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OPERATION & MAINTENANCE

TRAINING PROGRAM

KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

This module describes the introduce plants which are in Utilities Section: water for the
Introduction plant, boiler feed water, the manufacture and distribution of steam, electricity, nitrogen,
water coolers.

Duration 2 hours

I. Learning Outcomes:

1. The trainee can be able to completely describe overall General Utilities.


2. The trainee will know the tasks and responsibility of Utilities Section.
3. The Trainee able to understand the processes at each plant in the Utilities section

II. Definition of Terms :

1 Plant-36,48,49 : Water Treatment Plant.


2. Plant-31 : Steam and Power Generator.
3. Plant-29,35 : Nitrogen and Air Compressed
4 Plant-32 : Cooling Water System.

III. Document Reference

1. P&ID Plant-29/31/32/35/36/48/49
2. Operating Manual Book Utilities
3. Operation Manual Book

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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

IV. Safety Precautions

1. General Safety Considerations

All personnel should be familiar with safe operation practices and procedures. There are correct and
proper ways to sample process streams, vent gases, drain liquids and perform other routine
operations with potentially hazardous nature. Observe the rules and work safely.

2. Pre-commissioning, all system piping must be checked for the followings:


a. Block valves must be checked for operability
b. Control valves are working properly
c. All temperature and pressure gauges are in place and working properly
d. Check pipe plugs, and vent valves
e. Check valves are installed properly
f. Pipe insulation has been installed properly

3. Commissioning
a. Maintenance activities must not be carried out on the equipment until work permit and safety
permit have been signed and handed over to the person carrying out the activities. The permit
must be retained by the worker until the job is completed or stopped by the authority.
b. If maintenance is required on the LNG-LPG, Refrigerant system, hydrocarbon condensate lines
or equipment, the line must be blocked and depressurized with all drain valves is left open.

4. Preventive Measure
a. Personal Protective Equipment: Working in zone one area the Safety goggles or glasses, Safety
shoes, safety shower must be weared.
b. Leak And Spill Procedures: Use appropriate protective equipment. Ensure to purge piping with
an inert gas prior to attempting leak repairs.
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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

c. Storage Requirements: Protect storage from physical damage. Post "No Smoking or Open
Flames" signs in the storage or use area. There should be no sources of ignition in the storage
or use area.

V. Main Equipments

1 Plant-36/48/49:

- Aerator :

- Filtration

- Demineralizer Unit

2 Plant-31

- Boilers

- Generator (Backpressure Turbine, Condensing Turbine, Gas Turbine)

3 Plant-29/35

- N2 Coldbox

- Air compressor

4 Plant-32

- Cooling Water pump

- Chlorine Generator

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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

VI. Detailed Process Description

1. Plant-36/48/49: Water Treatment Plant


a. Water treatment Facility
Water Treatment facility has function to alter the collected ground water quality to the minimum
specification of Boiler Feed Water (BFW). The raw water is taken from ground water, and
treated to meet Boiler specification and to prevent any problem occurring in Boiler tubes (such
as deposit, scaling, corrosion, etc).
The ground water is supplied from several Deep Water Wells that is equipped with submersible
Pump to transfer water from the ground aquifier into the feed for the Water Treatment Plant
(WTP). Currently PT Badak NGL operates 7 Deep Water Well with depths around 200 m, and
water surface around 10-15 m below the ground surface.

Figure 1. Ground Water


b. Raw Water
The raw water is ran to the header piping to become the feed water for WTP-36 (for Plant facility),
WTP-48 (for community potable water), and for WTP-49 (for community potable water). WTP-48
and WTP-49 are used to produce potable water to be distributed in the community area in PT Badak
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OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

NGL (PC, HOP, and office area). Meanwhile WPT #36 is used to treat raw water to meet such
specification, in order for being fed to Boiler as BFW. Basically, raw water shall pass several
treatment processes in WTP-36, which is: Aeration, Filtration, and Demineralization. The end
product from this step will meet the specification of BFW.

c. Aerator
Aeration/oxidation process takes place in Aerator. The water taking from the wells is temporarily
kept in the aerator tank. And then, compressed air is blown from the bottom of the tank which will
blow the entering gas and make a perfect oxidation process
This process should lead the water in tank to evenly mixed with the air in order to eliminates
corrosive dissolved gases (CO2, NH3, H2S) that drop the water pH which contributes in corrosions
process. It also should oxidize the dissolved iron and manganese metal elements (Ferrocarbonat or
Ferrosulfat)/(Fe++ and Mn++ ) to Ferrioxide and Manganoxside (Fe+++and Mn+++) which will not
be dissolved in the water.
In order aeration process goes well then the pH of the water should be maintained at 6.8 sd 7.0
by injecting NaOH solution into Aerator. The water result is then supplied to the Iron Removal
Filter (IRF).

d. Iron Removal Filter (IRF)


IRF is a pressurized filter in the form of a closed cylindrical vessel containing particles Anthracide
and equipped with Manganese Dioxide Coated Filter Media.
This filter serves to hold the iron compounds precipitated Fe(OH)3 which is soluble in water
pumped from the aerator Surge tanks, as well as oxidizing ions are not oxidized Ferro at aerator.
Where Manganese Dioxide serves as a catalyst for the oxidation.

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OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

e. Demin

Demineralization is a process to remove all the mineral salts contents in the water. Demineralizer
unit is one of the tools in demineralization that uses ion exchange system (ion exchanger). The
working principle of the demineralizer is the exchange of ion in water with the ion in resin. Ion
exchange occurs in the demineralizer is divided into two parts, Cation Exchange, and Anion
Exchange.
The implementation of ion exchange between the water ion and the resin cations and anions can be
done in a single vessel (mixed bed units) which is filled by the two types of coating, Cation resin and
Anion resins. But it can also be done in two different vessels, where one vessel contains cation
resin and the other vessel contains anion resin

Figure 2. Process Flow of Water Treatment

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OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

2. Plant-31: Steam & Power Generator


a. Boilers
A steam boiler is designed to absorb the maximum amount of heat released from the process
of combustion. Heat transfer within steam boiler is accomplished by three methods:
a. Radiation
b. Convection
c. Conduction
The heating surface in the furnace area receives heat primarily by radiation. The remaining
heating surface in the steam boiler receives heat by convection from the hot flue gas. Heat
received by the heating surface travels through the metal by conduction. Heat is then
transferred from the metal to the water by convection.

Figure 3. Boiler Mitsubishi UV-60 Type

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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

b. Chemical Injection
Chemical injection purpose is to control the BFW parameters within prescribed limits to
minimize scale, corrosion, carryover and other specific problems. The Tri Sodium Phosphate
(TSP) and Tri Poly Phosphate (TPP) are injected to maintain suitable phosphate content in the
BFW, as part of the pH/phosphate control program to precipitate scale forming contaminants to
be removed further as blowdown. A dispersant, phosphate is injected into each boiler to control
deposits and keep surfaces clean.

Figure 4. pH- Phosphatcorrelation for Boiler Water Treatment

c. Steam usage and distribution is as follow:


High pressure steam is used to drive the turbine generators and is
supplied to the process area. It can also be supplied to the medium
pressure system during abnormal operating conditions via on on-plot
pressure reducing and de-superheating station
Medium pressure stem is supplied from the exhaust of the backpressure
turbine generators. An additional supply is available as described above.

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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

Medium pressure steam is used in the utility area for turbine drives, such
as the boiler feed pump drivers, forced draft fan drivers, steam jet air
ejectors, and is also supplied to the process area. As with the high it can
be supplied to the low pressure steam system via on-plot pressure
reducing and de-superheating station.
Low pressure steam is supplied by the exhausts of the turbine drivers
operating on the medium pressure steam system, boiler blow down
recovery, the backpressure turbine generator gland leak-off, and if
required, from an extraction point on the condensing turbine generator.
An additional service is the let-down station described above. Low
pressure steam is used in the utility area for heating the fuel gas knock
out drum, the de-aerators, and the nitrogen vaporizer, for electrical
generation via the induction admission of the condensing turbine
generator, and as make up to the de-superheated low pressure system.
This steam is also supplied to the process area for heating, and to the
loading facilities for heating the bunker C fuel storage tank.

d. Electric Power Generator


Electrical power is generated by 13 steam turbine driven generators and one
gas turbine generator. The turbine generators include lube oil system, gland
steam system, condensers and air removal equipment, cooling water system,
and controls. The gas turbine generator includes lube oil and hydraulic oil
system, a starting air systems , fuel systems, gas turbine and generator
control systems.

The generator supply 3 phases, 50 Hertz power at 13,800 volts to the power
station main bus. Distribution from the power station and appropriate step
down transformers is at:

13,800 volts, 3 phase


4,160 volts, 3 phase
480 volts, 3 phase
220 volts, 3 phase
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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

Electrical usage and distribution within the plant is as follow:

13,8 kV is the generator terminal voltage and is used to supply the two
main distribution buses. It goes direct to the loading facility for the cooling
water pumps and various step down transformers throughout the plant
and community. None of the 13,8 kV power is used directly in the utility
plant.
4.16 kV is supplied via transformers for motor loads above 187 kW (250
hp). The air compressor motors and motor drivers on the FD fans of
boilers 31F-09, 10 and BFW pump motor 31GM-5B are the only users
within the utility plant.
480 V supplied through the distribution net work throughout the plant and
is used in the utility area for smaller motor.
220 V is distributed throughout the plant and is used in the utility area for
lighting and some controls. It is also used for some of the smaller motors.

e. Gas Turbine Generator


The gas turbine generator is essential for bringing up the plant from a black
start and to supply power under emergency conditions. Therefore, it is
important that it be maintained on ready standby at all times. A complete log
of operating temperatures, pressures, kilowatt loads, vibration levels, etc.
should be kept to reveal long term trends of possible trouble.
In addition to its black start responsibilities, the gas turbine generator will
also be used under several plant operating conditions to reduce load on the
turbine generators (refer to drawing 31RA-10). Before being paralleled with a
turbine generator, the gas turbine governor must be placed in droop mode.
The gas turbine should be allowed to run in Isochronous only when it is the
only machine on the line.

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TURBINE CONDENSING CONTROL SYSTEM


60Kg/cm2
31 TG 04 / 05 / 11 / 12 / 14
450oC PIC-67-4/5

HP STEAM HIC-33-4/5
GENERATOR
PT-67-4/5

LP STEAM

TURBINE

3000 RPM

EXTRAKSI / INDUKSI
PORT

TO LP STEAM HEADER
CW IN
VACUUM -60cmHg 12.5 MW
13.8 KV
CONDENSOR
TO CONDENSATE SYSTEM ELECTRIC POWER
TO BUS
COND CW OUT
10mhos

Figure 5. Condensing Turbine

31 TG 02 / 03 / 06 / 08 / 9 / 10 / 13
HP STEAM
62Kg/cm2
450oC

TURBINE GENERATOR

3000 RPM

18Kg/cm2
338oC

MP STEAM HEADER 12.5 MW


13.8 KV
ELECTRIC
POWER TO BUS

Figure 6. Backpressure Turbine

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OPERATION & MAINTENANCE
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KNOWLEDGE BASED TRAINING

OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

3. Plant-29/35: Nitrogen and Compressed Air


a. Compressed Air
The compressed air is utilized as utility air, instrument air and feed to nitrogen generation plant.
Therefore, Compressed Air Unit is designed for providing pressurized air to support the
operation of the LNG Trains. As much as 8 (eight) units of main Air Compressors are available
to deliver the compressed air to fulfill the above requirement.

Compressed air is maintained at 9.2 - 9.5 kg/cm2 and collected in the Air Receiver. Then, it is
distributed to each users which are: Utility Air, Instrument Air, and Nitrogen Plant.

Figure 7. Air compressed distribution

b. Nitrogen Generation
In Nitrogen generation plant, feed air is coming from surrounding air then it is pressurized by
air compressor up to 8.4 kg/cm2g. Afterward, the compressed air enters the tubes of the Air
Chiller where it is cooled by refrigerant to approximately 4.5oC to condense as much
moisture as possible from the air without forming ice in the evaporator tubes.

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OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

Figure 8 : Simplified Diagram of Chiller Unit

4. Plant-32

a. Cooling Water
The cooling water is taken from open sea water, by using a total of 22 cooling water pumps with
once through scheme, which means that the outlet sea water stream will be routed back to the
open sea (It does not fed back to cooling water pump suction).

Before entering cooling water pumps; any foreign contaminants/trash in the sea water is firstly
filtered by using a bar screen / trash rack.

b. Chlorine system

The Chlorine used in the cooling water system is Sodium Hypochlorite. Chlorine is injected in the
net screen/bar screen facility to control sea water micro organism growth. Without the Chlorine
injection, micro organism can grow up along the cooling water piping network and inside the heat
exchanger. This may further more disrupt the cooling water flow and reduce the heat transfer
efficiency inside heat exchanger. The Chlorine is produced in the Chlorine generator plant by

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OPERATION MODULE # 08: GENERAL UTILITIES

No: MOD/TRGS/BJ50/OP-218 Rev - 0

using the electrolysis principle which is injected into the sea water feed through the 6 Fiber
Reinforced Pipe (FRP) header to the injection section and distributed to each intake basin
through several 2 FRP injection lines.

The target of Chlorine injection is to reach 1 ppm of Chlorine content in the sea water feed, prior
entering cooling water pump. With the specified target of injection, the Chlorine content in the
outler cooling water flow from process train area (Outfall Canal) shall meet 0.2~0.5 ppm which is
regularly checked twice a week.

Daya 3.3 MW BOVING


Kap. 14.763 m3/h AMRY
Put. 600 rpm
PERMISS. START
MOTOR
HWS
PAH L/O PRESS
VENT VALVE OPEN PRESS HYD 100

CHLORINE 0,2 ~ 0,5 PPM


AMRY OPEN Kg/cm2
PAH BOV. HYD
BOVING REMOTE PRESS HYD 100
AUX.PUMP AUTO Kg/cm2
65000 GPM
3MW

LUBE WATER FILTER

M MAIN L/O PUMP


C/W SUPPLY

OIL TANK

VENT VALVE
PUMP

FILTER
COOLER

Figure 9 : Cooling Water Pump

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No: MOD/TRGS/BJ50/OP-218 Rev - 0

VII. Instrument and Process Control

Equipment installed instrumentation to monitor plant operating conditions in order to operate smoothly
and continuously secure: if there is any disruption will soon be overcome so as not to cause the plant to
stop production. In general the instrumentation is installed should include the following:
a. Level

b. Pressure.

c. Temperature

d. Flow

e. Differential Pressure

f. Process Control.:

VIII. General Operation Activities


a. Start up plant and equipment partial

b. Shutdown plant or equipment partial.

IX. Emergency Condition and Corrective Action

a. Emergency Power Failure

b. Instrument Air Failure

c. Emergency Shutdown.

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