and other BOP
areas.

If the flow rate of cooling water supply header reaches low-low condition, low alarm in 04-FALL302 will active and initiate Compressed Air system to shut down.

Level 3

1
High temperature at discharge compressor, 10-TSH-526 A/B/C will initiate Air Compressor (01GB-10527-A/B/C) to shutdown to prevent the compressor from being totally damaged. 1
High temperature at discharge Water Cooled Exchanger, 10-TSHH-527 A/B/C will initiate Air
Compressor (01-GB-10527-A/B/C) to shutdown due to Water Cooled Exchanger does not work
properly.

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Level 4
In case of maintenance or turnaround period, Compressed Air System package can be shutdown by
push bottom located in LCP Compressed Air System.
3.7. Cooling Water System

Level 1
In case of emergency case (ESD),such as power failure or F&G system is activated, Cooling Water
System Package shall be shutdown.

Level 2
If the flow rate of cooling water supply header reaches low-low condition, low alarm in 04-FALL-302
will active and initiate Level 2 Shutdown for PB,HRSG, GTG system, and Compressed Air system.
1
Level 3
Low liquid level at Filtered Water Tank, 07-LSLL-462 will initiate Make-up Cooling Tower Pump
(01-GA-04301-A/B-M) to shutdown.
Low liquid level at Cooling Tower Basin, 04-LALL-301 will initiate Circulating CW Pump (01-GA04307-A/B-M) to shutdown to prevent pump cavitation.

High-high vibration at Cooling Tower Fan, 04-VAH-302 A/B will initiate Cooling Tower Fan (01CW-04304-A/B) to shutdown to prevent the Cooling Tower Fan from being totally damaged from
high vibration.
Low lube oil level at Cooling Tower Fan Motor, 04-LSL-302 A/B will initiate Cooling Tower Fan
(01-CW-04304-A/B) to shutdown to prevent the Cooling Tower Fan from damage.
1

Level 4

In case of maintenance or turnaround period, Cooling Tower System package can be shutdown
by push bottom located in LCP Cooling Tower System.
In case of maintenance, Make-up Cooling Tower Pump (01-GA-04301-A/B-M) can be shutdown
by local Hand Switch (HS).
In case of maintenance, Circulating CW Pump (01-GA-04307-A/B-M) can be shutdown by local
Hand Switch (HS).
3.8. Service Water & Potable Water System
Level 1

In case of emergency case (ESD),such as power failure or F&G system is activated, Service Water
and Potable Water System shall be shutdown.

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Level 3
Low liquid level at Dual Media Filter Tank, 05-LAL-326 will initiate Service Pump (01-GA-05374
A/B-M) to shutdown to prevent pump cavitation.

Level 4
In case of maintenance, Service Pump (01-GA-05374 A/B-M) can be shutdown by local Hand
Switch (HS).

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