Sie sind auf Seite 1von 517

EPIC for Gas Sweetening Facilities Project (GSF)

at Mesaieed & Dukhan Rev.: 0


Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 2 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

REVISION DESCRIPTION SHEET

Rev. Para. Revision Description


0 For Review

Hold
Para. Description of Hold
No.
1 2.3.1 Vendor supplied MSDS of MDEA
2 2.3.2 Vendor supplied MSDS of Antifoam
3 2.3.3 Vendor supplied MSDS of Corrosion Inhibitor
4 2.3.4 Vendor supplied MSDS of Caustic
5 2.3.5 Vendor supplied MSDS of Biocide
6 2.3.6 Vendor supplied MSDS of Scale Inhibitor
7 2.3.7 Vendor supplied MSDS of Oxygen Scavenger
8 2.3.8 Vendor supplied MSDS of Complex Product

4.5.4 Instrument Air Compressor loading and unloading pressure set


9 points/lead/lag compressor loading and unloading pressure set
5.4.3 points
4.11.3.1
4.11.3.2 Demineralized Water Package operating set point/alarm and trip
10
4.11.3.3 set points
7.2.6
4.13.3.1
4.13.3.2
4.13.3.4
Steam Generation Package: operating set point/alarm and trip
11 4.13.3.5
set points
4.13.3.6
4.13.3.7
7.2.8
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 3 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

CONTENTS

SECTION I INTRODUCTION ...................................................... 10


1.1 OBJECTIVE ............................................................................. 11
1.2 ABBREVIATION ......................................................................... 11
1.3 UNITS OF MEASUREMENT ............................................................. 12
1.4 GENERAL DESCRIPTION ............................................................... 13
SECTION II HEALTH SAFETY AND ENVIRONMENT ............................ 15
2.1 HEALTH, SAFETY AND ENVIRONMENT (HSE) ....................................... 16
2.2 LEAKAGE OF ACID GAS ................................................................ 16
2.3 HAZARDS IN HANDLING CHEMICALS ................................................. 17
2.3.1 MDEA .................................................................................... 17
2.3.2 Antifoam ............................................................................... 17
2.3.3 Corrosion Inhibitor .................................................................... 17
2.3.4 Caustic .................................................................................. 17
2.3.5 Biocide .................................................................................. 17
2.3.6 Scale inhibitor ......................................................................... 17
2.3.7 Oxygen Scavenger ..................................................................... 17
2.3.8 Complex Product ...................................................................... 17
2.3.9 Hydrogen Sulphide .................................................................... 17
SECTION III OVERVIEW OF SRU UPGRADE FACILITIES ........................ 20
3.1 PROCESS ................................................................................ 21
3.1.1 SRU Upgrade Facilities Overview ................................................... 21
3.1.2 Acid Gas Enrichment Unit (AGEU) .................................................. 21
3.1.3 Sulphur Recover Unit Process Description ......................................... 24
3.1.4 Tail Gas Treatment Unit (TGTU) .................................................... 26
3.1.5 Tail Gas Incinerator ................................................................... 29
3.1.6 Amine Drain System .................................................................. 31
3.2 NEW UTILITY FACILITIES.............................................................. 33
3.2.1 Instrument and Plant Air ............................................................. 33
3.2.2 Demineralised Water System ........................................................ 35
3.2.3 Sea Cooling Water System ........................................................... 37
3.2.4 Boiler Feed Water System ........................................................... 39
3.2.5 Steam Generation Package 6848-A-02A/B/C...................................... 41
3.2.6 Fuel Gas System ....................................................................... 44
3.2.7 Effluent and Waste Water Treatment Unit ........................................ 46
3.3 FIRE WATER & DELUGE SYSTEM ..................................................... 48
3.3.1 Fire Water System .................................................................... 48
3.3.2 Deluge System ......................................................................... 48
SECTION IV PROCESS AND CONTROL DESCRIPTION.......................... 50
4.1 ACID GAS ENRICHMENT UNIT (AGEU) ............................................... 51
4.1.1 Equipment Specification ............................................................. 51
4.1.2 AGEU PROCESS DESCRIPTION & CONTROL ......................................... 58
4.2 SULPHUR RECOVERY UNIT ........................................................... 75
4.2.1 Equipment Details .................................................................... 75
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 4 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.2.2 Revamped Claus Unit Process Chemistry .......................................... 77


4.2.3 Revamped Claus Unit Process Description ......................................... 78
4.2.4 Sulphur Recovery Unit Process Control ............................................ 79
4.3 TAIL GAS TREATMENT UNIT .......................................................... 89
4.3.1 Tail Gas Treatment Unit Equipment Specification ............................... 89
4.3.2 Tail Gas Treatment Unit (TGTU) Process Description............................ 92
4.3.3 Tail Gas Treatment Unit Control Description ..................................... 94
4.4 INCINERATOR ......................................................................... 102
4.4.1 Equipment Specification ............................................................ 102
4.4.2 Process Description and Control ................................................... 103
4.5 INSTRUMENT AIR PACKAGE.......................................................... 107
4.5.1 Instrument Air Compressor Package ............................................... 107
4.5.2 Instrument Air Dryer Package ...................................................... 108
4.5.3 Instrument Air Package Description ............................................... 109
4.5.4 Instrument Air Package Control Description ..................................... 110
4.6 EFFLUENT & WASTE WATER TREATMENT ......................................... 112
4.6.1 Equipment Specification ............................................................ 112
4.6.2 Effluent and Waste Water Treatment Process Description .................... 116
4.6.3 Effluent & Waste Water Treatment Control Description ....................... 118
4.7 LP FUEL GAS .......................................................................... 123
4.7.1 Equipment Specification ............................................................ 123
4.7.2 Fuel Gas System Process Description.............................................. 123
4.8 SEA COOLING WATER SYSTEM ...................................................... 125
4.8.1 Equipment Specification ............................................................ 125
4.8.2 Sea Cooling Water System Process Description .................................. 126
4.8.3 Sea Cooling Water Control .......................................................... 127
4.9 Electrochlorination Package ........................................................ 128
4.9.1 Equipment Specification ............................................................ 128
4.9.2 Electro Chlorination System Description ......................................... 131
4.9.3 Electro chlorination Package Control ............................................. 132
4.10 NGL-4 SEA WATER FILTERS.......................................................... 133
4.10.1 Equipment Specification ............................................................ 133
4.10.2 NGL-4 Sea Water Filters S-8840A/B Description ................................. 134
4.11 DEMINERALISED WATER SYSTEM ................................................... 134
4.11.1 Equipment specification ............................................................ 134
4.11.2 Demineralised Water System Process Description............................... 138
4.11.3 Demineralised Water System Control description ............................... 141
4.12 BOILER FEED WATER DEAERATOR SYSTEM ........................................ 144
4.12.1 Equipment specification ............................................................ 144
4.12.2 Boiler Feed Water De-aerator Description ....................................... 146
4.12.3 Boiler Feed Water Deaerator Control Description ............................... 148
4.13 STEAM GENERATION PACKAGE ..................................................... 151
4.13.1 Equipment Specifications ........................................................... 151
4.13.2 Steam Generation Package Process Description ................................. 154
4.13.3 Control Description .................................................................. 165
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 5 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.14 CHEMICAL INJECTION SYSTEMS ..................................................... 177


4.14.1 Antifoam Injection Package 9103-A-11 ........................................... 177
4.14.2 Caustic Injection Package 9103-A-13.............................................. 179
4.14.3 Corrosion Inhibitor Injection Package 9103-A-12 ................................ 181
4.14.4 Complex Product Injection Package 6834-A-09 .................................. 184
4.14.5 Oxygen Scavenger Injection Package 6834-A-09................................. 187
4.14.6 Biocide Injection Package 6932-A-06.............................................. 189
4.14.7 Scale Inhibitor Injection Package 6932-A-07 ..................................... 192
4.14.8 Catalyst Injection Package 9101-A-01............................................. 195
SECTION V PRE-REQUISITE FOR START-UP ................................... 198
5.1 GENERAL .............................................................................. 199
5.2 INTERFACE ACTIVITIES............................................................... 200
5.3 START-UP OF UTILITIES.............................................................. 202
5.3.1 Start-up Sequence ................................................................... 202
5.4 Instrument Air/Plant Air System ................................................... 202
5.4.1 Pre Start-up Checks.................................................................. 202
5.4.2 Instrument Air compressor Start-up ............................................... 203
5.4.3 Start-up permissive conditions: .................................................... 204
5.4.4 Instrument Air Dryer start-up ...................................................... 208
5.4.5 Instrument Air Dryer Start-up Checks ............................................. 208
5.4.6 Dryer Start ............................................................................ 208
5.5 Nitrogen system ...................................................................... 211
5.5.1 Lining up of Nitrogen from existing system to the New Distribution Header 211
5.6 Drinking water system ............................................................... 212
5.6.1 Lining up of Drinking Water to existing network ................................ 212
5.6.2 Lining up of Drinking Water to DMW Package .................................... 212
5.7 Effluent & Waste Water Treatment system ...................................... 213
5.7.1 Lining up of Waste Water Degasser 6922-V-07 ................................... 213
5.7.2 Lining up of Sour Water Stripper 6922-C-01...................................... 214
5.7.3 Lining up of Stripper Overhead Circulation Pump 6922-P-11A/B ............. 215
5.7.4 Lining up of Sour Water Stripper overhead Sour Gas ........................... 215
5.7.5 Pressurising Waste Water Degasser 6922-V-07 with Nitrogen ................. 215
5.7.6 Lining up of Sour Water Stripper Reboiler ........................................ 216
5.8 Flare system .......................................................................... 217
5.8.1 Start-up of LP Flare System ........................................................ 217
5.8.2 LP ACID GAS FLARE SYSTEM......................................................... 218
5.9 Fuel Gas System ...................................................................... 219
5.9.1 Line-up Fuel Gas from the Existing 1st Stage Booster Compressor
6701-K-10/20/30 in NGL-3 .......................................................... 219
5.10 Sea cooling water system ........................................................... 220
5.10.1 Pre-start up checks .................................................................. 220
5.10.2 Initial Starting and Lining Up of Sea Cooling Water ............................. 221
5.11 Electro Chlorination Package Start-up ............................................ 221
5.11.1 Normal start-up of Electro Chlorination Plant: .................................. 222
5.12 Chemical Injection System ......................................................... 224
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 6 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.12.1 Complex Product Injection Package (6834-A-09) ................................ 224


5.12.2 Oxygen Scavenger Injection Package (6834-A-09)............................... 225
5.12.3 Biocide Injection Package (6932-A-06)............................................ 226
5.12.4 Scale Inhibitor Injection Package (6932-A-07) ................................... 227
5.12.5 Catalyst Injection Package (9101-A-01)........................................... 228
5.12.6 Antifoam Injection Package (9103-A-11) ......................................... 229
5.12.7 Corrosion Inhibitor Injection Package (9103-A-12) .............................. 230
5.12.8 Caustic Injection Package (9103-A-13)............................................ 231
5.13 Demineralized Water System ....................................................... 231
5.13.1 Demineralized Water Unit Start-up ............................................... 231
5.13.2 Demineralized Water Unit Sequence .............................................. 235
5.13.3 Neutralization Pit .................................................................... 238
5.14 Boiler Feed Water Deaerator system .............................................. 241
5.14.1 Lining up of Steam Condensate Flash Drum 6834-V-05 ......................... 241
5.14.2 Lining up of BFW Deaerator Package 6834-A-08 ................................. 242
5.15 Steam Generation Package Start-up .............................................. 243
5.15.1 Checks for Start-up .................................................................. 243
5.15.2 Water Filling .......................................................................... 244
5.15.3 Fuel Gas Line-up ..................................................................... 245
5.15.4 FD Fan Start-up....................................................................... 245
5.15.5 Burner Start-up ....................................................................... 246
5.15.6 Boiler Normal Start-up .............................................................. 250
5.15.7 Start-up from Cold Condition (Manual Mode) .................................... 251
5.15.8 Start-up from Hot Condition........................................................ 254
5.15.9 Going On Line......................................................................... 254
5.16 LEAK CHECKING OF SYSTEMS ....................................................... 255
5.17 PURGING............................................................................... 256
SECTION VI START-UP OF PLANT .............................................. 258
6.1 GENERAL .............................................................................. 259
6.2 START-UP SEQUENCE ................................................................ 259
6.3 START-UP OF PROCESS .............................................................. 260
6.3.1 Start-up of Incinerator 9101-F-14.................................................. 260
6.3.2 Start-Up of Acid Gas Enrichment Unit ............................................ 267
6.3.3 Start-Up of Sulphur Recovery Unit................................................. 283
6.3.3.1 Start-up of Reaction Furnace (9101-F-01) Burner ............................... 283
6.3.3.2 Heating Up the System .............................................................. 290
6.3.4 Start-up of Tail Gas Treatment Unit .............................................. 304
6.4 RAMP UP OF PLANT LOAD ........................................................... 319
SECTION VII OPERATION & MONITORING ...................................... 320
7.1 PROCESS PLANT OPERATION AND MONITORING .................................. 321
7.1.1 Acid Gas Enrichment Unit ........................................................... 321
7.1.2 Sulphur Recovery Unit ............................................................... 326
7.1.3 Tail Gas Treatment Unit ............................................................ 331
7.1.4 Instrumentation ...................................................................... 337
7.1.5 Process On-Stream Analysis and Testing .......................................... 337
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 7 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

7.1.6 Tail Gas Incinerator .................................................................. 339


7.2 UTILITIES .............................................................................. 341
7.2.1 Instrument Air & Plant Air .......................................................... 341
7.2.2 Effluent & Waste Water Treatment ............................................... 343
7.2.3 Fuel gas system....................................................................... 345
7.2.4 Sea Cooling Water System .......................................................... 345
7.2.5 Electro Chlorination Package....................................................... 346
7.2.6 DM Water Package ................................................................... 348
7.2.7 Boiler feed water system ........................................................... 351
7.2.8 Steam Generation .................................................................... 353
SECTION VIII START-UP AFTER EMERGENCY SHUTDOWN .................... 357
8.1 GENERAL .............................................................................. 358
8.2 Tail Gas Incinerator Restart ........................................................ 358
8.3 Acid Gas Enrichment Unit Restart ................................................. 358
8.4 Sulphur Recovery Unit Restart ..................................................... 359
8.5 TGTU Restart ......................................................................... 359
SECTION IX TROUBLE SHOOTING OPERATIONS.............................. 361
9.1 PROCESS ............................................................................... 362
9.1.1 Incinerator ............................................................................ 362
9.1.2 Acid Gas Enrichment Unit ........................................................... 362
9.1.3 Sulphur Recovery Unit ............................................................... 364
9.1.4 Tail Gas Treating Unit ............................................................... 365
9.2 UTILITIES .............................................................................. 366
9.2.1 Instrument air package.............................................................. 366
9.2.2 Effluent & Waste Water Treatment Unit ......................................... 368
9.2.3 Electro Chlorination Package....................................................... 368
9.2.4 Chemical Injection Packages ....................................................... 369
9.2.5 DM Water Package ................................................................... 376
9.2.6 Boiler Feed Water System .......................................................... 376
9.2.7 Steam Generation Package ......................................................... 377
SECTION X PLANNED SHUTDOWN ............................................. 380
10.1 Planned Shutdown - Process ........................................................ 381
10.1.1 TGTU Shutdown ...................................................................... 381
10.1.2 SRU Shutdown ........................................................................ 384
10.1.3 Acid Gas Enrichment Unit Shutdown .............................................. 386
10.1.4 Incinerator Shutdown................................................................ 387
10.2 UTILITIES .............................................................................. 389
10.2.1 Steam Generation Package Shutdown ............................................ 389
10.2.2 Boiler Feed Water System Shutdown .............................................. 390
10.2.3 DM water package Shutdown ....................................................... 391
10.2.4 Chemical Injection System Shutdown ............................................. 392
10.2.5 Electro Chlorination Package Shutdown .......................................... 395
10.2.6 Sea cooling water Shutdown ....................................................... 396
10.2.7 Fuel Gas system Shutdown.......................................................... 396
10.2.8 Effluent & Waste Water Unit Shutdown .......................................... 397
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 8 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

10.2.9 Instrument air Shutdown ............................................................ 398


SECTION XI EMERGENCY SHUTDOWN ......................................... 400
11.1 GENERAL .............................................................................. 401
11.2 PROCESS ............................................................................... 403
11.2.1 Acid Gas Enrichment Unit ........................................................... 403
11.2.2 Sulphur Recovery Unit ............................................................... 411
11.2.3 Tail Gas Treatment Unit ............................................................ 423
11.2.4 Incinerator ............................................................................ 430
11.3 UTILITIES .............................................................................. 432
11.3.1 Steam Generation System .......................................................... 432
11.3.2 Boiler Feed Water System .......................................................... 434
11.3.3 DM water system ..................................................................... 437
11.3.4 Chemical Injection System ......................................................... 439
11.3.5 Electro Chlorination System ........................................................ 444
11.3.6 Sea Cooling Water System .......................................................... 444
11.3.7 Fuel Gas System ...................................................................... 445
11.3.8 Effluent Waste Water System ...................................................... 446
11.3.9 Instrument Air Compressors ........................................................ 450
11.4 Utility Failure ......................................................................... 450
11.4.1 LP Steam Failure ..................................................................... 451
11.4.2 Sea Cooling Water Failure .......................................................... 451
11.4.3 Instrument Air Failure ............................................................... 452
11.4.4 Power Failure ......................................................................... 452
11.4.5 Boiler Feed Water Failure .......................................................... 452
11.4.6 Fuel Gas Failure ...................................................................... 452
SECTION XII MAINTENANCE ...................................................... 454
12.1 General ................................................................................ 455
12.2 PREVENTIVE MAINTENANCE ......................................................... 455
12.2.1 Process ................................................................................ 455
12.2.2 UTILITIES .............................................................................. 470
12.3 SHUTDOWN MAINTENANCE .......................................................... 485
12.4 Catalyst Loading & special procedures ........................................... 485
12.4.1 SRU 1st Stage & 2nd Stage Converters/Hydrogenation Reactor................. 486
12.4.2 Catalyst Activity & Life Expectancy ............................................... 497
12.4.3 Catalyst Preparation ................................................................. 499
12.4.4 Catalyst Management................................................................ 501
12.4.5 SRU Converter Catalyst Rejuvenation: ............................................ 502
12.4.6 SRU Converter Catalyst Stripping .................................................. 503
12.4.7 TGTU Hydrogenation Reactor Catalyst Oxidation: .............................. 505
12.4.8 Hydrogenation Reactor Sulphiding in Series with the SRU ..................... 510
12.5 Combustion Air Blower 9102-K-11A lube oil replacement...................... 512
SECTION XIII ANNEXURE ........................................................... 513
13.1 PFD/P&ID .............................................................................. 514
13.2 HEAT AND MATERIAL BALANCE ..................................................... 514
13.3 CAUSE AND EFFECT DIAGRAM....................................................... 514
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 9 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

13.4 DESIGN BASIS ......................................................................... 514


13.5 MSDS ................................................................................... 514
SECTION XIV REFERENCE DOCUMENTS .......................................... 515
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 10 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION I INTRODUCTION
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 11 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

1.1 OBJECTIVE

The purpose of this Operating & Maintenance Manual (O&M) is to provide guidance to
the operators for safe and efficient operation of the Utilities and Processing Facilities
at the SRU Upgrade Facilities at Mesaieed. This O&M Manual provides detailed
guidance on the start-up, shut-down and safe operation of the Utilities and Processing
Facilities at SRU Upgrade Facilities.

1.2 ABBREVIATION

AG Acid Gas
AGEU Acid Gas Enrichment Unit
AGRU Acid gas removal unit
ATM Atmospheric
BCS Boiler control system
BFW Boiler Feed Water
BMS Burner Management System
BSR Beavon Sulphur Recovery
BTEX Benzene, Toluene, Ethyl Benzene, Xylene
CCR Central Control Room
DCC Desuperheater/Contact Condenser
DCS Distributed Control System
DMW Demineralised Water
ECP Electro Chlorination Package
ESD Emergency Shutdown
FD Forced Draft
FV Flow Control Valve
F&G Fire and Gas
HAZOP Hazard & Operability Study
HCV Hand Control Valve
HMI Human Machine Interface
HP High Pressure
HSE Health, Safety and Environment
ICSS Integrated Control and Safety System
ITR Inspection and Test Report
KOD Knock Out Drum
LCP Local Control Panel
LCS Local Control Station
LEL Lower Explosive Limit
LER Local Equipment Room
LOR Local Off Remote
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 12 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

LP Low Pressure
LPM litres per minute
LV Level Control Valve
MCC Motor Control Centres
MDEA Methyl Di Ethanol Amine
MMS Machine Monitoring System
MP Medium Pressure
MSDS Material Safety Data Sheet
NGL Natural Gas Liquids
O&M Operation & Maintenance
PFD Process Flow Diagram
P&ID Piping and Instrument Diagram
PIL Petrofac International Limited
PPE Personal Protective Equipment
PSV Pressure Safety Valve
PV Pressure Control Valve
QP Qatar Petroleum
RGG Reducing Gas Generator
SRU Sulphur Recovery Unit
TGTU Tail Gas Treatment Unit
TLV Threshold Limit Value
TV Temperature Control Valve
TSV Temperature Safety Valve
UCP Unit Control Panel
UEL Upper Explosive Limit
UPS Uninterrupted Power Supply
VFD Variable Frequency Drive

1.3 UNITS OF MEASUREMENT

Sm3/hr Standard cubic meter per hour


3
Nm /hr Normal cubic meter per hour
m/hr Cubic meter per hour
l/hr Litres per hour
T/hr Tonnes per hour
mg/l Milligram per Litre
Kg/hr Kilograms per hour
Bar (a) Bar absolute
Bar (g) Bar gauge
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 13 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

mbar Milli bar


Ppb Parts Per Billion
ppmv Parts Per Million by Volume
ppmw Parts Per Million by Weight
M Meters
Mm Milli meters
2
m Square meters
Kcal/hr Kilo calories per hour
kW Kilo Watt

1.4 GENERAL DESCRIPTION

The primary objective of the Sulphur Recovery Upgrade project is to comply with State
Environmental Regulations. The objective is met by upgrading the existing Sulphur
Recovery Facilities at NGL-3, in Mesaieed, to achieve a minimum sulphur recovery of
99.5% during normal operation.

The upgrade of the SRU includes routing additional sour gas streams from other NGL
plants (NGL-1, 2 and 4) to SRU unit along with NGL-3 AGRU 1 & 2 acid gases.

New Process systems that are included in this upgrade project are:

Acid Gas Enrichment Unit (AGEU)


Tail Gas Treating unit (TGTU)
Tail Gas Incinerator

Existing SRU is upgraded.


New utility systems that are included in this upgrade project are:

Instrument Air and Plant Air System


Nitrogen System
Drinking Water System
Oily Water Drain System
Effluent & Waste Water Treatment System
Flare System
LP Fuel Gas System
Sea Cooling Water System
Demineralised Water System
Boiler Feed Water Deaerator System
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 14 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Steam Generation System


Electrical Power System
Control and Safety System
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 15 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION II HEALTH SAFETY AND ENVIRONMENT


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 16 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

2.1 HEALTH, SAFETY AND ENVIRONMENT (HSE)

This safety section briefs about the safety features of the Sulphur Recovery Upgrade
facilities at Mesaieed which provide safety systems to protect personnel, environment
and assets from the threats of production hazards. The safety of the plant facilities is
maintained at a minimum risk level by adopting the following safety design aspects:
1. Avoiding Exposure to Potential Hazards
2. Minimising the Potential (frequency) for Hazardous occurrences (release of
Hydrocarbons, Hydrocarbon Flammable Gases and any other abnormal hazardous
event)
3. Containing and Minimising the Consequence (Fire, Explosion and Toxic Gas
releases) of the Hazards
4. Providing the Means of Escape and Evacuation from such Hazards
5. Proving a Safe Working Environment for the Plant Personnel.

2.2 LEAKAGE OF ACID GAS

While starting up of Acid Gas System that contains H2S & CO2, it is necessary to take
special precautions as follows:

1. Area around the specific area is barricaded to prevent personnel approaching the
worksite.
2. Personnel carrying out this operation have to take Work Permit and be aware of
the hazards associated with Nitrogen (N2), Carbon Di-oxide (CO2) and Hydrogen
Sulphide (H2S).
3. Wear appropriate Personal Protective Equipment (PPE).
4. As far as possible, the system to be entered is purged using N2/water prior to
opening. This also negates the threat of elemental sulphur and associated
corrosion and cracking.
5. Pyrophoric fire prevention measures are put in place (including availability of
relevant portable fire extinguishers).
6. Personnel involved in the operation should wear Breathing Apparatus (BA) sets.
7. Check H2S concentration frequently after wedge open the flange.
8. Purging using N2 is continued as necessary.
9. When H2S concentration is NIL, the All Clear is given and normal work activities
can recommence.
10. Ensure O2 supply by circulating fresh air through the equipment prior to making
vessel entry.
11. Follow PTW of QP.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 17 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

2.3 HAZARDS IN HANDLING CHEMICALS

2.3.1 MDEA

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.2 Antifoam

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.3 Corrosion Inhibitor

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.4 Caustic

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.5 Biocide

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.6 Scale inhibitor

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.7 Oxygen Scavenger

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.8 Complex Product

Refer the Vendor supplied MSDS in Section XIII (Annexure)


2.3.9 Hydrogen Sulphide

Accidental Release Measures

1. Personal Precautions: Keep unnecessary personnel away. Ensure adequate


ventilation. Do not touch or walk through spilled material.
2. Methods of containment: Stop the flow of material, if this is without risk.
Eliminate all ignition sources (no smoking, flares, sparks or flames in immediate
area). Prevent entry into waterways, sewers, basements or confined areas.
3. Methods for cleaning up: Avoid dust formation. Vacuum or sweep up material and
place in a disposal container.
4. It is likely that the liquid in the system may contain pyrophoric iron sulphide. Even
after steam-out/water washing, this may ignite when drying out in the presence
of air. Therefore, water connections for flushing should be readily available
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 18 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Hazards Identification

1. Health Hazards:
Hydrogen Sulphide is a highly toxic gas, rapidly causing death when inhaled in high
concentrations. Even at low concentrations irritation of the eyes, nose and throat
are possible. The following table illustrates the hazard of varying concentrations:
TLV for prolonged exposure: 10 ppm
Slight symptoms after several hours exposure: 70-150 ppm
Maximum Concentrations that can be inhaled for one hour without serious
effects: 170-300 ppm
Dangerous after exposure of 30 minutes to one hour: 400-700 ppm
Fatal in 30 minutes: 700 ppm and above

Skin absorption has been reported but is not considered significant


Hydrogen Sulphide can be recognized by its rotten egg odour. However its odour
should never be used as a means of detection because exposure even to low
concentrations may dull the sense of smell
Acute toxicity: The greatest danger from the inhalation of hydrogen sulphide is
from its acute effects; it is not cumulative in action
Exposure to moderate concentrations causes headache, dizziness, nausea and
vomiting in that order. Continued exposure may cause loss of consciousness,
respiratory failure and death if the gas concentration is high enough. In exposures
to high concentrations, loss of consciousness may occur rapidly and respiratory
failure may follow a few minutes later. After severe exposures to hydrogen
sulphide the individual may regain consciousness after several hours of treatment
but he may show evidence of permanent severe brain damage. Persons having a
significant exposure to hydrogen sulphide may develop a complete and permanent
loss of the sense of smell thus destroying any ability to detect the presence of
hydrogen sulphide
2. Chronic Exposure
Prolonged exposure to low concentrations of Hydrogen Sulphide has an irritant
effect on the mucous membranes, eyes and the respiratory tract. Eye effects have
been reported at concentrations of 20 ppm or below.

First-Aid Measures

1. General Principles: in case of exposure to hydrogen sulphide the patient should be


removed to fresh air as quickly as possible. The rescuer must be certain that he is
adequately protected against breathing the gas.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 19 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

2. Contact with skin and mucous membranes: Skin absorption is very low. Skin
discoloration is possible after contact with liquid hydrogen sulphide. If such skin
contact is suspected, the area should be thoroughly washed.
3. Contact with eyes: Eye contact with liquid and gas will cause painful irritation. In
case of eye contact keep patient in darkened room; apply ice compresses; put ice
on forehead. Send for physician. Eye irritation caused by exposure to hydrogen
sulphide requires treatment by a physician, preferably an eye specialist.
4. Inhalation: A worker who has been overcome by hydrogen sulphide must be carried
at once into uncontaminated atmosphere. If breathing has stopped, mouth to
mouth resuscitation should be started immediately. If Oxygen inhalation apparatus
is available, Oxygen should be administered by a competent person. Keep the
patient quiet and warm. Call a physician immediately. Do not give anything by
mouth to an unconscious patient.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 20 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION III OVERVIEW OF SRU UPGRADE FACILITIES


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 21 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.1 PROCESS

3.1.1 SRU Upgrade Facilities Overview

The following facilities are part of the Sulphur Recovery Upgrade Project:

New Acid Gas Enrichment Unit (AGEU)


New Tail Gas Treating Unit (TGTU)
New Tail Gas Incinerator

Existing SRU upgrade/modification


Existing SRU upgrade - The SRU plant is upgraded to process the acid gas flow from
the two AGRU trains, along with the acid gas streams from NGL 1/2/4 units.

Utilities System Upgrade: Sea Water Cooling System, Boiler Feed Water System,
Steam Generation System, Instrument/Plant Air System, Fuel Gas System, Waste
Water System, Electrical Power System, Control & Safety System.
AGEU & TGTU are provided with common Amine System. Proprietary Amine solvent
(Dow Ucarsol HS-103) has been selected for this purpose.

3.1.2 Acid Gas Enrichment Unit (AGEU)

Lean acid gas enters the unit at a temperature of 53C and a pressure of 0.55 barg.
This stream is cooled in an Acid Gas Coolers (9103-E-101A/B), before passing to the
Lean Acid Gas KO Drum (9103-V-14). The Lean Acid Gas KO Drum allows bulk removal
of any condensed/entrained liquid from upstream. The liquid level in the Lean Acid
Gas KO Drum is controlled by pumping the liquid via the Acid Gas KO Drum Return
Pumps (9103-P-14A/B) to the existing MDEA storage tank. Alternatively, the sour water
can be routed to the sour water stripper, via a normally closed isolation valve.

Vapour leaves the Lean Acid Gas KO Drum and fed to the Acid Gas Amine Absorber
(9103-C-11), at the bottom. The vapour passes upwards through a trayed bed in
contact with a lean amine solution. The counter current contact with the amine
solution essentially removes all the H2S and some of the mercaptans and part of the
CO2 from the vapour stream. If any BTEX exists in the lean acid gas, it is expected that
80-90% will slip directly to the Incinerator.

Treated gas leaving the top of the absorber (9103-C-11) goes to the Incinerator (9101-
F-14). The rich amine solution, containing absorbed acid gas, is combined with solvent
from the Tail Gas Amine Absorber (9102-C-12). It is removed from the column by the
Acid Gas Rich Amine Pump (9103-P-12A/B). This stream is then heated in the
Lean/Rich Exchanger, before it is fed to the Amine Regenerator (9103-C-12). The rich
amine flow rate is controlled to maintain the level in the Acid Gas Amine Absorber.

The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas
Treatment Units are shared with the use of a common solvent.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 22 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

In the Amine Regenerator, the rich solution is stripped counter currently with vapours
generated by the Amine Regenerator Reboiler. The bottom of the column is
maintained at a temperature by regulating the LP steam flow rate into the
Regenerator Reboiler (9103-E-13). The stripping action in the lower section removes
and releases the contaminants from the solution, such as the acid gases, mercaptans
and residual dissolved hydrocarbons.

The stripped vapours are cooled in the Regenerator Condenser (9103-E-12), and the
Regenerator Condenser Trim Cooler (9103-E-16), by regulating air flow by fans in
Regenerator Condenser and adjusting the flow rate of Sea water to the Regenerator
Condenser Trim Cooler. Any water and amine in the overhead stream is condensed and
collects in the Regenerator Reflux Drum (9103-V-12). The reflux flow rate is controlled
by maintaining the liquid level in the Regenerator Reflux Drum. Acid gas from the
Regenerator Reflux Drum passes overhead to the Sulphur Recovery Unit.

Hot lean amine solution from the Regenerator is pumped to the Amine Surge Tank
(9103-T-11) by the Hot Lean Amine Pump (9103-P-17 A/B). The Lean/Rich Exchanger
(9103-E-11), Lean Amine Cooler (9103-E-14) and Lean Amine Trim Cooler (9103-E-15)
cool the solution prior to the Amine Surge Tank. The lean solution from the Amine
Surge Tank is pumped to the Acid Gas Amine Absorber and the Tail Gas Amine
Absorber via the Lean Amine Pump (9103-P-13A/B). A slipstream is taken off after the
pump and returns to the surge tank through the Lean Amine Filter (9103-S-11), Carbon
Filter (9103-S-12) and the Fines Filter (9103-S-13). The filters remove particulate
matter from the stream as well as hydrocarbons that accumulate in the Amine
solution.

The Amine Surge Tank (9103-T-11) receives the recycle flow from the filter circuit and
the regenerator. It has the capacity to hold the whole system inventory at shut down.
The Amine Surge Tank is maintained at a slightly positive pressure, however not high
enough to be able to float on the flare header to maintain pressure and stop ingress of
Oxygen. Therefore it is provided with Nitrogen blanketing to prevent air ingress and to
minimise the risk of solution degradation.
EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan
Rev.: 0
Part-1 SRU (Mesaieed)
Date: 03/09/2012
Doc. No.: 2970-0-22-0001
Page: 23 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 1 Acid Gas Enrichment Unit


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 24 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.1.3 Sulphur Recover Unit Process Description

The acid gas stream from the gas treating plant enters the Acid Gas KO Drum (9101-V-
04) where acid water is knocked out and pumped to Amine Sump (9103-V-14). The gas
stream flows to exchanger (9101-E-06) for preheating before entering the Reaction
Furnace (9101-F-01), where the acid gas is burnt by the high intensity burner with a
controlled amount of air. Air is supplied by an electrically driven blower (9101-K-
01A/B) & preheated by exchanger (9101-E-05). The products of the combustion are
cooled in passing through the tube section of the Waste Heat Boiler (9101-E-07) where
a 24 barg steam is generated in the shell side. Gases and any condensed liquid sulphur
from the Waste Heat Boiler flow to the Sulphur Condenser (9101-E-01) where the gases
are cooled and the additional sulphur is condensed. The gases then passes through the
Auxiliary Burner (9101-F-02) where they are reheated by burning a split stream of acid
gas (or fuel gas) with air, before entering the first Claus Converter (9101-V-01). In this
converter the gases flow downwards through a bed of CR 4/8 mm activated alumina,
top loaded with a layer of AM 4/8 catalyst. In the converter, additional elemental
sulphur is produced and carried over in vapour phase by the hot gases. The exothermic
Claus reaction results in a temperature increase through the adiabatic converter. The
hot gases leaving the first converter are cooled in the Sulphur Condenser (9101-E-02)
by generating 5 barg steam, the condensed sulphur flows to the Sulphur Degassing Pit
(9101-T-01/01Z) through Sultraps. The gases from the Sulphur Condenser (9101-E-02)
flow through a coalescer equipped with SS wire mesh pads for the removal of any
entrained sulphur. The gases then passes through the second stage auxiliary burner
(9101-F-03) where they are reheated by burning a split stream of acid gas (or fuel gas)
with air, before entering the second Claus Converter (9101-V-02), loaded with a more
active catalyst CRS 31 and a layer of AM 4/8 mm catalyst on the top of the bed. The
Final Condenser (9101-E-04) ensures cooling of the process gases by preheating the
boiler feed water which is used in the Waste Heat Boiler (91 01-E-07) and the two LP
steam producing 1st stage & 2nd stage condenser (9101-E-01 & 9101-E-02). The process
gases from Final Condenser passes through a Final Separator (9101-V-05) to achieve
complete removal of liquid sulphur drops from the process gases. A coalescer is
provided in Final Separator (9101-V-05). From final separator, the process gas is
routed to Incinerator (9101-F-14), where all remaining sulphur compounds are burnt to
sulphur dioxide. Incineration is achieved by burning fuel gas with a slight excess of air
at a temperature of 800C. The incinerated gas is disposed of to the atmosphere via
stack (9101-X-11). The sulphur produced in the process is extracted from all sulphur
condensers through sultraps and is routed to the Sulphur Degassing Pit (9101-T-01).
The sulphur is degassed through AQUISULF sulphur degassing process. The degassed
sulphur is then transferred to the Storage Tank 9101-T-02 by Sulphur Transfer Pumps
(9101-P-04A/B).
EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan
Rev.: 0
Part-1 SRU (Mesaieed)
Date: 03/09/2012
Doc. No.: 2970-0-22-0001
Page: 25 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 2 - Sulphur Recovery Unit


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 26 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.1.4 Tail Gas Treatment Unit (TGTU)

The purpose of the Tail Gas Treating Unit is to reduce the hydrogen sulphide
concentration in the tail gas to a level corresponding to >99.5% total sulphur recovery.
All residual hydrogen sulphide is oxidised to sulphur dioxide before it is released to the
atmosphere.

The BSR/Amine process consists of a Beavon Sulphur Recovery (BSR) reducing or


hydrogenation section and a selective amine section. The process uses the BSR
technology to reduce all sulphur compounds in the SRU tail gas to hydrogen sulphide.
This section includes water condensation and separation upstream of the amine
section with a caustic circulation system to protect against SO2 breakthrough, which
degrades the amine and causes severe corrosion.

The amine section uses an amine solution to remove most of the hydrogen sulphide
from the treated sulphur plant tail gas while minimising the co-absorption of carbon
dioxide.

The Claus tail gas from the Final Sulphur Condenser 9101-E-04 is fed to the Reducing
Gas Generator (RGG). The purpose of the Reducing Gas Generator is to generate
reducing gases (H2 and CO). This is achieved by the combustion of fuel gas with a sub-
stoichiometric quantity of air. The production of reducing gases is regulated by
controlling the flow of the fuel gas and air. Air flow is set by the outlet temperature of
the Reducing Gas Generator 9102-F-01 whilst the fuel gas flow rate is set to be a fixed
proportion of the air flow. LP steam is fed to the Reducing Gas Generator to suppress
the formation of carbon. The flow rate of the steam is ratio-controlled according to
the fuel gas flow rate. The tail gas from the Final Sulphur Condenser is mixed with the
hot combustion products in the Reducing Gas Generator to ensure a temperature that
will favour the desired reactions in the Hydrogenation Reactor (9102-V-01).

The Hydrogenation Reactor contains a fixed bed Cobalt/Molybdenum (CoMo) catalyst.

The reactions are exothermic resulting in a temperature rise across the reactor. The
gas is cooled by the generation of LP steam in the Reactor Effluent Cooler.

The tail gas is then desuperheated and the excess water removed in the
Desuperheater/Contact Condenser (9102-C-01). This tower contains an upper packed
section, a chimney tray and a lower section containing packing and bubble cap trays.
In the lower packed section of the tower (Desuperheater section), tail gas is contacted
with a circulating stream of a mildly caustic water solution. This removes sulphur
dioxide and cools the tail gas down. The Desuperheater Circulation Pump (9102-P-
11A/B) pumps the caustic water solution from the bottom of the tower to the top of
the packing. Water make up is provided to the lower (Desuperheater) section, under
level control, from the top (Contact Condenser) section circulation.

The solution is maintained at an alkaline pH of around 9.0 to protect against SO2


breakthrough from the reactor. SO2 causes corrosive conditions in the Desuperheater
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 27 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Contact Condenser and the Amine Absorber, and degrades the amine. The pH of the
circulating liquid is monitored by a continuous analyser and controlled by periodic,
manual addition of fresh caustic solution. An intermittent bleed from this section
removes accumulated contaminants from the circuit.

The desuperheated gas and water vapour then passes through the (wash) bubble cap
trays and the chimney tray into the upper (Contact Condenser) packed section. Here
the gas is cooled by direct contact with a circulating water stream. The water is
pumped by the Cooling Water Circulation Pump from the chimney tray, through the
Contact Condenser Cooler where it is cooled, and back to the top of the tower. The
water that is condensed in this section is slightly sour. Some is used as make up on
demand to the lower Desuperheater section and the remainder is taken off under level
control and sent to effluent treatment. The condensed water loop is kept separate
from the water in the desuperheater circulation loop to avoid contamination with salt
products that may be formed in the Desuperheater section.

The tail gas leaves the Desuperheater Contact Condenser (9102-C-11) at a temperature
of approximately 40C and is sent to the Tail Gas Amine Absorber (9102-C-12) which
uses a lean amine solution to remove the hydrogen sulphide from the tail gas, whilst
minimising the co-absorption of carbon dioxide.

The gas enters at the bottom of the absorber and passes through a packed bed counter
current to the lean amine solution that preferentially absorbs H2S. The lean amine
solution is supplied from the Amine Regenerator.

The Tail Gas Rich Amine Pump (9102-P-16 A/B) pumps the rich solvent solution from
the bottom of the Tail Gas Amine Absorber (9102-C-12) to the Acid Gas Amine
Absorber (9103-C-11) before it is regenerated in the Amine regenerator (9103-C-12).

The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas
Treatment Units are shared with the use of a common solvent. The H2S that is stripped
from the rich amine solution in the Amine Regenerator is fed to the Sulphur Recovery
section, thus closing the recycle loop around the SRU and TGTU sections.

Treated gas from the Tail Gas Amine Absorber passes to the Incinerator along with
that from the Acid Gas Amine Absorber and from the Sulphur Pit. The incinerator is
designed to incinerate all sulphur compounds in the streams under normal operation.
It is also used to incinerate additional streams while the TGTU is bypassed or during
start-up or abnormal operating conditions. The flue gas is released to the atmosphere
through the Stack (9101-X-11).
EPIC for Gas Sweetening Facilities Project (GSF) at Mesaieed & Dukhan
Rev.: 0
Part-1 SRU (Mesaieed)
Date: 03/09/2012
Doc. No.: 2970-0-22-0001
Page: 28 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 3 - Tail Gas Treatment Unit

LV-1305
FV-1314
XV-1331
FV-1304
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 29 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.1.5 Tail Gas Incinerator

An Incinerator is provided to thermally oxidise all possible sulphur compounds to SO2 in


off gas effluents from the Acid Gas Amine Absorber, Tail Gas Amine Absorber, SRU tail
gases and vent gases from the sulphur Degassing Package. Moreover all BTEX content
of off gas effluent is also destructed.

To ensure complete combustion of these sulphur compounds the Incinerator's


combustion chamber temperature is maintained at a temperature of about 817C by
burning fuel gas supplied with combustion air in the unit's burner. Combustion air is
supplied from 2 x 100% Incinerator Air Blowers (9101-K-12 A/B). The flows of fuel gas
and combustion air are each measured by flow and then ratio controlled to ensure the
correct amount of excess air is always maintained in the Incinerators combustion
chamber to allow the oxidation of the sulphur compounds in the tail and vent gases to
take place. An Oxygen analyser located in the Incinerator outlet combustion gases
ducting monitors the excess O2 in the Incinerators combustion gases. Adjustments may
be made to the fuel gas to air ratio controller to ensure the correct excess of O2 (3% by
Mol) is seen in the stack gases. A SOX/NOX analysers, located part way up the
Incinerator Stack (9101-X-11), monitors the Incinerator stack gases for SOX/NOX
content.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 30 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 4 - Tail Gas Incinerator


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 31 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.1.6 Amine Drain System

Amine drained from pumps and other equipment during times of maintenance and
plant overhaul, is collected in the Amine Sump. The Amine Sump Pump must be
started manual by operations in order to transfer the amine to the Amine System via
the Amine Sump Filter. A differential pressure indicator across the filter monitors the
filter pressure drop. In the event that the amine sump pump is not manually stopped
when the low level alarm is activated then a low low level switch will stop the pump
to prevent loss of suction damage to the pump.

To prevent air ingress into the amine sump a small flow of Nitrogen is introduced into
the amine sump and allowed to pass out of the sump to the atmosphere through
carbon canister.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 32 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 5 - Amine Sump and Pump


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 33 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2 NEW UTILITY FACILITIES

3.2.1 Instrument and Plant Air

The new air compressor package consists of the following:

1. Two Air Compressors (6837-K-02A/B) having a capacity of 900 Nm3/hr (dry basis)
2. One air compressor discharge drum, (6837-V-10) is provided
Two Instrument Air Dryer packages, (6837-A-03/04) running at 2 X 50%, each
dryer capacity is 300 Nm3/hr (dry basis)

One Instrument Air Receiver (6837-V-11) with storage capacity to provide


instrument air for a period of 20 minutes following a compressor trip
The new Air System will supply instrument and plant air with the following supply
battery limit conditions for both instrument and plant air:

Design Operating
Pressure bar (g) 9.7 7.0
Temperature (C) 85 55/60

The new instrument and plant air headers are connected to the existing NGL-3
instrument and plant air headers respectively through cross over connection lines with
(manual isolation valves) for operation flexibility.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 34 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 6 Plant/Instrument Air System


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 35 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.2 Demineralised Water System

The supply of fresh water to the new DMW Package is taken from existing Drinking
Water Storage Tanks (6834-T-01 A/B) by means of new Drinking Water Feed Pumps
(6834-P-23 A/B, one operating, one standby). Each pump is designed for a flow of
10 m3/h and supplies fresh water to the following users:
Demineralised Water Package
Cross connection to the existing fresh water network
Utility water to utility stations, safety showers and eye wash stations.
The Demineralised Package is based on ion exchange technology (similar to the
existing DMW Package) and consists of two identical trains. The following equipment
items are envisaged to form part of the package:
Two Cation Exchangers
Two Anion Exchangers
Two Demineralised-Water Regeneration Pumps
two Demineralised-Water Recirculation Pumps
One Hydrochloric Acid (HCL) Storage Tank
There HCL Injection Pumps
One Caustic (NaOH) Storage Tank
Three NaOH Injection Pumps
One Neutralisation Pit

One Neutralisation Pump


The DMW Package operates continuously and automatically and thus requires minimum
operator intervention. The package includes the necessary control and safety devices.
The Demineralised Water from the DMW Package is routed to Demineralised Water
Storage Tank (6834-T-08). Capacity of Demineralised Water Storage Tank is 83 m3.

Centrifugal type, DMW Feed Pumps (6834-P-24A/B one running, one standby) are used
to supply demineralised water at 3.7 barg pressure and ambient temperature, from
DMW Storage Tank to the:
Steam Condensate Flash Drum (6834-V-05)

Amine Surge Tank (9103-T-11)


Make-up water to Cooling Water Circulation Pump (9102-P-12 A/B)
Start-up water to Stripper Overhead Circulation Pump (6922-P-11 A/B)
Make-up water to Amine Regenerator Reflux Drum (9103-V-12)
Existing DMW Network System (for operational flexibility, normally no flow).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 36 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 7 Demineralized Water System


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 37 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.3 Sea Cooling Water System

Two Seawater Cooling Pumps 6932-P-04A/B are installed on a new jetty and take
suction from the sea. The pumps are vertical-shaft, constant speed centrifugal pumps
and are electric motor driven. The seawater cooling pumps have a design capacity of
1600 m3/h (each) at a discharge pressure of 5.0 barg.

One pump is normally running, while the other is on standby. Each pump is capable of
supplying a normal flow of 1200 m3/h to users for SRU upgrade.

The water enters the pump through a suction pipe (stilling tube) to reduce turbulence.
A coarse mesh bar suction screen is installed at each pump to prevent seaweed and
other debris from entering the seawater supply system.

From the common discharge of seawater cooling pumps, seawater stream flows via a
new dedicated 24 main supply header to the new Filtration Package Unit (6932-S-
02A/B). The self cleaning rotary type Seawater Filters (one in operation and one on
standby) are capable of removing particle sizes greater than 1000 microns from
seawater and each unit is designed for a flow of 1600 m3/h. The filtered water from
filters is routed to the heat exchangers located in AGEU/TGTU and other users.

The filter skid comprises:

Two Rotary Filters (6932-S-02A/B) and motors


The 2 x 100% filters are equipped with an automatic back-flushing mechanism
which operates on intermittent basis
A small portion of the main seawater (cooling water) flow is diverted downstream of
the filters to provide seawater supply for the Electro Chlorination Unit (6932-A-05).

The Electro Chlorination Unit generates sodium hypochlorite solution. The sodium
hypochlorite solution is injected into Sea Cooling Water Pumps suction lines to control
growth of marine organisms in the Sea Cooling Water System. There is one dedicated
new Electro Chlorination Unit.

In addition, a dedicated Biocide Injection Unit (6932-A-06) for effective control of


growth of marine organisms and a dedicated Scale Inhibitor Injection Unit (6932-A-07)
to prevent formation of mineral scales in the Sea Cooling Water system are also
provided for existing as well new Sea Cooling Water Systems.

The new Cooling Water System is a once through system and the seawater returned
from the SRU upgrade facilities is discharged into existing Seawater Observation Sump
(6932-X-01) which has a retention capacity of 60 m3.

From the sump the seawater overflows to the sea. To prevent fouling the temperature
of cooling water from each exchanger outlet should not exceed the maximum
allowable temperature limit of 45C. A tie in to the existing NGL-3/4 seawater supply
system is also provided to supply seawater from the new Sea Water Pumps.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 38 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 8 Sea Cooling Water System


To Existing Sea Cooling Water System

6932-S-02A/B
Cooling
Water
Filters

6848-T-02
9103-E-101 9103-E-15 9103-E-16 9102-E-13A/B Boiler Blow
Acid Gas Lean Amine Regenerator Contact Down Pit
Cooler Trim Cooler Condenser Condenser
Trim Cooler Trim Cooler

Steam Generation
Package
Acid Gas Enrichment Unit Tail Gas Tr. Unit

6932-A-05 To Observation Sump


M M 6932-X-01
Electro Chlorination
Package

Sea Cooling
Water Pumps

6932-P-04A 6932-P-04B

6932-A-06 6932-A-07
Biocide Injection Package Scale Inhibitor
Injection Package

6932-T-01
Local Chemical Drain Pit
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 39 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.4 Boiler Feed Water System

Boiler Feed Water (BFW) is required for the generation of MP and LP steam in the gas
fired water Steam Generators (6848-A-02 A/B/C). The Boiler Feed Water, consists of a
mixture of LP steam condensate and Demineralised Water make-up.

The Boiler Feed Water system includes the following equipment:

Description Equipment Tag No.


Steam condensate Flash Drum 6834-V-05
Deaerator Feed Pumps 6834-P-20A/B
Steam Condensate Cooler 6834-E-02
Boiler Feed Water Deaerator Package 6834-A-08
Boiler Feed Water Pumps 6834-P-22 A/B/C
BFW Chemical Injection Package
O2 Scavenger Injection Pumps 6834-A-09
Complex Product Injection Pumps

The Boiler Feed Water passes through a Steam Condensate Flash Drum 6834-V-05
where the flash steam cools down the inventory to 102C to prevent cavitations in
Deaerator Feed Pumps.

The DMW Condensate is pumped by the Deaerator Feed Pumps to the heating section
of a Thermal Deaerator where all the free carbon dioxide and the oxygen up to 5 ppb
are removed by heating and scrubbing the water with the LP saturated steam at
0.2 barg pressure.

The extracted dissolved gases such as O2, CO2 and water vapour are discharged
through restriction orifice (68-RO-1305) to atmosphere.

A dose of Oxygen Scavenger is injected into the hold up section of the Deaerator to
completely eliminate the residual oxygen from the water. The capacity of the holding
section in the Deaerator is equivalent to 20 minutes.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 40 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 9 Boiler Feed Water System


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 41 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.5 Steam Generation Package 6848-A-02A/B/C

The MP steam boiler package 6834-A-02A/B/C includes three boilers, two operating
and one stand-by. Each boiler has a nominal steam generating capacity of 45 T/h.

The Boiler Feed Water enters the external Economizer 6848-E-01A, which is a finned
tubes heat exchanger (water/flue gas). The feed water is heated by the flue gas
thermal heat in the flue gas path. In case sour fuel gas is used, the boiler feed water is
sent to a preheating water circuit installed inside the water drum, before going to the
Economiser 6848-E-01A. This is to avoid acid condensation inside the flue gas duct.

From the Economizer outlet, the feed water enters into the boiler upper drum called
Steam Drum 6848-V-02A. Boiler functioning relies on steam/water natural
circulation, with evaporating rising circuits formed by the hottest tubes of boiler
evaporating bank. Remaining tubes acts as downcomers, which feed the rising circuits.

In the boiler evaporating tubes, the mixture of saturated water & steam is produced.
Then through the steam drum internal separators, the saturated steam is separated
from the saturated water droplets. The steam then passes through the steam header
and reaches the temperature and pressure controlling stations. The pressure is
controlled by a pressure control valve 68-PV-1524 and the temperature is controlled by
water injection type Desuperheater 6848-X-03A.

The combustion air for the boiler is supplied by a Forced Draft Fan 6848-K-02A, driven
by an electric motor. At the inlet of the FD Fan 6848-K-02A, a Grid Filter 684803A, a
Sand Filter 6848-S-02A and a silencer 6848-X-06A are provided. Downstream of this,
the modulating inlet control damper is provided. At the outlet the air passes through a
duct that delivers air to wind box. The combustion air measuring device 68-FE-1526 is
provided in this duct. Air is supplied to the burners through the wind box.

When the combustion takes place, the high temperature flue gas pass through the
boiler furnace, enclosed by water cooled tubes.

The flue gases at the end of the combustion chamber, turn to 180 and pass through
the evaporative convective section. The convective section is located on the right side
of the furnace.

The flue gases then pass through the Economizer and reach the stack.

A Flue Gas Recirculation Fan 6848-K-03A, which takes suction from the flue gas
Economizer downstream duct and discharges to the combustion air measuring device
68-FE-1526 provided in combustion air duct, is provided. In order to meet the
specified low emissions target, at high boiler load, the burners can be operated in flue
gas recirculation mode, the combustion air is mixed with a proper flue gas flow rate
(about 15% of nominal flow rate).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 42 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The steam generator is provided with one burner, designed to burn both sour and
sweet fuel gas. The burner is designed to have a turndown of 10:1. Burner is provided
with a pilot which is of high energy type.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 43 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 10 Steam Generation System

PV-1523
TV-1522
XV-1527
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 44 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.6 Fuel Gas System

LP fuel gas is required for


New Steam Generation Boilers 6848-A-02A/B/C
The main normal LP fuel gas supply for the new MP Steam Boiler Package (6848-A-02-
A/B/C) and Waste Water Degasser (6922-V-07) blanketing is supplied from the first
stage suction of the existing Booster Compressors (6701-K-10120/30) in NGL-3. In
addition, two back up sources are provided; the first is the fuel gas from (6103-K-01
A/B) with a second backup from existing 30 line to Point B. The new fuel gas supply
system will consist of a letdown station, Fuel Gas KO Drum (6236-V-05), and a supply
header to the Steam Boilers and Waste Water Degasser. The source pressure from the
take-off point is let down to 7 barg through the pressure control valve 62-PV-1301A
before entering the LP Fuel Gas KO Drum. The source pressure of the fuel gas from
6103-K-01 A/B is 20 barg whilst that of feed gas from the 30 line is 45 barg. The
former is let down to 7 barg through the pressure control valve 62-PV-1301 B and the
latter via 62-PV-1302.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 45 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 11 Fuel Gas System


Hydro Carbon Gas PV-1303
Flare Header
To LP Flare

To Steam Boiler Package


6848-A-02A/B/C
XV-1301

From 1st Stage


Booster Compressor
(6701-K-10/20/30)

PV-1301A
Suction Header
E-19

To LP Hydrocarbon Flare LP Fuel Gas


Header KO Drum

6236-V-05

XV-1302 PV-1301B

Backup Supply Fuel


Gas from 6103-K-01A/B

XV-1303 PV-1302

To Flare Header
Backup Supply Fuel Gas
from 30" Existing Line
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 46 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.2.7 Effluent and Waste Water Treatment Unit

The sour water resulting from the new facilities added as part of the SRU Upgrade
Project contains high levels of dissolved sulphides which need to be removed before
the waste water can be discharged to the marine environment. The acceptable levels
of sulphides is 0.1 mg/l (0.1 ppmw) and to achieve this the sour water is treated in the
sour water treatment system.
Sour water from various sources is collected in the Degassing Drum, which provides
over 20 minutes of hold-up for the waste water. The flow of waste water from
Desuperheater/Contact Condenser (9102-C-11) is continuous at a rate of 8.7 m3/h
whilst all other sources are intermittent. The sour water from the degasser is
continuously pumped under flow control by Waste Water Degasser Pumps (6922-P-
08A/B) to the Sour Water Stripper Unit for treatment.
In the event the Sour Water Treatment System is unavailable due to a process upset,
provision exists for manually routing the degasser liquids directly to the Observation
Sump (6922-X-04).
A balance line between Degassing Drum and Sour Water Stripper 6922-C-01 means that
the pressure in the Degassing Drum floats on the stripper operating pressure (i.e.
1.0 barg). A nitrogen supply line is provided to maintain pressure in the drum if it falls
below a certain minimum as liquids are pumped out.
The sour water from degasser drum is filtered in 6922-S-06 and then preheated in Sour
Stripped Water Exchanger 6922-E-01 before feeding to Sour Water Stripper 6922-C-01.
The Sour Water Stripper operates at 1.0 barg and has an upper section and a lower
tray section.
The sour water is stripped by the vapours generated from the Sour Water Stripper
Reboiler 6922-E-04. The Reboiler utilises LP steam to heat the sour water that comes
from the bottom of the Sour Water Stripper to 126C. The condensed steam from the
Reboiler is sent to the LP Condensate system through level control.

Reflux for the column is provided by a pump-around system. Water is taken from below
tray 33 pumped by Stripper Overheads Circulation Pumps 6922-P-11A/B under flow
control, cooled in Stripper Overheads Cooler 6922-E-03 and then returned to the top tray.
The stripper overhead acid gases are routed to the AGEU (upstream of 9103-V-14). In
the event of high column pressure, excess gases are diverted to LP Acid Gas flare.

The stripped water from the stripper is pumped under level control cascaded to a flow
controller via Stripped Water Pump 6922-P-10A/B to the Sour/Stripped Water
Exchanger 6922-E-01 to preheat the feed to the stripper. The water is then routed to
the Stripper Water Cooler 6922-E-02 where it is cooled to 55C before discharge to the
Observation Sump.
An analyser is provided in the line to the Observation Sump to monitor the sulphide
content of the stripped water stream.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 47 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 12 Waste Water Treatment Unit


Balance Line
LP Fuel Gas from
6236-V-05
Sour Gas to TGTU
PV 1315A XV 1313
PV-1307
Waste Water from Cooling
Water Circulation pumps
9102-P-12A/B Stripper Overheads Cooler
PV 1315B To LP Acid Gas Flare
6922-E-03

XV 1312
Pressurised drain from

PV 1307
9102-P-12A/B
LV-1325 M Water for Startup

Sour Water from Regenerator


Reflux Drum 9103-P-11A/B
Corrosion Inhibitor
NC

Waste Water Degasser FV 1316


6922-V-07

Waste
Water
Stripper Stripper Overheads

FV 1314
6922-C-01 Circulation Pumps
6922-P-11 A/B
TV 1327

Sour Water Desuperheater FV 1315


Stripper 6922-X-01 From LP Steam
Reboiler
6922-E-04

Waste Water Sour Water Filter


6922-S-06 Reboiler
Degasser Pumps
Condensate
6922-P-08A/B
Drum
6922-V-09

LV 1327 LP
Sour Stripped Condensate
Water Exchanger
Stripped Water Pumps
6922-E-01
6922-P-10A/B

Stripped Water Cooler


6922-E-02 FV 1317

Stripped Water to
M Observation Sump
6922-X-04
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 48 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3.3 FIRE WATER & DELUGE SYSTEM

3.3.1 Fire Water System

The fire water ring main for the new Process facilities is connected to the existing 12
ring main and tie-in provided at two existing fire water ring mains 12-6533-FW-001-
C12T & 12-6533-FW-002-C12T.

The fire water ring main for the new Utilities is connected to the existing 12 ring
main and tie-in provided at two existing fire water ring mains 12-6533-FW-006-C121
& 12-6533-FW-107-C120.

Fire water ring main is buried with minimum 1 meter cover. Ring main block valves are
post indicator type and accessible from surface.

Fire hydrants and monitors are located at 1.5 m from road. If the distance is shorter, a
crash barrier is provided. The fire hydrants and monitors are located at 15 m from
plant/equipment/buildings they intended to protect. All fire hydrants face the plant
equipment.

Fire hydrants are 4-way outlet hydrant valves with (1000 LPM) inbuilt pressure
regulating device. Each hydrant is provided with 6 riser pipe bib nosed 3 branch
inlet and 2.5 instantaneous hose connection.

Monitors are suitable for manual operation with locking facilities in both horizontal
and vertical planes. It is capable of 360 horizontal movement and elevation 75
above and 30 below the horizontal.

3.3.2 Deluge System

Deluge Skid is used in the new facilities as per details below.

Deluge Skid No. Deluge Valve Size Equipment protected


91-DV-1711 4 Hydrogenation Reactor (9101-V-11)
Acid Gas Cooler (9103-E-101)
91-DV-1712 8 Lean Acid Gas KO Drum (9103-V-14)
Acid Gas Amine Absorber (9103-C-11)

Deluge valves are activated by:

Automatically activated upon fire detection via F&G System/fusible plug loop

Manually locally activated by hand lever through HCV/Push button at safe distance
Manually/remotely activated from F&G console.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 49 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 13 Deluge Valve Typical Installation

LO

6 Lit. Capacity
Air Vessel
NC

LC
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 50 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION IV PROCESS AND CONTROL DESCRIPTION


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 51 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.1 ACID GAS ENRICHMENT UNIT (AGEU)

4.1.1 Equipment Specification

Acid Gas Coolers


Equipment Tag No. 9103-E-101A/B
Process Medium (Shell/Tube) Acid Gas/Sea Water
Design Pressure Shell Side, barg 6.2
Design Pressure Tube Side, barg 8.0
Design Temperature Shell Side, (Max./Min.), C 175/0
Design Temperature Tube Side, (Max./Min.),C 85/0
Operating Pressure Shell/Tube Side, barg 0.51/1.7
Operating Temperature, Shell Side (In/Out) C 63/53
Operating Temperature, Tube Side (In/Out) C 35/41.76
Design Duty, kW 164
Material of Construction, Shell/Tube SS316L/Titanium Grade 2

Lean Acid Gas KO Drum


Equipment Tag No. 9103-V-14
Tower Diameter/Height, mm 3000/7000
Process Medium Acid Gas
Design Pressure, barg 3.5/FV
Design Temperature, C (Max./Min.) 175/0
Operating Pressure, barg 0.38
Operating Temperature, C 53
Material of Construction, Shell/Internals CS/SS316L

Acid Gas KO Drum Return Pump


Equipment Tag No. 9103-P-14A/B
Process Medium Sour Water
3
Capacity, m /hr (Normal/Rated) 5/6.7
Driver Type Motor
Rated Power, kW 7.5
Suction Pressure, bar(a) (Rated/Max.) 1.66/5.23
Discharge Pressure, bar(a) 5.0
Operating Temperature, C 49
Design Temperature, C (Max./Min.) 85/0
Material of Construction - Casing/Impeller A351-CF8M/SS316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 52 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Acid Gas Amine Absorber


Equipment Tag No. 9103-C-11
Tower Diameter, mm 4100
Tower Height, mm 20040
Tray Nos. 10
Process Medium Acid Gas/MDEA
Design Pressure, barg (Max./Min.) 3.5/FV
Design Temperature, C (Max./Min.) 175/0
Operating Pressure, Top/Bottom, barg 0.19/0.38
Operating Temperature, Top/Bottom, C 46/58.1
Material of Construction, Top section CS+SS316L CLAD
Material of Construction, Bottom section CS
Material of Construction, Internals SS316L

Acid Gas Rich Amine Pumps


Equipment Tag No. 9103-P-12A/B
Process Medium Rich Amine
3
Capacity, m /hr (Normal/Rated) 682/750.2
Driver Type Motor
Rated Power, kW 195
Suction Pressure, bar(a) (Rated/Max.) 1.99/6.1
Discharge Pressure, bar(a) 8.5
Operating Temperature, C 56
Design Temperature, C (Max./Min.) 85/0
Material of Construction Casing/Impeller A351-CF8M/SS316L

Lean/Rich Amine Exchanger


Equipment Tag No. 9103-E-11A/B
Process Medium Rich Amine/Lean Amine
Design Pressure Lean Amine Side, barg 14.3
Design Pressure Rich Amine Side, barg 13.6
Design Temperature (Max./Min.)C 150/0
Operating Pressure Lean/Rich Amine Side bar(g) 5.8/5.32
Operating Temperature, Lean Amine Side
129/85
(In/Out) C
Operating Temperature, Rich Amine Side
55/101
(In/Out) C
Design Duty, kW 34669
Material of Construction, Plates SS 316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 53 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Amine Regenerator
Equipment Tag No. 9103-C-12
Tower Diameter, mm 5650
Tower Height, mm 24450
Tray Nos. 24
Design Pressure, barg (Max./Min.) 7.0/FV
Design Temperature, C (Max./Min.) 175/0
Operating Pressure, Top/Bottom, bar(a) 2.21/2.44
Operating Temperature, Top/Bottom, C 118/131
Material of Construction, Top section CS+SS316L CLAD
Material of Construction, Bottom section CS
Material of Construction, Internals SS316L

Hot Lean Amine Pumps


Equipment Tag No. 9103-P-17A/B
Process Medium Lean Amine
3
Capacity, m /hr (Normal/Rated) 717/789
Driver Type Motor
Rated Power, kW 195
Suction Pressure, bar(a) (Rated/Max.) 2.84/8.9
Discharge Pressure, bar(a) 7.8
Operating Temperature, C 131
Design Temperature, C (Max./Min.) 150/0
Material of Construction Casing/Impeller A351-CF18M/SS316L

Regenerator Condenser Cooler


Equipment Tag No. 9103-E-12
Type Forced Draft Air Cooler
Process Medium Acid Gas
No. of Fans 12
Fan Power, kW/Fan 22
Design Pressure, barg 7.0/FV
Design Temperature (Max./Min.)C 175/0
Operating Pressure bar(a) 2.18
Operating Temperature, (In/Out) C 118/54
Design Duty, kW 18574
Material of Construction, Header & Tubes Alloy 825
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 54 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Regenerator Condenser Trim Cooler


Equipment Tag No. 9103-E-16
Process Medium (Shell/Tube) Acid Gas/Sea Water
Design Pressure Shell Side barg (Max./Min.) 8.0/FV
Design Pressure Tube Side barg (Max./Min.) 8.0/FV
Design Temperature Shell Side(Min./Max.) C 150/0
Design Temperature Tube Side (Min./Max.) C 85/0
Operating Pressure Shell/Tube Side, barg 1.07/5.0
Operating Temperature, Shell Side (In/Out) C 54/49
Operating Temperature, Tube Side (In/Out) C 35/42
Design Duty, kW 271
Material of Construction Shell/Tube SS316L/Titanium Grade-2

Regenerator Reflux Drum


Equipment Tag No. 9103-V-12
Process Medium Acid Gas
Drum Diameter, mm 1500
Drum Height, mm 4520
Design Pressure, barg (Max./Min.) 7.0/FV
Design Temperature, C (Max./Min.) 175/0
Operating Pressure, barg 1.02
Operating Temperature, C 49
Material of Construction SS316

Regenerator Reflux Drum Pumps

Equipment Tag No. 9103-P-11A/B


Process Medium Regenerator Reflux Liquid
Capacity, m3/hr (Normal/Rated) 26.15/31.4
Driver Type Motor
Rated Power, kW 22
Suction Pressure, bar(a) (Rated/Max.) 2.27/8.6
Discharge Pressure, bar(a) 8.41
Operating Temperature, C 49
Design Temperature, C (Max./Min.) 85/0
Material of Construction, Casing/Impeller A351-CF8M/SS316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 55 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Regenerator Reboiler Condensate Pot


Equipment Tag No. 9103-V-13
Process Medium Condensate
Drum Diameter, mm 2100
Drum Height, mm 4100
Operating Pressure, barg 4.5
Operating Temperature, C 155
Design Pressure, barg (Max./Min.) 7.0/FV
Design Temperature, C (Max./Min.) 185/0
Material of Construction CS

Regenerator Reboiler
Equipment Tag No. 9103-E-13
Process Medium Amine
Design Pressure, Shell Side, barg 7.0/FV
Design Pressure, Tube Side barg 7.0/FV
Design Temperature, Shell side C 150/0
Design Temperature, Tube side C 185/0
Operating Pressure, Shell, Side barg 1.356
Operating Pressure, Tube Side barg 4.5
Operating Temperature, Shell side C 130
Operating Temperature, Tube side C 159
Design Duty, kW 48413
Material of Construction, Shell side CS
Material of Construction, Tube side SS316L

Lean Amine Cooler


Equipment Tag No. 9103-E-14
Process Medium Lean Amine
Design Pressure, barg, (Max./Min.) 14.3/FV
Design Temperature C 175/0
Operating Pressure barg 4.3
Operating Temperature C 85
Design Duty, kW 30318
Material of Construction Header/Tubes Alloy 825
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 56 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Lean Amine Trim Cooler


Equipment Tag No. 9103-E-15
Process Medium Lean Amine
Design Pressure, Lean Amine Side, barg 14.3
Design Pressure, Sea Water Side, barg 8.0
Design Temperature Lean Amine Side C 90/0
Design Temperature Sea Water Side C 85/0
Operating Pressure Lean Amine Side barg 5.30
Operating Pressure Sea Water (In/Out) Side
2.6
barg
Operating Temperature, Lean Amine Side
54/45
(In/Out) C
Operating Temperature, Sea Water Side
35/45
(In/Out) C
Design Duty, kW 6821
Material of Construction, Plates Titanium SB265

Amine Surge Tank


Equipment Tag No. 9103-T-11
Process Medium MDEA
Size (ID/Height), mm 1100/5500
Design Pressure, barg (Max./Min.) 0.075/-0.005
Design Temperature, C (Max./Min.) 85/0
Operating Pressure, barg 0.02
Operating Temperature, C 45
Material of Construction CS

Lean Amine Pumps


Equipment Tag No. 9103-P-13A/B
Process Medium Lean Amine
3
Capacity, m /hr, Normal/Rated 835/919
Driver Type Motor
Rated Power, kW 240
Suction Pressure, bar(a) (Rated/Max.) 1/1.59
Discharge Pressure, bar(a) 7.50
Operating Temperature, C 45
Design Temperature, C 85
Material of Construction, Casing/Impeller A351-CF8M/SS316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 57 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Lean Amine Filter


Equipment Tag No. 9103-S-11
Process Medium Lean Amine
Operating Pressure, barg 2.8
Clean Pressure drop, bar 0.1
Max. Allowed Pressure drop, bar, dirty 0.7
Operating Temperature, C 45
Design Temperature, C 85/0
Design Pressure, barg 9.4
3
Flow rate, m /hr 184
Material of Construction CS

Activated Carbon Filter


Equipment Tag No. 9103-S-12
Process Medium Lean Amine
Operating Pressure, barg 2.1
Clean Pressure drop, bar 0.3
Max. Allowed Pressure drop, bar 0.7
Operating Temperature, C 45
Design Temperature, C 85/0
Design Pressure, barg 9.4
Flow rate, m3/hr 184
Material of Construction CS

Fines Filter
Equipment Tag No. 9103-S-13
Process Medium Lean Amine
Operating Pressure, barg 1.4
Clean Pressure drop, bar 0.1
Max. Allowable Pressure drop, bar 0.7
Operating Temperature, C 45
Design Temperature, C 85/0
Design Pressure, barg 9.4
3
Flow rate, m /hr 184
Material of Construction CS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 58 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Amine Sump
Equipment Tag No. 9103-V-10
Process Medium MDEA
Vessel size (ID/T/T) mm 4200/8500
Design Temperature, C (Max./Min.) 175/0
Design Pressure, barg (Max./Min.) 7.0/FV
Operating Temperature, C Ambient
Operating Pressure, barg 0.05
Material of Construction CS

Amine Sump Pump


Equipment Tag No. 9103-P-15
Process Medium Amine
3
Capacity, m /hr (Normal/Rated) 11.8
Driver Type Motor
Rated Power, kW 15
Suction Pressure, bara, Max./Rated 8.4/1.03
Operating Temperature, C 20
Design Temperature, C (Max./Min.) 175/0
Material of Construction, Casing/Impeller A351-CF8M/SS316L

Amine Sump Filter


Equipment Tag No. 9103-S-14
Process Medium Amine
Size (ID/T/T), mm 308/920
Design Temperature, C 175/0
Design Pressure, barg 17.7
3
Flow rate, m /hr 10
Material of Construction CS

4.1.2 AGEU PROCESS DESCRIPTION & CONTROL

4.1.2.1 Acid Gas Enrichment Unit Process Chemistry

The function of the amine solvent is:

To enrich the week acid gas stream from the upstream gas sweetening units in an Acid
Gas Amine Absorber so that the H2S content of the acid gas is increased to a point that
will make the gas easier to process in the downstream SRU.

The H2S in the acid gases from the upstream gas sweetening unit are absorbed by
amine solvent in the Acid Gas Amine Absorber. Similarly the H2S gases produced in the
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 59 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

TGTU are absorbed by amine in the Tail Gas Amine Absorber. The combined rich
amines from both the absorber are routed to the Amine Regenerator where the H2S is
stripped from the amine by heating. The stripped gases from the regenerator system
are routed to SRU.

Hydrogen Sulphide, H2S or HSH is a weak acid and ionizes in water to form hydrogen
ions and sulphide ions.

HSH H+ + SH-

Since it is a weak acid, only a small fraction of the HSH will ionize.

Ethanolamines are weak bases and ionize in water to form amine ions and hydroxyl
ions:

(CH3)z (CH3)z
 
(CH2OHCH2)x NHy + H2O (CH2OHCH2)x NHy+1 + OH-
Where for MDEA x = 2, y = 0, z = 1

When H2S dissolves into the solution containing the amine ions, it will react to form a
weakly bonded salt of the acid and the base.

(CH3)z (CH3)z
 
(CH2OHCH2)x NHy+1 + SH- (CH2OHCH2)x NHyS
The sulphide ion is thus absorbed by the amine solution.

This salt formation reaction does not go to completion. As the arrow indicates, and
equilibrium level of sulphide ion, SH- remains in the sour gas stream. The overall
reaction can be summarized by the following equation:
(CH3)z (CH3)z
 
(CH2OHCH2)x NHy + H2S (CH2OHCH2)x N HyS
Operating variables are adjusted to favour the forward reaction (absorption process)
and conversely, adjusted to favour the reverse reaction (regeneration process).

4.1.2.2 Acid Gas Enrichment Unit Process Description

Lean acid gas enters the unit at a temperature of 53C and a pressure of 0.55 barg.
This stream is cooled in Acid Gas Coolers (9103-E-101A/B), before passing to the Lean
Acid Gas KO Drum (9103-V-14). The Acid Gas Coolers (9103-E-101A/B) are cooled by
sea cooling water. The outlet temperature of the Acid Gas Coolers (9103-E-101A/B) is
maintained at 49C.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 60 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The Lean Acid Gas KO Drum allows bulk removal of any condensed/entrained liquid
from upstream. The liquid level in the Lean Acid Gas KO Drum is controlled by
pumping the liquid through the Acid Gas KO Drum Return Pumps (9103-P-14A/B) to the
existing MDEA storage tank. Alternatively, the sour water can be routed to the sour
water stripper, through a normally closed isolation valve.

Vapour leaves the Lean Acid Gas KO Drum and fed to the Acid Gas Amine Absorber
(9103-C-11), at the bottom. The vapour passes upwards through a trayed section in
contact with a lean amine solution. The counter current contact with the amine
solution essentially removes all the H2S and some of the mercaptans and part of the
CO2 from the vapour stream. If any BTEX exists in the lean acid gas, it is expected that
80-90% will slip directly to the Incinerator.

The Acid Gas Amine Absorber (9103-C-11) consists of 10 numbers of valved trays. The
feed gas enters below the bottom of the bottom tray. The lean amine enters over the
top of the top tray.

Lean amine flow to the Acid Gas Amine Absorber is controlled by the flow controller
91-FIC-1501; set point for the controller 91-FIC-1501 is calculated in the block 91-FFY-
1502 by multiplying the acid gas/lean amine ratio set point (0.02) provided through
91-HIC-1502, with the pressure and temperature compensated acid gas flow (91-FY-
1502). 91-FIC-1501 regulates the lean amine flow to the acid gas amine absorber via
the control valve 91-FV-1501.

Acid gas amine absorber (9103-C-11) top pressure is controlled at 0.2 barg by the
pressure controller 91-PIC-1502. The pressure is maintained through the pressure
control valve 91-PV-1502 located in the treated gas line to the Incinerator.

Rich amine from the Tail Gas Amine Absorber enters at the bottom of the column.

Treated gas leaving the top of the absorber (9103-C-11) goes to the Incinerator
(9101-F-14). The rich amine solution, containing absorbed acid gas, is combined with
solvent from the Tail Gas Amine Absorber (9102-C-12). It is removed from the column
by the Acid Gas Rich Amine Pump (9103-P-12A/B). This stream is then heated in the
Lean/Rich Exchanger, before it is fed to the Amine Regenerator (9103-C-12). The rich
amine flow rate is controlled to maintain the level in the Acid Gas Amine Absorber.

The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas
Treatment Units are shared with the use of a common solvent.

The Amine Regenerator 9103-C-12 consists of 24 numbers of valved trays and one
chimney tray. The rich amine enters over the top of the 3rd tray from the top. The rich
amine flow is controlled by the flow controller 91-FIC-1520B. The pressure of the
Regenerator is controlled by supplying nitrogen through a pressure controller 91-PIC-
1539. The Regenerator Reboiler vapours enter the bottom of the vessel.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 61 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The Reboiler is heated by LP Steam which is drawn from the steam distribution
header. Steam flow to the Regenerator Reboiler is controlled by 91-FIC-1503 which
regulates the control valve 91-FV-1503. Set point-1 (SP1) for the steam flow control is
received from the calculation block 91-FFY-1503A which multiplies the rich amine flow
controller 91-FIC-1520A output and manually provided set ratio (118.5) between steam
and rich amine through 91-HIC-1503. Set point-2 (SP2) is received from the output of
the Regenerator overhead temperature controller 91-TIC-1510. During normal
operation SP1 take precedence and when the temperature of the Regenerator over
head reaches more than 118C SP2 will take precedence.

In the Amine Regenerator, the rich solution is stripped counter currently with vapours
generated by the Amine Regenerator Reboiler. The bottom of the column is
maintained at a temperature by regulating the LP steam flow rate into the
Regenerator Reboiler (9103-E-13). The stripping action in the lower section removes
and releases the contaminants from the solution, such as the acid gases, mercaptans
and residual dissolved hydrocarbons.

The stripped vapours are cooled in the Regenerator Condenser Cooler (9103-E-12), and
the Regenerator Condenser Trim Cooler (9103-E-16), by regulating air flow by fans in
Regenerator Condenser Cooler and adjusting the flow rate of Sea water to the
Regenerator Condenser Trim Cooler. Any water and amine in the overhead stream is
condensed and collects in the Regenerator Reflux Drum (9103-V-12). The liquid
collected from the Regenerator Reflux Drum is pumped by the Regnerator Reflux Drum
Pumps 9103-P-11 A/B back to the Regenerator. There is a provision to send the liquid
to the Waste Water Degasser 6922-V-07. The reflux flow rate is controlled by
maintaining the liquid level in the Regenerator Reflux Drum. Acid gas from the
Regenerator Reflux Drum passes overhead to the Sulphur Recovery Unit.

Hot lean amine solution from the Regenerator is pumped to the Amine Surge Tank
(9103-T-11) by the Hot Lean Amine Pump (9103-P-17 A/B). The Lean/Rich Exchanger
(9103-E-11), Lean Amine Cooler (9103-E-14) and Lean Amine Trim Cooler (9103-E-15)
cool the solution prior to the Amine Surge Tank. The lean solution from the Amine
Surge Tank is pumped to the Acid Gas Amine Absorber and the Tail Gas Amine
Absorber via the Lean Amine Pump (9103-P-13A/B). A slipstream is taken off after the
pump and returns to the surge tank through the Lean Amine Filter (9103-S-11),
Activated Carbon Filter (9103-S-12) and the Fines Filter (9103-S-13). The filters remove
particulate matter from the stream as well as hydrocarbons that accumulate in the
Amine solution.

The Amine Surge Tank (9103-T-11) receives the recycle flow from the filter circuit and
the Regenerator. It has the capacity to hold the whole system inventory at shut down.
The Amine Surge Tank is maintained at a slightly positive pressure, however not high
enough to be able to float on the flare header to maintain pressure and stop ingress of
Oxygen. Therefore it is provided with Nitrogen blanketing to prevent air ingress and to
minimise the risk of solution degradation.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 62 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

All the amine drains from the unit is collected in the Amine Sump 9103-V-10. The
collected amine is pumped to the Amine Surge Tank through the amine filters. The
amine sump is blanketed with nitrogen at a slightly positive pressure.

4.1.2.3 Acid Gas Enrichment Unit Process Control

4.1.2.3.1 Lean Acid Gas Knock Out Drum Level Control

Lean acid gas knock out drum (9103-V-14) level is maintained by ON/OFF gap
controller 91-LIC-1501 which controls the acid gas KO drum return pumps (9103-P-14
A/B) & the discharge line control valve 91-LV-1501.

91-LIC-1501 controls the ON/OFF of Acid Gas Knock Out Drum Return Pumps and
discharge line valve by sending the signal 0% or 100%.

High level of the level controller 91-LIC-1501 starts the duty Acid Gas Knock Out Drum
Return Pump & opens the level control valve 91-LV-1501. Low level of the controller
closes the level control valve 91-LV-1501 and stops the duty Acid Gas Knock Out Drum
Return Pump.

Acid Gas Knock Out Drum Return pumps ON or OFF can be done by the controller only
when the pumps are in auto mode which is selected through the switch (91-HS-1562 &
91-HS-1563).

Controller Alarm
Control Description Unit
Tag Low High
91-LIC-1501 Lean Acid Gas KO Drum level control % 12 37

High high level alarm (91-LAHH-1502) in Lean acid gas KO drum closes the acid gas
block valve 91-XV-1501
Low low level alarm (91-LALL-1503) in Lean acid gas KO drum trips the acid gas return
pumps (9103-P-14A/B) and closes the on/off valve 91-XV-1503 located at the liquid
outlet line from acid gas KO drum (downstream of the control valve 91-LV-1501)
Acid Gas KO Drum Return Pumps discharge control valve 91-LV-1501 closes on
instrument air failure
4.1.2.3.2 Acid Gas Absorber Top Pressure Control

Acid gas amine absorber (9103-C-11) top pressure is controlled by the pressure
controller 91-PIC-1502. The pressure is maintained through the pressure control valve
91-PV-1502 located in the treated gas line to the Incinerator.

Controller Operating Alarm


Control Description Unit Set Point
Tag Low High
Amine absorber top pressure
91-PIC-1502 bar(g) 0.2 NA NA
control
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 63 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Acid gas amine absorber top pressure control valve 91-PV-1502 opens on instrument air
failure.

4.1.2.3.3 Acid Gas/Lean Amine Flow Ratio Control

Acid gas flow to the acid gas amine absorber (9103-C-11) is measured by 91-FT-1502.

Lean amine flow to the Acid Gas Amine Absorber is controlled by the flow controller
91-FIC-1501; set point for the controller 91-FIC-1501 is calculated in the block
91-FFY-1502 by multiplying the acid gas/lean amine ratio set point (0.02) provided
through 91-HIC-1502, with the pressure and temperature compensated acid gas flow
(91-FY-1502).

91-FIC-1501 regulates the lean amine flow to the acid gas amine absorber via the
control valve 91-FV-1501.

Control Loop

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
3
91-FIC-1501 Lean amine flow to absorber m /hr 487 390 536

High high level alarm (91-LAHH-1504) in Acid Gas Amine Absorber bottom closes the
lean amine ON/OFF valve 91-XV-1504 located at the downstream of 91-FV-1501.
Lean amine flow control valve 91-FV-1501 to acid gas amine absorber closes on
instrument air failure.
4.1.2.3.4 Acid Gas Amine Absorber Level Control

Rich amine solution from the TGTU Tail Gas Amine Absorber combines with the rich
amine at the bottom section of the Acid Gas Amine Absorber.

The master level controller 91-LIC-1505 controls the rich amine level at the bottom of
the Acid Gas Amine Absorber by controlling the cascaded slave rich amine flow
controller 91-FIC-1520B, which regulates the Acid Gas Rich Amine Pumps (9103-P-
12A/B) discharge flow to Amine Regenerator 9103-C-12 via Lean/Rich Amine Exchanger
9103-E-11A/B through the control valve 91-FV-1520 located at the inlet of the Amine
Regenerator 9103-C-12.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
91-LIC-1505 Absorber level control % 50 12 86
Rich amine flow to Amine
91-FIC-1520B m3/hr 635 500 NA
Regenerator

High high level alarm (91-LAHH-1504) in Acid Gas Amine Absorber bottom activates
the ESD Level-2 shutdown
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 64 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Low low level alarm (91-LALL-1516) in Acid Gas Amine Absorber bottom trips the
Acid Gas Rich Amine Pumps (9103-P-12A/B)

Rich amine flow control valve 91-FV-1520 to Amine Regenerator closes on


instrument air failure.
4.1.2.3.5 Acid Gas Rich Amine Pumps Minimum Flow Control

Acid Gas Rich Amine Pumps (9103-P-12A/B) discharge flow is measured by 91-FT-1508
and minimum flow to Acid Gas Amine Absorber bottom is controlled by 91-FIC-1508.

The controller 91-FIC-1508 controls the pump minimum flow control valve 91-FV-1508
to Acid Gas Amine Absorber bottom.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Acid Gas Rich Amine Pump
91-FIC-1508 m3/hr 375 330 NA
minimum flow

Low low flow alarm (91-FALL-1510) set at 300 m3/hr in 9103-P-12A/B discharge,
trips the Acid Gas Rich Amine Pumps 9103-P-12A/B
Pump minimum flow control valve 91-FV-1508 opens on instrument air failure.
4.1.2.3.6 Rich Amine to Regenerator Temperature Control

Rich amine solution leaving the Lean/Rich Amine Exchanger (9103-E-11-A/B)


temperature is maintained by the temperature controller 91-TIC-1513.

Temperature controller 91-TIC-1513 is located at hot rich amine outlet leaving the
exchanger. The output from this controller resets the control valve 91-TV-1513 on the
hot lean amine solution bypass line around the Lean/Rich Amine Exchanger.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Rich Amine to Amine
91-TIC-1513 Regenerator temperature C 104 99 109
Control

Hot lean amine bypass control valve 91-TV-1513 locks on instrument air failure.

4.1.2.3.7 Amine Regenerator Overhead Pressure Control

Amine regenerator overhead pressure is controlled by the pressure controller 91-PIC-


1539. The pressure is maintained through the pressure control valve 91-PV-1539 by
controlling the nitrogen supply to the Regenerator.

91-PIC-1539 opens the Nitrogen control valve 91-PV-1539 on falling pressure in the
Regenerator over head to Regenerator Condenser Cooler.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 65 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Amine Regenerator top
91-PIC-1539 Bar g 1.2 0.95 1.4
pressure control

Amine Regenerator 9103-C-12 top pressure nitrogen control valve 91-PV-1539 opens on
instrument air failure.

4.1.2.3.8 Amine Regenerator Level Control

The master level controller 91-LIC-1510 maintains the bottom level of Amine
Regenerator by controlling the cascaded slave lean amine flow controller 91-FIC-1530,
which regulates the Hot Lean Amine Pumps (9103-P-17A/B) discharge flow to Lean Rich
Amine Exchanger through the control valve 91-FV-1530 located at the outlet of Lean
Amine Trim Cooler 9103-E-15.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Amine Regenerator bottom
91-LIC-1510 % 50 17 82
level control
Lean amine flow to
91-FIC-1530 m3/hr 669 NA NA
9103-T-11

Low low level alarm (91-LALL-1517) in Amine Regenerator bottom trips the Hot
Lean Amine Pumps (9103-P-17A/B) and closes the Hot Lean Amine ON/OFF valve
91-XV-1507 to Lean Rich Exchanger
High high level alarm (91-LAHH-1509) in Amine Regenerator bottom activates the
ESD level-2 shutdown
Lean amine outlet flow control valve 91-FV-1530 to Amine Surge Tank closes on
instrument air failure
4.1.2.3.9 Hot Lean Amine Pumps Minimum Flow Control

Hot lean amine pumps (9103-P-17A/B) discharge flow is measured by 91-FT-1512 and
pumps minimum flow to Amine Regenerator bottom is controlled by 91-FIC-1512.

Output of the controller 91-FIC-1512 controls the pump minimum flow control valve
91-FV-1512.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Hot Lean Amine Pump min
91-FIC-1512 m3/hr 250 220 NA
flow
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 66 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Hot Lean Amine Pumps 9103-P-17A/B discharge flow low low alarm (91-FALL-1509)
set at 200 m3/hr will activate the tripping of 9103-P-17A/B.
Pump minimum flow control valve 91-FV-1512 opens on instrument air failure.
4.1.2.3.10 Regenerator Condenser Cooler Control

Temperature of the acid gas flow from the Amine Regenerator overhead is controlled
by cooling the fluid to Tmax=54C in summer and not less than Tmin=49C in winter using
one fixed speed fan (on/off) control, and another two VSD controlled fans working
simultaneously.

The Regenerator Condenser Cooler outlet temperature is measured by 91-TT-1516 and


received by the temperature controller 91-TIC-1516. The output of this controller
sends the control signal to control the three fans.

In auto mode, the temperature controller maintains the cooler outlet temperature at
Tset= (54C + 49C)/2=52C by changing the VSD rates of the following cooler fans:
9103-EM-12AB
9103-EM-12AC

9103-EM-12BB
9103-EM-12BC
9103-EM-12CB
9103-EM-12CC
9103-EM-12DB

9103-EM-12DC
The fixed speed fan (9103-EM-12AA/BA/CA/DA) operates on gap control set point
between the values Tmax=54C & Tmin=49C.

This scheme will be applicable for all the 4 bays simultaneously.

Details of control tags are tabulated below:

Sl. # Motor No. Control Tag Remarks


1 9103-EM-12AA 91-HS-1512 Fixed speed fan
2 9103-EM-12AA 91-SY-1513 VSD
3 9103-EM-12AA 91-SY-1552 VSD
4 9103-EM-12BA 91-HS-1553 Fixed speed fan
5 9103-EM-12BB 91-HS-1554 VSD
6 9103-EM-12BC 91-HS-1555 VSD
7 9103-EM-12CA 91-HS-1556 Fixed speed fan
8 9103-EM-12CB 91-HS-1557 VSD
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 67 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sl. # Motor No. Control Tag Remarks


9 9103-EM-12CC 91-HS-1558 VSD
10 9103-EM-12DA 91-HS-1559 Fixed speed fan
11 9103-EM-12DB 91-HS-1560 VSD
12 9103-EM-12DC 91-HS-1561 VSD

High high vibration alarm of each fan trips the respective fan motors.

4.1.2.3.11 Regenerator Condenser Trim Cooler Outlet Temperature Control

91-TIC-1502 located at the outlet of the Regenerator Condenser Trim Cooler,


maintains the outlet temperature of the acid gas condensate to Regenerator Reflux
Drum.

The temperature controller adjusts the bypass control valve 91-TV-1502 and maintains
the Regenerator Condenser Trim Cooler outlet temperature 91-TT-1502.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regenerator Condenser Trim
91-TIC-1502 C 49 44 54
Cooler Outlet Temperature

Regenerator Condenser Cooler 9103-E-12 outlet temperature control valve 91-TV-1502


to reflux drum opens on instrument air failure.

4.1.2.3.12 Regenerator Reflux Drums Level Control

Bottom level in the Regenerator Reflux Drum level is maintained by controlling the
reflux return to the Amine Regenerator via Reflux Drum Pumps 9103-P-11A/B.
Regenerator reflux drum bottom level is controlled by the master controller 91-LIC-
1506 cascaded with the reflux pumps discharge flow slave controller 91-FIC-1531,
which regulates the control valve 91-FV-1531 located in the reflux inlet to Amine
Regenerator.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regenerator reflux drum
91-LIC-1506 % 50 16 80
level control
91-FIC-1531 Reflux to amine regenerator m3/hr 26 NA NA

Low low level alarm (91-LALL-1518) in Regenerator Reflux Drum trips the Reflux
Drum Pumps (9103-P-11A/B)
High high level alarm (91-LAHH-1507) in Regenerator Reflux Drum closes the DM
water ON/OFF valve 91-XV-1517 to Regenerator Reflux Drum
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 68 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Reflux flow control valve 91-FV-1531 to Amine Regenerator opens on instrument


air failure.
4.1.2.3.13 Regenerator Reflux Drums Condensate Control

Condensate flow to the Regenerator Reflux Drum bottom is measured by 91-FT-1521


and controlled by 91-FIC-1521.

Condensate flow is controlled through the control valve 91-FV-1521.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regenerator reflux drum
91-FIC-1521 m3/hr 0.6 0.4 0.8
condensate flow control

ESD valve 91-XV-1517 located at the upstream of the control valve 91-FV-1521
closes on high high level alarm 91-LAHH-1507 of Regenerator Reflux Drum
Condensate flow control valve 91-FV-1521 closes on instrument air failure.
4.1.2.3.13 Regenerator Reflux Drums Pressure Control

A split range pressure controller 91-PIC-1503 is provided to maintain the pressure of


Regenerator Reflux Drum (9103-V-12) by controlling the following valves:

Acid gas control valve 91-PV-1503B (0-50%) to acid gas KO drum 9101-V-04
Acid gas control valve 91-PV-1503A (50-100%) to LP Acid Gas Flare
On rising pressure 91-PIC-1503 first opens the acid gas to Acid Gas KO Drum control
valve 91-PV-1503B; further increase in pressure causes the pressure controller to open
the vent valve 91-PV-1503A to release gases to the LP Acid Gas Flare.

Fig. 14 91-PIC-1503 Controller Output

The above drawing shows the split range operation of 91-PV-1503A & 91-PV-1503B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 69 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regenerator Reflux Drum bar(g
91-PIC-1503 1 0.787 1.2
pressure )

ESD valve 91-XV-1516 located at the acid gas to Acid Gas KO Drum control valve
downstream

Control valve 91-PV-1503B closes on ESD-Level-0, Level-1 & Level-2 shutdown


Regenerator Reflux Drum 9103-V-12 pressure control valve 91-PV-1503A to LP flare
opens on instrument air failure

Regenerator Reflux Drum 9103-V-12 pressure control valve 91-PV-1503B to Acid


Gas KO Drum closes on instrument air failure.
4.1.2.3.14 Regenerator Reflux Pumps Minimum Flow Control

Regenerator Reflux Pumps (9103-P-11A/B) discharge flow is measured by 91-FT-1505


and minimum flow to Amine Regenerator is controlled by 91-FIC-1505.

Output of the controller 91-FIC-1505 controls the pump minimum flow control valve
91-FV-1505.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regenerator Reflux Drum
91-FIC-1505 m3/hr 20 17.6 NA
pumps to Regenerator

Low low flow alarm (91-FALL-1506) set at 16 m3/hr trips the Regenerator Reflux
Pumps 9103-P-11A/B

Pump minimum flow control valve 91-FV-1505 opens on instrument air failure.
4.1.2.3.15 Sour Water Flow Control to Waste Water Degasser

Sour water flow from the discharge of Regenerator Reflux Drum Pumps (9103-P-11A/B)
to the Waste Water Degasser (6922-V-07) is measured by 91-FT-1532 and sends the
signal to the flow controller 91-FIC-1532.

91-FIC-1532 regulates the flow to Waste Water Degasser via the control valve 91-FV-
1532.

Control Loop:

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Sour water flow to Waste
91-FIC-1532 m3/hr 0.17 NA NA
Water Degasser
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 70 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

ESD valve 91-XV-1575 located at the downstream of the sour water flow control
valve 91-FV-1532 closes on activation of waste water degasser level (69-LI-1311)
high high alarm
Sour water flow control valve 91-FV-1532 closes on instrument air failure.
4.1.2.3.16 Amine Regenerator Reboiler Temperature Control

Temperature in the amine regenerator is to be maintained to allow for optimum H2S


stripping from the rich amine. Temperature control is achieved by controlling the
steam flow to the Regenerator Reboiler.

Steam flow to the Regenerator Reboiler is controlled by 91-FIC-1503 which regulates


the control valve 91-FV-1503.

Set point-1 (SP1) for the steam flow control is received from the calculation block
91-FFY-1503A which multiplies the rich amine flow controller 91-FIC-1520A output and
manually provided set ratio (118.5) between steam and rich amine through 91-HIC-1503.

Set point-2 (SP2) is received from the output of the Regenerator overhead
temperature controller 91-TIC-1510. During normal operation SP1 take precedence and
when the temperature of the Regenerator over head reaches more than 118C SP2 will
take precedence.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Steam to Regenerator
91-FIC-1503 Kg/hr 72410 65816 80442
Re-boiler
Amine Regenerator (9103-C-
91-TIC-1510 C 118 113 123
12) overhead
91-FIC-1520A Rich amine flow control m3/hr 635 500 NA

ESD valve 91-XV-1505 located on the upstream of 91-FV-1503 closes on activation


of amine regenerator bottom level 91-LI-1509 high high alarm set at 50%
Steam control valve 91-FV-1503 to reboiler closes on instrument air failure.
4.1.2.3.17 Regenerator Re-Boiler Condensate Pot Level Control

Regenerator Reboiler condensate is collected in the Condensate Pot (9103-V-13). Level


of the Condensate Pot is measured by 91-LT-1508 and controlled by throttling the
control valve 91-LV-1508 to LC distribution header via 91-LIC-1508.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regenerator Re-boiler
91-LIC-1508 % 50 12 86
Condensate Pot level

Reboiler condensate control valve 91-LV-1508 will close on instrument air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 71 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.1.2.3.18 Lean Amine Cooler Temperature Control

Temperature of the lean amine from the Lean/Rich Exchanger (9103-E-11) is


controlled by cooling the fluid to Tmax=54C in summer and not less than Tmin=45C in
winter using three fans: one fixed speed fan (on/off) control, and another two VSD
controlled fans working simultaneously.

The Lean Amine Cooler 9103-E-14 outlet temperature is measured by 91-TT-1518 and
controlled by the temperature controller 91-TIC-1518. The output of this controller
sends the control signal to control the three fans.

In auto mode, the temperature controller maintains the cooler outlet temperature
T set= (54C + 45C)/2=50C by changing the following VSD rates:

(9103-EM-14AB/AC/BB/BC/CB/CC/DB/DC/EB/EC/FB/FC/GB/GC/HB/HC/IB/IC/JB/JC)

The fixed speed fan (9103-EM-14AA/BA/CA/DA/EA/FA/GA/HA/IA/JA) operates on gap


control set point between the values Tmax=54C & Tmin=45C.

This scheme will be applicable for all the 10 bays simultaneously.

Details of control tags are tabulated below:

Sl. # Motor No. Control Tag Remarks


1. 9103-EM-14AA 91-HS-1514 Fixed speed fan
2. 9103-EM-14AB 91-SY-1515 VSD
3. 9103-EM-14AC 91-SY-1558 VSD
4. 9103-EM-14BA 91-HS-1519 Fixed speed fan
5. 9103-EM-14BB 91-SY-1520 VSD
6. 9103-EM-14BC 91-SY-1521 VSD
7. 9103-EM-14CA 91-HS-1522 Fixed speed fan
8. 9103-EM-14CB 91-SY-1523 VSD
9. 9103-EM-14CC 91-SY-1524 VSD
10. 9103-EM-14DA 91-HS-1525 Fixed speed fan
11. 9103-EM-14DB 91-SY-1526 VSD
12. 9103-EM-14DC 91-SY-1527 VSD
13. 9103-EM-14EA 91-HS-1528 Fixed speed fan
14. 9103-EM-14EB 91-SY-1529 VSD
15. 9103-EM-14EC 91-SY-1530 VSD
16. 9103-EM-14FA 91-HS-1531 Fixed speed fan
17. 9103-EM-14FB 91-SY-1532 VSD
18. 9103-EM-14FC 91-SY-1533 VSD
19. 9103-EM-14GA 91-HS-1534 Fixed speed fan
20. 9103-EM-14GB 91-SY-1535 VSD
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 72 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sl. # Motor No. Control Tag Remarks


21. 9103-EM-14GC 91-SY-1536 VSD
22. 9103-EM-14HA 91-HS-1537 Fixed speed fan
23. 9103-EM-14HB 91-SY-1538 VSD
24. 9103-EM-14HC 91-SY-1539 VSD
25. 9103-EM-14IA 91-HS-1540 Fixed speed fan
26. 9103-EM-14IB 91-SY-1541 VSD
27. 9103-EM-14IC 91-SY-1542 VSD
28. 9103-EM-14JA 91-HS-1543 Fixed speed fan
29. 9103-EM-14JB 91-SY-1544 VSD
30. 9103-EM-14JC 91-SY-1545 VSD

High high vibration alarm of each fan trips the respective fan motors.

4.1.2.3.19 Lean Amine Trim Cooler Outlet Temperature Control

91-TIC-1509 located at the outlet of the Lean Amine Trim Cooler (9103-E-15) maintains
the outlet temperature of the lean amine to Amine Surge Tank (9103-T-11).

The temperature controller 91-TIC-1509 adjusts the control valve 91-TV-1509 located
in the bypass line of Lean Amine Trim Cooler maintains the lean amine outlet
temperature.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Lean amine Cooler to amine
91-TIC-1509 C 45 40 50
surge tank

Lean amine cooler bypass control valve 91-TV-1509 closes on instrument air failure.

4.1.2.3.20 Lean Amine Surge Tank Pressure Control

A split range pressure controller 91-PIC-1526 is provided to maintain the vapour space
of the tank under a slightly positive pressure. On rising pressure in the tank, 91-PIC-
1526 closes (0-50%) the nitrogen flow to tank via the control valve 91-PV-1526A, on
further increase in pressure the pressure controller 91-PIC-1526 opens (50-100%) the
vent valve 91-PV-1526B to release gases to the atmosphere.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Lean amine surge tank
91-PIC-1526 bar(g) 0.02 0.01 0.03
(9103-T-11) pressure
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 73 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 15 91-PIC-1526 Controller Output

The above drawing shows the split range operation of 91-PV-1526A & 91-PV-1526B.

Amine Surge Tank 9103-T-11 nitrogen line control valve 91-PV-1526A closes on
instrument air failure.
Amine Surge Tank 9103-T-11 control valve control valve 91-PV-1526B opens on
instrument air failure.
4.1.2.3.21 Lean Amine Pumps Minimum Flow Control

Lean amine pumps (9103-P-13A/B) discharge flow is measured by 91-FT-1511 and


minimum flow to Amine Surge Tank is controlled by 91-FIC-1511.

Output of the controller 91-FIC-1511 throttles the pump minimum flow control valve
91-FV-1511.

Control Loop:

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Lean Amine Pumps
91-FIC-1511 m3/hr 375 330 NA
discharge

Low low flow (91-FALL-1515) alarm set at 300 m3/hr trips the Lean Amine Pumps
9103-P-13A/B.

4.1.2.3.22 Amine Sump Pressure Control

A split range pressure controller 91-PIC-1527 is provided to maintain the vapour space
of the tank under a slightly positive pressure. On rising pressure in the tank, 91-PIC-
1527 closes (0-50%) the nitrogen flow to tank via the control valve 91-PV-1527A, on
further rising pressure, the pressure controller 91-PIC-1527 opens (50-100%) the vent
valve 91-PV-1527B to release gases to the atmosphere.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 74 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The below drawing shows the split range operation of 91-PV-1527A & 91-PV-1527B:

Fig. 16 91-PIC-1527 Controller Output

Control Loop:

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Amine Sump pressure
91-PIC-1527 bar(g) 0.05 0.027 0.07
control

Amine sump 9103-V-10 nitrogen line control valve 91-PV-1527A closes on


instrument air failure
Amine Sump 9103-V-10 nitrogen control valve 91-PV-1527B opens on instrument air
failure.
4.1.2.3.23 Lean Amine Pumps Flow to Filter

Lean Amine Pumps (9103-P-13A/B) discharge flow to Lean Amine Filter (9103-S-11) is
controlled by 91-FIC-1507.

Output of the controller 91-FIC-1507 resets the control valve 91-FV-1507.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Lean Amine Pumps to Lean
91-FIC-1507 m3/hr 155.6 125 NA
Amine Filter

Lean Amine Pumps 9103-P-13A/B flow control valve 91-FV-1507 to filter closes on
instrument air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 75 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.2 SULPHUR RECOVERY UNIT

4.2.1 Equipment Details

Process Air Blowers


Equipment Tag No. 9101-K-01A/B
Process Medium Air
Rated Capacity (Dry Base), kg/hr 29478
Inlet Pressure, bar(a) 1.01
Inlet Temperature, C 43
Discharge Pressure, bar(a) 1.90
Discharge Temperature, C 49
Design Temperature, C 120
Drive Type Motor

Sulphur Degassing Pumps


Equipment Tag No. 9101-P-03A/B
Pump Type Vertical Centrifugal
Process Medium Liquid Sulphur
3
Capacity, m /hr (Normal/Rated) 130/130
Suction Pressure, bar(a), Rated/Max. 1.0/1.61
Discharge Pressure, bar(a) 8.6
Operating Temperature, C, Normal/Max. 140/160
Design Temperature, C 185
Driver Type Motor
Rated Power, kW 45
Material of Construction, Casing/Impeller Duplex SS

Sulphur Product Pumps


Equipment Tag No. 9101-P-04A/B
Pump Type Vertical Centrifugal
Process Medium Liquid Sulphur
3
Capacity, m /hr (Normal/Rated) 130/130
Suction Pressure, bar(a), Rated/Max. 1.0/1.61
Discharge Pressure, bar(a) 8.6
Operating Temperature, C, Normal/Max. 140/160
Design Temperature, C 185
Driver Type Motor
Rated Power, kW 45
Material of Construction, Casing/Impeller Duplex SS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 76 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sulphur Tank Pumps


Equipment Tag No. 9101-P-15A/B
Process Medium Liquid Sulphur
3
Capacity, m /hr (Normal/Rated) 7.4/8.14
Suction Pressure, bar(a), Rated/Max. 0.9/2.5
Discharge Pressure, bar(a) 9.6
Operating Temperature, C, Normal/Max. 160
Design Temperature, C 185
Driver Type Motor
Rated Power, kW 11
Material of Construction, Casing/Impeller A216WCB

Sulphur Degassing Pit


Equipment Tag No. 9101-T-01B
Size, (L/W/D), mm 10800/7000/3000
Process Medium Liquid Sulphur
Operating Temperature, C, Normal/Min. 140/127
Operating Pressure, bar(g) ATM
Design Temperature, C 185
Design Pressure, bar(g) 0.02/-0.005
Material of Construction Reinforced Concrete

Sulphur Degassing Pumps


Equipment Tag No. 9101-P-09A/B
Pump Type Vertical Centrifugal
Process Medium Liquid Sulphur
3
Capacity, m /hr (Normal/Rated) 130/130
Suction Pressure, bar(a), Rated/Max. 1.0/1.61
Discharge Pressure, bar(a) 8.6
Operating Temperature, C, Normal/Max. 140/160
Design Temperature, C 185
Driver Type Motor
Rated Power, kW 45
Material of Construction, Casing/Impeller A 995 1B/A 995 1B
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 77 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sulphur Product Pumps


Equipment Tag No. 9101-P-10A/B
Pump Type Vertical Centrifugal
Process Medium Liquid Sulphur
3
Capacity, m /hr (Normal/Rated) 130/130
Suction Pressure, bar(a), Rated/Max. 1.0/1.61
Discharge Pressure, bar(a) 8.6
Operating Temperature, C, Normal/Max. 140/160
Design Temperature, C 185
Driver Type Motor
Rated Power, kW 45
Material of Construction, Casing/Impeller Duplex SS

Catalyst Tank
Equipment Tag No. 9101-T-09
Size, (ID/Ht), mm 700/1000
Process Medium Catalyst
Design Temperature, C 85
Design Pressure, bar(g) ATM

Catalyst Metering Pumps


Equipment Tag No. 9101-P-11A/B
Process Medium Catalyst
Design Temperature, C 85
Design Pressure, bar(g) 2.0
Drive Motor
Rated Power, kW 0.55

Steam Ejector
Equipment Tag No. 9101-X-03
3
Capacity, Nm /hr 500
Design Temperature, C 185
Differential Pressure, bar 0.1

4.2.2 Revamped Claus Unit Process Chemistry

The function of a SRU is to process H2S rich acid gases to produce liquid elemental
Sulphur. The sulphur recovery Claus process combines 2 mols of H2S with 1 mol. of SO2
to form elemental sulphur.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 78 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

In the modified Claus process some of the H2S rich acid gas is burnt with the correct
amount of Oxygen (from air) to oxidise one third of the H2S to SO2:

Main Reactions:

H2S + 3/2O2 > SO2 + H2O

This reaction produces a high enough temperature to trigger the Claus reaction
thermally:

2H2S + SO2 > 3S + 2H2O

The Claus reaction is continued at progressively lower temperatures in the two


catalytic stages where the remaining H2S then combines with the SO2 & produce
elemental Sulphur.

4.2.3 Revamped Claus Unit Process Description

The acid gas stream from the gas treating plant enters the Acid Gas KO Drum (9101-V-
04) where acid water is knocked out and pumped to Amine Sump 9103-V-10 by the
Acid Water Pumps 9101-P-01A/B. The gas stream flows to Acid Gas Preheater (9101-E-
06) for preheating before entering the Reaction Furnace (9101-F-01), where the acid
gas is burnt by the high intensity burner with a controlled amount of air. Air is
supplied by an electrically driven Process Air Blower (9101-K-01A/B) & preheated by
Air Preheater (9101-E-05).

The products of the combustion are cooled in passing through the tube section of the
Reaction Furnace Boiler (9101-E-07) where a 24 bar(g) steam is generated in the shell
side. Gases and any condensed liquid sulphur from the Reaction Furnace Boiler flow to
the Reaction Furnace Condenser (9101-E-01) where the gases are cooled and the
additional sulphur is condensed. The gases then passes through the 1st Stage Auxiliary
Burner (9101-F-02) where they are reheated by burning a split stream of acid gas (or
fuel gas) with air, before entering the 1st Stage Converter (9101-V-01).

In this converter the gases flow downwards through a bed of CR 4/8 mm activated
alumina, top loaded with a layer of AM 4/8 catalyst. In the converter, additional
elemental sulphur is produced and carried over in vapour phase by the hot gases. The
exothermic Claus reaction results in a temperature increase through the adiabatic
converter. The hot gases leaving the first converter are cooled in the 1st Stage
Condenser (9101-E-02) by generating 5 barg steam, the condensed sulphur flows to the
Sulphur Degassing Pit (9101-T-01/01B) through Sultraps.

The gases from the Sulphur Condenser (9101-E-02) flow through a coalescer equipped
with SS wire mesh pads for the removal of any entrained sulphur. The gases then
passes through the 2nd Stage Auxiliary Burner (9101-F-03) where they are reheated by
burning a split stream of acid gas (or fuel gas) with air, before entering the 2nd Stage
Converter (9101-V-02), loaded with a more active catalyst CRS 31 and a layer of AM
4/8 mm catalyst on the top of the bed.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 79 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The Last Condenser (9101-E-04) ensures cooling of the process gases by preheating the
Boiler Feed Water which is used in the Reaction Furnace Boiler (9101-E-07) and the
two LP steam producing Reaction Furnace Condenser (9101-E-01) & 1st Stage
Condenser (9101-E-02). The process gases from Last Condenser passes through a Final
Separator (9101-V-05) to achieve complete removal of liquid sulphur drops from the
process gases. A coalescer is provided in Final Separator (9101-V-05).

From final separator, the process gas is routed to Tail Gas Treatment Unit, where the
hydrogen sulphide concentration in the tail gas is reduced to a level corresponding to
>99.5% total sulphur recovery.

The sulphur produced in the process is extracted from all sulphur condensers through
sultraps and is routed to the Sulphur Degassing Pits (9101-T-01/9101-T-01B). The
sulphur is degassed through AQUISULF sulphur degassing process. The degassed sulphur
is then transferred to the Sulphur Storage Tank 9101-T-02 by Sulphur Product Pumps
(9101-P-04A/B & 9101-P-10A/B).

4.2.4 Sulphur Recovery Unit Process Control

4.2.4.1 Pipe Separator Level Control

The acid gas stream from NGL-3 AGRU-1 & 2 enters the pipe separator where the acid
gas is routed to the top of the separator to AGEU acid gas coolers and the bottom
liquid is drained to amine drain distribution header.

Level in the vessel is maintained by regulating the control valve 91-LV-1053, in the
pipe separator bottom to amine drain distribution header through 91-LIC-1053.

Control Loops:

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
91-LIC-1053 Pipe separator level control % 50 14 98

Low low level alarm (91-LALL-1054) set at 33% in the pipe separator closes the
liquid outlet block valve 91-XV-1109.
Pipe separator level control valve 91-LV-1503 to amine drain distribution header
closes on instrument air failure.
4.2.4.2 BFW Pre-heater Temperature Control

Temperature of the heated water outlet from the BFW pre heater is monitored by
91-TT-1091 and controlled by 91-TIC-1091.

Temperature control is achieved by regulating the LP steam flow control valve


91-FV-1057 to BFW Preheater by 91-FIC-1057. The MASTER temperature controller
91-TIC-1091 is cascaded with SLAVE steam flow controller 91-FIC-1057.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 80 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
BFW Preheater outlet
91-TIC-1091 C 120 115 125
temperature
LP steam flow to BFW
91-FIC-1057 Kg/hr 860 775 947
Preheater

LP steam control valve 91-FV-1057 closes on instrument air failure.

4.2.4.3 Last Condenser Outlet Tail Gas Control

Tail gas from the Last Condenser is routed to the Incinerator through 91-XV-1097
during start-up and during normal operation tail gas is routed to TGTU through 91-XV-
1098.

This diversion is achieved by activating the selector switch 91-HS-1052A. This opens
the valve 91-XV-1098, when 91-XV-1098 is fully open the valve 91-XV-1097 closes.

This ensures that at least one path is fully open for the tail gas to pass through without
pressuring the upstream reaction furnace.

High high pressure alarm 91-PAHH-1055 set at 0.73 barg opens the valve 91-XV-
1097 to Incinerator and closes the valve 91-XV-1098 to RGG
ESD valve 91-XV-1097 opens on instrument air failure
ESD valve 91-XV-1098 closes on instrument air failure
4.2.4.4 New Sulphur Degassing Pit Level Control

New Sulphur Degassing Pit (9101-T-01B) level is measured by 91-LT-1051 which sends
the signal to the level controller 91-LIC-1051.

Level control is achieved by regulating the control valve 91-LV-1051 to the sulphur
storage tank (9101-T-02).

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
91-LIC-1051 Sulphur Degassing Pit level % 50 17 80

Low low level alarm 91-LALL-1052 set at 10% trips the Sulphur Degassing Pumps
(9101-P-09A/B) and Sulphur Product Pumps (9101-P-10A/B)
Sulphur Degassing Pit level control valve 91-LV-1051 closes on instrument air
failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 81 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.2.4.5 Combustion Control for 1st Stage Auxiliary Burner

During normal operation the Air/Acid Gas ratio controller maintains the temperature
of the process gas and when the acid gas flow decreases, the temperature of the
process gas is maintained by the Air to Fuel gas ratio controller. Selection of this
controller can be either manual through 91-HS-1028A or automatically when the
temperature 91-TICA-1007 of the 1st stage burner outlet reduces below the desired set
point (210C). This reduction in temperature stops the acid gas flow in the 1st stage
auxiliary burner.

Acid gas flow to 1st stage auxiliary burner is controlled by 91-FIC-1019 and fuel gas flow
is controlled by 91-FIC-1020, set point for both the controllers is provided by 91-TICA-
1007 via selector switch 91-HS-1028A. 91-FIC-1019 commands the acid gas flow valve
91-FV-1019 and 91-FIC-1020 commands the fuel gas control valve 91-FV-1020.

Ratio set point (air/fuel gas) and (air/acid gas) is provided via 91-HIC-1018A and
91-HIC-1018B, respectively.

Combustion air flow is controlled by 91-FIC-1018. Set point for the controller is
provided by air/acid gas or air/fuel gas ratio calculation as per selection through
91-HS-1028B and output of the combustion air flow controller 91-FIC-1018 directly
commands the air damper valve 91-FV-1018.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
st
1 Stage Auxiliary Burner
91-TICA-1007 C 230 210 250
temperature
91-FIC-1019 acid gas flow Sm3/hr 281.939 111 332
3
91-FIC-1018 comb air flow Sm /hr 908.768 NA 981
3
91-FIC-1020 fuel gas flow Sm /hr 159.635 8 170
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 82 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The schematic diagram for 1st stage auxiliary burner temperature control is shown
below:

Fig. 17 1st Stage Auxiliary Burner Temperature Control


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 83 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

1st Stage Auxiliary Burner combustion air flow (91-FI-1133) low low alarm set at
253 Sm3/hr, acid gas flow (91-FI-1134) low low alarm set at 105 Sm3/hr and Fuel
gas Flow (91-FI-1135) low low alarm set at 7 Sm3/hr activates the following:
Closure of Fuel gas block valves 91-XV-1028 and 91-XV-1031.
Opening of fuel gas vent valve 91-XV-1132

Closure of fuel gas control valve 91-FV-1020


Closure of acid gas control valve 91-FV-1019
Closure of combustion air control valve 91-FV-1018

1st stage combustion air damper/control valve 91-FV-1018 opens on instrument air
failure
1st stage acid gas control valve 91-FV-1019 closes on instrument air failure

1st stage fuel gas control valve 91-FV-1020 closes on instrument air failure.
4.2.4.6 Combustion Control for 2nd Stage Auxiliary Burner

During normal operation the Air/Acid Gas ratio control maintains the temperature of
the process gas flowing through the catalytic converter and then to sulphur condenser.
When the Acid gas flow decreases, the temperature of the process gas is maintained
by the Air to Fuel gas ratio controller. The selection of this controller can be either
manual through 91-HS-1029A or automatically when the temperature 91-TIC-1019
reduces below the desired set point (210C). This reduction in temperature stops acid
gas flow and introduce fuel gas flow in the 2nd stage Auxiliary burner.

Acid gas flow to 2nd Stage Auxiliary Burner is controlled by 91-FIC-1026 and the fuel gas
flow is controlled by 91-FIC-1027. Set point for both the controllers is provided by 2nd
Stage Auxiliary Burner temperature controller 91-TIC-1019 via selector switch
91-HS-1029A. Output of the controller 91-FIC-1026 commands the acid gas flow control
valve 91-FV-1026 and Output of the controller 91-FIC-1027 commands the fuel gas
control valve 91-FV-1027.

Ratio set point (air/fuel gas) and (air/acid gas) is provided by operator via 91-HIC-
1025A and 91-HIC-1025B, respectively.

Combustion air flow is controlled by 91-FIC-1025. Set point for the controller is
provided by air/acid gas or air/fuel gas ratio calculation as per selection through
91-HS-1029B. Output of the combustion air flow controller 91-FIC-1025 commands the
air damper valve 91-FV-1025.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
nd
2 stage auxiliary burner
91-TICA-1019 C 210 190 230
temperature
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 84 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
3
91-FIC-1026 Acid gas flow Sm /hr 155.382 80 175
3
91-FIC-1025 combustion air flow Sm /hr 519.541 NA 523
3
91-FIC-1027 fuel gas flow Sm /hr 159.635 8 170

2nd stage burner combustion air flow (91-FI-1136) low low alarm set 180 Sm3/hr,
acid gas flow (91-FI-1137) low low alarm set at 76 Sm3/hr and Fuel gas Flow (91-FI-
1138) low low alarm set at 7 Sm3/hr activates the following:
closure of Fuel gas block valves 91-XV-1031 and 91-XV-1133
opening of fuel gas vent valve 91-XV-1134

closure of fuel gas control valve 91-FV-1027


closure of acid gas control valve 91-FV-1026
closure of combustion air control valve 91-FV-1025
2nd stage combustion air damper/control valve 91-FV-1025 closes on instrument air
failure.
2nd stage acid gas control valve 91-FV-1026 closes on instrument air failure
2nd stage fuel gas control valve 91-FV-1027 closes on instrument air failure
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 85 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The schematic diagram for 2nd stage auxiliary burner temperature control is shown
below:

Fig. 18 - 2nd Stage Auxiliary Burner Temperature Control

9101-V-02
nd
2 Stage Converter

X
SP Selector
Air
Ratio HIC FY
FIC MV HS TICA
Acid Gas 1025B 1025B PV PV
1026 1029A 1019

FT
1026
Acid Gas to
2nd Stage
Burner SP FV-1026
9101-F-03
FIC 2nd Stage
PV 1027 MV Auxiliary
FT Burner
1027
Fuel Gas to
2nd Stage
Burner FV-1027

PV X
Air
Ratio HIC FY
Fuel Gas 1025A 1025A HS
1029B
Selector
SP
FIC MV
FT 1025
PV
1025
Combustion
Air to 2nd
Stage Burner FV-1025
Comp
PT TT FY
1002 1004 1025
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 86 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.2.4.7 Combustion Control for Reaction Furnace

Combustion temperature in the Reaction Furnace is maintained by controlling the ratio


of fuel gas, combustion air flow rates during start-up and by acid gas, combustion air
flow rates during normal operations.

Fuel gas flow to reaction furnace is controlled by 91-FIC-1009 which commands the
fuel gas control valve 91-FV-1009. Secondary combustion air flow to reaction furnace
is controlled by 91-FIC-1002B; Set point for the controller is calculated in the block
91-FY-1009 by multiplying fuel gas flow with AIR/FG ratio, which is manually provided
via 91-HIC-1009. Secondary air flow is regulated by 91-FV-1002B.

Trim air (make-up) flow is controlled by 91-FIC-1003; set point for the controller is
provided by analyzer controller 91-AIC-1001 which measures the H2S/SO2 ratio (4:1).
91-FIC-1003 throttles the damper 91-FV-1003.

Air selection to the reaction furnace is done by 91-HS-1142 (Secondary air during
start-up and trim air during normal operations).

Acid gas flow to the reaction furnace is measured by 91-FT-1001 which determines the
quantity of combustion air to the reaction furnace. Pressure, temperature
Compensated acid gas flow to reaction furnace is indicated by 91-FI-1001A.

Acid gas analyzer value in the reflux drum is measured by 91-AI-1502. 91-HIC-1001 bias
range (80%-120%) is manually provided as (Main air flow)/(total air flow) * 100.

Main combustion air flow is controlled by 91-FIC-1002, and set point for the main
combustion air flow controller is calculated in the block 91-FFY-1001A as: 2.38*(91-AI-
1502/100)* (91-FI-1001A)*(91-HIC-1001)/100.

91-FFY-1001B a bias block receives the remote set point from 91-FFY-1001A, which adds
or subtracts the bias value received from the selector/auto trigger switch 91-HS-1142.

When the manipulated variable received by 91-HS-1142 is >=80%, then it adds 1.25% of
91-FIC-1002 set point at each 30sec to the bias block 91-FFY-1001B and when the
manipulated variable received by 91-HS-1142 is <=20%, then it subtracts 1.25% of
91-FIC-1002 set point at each 30 sec to the bias block 91-FFY-1001B.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
3
91-FIC-1009 Fuel gas flow Sm /hr 357.802 330 380
3
91-FIC-1002 Main comb air flow Sm /hr 21124.6 18437 22534
3
91-FIC-1002B Sec comb air flow Sm /hr 5744.1 NA NA
3
91-FIC-1003 Trim air flow Sm /hr 2057.59 NA NA

Reaction Furnace combustion air damper/control valve 91-FV-1002, 91-FV-


1002B and 91-FV-1003 closes on instrument air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 87 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Reaction furnace 9101-F-01 acid gas control valve 91-FV-1019 closes on


instrument air failure.

Reaction furnace 9101-F-01 fuel gas control valve 91-FV-1009 closes on


instrument air failure.
Reaction furnace combustion air flow low low alarm (91-FI-1129) set at
16722 sm3/hr, acid gas flow low low alarm (91-FI-1140) set at 10912 sm3/hr and
fuel gas flow low low alarm (91-FI-1130) set at 64 sm3/hr activates the tripping
of reaction furnace, 1st stage auxiliary burner and 2nd stage auxiliary burners.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 88 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The schematic representation of Reaction Furnace control is shown below:


Fig. 19 Reaction Furnace Combustion control
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 89 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.3 TAIL GAS TREATMENT UNIT

4.3.1 Tail Gas Treatment Unit Equipment Specification

Combustion Air Blowers


Equipment Tag No. 9102-K-11A/B
Process Medium Air
Rated Capacity, kg/hr, Rated/Normal/
3175/2886/606
Turndown
Design Temperature, C 150
Inlet Pressure, bara 1.01
Discharge Pressure, bara 1.55
Drive Type Motor
Diver Power, kW 145
Material of Construction, Impeller SS Grade 15-5PH

Reducing Gas Generator


Equipment Tag No. 9102-F-11
Size (ID/T/T), mm 1500/4300
Operating Pressure, barg 0.44
Operating Temperature, C 290
Design Temperature, Metal/Refractory, C 340/1800
Design Pressure, barg 5
Material of Construction, Shell CS

Hydrogenation Reactor
Equipment Tag No. 9102-V-11
Size (ID/T/T), mm 3100/6100
Design Temperature, Metal/Refractory, C 340
Design Pressure, barg 3.5
Operating Pressure, barg 1.45
Operating Temperature, Inlet/Outlet C 290/327
Material of Construction, Shell CS, Refractory lined
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 90 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Reactor Effluent Cooler


Equipment Tag No. 9102-E-11
Process Medium Process Gas
Design Pressure, Shell Side, barg 7.0/FV
Design Pressure, Tube Side, barg 7.0
Design Temperature, Shell Side, C 185/0
Design Temperature, Tube Side, C 340/0
Operating Pressure, Shell Side barg 6.0
Operating Pressure, Tube Side, barg 0.38
Operating Temperature, Shell Side, LP BFW/
105/159
LP Steam, C
Operating Temperature, Tube Side (In/Out) C 320/178
Design Duty, kW 2152
Material of Construction, Shell & Tube CS

Start-up Gas Steam Ejector


Equipment Tag No. 9102-X-11
Design Temperature, C 225
Design Pressure, barg 7.0
Motive Fluid LP Steam
Steam Inlet Pressure, barg 4.5
Steam Inlet Temperature, C 159
Material of Construction CS

Desuperheater/Contact Condenser
Equipment Tag No. 9102-C-11
Size (ID X T/T), mm 2900/3400 X 27470
Design Temperature, C 193/0
Design Pressure, barg 3.5/FV
Operating Pressure, Top/Bottom, barg 0.18/0.30
Operating Temperature, Top/Bottom, C 42/82
Material of Construction, Shell/Internal CS/SS316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 91 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Cooling Water Circulation Pumps


Equipment Tag No. 9102-P-12A/B
3
Capacity, m /hr (Normal/Rated) 210.6/252.7
Suction Pressure, bar(a) (Rated/Max.) 2.8/6.4
Discharge Pressure, bar(a) 8.4
Operating Temperature, C 71
Design Temperature, C (Max./Min.) 150/0
Driver Type Motor
Rated Power, kW 75
Material of Construction, Casing/Impeller A351-CF8M/SS316L

Desuperheater Circulation Pumps


Equipment Tag No. 9102-P-11A/B
3
Capacity, m /hr (Normal/Rated) 240
Suction Pressure, bar(a) (Rated/Max.) 1.5/5.1
Discharge Pressure, bar(a) 5.6
Operating Temperature, C 80
Design Temperature, C (Max./Min.) 150/0
Driver Type Motor
Rated Power, kW 55
Material of Construction, Casing/Impeller A351-CF8M/SS316L

Wash Water Filter


Equipment Tag No. 9102-S-15
Size (ID/T/T), mm 736/2080
Design Temperature, C 150/0
Design Pressure, barg 9.6
3
Flow rate, m /hr 240
Operating Temperature, C 82
Operating Pressure, barg 4.5
Clean Pressure Drop, bar 0.1
Max. Allowed Pressure Drop, bar 0.7
Size of particles to be removed, microns 5
Material of Construction CS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 92 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Contact Condenser Cooler


Equipment Tag No. 9102-E-12
Tube Side Design Pressure, barg 12.4
Tube Side Design Temperature, C 150/0
Operating Pressure bar(a) 6.0
Operating Temperature, In/Out, C 73/40
Design Duty, kW (Summer/Winter) 4593/7985
Material of Construction, Tubes Alloy 825

Contact Condenser Trim Cooler


Equipment Tag No. 9102-E-13A/B
Design Pressure Shell Side, barg 12.4
Design Pressure Tube Side, barg 9.55
Design Temperature Shell Side, (Min./Max.), C 150/0
Design Temperature Tube Side (Min./Max.)C 85/0
Operating Pressure Shell/Tube Side barg 3.95/1.7
Operating Temperature, Shell Side, (In/Out), C 54/40
Operating Temperature, Tube Side (In/Out) C 35/45
Design Duty, kW 3387
Material of Construction, Shell/Tube SS316L/Titanium Grade-2

Blowdown Pit
Equipment Tag No. 9102-T-01
Size, (L/W/H), m 1/1/1
Design Pressure, barg 0
Design Temperature, C 185
Material of Construction Concrete

4.3.2 Tail Gas Treatment Unit (TGTU) Process Description

The Tail Gas Treating Unit reduces the hydrogen sulphide concentration in the tail gas
to a level corresponding to >99.5% total sulphur recovery. All residual hydrogen
sulphide is oxidised to sulphur dioxide before it is released to the atmosphere.

The BSR/Amine process consists of a Reducing Gas Generator section, Hydrogenation


section, Desuperheater/Contactor section and a selective amine absorption section.
The process uses the BSR technology to reduce all sulphur compounds in the SRU tail
gas to hydrogen sulphide. This section includes water condensation and separation
upstream of the amine section with a caustic circulation system to protect against SO2
breakthrough, which degrades the amine and causes severe corrosion.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 93 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The amine section uses an amine solution to remove most of the hydrogen sulphide
from the treated sulphur plant tail gas while minimising the co-absorption of carbon
dioxide.

The Claus tail gas from the Final Separator 9101-V-05 is fed to the Reducing Gas
Generator (RGG) 9102-F-11. The purpose of the Reducing Gas Generator is to generate
reducing gases (H2 and CO). This is achieved by the combustion of fuel gas with a sub-
stoichiometric quantity of air. The production of reducing gases is regulated by
controlling the flow of the fuel gas and air. Air flow is set by the outlet temperature of
the Reducing Gas Generator 9102-F-11 while the fuel gas flow rate is set to be a fixed
proportion of the air flow. LP steam is fed to the Reducing Gas Generator to suppress
the formation of carbon. The flow rate of the steam is ratio-controlled according to
the fuel gas flow rate. The tail gas from the Final Separator 9101-V-05 is mixed with
the hot combustion products in the Reducing Gas Generator to ensure a temperature
that will favour the desired reactions in the Hydrogenation Reactor (9102-V-11).

The Hydrogenation Reactor contains a fixed bed Cobalt/Molybdenum (CoMo) catalyst.

The reactions are exothermic resulting in a temperature rise across the reactor. The
gas is cooled by the generation of LP steam in the Reactor Effluent Cooler 9102-E-11.

The tail gas is then desuperheated and the excess water removed in the
Desuperheater/Contact Condenser (9102-C-11). This tower contains an upper packed
section, a chimney tray and a lower section containing packing and bubble cap trays.
In the lower packed section of the tower (Desuperheater section), tail gas is contacted
with a circulating stream of a mildly caustic water solution. This removes sulphur
dioxide and cools the tail gas down. The Desuperheater Circulation Pump (9102-P-
11A/B) pumps the caustic water solution from the bottom of the tower to the top of
the packing. Water make up is provided to the lower (Desuperheater) section, under
level control, from the top (Contact Condenser) section circulation.

The solution is maintained at an alkaline pH of around 9.0 to protect against SO2


breakthrough from the reactor. SO2 causes corrosive conditions in the Desuperheater
Contact Condenser and the Amine Absorber, and degrades the amine. The pH of the
circulating liquid is monitored by a continuous analyser and controlled by periodic,
manual addition of fresh caustic solution. An intermittent bleed from this section
removes accumulated contaminants from the circuit.

The desuperheated gas and water vapour then passes through the (wash) bubble cap
trays and the chimney tray into the upper (Contact Condenser) packed section. Here
the gas is cooled by direct contact with a circulating water stream. The water is
pumped by the Cooling Water Circulation Pump from the chimney tray, through the
Contact Condenser Cooler 9102-E-12 and Contact Condenser Trim Cooler 9102-E-13A/B
where it is cooled, and back to the top of the tower. The water that is condensed in
this section is slightly sour. Some is used as make up on demand to the lower
Desuperheater section and the remainder is taken off under level control and sent to
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 94 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

effluent treatment. The condensed water loop is kept separate from the water in the
Desuperheater circulation loop to avoid contamination with salt products that may be
formed in the Desuperheater section.

The tail gas leaves the Desuperheater Contact Condenser (9102-C-11) at a temperature
of approximately 40C and is sent to the Tail Gas Amine Absorber (9102-C-12) which
uses a lean amine solution to remove the hydrogen sulphide from the tail gas, while
minimising the co-absorption of carbon dioxide.

The gas enters at the bottom of the absorber and passes through a trayed section
counter current to the lean amine solution that preferentially absorbs H2S. The lean
amine solution is supplied from the Lean Amine Pumps 9103-P-13A/B.

The Tail Gas Rich Amine Pump (9102-P-16 A/B) pumps the rich solvent solution from
the bottom of the Tail Gas Amine Absorber (9102-C-12) to the Acid Gas Amine
Absorber (9103-C-11) before it is regenerated in the Amine regenerator (9103-C-12).

The amine regeneration facilities required for the Acid Gas Enrichment and Tail Gas
Treatment Units are shared with the use of a common solvent. The H2S that is stripped
from the rich amine solution in the Amine Regenerator is fed to the Sulphur Recovery
section, thus closing the recycle loop around the SRU and TGTU sections.

Treated gas from the Tail Gas Amine Absorber passes to the Incinerator along with
that from the Acid Gas Amine Absorber and from the Sulphur Pit.

4.3.3 Tail Gas Treatment Unit Control Description

4.3.3.1 Controls for RGG Combustion Air Blower (9102-K-11A/B)

4.3.3.1.1 Surge Protection

The basic objectives of the surge protection system are:

To prevent surge-induced compressor damage and process upsets without


sacrificing energy efficiency
To maintain selected process-limiting variables within safe or acceptable range
To achieve these objectives, the anti surge controller manipulates the position of
a blow-off valve and IGV (inlet pressure control)
4.3.3.1.2 Anti surge Protection

The regulation of the combustion air blower valves is implemented on the CCC Anti-
surge controller.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 95 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

CCC receives the following signals from the compressor skid (9102-K-11A/B) to perform
the pressure and anti-surge regulation:

9102-K-11A 9102-K-11B
Sl. # Service
Tag No. Tag No.
1. 91-PT-1452 91-PT-1712 Discharge air pressure
2. 91-TT-1454 91-TT-1714 Discharge air temperature
3. 91-FT-1452 91-FT-1712 Discharge air flow
4. 91-PT-1454 91-PT-1714 Compressor inlet air pressure
5. 91-TT-1455 91-TT-1715 Compressor inlet air temperature
6. 91-PT-1456 91-PT-1716 Discharge air pressure after check valve
7. 91-ZT-1453 91-ZT-1713 IGV valve position transmitter
8. 91-ZT-1451 91-ZT-1711 Blow-off valve position transmitter
9. 91-II-1470 91-II-1730 Main motor current signal

Note: 9102-K-11A controls are discussed in the following section.

After processing all the above signals, CCC controls the IGV 91-PCV-1453 and blow-off
valve 91-FCV-1451.

CCC also provides trip signal 91-XS-1464 for excessive surge to ESD to stop the
compressor.

When the blower is started IGV 91-PCV-1453 receives a minimum opening signal from
CCC which is a pre-set value on CCC and the blow-off valve 91-FCV-1451 remains open.

When the compressor is loaded, CCC modulates the IGV 91-PCV-1453 and blow-off
valve 91-FCV-1451 to maintain the discharge air pressure constant.

4.3.3.1.3 IGV 91-PCV-1453

The regulation system of compressor IGV valve 91-PCV-1453 is of the constant pressure
type.

After the loading of compressor the pressure regulation loop stabilizes and the IGV
91-PCV-1453 opens or closes only when the air required by the machine varies, so as to
maintain the discharge pressure of the blower within the set-point defined.

4.3.3.1.4 Blow-off Valve 91-FCV-1451

The anti-surge regulation loop provides to regulate the blow-off valve 91-FCV-1451 by
a continuous calculation of the discharge pressure 91-PT-1452 and discharge flow
91-FT-1452. When the flow is higher than the pressure the result of the calculation
closes the blow-off valve. When the pressure is higher than the flow the result of the
calculation opens the blow-off valve.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 96 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.3.3.2 Reducing Gas Generator Controls

4.3.3.2.1 Hydrogenation Reactor I/L Temperature Control

The Hydrogenation Reactor inlet temperature is controlled through 91-TIC-1307 by


adjusting the air and the fuel Gas flow rates to the Reducing Gas Generator.

The Hydrogenation Reactor inlet temperature is controlled by 91-TIC-1307, output of


the controller 91-TIC-1307 is directly fed to the combustion air flow controller 91-FIC-
1304 as a set point and output of the controller 91-FIC-1304 regulates the air flow
damper 91-FV-1304.

Fuel gas flow is controlled by 91-FIC-1311; set point for the fuel gas controller is
derived in the block 91-UY-1304 by multiplying the air flow with AIR/FG ratio set value
provided from 91-HIC-1304 (Range: 0.09 to 0.15).

Output of the controller 91-FIC-1311commands the fuel gas control valve 91-FV-1311.

If the Hydrogenation Reactor inlet temperature increases, then controller 91-TIC-1307


shall first decrease the Set point of combustion air flow controller 91-FIC-1304, which
in turn decrease the set point of fuel gas controller 91-FIC-1311 and vice versa.

4.3.3.2.2 Steam Flow Control

LP steam is injected directly in to the RGG burner in a ratio of steam to fuel gas to
suppress the formation of soot. Steam flow to RGG is measured by 91-FT-1310 which is
fed as a process variable to the steam flow controller 91-FIC-1310, set point for the
controller is calculated by multiplying the process variable from 91-FIC-1311(FG flow)
with the STEAM/FG ratio manually provided via 91-HIC-1311(2.0:1.0).

Output (0-100%) of the controller 91-FIC-1310 directly commands the control valve
91-FV-1310.

Operating Alarm
Controller Control Loop Unit
Set Point Low High
Hydrogenation reactor I/L
91-TIC-1307 C 290 285 295
temperature
91-FIC-1304 RGG comb air flow Sm3/hr 2371.6 2134 2609
3
91-FIC-1311 RGG fuel gas flow Sm /hr 263.7 237 290
91-FIC-1310 RGG quench steam flow kg/hr 400 360 440
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 97 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 20 - Reducing Gas Generator Temperature Control

9102-V-11
SP
Hydrogenation Reactor
PV FIC
1304 MV

X Comp
Tail Gas
FY TIC TT
1304 1307 1307

FT PT TT
1304 1304 1304

Combustion
Air to RGG FV-1304 9102-F-11
Reducing
Gas
Generator

PV X MV
Fuel Gas
Ratio HIC UY FIC
Air 1304 1304 SP 1311
PV

FT
1311

Fuel Gas to
RGG FV-1311
X

Steam HIC UY PV
Ratio
Fuel Gas 1311 SP 1311

SP

FIC MV
PV 1310

FT
1310

Steam to
RGG FV-1310
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 98 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.3.3.3 Reactor Effluent Cooler Controls

4.3.3.3.1 Reactor Effluent Cooler Level Control

Hydrogenated process gases from the Hydrogenation Reactor are cooled in the Reactor
Effluent Cooler (9102-E-11) and generates LP steam in the shell side of the cooler.

The water level in the Reactor Effluent Cooler is maintained by level controller 91-LIC-
1302 by monitoring the level through 91-LT-1302, level control is achieved by
controlling the boiler feed water inlet to the Reactor Effluent Cooler through the
control valve 91-LV-1302.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Reactor Effluent Cooler
91-LIC-1302 % 85 81 92
level Control

Low low level alarm (91-LALL-1309) set at 76% in reactor effluent activates the
RGG (9102-F-11), TGTU and SRU shutdown
BFW inlet to reactor effluent control valve 91-LV-1302 opens on instrument air
failure.
4.3.3.3.2 Reactor Effluent Cooler Outlet Tail Gas Control

In normal operation tail gas from the Reactor Effluent Cooler will be routed to Contact
Condenser but during start-up tail gas is diverted to the Incinerator.

This diversion of tail gas is accomplished by activating the selector switch 91-HS-
1303A. This opens the valve 91-XV-1332 (tail gas going to the Contact Condenser) and
when it is fully open the valve 91-XV-1331 will close (tail gas going to the incinerator).

This ensures that at least one path is fully open for the tail gas to pass through without
pressuring the upstream reducing gas generator RGG.

4.3.3.4 Desuperheater/Contact Condenser Controls

4.3.3.4.1 Desuperheater/Contact Condenser Column Bottom Level Control

The Desuperheater Circulation Pump (9102-P-11A/B) takes suction from the


Desuperheater/Contact Condenser (9102-C-11) bottom and circulates water to the
column through Wash Water Filter (9102-S-15). The Desuperheater/Contact Condenser
column bottom level is maintained by the level controller 91-LIC-1307, regulating the
level control valve 91-LV-1307, which controls slip stream of water flow from the
Cooling Water Circulation Pumps (9101-P-12A/B) to the bottom section of the column
as top up water.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 99 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Desuperheater/Contact
91-LIC-1307 Condenser column bottom % 50 22 93
level

Low low level alarm (91-LALL-1306) in Desuperheater/Contact Condenser column


bottom trips the Desuperheater Circulation Pumps 9102-P-11A/B

Desuperheater/Contact Condenser column bottom level control valve 91-LV-1307


opens on instrument air failure.
4.3.3.4.2 Circulating Water Return Flow to Desuperheater Control

The Desuperheater Circulation Pump (9102-P-11A/B) takes suction from the column
(9102-C-11) bottom and circulates water to the column through Wash Water Filter
(9102-S-15). Flow from the Wash Water Filter to the column bottom is maintained by
the flow controller 91-FIC-1314 which regulates the flow control valve 91-FV-1314.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Circulating water return to
91-FIC-1314 m3/hr 199 179 219
Desuperheater

Low low flow alarm (91-FALL-1306) set at 30 m3/hr in circulating water return to
de super heater trips the de super heater circulation pumps 9102-P-11A/B
Circulating water return to de super heater flow control valve 91-FV-1314 opens
on instrument air failure.
4.3.3.4.3 Desuperheater/Contact Condenser Top Level Control

The cooling water circulation in the Contact Condenser top section is carried out by
Cooling Water Circulation Pump (9101-P-12A/B). The Contact Condenser (9102-C-11)
top level is maintained by the level controller 91-LIC-1305 through the level control
valve 91-LV-1305, which controls the excess water flow from the Cooling Water
Circulation Pumps discharge to the Waste Water Degasser (6922-V-07).

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Desuperheater/Contact
91-LIC-1305 % 50 32 90
Condenser top level

Low low level alarm (91-LALL-1304) in Desuperheater/Contact Condenser column


top trips the Cooling Water Circulation Pump 9102-P-12 A/B
Desuperheater/Contact Condenser column top level control valve 91-LV-1305
closes on instrument air failure
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 100 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.3.3.4.4 Desuperheater/Contact Condenser Top Circulating Water Flow Control

Cooled circulating water return from the Contact Condenser Trim Cooler (9102-E-
13A/B) flows to top of the de-super heater/contact condenser column (9102-C-11) is
measured by 91-FT-1307 and controlled by the flow controller 91-FIC-1307 which
regulates the flow control valve 91-FV-1307.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Desuperheater/ Contact
91-FIC-1307 m3/hr 197 177.3 216.7
Condenser top CW

Desuperheater/Contact Condenser column top cooling water control valve 91-FV-


1307 opens on instrument air failure
4.3.3.4.5 Desuperheater/Contact Condenser Top Pressure Control

In normal operation Desuperheater/Contact Condenser column (9102-C-11) tail gas


flows to the Tail Gas Amine Absorber 9102-C-12 but during start-up, flow will be
diverted to the Incinerator and the tail gas pressure is maintained by the pressure
controller 91-PIC-1308 by monitoring the pressure transmitter 91-PT-1308 located in
the start-up bypass line to Incinerator. If the pressure increases then the control valve
91-PV-1308 opening will increase to pass more gas to the Incinerator (9101-F-14).

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Desuperheater/ Contact
91-PIC-1308 Condenser column top bara 1.19 NA NA
pressure

Desuperheater/Contact Condenser column top pressure control valve 91-PV-1308


to incinerator opens on instrument air failure
4.3.3.4.6 Contact Condenser Cooler Temperature Control

Temperature of the circulating water from the Cooling Water Circulation Pumps
(9102-P-12-A/B) is controlled by cooling the fluid to 54C (maximum temperature) in
summer and not less than 40C (minimum temperature) in winter using three fans: one
fixed speed fan (on/off) control (column 1), and another two VSD controlled fans
working simultaneously (in column 2 & 3).

The contact condenser cooler outlet temperature is measured at outlet of Contact


Condenser Trim Cooler by 91-TT-1301 and received by the temperature controller
91-TIC-1301. The output of this controller sends the control signal to control the three
fans and also to control the bypass control valve 91-TV-1301 of Contact Condenser
Trim Cooler.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 101 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

In auto mode, the temperature controller shall follow up the cooler outlet
temperature changes by changing the VSD (9102-EM-12AB/AC/BB/BC) rates to
maintain the temperature set point-1 = (54C + 40C)/2=47C.

The fixed speed fan (9102-EM-12AA/BA) will operate on gap control set point between
the values Tmax=54C & Tmin=42C.

The temperature control valve will be used only in case the cooler outlet temperature
goes to pre-determined temperature T=42C, then the control valve shall open
gradually to maintain the cooler temperature and keep it around the set point-2
(42C).

4.3.3.5 Tail Gas Amine Absorber Controls

4.3.3.5.1 Tail Gas Absorber Level Control

The tail gas from the Desuperheater/Contact Condenser (9102-C-11) enters at the
bottom of Tail Gas Amine Absorber 9102-C-12. Bottom level in the Tail Gas Amine
Absorber (9102-C-12) is maintained by controlling the rich amine flow from the bottom
of the column to Acid Gas Amine Absorber (9103-C-11) through 9103-P-16A/B.

Tail gas absorber bottom level is controlled by 91-LIC-1308; Tail Gas Rich Amine Pumps
9102-P-16A/B discharge flow to Acid Gas Amine Absorber is measured by 91-FT-1325
and controlled by the flow controller 91-FIC-1325; set point for the SLAVE flow
controller 91-FIC-1325 is received from the tail gas absorber MASTER level controller
91-LIC-1308.

Output of the flow controller 91-FIC-1325 directly controls the control valve
91-FV-1325 in the Tail Gas Rich Amine Pumps 9102-P-16A/B discharge flow to the acid
gas amine absorber.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Tail Gas Amine Absorber
91-LIC-1308 % 50 11 82
bottom level
Rich amine flow to 9103-C-
91-FIC-1325 m3/hr 136 NA NA
11

High high level alarm (91-LAHH-1310) in Tail Gas Amine Absorber bottom closes
the lean amine inlet valve 91-XV-1310 to Tail Gas Amine Absorber
Low low level alarm (91-LALL-1301) in Tail Gas Amine Absorber bottom trips the
Tail Gas Rich Amine Pumps (9102-P-16A/B) and closes tail gas rich amine valve
91-XV-1309.

Rich amine flow control valve 91-FV-1325 to Acid Gas Amine Absorber closes on
instrument air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 102 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.3.3.5.2 Lean Amine to Tail Gas Amine Absorber Flow Control

Lean amine solution from Lean Amine Pumps (9103-P-13A/B) and tail gas from
Desuperheater/Contact Condenser (9102-C-11) enters the Tail Gas Amine Absorber
(9102-C-12).
Lean amine flow to the absorber is measured by 91-FT-1301 and controlled by
91-FIC-1301. Output of the flow controller directly regulates the lean amine flow
control valve 91-FV-1301.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Lean amine flow to Tail Gas
91-FIC-1301 m3/hr 135 110 148.5
Amine Absorber

High high level alarm (91-LAHH-1310) in Tail Gas Amine Absorber bottom closes
the lean amine inlet valve 91-XV-1310 to Tail Gas Amine Absorber located on the
downstream of 91-FV-1301.

Lean amine inlet valve 91-XV-1310 closes on activation of ESD-0, ESD-1 and ESD-2
shutdown.
4.3.3.5.3 Tail Gas Rich Amine Pumps Minimum Flow Control

Tail Gas Rich Amine Pumps (9102-P-16A/B) minimum flow to Tail Gas Amine Absorber
bottom is controlled by 91-FIC-1303.
Output of the controller 91-FIC-1303 controls the fail open control valve 91-FV-1303.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Tail Gas Rich Amine Pump
91-FIC-1303 m3/hr 31.25 27.5 NA
min flow

Tail Gas Rich Amine Pump discharge flow Low low alarm (91-FALL-1305) set at
25 m3/hr trips the Tail Gas Rich Amine pumps (9102-P-16A/B).
4.4 INCINERATOR

4.4.1 Equipment Specification

Incinerator Air Blowers


Equipment Tag No. 9101-K-12A/B
Process Medium Air
Rated Capacity, ACMH 63,402
Design Temperature, (Min./Max.), C 0/52
Drive Type Motor
Driver Power, kW 94
Material of Construction, Impeller Corten Steel
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 103 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Incinerator
Equipment Tag No. 9101-F-14
Size, (OD/L), m 3.886/17.374
Process Medium Tail Gas/Air/Fuel Gas
Design Temperature, shell, C 343
Design Pressure, barg 3.8

Burner
Model GSLF-24J
Size 82
Quantity 1
Duty 32.2 MW-H
Turndown 5:1
Pilot Type AR/GS-1
Design Temperature, shell, C 343
Design Pressure, barg 3.8

Incinerator Stack
Equipment Tag No. 9101-X-11
Process Medium Flue Gas
Shell OD/Height, m 2.438/110
Design Temperature, (Shell/Refractory), C 343/1538
Design Pressure, barg ATM.
Internal Lining YES, L.W. Castable

4.4.2 Process Description and Control

4.4.2.1 Tail Gas Incinerator Process Description

An Incinerator 9101-F-14 is provided to thermally oxidise all possible sulphur


compounds to SO2 in off gas effluents from the Acid Gas Amine Absorber 9103-C-11,
Tail Gas Amine Absorber 9102-C-12, SRU tail gases and vent gases from the Sulphur
Degassing Pit 9101-T-01/01B. Moreover all BTEX content of off gas effluent is also
destructed.

To ensure complete combustion of these sulphur compounds the Incinerator's


combustion chamber temperature is maintained at a temperature of about 800C by
burning fuel gas supplied with combustion air in the unit's burner.

Combustion air is supplied from 2 x 100% Incinerator Air Blowers (9101-K-12 A/B, One
Operating and One Standby). The Blowers are driven by VFD motors. Each Blower is
provided with an Air Intake Stack with Bird Screen, Sand Filter and Rain Hood.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 104 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fuel gas to the Incinerator is supplied from the existing Fuel Gas network. A tapping is
taken from the existing fuel gas line 6-6536-FG-101-C12P and fuel gas is supplied to
the Incinerator 9101-F-14 and Reducing Gas Generator 9102-F-11.

The flows of fuel gas and combustion air are each measured by flow and then ratio
controlled to ensure the correct amount of excess air is always maintained in the
Incinerator combustion chamber to allow the oxidation of the sulphur compounds in
the tail and vent gases to take place.

An Oxygen Analyser 91-AE-1051 located in the Incinerator outlet combustion gases


Stack 9101-X-11 monitors the excess O2 in the Incinerator combustion gases.
Adjustments may be made to the fuel gas to air ratio controller to ensure the correct
excess of O2 (3% by Mol) is seen in the stack gases.

A sulphur dioxide analyser AE-1052, located at the Incinerator Stack (9101-X-11),


monitors the Incinerator stack gases for SO2 content. A NOX analyser 91-AE-1053,
located at the Incinerator Stack (9101-X-11), monitors the Incinerator stack gases for
NOX content.

4.4.2.2 Tail Gas Incinerator Process Control

4.4.2.2.1 Incinerator Temperature control (91-TIC-1155)

Normal operating temperature of the Incinerator is 817C; the temperature in the


Incinerator is controlled by modulating the flow of fuel gas and combustion air.

Temperature in the Incinerator is measured by 91-TT-1155 and controlled by 91-TIC-


1155. The output of the controller 91-TIC-1155 is fed to a splitter 91-TY-1155A where
the output is splitted into 0-50% which is fed to 91-TY-1155C for regulating the
combustion air flow and 50-100% which is fed to 91-TY-1155B for regulating the fuel
gas flow.

0-50% output of 91-TIC-1155 is scaled to 0-100% and is reversed in 91-TY-1155C (This is


for regulating the temperature of Incinerator during normal operation by varying the
speed of the air blower). This value is then fed to a high selector function block 91-FY-
1156C. The other input of 91-FY-1156C is received from 91-FY-1155A (This determines
the quantity of combustion air required based on fuel gas flow).

The combustion air flow rate from Air Blowers is measured in the common discharge
line by 91-FT-1156.

91-FIC-1156 receives the PV from 91-FT-1156 and set point (SP) from 91-FY-1156C. The
output (MV) of 91-FIC-1156 is then scaled to 4-20 mA. The scaled current signal is sent
to VSD panel of Duty Air Blower for controlling its speed. The speed of the Air Blower
determines the quantity of combustion air required.

The main fuel gas flowing to the burner is measured by 91-FT-1155 and the PV is sent
to 91-FIC-1155.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 105 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The set point for 91-FIC-1155 is derived from the temperature controller 91-TIC-1155.
i.e. The output (MV) of 50-100% is scaled to 0-100% and is fed as SP through 91-TY-
1155B to 91-FIC-1155.

The ratio set point is manually entered by operator via 91-HIC-1155A. The fuel gas
flow value (PV) of 91-FIC-1155 is multiplied by ratio set point in function block 91-FY-
1155A. The ratio set point gives the correct ratio of air to fuel gas based on a manually
determined composition. The multiplication factor is a manual entry and is based on
the design composition of the feed gas. The output value of 91-FY-1155A is given to
the selector function block 91-FY-1156C.

The actual ratio of combustion air to fuel gas is displayed in function block 91-FY-1155A.

Fuel gas flow control is achieved via 91-FIC-1155 by controlling 91-FV-1155

This reversed output and air/fuel ratio provided via 91-HIC-1155A is allowed to pass
through the high demand selector 91-FY-1156C which provides the set point to
combustion air flow controller 91-FIC-1156. Output of the controller modulates the
combustion air flow by changing the Combustion air fan 9101-K-12A/B VFD set point.

50-100% output of 91-TIC-1155 is scaled to 0-100% in 91-TY-1155B, which provides the


set point to the fuel gas controller 91-FIC-1155 and output of the controller 91-FIC-
1155 commands the fuel gas control valve 91-FV-1155.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
91-TIC-1155 Incinerator stack temp C 800 NA 850
3
91-FIC-1155 Incinerator Fuel gas flow Sm /hr 2256.9 NA NA
Incinerator combustion air
91-FIC-1156 Sm3/hr 46938.7 NA NA
flow
High high temperature alarm (91-TAHH-1160) set at 900C, low low combustion air
flow alarm (91-FALL-1156B/C) set at 8383 Sm3/hr, low low fuel gas pressure alarm
(91-PALL-1156) set at 0 barg and high high fuel gas pressure alarm (91-PAHH-1156)
set at 4 barg at Incinerator
Closes the following valves:
Fuel gas block valve 91-XV-1555 to burner
Fuel gas block valve 91-XV-1557 to burner
Pilot gas block valve 91-XV-1558 to burner
Pilot gas block valve 91-XV-1560 to burner
Instrument air block valve 91-XV-1161
Pilot air block valve 91-XV-1162
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 106 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Opens the following valves:


Fuel gas vent valve 91-XV-1158
Pilot gas vent valve 91-XV-1159
Fuel gas supply control valve 91-FV-1155 to Incinerator furnace closes on
instrument air failure.
The schematic diagram for Incinerator temperature control is shown below:

Fig. 21 - Incinerator Temperature Control

Master
TE TT TIC
1155 1155 1155

Incinerator
9101-F-14
X
50-100% Split
TY TY
1155B 1155A

Slave SP X

MV FIC FY 0-50%
1155 PV 1155A
PV X
Burner TY
1155C

FT HIC Fuel Ratio


1155 1155A Air
Combustion
Air
Fuel Gas to
Incinerator
FV
1155

Slave >

FT FIC SP FY
1156A 1156 1156C
Combustion Air Fan PV
MV High Selector

FY-1156A
VFD

9101-K-12A

Combustion Air Fan

FY-1156B
VFD

9101-K-12B
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 107 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.5 INSTRUMENT AIR PACKAGE

4.5.1 Instrument Air Compressor Package

4.5.1.1 Equipment Specification

Screw Compressors
Tag No. 6837-K-02A/B
Rotary, Dry Screw, 2 stage,
Type
Air-cooled
No. of units Two (1 Working + 1 Standby)
3
Capacity, Nm /hr (Total) @52C & 100% RH 900
Design Pressure, barg 8.6
Design Temperature, C 52/0
Compressor Inlet Pressure, barg ATM
Compressor Inlet Temperature, C AMB (0-52)
Compressor Outlet Pressure, barg 8
Driver Motor
Driver Power, kW 200

Pre-cooler
Tag No. 6837-E-03A
Design Pressure, barg 11
Design Temperature, C 260

Inter-cooler
Tag No. 6837-E-03A
Design Pressure, barg 3.7
Design Temperature, C 180

After-cooler
Tag No. 6837-E-03A
Design Pressure, barg 13.7
Design Temperature, C 200

After-cooler
Tag No. 6837-E-04A
Design Pressure, barg 10.5
Design Temperature, C 160
Max. Capacity, L/S 650
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 108 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Discharge Air Receiver


Tag No. 6837-V-10
Size, mm, (Dia x T/T) 2400 x 7200
Design Pressure, barg 9.7
Design Temperature, C 85
Operating Pressure, barg 7
Operating Temperature, C 60
Material of Construction CS

4.5.2 Instrument Air Dryer Package

4.5.2.1 Equipment Specification

Air Dryer
Tag No. 6837-A-03/04
Twin Tower, pressure swing
Dryer Type absorption with heatless
regeneration
Capacity, Nm3/hr 300
Design Pressure, barg 9.7
Design Temperature, C 85/0
Operating Pressure, barg 8
Operating Temperature, C 60
Activated Alumina/Molecular
Desiccant Type
Sieve

Pre-Filter
Tag No. 6837-S-07A/B & 6837-S-09A/B
Size (Dia x L), mm 190 x 621
Design Pressure, barg 9.7
Design Temperature, C 85
Material of Construction Cast Aluminium

Dryer Vessels
Tag No. 6837-V-14A/B & 6837-V-15A/B
Size (Dia x T/T), mm 550 x 1500
Design Pressure, barg 9.7
Design Temperature, C 85
Material of Construction CS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 109 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

After-Filters
Tag No. 6837-S-08A/B & 6837-S-10A/B
Size (Dia x L), mm 190 x 621
Design Pressure, barg 9.7
Design Temperature, C 85
Material of Construction Cast Aluminium

Instrument Air Receiver


Tag No. 6837-V-11
Size mm, (Dia x T/T) 3700 x 7400
Design Pressure, barg 9.7
Design Temperature, C 85/0
Operating Pressure, barg 7.1
Operating Temperature, C 60
Material of Construction CS

4.5.3 Instrument Air Package Description

The new air compressor package consists of the following:

1. Two (2x100%) single base frames mounted Air Compressors (6837-K-02A/B), each
having a capacity of 900 Nm3/hr (dry basis).
2. Each Compressor is supplied with an individual After Cooler.
3. One air compressor discharge drum, (6837-V-10) is provided.
4. Two Instrument air dryer packages, (6837-A-03/04) running at 2X50%, each dryer
capacity is 300 Nm3/hr (dry basis).
5. Pre and After Filters for each dryer.
6. One instrument air receiver (6837-V-11) with storage capacity to provide
instrument air for a period of 20 minutes following a compressor trip.
7. Dew point analyzers are provided for individual dryer package.
The compressors are air-cooled, oil free, rotary screw type and are sized 100% of duty.
Both Compressors operate in Duty/Standby configuration (with automatic changeover
of the standby unit compressor).

The dryer consists of two 50% heater-less desiccant dryers each consisting of two
vessels (one drying, one regenerating), a set of duplex pre and after filters. Each dryer
is 50% of design capacity (Single Compressor supply).

Compressors and Dryers have locally mounted instruments and junction boxes and
operate from the UCP, with DCS and ESD remote monitoring, through TCP/IP.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 110 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Based on air demand only one compressor under normal conditions will be loaded, the
second unit can start but will have load inhibitors to ensure only one unit is loaded.
Each dryer has a sonic nozzle at the discharge header to ensure the protection against
the greater flow.

Each compressor is monitored and controlled by the Package Controller (UCP) which
provides information to the ICSS. There is only a push button station available at each
equipment station in the field (LCP). However this LCP still only communicates with
the UCP which then sends signals to the DCS. All the signals are hardwired to UCP. The
subsystems MCC, ESD and ICSS are hardwired to the UCP and linked also through a
redundant modbus TCP/IP communication link.

Compressor instrumentation and solenoids are all wired to junction boxes, the UCP
system receives an external net air pressure signal and then starts, loads/unloads and
stops the available compressor based on its own selecton routine. The ICSS supervises
the system status via the UCP connected to the junction boxes shown in the Electrical
Service Diagram.

The new Air System will supply instrument and plant air with the following supply
battery limit conditions for both instrument and plant air:

Design Operating
Pressure bar (g) 9.7 7.0
Temperature (C) 85 55/60

The new instrument and plant air headers are connected to the existing NGL-3
instrument and plant air headers respectively through cross over connection lines with
(manual isolation valves) for operation flexibility.

4.5.4 Instrument Air Package Control Description

A. Loading/Unloading

The compressor always starts to run in unloaded condition, up to first 20 seconds


known as the load delay, this is to ensure the oil pressure is stabilised. After the load
delay compressor will load unless either the operator manually selects to unload or
there is no air demand. If there is no air demand the compressor runs unloaded and is
said to be idle.

To load the compressor the solenoid valve 68-XY-1401 shall be energized, similarly to
unload the compressor solenoid valve 68-XY-1401 shall be de-energised and solenoid
valve 68-XY-1403 shall be energised.

When the compressor is in remote mode, loading/unloading of every compressor is


based on the net air pressure signal 68-PT-1311.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 111 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

When the compressor is in local mode loading/unloading of every compressor is based


on the compressor O/L pressure signal transmitter 68-PT-1406.

If the air demand is low, i.e. when the pressure transmitter signal is above the load
set point then UCP unloads the compressor and if the air demand is high, i.e. when the
pressure transmitter signal is below the load set point then UCP loads the compressor.

The loading/unloading set pressure in barg is given below:

Compressor Control Loading Unloading Status


Compressor A lead XX XX running
Compressor B lag XX XX standby

Note: XX Loading and Unloading set points will be set at site while commissioning the
Air Compressor.
B. Lead/Lag Control in Remote Mode

Only in Remote-Auto mode the compressors shall follow the Lead, Lag logic. The
purpose of Lead/Lag control is to allow two compressors to operate at once, with one
operating as LEAD and maintaining system pressure, and the other operating as LAG
and loading only as necessary when system pressure drops.

When air demand is lower or equal to the air generation from one compressor, only
the Lead compressor gets loaded. When the air demand increases above the capacity
of one compressor, the lag Compressors gets loaded in sequence as per demand
requirements.

C. Compressor Auto changeover

Compressor auto change over occurs on the 2 following conditions:

1. If the stand-by compressor was selected in remote mode then after 24 hours of
duty compressor usage stand-by compressor will start automatically.
2. Duty compressor failure will start the standby compressor immediately.
If the failed compressor was loaded and the air demand is still required, the unit will
go in to loaded mode straight away after the starting delay (20 seconds).

D. Dry Air Purge

When the compressor is in standby mode, solenoid 68-XY-1407 is activated and this
opens the purge air line allowing a small flow of dry air protecting the compressor
during stand-by, also immediately when the status stand-by is changed to duty,
solenoid 68-XY-1407 is de-energised.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 112 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

E. Water Separators Level Control

Inter cooler and after cooler water Separators level is maintained by level indicators
(68-XI-1402 and 68-XI-1406) via opening or closing of valves 68-XY-1402 and 68-XY-1406
respectively.

F. Instrument Air Header Pressure Control

The pressure on the discharge line from the instrument air receiver is monitored by a
transmitter 68-PT-1310; pressure on the discharge line of the plant air header is
controlled by 68-PIC-1310.

Decrease in the instrument pressure signal will tends to close the control valve
68-PCV-1310 in the plant air line.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Inst air header
68-PIC-1310 bar(g) 6 5.5 NA
pressure control

Instrument Air pressure 68-PI-1312A/B/C/low low alarm set at 5 barg activates


ESD Level-2 shutdown.
Instrument air pressure control valve 68-PCV-1310 closes on instrument air failure.
4.6 EFFLUENT & WASTE WATER TREATMENT

4.6.1 Equipment Specification

Waste Water Degasser


Equipment Tag No. 6922-V-07
Process Medium Waste/Sour Water
Size (ID/T/T), mm 1500/4500
Design Temperature, C 165/0
Design Pressure, barg 3.5/FV
Operating Temperature, C 73
Operating Pressure, barg 1
Material of Construction CS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 113 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Waste Water Degasser Pumps


Equipment Tag No. 6922-P-08A/B
Pump Type Horizontal, Centrifugal
Process Medium Waste/Sour Water
3
Capacity, Normal/Rated, m /hr 8.62/9.48
Shut off Pressure, bar(g) 14.6
Suction Pressure, bar(a), Normal/Rated 0.99/4.66
Discharge Pressure, bar(a) 8.8
Design Temperature, C 95/0
Operating Temperature, C 73
Driver Type Motor
Rated Power, kW 15
Material of Construction, Casing/Internals Duplex SS/Duplex SS

Sour Water Filter


Equipment Tag No. 6922-S-06
Process Medium Sour Water
Size (ID/T/T), mm 1500/4500
Design Throughput, m3/hr 9.48
Design Temperature, C 95/0
Design Pressure, barg 14.6
Operating Temperature, C 73
Operating Pressure, barg 7
Material of Construction CS

Sour/Stripped Water Exchanger


Equipment Tag No. 6922-E-01
Process Medium Sour/Stripped Water
Design Pressure Shell Side (Stripped Water), barg 11.3
Design Pressure Tube Side (Sour Water), barg 14.6
Design Temperature Shell Side (Stripped Water), C 160/0
Design Temperature Tube Side (Sour Water), C 160/0
Operating Pressure Shell Side (Stripped Water), bar(a) 6.80
Operating Pressure Tube Side (Sour Water), bar(a) 7.4
Operating Temperature, Shell Side (Stripped Water),
126/104
(In/Out) C
Operating Temperature, Tube Side (Sour Water),
73/96
(In/Out) C
Design Duty, kW 276
Material of Construction, Shell/Tube CS/SS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 114 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sour Water Stripper


Equipment Tag No. 6922-C-01
Design Pressure, barg (Max./Min.) 3.5/FV
Design Temperature, C (Max./Min.) 165/0
Process Medium Sour Water
Max. Liquid Level, Top Section, mm 700
Max. Liquid Level, Bottom Section, mm 1200
Tray Nos. 38
Tower Diameter, mm 1000
Tower Height, mm 25000
Operating Pressure, bar(a) 1.20
Operating Temperature, C, Top/Bottom 82.2/126.1
Material of Construction, Top section CS+SS316L CLAD
Material of Construction, Bottom section CS
Material of Construction, Internals SS316L

Stripped Water Pumps


Equipment Tag No. 6922-P-10A/B
Pump Type Horizontal, Centrifugal
Process Medium Stripped Water
3
Capacity, Normal/Rated, m /hr 9.31/13.03
Shut off Pressure, bar(g) 11.2
Suction Pressure, bar(a), Rated/Design 2.81/5.11
Discharge Pressure, bar(a) 8.6
Design Temperature, C 160/0
Operating Temperature, C 126
Driver Type Motor
Rated Power, kW 11
Material of Construction, Casing/Internals Duplex SS/Duplex SS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 115 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Stripper Overhead Circulation Pumps


Equipment Tag No. 6922-P-11A/B
Pump Type Horizontal, Centrifugal
Process Medium Water
3
Capacity, Normal/Rated, m /hr 13.23/19.85
Suction Pressure, bar(a), Rated/Max. 3.9/7
Discharge Pressure, bar(a) 8.0
Design Temperature, C 150/0
Operating Temperature, C 121
Driver Type Motor
Rated Power, kW 7.5
Material of Construction, Casing/Internals Duplex SS/Duplex SS

Sour Water Stripper Reboiler


Equipment Tag No. 6922-E-04
Process Medium Sour Water
Design Pressure, Shell Side barg 7.0/FV
Design Pressure, Tube Side barg 7.0/FV
Design Temperature, Shell side C 165/0
Design Temperature, Tube side C 185/0
Operating Pressure, Shell, Side barg 1.40
Operating Pressure, Tube Side barg 3.5
Operating Temperature, Shell side C 126.1
Operating Temperature, Tube side C 147.7
Design Duty, kW 1803 kW
Material of Construction, Shell side CS
Material of Construction, Tube side SS316L

Re boiler Condensate Drum


Equipment Tag No. 6922-V-09
Process Medium Steam Condensate
Size (ID/T/T), mm 800/2400
3
Design Throughput, m /hr 9.48
Design Temperature, C 185/0
Design Pressure, barg 7/FV
Operating Temperature, C 155
Operating Pressure, barg 4.5
Material of Construction CS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 116 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Stripper Overhead Cooler


Equipment Tag No. 6922-E-03
Type Forced Draft
Process Medium Stripper Overhead Vapours
Design Pressure, barg 11.1
Design Temperature, C 150/0
Operating Pressure, barg 2.7
Operating Temperature, C 121/55
Design Duty, kW 998
Material of Construction CS
Number of Fans 2
Driver Type Motor
Rated Power, kW 15

Stripped Water Cooler


Equipment Tag No. 6922-E-02
Type Forced Draft
Process Medium Stripped Water
Design Pressure, barg 11.2
Design Temperature, C 130/0
Operating Pressure, bar(g) 5.7
Operating Temperature, C 104/52
Design Duty, kW 630
Material of Construction CS
Number of Fans 2
Driver Type Motor
Rated Power, kW 11

4.6.2 Effluent and Waste Water Treatment Process Description

Sour water from various sources is collected in the Waste Water Degasser 6922-V-07,
which provides over 20 minutes of hold-up for the waste water. The flow of waste
water from TGTU Cooling Water Circulation Pumps 9102-P-12A/B is continuous at a
rate of 8.7 m3/hr. The pressurised drain from Cooling Water Circulation Pumps 9102-P-
12A/B and the flow from Regenerator Reflux Drum Pumps 9103-P-11A/B are
intermittent. The sour water from the Waste Water Degasser 6922-V-07 is continuously
pumped under flow control by Waste Water Degasser Pumps (6922-P-08A/B) to the
Sour Water Stripper 6922-C-01 for treatment.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 117 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

In the event the Sour Water Treatment System is unavailable due to a process upset,
provision exists for manually routing the Waste Water Degasser liquids directly to the
Observation Sump (6922-X-04).

A balance line between Waste Water Degasser 6922-V-07 and Sour Water Stripper
6922-C-01 means that the pressure in the Waste Water Degasser 6922-V-07 floats on
the Sour Water Stripper 6922-C-01 operating pressure (i.e. 1.0 barg). A nitrogen supply
line is provided to maintain pressure in the Waste Water Degasser 6922-V-07 if it falls
below a certain minimum as liquids are pumped out.

The sour water from Waste Water Degasser 6922-V-07 is filtered in Sour Water Filter
(6922-S-06) to remove particle size of 10 micron e.g. sand, pipe scale and salts and
then preheated in Sour/Stripped Water Exchanger (6922-E-01) before feeding to Sour
Water Stripper. The Sour Water Stripper operates at 1.0 barg and has an upper section
and a lower tray section. The upper section is provided with temperature indication
locally as well as in DCS. A differential pressure transmitter is also provided across
trays 33 to 38 with indication in DCS. The middle section of the column is also
provided with a temperature indication locally as well as in DCS. A differential
pressure transmitter is also provided across trays 1 to 32 with indication in DCS. The
bottom section of the column is provided with temperature and level indications
locally as well as in DCS.

The sour water is stripped by the vapours generated from the Sour Water Stripper
Reboiler 6922-E-04. The Reboiler utilises LP steam to heat the sour water that comes
from the bottom of the Sour Water Stripper to 126C. The condensed steam from the
Reboiler is sent to the LP Condensate system through level control.

Reflux for the column is provided by a pump-around system. Water is taken from
below tray 33 pumped by Stripper Overheads Circulation Pumps (6922-P-11A/B) under
flow control, cooled in Stripper Overheads Cooler (6922-E-03) and then returned to the
top tray.

The stripper overhead acid gases are routed to the TGTU (upstream of
Desuperheater/Contact Condenser, 9102-C-11). In the event of high column pressure,
excess gases are diverted to LP Acid Gas Flare.

The stripped water from the stripper is pumped under level control cascaded to a flow
controller via Stripper Water Pump (6922-P-10A/B) to the Sour/Stripped Water
Exchanger (6922-E-01) to preheat the feed to the stripper. The water is then routed to
the Stripped Water Cooler (6922-E-02) where it is cooled to 55C before discharge to
the Observation Sump.

An analyser is provided in the line to the Observation Sump to monitor the sulphide
content of the stripped water stream.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 118 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.6.3 Effluent & Waste Water Treatment Control Description

4.6.3.1 Waste Water Degasser Pressure Control

Waste Water Degasser (6922-V-07) pressure is maintained by the pressure controller


69-PIC-1307 by monitoring the pressure through 69-PT-1307 located at the top of the
vessel. The pressure is maintained by regulating the pressure control valve 69-PV-1307
in the nitrogen line to the Waste Water Degasser.

69-PIC-1307 opens the nitrogen control valve 69-PV-1307 on falling pressure in the
Waste Water Degasser.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Waste Water Degasser top
69-PIC-1307 barg 1 0.8 1.2
pressure

High high pressure alarm (69-PAHH-1311) set at 1.3 barg in Waste Water Degasser
closes the nitrogen inlet valve 69-XV-1315
High high level alarm (69-LAHH-1311) set at 77% in Degasser closes the nitrogen
inlet valve 69-XV-1315
Waste Water Degasser 6922-V-07 nitrogen pressure control valve 69-PV-1307 closes
on instrument air failure.
4.6.3.2 Waste Water Degasser Level Control

Waste Water Degasser (6922-V-07) level is monitored by 69-LT-1301 and controlled by


69-LIC-1301. Level in the Degasser is controlled by controlling the sour water outlet
from Sour/Stripped Water Exchanger (6922-E-01). Master controller 69-LIC-1301 acts in
cascade and provides the set point to sour water flow Slave controller 69-FIC-1314
which regulates the control valve 69-FV-1314 in the outlet of Sour/Stripped Water
Exchanger 6922-E-01.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
69-LIC-1301 Waste Water Degasser level % 50 33 53
Sour water to Stripper
69-FIC-1314 m3/hr 8.2 7.4 9
column

High high level alarm (69-LAHH-1311) set at 77% in Degasser closes the nitrogen
inlet valve 69-XV-1315 and waste water valve 69-XV-1312 from the Cooling Water
Circulation Pumps 9102-P-12A/B
Low low level alarm (69-LALL-1311) set at 20% in Degasser 6922-V-07 trips the
Waste Water Degasser Pumps 6922-P-08A/B
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 119 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sour water to Stripper column control valve 69-FV-1314 closes on instrument air
failure.
4.6.3.3 Sour Water Stripper Pressure Control

A split range pressure controller 69-PIC-1315 is provided to maintain the top pressure
of Sour Water Stripper (6922-C-01) by throttling the sour gas to TGTU control valve
69-PV-1315A (0-50%) and sour gas to LP acid gas flare drum control valve 69-PV-1315B
(50-100%).

On rising pressure 69-PIC-1315 first opens the sour gas to TGTU control valve 69-PV-
1315A; further increase in pressure causes the pressure controller to open the vent
valve 69-PV-1315B to release gases to the LP Acid Gas Flare.

Fig. 22 69-PIC-1315 Controller Output

The above drawing shows the split range operation of 69-PV-1315A & 69-PV-1315B.

69-XV-1313 located at the downstream of sour water stripper top pressure control
valve 69-PV-1315A to TGTU closes on activation on ESD-0 and ESD-1 shutdown
Sour Water Stripper Column 6922-C-01 control valve 69-PV-1315A to TGTU closes
on instrument air failure
Sour Water Stripper Column 6922-C-01 control valve 69-PV-1315B to LP flare opens
on instrument air failure.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Sour Water Stripper top
69-PIC-1315 bar(g) 1 0.8 1.2
pressure
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 120 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.6.3.4 Sour Water Stripper Bottom Level Control

Stripped water from the bottom of the Sour Water Stripper 6922-C-01 is pumped via
Stripped Water Pumps (6922-P-10A/B) to the Sour/Stripped Water Exchanger (6922-E-
01). Outlet from the Sour/Stripped Water Exchanger 6922-E-01 enters in to the
Stripped Water Cooler (6922-E-02) and the cooled stripped water is sent to
Observation and Buffer Sump.

Sour Water Stripper (6922-C-01) bottom level is controlled by regulating the stripped
water cooler outlet to the Observation and Buffer Sump.

Sour Water Stripper MASTER level controller 69-LIC-1306 acts in cascade and provides
the set point to the Stripped Water Cooler outlet SLAVE flow controller 69-FIC-1317
which regulates the flow control valve 69-FV-1317.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Sour Water Stripper bottom
69-LIC-1306 % 50 21 73
level
Stripped Water Cooler
69-FIC-1317 m3/hr 8 6 10
outlet flow

Low low level alarm (69-LALL-1316) in Sour Water Stripper 6922-C-01 bottom trips
the Stripped Water Pumps 6922-P-10A/B and closes the stripper outlet valve
69-XV-1339.

High high level alarm (69-LAHH-1316) Sour Water Stripper 6922-C-01 bottom trips
the Waste Water Degasser Pumps 6922-P-08A/B and closes the Waste Water
Degasser 6922-V-07 outlet valve 69-XV-1316.
Stripped Water Cooler 6922-E-02 outlet valve 69-FV-1317 to buffer sump closes on
instrument air failure.
4.6.3.5 Sour Water Stripper 6922-C-01 Top Level Control

Water from the Stripper Overheads Cooler (6922-E-03) is circulated to the top of the
Stripper through the Stripper Overhead Circulation Pumps (6922-P-11A/B). Stripper top
level is maintained by controlling the start-up-water which is mixed with the
circulated water from the Sour Water Stripper column at the suction of the Stripper
Overheads Circulation Pumps (6922-P-11A/B).

Stripper top level is monitored and controlled by 69-LIC-1325 which directly controls
the control valve 6922-LV-1325 in the start-up-water line.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Sour Water Stripper top
69-LIC-1325 % 50 30 74
level
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 121 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Low low level alarm (69-LALL-1315) in Sour Water Stripper top trips the Stripper
Overhead Circulation Pump 6922-P-11A/B
Start-up water control valve 69-LV-1325 closes on instrument air failure.
4.6.3.6 Circulating Water Flow to Stripper Overhead Cooler Control

Circulated water from the Sour Water Stripper (6922-C-01) top is pumped by Striper
Overhead Circulation Pumps (6922-P-11A/B) to Stripper Overhead Cooler (6922-E-03).
Circulated water flow to stripper overheads is measured by 69-FT-1316 and controlled
by the flow controller 69-FIC-1316 which directly controls the flow control valve
69-FV-1316 located in the common discharge of 6922-P-11A/B.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
CW to Stripper Overhead
69-FIC-1316 m3/hr 13.6 12.2 15
Cooler

Circulating water flow control valve 69-FV-1316 to Stripper Overhead Condenser


opens on instrument air failure
4.6.3.7 Sour Water Stripper Reboiler Temperature Control

Temperature control is achieved by controlling the steam flow to the stripper reboiler.
LP steam flow to the Sour Water Stripper Reboiler 6922-E-04 is controlled by 69-FIC-
1315 which regulates the LP steam flow control valve 69-FV-1315.

Set point for the steam flow control is received from the calculation block 69-UY-1315,
where the sour water flow from 91-FIC-1314 is multiplied with manually set ratio (193)
between LP steam and sour water which is provided via 69-HIC-1315.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
LP steam flow to the
69-FIC-1315 kg/hr 2154 1725 3015
Stripper Reboiler

LP steam valve 69-XV-1314 located on the upstream of the control valve 69-FV-
1315 closes on activation of Waste Water Degasser pressure high high alarm set at
1.3 barg.
LP steam flow control valve 69-FV-1315 to reboiler closes on instrument air
failure.
4.6.3.8 Stripper Reboiler Steam Temperature Control

Temperature control of LP steam is achieved by passing the LP steam to


Desuperheater (6922-X-01), where the temperature is maintained by injecting Boiler
Feed Water.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 122 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

LP steam outlet temperature from the Desuperheater is monitored by 69-TT-1327 and


controlled by 69-TIC-1327.

Temperature Controller 69-TIC-1327 directly regulates the boiler feed water flow via
69-TV-1327 located at the inlet of De-super heater.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
LP steam temperature to
69-TIC-1327 C 148 NA 153
the Stripper Reboiler

BFW control valve 69-TV-1327 to LP steam closes on instrument air failure


4.6.3.9 Re-boiler Condensate Level Control

LP condensate from the Sour Water Stripper Reboiler 6922-E-04 is collected in Re-
boiler Condensate Drum (6922-V-09). Condensate level is monitored by 69-LT-1327 and
controlled by 69-LIC-1327. Condensate level is maintained by throttling the control
valve 69-LV-1327 which regulates the condensate flow to the LP condensate header.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Re-boiler Condensate Drum
69-LIC-1327 % 50 17 75
level

Re boiler condensate control valve 69-LV-1327 to LP condensate header closes on


instrument air failure
4.6.3.10 Stripper Overheads Cooler Temperature Control

Circulating water from the Stripper Overheads Circulation Pumps (6922-P-11A/B)


enters in to the Stripper Overheads Cooler (6922-E-03) where the water is cooled and
passes to the Sour Water Stripper.

Temperature of the circulating water to the Sour Water Stripper (6922-C-01) is


monitored at the outlet of the Stripper Overheads Cooler by 91-TT-1315 and controlled
by 69-TIC-1315.

Temperature controller 69-TIC-1315 output controls the speed of the stripper


overhead cooler fans VSDs at the same time.

The temperature controller, 69-TIC-1315 regulates the speed of the sour water
Stripper Overheads Cooler VSDs (6922-EM-03AA, 6922-EM-03AB) to maintain the
temperature of circulation water to Sour Water Stripper.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 123 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Stripper overheads cooler to
69-TIC-1315 C 55 50 60
sour water stripper

Details of control tags for VSDs are tabulated below:

S No. Motor-no Control Tag Remarks


1. 6922-EM-03AA 69-SY-1324 VSD
2. 6922-EM-03AB 69-SY-1329 VSD

High high vibration alarm of each fan trips the respective fan motors

4.7 LP FUEL GAS

4.7.1 Equipment Specification

LP Fuel Gas KO Drum


Tag No. 6236-V-05
Size, mm, (Dia x T/T) 1100 x 2400
Design Pressure, barg 9.0
Design Temperature, C 100/0
Operating Pressure, (Normal/Max), barg 6/7
Operating Temperature, C 25-50
Material of Construction CS

4.7.2 Fuel Gas System Process Description

4.7.2.1 Introduction

LP Fuel Gas is required for New Steam Generation Boiler Packages 6848-A-02A/B/C.

4.7.2.2 Process Description

The new Fuel Gas requirements under the SRU upgrade project will be secured from
two separate sources as follows.

Source 1 Supply

The main normal LP Fuel Gas supply for the new MP Steam Boiler Package (6848-A-
02A/B/C) is supplied from the first stage suction of the existing Booster Compressors
(6701-K-10/20/30) in NGL-3. In addition, two back up sources are provided; the first is
the fuel gas from 6103-K-01A/B with a second backup from existing 30 line (T-10).
The new fuel gas supply system will consist of a letdown station, Fuel Gas KO Drum
(6236-V-05) and a supply header to the steam boilers. The source pressure from the
take-off point will be let down to 7 barg through the pressure control valve 62-PV-
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 124 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

1301A before entering the LP Fuel Gas KO Drum. The source pressure of the fuel gas
from 6103-K-01 A/B is 20 barg whilst that of feed gas from the 30 line is 45 barg. The
former is let down to 7 barg through the pressure control valve 62-PV-1301B and the
latter via 62-PV-1302.

Source 2 Supply

LP fuel gas for SRU upgrade new users (Reducing Gas Generator 9102-F-11 and new
Incinerator, 9101-F-14) will be sourced from the existing LP fuel gas header at NGL-3
as there is sufficient spare capacity available for there.

4.7.2.3 Operating and Control System

The fuel gas for the LP fuel gas system is taken from the first stage suction of the Lean
Gas Booster Compressors (6701-K-10/20/30), through 62-PV-1301A via pressure
controller 62-PIC-1301 located in the top of the LP Fuel Gas KO Drum (6236-V-05).

In the event of loss of lean gas supply from the Booster Compressors, the pressure
controller 62-PIC-1301 signal is routed to 62-PV-1301B via soft valve selector 62-PY-
1301. In addition if there is an emergency shutdown of NGL Extraction unit (from
where fuel gas is ultimately supplied) valve selector 62-PY-1301 is overridden and the
signal from 62-PIC-1301 is automatically routed to 62-PV-1301B. This allows back up
fuel gas taken from 6103-K-01A/B.

The takeoff for the second back up supply is from 30" existing line (T-10) routed
through 62-PV-1302 via pressure controller 62-PIC-1302.

A fast acting pressure control valve 62-PV-1303 controlled by pressure controller


62-PC-1303 is provided on the overhead line from 6236-V-05 to route fuel gas to LP
flare in the event the pressure in the KO drum continues to increase beyond the
normal operating range.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
LP fuel gas from existing
62-PIC-1301 bar g 7 5.3 7.8
Booster compressors
62-PIC-1302 LP fuel gas to new SRU bar g 7 5.3 7.8
62-PIC-1303 Fuel gas to LP flare bar g 7 NA 7.8

High high pressure alarm (62-PAHH-1304) set at 8.2 barg in LP fuel gas trips the
boiler packages and closes the fuel gas inlet on/off valves 62-XV-1301, 62-XV-1302
and 62-XV-1303.
LP fuel gas inlet pressure control valves 62-PV-1301A, 62-PV-1301B and 62-PV-1302
close on instrument air failure.
Fuel Gas vent to LP flare pressure control valve 62-PV-1303 opens on instrument
air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 125 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.8 SEA COOLING WATER SYSTEM

4.8.1 Equipment Specification

Sea Cooling Water Pumps


Equipment Tag No. 6932-P-04A/B
Pump Type Vertical, Centrifugal
Process Medium Sea Water
Capacity, m3/hr 1600
Suction Pressure, barg, Normal/Max. 0.07/0.25
Discharge Pressure, barg 5.0
Design Pressure, bar(g) 8.0
Design Temperature, C 85/0
Operating Temperature, C 35
Driver Type Motor
Rated Power, kW 340
Material of Construction, Casing/Internals Duplex SS/Duplex SS

Sea Cooling Water Filters


Equipment Tag No. 6932-S-02A/B
Process Medium Sea Water
Size (ID/T/T), mm 610/1016
Design Throughput, m3/hr 1600
Design Temperature, C 85/0
Design Pressure, barg 8
Operating Temperature, C 15-40
Operating Pressure, barg 5
Material of Construction Duplex SS

Local Biocide Drain Pit


Equipment Tag No. 6932-T-06
Size (L/W/H), mm 1000/1000/1000
Design Temperature, C 85/0
Design Pressure, barg 0
Material of Construction Concrete

Local Chemical Drain Pit


Equipment Tag No. 6932-T-01
Size (L/W/H), mm 1000/1000/1000
Design Temperature, C 85/0
Design Pressure, barg 0
Material of Construction Concrete
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 126 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.8.2 Sea Cooling Water System Process Description

Sea Cooling Water system is required to supply cooling water for the coolers in the SRU
upgrade facilities. A part of sea cooling water is also supplied to existing sea water
supply system. The Sea Cooling Water system includes two Sea Cooling Water Pumps
(6932-P-04A/B, one operating and one standby), one Electro Chlorination Package
(6932-A-05), one Biocide Injection Package (6932-A-06) and one Scale Inhibitor
Injection Package (6932-A-07).

Two Sea cooling Water Pumps 6932-P-04A/B are installed on a new jetty and take
suction from the sea. The pumps are vertical-shaft, constant speed centrifugal pumps
and are electric motor driven. The sea water cooling pumps have a design capacity of
1600 m3/h (each) at a discharge pressure of 5.0 barg.

To meet the design flow requirements, one pump will be normally running, whilst the
other is on standby. Each pump is capable of supplying a normal flow of 1200 m3/h to
the users for SRU upgrade.

The water enters the pump body through a suction pipe (stilling tube) shaped to
reduce turbulence. A coarse mesh bar suction screen is installed at each pump to
prevent seaweed and other debris from entering the sea water system.

From the common discharge of seawater cooling pumps, seawater stream flows via a
new dedicated 24 main supply header to the new filtration package unit (6932-S-
02A/B). The self cleaning rotary type Sea Water Filters (one in operation and one on
standby) are capable of removing particle sizes greater than 1000 microns from
seawater and each unit is designed for a flow of 1600 m3/h. The filtered water from
filters is routed to the heat exchangers located in AGEU/TGTU another users.

A small portion of the main seawater (cooling water) flow is diverted downstream of
the filters to provide seawater supply for the Electro Chlorination Unit (6932-A-05).
The Electro Chlorination unit generates sodium hypochlorite solution. The sodium
hypochlorite solution is injected into Sea Cooling Water system. There is one
dedicated new Electro Chlorination Unit.

In addition, a dedicated Biocide Injection Unit (6932-A-06) for effective control of


growth of marine organisms and a dedicated Scale Inhibitor Injection Unit (6932-A-07)
to prevent formation of mineral scales in the Sea Cooling Water system are also
provided for existing as well as new sea cooling water systems.

The new cooling water system is a once through system and the sea water returned
from the SRU upgrade facilities is discharged into existing Seawater Observation Sump
(6932-X-01) which has a retention capacity of 60 m3. From the sump the seawater
overflows to the sea.

To prevent fouling the temperature of cooling water from each exchanger outlet
should not exceed the maximum allowable temperature limit of 45C.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 127 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

A tie in to the existing NGL-3/4 seawater supply system is also provided to supply
seawater from the new seawater pumps.

4.8.3 Sea Cooling Water Control

4.8.3.1 Sea Cooling Water Pumps (6932-P-04A/B)

The cooling water pumps can be started and stopped from the DCS by means of one of
the hand switches 69-HS-1311/1322. The running status indication of the pumps is
provided in the DCS. In addition, pump discharge low pressure alarms with indication
in the DCS (69-PIA-1301/1303), a pressure transmitter (69-PT-1301/1303), and a
sample connection (69-SC-013/014) are provided for each pump.

The chlorination, biocide and scale inhibitor lines to the pumps are provided with flow
indicators to monitor injection of these chemicals into the pump suction.

The cooling water flow through each heat exchanger may be manually regulated by
butterfly valves located upstream/downstream of the exchanger. The valves are
within view of the respective process side temperature indicator locations.

For operational flexibility a 18 crossover connection between sea cooling water pump
discharge line 24-6932-SW-259-A7A2 is provided to supply sea cooling water to NGL-
3/4. The crossover line contains two 18 butterfly valves which are normally closed.

4.8.3.2 Filtration System

The Sea Cooling Water Filtration system comprises of two self cleaning rotary type
Cooling Water Filters (6932-S-02A/B), one operating and one standby. Each filter is
designed for a flow of 1600 m3/hr and is capable of removing particle sizes greater
than 1000 microns. In addition each filter is equipped with an automatic back flushing
mechanism which operates on an intermittent basis when filter cleaning is required.

Across a cleaner seawater filter the normal pressure drop is 0.2 bar. During normal
operation the filter will become dirty over a period of time and the pressure drop
across it will increase. To ensure periodic cleaning of the online filter, a timer facility
within the filter control panel automatically initiates the cleaning cycle after a preset
interval and terminates it after a preset duration. The cleaning sequence involves the
start of the cleaning gear and opening of the drain ON/OFF valve 69-XV-1340/1341.
The former causes the debris trapped across the filter mesh to be loosened as the
mesh rotates against static scrapers whilst the latter allows the loosened debris to be
discharged back to the sea. The cleaning cycle lasts for approximately 90 seconds
after which the drain ON/OFF valve closes and the cleaning gear stops by
de-energising the contactor.

In addition to the timer, a differential pressure transmitter (PDT-1309/1310) can also


initiate the cleaning cycle when the filter pressure drop reaches a specified value
(0.5 barg). After the completion of the cleaning sequence the timer is also reset.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 128 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The cleaning sequence may be stopped via hand switch (69-HS-1309/1310).

In the event the cleaning gear is stuck, a common alarm 69-XA-1309/1310 is initiated.
In addition a high high pressure drop alarm (69-PDAH-1309/1310) is also provided to
alert the operator in the event of problems with the cleaning of the filter.

The downstream isolation valves of both (operating and standby) filters are kept open
at all the times during normal operation. The inlet isolation valve (MOV-1303/1304) of
the standby filter is kept in closed position during normal operation.

The selection of the operating filter must be made from the DCS via hand switches
(HS-1309/1310).

4.8.3.3 Sea Cooling Water Outlet Pressure Control

Sea Cooling Water Pumps (6932-P-04A/B) outlet is routed to Sea Cooling Water Filters
(6932-S-02A/B) and the outlet pressure is maintained by the pressure controller
69-PIC-1306 by monitoring the pressure through 69-PT-1306 located in the common
discharge of the Sea Cooling Water Pumps. The pressure is maintained by regulating
the pressure control valve 69-PV-1306 in the cooling water drain line connected to the
sea.

69-PIC-1306 opens the drain line control valve 69-PV-1306 on rising pressure in the
outlet of Sea Cooling Water Pumps common discharge.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Sea Cooling Water Pumps
69-PIC-1306 barg 6 NA 6.5
outlet pressure

Sea cooling water drain control valve 69-PV-1306 opens on instrument air failure
4.9 ELECTROCHLORINATION PACKAGE

4.9.1 Equipment Specification

Electro Chlorination Package


Equipment Tag No. 6932-A-05
Process Medium Sea Water
Design Throughput, kg/hr 10
Design Temperature, C 85/0
Design Pressure, barg 8
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 129 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Auto Backwash Filter


Equipment Tag No. 6932-S-03A/B
Process Medium Sea Water
Auto Self Cleaning, Backwash
Type
type
Design Throughput, m3/hr 14
Design Temperature, C 85/0
Design Pressure, barg 6
Filtration Rate, Microns 500
Pressure Drop, Clean, bar 0.1
Pressure Drop, Dry, bar 0.22
Material of Construction, Body/Internal GRP/Monel

Transformer Rectifier
Equipment Tag No. 6932-RC-101A/B
Rating, kVA 52.7
Power Supply 415 V, 3ph, 50 Hz
Output Voltage 44V DC
Output Current 922 Amps DC
Cooling Air Natural Air Forced
Design Temperature, C 85/0

Electrolyser
Equipment Tag No. 6932-G-01A/B
Type Panchlor (Bi Polar)
Capacity Per Cell, kg/hr 10
Design Pressure, barg 6.0
Design Temperature, C 85/0
Orientation Horizontal
Casing GRP with uPVC Lining
Titanium Coated with Coating
Anode
of Platinum group Mixed oxide
Cathode Titanium
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 130 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Degassing Tank
Equipment Tag No. 6932-T-02
Process Medium Sea Water
Capacity, m3/hr 5.0
Design Temperature, C 80/0
Atmospheric + Fully Filled
Design Pressure, barg
Liquid
Residence Time, mins. 15
Material of Construction Glass Reinforced Vinyl Ester

Hydrogen Dilution Blowers


Equipment Tag No. 6932-K-01A/B
Process Medium Air
3
Capacity, m /hr 362
Design Temperature, C 85/0
Design Pressure, mmWG 150
Motor Rating, kW 1.1
Material of Construction SS316L

Dosing Pumps
Equipment Tag No. 6932-P-05A/B
Type Centrifugal
3
Capacity, m /hr, Continuous/Shock Dosing 7.0/14.0
Design Temperature, C 85/0
Design Pressure, barg 7.5
Motor Rating, kW 5.5
Material of Construction Titanium

Acid Wash Tank


Equipment Tag No. 6932-T-03
Type Vertical
Process Medium HCl
3
Capacity, m 2.0
Design Temperature, C 80/0
Atmospheric + Fully Filled
Design Pressure, barg
Liquid
Working Pressure ATM.
Material of Construction Glass Reinforced Vinyl Ester
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 131 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Acid Wash Pump


Equipment Tag No. 6932-P-06
Type Magnetic Drive
Process Medium HCl
3
Capacity, m /hr, Continuous/Shock Dosing 5.0
Design Temperature, C 85/0
Design Pressure, barg 6.0
Motor Rating, kW 2.2
Material of Construction Poly Propylene

Acid Bund
Material of Construction GRP

4.9.2 Electro Chlorination System Description

During normal operation the Electro Chlorination Unit supplies Sodium Hypochlorite
that is injected into the suction lines of the Seawater Supply Pumps (6932-P-04A/B).

The hypochlorite controls the growth of marine organisms in sea cooling water system.

A small portion of the main sea cooling water flow to the new units of SRU is diverted
downstream of the filters 6932-S-02A/B and this provides the sea water supply for the
Electro Chlorination Unit 6932-A-05.

The required flow of sea water is fed to each electrolyser module designed to produce
10kg/h of active chlorine. Direct current is passed through the sea water producing a
sodium hypochlorite solution and hydrogen. The amount of active chlorine (sodium
hypochlorite) produced, is directly proportional to the current passed through the
cells. Hence, sea water is not normally varied. Any required reduction in active
chlorine demand can be achieved by manually adjusting electrical current to the
electrolysers at the local control panel.

4.9.2.1 Biocide and Scale Inhibitor Injection Packages

During normal operation, the biocide from the Biocide Injection Package is directly
injected into the hypochlorite injection line from Electro Chlorination Package just
before the injection point into the Sea Cooling Water Pump Suction of existing
(P-3001A/B/C & P-1618AR/BR/CR) and new 6932-P-04A/B sea cooling water systems.
The injection is to be carried out at a concentration of 6.6 ppm three times daily for a
15 minute period. The biocide filling into the Biocide Storage Tank inside the package
is a manual operation using flexible hose.

During normal operation the scale inhibitor from the Scale Inhibitor Injection Package
is injected into Sea Cooling Water Pump suction of existing (P-3001A/B/C &
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 132 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

P-1618AR/BR/CR) and new 6932-P-04A/B Sea Cooling Water Pumps. The injection is
carried out continuously at a concentration of 1.5 ppm. The scale inhibitor filling into
the storage tank inside the package is a manual operation using flexible hose.

4.9.3 Electro chlorination Package Control

4.9.3.1 Changeover of Auto Back Wash Filter

Sea water is supplied to the skid at a rate of 14 m3/hr. 69-PCV-1463 maintains the
system sea water pressure at 3.5 bar g from the inlet pressure of 5 bar (g).

Sea water is filtered to 500 microns to supply to the electrolyser. An auto back wash
filter (6932-S03A/6932-S-03B) is installed which operates on a duty/stand by basis,

During the initiation of changeover/backwash the actuated discharge valve (69-XV-


1453/69-XV-1456) of duty filter will close, the actuated backwash valve of duty filter
(69-XV-1452/69-XV-1455) will open and the actuated discharge valve (69-XV-1453/
69-XV-1456) of stand by filter will open which ensures the filter changeover was
happened.

Following are the causes for filter change over to occur:

Sl. # Tag No. Service Limit Unit Value


1. 69-PDI-1452 DP across 6932-S-03A High-high barg 0.2
2. 69-PDI-1453 DP across 6932-S-03B High-high barg 0.2
3. 69-PI-1455 Filter common discharge Low-low barg 2.75
3
4. 69-FI-1456 Electrolyser common I/L Low-low m /hr 8.0

4.9.3.2 Changeover of Electrolyser

Electrolyser stream (6932-G-01A/6932-G-01B) operates on duty/standby basis.

Following are the causes for electrolyser changeover to occur:

Sl. # Tag No. Service Limit Unit Value


3
I. 69-FI-1451 Inlet flow to 6932-G01A Low-low m /hr 10
3
II. 69-FI-1452 Inlet flow to 6932-G01B Low-low m /hr 10
III. 69-PI-1455 Filter common discharge High-high barg 4.5

Also if the temperature difference between electrolyser upstream temperature (69-


TT-1451) and downstream of the individual electrolyser temperature (69-TT-1452/69-
TT-1453) is 5C then controlled shutdown is initiated and the standby electrolyser unit
is started.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 133 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.9.3.3 Dosing Pumps Discharge Flow Control

Dosing pumps (6932-P-05A/B) discharge flow is controlled via flow controller 69-FIC-1453.

Dosing pump discharge flow rate is measured by magnetic flow transmitter 69-FT-1453
and controlled by 69-FIC-1453, set point is locally provided on the HMI.

Output of 69-FIC-1453 directly commands the control valve 69-FV-1453.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Dosing pumps discharge
68-FIC-1453 m3/hr 2 & 11 1.8 13.0
flow control

Note: The controller 68-FIC-1453 has 2 Set Points based on the Continuous Dosing and
Shock Dosing. When continuously dosed, set point is 2m3/hr whereas for Shock Dosing,
set point is 11m3/hr.

4.9.3.4 Acid Pumps Control

The acid wash system is a manual system.

To maintain the efficiency of the electrolyser streams, regular washing with dilute HCL
is required to remove the hydroxide deposits.

Following are the causes for tripping of Acid Wash Pump 6932-P-06:

Sl. # Tag No. Service Limit Unit Value


1. 69-LI-1454 Acid Wash Tank level Low-low mm 370
Conductivity of acid wash
2. 69-AI-1451 High-high S/cm 77000
solution

4.10 NGL-4 SEA WATER FILTERS

4.10.1 Equipment Specification

Sea Water Filters


Equipment Tag No. S-8840A/B
Process Medium Sea Water
Capacity, kg/hr, Min./Max. 138240/309760
Design Temperature, C 85/0
Design Pressure, barg 7.0
Operating Temperature 40/15
Operating Pressure, barg 4
Material of Construction, Casing/Elements SA240UNS S31803/Duplex SS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 134 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.10.2 NGL-4 Sea Water Filters S-8840A/B Description

Two Sea Water Filters S-8840A/B are installed in the existing sea water from cooling
water supply line 8-88-32-WR-0066-001W.

The filter consists of a pressure containment body with inlet, outlet, drain/backwash
outlet, PSV and vent connections. Filter Basket has been sized for the design flow
conditions. Access to the filter basket is via the bolted cover at the top of the
assembly. Sealing of the cover to the body is via a spiral wound gasket and stud bolts.
A simple devit arm is provided to allow removal and support of the cover during
maintenance operations.

Across a clean Seawater Filter S-8840A/B the normal pressure drop is 0.2 bar. During
normal operation the filter will become dirty over a period of time and the pressure
drop across it will increase. The differential pressure transmitter (88-PDT-801) raises
an alarm when the filter pressure drop reaches a specified value (0.4 bar). This means
the filter needs cleaning and the clean filter is brought on line.

4.11 DEMINERALISED WATER SYSTEM

4.11.1 Equipment specification

DM Water Package
Equipment Tag No. 6834-A-07
Process Medium DM Water
3
Capacity, m /hr 8.0
Design Temperature, C 85/0
Design Pressure, barg 12.3

Cationic Exchangers Bed


Equipment Tag No. 6834-S-21A/B
Process Medium Fresh Water
ID, mm 600
3
Capacity, m /hr 10.5
3
Flow Rate, m /hr 7.0
Design Temperature, C 85/0
Design Pressure, barg 12.3
Operating Temperature, C 49
Operating Pressure, bar 4.0
Material of Construction, Casing/Elements CS
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 135 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Anionic Exchangers Bed


Equipment Tag No. 6834-S-22A/B
Process Medium Fresh Water
ID, mm 950
3
Capacity, m /hr 10.5
3
Flow Rate, m /hr 7.0
Design Temperature, C 85/0
Design Pressure, barg 12.3
Operating Temperature, C 49
Operating Pressure, bar 4.5
Material of Construction, Casing/Elements CS

DM Water Recycle Pumps


Equipment Tag No. 6834-P-37A/B
Process Medium DM Water
3
Capacity, m /hr, Normal/Rated 10.5/10.5
3
Minimum flow, m /hr 1.11
Design Pressure, barg 12.3
Design Temperature, C 85/0
Suction Pressure, bara, Rated 2
Operating Temperature, C 43
Operating Pressure, bara 6
Driver Type Motor
Driver Power, kW 5.5
Material of Construction, Casing/Elements SS316L

Resin Trap
Equipment Tag No. 6834-SP-11A/B/C/D
Diameter, mm 60.3
Length, mm 300
Design Temperature, C 85/0
Design Pressure, barg 12.3
Material of Construction, Casing/Elements SS316L
Mesh Size, mm 0.202
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 136 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

DM Water Feed Pumps


Equipment Tag No. 6834-P-24A/B
Process Medium DM Water
3
Capacity, m /hr 12.0
Design Pressure, barg 5.1
Design Temperature, C 85/0
Suction Pressure, bara, Design/Rated 1.57/0.96
Operating Temperature, C 43
Operating Pressure, bara 4.7
Material of Construction, Casing/Elements A743CF3M/SS316L

DM Water Regeneration Pump


Equipment Tag No. 6834-P-36A/B
Process Medium DM Water
3
Capacity, m /hr 3.0
Suction Pressure, bara 1
Operating Temperature, C 30
Operating Pressure, bara 5
Drive Type Motor
Driver Power, kW 5.5
Material of Construction, Casing/Elements SS

DM Water Neutralization Pumps


Equipment Tag No. 6834-P-38A/B
Process Medium DM Water
3
Capacity, m /hr, Normal/Rated 10.0/10.0
3
Minimum flow, m /hr 1.0
Design Pressure, barg 2.2
Design Temperature, C 85/0
Suction Pressure, kg/cm2(a), Design/Rated 0.8/0.78
Operating Temperature, C 30
Operating Pressure, bara 2.6
Drive Type Motor
Drive Power, kW 4.0
Material of Construction, Casing/Impeller PP/PP
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 137 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

HCl Dosing Pumps


Equipment Tag No. 6834-P-35A/B
Process Medium HCl
Double Hydraulic Diaphragm
Type
Metering Pump
Capacity, Lit/hr 180
Design Pressure, barg 3.7
Design Temperature, C 85/0
Operating Temperature, C 30
Operating Pressure, bara 3.0
Driver Type Motor
Driver Power, kW 1.1
Material of Construction PP

HCl Storage Tank


Equipment Tag No. 6834-T-16
Process Medium HCl
ID/Height, mm 1400/2730
3
Capacity, m 4
Design Pressure, barg ATM
Design Temperature, C 85/0
Material of Construction GRP

HCl Unloading Pump


Equipment Tag No. 6834-P-38
Process Medium HCl
Capacity, L/hr 150
Design Pressure, barg 3.5
Design Temperature, C 85/0
Material of Construction PTFE/PVDF
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 138 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

NaOH Dosing Pumps


Equipment Tag No. 6834-P-34A/B/C
Process Medium NaOH
Double Hydraulic Diaphragm
Type
Metering Pump
Capacity, Lit/hr 301
Design Pressure, barg 3.7
Design Temperature, C 85/0
Suction Pressure, bara 1
Discharge Pressure, bara 3
Operating Temperature, C 30
Driver Type Motor
Driver Power, kW 2.2
Material of Construction SS316L/PTFE

NaOH Storage Tank


Equipment Tag No. 6834-T-15
Process Medium HCl
ID/Height, mm 1400/2730
3
Capacity, m 4
Design Pressure, barg ATM
Design Temperature, C 85/0
Material of Construction SS

NaOH Unloading Pump


Equipment Tag No. 6834-P-39
Process Medium NaOH
Capacity, L/hr 150
Design Pressure, barg 3.5
Design Temperature, C 85/0
Material of Construction PTFE/PVDF

4.11.2 Demineralised Water System Process Description

Demineralised Water Package Unit 6834-A-07 (one operating, one standby/


regenerating), is designed to produce flow of 7 m3/h of demineralised water. The
Demineralised water is supplied to the new heating system and connectivity to the
existing DMW header is also provided to allow operation flexibility.

Demineralised water unit will provide DMW to the following users:


Make up water to Steam Condensate Flash Drum (6834-V-05)
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 139 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Amine Surge Tank (9103-T-11)


Make up water to Cooling Water Circulation Pump (9102-P-12A/B)
Start-up water to Stripped Overhead Circulation Pump (9102-P-11A/B)
Make up water to Amine Regenerator Reflux Drum (9103-V-12)
Existing DMW network system (for operational flexibility, normally no flow)
4.11.2.1 Demineralised Water Package

The Demineralised Water Package is based on ion exchange technology (similar to the
existing DMW package) and consists of two identical trains.

The DMW package operates continuously and automatically and thus requires minimum
intervention. The package includes the necessary control and safety devices. The
Demineralised Water from the DMW package is routed to Demineralised Water Storage
Tank (6834-T-08). Capacity of Demineralised Water Storage Tank is 83 m3.

Fresh water is sent to the new users (DMW package & utility) continuously by means of
the Drinking Water Feed Pumps (6834-P-23A/B, one operating, one standby) each
having a design capacity of 10 m3/h. The duty/standby is selected via a selector switch
in the DCS. The pumps are manually started and stopped through hand switches 68-HS-
1305/1306 and operated continuously.

A minimum continuous flow recycle line with a restriction orifice (6834-RO-1303)


ensures that there is always a minimum flow through the pump.

Low low level alarms (68-LALL-006/007, via existing manual selector 68-HS-008) will
shutdown the operating pump in the event of low-low level in Drinking Water Storage
Tanks.

The control ensures a safe and continuous operation and is summarized below:

A. Flow Totaliser

A flow totaliser placed in the main fresh inlet line to each ion exchange train sums the
total water passing through the DMW unit. In normal operation, the end of a treatment
cycle is determined on a volumetric basis by the totaliser which generates the order to
switch from the online train to standby train. Following the switch over the
regeneration sequence is commenced for the offline train.

B. Conductivity Meter

If high conductivity is reached before the end of the volumetric cycle, then the
respective conductivity meter initiates the same automatic switch over order as
generated by the volumetric cycle. If, in spite of this order, the conductivity continues
to increase, then a separate high-high conductivity meter initiates a complete
shutdown.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 140 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

C. Differential Pressure

A differential pressure transmitter switch installed across the ion exchangers, also
initiates the same switchover as the above volumetric cycle.

D. Regeneration

Demineralised water is used as service water for regeneration. From the storage tank
(6834-T-08), regeneration DMW is delivered by means of the Regeneration Water
Pumps 6834-P-36A/B.

A solution of Caustic Soda is used to regenerate the anion resins. Concentrated Caustic
Soda is stored in a storage tank. Before injection into the exchanger bed, the caustic
soda is diluted by means of an in-line mixer.

A solution of Hydrochloric Acid is used for cation resin regeneration. It is stored in the
HCl storage Tank. The required dilution before injection into the exchanger bed is
made by means of an in-line mixer.

The regeneration effluents are collected in the concrete Neutralisation Pit where they
are neutralised before being pumped out for disposal to effluent treatment plant.

The pit is fitted with a pH-meter controller which controls acid dosing or caustic
dosing to achieve neutralisation. Neutralisation Pit Pump re-circulates the effluent
mixture for homogenisation. Plant air diffusion is also provided to enhance mixing.

E. DMW Storage Tank (6834-T-08)

The DMW package outlet line includes an automatic ON/OFF valve which is actuated
by means of a signal coming from low/high level signal (68-LT-1305) on the DMW
Storage Tank (6834-T-08).

De-mineralized water from the DMW storage tank is directed, at a pressure and
temperature of 3.7 barg and ambient temperature respectively by means of DMW Feed
Pumps (6834-P-24A/B) to condensate flash drum (6834-V-05).

The DMW storage tank is equipped with level alarms, High-High/Low-Low liquid level
(LAHH-1306/LALL-1307). The former generates a High-High liquid level alarm in the
control room, whilst the latter initiates Low low liquid level trip which shuts down the
Regeneration Pumps 6834-P-36A/B in the DMW Package and DMW Feed Pumps.

F. Demineralised Water Feed Pumps (6834-P-24A/B)

Centrifugal type, DMW feed pumps (one running, one standby) are used to supply
demineralised water at 3.7 barg pressure and ambient temperature, from DMW storage
tank.

Each pump is designed for a flow of 12 m3/hr based in heating system start-up (Filling
inventory vessels such as condensates flash drum, De-aerator and Boilers in one shift).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 141 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

A minimum flow recycle line with a restriction orifice (6834-RO-1301) ensures that
there is always a minimum flow through the pump.

These pumps can be stopped automatically, by the low low alarm (68-LALL-1307) or
manually, from the central control room using hand switch (68-HS-1307B/1308B) or
local panel (68-HS-1307A/1308A).

In the event of non ESD trip of operating pump, standby pumps will start
automatically.

4.11.3 Demineralised Water System Control description

4.11.3.1 Demineralised Water Flow Control 68-FIC1828

Demineralised water outlet to the DM water storage tank (6834-T-08) is controlled by


68-FIC-1828.

Fresh water flow to the Train-1 & 2 is measured by 68-FT-1825 and 68-FT-1827
respectively and final treated DM water to the DM water storage tank is measured by
68-FT-1828.

Flow controller 68-FIC-1828 takes any of the above transmitters value as per the train
selection, for calculating the output which directly commands the DM water storage
tank control valve 68-LCV-1827.

DM water storage tank MASTER level controller 68-LIC-1305 cascaded with SLAVE
68-FIC-1828 for allowing a maximum flow rate equal to the inlet flow rate available to
DM package in order to guarantee a minimum recirculation flow rate.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
DM Water Storage
68-LIC-1305 % XX XX XX
Tank level
DM Water package
68-FIC-1828 m3/hr XX XX XX
O/L flow

DM Water Package flow low low alarm 68-FALL-1830 set at XXXX trips the
Recirculation Pump 6834-P-37A/B
DM Water Storage Tank level control valve 68-LCV-1827 closes on instrument air
failure.
4.11.3.2 Recirculation Water Flow Control 68-FIC-1826/68-FIC1829

Recycling fresh water flow controller 68-FIC-1826 (Train-A), 68-FIC-1829 (Train-B)


determines the amount of recirculation flow passes through the control valve 68-FV-
1826 (Train-A), 68-FV-1829 (Train-B) to the cationic exchangers bed during phase no 1
(Service) and phase no 6 (Final rinse with recirculation).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 142 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Recycle water pumped from 6834-P-37A is measured by a vortex type flow meter
68-FT-1826 (Train-A) and 68-FT-1829 (Train-B).

Set points for the above controllers are provided locally.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Train-A recirculation
68-FIC-1826 m3/hr XX XX XX
flow control
Train-B recirculation
68-FIC-1829 m3/hr XX XX XX
flow control

Recirculation Pump 6834-P-37A discharge flow low low alarm 68-FALL-1837 trips
the Recirculation Pump 6834-P-37A in MCC.
Recirculation Pump 6834-P-37B discharge flow low low alarm 68-FALL-1838 trips
the Recirculation Pump 6834-P-37B in MCC.
Recirculation flow control valve 68-FV-1826 (Train-A) and 68-FV-1829 (Train-B)
closes on instrument air failure.
4.11.3.3 Regeneration Water Flow Control

Regeneration water from the DM Water Storage Tank (6834-T-08) to static mixers
6834-M-02A and 6834-M-02B is controlled by the flow controller 68-FIC-1835 and
68-FIC-1836 respectively.

Regeneration water to static mixer 6834-M-02A and 6834-M-02B is measured by 68-FT-


1835 and 68-FT-1836. Set points for both the controllers are provided locally.

Output of the controllers 68-FIC-1835 and 68-FIC-1836 directly commands the control
valve 68-FV-1835 and 68-FV-1836, respectively.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Regeneration Pump discharge
68-FIC-1835 m3/hr XX XX XX
to Static Mixer 6834-M-02A
Regenerated Pump discharge
68-FIC-1836 m3/hr XX XX XX
to Static Mixer 6834-M-02B

Regeneration Pump 6834-P-36A/B discharge flow low low alarm 68-FALL-1839 trips
the Regeneration Pump 6834-P-36A/B, HCl Dosing Pumps 6834-P-35A/B and
Caustic Dosing Pump 6834-P-34A/B.

Regeneration water flow control valves 68-FV-1835 and 68-FV-1836 closes on


instrument air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 143 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.11.3.4 Pump ON/OFF Controls

1. Acid Dosing Pumps

Tag/Alarm Description Pump Tag No. Action


Pump diaphragm Trips the pump and
68-PI-1825 6834-P-35A
failure start the stand by pump
Pump diaphragm Trips the pump and
68-PI-1826 6834-P-35B
failure start the stand by pump
Pump diaphragm Trips the pump and
68-PI-1827 6834-P-35C
failure start the stand by pump
HCL storage tank
68-LI-1825 6834-P-35A, B & C Trips the running pumps
level low
Regeneration Pump
Trips all the running
68-FI-1839 discharge flow low 6834-P-35A, B & C
pumps
low
DMW Storage Tank Trips all the running
68-LI-1307 6834-P-35A, B & C
level low pumps
Neutralisation Pump
68-AI-1831 6834-P-35A, B & C Starts the duty pump
discharge
Neutralisation Pit
68-LI-1830 6834-P-35 B & C Trips the pump
low level

2. Caustic Dosing Pumps

Tag/Alarm Description Pump Tag No. Action


pump diaphragm Trips the pump and
68-PI-1828 6834-P-34A
failure start the stand by pump
pump diaphragm Trips the pump and
68-PI-1829 6834-P-34B
failure start the stand by pump
pump diaphragm Trips the pump and
68-PI-1830 6834-P-34C
failure start the stand by pump
NaOH Storage Tank
68-LI-1827 6834-P-34A, B & C Trips the running pumps
level low low
Regeneration Pump Trips all the running
68-FI-1839 6834-P-34A, B & C
discharge pumps
DMW storage tank Trips all the running
68-LI-1307 6834-P-34A, B & C
level low pumps
Neutralisation Pump
68-AI-1831 6834-P-34A, B & C Starts the duty pump
discharge
Neutralisation Pit
68-LI-1830 6834-P-34 B & C Trips the pump
low level
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 144 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3. Regeneration Pumps

Tag/Alarm Description Pump Tag No. Action


DMW storage tank
68-LI-1307 6834-P-36A & B Trips both the pump
level low-low
Regeneration Pump
68-FI-1839 6834-P-36A & B Trips both the pump
flow low-low
Static Mixer 6834-M-
Starts the stand-by
68-FI-1835 02A inlet DM Water 6834-P-36A & B
pump
flow low
Static Mixer 6834-M-
Starts the stand-by
68-FI-1836 02B inlet DM Water 6834-P-36A & B
pump
flow low

4. Recirculation Pumps

Tag/Alarm Description Pump Tag No. Action


Recirculation pump
68-FI-1837 6834-P-37A Trips the pump
flow low low
Recirculation pump
68-FI-1838 6834-P-37B Trips the pump
flow low low

5. Neutralization Pumps

Tag/Alarm Description Pump Tag No. Action


Neutralisation tank
68-LI-1831 6834-P-38A/B Starts the duty pump
level high
Neutralisation tank
68-LI-1830 6834-P-38A/B Trips both the pump
level low

4.12 BOILER FEED WATER DEAERATOR SYSTEM

4.12.1 Equipment specification

Steam Condensate Flash Drum


Equipment Tag No. 6834-V-05
Size, (ID X T/T), mm 2600/7800
Design Pressure, barg 3.5/FV
Design Temperature, C, Min./Max. 0/150
Operating Pressure, barg 0.1
Operating Temperature, C, 102
Material of Construction CS + 1.5mm CA
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 145 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

De-aerator Feed Pumps


Equipment Tag No. 6834-P-20A/B
Type Horizontal Centrifugal
3
Design Capacity, m /hr 221
Design Pressure, barg 8.5
Design Temperature, C, Min./Max. 0/150
Suction Pressure, bara, Normal/Rated 1.82/5.54
Discharge Pressure, bara 4.51
Operating Temperature, C 102
Driver Type Motor
Driver Rating, kW 30
Material of Construction, Casing/Impeller CS/SS316

Steam Condensate Cooler


Equipment Tag No. 6834-E-02
Type Forced Draft
Design Duty, kW 5422
Design Pressure, barg 8.5
Design Temperature, C, Min./Max. 0/150
Inlet Pressure, barg 1.75
Operating Temperature, C, In/Out 102/59
No. of Fans 3
Fan Driver Type Motor
Driver Rating, kW 15
Material of Construction, Casing/Impeller CS

BFW De-aerator Package


Equipment Tag No. 6834-A-08
3
Design Capacity, m /hr 110
Design Pressure, barg 3.5/FV
Design Temperature, C, Min./Max. 0/185
Operating Pressure, barg 0.2
Operating Temperature, C 105
Material of Construction, Casing/Impeller CS + 3mm CA
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 146 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Boiler Feed Water Pumps


Equipment Tag No. 6834-P-22A/B/C
Type Centrifugal
3
Flow Rate, m /hr 55
Design Pressure, barg 31
Design Temperature, C, Min./Max. 0/185
Suction Pressure, barg, Max./Rated 5.55/1.92
Discharge Pressure, bara 21.8
Operating Temperature, C 105
Driver Type Motor
Driver Rating, kW 110
Material of Construction, Casing/Impeller CS/SS316

4.12.2 Boiler Feed Water De-aerator Description

4.12.2.1 Steam Condensate Flash Drum (6834-V-05)

The LP steam condensates mixtures are collected in the Steam Condensate Flash
Drum. The purpose of this vessel is to stabilise the steam condensate entering the
drum and to cool down the inventory to 102C to prevent cavitations in De-aerator
Feed Pumps.

The Flash Drum receives fluids from two phase steam condensates from condensate
distribution header and DMW from DMW Feed Pumps 6834-P-24A/B.

The operating pressure in the Flash Drum is 0.1 barg. During normal operation,
minimum or no flow across 68-RO-1302 is expected and which is sized for steam
condensate cooler failure case. Pressure relief valves (68-RV-1091A/B, one operating
and one spare) protect the drum against overpressure. The RVs relieve to the
atmosphere and are set at 3.5 barg.

4.12.2.2 Steam Condensate Cooler (6834-E-02)

The relatively cool (43C) DMW feed make-up entering the mixing compartment of the
Steam Condensate Flash Drum picks up heat from the incoming hot condensate
stream. To maintain its liquid state, the demineralised water/condensate mixture in
the drum is continuously circulated through the Seam Condensate Cooler by the
De-aerator Feed Pump 6834-P-20A/B. The temperature is controlled at 102C by using
temperature control valve (68-TV-1301) prior to forwarding the water to the Boiler
Feed Water De-aerator unit for further treatment.

4.12.2.3 De aerator Feed Pumps (6834-P-20A/B)

Centrifugal type, De-aerator Feed Pumps (6834-P-20A/B, one running, one standby)
has a dual purpose: first to recycle approximately 49.8 % of the total normal discharge
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 147 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

flow back to the flash drum via the Steam Condensate Cooler. The second is to feed
the balance of the pump discharge flow to the Boiler Feed De-aerator package
(6834-A-08) for further treatment.

These pumps will be stopped automatically, by the low-low alarm (68-LALL-1309) or


manually, from the central control room using hand switch (68-HS-1309/1310) or local
panel (68-HS-1309).

In the event of a non ESD trip of the operating pump, the standby pump will start
automatically.

4.12.2.4 Boiler Feed Water De-aerator Package (6834-A-08)

The boiler feed water stream enters the BFW De-aerator Package (6834-A-08) at the
top of the De-aerator column. It is contacted counter-currently with stripping steam,
which heats and scrubs the incoming feed, forcing the water to give up its CO2 and
most of its O2 content. Oxygen Scavenger is added to the water in the hold up section
of the De-aerator to further reduce the O2 content.

The De-aerator pressure is controlled at 0.2 barg by means of a pressure controller


(68-PIC-1304) which acts on pressure control valve (68-PV-1304) located in the LP
stripping steam line.

The De-aerator is protected from over pressure by a set of pressure relief valves
(68-PSV-1337A/B), set at 3.5 barg. The De-aerator package is designed for FV. The
liquid level in the De-aerator drum is maintained by 68-LIC-1302 through 68-LV-1302 in
the BFW feed inlet line.

The Boiler Feed Water pumps (6834-P-22 A/B/C) take suction from a common
manifold. The discharge pressure of Boiler Feed Water Pump is 20.8 barg. The
minimum flow is controlled by 68-FIC-1305 using 68-FV-1305 and discharged liquid
back to De-aerator drum.

4.12.2.5 Chemical Injection Package (6834-A-09)

The BFW Chemical injection Package is used to inject Boiler Feed water with O2
Scavenger and a Complex Product. The Complex Product is administrated to increase
pH value of the boiler feed water from 7 to between 9.0 and 10.5 to protect the
internal walls of the steam drums against corrosion and scaling. The amount of
complex product solution is proportional to the boiler feed water flow and is injected
at the discharge of Boiler Feed Water pumps.

The package includes for each chemical, a set of Chemical Storage Tank, Chemical
Injections Pumps and Chemical Unloading Pump.

Chemical Injection Pumps are of reciprocating, positive displacement, automatic


metering type i.e. the amount of chemical injected is proportional to the boiler feed
water flow as measured by the dedicated chemical pumps speed variation controllers.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 148 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

There are two sets of Chemical Injection Pumps (each comprising two electric motor
driven gear pumps) provided for each chemical as follows;

Two Oxygen Scavenger Injection Pumps 6834-P-39A/B for De-aerator (6834-A-


08) treatment
Two Complex Product Injection Pumps 6834-P-41A/B for Steam Boiler (6834-A-
02A/B/C) Feed Water treatment
4.12.2.6 Boiler Feed Water Pumps (6834-P-22A/B/C)

Centrifugal type Boiler Feed Water Pumps (two running, one standby) have dual
purpose; the first is to supply Boiler Feed Water at 18.5 barg and 105C to Steam
Generation Package and the second is to supply BFW to the TGTU. A small stream is
also connected to Sour Water Stripper Reboiler 6922-E-04 for desuperheating purpose.

The pumps are designed to supply a normal continuous flow of oxygen free and pH
controlled Boiler Feed Water to the Steam Boilers 6834-A-02 A/B/C and Reactor
Effluent Cooler (9102-E-11).

The minimum flow is controlled by flow controller 68-FIC-1305 by acting on flow


control valve 68-FV-1305 which returns part of the pump discharge flow back to the
Deaerator.

In the event of a non ESD trip of the operating pump, the standby pump will start
automatically.

4.12.3 Boiler Feed Water Deaerator Control Description

4.12.3.1 Steam Condensate Flash Drum Level Control

Level in the Steam Condensate Flash Drum 6834-V-05 is maintained by 68-LIC-1301 by


monitoring the level through the transmitter 68-LT-1301. Level is controlled by
regulating the makeup DMW through the control valve 68-LV-1301.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Steam Condensate Flash
68-LIC-1301 % 50 18 79
Drum level

High high level alarm 68-LAHH-1308 in Steam Condensate Flash Drum trips the DM
Water Feed Pumps 6834-P-24A/B.
Low low level alarm 68-LALL-1309 in Steam Condensate Flash Drum trips the
Deaerator Feed Pumps 6834-P-20A/B.
Steam Condensate Flash Drum level control valve 68-LV-1301 closes on instrument
air failure.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 149 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.12.3.2 Steam Condensate Flash Drum Outlet Temperature Control

Steam Condensate Flash Drum 6834-V-05 outlet temperature is monitored by 68-TT-


1301 and controlled by 68-TIC-1301 located in the suction of Deaerator Feed Pumps
6834/P-20A/B.

Temperature control is achieved by regulating the steam condensate from the cooler
6834-E-02 through the control valve 68-TV-1301 located in the Steam Condensate
Cooler outlet line entering in to the Steam Condensate Flash Drum.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Steam Condensate Flash
68-TIC-1301 C 102 97 107
Drum temperature

Steam Condensate Flash Drum temperature control valve 68-TV-1301 opens on


instrument air failure
4.12.3.3 Deaerator Feed Pumps Minimum Flow Control

Deaerator feed pumps 6834-P-20A/B discharge one stream is routed to BFW Deaerator
package and other stream is routed to Steam Condensate Cooler for maintaining
temperature in the flash drum.

Deaerator Feed Pumps 6834-P-20A/B minimum flow control is achieved by regulating


the control valve 68-FV-1301 (located in the bypass of 68-TV-1301) which allows the
minimum flow to pass even when the 68-TV-1301 is fully closed.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
Deaerator Feed Pumps
68-FIC-1301 m3/hr 83 66.6 NA
flow control

De-aerator feed pumps minimum flow control valve 68-FV-1301 opens on


instrument air failure
4.12.3.4 Deaerator Level Control

Level in the Deaerator is monitored by the level transmitter 68-LT-1302 and controlled
by the level controller 68-LIC-1302.

Level control is achieved by regulating the control valve 68-LV-1302 located in the
Deaerator Feed Pumps flow to the Deaerator.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
68-LIC-1302 Deaerator level control % 50 16 86
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 150 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

High high Level alarm 68-LAHH-1312 in Deaerator closes the Deaerator inlet
ON/OFF valve 68-XV-1301.

Low low level alarm 68-LALL-1310 in Deaerator executes the following actions:
Boiler 6848-A-02A fuel gas inlet ON/OFF valve 68-XV-1302 close

Boiler 6848-A-02B fuel gas inlet ON/OFF valve 68-XV-1303 close


Boiler 6848-A-02C fuel gas inlet ON/OFF valve 68-XV-1304 close
BFW Pumps 6834-P-22A/B/C trip
De-aerator Feed Pumps 6834-P-20A/B trip
Steam Condensate Cooler Fans 6834-EM-2A1/2A2/2B1/2B2/2C1/2C2 trip
Boilers 6848-A-02A/B/C shutdown
68-LV-1302 closes on instrument air failure.
4.12.3.5 Boiler Feed Water Pumps Minimum Flow Control

Boiler Feed Water Pumps 6834-P-22A/B/C discharge flow to the Steam Generation
units is measured by 68-FT-1305 and minimum recirculation flow to Deaerator is
controlled by 68-FIC-1305.

The controller 68-FIC-1305 throttles the fail open control valve 68-FV-1305.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
BFW Pumps minimum
68-FIC-1305 m3/hr 35 30 NA
flow

4.12.3.6 Deaerator Pressure Control

Deaerator 6834-A-08 pressure is monitored by 68-PT-1304 and controlled by the


pressure controller 68-PIC-1304. The pressure is maintained through the pressure
control valve 68-PV-1304 in the LP stripping steam inlet to the top of the Deaerator
tank.

68-PIC-1304 opens the steam control valve 68-PV-1304 on falling pressure in the
Deaerator.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
De-aerator top pressure
68-PIC-1304 barg 0.2 NA 0.3
control

Steam control valve 68-PV-1304 closes on instrument air failure.


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 151 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.13 STEAM GENERATION PACKAGE

4.13.1 Equipment Specifications

Equipment Tag No. 6848-A-02A/B/C


Water Tube Steam
Type
Generator
Capacity, T/hr (Each Boiler) 45
Design Pressure, barg 22
Design Temperature, C 220
Steam Outlet Temperature at LP Header, C 163
Feed Water Temperature, C, Min./Normal 43/105
Saturated Steam Outlet Pressure at LP Header, barg 5
Steam Pressure at Drum, barg 16.4
Feed Water Pressure, barg 18.5
Feed Water Flow, T/hr 45.409
Desuperheater Water Flow, kg/hr 541
Type of Fuel Natural Gas
3
Fuel Flow, Nm /hr 3296
Fuel Temperature, C, (Operating/Design) 25-50/100
Fuel Pressure, barg, (Operating/Design) 6-7/9
Excess Air, % 10
3
Air Flow, Nm /hr 33860
Air Temperature at Air Heater Inlet, C 25
Flue Gas Temperature at Furnace Outlet, C 1037
Flue Gas Temperature at Economizer Inlet, C 278
Flue Gas Temperature at Economizer Outlet, C 157
Flue Gas Temperature at Stack, C 157
Pressure Drop in Air Duct, mmWC 110
Air Pressure Drop in Burners, mmWC 160
Flue Gas Pressure Drop in Convection Coil, mmWC 67
Flue Gas Pressure Drop in Economizer, mmWC 42
Air Pressure at Fan Outlet, mmWC 364
Radiant Loss, %LHV 0.55
Unburned Loss, %LHV 0
Heat Loss in Flue Gas Stack, %LHV 4.72
Efficiency Calculated, (With Economizer), %LHV 93.49
Efficiency Calculated Without Drain, %LHV 93
Heat Introduced in Furnace, Kcal/h 27.2E6
2
Heat Density in Furnace, Kcal/h.m 269306
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 152 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Drums
Drum Upper Lower
Outside Diameter, mm 1326 908
Cylindrical Length, mm 9550 9550
Thickness, mm 28 22
Material SA 515 Gr 70 SA 515 Gr 70
Type of Head Elliptical Elliptical

Combustion Chamber
Size, L X W X H, m 8.787 X 2.727 X 3.778
Type of Screen Membrane Water Tube Type
Tubes Outer Diameter and Thickness, mm 76.1 x 4
Tube Fixation Type Expanded/Welded
Projected Surface, m2 98.74
Screen Header Numbers 4
Header Outer Diameter x Thickness, mm 219.1 x 12.7

Desuperheater
Type Multi Nozzle Spray
Steam Pressure Reducing and
Location
Desuperheating Station

Convection Coil
Surface, m2 729
Furnace Side/Parallel to
Location
Drums
Type Expanded Tubes
Tubes Outer Diameter x Length, mm 51 x 3400
Pitch Trans. x Length, mm 96 x 95
Material ASTM A 210 Gr A1

Economizer
Surface, m2 724
Location In the Flue Gas Duct
Type Finned Tube Type
Tubes Outer Diameter x Length, mm 48 x 2220
Pitch Trans. x Length, mm 114.3 x 90
Material SA210GrA1
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 153 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Casing
Boiler Material/Thickness, mm CS
Insulation Mineral Wool with Cladding
Type Expanded Tubes
Refractory, Combustion Chamber, Front Wall Refractory Cement Bricks
Refractory, Combustion Chamber, Other Walls Refractory Cement Bricks
Material ASTM A 210 Gr A1

Burners
Number 1
Type Low NOx
Location/Arrangement Front Wall
Pilots or Igniters 1
Flame Failure Detector 2

Fan
Number 1
Type Centrifugal
3
Air Flow Normal, Nm /hr 51000
Static Pressure, mmWC 500
Driver Electric Motor
Driver Power, kW 110
Speed, RPM 1550
Coupling Flexible Coupling
Air Regulating Inlet Damper
Material CS

Air Duct
Material CS
Thickness, mm 4

Flue Gas
Discharge Flow Rate, kg/hr 46112.4
Discharge Temperature, C 155
Molecular Weight 27.59
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 154 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Flue Gas Duct


CS (Rated for High
Material
Temperature Service)
Thickness, mm 6

Stack
Type Self Supporting
Height/Top Dia/Bottom Dia, m 30/1/2
CS (Rated for High Temp.
Material
Service)
Thickness, mm, (min.) 5

Boiler Blow Down Pit


Tag No. 6848-T-02
Dimension 2200 x 1800 x 1000
Design Pressure, barg 0
Design Temperature, C 220
Material of Construction Concrete

4.13.2 Steam Generation Package Process Description

Auxiliary Steam Boiler Package is essentially constituted by: Three water tube
Clajtub type saturated steam boilers.

4.13.2.1 Steam Generation Package 6848-A-02A

The main purpose of Steam Generation Package 6848-A-02A is to generate steam and
supply steam to the Customer steam network grid at the required pressure and
temperature.

4.13.2.1.1 Water/Steam Circuit

The Water/Steam circuit of the Steam Generator is realised in the following way:

Boiler Feed Water enters into the external Economiser (6848-E-01A), which is a
heat exchanger (water/flue gas) constituted by finned tubes. In this section, the
feed water temperature is increased by absorption of the flue gas thermal heat.
When Sour fuel gas is used, the Boiler Feed Water is first sent to a preheating
water circuit installed inside the water drum, before entering the Economiser
(6848-E-01A). This preheating circuit prevents acid condensation inside the flue
gas system (including the Economiser [6848-E-01A] outer surface) by keeping the
temperature of the flue gas above the dew point of the acid gas.
From the Economiser (6848-E-01A) outlet, the feed water enters into steam drum
6848-V-02A.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 155 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Boiler functions on the basis of steam/water natural circulation, with


evaporating rising circuits formed by the hottest tubes of boiler. Remaining tubes
act as down comers, which feed the rising circuits. All the evaporating tubes are
(except, where indicated in the boiler pressure parts drawings) expanded on both
steam drum and water drum.
In the boiler evaporating tubes, a mixture of saturated water & steam is
produced. Then the saturated steam is separated from the water droplets in the
Steam Drum 6848-V-02A Separators.
The saturated steam from the steam drum is then sent to a temperature and
pressure controlling section;
Pressure of the saturated steam is controlled by the Pressure Control Valve 68-PV-
1524 which gets the input from the Pressure Indicator Controller 68-PIC-1819. A
pressure transmitter 68-PT-1819 senses the pressure in the steam header and
provides the input to the 68-PIC-1819.
The temperature of the saturated steam is controlled by the Desuperheater (6848-
X-03A). Boiler Feed Water from the Boiler Feed Water Pumps 6834-P-22A/B/C
discharge is injected into the Desuperheater 6848-X-03A. The flow of the Boiler
Feed Water is controlled by a Temperature control valve 68-TV-1522. The
temperature control valve gets the temperature input from 68-TIC-1522 which in
turn gets the input from the Temperature Transmitter 68-TT-1522 which measures
the temperature of the saturated steam.
The steam from the Desuperheater 6848-X-03A is then routed to the Main LP
steam header.
4.13.2.1.2 Air/Flue Gas Circuit

The air/flue gas ducts of each of the three steam generator is arranged in the
following way:

Combustion air is taken from the atmosphere by means of a Forced Draft Fan
(6848-K02A), driven by an electric motor (6848-KM-02A). At the suction the
combustion air passes through a Grid Filter 6848-S-03A, Sand Filter (6848-S-02A)
and vertical air Silencer (6848-X-06A) and then a goose type vertical duct designed
to have multiple stage inertial filtration of the entering combustion air. The inlet
Sand Filter 6848-S-02A does not need any kind of maintenance or cleaning (self
discharging type), goose neck type duct is advisable to be inspected through its
lower manhole at least once in 6 months

Downstream of the Silencer 6848-X-06A, the air passes through the modulating
inlet control damper (68-FV-1626) (pneumatically actuated); downstream of the
Forced Draft Fan 6848-K-02A, the combustion air passes through a duct that
delivers air to the wind-box
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 156 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Combustion air measuring device 68-FE-1526 (AIR-FOIL type) is installed


downstream of the Forced Draft Fan 6848-K-02A

In the wind box the air is evenly distributed to the burner in order to optimise the
combustion
Once the combustion takes place in the burner, the high temperature flue gases
pass through the boiler furnace, enclosed by water cooled tubes. The water tubes
assure a perfect tightness for the flue gases. At the end of combustion chamber,
the flue gases turn to 180 entering through the evaporating convective section.
The convective section is located on the right side of the furnace. At boiler outlet,
the flue gases go through a connection duct and then pass through the external
Economiser 6848-E-01A, where the flue gas temperature decreases by means of a
heat transfer to Boiler Feed Water
Downstream of the Economiser 6848-E-01A, the flue gases pass through flue gas
duct that connects the Economiser 6848-E-01A to the stack

Then the flue gases are discharged through the stack into the atmosphere
Air/flue gas circuit is provided also with a recirculation flue gas duct, that re
circulates flue gas from Economiser outlet to AIR FOIL 68-FE-1526 and
subsequently to burner wind-box inlet. The flue gas recirculation fan (FGRF)
6848-K-03A is installed in the Flue Gas Recirculation duct
4.13.2.1.3 Steam Generator Design & Process Main Data

The Steam Generator data are summarised in the following table. These data are
applicable to the Maximum operating Continuous Rate (MCR):

Operating Data @ MCR


Sl. # Data Unit Value
Operating Data
1. Steam flow at boiler outlet t/h 44.96
Steam flow at battery limit (net to
2. t/h 45
Customer)
3. Steam temperature at battery limit C 163
4. Steam pressure at battery limit barg 5
5. Feed water temperature C 105
Design Data
1. Design pressure (boiler - economiser) barg 22
Hydraulic test pressure (boiler -
2. barg 33
economiser)
ASME I EDITION 2007
3. Design Code
ADDENDA 2009
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 157 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.13.2.1.4 Boiler Drums

The Water Drum 6848-V-03A and steam drum 6848-V-02A are symmetrically
located on right side of the boiler when viewed from the burner side
The drums are manufactured with high quality steel according to ASME Code with
submerged arc automatic welding
The drums are provided with manholes at both ends allowing a full inspection of
the boiler and accessibility to all tubes for easy maintenance

From the upper part of water drum all water tubes converge into the lower part of
the steam drum, ensuring the natural circulation
The Steam Drum 6848-V-02A is provided with internal Separators/Dryers, that
ensure a very high steam purity, flanged nozzles for continuous blow down (CBD)
outlet, Boiler Feed Water inlet, saturated steam outlet to common header, safety
valves, level indicators and transmitters, pressure gauges and pressure
transmitter, chemical injection inlet nozzle, nitrogen inlet and some spare
connections (provided with blind flanges)
The water drum is provided with two nozzles to drain the boiler (to be opened
only when the water inside the boiler is at ambient temperature)
4.13.2.1.5 Steam Drum

Sl. # Data Unit Value


Steam Drum
1. Internal diameter mm 1270
2. Shell thickness mm 28
3. Material SA516 Gr.70
Water Drum
1. Internal diameter mm 864
2. Shell thickness mm 28
3. Material SA516 Gr.70

Note: Before closing the steam drum manholes, Operator must verify that demisters
are correctly installed inside the steam drum as shown in the following figure. That is
with the perforated plate positioned above the wire mesh filters.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 158 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 23 - Steam Drum

4.13.2.1.6 Boiler Furnace

All the furnace walls are constituted by water-cooled membraned tubes. These
tubes are seamless type

The tubes constituting the D shape are directly connected to the drums by
mechanical expansion and seal welding. The front and rear wall tubes are welded
to dedicated lower and upper headers
The front tubes are bent to create the burners throats, while the rear tubes are
bent to allocate an inspection access door and two peep holes
The furnace dimensions are designed to assure an adequate cooling of the
combustion gases
All tubes of the furnace are equally shaped and its membranes are welded each
other to assure very high flue gas tightness and an equilibrated circulation of
boiling water
Lower and upper headers of front and rear wall tubes are connected to both drums
by external suppliers and risers tubes
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 159 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sl. # Data Unit Value


Furnace Tubes
1. Outer diameter mm 76.1
2. Thickness mm 4
3. Material ASTM A210 Gr.A1
Furnace Headers
1. Outer diameter mm 219.1
2. Thickness mm 12.7
3. Material ASTM A106 Gr.B

4.13.2.1.7 Evaporating Tube Bank

The evaporating tube bundle is located in the convective section, which is formed by
adequately spaced tubes, heated by the cross flow of flue gas.

The outer tubes, forming the external enveloping walls, are welded over the whole
length thus providing a continuous tight gas enclosure membraned wall.

A few tubes, in the enveloping external wall, have been bent in order to create the
free area to locate two inspection doors (one in SH bank and the other in the middle
of the convective section) for access and/or maintenance purposes.

Sl. # Data Unit Value


Convective Bank Tubes
1. Outer diameter mm 51
2. Thickness mm 3.2
3. Material ASTM A210 Gr.A1
Enclosure Tubes
1. Outer diameter mm 76.1
2. Thickness mm 4
3. Material ASTM A210 Gr.A1

4.13.2.1.8 Economiser

At the outlet of the flue gas from the steam generator, an external Economiser
6848-E-01A is located
This thermal heat exchanger consists of seamless tubes adequately finned and
spaced so as to increase heat transfer coefficient
The flue gas heats the economizer tubes in cross flow
All the tubes are welded to the inlet and outlet horizontal headers. In order to
separate the feed water circuitry, some baffles are installed inside the inlet and
outlet headers
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 160 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

A carbon steel casing, externally insulated, constitutes the enveloping economizer


enclosure

The Economiser 6848-E-01A is provided with adequate drain and vent valves. The
Economiser 6848-E-01A cannot be by-passed, so it is not necessary to provide a
dedicated pressure safety valve.

Sl. # Data Unit Value


Economiser Tubes
1. Outer diameter mm 48.3
2. Thickness mm 3.2
3. Material ASTM A210 Gr.A1
Economiser Fins
1. Height mm 19
2. Thickness mm 1.5
3. Number of fins per meter 200
4. Material Fe P04 UNI EN 10130
Economiser Headers
1. Outer diameter mm 114.3
2. Thickness mm 11.13
3. Material ASTM A106 Gr.B

4.13.2.1.9 Refractory

Refractory tiles are used to cover the furnace floor of the steam generator, both
to reduce the absorbed thermal heat (increasing the natural circulation) and to
allow future accessibility for any maintenance and/or inspection reasons
Refractory tiles are also used to protect the burner throats where combustion
takes place
These refractory tiles are manufactured with high Alumina content and are
suitable for high temperature operation.
4.13.2.1.10 External Insulation and Cladding

The steam generator is insulated with high-density mineral wool panels of suitable
thickness entirely applied to all external walls.

Sl. # Data Unit Value


Boiler Thermal Insulation
1. Material Mineral wool
140 (2 layers, 70 mm
2. Thickness mm
each)
3. Density kg/m3 120
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 161 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The external insulation panels are enclosed in a cladding, made of painted aluminium,
properly spaced and fixed through screws to allow an easy removal.

4.13.2.1.11 Air and Flue Gas Ducts

The steam generator is provided with combustion air ducts, located at the suction
and at the delivery of the Forced Draft Fan 6848-K-02A that convey the
combustion air from ambient to boiler wind-box
The steam generator is provided also with flue gas ducts that convey the flue gas
from boiler outlet to Economiser 6848-E-01A inlet and from Economiser 6848-E-
01A outlet to steel stack
The steam generator is provided also with recirculation flue gas ducts, located at
the suction and at the delivery of the Flue Gas Recirculation Fan 6848-6848-K-03A
that re-circulates the required flow rate of flue gas from Economiser 6848-E-01A
outlet to Boiler wind-box inlet through a dedicated entrance in Air-Foil 68-FE-1526
duct

Sl. # Data Unit Value


Combustion Air Ducts
1. Material S275 JR EN 10025
Thickness (all air ducts except intake
2. mm 4
air duct)
3. Thickness (intake air duct) mm 7
Flue Gas and Flue Gas Recirculation Ducts
1. Material S275 JR EN 10025
2. Thickness mm 5

Boiler Base Frame

The steam generator body is mounted on a steel base-frame, which supports it with a
uniform load distribution.

Ladders, Platforms and Stairways

The Boiler, the Deaerator, the Stack and the air intake duct are provided with stairs,
platforms and ladders in order to allow an easy access to the equipment and/or to the
instruments installed on the equipments.

Platforms area is completed with open grating, guards and handrails.

Burners
One burner 6848-X-05A is installed in the Steam Generator, designed to burn both
Sour type and Sweet type (FG2 and FG1) of fuel gas
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 162 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Burner is designed to have a turndown of 10:1


Burner is provided with a pilot (Class 3 type) that can be fed by FG2 and FG1
The pilot ignitor is of high energy type
During pilot operation, the combustion air to pilot is provided by the Forced Draft
Fan 6848-K-02A, providing the minimum combustion air flow rate
In order to meet the specified low emissions target, at high boiler load, the
burners can be operated in flue gas recirculation mode. The combustion air is
mixed with a proper flue gas flow rate (about 15% of nominal flow rate), upstream
of the boiler wind-box. The recirculation flue gas flow rate is provided by the Flue
Gas Recirculation Fan 6848-K-03A
The burner is mainly composed of the following equipment:

Air swirler adjustable manually by Operator from external burner front, by means
of proper handle. The air register deliver the combustion air at the desired
velocity and rotation into the burner throat
Burner front plate assembly complete with one viewing port and two openings for
flame detectors (complete with ball swivels)
FG distribution system, complete with multiple gas lances and relevant nozzles
Central gas gun, complete with diffuser
One pilot complete with high energy ignitor, relevant transformer (installed in a
dedicated junction box) and cable
Two flame detectors both to sense the burner main flame and the pilot flame
One observation peep hole
Burner refractory throat made of several pre formed bricks
Flexible hoses for FG both for pilot, distribution system to gas lances and central
gas gun
During boiler operation, in order to optimise the combustion, the FG flow rate is fed
both to distribution system to multiple gas lances and to central gas gun.

Forced Draft Air Fan (6848-K-02A)

The Steam Generator is provided with one Forced Draft Air Fan (6848-K-02A) and its
electric motor 6848-KM-02A.

The combustion air flow rate is controlled by means of a modulating inlet control
damper (pneumatically actuated) installed upstream of the Forced Draft Air Fan
(6848-K-02A) suction.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 163 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The unit basically includes:

Grid Filter 6848-S-03A at inlet duct (installed at inlet section of the air intake
duct)
Sand Filter 6848-S-02A at inlet duct (installed at inlet section of the air intake
duct)

Combustion air Silencer 6848-X-06A (installed after Sand Filter 6848-S-02A)


Split housing (for rotor removal) provided with one inspection door and one
plugged drain
Impeller (wheel and hub) statically and dynamically balanced in the manufacturer
workshop to reduce vibration and noise
Shaft and relevant guard

Shaft seal
Flexible coupling and relevant guard
Anti-friction bearings
Electric motor 6848-KM-02A
Inlet vane control damper 6848-FV-1626 complete with pneumatic actuator
Thermal insulation on fan casing
flexible connections at suction and discharge sections
basement common for fan and electric motor
Flue Gas Recirculation Fan

The Steam Generator is provided with one Flue Gas Recirculation Fan (FGRF) 6848-K-
03A, coupled with its electric motor 6848-KM-03A.

The flue gas recirculation flow rate is controlled by means of a modulating inlet
control damper 6848-FV-1524 (pneumatically actuated), installed upstream of the Flue
Gas Recirculation Fan 6848-K-03A suction connection.

The unit basically includes:

Housing, provided with one inspection door and one drain


Impeller (wheel and hub), statically and dynamically balanced in the manufacturer
workshop to reduce vibration and noise
Shaft and relevant guard
Shaft seal
Transmission belts and pulley and relevant guard
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 164 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Anti-friction bearings
Electric motor 6848-KM-03A
Inlet vane control damper 6848-FV-1524, complete with pneumatic actuator
Outlet non return damper
Flexible connections, at suction and discharge sections
Thermal insulation on fan casing

Basement, common for fan and electric motor


Chemical Dosing Units

Each Steam Generator is provided with one Phosphate chemical dosing unit, whose
purpose is to inject Phosphate into boiler Steam Drum 6848-V-02A.

Each unit basically includes:

One Phosphate Storage Tank 6848-T-03A

Two Phosphate Dosing Pumps 6848-P-01A/02A, one working and the other stand-by
and respective electric motors 6848-PM-01A/02A, piping, valves and instruments
One tank mixer 6848-M-01A and its electric motor 6848-MM-01A
One steel catch basin
Sampling System

Each Steam Generator is provided with one sampling system for two samples: one
for boiler feed water at Economiser 6848-E-01A inlet, one for saturated steam
The sampling system consists of sample conditioning bench, relevant piping,
measurement and safety instruments, all mounted on a common panel

All samplings are manual type sample


All the samples of the sampling system are cooled by Demineralised Water. The
required cooling water flow rate is taken from raw water line supply.
Stack

Each Steam Generator is provided with a double dedicated steel stack 6848-X-01A,
that discharges the flue gas from boiler to the atmosphere
The stack is cylindrical self-supporting type, manufactured into three sections for
shipping reasons
Each section is connected to the other by means of coupling flanges
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 165 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The stack has the following characteristics:

Sl. # Data Unit Value


Steel Stack 6848-X-01A
1. Material S275 JR
2. Internal Diameter Mm 1240
1700 till 11.45m
3. Outer Diameter Mm
1500 up to top
4. Thickness (Inner Duct) Mm 8
5. Thickness (Outer Duct) Mm 8
6. Total Height M 30

The Stack 6848-X-01A is provided with proper insulation between the two jackets
Platform is provided at 6 m and 12 m elevation and ladders are provided for
approaching the platforms
A manhole is provided at the bottom of the Stack for internal inspection

The Stack 6848-X-01A is also provided with nozzles necessary for instruments
installation including CEMS installation
A drain is provided at the bottom of the Stack
An internal plate conveys the possible condensate (from flue gas condensation or
external atmospheric events) to the drain system
This drain must be periodically opened to empty the stack of any condensate
accumulation
Steam Silencer

Each Steam Generator is provided with one Steam Silencer 6848-X-02A for start-up
vent in order to respect the required noise limit.

4.13.3 Control Description

The Steam Generator is provided with a Boiler Control Panel containing the Burner
Management System (BMS) and the Boiler Control System (BCS).

The Steam Generator is provided with its own Local Panel (LP) connected to the Boiler
Control Panel.

Boiler control system (BCS) is responsible for the continuous control of the boilers and
all the below mentioned controls are implemented in BCS (PLC).

4.13.3.1 Boiler Level Control

The boiler level control is performed with single or three elements philosophy.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 166 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

If the steam flow (68-FT-1524) is greater than the settable threshold then the boiler
level control is allowed to work in three element controls.

If the steam flow (68-FT-1524) is less than the settable threshold then the boiler level
control is allowed to work in single element behaviour.

But there is also a provision to select three element controls at any time.

Single Element Control

When the single element philosophy is active the Inverse acting level controller 68-LIC-
1522 regulates the feed water flow control valve 68-LV-1522 to maintain the boiler
level.

The boiler drum level is measured by 68-LIT-1522 and controlled by 68-LIC-1522; set
point is set locally and 0-100% output of 68-LIC-1522 directly controls the level control
valve 68-LV-1522.

Three Element Control

Three elements used in this controls are Feed water flow (68-FT-1522), boiler level
(68-LT-1522) and steam flow (68-FT-1524).

When the three element philosophy is active the Inverse acting feed water flow
controller 68-FIC-1522 regulates the feed water flow control valve 68-LV-1522 to
maintain the boiler drum level.

The main compensated steam flow 68-FT-1524 is applied to the output of the level
controller 68-LIC-1522 to adjust the set point to the feed water control 68-FIC-1522
proportional to varying steam demands.

0-100% output of 68-FIC-1522 directly commands the level control valve 68-LV-1522.

Operating Alarm
Controller Control Loop Unit
Set point Low High
68-LIC-1522 Boiler drum level % 50 34 62
3
68-FIC-1522 Boiler Feed Water flow m /hr XX NA NA

High high level alarm (68-LAHH-1523A/B/C) set at 72% and low low level alarm
(68-LALL-1523A/B/C) set at 23% in boiler drum.

1. Closes the following valves:


Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529
Pilot gas shut off valves 68-XV-1531 & 68-XV-1532
2. Opens the following valves:

Main fuel gas vent valve 68-XV-1530


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 167 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Pilot gas venting valve 68-XV-1533


3. Trips the following:
FD fan 6848-K-01A
Re-circulation Glue Gas Fan 6848-K-02A
Boiler feed water level control valve 68-LV-1522 closes on instrument air
failure.
Schematic diagram of level control is shown below.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 168 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 24 Schematic of Boiler 1 Element/3 Element Drum Level


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 169 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.13.3.2 SH Steam Temperature Control

Super heated steam temperature control is achieved by direct acting temperature


controller 68-TIC-1552 which regulates the water flow to the Desuperheater.

SH steam temperature is controlled by 68-TIC-1522. Set point of 68-TIC-1522 set by


operator on the HMI and is corrected by output of LP steam header direct acting
temperature controller 68-TIC-1820 and commands the Desuperheater control valve
68-TV-1522.

Controller Operating Alarm


Control Loop Unit
Tag. Set Point Low High
68-TIC-1522 SH steam temperature C 163 158 168
68-TIC-1820 Steam header C XX 158 168

Desuperheater control valve 68-TV-1522 closes on instrument air failure


4.13.3.3 Boiler Steam Pressure Control

The Steam Drum 6848-V-02A pressure is maintained by inverse acting pressure


controller 68-PIC-1523A which determines the burner load to maintain the drum
pressure.

Boiler drum steam pressure is measured by 68-PT-1523 which is fed as a Process


variable to 68-PIC-1523A and the set point is set by operator on the HMI. 0-100% CV of
the controller 68-PIC-1523A is the power that burner should produce to maintain the
steam pressure to the set point value. The required power is expressed as

MWreq=CV*Pmax [MW]

Where

Pmaxmaximum power that can be produced with the burner lighted at the maximum
load (set by the supplier).

Operating Alarm
Controller Control Loop Unit
Set Point Low High
68-PIC-1523A Boiler drum pressure bar 16.4 19 20

High high steam pressure alarm (68-PAHH-1522A/B/C) in Boiler Drum


1. Closes the following valves:
Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529
Pilot gas shut off valves 68-XV-1531 & 68-XV-1532
2. Opens the following valves:

Main fuel gas vent valve 68-XV-1530


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 170 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Pilot gas venting valve 68-XV-1533


3. Trips the following:
FD Fan 6848-K-01A
Re-circulation Flue Gas Fan 6848-K-02A
4.13.3.4 Fuel Gas Flow Control

Fuel gas flow to produce the required power MWreq is determined by the Inverse
acting flow controller 68-FIC-1525.

Fuel gas flow is measured by the transmitter 68-FT-1525A and controlled by 68-FIC-
1525.

Set point is the required FG flow, which is calculated from the formula

QNG REQ =min {3.6 *106 * MWREQ/HVFG, QFG STOICH} [kg/h],

Where

HVFG [kJ/kg] - Fuel gas heat value

QFG STOICH - stoichiometric fuel gas flow required for actual combustion air flow.

MWREQ- Required power for the burner is calculated from steam pressure controller
68-PIC-1523A.

Output (0-100%) of 68-FIC-1525 directly commands the fuel gas control valve
68-FV-1525.

68-FIC-1525 is turned on to manual mode after 5 seconds the 68-FIC-1526 (combustion


air flow controller) has been turned on manual mode.

Operating Alarm
Controller Control Loop Unit
Set Point High 1 High 2
68-FIC-1525 Fuel gas flow to boiler kg/hr XX 2800 2900

High high-1 flow alarm (68-FAHH-1525B/C/D) set at 2900 Kg/hr and high high-2 flow
alarm (68-FAHH-1525 B/C/D) set at 3020 Kg/hr in boiler

1. Closes the following valves:


Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529.

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532.


2. Opens the following valves:
Main fuel gas vent valve 68-XV-1530.

Pilot gas venting valve 68-XV-1533.


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 171 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3. Trips the following:


FD fan 6848-K-01A.
Re-circulation Flue Gas Fan 6848-K-02A
Fuel gas flow control valve 68-FV-1525 to boiler closes on instrument air failure.

4.13.3.5 Combustion Air Flow Control

Combustion air flow required to burn the amount of fuel gas is determined by the
Inverse acting air flow controller 68-FIC-1526.

Combustion air flow is measured from the transmitter 68-FT-1526A and controlled by
68-FIC-1526; the set point is determined by the formula

QAIR REQ = (QFG * STOICH) [kg/h],

Where

QFG =max {QFG req, QFG meas} [kg/h],

STOICH [KG/KG]-Air/FG stoichiometric ratio.

QFG req is calculated from the fuel gas controller set point 68-FIC-1525 and QFG mean
value is taken from the fuel gas flow transmitter 68-FIT-1525.

O2 correction calculated from 68-AIC-1522 is also applied for adjusting airflow set
point.

Output (0-100%) of 68-FIC-1526B directly commands the air control damper


68-FV-1526.

68-FIC-1526 is turned on to manual mode after 5 seconds the 68-FIC-1525A (fuel gas
flow controller) has been turned on manual mode.

Operating Alarm
Controller Control Loop Unit
Set Point Low High
Combustion air flow to
68-FIC-1526 kg/hr XX NA NA
boiler

Low low combustion air flow alarm (68-FALL-1525 B/C/D) set at 38,500 Kg/hr in
boiler
1. Closes the following valves:
Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529.

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532.


2. Opens the following valves:
Main fuel gas vent valve 68-XV-1530.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 172 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Pilot gas venting valve 68-XV-1533.


3. Trips the following:
FD Fan 6848-K-01A
Re-circulation Flue Gas Fan 6848-K-02A
combustion air flow control valve 68-FV-1525 to boiler locks at the position on
instrument air failure
4.13.3.6 Oxygen Control

Oxygen concentration in the stack flue gas is maintained by the Inverse acting oxygen
controller 68-AIC-1522 which determines the increase/decrease factor of the excess
air which is used in the set point determination of 68- FIC-1526B (combustion air flow).

Set point is determined by the expected oxygen for the required load MW REQ and is
obtained by linear interpolation on the oxygen curve (provided by BONO).

Output (0-100%) of 68-AIC-1522 is scaled to the range 1.3 0.7 which is the correction
factor applied to the air excess in the calculation of the combustion air flow set point
(68-FIC-1526B).

Above control can be disabled/enabled from the HMI as required.

Operating Alarm
Controller Control Loop Unit
Set Point Low High
68-AIC-1522 Oxygen analyzer controller % XX 2.2 6.7

4.13.3.7 Flue Gas Recirculation Control

The position of the flue gas recirculation damper 68-FV-1524 is measured by 68-FZT-
1524 and controlled by controller 68-ZIC-1524.

Set point is the desired position of the flue gas damper for the required load and is
obtained by linear interpolation on the flue gas recirculation curve (provided by
BONO).

Output (0-100%) of 68-ZIC-1524 directly commands the flue gas recirculation damper
68-FV-1524.

Flue gas control can be enabled/disabled by operator by means of software selector on


local HMI and on remote DCS.

Operating Alarm
Controller Control Loop Unit
Set Point Low High
Flue gas damper position
68-ZIC-1524 % XX NA NA
controller
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 173 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Flue gas flow control valve 68-FV-1524 to boiler locks at the position on instrument air
failure.

4.13.3.8 Boiler Steam Pressure (VENT) Control

Saturated steam flow through the vent valve to maintain the boiler steam pressure is
controlled by a direct acting pressure controller 68-PIC-1523B.

Steam drum pressure transmitter 68-PIT-1523; Set point is provided by the operator on
the HMI and output (0-100%) directly commands the vent control valve 68-PV-1523.

If the boiler steam pressure increases then the controller 68-PIC-1523B increases the
output to open the vent control valve 68-PV-1523, which maintains the steam pressure
nearer to the set value.

Operating Alarm
Controller Control Loop Unit
Set Point Low High
68-PIC-1523B Steam pressure vent bar 17.4 NA NA

High high steam pressure alarm (68-PAHH-1522A/B/C) set at 20barg in boiler drum
1. Closes the following valves:
Main fuel gas shutoff valves 68-XV-1528 & 68-XV-1529.

Pilot gas shut off valves 68-XV-1531 & 68-XV-1532.


2. Opens the following valves:
Main fuel gas vent valve 68-XV-1530.
Pilot gas venting valve 68-XV-1533.
3. Trips the following:

FD Fan 6848-K-01A
Re-circulation Flue Gases Fan 6848-K-02A

Steam pressure vent control valve 68-PV-1523 closes on instrument air failure.
4.13.3.9 Header Steam Pressure Control

The three boilers supplied by BONO are connected via an Ethernet link and exchange
the data themselves to co-operate on MASTER/SLAVE logic to maintain the desired
pressure in the steam header. As per design only two boilers can feed the steam to the
header continuously.

Each boiler generates a signal named consent to modulation for header PIC and this
signal is set when the following conditions are verified:

Burner is lighted
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 174 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

68-MOV-1522 located in super heated steam to LP steam header is not closed


The boiler pressure has reached the opening threshold for the 68-MOV-1522
At least one of the other two boiler control systems has not set the signal
consent to modulation for header PIC.
Header steam pressure direct acting controller 68-PIC-1819 purpose is to maintain the
steam header pressure and management is performed by the control system of the
MASTER boiler (first boiler which starts to feed the header through its 68-MOV-1522).

Steam header pressure is measured by 68-PIT-1819 and controlled by 68-PIC-1819, set


point is provided by the operator on the HMI of the MASTER boiler.

Output of the controller (0-100%) pass through the split range function 68-PY-1819,
where the two outputs of the split range function commands directly the header
pressure control valve 68-PV-1524 of the MASTER, SLAVE boilers (second boiler
which starts to feed the header through its 68-MOV-1522 is known as slave boiler) and
the commands of 68-PV-1523 to the third boiler is forced to 0%.

4.13.3.10 Fan Controls

Forced Draft Fan (6848-K-02A)

The FD Fan motor can be started only if all the following conditions are verified:
Presence of motor available signal (68-ZL-1548)
Absence of motor fault signal (68-ZA-1548)
Presence of close limit switch of combustion air damper 68-FV-1526 (68-ZSC-1526)
Fan motor can be started and stopped manually from the HMI.

Flue Gas Recirculation Fan (6848-K-03A)

The flue gas recirculation fan motor can be started only if all the following conditions
are verified:
Presence of motor available signal (68-ZL-1549)
Absence of motor fault signal (68-ZA-1549)
Presence of close limit switch of the flue air damper 68-FV-1524 (68-ZSC-1524)
Fan motor can be started and stopped manually from the HMI.

Start/stop tag details for Forced draft and recirculation fans are as follows:
Sl. # Tag No. Description
1. 68-HSOA-1548 Forced draft fan start
2. 68-HSCA-1548 Forced draft fan stop
3. 68-HSOA-1549 Recirculation air fan start
4. 68-HSCA-1549 Recirculation air fan stop
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 175 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.13.3.11 Valve Management

ON/OFF MOV1522

Each boiler contains a MOV which feeds the steam to the header

Valve can be operated in Local/Remote by changing the selecting switch (68-HSR-


1522C) located in the local panel.

If the valve fault status signal (68-XA-1522) is active then the valve cannot be
controlled from BCS.

Automatic Mode

Automatic mode of the MOV can be selected from the HMI and if the valve is not in
fault mode then the valve will open automatically on the following conditions:

Burner is ON
Steam Drum pressure 68-PT-1523 is higher than threshold (68-PSH-1523C)

other two boilers have not yet set the consent to modulation for header PIC signal
If any of the above condition is not satisfied then the valve will close automatically.

Manual Mode

When the manual mode of MOV is selected from HMI then the valve can only be
operated from the HMI open/close commands (68-HSO-1522A/68-HSC-1522B).

On/Off Valve Controls

Boiler Blow Down Valve (68-XV-1525)

The valve is opened automatically if at least any one of the following conditions is
satisfied:

The burner is ON
Hot standby mode is active (enabled manually) and the boiler level is higher than
a opening threshold value
The valve is closed automatically if at least any one of the following conditions is
satisfied:

The burner is off


Hot standby mode is not active

Hot standby mode is active and the boiler level is lower than a closure threshold
value
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 176 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Hot Stand-by Boiler Pressure Valve (68-XV-1523)

The valve is opened automatically when all the following conditions are satisfied:
Hot standby mode is active

The Steam Drum pressure 68-PT-1523 is lower than an opening threshold


(PSL-1523)
The valve is closed automatically if at least any one of the following conditions is
satisfied:

Hot standby mode is not active


Hot standby mode is active and the upper drum boiler pressure 68-PT-1523 is
higher than a closure threshold (PSH-1523)
Pre heating Feed Water Valves (68-XV-1523, 68- XV-1524)

For commanding the above valves to permit feed water to boiler lower drum,
following conditions needs to be satisfied:
Burner is OFF
Operator has selected FG2 (H2S) from the HMI
4.13.3.12 LP Steam Header Pressure Control

Saturated steam from all the three boiler packages are connected in to the LP steam
header and the pressure in the header is measured by 68-PT-1306 and controlled by
the pressure controller 68-PIC-1306. Pressure in the header is maintained by the
control valve 68-PV-1306 located in the steam vent line to atmosphere.

Increase of pressure above the operating range will route the steam to the vent
through the control valve 68-PV-1306.

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
68-PIC-1306 LP steam header pressure barg 5 4.5 5.5

LP steam header pressure low low pressure 2oo3 (68-PALL-1303A/B/C) alarm set
at 4 barg initiates the following:

Fuel gas on/off valve 68-XV-1302 to the boiler 6848-A-02A close


Fuel gas on/off valve 68-XV-1303 to the boiler 6848-A-02B close
Fuel gas on/off valve 68-XV-1304 to the boiler 6848-A-02C close
Deaerator Feed Pumps 6834-P-20A/B trip
BFW Pumps 6834-22A/B/C trip
Steam Condensate Cooler Fans trip
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 177 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Boiler Packages 6848-A-02A/B/C shutdown


Steam to vent valve 68-PV-1306 opens on instrument air failure
4.14 CHEMICAL INJECTION SYSTEMS

4.14.1 Antifoam Injection Package 9103-A-11

4.14.1.1 Equipment Specification

Antifoam Storage Tank


Equipment Tag No. 9103-T-12
Size, ID/Height, mm 1550/1600
Chemical Antifoam
Design Pressure bar(a) 1.01
Design Temperature C 85/0
Operating Pressure bar(g) ATM.
Operating Temperature, C 52
Material of Construction AISI 316L

Antifoam Injection Pumps


Equipment Tag No. 9103-P-16A/B
Pump Type Double Diaphragm
Chemical Antifoam
Capacity, L/hr 55
Design Pressure, bar(g) 12
Discharge Pressure, bar(g) 8.5
Design Temperature, C 120/0
Driver Type Motor
Rated Power, kW 0.37
Material of Construction SS316TI/PTFE

Antifoam Unloading Pump


Equipment Tag No. 9103-P-19
Pump Type Air Operated Pump
Chemical Antifoam
Capacity, L/hr 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction AISI 316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 178 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Antifoam Tank Agitator


Equipment Tag No. 9103-M-12
Speed, RPM 155
Driver Rating, kW 0.37
Material of Construction AISI 316L6

4.14.1.2 Antifoam Package 9103-A-11 Description

Antifoam Package consists of an Antifoam Storage Tank 9103-T-12 and two numbers of
Antifoam Injection Pumps 9103-P-16A/B.

The Antifoam Storage Tank 9103-T-12 is having an agitator 9103-M-12. Antifoam from
drums are transferred to the tank through an unloading pump 9103-P-19.

The Antifoam Injection Pumps 9103-P-16A/B are having discharge pulsation dampner
and calibration pots at the suction line.

4.14.1.3 Antifoam Injection Package Control Description

The Antifoam Storage Tank (9103-T-12) level is monitored by 91-LI-1521 and antifoam
from the storage tanks is injected to the following areas via the injection pumps
(9103-P-16A/B):

Acid Gas Amine Absorber 9103-C-11


Lean/Rich Amine Exchangers 9103-E-11A/B
Amine Regenerator 9103-C-12
Tail Gas Amine Absorber 9102-C-12
Following parameters are to be monitored:

Alarm
Tag No. Description Unit
High Low
91-FI-1533 9103-P-16A/B common discharge flow LPH 40 70
91-PI-1559 9103-P-16A discharge pressure barg NA 9.5
91-PI-1560 9103-P-16B discharge pressure barg NA 9.5
91-LI-1521 antifoam storage tank level (9103-T12) % 6 NA

Following are the details of the switches & alarm related to motor controls:

Tag No. Description


91-HSOA-1582 Remote START for the Pump 9103-P-16A
91-HSOA-1583 Remote START for the Pump 9103-P-16B
91-HSCA-1582 Remote STOP for the Pump 9103-P-16A
91-HSCA-1583 Remote STOP for the Pump 9103-P-16B
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 179 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Tag No. Description


91-ZL-1582 9103-P-16A Pump Available signal
91-ZL-1583 9103-P-16B Pump Available signal
91-XS-1582 9103-P-16A Pump ESD trip signal
91-XS-1583 9103-P-16B Pump ESD trip signal
91-ZI-1582 9103-P-16A Pump running indication
91-ZI-1583 9103-P-16B Pump running indication

Low low level alarm (91-LALL-1520) set at 3% in Antifoam Storage Tank 9103-T-12
trips the Antifoam Injection Pumps (9103-P-16A/B)

High high diaphragm pressure alarm (91-PAHH-1565) set at 8.5 barg in Antifoam
Injection Pump 9103-P-16A initiates the pump changeover

High high diaphragm pressure alarm (91-PAHH-1566) set at 8.5 barg in Antifoam
Injection Pump 9103-P-16B initiates the pump changeover
ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Antifoam
Injection Pumps (9103-P-16A/B).
4.14.2 Caustic Injection Package 9103-A-13

4.14.2.1 Equipment Specification

Caustic Storage Tank


Equipment Tag No. 9103-T-14
Size, ID/Height, mm 1550/1600
Chemical Caustic
Design Pressure bar(a) 1.01
Design Temperature C 85/0
Operating Pressure bar(g) ATM.
Operating Temperature, C 52/0
Material of Construction AISI 316L

Caustic Injection Pumps


Equipment Tag No. 9103-P-103A/B
Pump Type Double Diaphragm
Chemical Caustic
Capacity, L/hr 55
Design Pressure, bar(g) 11.5
Discharge Pressure, bar(g) 5
Design Temperature, C 120/0
Driver Type Motor
Rated Power, kW 0.37
Material of Construction SS316TI/PTFE
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 180 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Caustic Unloading Pump


Equipment Tag No. 9103-P-104
Pump Type Air Operated Pump
Chemical Caustic
Capacity, L/hr 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction AISI 316L

Caustic Tank Agitator


Equipment Tag No. 9103-M-14
Chemical Caustic
Speed, RPM 155
Material of Construction AISI 316L

4.14.2.2 Caustic Package 9103-A-13 Description

Caustic is injected to the suction of Desuperheater Circulation Pumps 9102-P-11.

Caustic Package consists of a Caustic Storage Tank 9103-T-14 and two numbers of
Caustic Injection Pumps 9103-P-103A/B.

The Caustic Storage Tank 9103-T-14 is having an agitator 9103-M-14. Caustic from
drums are transferred to the tank through an unloading pump 9103-P-104.

The Caustic Pumps 9103-P-103A/B are having discharge pulsation dampner and
calibration pots at the suction line.

4.14.2.3 Caustic Injection Package Control Description

Following parameters are to be monitored:


Alarm
Tag No. Description Unit
Low High
91-FI-1535 9103-P-103A/B common discharge flow LPH 40 70
91-PI-1563 9103-P-103A discharge pressure barg NA 7.5
91-PI-1564 9103-P-103B discharge pressure barg NA 7.5
91-LI-1525 caustic storage tank level (9103-T14) % 6 NA
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 181 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Following are the details of the switches & alarm related to motor controls:
Tag No. Description
91-HSOA-1586 Remote START for the Pump 9103-P-103A
91-HSOA-1587 Remote START for the Pump 9103-P-103B
91-HSCA-1586 Remote STOP for the Pump 9103-P-103A
91-HSCA-1587 Remote STOP for the Pump 9103-P-103B
91-ZL-1586 9103-P-103A Pump Available signal
91-ZL-1587 9103-P-103B Pump Available signal
91-XS-1586 9103-P-103A Pump ESD trip signal
91-XS-1587 9103-P-103B Pump ESD trip signal
91-ZI-1586 9103-P-103A Pump running indication
91-ZI-1587 9103-P-103B Pump running indication

Low low level alarm (91-LALL-1524) Set at 3% in caustic storage tank 9103-T-14
trips the Caustic Injection Pumps (9103-P-103A/B)
High high diaphragm pressure alarm (91-PAHH-1569) set at 5 barg in Caustic
Injection Pump 9103-P-103A initiates the pump changeover

High high diaphragm pressure alarm (91-PAHH-1570) set at 5 barg in Caustic


Injection Pump 9103-P-103B initiates the pump changeover
ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Caustic
Injection Pumps (9103-P-103A/B)

4.14.3 Corrosion Inhibitor Injection Package 9103-A-12

4.14.3.1 Equipment Specification

Corrosion Inhibitor Storage Tank

Equipment Tag No. 9103-T-13


Size, ID/Height, mm 1550/1600
3
Storage Capacity m 3
Chemical Corrosion Inhibitor
Design Pressure bar(a) 1.2
Design Temperature C 85/0
Operating Pressure bar(g) ATM.
Operating Temperature, C 52/0
Material of Construction SS 316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 182 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Corrosion Inhibitor Injection Pumps

Equipment Tag No. 9103-P-101A/B


Pump Type Double Diaphragm
Chemical Corrosion Inhibitor
Capacity, L/hr 55
Design Pressure, bar(g) 12
Discharge Pressure, bar(g) 8.5
Design Temperature, C 85/0
Driver Type Motor
Rated Power, kW 0.37
Material of Construction SS 316TI/PTFE

Corrosion Inhibitor Unloading Pump

Equipment Tag No. 9103-P-102


Pump Type Air Operated Pump
Chemical Corrosion Inhibitor
Capacity, L/hr 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction AISI 316L

Corrosion Inhibitor Tank Agitator

Equipment Tag No. 9103-M-13


Speed, RPM 155
Rated Power, kW 0.37
Material of Construction AISI 316L

4.14.3.2 Corrosion Inhibitor Package 9103-A-12 Description

Corrosion Inhibitor Package consists of a Corrosion Inhibitor Storage Tank 9103-T-13


and two numbers of Corrosion Inhibitor Injection Pumps 9103-P-101A/B.

The Corrosion Inhibitor Storage Tank 9103-T-13 is having an agitator 9103-M-13.


Corrosion Inhibitor from drums is transferred to the tank through an unloading pump
9103-P-102.

The Corrosion Inhibitor Pumps 9103-P-101A/B are having discharge pulsation dampner
and calibration pots at the suction line.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 183 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.3.3 Corrosion Inhibitor Injection Package Control Description

Following parameters are to be monitored:

Alarm
Tag No. Description Unit
Low High
9103-P-101A/B common discharge
91-FI-1534 LPH 40 70
flow
91-PI-1561 9103-P-101A discharge pressure barg NA 9.5
91-PI-1562 9103-P-101B discharge pressure barg NA 9.5
91-LT-1523 corrosion inhibitor storage tank % 6 NA

Following are the details of the switches & alarm related to motor controls:

Tag No. Description


91-HSOA-1584 Remote START for the Pump 9103-P-101A
91-HSOA-1585 Remote START for the Pump 9103-P-101B
91-HSCA-1584 Remote STOP for the Pump 9103-P-101A
91-HSCA-1585 Remote STOP for the Pump 9103-P-101B
91-ZL-1584 9103-P-101A Pump Available signal
91-ZL-1585 9103-P-101B Pump Available signal
91-XS-1584 9103-P-101A Pump ESD trip signal
91-XS-1585 9103-P-101B Pump ESD trip signal
91-ZI-1584 9103-P-101A Pump running indication
91-ZI-1585 9103-P-101B Pump running indication

Low low level alarm 91-LALL-1523 set at 3 % in Corrosion Inhibitor Storage Tank
9103-T-13 trips the Corrosion Inhibitor Injection Pumps (9103-P-101A/B)
High high diaphragm pressure alarm 91-PAHH-1567 set at 8.5 barg in Corrosion
Inhibitor Injection Pump 9103-P-101A initiates the pump changeover

High high diaphragm pressure alarm 91-PAHH-1568 set at 8.5 barg in Corrosion
Inhibitor Injection Pump 9103-P-101B initiates the pump changeover

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Corrosion
Inhibitor Injection Pumps 9103-P-101A/B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 184 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.4 Complex Product Injection Package 6834-A-09

4.14.4.1 Equipment Specification

Complex Product Storage Tank

Equipment Tag No. 6834-T-18


Size, ID/Height, mm 950/1500
3
Storage Capacity m 1
Chemical Complex Product
Design Pressure bar(a) 1.01
Design Temperature C 85/0
Operating Pressure bar(g) ATM.
Operating Temperature, C 52/0
Material of Construction AISI 316L

Complex Product Injection Pumps

Equipment Tag No. 6834-P-41A/B


Pump Type Double Diaphragm
Chemical Complex Product
Capacity, L/hr 1.87
Design Pressure, bar(g) 31
Discharge Pressure, bar(g) 25
Design Temperature, C 120/0
Driver Type Motor
Rated Power, kW 0.18
Material of Construction SS 316TI/PTFE

Complex Product Unloading Pump

Equipment Tag No. 6834-P-42


Pump Type Air Operated Pump
Chemical Complex Product
Capacity, L/hr 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction AISI 316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 185 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Complex Product Tank Agitator

Equipment Tag No. 6834-M-04


Speed, RPM 243
Rated Power, kW 0.25
Material of Construction AISI 316L

4.14.4.2 Complex Product Injection Package Description

Complex Product Injection Package consists of a Complex Product Storage Tank


6834-T-18 and two numbers of Complex Product Injection Pumps 6834-P-41A/B.

The Complex Product Storage Tank 6834-T-18 is having an agitator 6834-M-04.


Complex Product from drums is transferred to the tank through an unloading pump
6834-P-42.

The Complex Product Injection Pumps 6834-P-41A/B are having discharge pulsation
dampner and calibration pots at the suction line.

4.14.4.3 Complex Product Injection Process control Description

The complex product is injected to the boiler feed water going to the steam
generation package and to the boiler feed water going to TGTU.

The control is achieved by maintaining the ratio between the total Boiler Feed Water
flow and Complex Product flow.

The Boiler Feed Water flow rate to Steam Generation Boiler A/B/C is measured by 68-
FT 1522, 68-FT-1622, 68-FT-1722 respectively and 68-FT-1304 measures the boiler feed
water flow rate to TGTU.

The Complex Product Pumps (6834-P-41A/B) common discharge flow rate is measured
by 68-FT-1311.

Total summation of all the above BFW flow is summated in the calculation block
68-FY-1304 and multiplied with the fixed ratio X (X=complex product/total BFW) in the
multiplication block 68-FFY-1311. The output from 68-FFY-1311 is fed as a set point to
the MASTER complex product flow controller 68-FIC-1311.

The complex product pumps 6834-P-41A/B stroke length (0-15 mm) is measured by the
stroke indicators 68-ZI-1303/1304 and the strokes are controlled by the position
controllers 68-ZIC-1303, 68-ZIC-1304.

Complex product flow controller 68-FIC-1311 is cascaded with the position controllers
68-ZIC-1303 and 68-ZIC-1304 and provides set point to the position controllers.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 186 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Controller Operating Alarm


Control Description Unit
Tag Set Point Low High
68-FIC-1311 Complex product flow control L/hr 1.78 0.2 1.78
68-ZIC-1303 6834-P-41A position control % 100 NA NA
68-ZIC-1304 6834-P-41B position control % 100 NA NA

The complex product injection pumps can be operated from the DCS when the Pumps
are selected to Remote at its local panel.

Following are the details of the switches & alarm related to motor controls:

Tag No. Description


68-HSOA-1324 Remote START for the Pump 6834-P-41A
68-HSOA-1332 Remote START for the Pump 6834-P-41B
68-HSCA-1324 Remote STOP for the Pump 6834-P-41A
68-HSCA-1332 Remote STOP for the Pump 6834-P-41B
68-ZL-1324 6834-P-41A Pump Available signal
68-ZL-1332 6834-P-41B Pump Available signal
68-XS-1324 6834-P-41A Pump ESD trip signal
68-XS-1332 6834-P-41B Pump ESD trip signal
68-ZI-1324 6834-P-41A Pump running indication
68-ZI-1332 6834-P-41B Pump running indication

Following parameters are to be monitored

Alarm
Tag No. Description Unit
Low High
68-PI-1318 6834-P-41A Pump discharge pressure barg NA 26.5
68-PI-1316 6834-P-41B Pump discharge pressure barg NA 26.5
Complex product storage tank
68-LI-1317 % 6 NA
6834-T18 level

Low low level alarm 68-LALL-1316 set at 3% in Complex Product Storage Tank trips
the Complex Product Injection Pumps 6834-P-41A/B

High high diaphragm pressure alarm 68-PAHH-1326 set at 25.0 barg in Complex
Product Injection Pump 6834-P-41A initiates the pump changeover
High high diaphragm pressure alarm 68-PAHH-1327 set at 25.0 barg in Complex
Product Injection Pump 6834-P-41B initiates the pump changeover
ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Complex
Product Injection Pumps 6834-P-41A/B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 187 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.5 Oxygen Scavenger Injection Package 6834-A-09

4.14.5.1 Equipment Specification

Oxygen Scavenger Storage Tank

Equipment Tag No. 6834-T-17


Size, ID/Height, mm 950/1500
3
Storage Capacity m 1
Chemical Oxygen Scavenger
Design Pressure bar(a) 1.01
Design Temperature C 85/0
Operating Pressure bar(g) ATM.
Operating Temperature, C 52/0
Material of Construction AISI 316L

Oxygen Scavenging Injection Pumps

Equipment Tag No. 6834-P-39A/B


Pump Type Double Diaphragm
Chemical Oxygen Scavenger
Capacity, L/H 0.55
Design Pressure, bar(g) 10.5
Discharge Pressure, bar(g) 6.5
Design Temperature, C 120/0
Driver Type Motor
Rated Power, kW 0.18
Material of Construction SS 316TI

Oxygen Scavenger Unloading Pump

Equipment Tag No. 6834-P-40


Pump Type Air Operated Pump
Chemical Oxygen Scavenger
Capacity, L/h 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction AISI 316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 188 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Oxygen Scavenger Tank Agitator

Equipment Tag No. 6834-M-03


Speed, RPM 243
Rated Power, kW 0.25
Material of Construction AISI 316L

4.14.5.2 Oxygen Scavenger Injection Package Description

Oxygen Scavenger Injection Package consists of a Oxygen Scavenger Storage Tank


6834-T-17 and two numbers of Oxygen Scavenger Injection Pumps 6834-P-39A/B.

The Oxygen Scavenger Storage Tank 6834-T-17 is having an agitator 6834-M-03. Oxygen
Scavenger from drums is transferred to the tank through an unloading pump 6834-P-40

The Oxygen Scavenger Injection Pumps 6834-P-39A/B is provided with discharge


pulsation dampener and calibration pots at the suction line.

4.14.5.3 Oxygen Scavenging Injection Process control Description

The oxygen scavenger is injected directly in to the De-aerator package (6834-A-08)


and the flow rate of Oxygen Scavenger is measured by 68-FT-1310.

Oxygen Scavenger Injection Pumps 6834-P-39A, 6834-P-39B stroke length is measured


by 68-ZT-1301 and 68-ZT-1302 respectively. Stroke length of 6834-P-39A, 6834-P-39B is
manually adjusted by the controllers 68-HIC-1301 and 68-HIC-1302, respectively.

The Oxygen Scavenger Injection Pumps can be operated from the DCS when the Pumps
are selected to Remote at its local panel

Following are the details of the switches & alarm related to motor controls:

Tag No. Description


68-HSOA-1323 Remote START for the Pump 6834-P-39A
68-HSOA-1331 Remote START for the Pump 6834-P-39B
68-HSCA-1323 Remote STOP for the Pump 6834-P-39A
68-HSCA-1331 Remote STOP for the Pump 6834-P-39B
68-ZL-1322 6834-P-39A Pump Available signal
68-ZL-1331 6834-P-39B Pump Available signal
68-XS-1322 6834-P-39A Pump ESD trip signal
68-XS-1331 6834-P-39B Pump ESD trip signal
68-ZI-1322 6834-P-39A Pump running indication
68-ZI-1331 6834-P-39B Pump running indication
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 189 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Following parameters are to be monitored:

Alarm
Tag No. Description Unit
Low High
68-PI-1317 6834-P-39A Pump discharge pressure barg NA 8
68-PI-1315 6834-P-39B Pump discharge pressure barg NA 8
Oxygen Scavenger Storage Tank
68-LI-1315 % 6 80
6834-T-17 level
68-FI-1310 Oxygen Scavenger Injection flow rate LPH 0.2 0.7

Low low level alarm 68-LALL-1314 set at 3 % in oxygen scavenger tank 6834-T-17
trips the Oxygen Scavenger Injection Pumps 6834-P-39A/B
High high diaphragm pressure alarm 68-PAHH-1324 set at 6.5 barg in Oxygen
Scavenger Injection Pump 6834-P-39A initiates the pump changeover
High high diaphragm pressure alarm 68-PAHH-1325 set at 6.5 barg in oxygen
scavenger Injection Pump 6834-P-39B initiates the pump changeover

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Oxygen
Scavenger Pumps 6834-P-39A/B.
4.14.6 Biocide Injection Package 6932-A-06

4.14.6.1 Equipment Specification

Biocide Storage Tank

Equipment Tag No. 6932-T-04


Size, ID/Height, mm 1300/2300
3
Storage Capacity m 3
Chemical Biocide
Design Pressure bar(a) 1.01
Design Temperature C 85/0
Operating Pressure bar(g) ATM.
Operating Temperature, C 52/0
Material of Construction AISI 316L
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 190 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Biocide Injection Pumps

Equipment Tag No. 6932-P-07A/B


Pump Type Double Diaphragm
Chemical Biocide
Capacity, L/H 12/65/110
Design Pressure, bar(g) 10
Discharge Pressure, bar(g) 5.5
Design Temperature, C 120/0
Driver Type Motor
Rated Power, kW 0.75
Material of Construction SS 316TI/PTFE

Biocide Unloading Pump

Equipment Tag No. 6932-P-08


Pump Type Air Operated Pump
Chemical Biocide
Capacity, L/h 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction AISI 316L

4.14.6.2 Biocide Injection Package Description

Biocide Injection Package consists of a Biocide Storage Tank 6932-T-04 and two
numbers of Biocide Injection Pumps 6932-P-07A/B.

Biocide from drums is transferred to the tank through an unloading pump 6932-P-08.

The Biocide Injection Pumps 6932-P-07A/B is provided with discharge pulsation


dampener and calibration pots at the suction line.

4.14.6.3 Biocide Injection Process control Description

The biocide storage tank 6932-T-04 level is measured by 69-LI-1328. Biocide from the
storage tank is injected to Sea Cooling Water through remote stroke adjusting pumps
(6932-P-07A/6932-P-07B).

Stroke lengths of 3 stage 6932-P-07A are measured by 69-ZT-1301, 69-ZT-1326 and


69-ZT-1328. Manual adjustment of stroke is done via the controllers 69-HIC-1301,
69-HIC-1326 and 69-HIC-1328.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 191 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Stroke lengths of 3 stage 6932-P-07B are measured by 69-ZT-1302, 69-ZT-1327 and


69-ZT-1329. Manual adjustment of stroke is done via the controllers 69-HIC-1302,
69-HIC-1327 and 69-HIC-1329.

Following parameters are to be monitored:


Alarm
Tag No. Description Unit
Low High
st
6932-P-07A/B 1 stage common
69-FI-1319 LPH 80 130
discharge flow
6932-P-07A/B 2nd stage common
69-FI-1323 LPH 80 130
discharge flow
6932-P-07A/B 3rd stage common
69-FI-1324 LPH 80 130
discharge flow
69-PI-1330 6932-P-07A 1st stage discharge pressure barg NA 6.5
nd
69-PI-1340 6932-P-07A 2 stage discharge pressure barg NA 6.5
rd
69-PI-1342 6932-P-07A 3 stage discharge pressure barg NA 6.5
st
69-PI-1331 6932-P-07B 1 stage discharge pressure barg NA 6.5
nd
69-PI-1341 6932-P-07B 2 stage discharge pressure barg NA 6.5
rd
69-PI-1343 6932-P-07B 3 stage discharge pressure barg NA 6.5
69-LI-1328 Biocide Storage Tank (6932-T-04) level % 6 NA

The Biocide injection pumps can be operated from the DCS when the Pumps are
selected to Remote at its local panel.

Following are the details of the switches & alarm related to motor controls:
Tag No. Description
69-HSOA-1352 Remote START for the Pump 6932-P-07A
69-HSOA-1353 Remote START for the Pump 6932-P-07B
69-HSCA-1352 Remote STOP for the Pump 6932-P-07A
69-HSCA-1353 Remote STOP for the Pump 6932-P-07B
69-ZL-1352 6932-P-39A Pump Available signal
69-ZL-1353 6932-P-39B Pump Available signal
69-XS-1352 6932-P-07A Pump ESD trip signal
69-XS-1353 6932-P-07B Pump ESD trip signal
69-ZI-1352 6932-P-07A Pump running indication
69-ZI-1353 6932-P-07B Pump running indication

Low low level alarm 69-LALL-1329 set at 10 % in biocide storage tank 6932-T-04
trips the Biocide Injection Pumps 6932-P-07A/B
High high diaphragm pressure alarm 69-PAHH-1344 set at 5.5 barg in 1st stage
Biocide Injection Pump 6932-P-07A initiates the pump changeover
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 192 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

High high diaphragm pressure alarm 69-PAHH-1346 set at 5.5 barg in 2nd stage
Biocide Injection Pump 6932-P-07A initiates the pump changeover

High high diaphragm pressure alarm 69-PAHH-1328 set at 5.5 barg in 3rd stage
Biocide Injection Pump 6932-P-07A initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1345 set at 5.5 barg in 1st stage
Biocide Injection Pump 6932-P-07B initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1347 set at 5.5 barg in 2nd stage
Biocide Injection Pump 6932-P-07B initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1329 set at 5.5 barg in 3rd stage
Biocide Injection Pump 6932-P-07B initiates the pump changeover
ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Biocide
Injection Pumps 6932-P-07A/B.
4.14.7 Scale Inhibitor Injection Package 6932-A-07

4.14.7.1 Equipment Specification

Scale Inhibitor Storage Tank

Equipment Tag No. 6932-T-05


Size, ID/Height, mm 2480/4900
3
Storage Capacity m 24
Chemical Scale Inhibitor
Design Pressure bar(a) 1.2
Design Temperature C 85/0
Operating Pressure bar(g) ATM
Operating Temperature, C 52/0
Material of Construction AISI 316L

Scale Inhibitor Injection Pumps

Equipment Tag No. 6932-P-09A/B


Pump Type Double Diaphragm
Chemical Scale Inhibitor
Capacity, L/H 26/41/4
Design Pressure, bar(g) 10
Discharge Pressure, bar(g) 5.5
Design Temperature, C 120/0
Driver Type Motor
Rated Power, kW 0.37
Material of Construction SS 316TI/PTFE
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 193 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Scale Inhibitor Unloading Pump

Equipment Tag No. 6932-P-10


Pump Type Air Operated Pump
Chemical Scale Inhibitor
Capacity, L/h 5000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction SS 316TI

4.14.7.2 Scale Inhibitor Injection Package Description

Scale Inhibitor Injection Package consists of a Scale Inhibitor Storage Tank 6932-T-05
and two numbers of Scale Inhibitor Injection Pumps 6932-P-09A/B.

Scale Inhibitor from drums is transferred to the tank through an unloading pump
6932-P-10.

The Scale Inhibitor Injection Pumps 6932-P-09A/B are having discharge pulsation
dampner and calibration pots at the suction line.

4.14.7.3 Scale Inhibitor Injection Process control Description

The Scale Inhibitor Storage Tank 6932-T-05 level is measured by 69-LI-1330. Scale
Inhibitor from the storage tank is injected to sea cooling water through Injection
Pumps 6932-P-09A/6932-P-09B.

Following parameters are to be monitored:

Alarm
Tag No. Description Unit
Low High
6932-P-09A/B 1st stage common discharge
69-FI-1322 LPH 2 8
flow
6932-P-09A/B 2nd stage common discharge
69-FI-1321 LPH 35 45
flow
6932-P-09A/B 3rd stage common discharge
69-FI-1320 LPH 20 30
flow
69-PI-1332 6932-P-09A 1st stage discharge pressure barg NA 6.5
69-PI-1333 6932-P-09A 2nd stage discharge pressure barg NA 6.5
69-PI-1334 6932-P-09A 3rd stage discharge pressure barg NA 6.5
69-PI-1335 6932-P-09B 1st stage discharge pressure barg NA 6.5
69-PI-1336 6932-P-09B 2nd stage discharge pressure barg NA 6.5
69-PI-1337 6932-P-09B 3rd stage discharge pressure barg NA 6.5
Scale Inhibitor Storage Tank (6932-T05)
69-LI-1330 % 6 80
level
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 194 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The scale inhibitor injection pumps can be operated from the DCS when the Pumps are
selected to Remote at its local panel.

Following are the details of the switches & alarm related to motor controls:

Tag No. Description


69-HSOA-1354 Remote START for the Pump 6932-P-09A
69-HSOA-1355 Remote START for the Pump 6932-P-09B
69-HSCA-1354 Remote STOP for the Pump 6932-P-09A
69-HSCA-1355 Remote STOP for the Pump 6932-P-09B
69-ZL-1354 6932-P-09A Pump Available signal
69-ZL-1355 6932-P-09B Pump Available signal
69-XS-1354 6932-P-09A Pump ESD trip signal
69-XS-1355 6932-P-09B Pump ESD trip signal
69-ZI-1354 6932-P-09A Pump running indication
69-ZI-1355 6932-P-09B Pump running indication

Low low level alarm 69-LALL-1331 set at 3% in Scale Inhibitor Storage Tank 6932-T-
05 trips the Scale Inhibitor Injection Pumps (6932-P-09A/B)
High high diaphragm pressure alarm 69-PAHH-1338 set at 5.5 barg in 1st stage
Scale Inhibitor Injection Pump 6932-P-09A initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1348 set at 5.5 barg in 2nd stage
Scale Inhibitor Injection Pump 6932-P-09A initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1350 set at 5.5 barg in 3rd stage
Scale Inhibitor Injection Pump 6932-P-09A initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1339 set at 5.5 barg in 1st stage
Scale Inhibitor Injection Pump 6932-P-09B initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1349 set at 5.5 barg in 2nd stage
Scale Inhibitor Injection Pump 6932-P-09B initiates the pump changeover
High high diaphragm pressure alarm 69-PAHH-1351 in 3rd stage Scale Inhibitor
Injection Pump 6932-P-09B initiates the pump changeover
ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Scale
Inhibitor Injection Pumps 6934-P-09A/B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 195 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.8 Catalyst Injection Package 9101-A-01

4.14.8.1 Equipment Specification

Catalyst Storage Tank

Equipment Tag No. 9101-T-01


Size, ID/Height, mm 950/1500
3
Storage Capacity m 1
Chemical Catalyst
Design Pressure bar(a) 1.01
Design Temperature C 85/0
Operating Pressure bar(g) ATM
Operating Temperature, C 52/0
Material of Construction AISI 316L

Catalyst Injection Pumps

Equipment Tag No. 9101-P-11A/B


Pump Type Double Diaphragm
Chemical Catalyst
Capacity, L/H 0.55
Design Pressure, bar(g) 8
Discharge Pressure, bar(g) 5
Design Temperature, C 85/0
Driver Type Motor
Rated Power, kW 0.37
Material of Construction SS 316TI/PTFE

Catalyst Unloading Pumps

Equipment Tag No. 9101-P-12


Pump Type Air Operated Pump
Chemical Catalyst
Capacity, L/h 2000
Design Pressure, bar(g) 8.7
Discharge Pressure, bar(g) 1.2
Design Temperature, C 85/0
Material of Construction SS 316TI
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 196 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4.14.8.2 Catalyst Injection Package Description

Catalyst Injection Package consists of a Catalyst Storage Tank 9101-T-01 and two
numbers of Catalyst Injection Pumps 9101-P-11A/B.

Catalyst from drums is transferred to the tank through an unloading pump 9101-P-12.

The Catalyst Injection Pumps 9101-P-11A/B are having calibration pots at the suction
line.

4.14.8.3 Catalyst Injection Process control Description

The Catalyst Storage Tank level 9101-T-01 is monitored by 91-LI-1127 and Catalyst
Injection Pumps 9101-P-11A/B common discharge flow is measured by 91-FI-1128.

Following parameters are to be monitored:

Alarm
Tag No. Description Unit
Low High
9101-P-11A/B common
91-FI-1128 LPH 0.2 0.7
discharge flow
91-PI-1127 9101-P-11A discharge pressure barg NA 6
91-PI-1129 9101-P-11B discharge pressure barg NA 6
catalyst storage tank 9101-T01
91-LI-1127 % 6 NA
level

Following are the details of the switches & Alarm related to motor controls:

Tag No. Description


91-HSOA-1129 Remote START for the Pump 9101-P-11A
91-HSOA-1130 Remote START for the Pump 9101-P-11B
91-HSCA-1129 Remote STOP for the Pump 9101-P-11A
91-HSCA-1130 Remote STOP for the Pump 9101-P-11B
91-ZL-1129 9101-P-11A Pump Available signal
91-ZL-1130 9101-P-11B Pump Available signal
91-XS-1129 9101-P-11A Pump ESD trip signal
91-XS-1130 9101-P-11B Pump ESD trip signal
91-ZI-1129 9101-P-11A Pump running indication
91-ZI-1130 9101-P-11B Pump running indication

Low low level alarm 91-LALL-1128 set at 3% in Catalyst Storage Tank 9101-T-01
trips the Catalyst Injection Pumps 9101-P-11A/B
High high diaphragm pressure alarm 91-PAHH-1128 set at 5 barg in Catalyst
Injection Pump 9101-P-11A initiates the pump changeover
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 197 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

High high diaphragm pressure alarm 91-PAHH-1130 set at 5 barg in Catalyst


Injection Pump 9101-P-11B initiates the pump changeover

ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Catalyst
Injection Pumps 9101-P-11A/B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date:03/09/2012
Doc. No.: 2970-0-22-0001 Page: 198 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION V PRE-REQUISITE FOR START-UP


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 199 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.1 GENERAL

For Start-up of the SRU Upgrade Facilities the pre-requisites are given below:

All vent and drain valves position are as per P&ID


All spectacle spacers and spectacle blinds are as per P&ID
Acid gas from AGRU 1 & 2 to the Acid Gas Enrichment Unit isolation valve 91-BV-
1881 is in closed condition
Electrical power is available

Fire & gas system of process unit is tested and in normal operation
Ensure that DCS, F&G and ESD systems are available
Acid gas flare system is in operation
LP Flare is in operation
All process line isolating valves are in closed condition
Ensure all Lock Open and Lock Closed valves are in their normal operating
positions as per P&ID
Ensure that all safety devices have been set to the appropriate set-point as per
P&ID
Ensure all mechanical equipment have been installed properly
All instrument root valves are open
All instrument vent/drain valves are closed
Ensure that no shutdown conditions are present (ESD)
Confirm availability of all tools, consumables, and spare parts that are required
for start-up
Confirm that the required valid Permit to Work has been issued prior to the
commencement of start-up activities
Ensure that fire protection system is ready for operation
Ensure that the AGRU 1 & 2 are running and ready to provide acid gas to the AGEU
Prior to the starting up of the plant there are several operations that must be
conducted to prepare the plant for the actual start-up. This section covers the work
required in preparing the unit for initial start-up. The jobs can be categorized as
follows:

Plant inspection
Final inspection of vessels and equipments
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 200 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Line and Equipment leak test


It is important that these above procedures to be carried out thoroughly and at
earliest possible to achieve a smooth, trouble free and steady normal operation.

5.2 INTERFACE ACTIVITIES

The following tie-ins between the NGL 1, 2, 3 & 4 and the SRU Upgrade Facilities are
to be completed before the start-up of the new facilities.

Process

Acid Gas from NGL-3 AGRU 1 & 2


Acid Gas from NGL 1 & 2 Blowers
Acid Gas from NGL-4 K-8201A/B

Acid Gas from AGEU Regenerator Reflux Drum 9103-V-12 to SRU


Sour Water from Acid Gas KO Drum Return Pump 9103-P-14A/B to SRU
Acid Water from SRU to Amine Sump 9103-V-10
Utilities

Sea Cooling Water from new Sea Cooling Water system to the existing Sea Cooling
Water system
Sea Cooling Water Return from AGEU/TGTU to existing Sea Water Observation
Sump 6932-X-01
20 LP Flare header interconnection from new units to the existing units
NGL-4 Sea Cooling Water system new Sea Water Filters S-8840A/B

Line from existing Drinking Water Storage Tank 6834-T-01A/B to the new Drinking
Water Pumps 6834-P-23A/B
Interconnection between existing Drinking Water Pumps 6834-P-01A/B and new
Drinking Water Pumps 6834-P-23A/B
Interconnection between new DM Water network to the existing DM Water network
Interconnection between the new plant air header to the old plant air header

Interconnection between the existing 6-GI-82-0357-C01A nitrogen header to the


new nitrogen header
Interconnection between the existing Lean Gas from Booster Compressor suction
to the LP Fuel Gas KO Drum 6236-V-05

Interconnection between the lean gas from 6103-K-01A/B and the LP Fuel Gas KO
Drum 6236-V-05
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 201 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Interconnection between the existing fuel gas line upstream of 65-XV-001 and the
LP Fuel Gas KO Drum 6236-V-05

Interconnection from existing fuel gas header 6-6536-FG-101-C12P to Incinerator


9101-F-14 and Reducing Gas Generator 9102-F-11
Interconnection of the following new flare lines to the existing LP Flare Header
10-6922-FL-013-C14P:
From LP Fuel Gas KO Drum 6236-V-05 drain line
LP Fuel Gas KO Drum 6236-V-05 PSVs 62-PSV-176/176S outlet lines
Fuel gas from steam generation package 6848-A-02A/B/C
From LP Fuel Gas KO Drum 6236-V-05 vent 62-PV-1303
From LP Fuel Gas KO Drum 6236-V-05 inlet pressure control valves 62-PV-
1301A/62-PV-1301B/62-PV-1302
Interconnection from existing fuel gas line 2-6536-FG-011-C12P to LP Acid Gas
flare header as purge gas
Interconnection from the existing Service Water Pump P-3103 discharge to the
Electro Chlorination Package 6932-A-05
Interconnection between the existing Instrument Air supply to the new Sea Cooling
Water Filters 6932-S-02A/B
Interconnection between the existing Plant Air supply to the Sea Cooling Water
Filters 6932-S-02A/B
Interconnection between the existing nitrogen supply system to the new Electro
Chlorination system
Interconnection between the existing Spent Caustic system and the new Spent
Caustic form Desuperheater Circulation Pumps 9102-P-11A/B
Oily Waste Water from SRU Upgrade new Utilities/Process area to the existing Oily
Waste Water Sump 6922-X-01
From new Stripped Water Cooler 6922-E-02/Cooling water return from
AGEU/TGTU to Sea Water Observation Sump 6932-X-01 analyzer 69-AT-1301 outlet
to the existing Observation & Buffer Sump 6922-X-04
Interconnection between the existing instrument air header and the new
instrument air header
Interconnection between the new Biocide Injection Package 6932-A-06 and the
existing Sea Cooling Water Pumps P-1618 AR/BR/CR suction
Interconnection between the new Scale Inhibitor Injection Package 6932-A-07 and
the existing Sea Cooling Water Pumps P-1618 AR/BR/CR discharge.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 202 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.3 START-UP OF UTILITIES

5.3.1 Start-up Sequence

Utilities are started in the following sequence:

1. Instrument Air/Plant Air System

2. Nitrogen System

3. Drinking Water System

4. Oily Water Drain System

5. Effluent and Waste Water Treatment System

6. Flare System

7. Fuel Gas System

8. Sea Cooling Water System

9. Chemical Injection System

10. DM Water System

11. Boiler Feed Water Deaerator System

12. Steam Generation System

5.4 INSTRUMENT AIR/PLANT AIR SYSTEM

5.4.1 Pre Start-up Checks

Ensure the following pre start-up checks are completed before the start-up:

1. Ensure the Readiness of Instrument Air Compressor, Instrument Air Dryer and all its
auxiliary equipments.
2. Ensure all the instruments are lined up.
3. Ensure that the Air Compressor Discharge Drum 6837-V-10 & Instrument Air
Receiver 6837-V-11 are clean.
Ensure the following PSVs are calibrated, reinstated and lined-up as shown in P&ID:

PSV Tag No. Description


68-PSV-1401 PSV after intercooler
68-PSV-1402 PSV after intercooler
68-PSV-1106/1106S Air compressor Discharge drum PSV
68-PSV-1107/1107S Instrument air receiver PSV
68-PSV-1408 Adsorber 6837-V-14A
68-PSV-1409 Adsorber 6837-V-14A
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 203 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

PSV Tag No. Description


68-PSV-1458 Adsorber 6837-V-15A
68-PSV-1459 Adsorber 6837-V-15B

5.4.2 Instrument Air compressor Start-up

There are two Instrument Air Compressors (2 x 100% capacity). The compressors
operate on Duty/Standby configuration.

Each compressor is monitored and controlled by the package controller (UCP) which
contains Siemens S7-400H series PLC and provides information to the DCS through
redundant modbus TCP/IP communication link.

Air Compressors LCP details are tabulated below:

Tag No.
Sl. # Service
6837-K-02A 6837-K-02B
1. 68-HS-1403 68-HS-1453 Local/Remote Selector Switch
2. 68-HS-1402 68-HS-1452 Load/Unload Selector switch
3. 68-HSOA-1414 68-HSOA-1464 Start Push Button
4. 68-HSCA-1415 68-HSOA-1465 Stop Push Button
5. 68-HS-1404 68-HS-1454 Lamp Test Push Button
6. 68-HS-1401 68-HS-1451 Emergency Stop Push Button
7. 68-HS-1405 68-HS-1455 Reset Push Button
8. 68-XL-1408 68-XL-1458 Voltage ON lamp (white)
9. 68-XL-1409 68-XL-1459 Compressor loaded lamp
10. 68-XL-1410 68-XL-1460 Automatic operation lamp
11. 68-XL-1411 68-XL-1461 General warning lamp
12. 68-XL-1412 68-XL-1462 General shutdown lamp

Details of DCS tags for Air Compressors are tabulated below:

Tag No.
Sl. # Service
6837-K-02A 6837-K-02B
1. 68-HSOA-1428 68-HSOA-1478 Remote Start Button
2. 68-HSCA-1428 68-HSOC-1478 Remote Stop Button
3. 68-UA-1401 68-UA-1451 Compressor common alarm

Note: Press lamp test push button in local control panel and ensure all the lamps are
in working normal.
The procedure for start-up of one unit (6837-K-02A) of IA Compressor is covered in this
section. The same procedure is applicable for other unit (6837-K-02B).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 204 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Instrument air compressor can be started in two modes.

I. Local Mode

In local mode, the start/stop of the compressor is done from the local control station
(LCS). For operating the Compressor in local mode, the selectors switch 68-HS-1403 in
Local Control Station to be selected to local position. The loading/unloading is done by
the operator using the loading/unloading switch 68-HS-1402 in the LCS. During Local
mode loading and unloading of the compressor is based on the compressor outlet
pressure transmitter signal 68-PT-1406. Local mode is used for service or maintenance
purposes.

II. Remote Mode

Remote-Auto and Remote-Manual modes are possible under remote mode of operation.

In Remote mode, start and stop of the individual compressors are initiated from
UCP/DCS operating stations. In Remote-Auto mode, the UCP sequence control has
total control over selection, start & stop and pressure control of both the compressors.
All local controls are disabled in this mode except emergency stop from field.

In Remote mode, the loading/unloading of compressors is based on the air receiver


pressure transmitter signal 68-PT-1311.

5.4.3 Start-up permissive conditions:

Availability of instruments and in healthy condition


Motor available signal (68-XU-1428) from MCC
Ensure the below mentioned interlocks in UCP of I/A Compressor are normal:

Tag No. Description


68-PAHH-1406 Compressor outlet pressure high-high
68-PDALL-1401 Compressor air inlet pressure low-low
68-PALL-1402 Compressor oil pressure low-low
68-PDAHH-1403 Compressor oil filter DP high-high
68-TAHH-1401 LP stage outlet temperature high-high
68-TAHH-1402 Compressor oil temperature high-high
68-TAHH-1403 LP stage inlet temperature high-high
68-TAHH-1405 Compressor outlet temperature high-high
68-TAHH-1406 Main motor (U1) winding temperature high-high
68-TAHH-1407 Main motor (V1) winding temperature high-high
68-TAHH-1408 Main motor (W1) winding temperature high-high
68-TAHH-1412 Main motor(U2) winding temperature high-high
68-TAHH-1413 Main motor (V2) winding temperature high-high
68-TAHH-1414 Main motor (W2) winding temperature high-high
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 205 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Tag No. Description


68-TAHH-1410 Main motor bearing (DE) temperature high-high
68-TAHH-1411 Main motor bearing (NDE) temperature high-high
68-HS-1401 Emergency stop button at LCP
68-XS-1424 ESD signal to UCP

Following interlocks are bypassed automatically during start-up of compressor:

68-PT-1402 (Lube oil pressure) low low alarm


Compressor trip (68-XZA-1428) and stop (68-XI-1428) feedback
Both the above interlocks are bypassed for 20 seconds.

The local start-up procedure for 6837-K-02A is given below:

1. Select both the compressors to Local from the Local Control panel through
selector switch
2. Open 6837-K-02A discharge isolation valve
3. Close the Plant air header pressure control valve 68-PV-1310 and the upstream
block valve
4. Close the Air Dryer Package pre-filter upstream isolation valves
5. Confirm Motor available signal (68-XU-1428) exists
6. Before starting the Compressor main motor, Set loading & unloading Pressure set
point at XX barg in UCP HMI
7. Start Compressor 6837-K-02A through Local Start Push Button and ensure that
compressor is started and running
8. Ensure that the Cooling Air Fans (6837-EFM-03AA/AB) and External After Cooler
Fan Motor (6837-EFM-04A) is running and its running indication in DCS/HMI
9. Ensure that oil pump is running and the oil pressure is 2.3 barg
10. Ensure compressor runs in unloaded condition for 20 seconds
11. Load the Air Compressor by Pressing Push button 68-HS-1402 in the local panel
12. Ensure that the compressor is loaded by checking the pressure 68-PT-1406 located
in the HP Stage compressor outlet
13. Confirm Loaded indication (68-XL-1409) in local control station
14. Confirm the Compressor loads up to XX barg, based on the value taken from 68-
PT-1406 located on the compressor outlet
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 206 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

15. Check the performance of the Compressor by monitoring the following


parameters:
Discharge Pressure (68-PI-1406)

Discharge Temperature (68-TI-1405)


Motor Amperage
Oil Temperature (68-TI-1402)

Oil Pressure (68-PI-1402)


Motor Winding Temperatures

Compressor vibration
Motor vibration
Compressor and motor bearing temperatures
Note: Instrument air compressors can also be started from DCS by selecting the
Remote in LCP and Auto/manual button to Auto in UCP-HMI.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 207 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 25 - IA Compressor Start-up

Instrument Air Compressor


Start Sequence 20 sec load delay, oil pressure trip Y
Manual Unload
(68-PT-1402) needs to be bypassed
up to this time
N

N Interlocks &
Take corrective Ready to load/unload
start-up permissive Note-A
action
healthy Set pressure
<Actual
Y Pressure N
Check load, (68-PT-1311)
Local/remote unload selector
selection switch
68-HS-1402 Unloading
Loading SOV SOV 68-XY-1403
Load 68-XY-1401 energizes
energizes Y
Local/remote Loading SOV 68-XY-1401 energizes
Selector switch in and unloading SOV 68-XY-1403 de-
LCP 68-HS-1403 energizes After 20 minutes
Local Compressor stops
Loading hour counter starts

Set pressure
PLC HMI N
<Actual
Remote Auto/ (Manual)
Pressure
Manual Loading
(68-PT-1406)
selection in HMI Unloading hour>Set
SOV 68-XY-1403 value
Loading SOV energizes
Auto DCS Y
68-XY-1401
c energizes Y
A B After 20 minutes Service change over-Running
Note A
Compressor stops compressor stop, reset the loading
hour counter and start the Motor available signal (68-XU-1428) from MCC
standby No emergency stop (68-HS-1401) active
B C
No ESD signal (68-XS-1424) active
Compressor O/L pressure high-high (68-PT-1406)
Compressor air I/L pressure low-low (68-PDT-1401)
Running hour counter starts
Compressor oil pressure low-low (68-PT-1402)
Disable control from UCP
Start signal activated Compressor oil filters DP high-high (68-PDT-1403)
and DCS
LP stage O/L temperature high-high (68-TT-1401)
Running hour Compressor oil temperature high-high (68-TT-1402)
Main motor, cooling fan motor and >24H LP stage I/L temperature high-high (68-TT-1403)
Start from LCP-68-
after cooler fan motor starts
HSOA-1414 Compressor O/L temperature high-high (68-TT-
Y 1405)
Auto change over-Running Overload relays of main motor, inter external after
20 sec load delay, Oil pressure trip cooler motors
Main motor, cooling fan compressor stop & reset the
(68-PT-1402) needs to be bypassed
motor and after cooler loading hour counter and start the Main motor winding temperatures high-high
up to this time
fan motor starts standby
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 208 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.4.4 Instrument Air Dryer start-up

The dryer package consists of two trains of dryers (6837-A-03 & 6837-A-04) which are
to be operated (2 X 50%) together and this repetitive operation is controlled from UCP
panel.

ON/OFF valve details in the dryer package are tabulated below:

Tag No.
Sl. # Service
6837-A-03 6837-A-04
1. 68-XV-1416 68-XV-1466 Purge on/off valve
2. 68-XV-1417 68-XV-1467 Purge on/off valve
3. 68-XV-1418 68-XV-1468 Air inlet on/off valve
4. 68-XV-1419 68-XV-1469 Air inlet on/off valve

Details of tags for Air dryers are tabulated below:

Tag No.
Sl. # Service
6837-A-03 6837-A-04
1. 68-HSOA-1408 68-HSOA-1458 Remote start Button
2. 68-HSCA-1409 68-HSOC-1459 Remote stop Button
3. 68-UA-1402 68-UA-1452 Dryer common alarm
4. 68-UA-1403 68-UA-1453 Dryer changeover failure alarm

5.4.5 Instrument Air Dryer Start-up Checks

1. Ensure the UCP for air dryers is powered up and ensure that all controls are in
place.
2. Close air supply towards the dew point analyzer AI-1401 & AI-1451 and by-pass its
alarm on both units 6837-A-03 & 6837-A-04.
3. Start the air compressor and wait for pressure to develop in the compressor
discharge drum.
4. Slowly open the pre-filters inlet manual isolation valve.
5. Check the connections of the air dryer for air leaks and repair if necessary.
5.4.6 Dryer Start

There are two Nos. Instrument Air Dryer Package (6837-A-03/04) consisting of heater-
less desiccant dryers of 2 X 50% capacity. Each Dryer Package consists of two vessels
(one drying, one regenerating), a set of duplex pre-filter and after-filter.

Unit start/stop of the package can be done either from UCP or from DCS. No local
mode of operation available for dryer package.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 209 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

At the initial start for the availability of the dryer, the position of valves is as follows:

68-XV-1418/68-XV-1468-open (tower - A in drying)

68-XV-1419/68-XV-1469-closed
68-XV-1416/68-XV-1466-Closed
68-XV-1417/68-XV-1467-open (tower - B in regeneration mode)
Also after opening the manual valves following are required to be checked to start the
dryer

Tower pressures 68-PT-1408/68-PT-1409


Tower pressures 68-PT-1458/68-PT-1459
Dryer available status has to be selected by the operator from HMI
All the alarm conditions for healthy status to be checked before start-up
Start the dryer by activating the following commands:

68-HSOA-1408 for Dryer-6837-A-03


68-HSOA-1458 for Dryer-6837-A-04
When drying is started, as a first step (step-0), ensure Adsorber-A (6837-V-14A) is
initialised into drying and Adsorber-B (6837-V-14B) is initialised into depressurizing for
5 seconds. Ensure the following valves condition:

68-XV-1418 & 68-XV-1417 are in OPEN condition


68-XV-1419 & 68-XV-1416 are in CLOSE condition
In step-1, ensure that Adsorber-A (6837-V-14A) is in the drying mode and Adsorber-B
(6837-V-14B) is being pressurised for 55 seconds. Ensure the following valves
condition:

68-XV-1418 & 68-XV-1419 are in OPEN Condition


68-XV-1417 & 68-XV-1416 are in CLOSE condition
Tower B will pressurize up to the running pressure (7.8 bar), after pressure is reached
both the towers will be operational for a brief period (5 seconds) together.

In step-2, ensure that Adsorber-A (6837-V-14A) is in the drying mode and Adsorber-B
(6837-V-14B) is in purge saving mode (this mode manually selected, when dew point is
more than -30C) until the dryer outlet dew point value is greater than the set point
for the dew point or for a maximum duration of 24 hours. Ensure the following valves
condition:

68-XV-1418 & 68-XV-1419 are in OPEN Condition


68-XV-1417 & 68-XV-1416 are in CLOSE condition
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 210 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

In step-3, ensure that Adsorber-A (6837-V-14A) is in the regenerating mode and


Adsorber-B (6837-V-14B) is in drying mode for 195 seconds. Ensure the following
valves condition:

68-XV-1419 & 68-XV-1416 are in OPEN condition


68-XV-1418 & 68-XV-1417 are in CLOSE Condition
In step-4, ensure that Adsorber-A (6837-V-14A) is in the pressurizing mode and
Adsorber-B (6837-V-14B) is in drying mode for 55 seconds. Ensure the following Valves
condition:

68-XV-1419 & 68-XV-1418 are in OPEN condition


68-XV-1417 & 68-XV-1416 are in CLOSE Condition
In step-5, ensure that Adsorber-A (6837-V-14A) is in the purge saving mode (this mode
Manually Selected, when dew point is more than -30C) and Adsorber-B (6837-V-14B) is
in drying mode until the dryer outlet dew point value is greater than the set point for
the dew point or for a maximum duration of 24 hours. Ensure the following Valves
condition:

68-XV-1419 is in OPEN condition


68-XV-1418,68-XV-1417 & 68-XV-1416 are in CLOSE Condition
In step-6, ensure that Adsorber-A (6837-V-14A) is in the drying mode and Adsorber-B
(6837-V-14B) is in regenerating mode for 195 seconds. Ensure the following valves
condition:

68-XV-1418 & 68-XV-1417 are in OPEN condition


68-XV-1419 & 68-XV-1416 are in CLOSE condition
Repeat the above test for TRAIN B (6837-V-15A & 6837-V-15B) dryers.

Steps 2 and 5 will be valid only when the purge saving is requested from UCP.

Following table shows the valve positions of Tower A, B with respect to the above
mentioned phase sequence.

Operational Valve Status


Sl. # Period
Phase Open Close
A: Drying
1. 5 sec XV-1418 XV-1417 XV-1416 XV-1419
B:Depressurising
A: Drying
2. 55 sec XV-1418 XV-1419 XV-1416 XV-1417
B: pressurising
A: Drying DEW>set
3. XV-1418 XV-1419 XV-1416 XV-1417
B:Purge saving Max-24 hrs
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 211 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Operational Valve Status


Sl. # Period
Phase Open Close
A: Regenerating
4. 195 sec XV-1419 XV-1416 XV-1417 XV-1418
B: Drying
A: Pressurising
5. 55 sec XV-1419 XV-1418 XV-1416 XV-1417
B: Drying
A: Purge saving DEW>set
6. XV-1419 XV-1418 XV-1416 XV-1417
B: Drying Max-24 hrs
A:Drying
7. 195 sec XV-1418 XV-1417 XV-1416 XV-1419
B:Regenerating

Note: In the above table only train-A dryer is considered.

5.5 NITROGEN SYSTEM

5.5.1 Lining up of Nitrogen from existing system to the New Distribution Header

Ensure that the following end user isolation valves are closed:

Nitrogen line to the Reaction Furnace 9101-F-01

Nitrogen line to the Antifoam Storage Tank 9103-T-12


Nitrogen line to the Reducing Gas Generator 9102-F-11
Nitrogen line to the Incinerator Package 9101-F-14
Utility stations in AGEU area

Nitrogen line to the Amine Sump 9103-V-10


Nitrogen line to the Amine Regenerator 9103-C-12
Nitrogen line to the Waste Water Degasser 6922-V-07
Nitrogen line to the Amine Surge Tank 9103-T-11
Nitrogen line to the Utility Station in Effluent & Waste Water Treatment area
Nitrogen line to Utility Station in TGTU area
Nitrogen line to the Steam Generation Package 6848-A-02A/B/C

Nitrogen line to the Utility station in Heating Medium system area


Nitrogen line to the Utility station in Fuel Gas area
Lining up of Nitrogen

Ensure that the vent and drain valves are closed in the header.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 212 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Open the 3 isolation valve 68-GV-1953 from the existing 6-GI-88-0357-C01A


Nitrogen header to the new distribution header slowly and pressurise the header
with Nitrogen.
Verify from the pressure gauge 68-PT-1309 that the pressure in the Nitrogen
header is increasing slowly.
After pressurising the main header, slowly open the isolation valves for the sub
headers 3-9138-IG-312-C12M, 3-6838-IG-126-C12M & 3-6838-IG-123-C12M to
process/utility area at battery limit and pressurise the lines.
Check that the headers are pressurised by checking the pressure gauges 68-PG-
1329/1331/1351.
Open the 2 isolation valves from the header for the utility stations of heating
medium system and the fuel gas system.
Open the end user isolation valves and purge the lines to remove oxygen content.
Check for any leak in the system.

5.6 DRINKING WATER SYSTEM

5.6.1 Lining up of Drinking Water to existing network

1. Ensure that the Drinking Water Storage Tank 6834-T-01A/B level is more than 50%.
3. Ensure that the isolation valve at the tie-in point (T-002) of the new and old
drinking water network is closed.
4. Ensure that the vent and drain valves near the tie-in point is closed.
5. Ensure that the new drinking water line to existing network is cleaned by flushing
and the leak test has been completed.
6. Open the Drinking Water isolation valves from the Tanks 6834-T-01A/B and slowly
fill up the new drinking water lines.
7. Prime the Drinking Water Pumps 6834-P-23A/B.
8. Start the Drinking Water Pump 6834-P-23A on minimum circulation.
9. Ensure that the line connecting the existing network is filled by opening the vent
and bleeding air near the tie-in point.
10. Check for any leaks in the line.
5.6.2 Lining up of Drinking Water to DMW Package

1. Ensure that the isolation valve at the inlet of the DMW Unit is closed.
2. Ensure that the drain valve upstream of the DMW Unit is closed.
3. Ensure that the new drinking water line to DMW Unit is cleaned by flushing and the
leak test has been completed.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 213 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4. Start the Drinking water pump 6834-P-23A and slowly open the discharge isolation
valve and fill the line connecting the DMW Unit by opening the drain line upstream
of the isolation valve.
5. Check for any leaks in the line.
6. After filling the line up to DMW Unit with Drinking water, it can be lined up to DMW
Unit whenever required.

5.7 EFFLUENT & WASTE WATER TREATMENT SYSTEM

5.7.1 Lining up of Waste Water Degasser 6922-V-07

1. Ensure that the Degasser and pipelines are flushed and cleaned and ready for
lining up.
2. Confirm that the drain and vent valves are closed.
3. Ensure that waste water from Tail Gas Treatment Unit is available and Cooling
Water Circulation Pumps 9102-P-12A/B are running.
4. Ensure that high high level alarm 69-LAHH-1311 and high high pressure 69-PAHH-
1311 of the Degasser is not active in the ICSS.
5. Reset ESD. Ensure that the waste water from Cooling Water Circulation Pumps
9102-P-12A/B inlet ON-OFF valve 69-XV-1312 is opened.
6. Ensure water level starts rising in the Degasser by monitoring 69-LT-1311 & 1301
and cross checked through 69-LG-1302.
7. Ensure that the low low level trip 69-LALL-1311 is cancelled after the level
reaches 300 mm and also ensure that the Waste Water Degasser Pumps 6922-P-
08A/B suction ON-OFF valve 69-XV-1316 is open.
8. Ensure that low level alarm 69-LAL-1301 is cancelled after the level reaches 450 mm.
9. Open the suction isolation valves of the Waste Water Degasser Pumps 6922-P-
08A/B.
10. Prime the Waste Water Degasser Pumps 6922-P-08A/B by opening the casing vents.
11. Energize Waste Water Degasser Pumps 6922-P-08A/B from MCC.
12. Put Waste Water Degasser Pumps 6922-P-08A/B LOR switch to Remote at Local
Control Station.
13. Select Waste Water Degasser Pump 6922-P-08A as DUTY and 6922-P-08B as
STANDBY from the ICSS.
14. Ensure the minimum flow recycle line 2 isolation valve is opened for the pump
6922-P-08A.
15. Start the DUTY pump 6922-P-08A from the ICSS.
16. Ensure that the pump is running without any abnormal noise and vibration.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 214 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.7.2 Lining up of Sour Water Stripper 6922-C-01

1. Slowly open the 2 discharge valve of the pump 6922-P-08A and line up sour water
to the Sour Water Filter 6922-S-06.
2. Ensure that the sour water from 6922-P-08A discharge to the observation sump 2
isolation valve is closed.
3. Slowly open the sour water filter 2 inlet isolation valve and fill the filter with the
sour water.
4. Open the 2 vent valve of the sour water filter and release air. Close the vent
isolation valve after filling the filter.
5. Slowly open the filter outlet 2 isolation valve and the Sour/Stripped Water
Exchanger 6922-E-01 tube side inlet 2 isolation valve.
6. Open the Sour/Stripped Water Exchanger 6922-E-01 tube side outlet 2 isolation
valve and the 69-FV-1314 upstream and downstream isolation valves.
7. Put 69-FV-1314 in manual and open the control valve slowly and allow the waste
water to flow through to the Sour Water Stripper.
8. Now put 69-LIC-1301 in auto mode with a set point of 50% and 69-FV-1314 in
remote mode.
9. Ensure that the level starts to build at the bottom of the Sour Water Stripper by
checking the level gauge 69-LG-1306.
10. Ensure low low level 69-LALL-1316 is cancelled in the Sour Water Stripper when
the level rises.
11. Ensure that the low level alarm 69-LAL-1306 is also cancelled as the level goes up.
12. Now open the 3 suction isolation valve of the Stripped Water Pumps 6922-P-10A/B
and prime the pumps.
13. Energize Stripped Water Pumps 6922-P-10A/B from MCC.
14. Put Stripped Water Pumps 6922-P-10A/B LOR switch to Remote at field control
panel.
15. Select Stripped Water Pumps 6922-P-10A as DUTY and 6922-P-10B as STANDBY
from the ICSS.
16. Ensure the minimum flow recycle line 2 isolation valve is opened for the pump
6922-P-10A.
17. Start the DUTY pump 6922-P-10A from the ICSS.
18. Ensure that the pump rated discharge pressure 8.6 bara is reached by checking the
discharge pressure gauge 69-PG-1322.
19. Open the Sour/Stripped Water Exchanger 6922-E-01 shell inlet and outlet 2
isolation valves.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 215 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

20. Open the Stripped Water Cooler 6922-E-02 inlet and outlet 2 isolation valves.
21. Start the Stripped Water Cooler fan motors 6922-EM-02 AA/6922-EM-02 AB.
22. Line up 69-FV-1317 upstream and downstream isolation valves.
23. Slowly open 69-FV-1317 manually and line up the stripped water to the
Observation & Buffer Sump 6922-X-04.
24. Line up the analyser 69-AT-1302 in the stripped water line.
5.7.3 Lining up of Stripper Overhead Circulation Pump 6922-P-11A/B

1. Line up start-up water through 69-LV-1325.


2. Prime the Stripper Overhead Circulation Pump 6922-P-11A/B.
3. Select the Pump 6922-P-11A as DUTY and 6922-P-11B as STANDBY from ICSS.
4. Start the Stripper Overhead Circulation Pump 6922-P-11A.
5. Take level controller 69-LIC-1325 in AUTO with a set point of 50% and ensure the
control valve 69-LV-1325 is controlling the level at 50%.
6. Take flow control valve 69-FV-1316 in AUTO with a set point 13.2 m3/hr.
7. Open the inlet and outlet isolation valves of the Stripper Overheads Cooler 6922-E-03.
8. Start Stripper Overheads Cooler 6922-E-03AA/6922-E-03AB fans.
9. Take 69-TIC-1315 in AUTO with a set point of 55C.
5.7.4 Lining up of Sour Water Stripper overhead Sour Gas

1. Ensure that 69-PV-1315A upstream and downstream isolation valves are closed.
2. Reset ESD and ensure that the ON-OFF valve 69-XV-1313 is open.
3. Ensure that the upstream and downstream isolation valves of 69-PSV-1303A are
lock open and the bypass valve is closed.
4. Ensure that the upstream isolation valves of 69-PSV-1303B are lock closed and the
downstream isolation valves are open.
5. Take 69-PIC-1315 in manual and close 69-PV-1315A fully.
6. Ensure that 69-PV-1315B upstream and downstream isolation valves are open and
close 69-PV-1615 fully.
7. Now put 69-PIC-1315 in Auto with a set point of 1.0 barg and take 69-PV-1315A/B
in Remote.
5.7.5 Pressurising Waste Water Degasser 6922-V-07 with Nitrogen

1. Ensure that the Nitrogen inlet shut down valve 69-XV-1315 is opened after
resetting the ESD.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 216 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

2. Close 69-PV-1307 fully on manual. Open the 69-PV-1307 upstream and downstream
isolation valves.
3. Slowly open 69-PV-1307 in manual till the pressure in the Degasser and Stripper
reaches 1.0 barg and indicated by 69-PT-1307/1311/1315. Now put the controller
69-PIC-1307 in auto with a set point of 1.0 barg.
4. Take 69-PIC-1315 in AUTO. Since the isolation valves of 69-PV-1315A are closed,
ensure that 69-PV-1315B opens when the pressure goes above 1.0 barg.
Line up 69-PV-1315A upstream and downstream isolation valves and line up sour
gas to TGTU.
5.7.6 Lining up of Sour Water Stripper Reboiler

1. Ensure that Sour Water Stripper Reboiler 6922-E-04 shell side is filled with sour
water by checking 69-LT-1317/69-LG-1307.
2. Ensure that the 2 isolation valves of the Steam line from the Reboiler Steam inlet
to the Reboiler vapour outlet line 2-6848-LS-138-C12W-HC are closed.
3. Put steam inlet control valve 69-FV-1315 in manual and close it fully.
4. Ensure that after resetting ESD, steam inlet line ON/OFF valve 69-XV-1314 is open.
5. Open the 2 vent valve in the steam inlet line to the reboiler and the condensate
outlet line from the reboiler.
6. Open the vents and drains in the Reboiler Condensate Drum 6922-V-09.
7. Open the 69-LV-1327 upstream drain and close the bypass valve.
8. Ensure that the steam inlet line is warmed up upstream of the 8 isolation valve
68-GV-1928 and steam is charged.
9. Open the 2 bypass valves of the flow control valve 69-FV-1315.
10. Open the steam inlet 2 warm up valve upstream of 68-XV-1314 slowly and admit
steam into the Reboiler.
11. The Reboiler and the Reboiler Condensate Drum are warmed up by the steam and
the condensed steam starts to come out of the drains and vents.
12. When full flow of steam comes out of the drains and vents, close all the vents and
drains.
13. Close the 2 steam inlet warm up bypass valve and open the steam inlet 8 main
isolation valve slowly.
14. Open 69-FV-1315 manually by 10%.
15. Close the bypass valves of the 69-FV-1315.
16. Ensure the temperature of the vapour line from the Reboiler increases as the
steam flow is increased.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 217 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

17. When the temperature of the vapour line measured by 69-TT-1314 is increased to
120C, put the steam flow controller 69-FIC-1315 in ratio control with the sour
water flow 69-FIC-1314.
18. Line up Boiler Feed Water to the Desuperheater 6922-X-01. Take the temperature
controller 69-TIC-1327 in AUTO with a set point of 148C.
19. Ensure that the condensate level starts to increase in the Reboiler Condensate
Drum 6922-V-09 through 69-LG-1308/69-LT-1327.
20. Ensure that the low level alarm 69-LAL-1327 (set at 400 mm) is cancelled when the
level is rising in the Reboiler Condensate Drum 6922-V-09.
21. When the level in the drum reaches 50%, line up the level control valve 69-LV-
1327, put it on AUTO with a set point of 50%.
5.8 FLARE SYSTEM

Reference: P&ID No. 2970-6-51-0033

5.8.1 Start-up of LP Flare System

1. Ensure that the isolation valve 62-BV-2211 is closed near the tie-in point T-18.
2. Ensure that the following new LP Flare lines are purged with Nitrogen and are
under Nitrogen pressure:
10-6236-FL-033-D14M from 62-PSV-176/176S

8-6848-FL-036-C12P from Steam Generation Package 6848-A-02A/B/C


2-6236-FL-053-D14M from 62-PV-1301A/B vents

6-6236-FL-052-D14M from 62-PV-1303

2-6236-BD-005-C14P-HI from LP Fuel Gas KO Drum 6236-V-05


3. Ensure that the vent and drain valves in the new flare header is closed.
4. Ensure that the spectacle blind in the new LP Flare header 10-6236-FL-033-D14M
connecting with the existing header at tie-in point T-18 is in open position.
5. Slowly open the 10 isolation valve in the new LP Flare header 10-6236-FL-033-
D14M connecting with the existing header at tie-in point T-18.
6. Line up 62-PV-1303 upstream and downstream isolation valves to LP Flare as
shown in P&ID.
7. Line up 62-PSV-176/176S upstream and downstream isolation valves from LP Fuel
Gas KO Drum 6236-V-05 to LP Flare header as per requirement.
8. Line up Steam Generation Package 6848-A-02A/B/C relief header 8-6848-FL-036-
C12P to LP Flare header as per requirement.
9. Line up the vent lines 2-6236-FL-053-D14M from 62-PV-1301A/B to the new LP
flare header as per requirement.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 218 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

10. Line up the drain line 2-6236-BD-005-C14P from new LP Fuel Gas KOD 6236-V-05
to the new LP flare header as per requirement.
11. Line up the drains and vents from the fuel gas system to LP Flare whenever
required by reversing the spectacle blind to open position and opening the drain/
vent valve as per requirement.
5.8.2 LP ACID GAS FLARE SYSTEM

Reference: P&ID No. 2970-6-50-0039

Start-up of LP Acid Gas Flare System

1. Ensure that the LP Flare header isolation valve is closed near the tie-in point T-69.
2. Ensure that the following new LP Acid Gas Flare lines are purged with Nitrogen
and are under Nitrogen pressure:
a. 2-6236-FG-131-C12P purge fuel gas line to the Acid Gas Flare header

b. 20-9103-AG-104-C14P from AGRU 1 & 2

c. 6-6922-AL-064-C14P from 69-PSV-1303A/1303B

d. 2-6922-AL-065-C14P from Sour Water Stripper 6922-C-01

e. 16-9103-AL-117-C14P from Regenerator Reflux Drum 9103-V-12

f. 2-9102-AG-116-A1C1 from sulphiding line of Hydrogenation Reactor 9102-V-11

g. 6-9103-AL-110-C14P from Regenerator Reflux Drum 9103-V-12 PSV-1505/1506

h. 6-9103-AL-101-C14P from Lean Acid Gas KO Drum 9103-V-14

i. 6-9103-AL-104-C14P from Acid Gas Amine Absorber 9103-C-11 PSV-1503/1504

j. 14-9101-AL-565-C14P from Acid Gas Pre-heater 9101-E-06 PSV-1071A/B

k. 2-9136-FG-056-C12P from Incinerator Fuel Gas Skid 9101-E-06

l. 12-9103-AL-107-C14P from Regenerator 9103-C-12 PSV-1508/1509

m. 6-9102-AL-102-C14P from Desuperheater/Contact Condenser 9102-C-11


PSV-1303/1304.

n. 8-9102-AL-110-C14P from Tail Gas Amine Absorber 9102-C-12 PSV-1334/1346

o. 2-9136-FG-202-C12P from Fuel Gas distribution

p. 20-9103-AL-113-C14P Acid Gas flare header

3. Slowly open the 20 isolation valve in the new LP Flare header 20-9103-AL-113-
C14P connecting with the existing header at tie-in point T-069.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 219 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4. Reverse the 2-6236-FG-131-C12P purge fuel gas line spectacle blind to open
position. Line up purge fuel gas to the Acid Gas Flare header as per requirement.
5. Line up AGRU 1 & 2, 20-9103-AG-104-C14P to Acid Gas flare as per requirement.
6. Line up 69-PSV-1303A/1303B from the Sour Water Stripper 6922-C-01 to the new
LP Acid Gas flare header as per requirement.
7. Line up 2-6922-AL-065-C14P from Sour Water Stripper 6922-C-01 69-PV-1315B to
the new LP Acid Gas flare header as per requirement.
8. Line up 16-9103-AL-117-C14P from Regenerator Reflux Drum 9103-V-12 to the
new LP Acid Gas flare header as per requirement.
9. Line up PSV-1505/1506 from Regenerator Reflux Drum 9103-V-12 to the new LP
Acid Gas flare header as per requirement.
10. Line up 6-9103-AL-101-C14P from Lean Acid Gas KO Drum 9103-V-14 to the new
LP Acid Gas flare header as per requirement.
11. Line up 91-PSV-1503/1504 from Acid Gas Amine Absorber 9103-C-11 to the new LP
Acid Gas flare header as per requirement.
12. Line up 91-PSV-1071A/B from Acid Gas Pre-heater 9101-E-06 to the new LP Acid
Gas flare header as per requirement.
13. Line up 2-9136-FG-056-C12P from Incinerator Fuel Gas skid 9101-E-06 to the new
LP Acid Gas flare header as per requirement.
14. Line up 91-PSV-1508/1509 from Regenerator 9103-C-12 to the new LP Acid Gas
flare header as per requirement.
15. Line up 91-PSV-1303/1304 from Desuperheater/Contact Condenser 9102-C-11 to
the new LP Acid Gas flare header as per requirement.
16. Line up 91-PSV-1334/1346 from Tail Gas Amine Absorber 9102-C-12 to the new LP
Acid Gas flare header as per requirement.
17. Line up 2-9136-FG-202-C12P from fuel gas distribution to the new LP Acid Gas
flare header as per requirement.
18. Line up 20-9103-AL-113-C14P Acid Gas flare header to the new LP Acid Gas flare
header as per requirement.
5.9 FUEL GAS SYSTEM

5.9.1 Line-up Fuel Gas from the Existing 1st Stage Booster Compressor 6701-K-10/
20/30 in NGL-3

1. Ensure that the fuel gas inlet isolation valves to the new Steam Boiler Package
6848-A-02A/B/C are in closed position and the lines are under Nitrogen pressure of
0.5 barg.
2. Ensure LP Fuel Gas KO Drum 6236-V-05 drain line isolation valve is closed.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 220 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3. Ensure Booster Compressor 6701-K-10/20/30 in NGL-3 is running.


4. Ensure 62-PV-1301A/B & 62-PV-1302 control valves are closed manually and the
upstream and downstream isolation valves are closed.
5. Ensure 62-XV-1301 in the fuel gas supply line from Booster Compressor 6701-K-10/
20/30 is open and the upstream isolation valve is closed.
6. Ensure 62-XV-1302 in the back-up supply fuel gas from 6103-K-01 A/B is open and
the upstream isolation valve is closed.
7. Ensure 62-XV-1303 in the back-up supply fuel gas from 30 existing line is open
and the upstream isolation valve is closed.
8. Ensure 62-PV-1303 is closed in auto with a set point of 7.8 barg and its upstream
and downstream isolation valves are open.
9. Ensure 62-PSV-176 inlet and outlet isolation valves are open and the bypass is
closed.
10. Ensure 62-PSV-176S inlet isolation valve is closed and outlet isolation valve is
open.
11. Ensure that the spectacle blind on fuel gas supply line from Booster Compressor
6701-K-10/20/30 is in open position.
12. Open the 6 isolation valve slowly from the Booster Compressor 6701-K-10/20/30
and pressurise the line up to 62-XV-1301 upstream isolation valve.
13. Open 62-XV-1301 upstream isolation valve slowly and gradually pressurise the line
up to 62-PV-1301A upstream isolation valve.
14. Open 62-PV-1301A bypass 3 isolation valves slowly and pressurise the fuel gas KO
Drum 6236-V-05 gradually up to 7.0 barg.
15. Close the 62-PV-1301A bypass 3 isolation valves.
16. Open the 62-PV-1301A downstream isolation valve.
17. Put 62-PIC-1301 in auto with a set point of 7.0 barg.
18. Open 62-PV-1303 upstream and downstream isolation valves.
19. Open the upstream and downstream isolation valves of 62-PV-1301B/1302.
5.10 SEA COOLING WATER SYSTEM

The start-up procedure for the Sea Cooling Water Pumps 6932-P-04A/B is given below:

5.10.1 Pre-start up checks

Before starting the pump the following checks should be made

1. Rotate the pump shaft by hand to make sure that the pump rotates freely and the
impellers are correctly positioned
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 221 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

2. The electric motor is properly lubricated


3. Direction of Rotation of the motor is checked and marked
4. Ensure all the piping connections are tight
5. Check for foundation bolts tightness
6. Check all bolting connections for tightness (coupling bolts, mechanical seal gland
bolts, driver bolts)
7. Ensure the coupling guard is in place
5.10.2 Initial Starting and Lining Up of Sea Cooling Water

1. Open the Sea Cooling Water Pump 6932-P-04A discharge MOV 69-MOV-1301 by 10%
2. Start pre-lubrication liquid flow for the pump
3. Start the pump and open the discharge MOV 69-MOV-1301 immediately within 30
seconds
4. Observe the operation of the pump for any abnormal noise and vibration.
5. Measure the pump shaft vibration and lube oil temperature at regular intervals.
6. Line up sea cooling water to the header.
7. Start Biocide Injection and Scale Inhibitor Injection as per section 5.12.3 and
5.12.4 and start injection of the chemicals.
8. Line up sea cooling water to the following heat exchangers one by one by opening
the high point vents and releasing air.
Lean Amine Trim Cooler 9103-E-15

Regenerator Condenser Trim Cooler 9103-E-16


Contact Condenser Trim Cooler 9102-E-13A/B
Acid Gas Cooler 9103-E-101A/B
5.11 ELECTRO CHLORINATION PACKAGE START-UP

Control of the package is via Allen Bradley compact logix PLC located in the control
panel which also contains an HMI which provides facility for the operator to input
selections of duty and stand-by equipments and adjustments of system parameters in
addition to providing system of status, indications and alarms.

Both automatic and manual operation of the package is possible, but manual operation
is recommended only for maintenance purpose.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 222 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Electro chlorination package switch details are listed below:

Sl. # Tag No. Service


1. 69-HSR-1480L Local selector switch
2. 69-HSR-1480R Remote selector switch
3. 69-HSOA-1451 Package start command from DCS
4. 69-HSCA-1451 Package stop command from DCS
5. 69-HS-1451 Package trip from UCP
6. 69-HS-1452 Package trip from field
7. 69-HS-1453 Package trip from field
8. 69-HSR-1470 Manual selected at transformer rectifier
9. 69-HSOA-1470 Transformer unit start
10. 69-HSCA-1470 Transformer unit stop

Control valve and ON-OFF valve details are tabulated below:

Sl. # Tag No. Description


1. 69-XV-1451 Auto back wash filter 69-S-03A valve
2. 69-XV-1454 Auto back wash filter 69-S-03B valve
3. 69-XV-1452 Auto back wash filter drain valve
4. 69-XV-1455 Auto back wash filter drain valve
5. 69-XV-1456 Auto back wash filter 69-S-03A discharge valve
6. 69-XV-1456 Auto back wash filter 69-S-03B discharge valve
7. 69-XV-1457 Electrolyser A inlet valve
8. 69-XV-1458 Electrolyser B inlet valve

5.11.1 Normal start-up of Electro Chlorination Plant:

Before starting the package, ensure the following emergency shutdown causes are
normal/healthy:

Sl. # Tag No. Description


1 69-HS-1451 Emergency stop in UCP
2 69-HS-1452 Emergency stop in ECP skid
3 69-HS-1453 Emergency stop in ECP skid
4 69-XS-1336 Sea cooling water pump (6932-P-04A/B) trip
5 66-GF-02-1801 Hydrogen gas high-high alarm
6 66-GF-02-1801 Hydrogen gas high-high alarm
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 223 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

1. Open the Electro chlorination I/L PCV 69-PCV-1463 upstream and downstream
isolation valves.
2. Open Auto Backwash Filters 6932-S-03A/B inlet and outlet isolation valves.
3. Open Electrolyser 6932-G-01A/B inlet and outlet isolation valves.
4. Open Hydrogen Dilution Blowers 6932-K-01A/B discharge isolation valves.
5. Ensure that Sea Cooling Water Pumps 6932-P-04A/B is started and running.
6. Open Auto Backwash Filter inlet PCV 69-PCV-1463, manually and slowly fill up the
Sea Water Filter 6932-S-03A. Put 69-PCV-1463 in auto with a set point of 3.5 barg.
7. Select LOCAL for the unit start-up from UCP.
8. Select Auto Backwash Filter 6932-S-03A as duty Filter from UCP.
9. Select Electrolyser Stream 6932-G-01A as duty form UCP.
10. Select Dilution Blower 6932-K-01A as duty blower from UCP.
11. Select Dosing Pump 6932-P-05A as duty pump from UCP.
12. Press start from UCP.
13. Ensure that system status indication changes to starting. Ensure that Start lamp
is flashing.
14. Ensure Auto Backwash Filter outlet XV, XV-1453 opens and sea water flow is
established through the filters.
15. Ensure that the duty dilution blower 6932-K-01A is started.
16. After a 30 second delay, Ensure that the Electrolyser inlet XV, XV-1457 is opened
and sea water flows through the Electrolyser.
17. Ensure that the Transformer/Rectifier 6932-TA-08A is energised after confirming the
flow through the Electrolyser with the help of Magnetic flow meter 69-FT-1451.
18. Ensure that the system running indication is illuminated.
19. Ensure that the Sodium Hypochlorite generated is sent to the Degassing Tank
6932-T-02.
20. Ensure that the level in Degassing Tank 6932-T-02 starts rising.
21. Fill the Dosing Pump 6932-P-05A by opening the suction isolation valve and
releasing air through the casing vent valve.
22. Ensure that the Dosing Pump 6932-P-05A starts after the level reaches the low
alarm level of 924 mm measured by 69-LT-1452.
23. Ensure that Sodium Hypochlorite is continuously dosed at a rate of 7 m3/hr and
1.25 ppm concentration to the Sea Cooling Water by dosing pumps (6932-P-
05A/05B).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 224 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

24. Ensure that Sodium Hypochlorite is shock dosed at a rate of 11 m3/hr and 6 ppm
concentration for 15 minutes in every 6 hours by dosing pumps (6932-P-05A/05B).
25. Ensure that the following indications are healthy
a. Autoback wash Filter Outlet Pressure Status Healthy

b. Autoback wash Filter 6932-S-03A/B Status Healthy

c. Electrolyser 6932-G-01A/B inlet flow healthy

d. Electrolyser Inlet Temperature Healthy

e. Hydrogen Blower Outlet Pressure Status Healthy

f. Transformer/Rectifier 6932-RC-101A/B Healthy.

26. Ensure that the time for START-UP is 5 minutes.


Manual start-up of electro chlorination package:

1. Manual operation is provided for maintenance and commissioning purposes only.


2. Select the Auto/Manual switch to manual mode in UCP HMI for manual start of
ECP.
3. Following manual controls are available:
Manual operation of each actuated on/off valve (69-XV-1457/69-XV-1458), (69-
XV-1453/69-XV-1456), (69-XV-1452/69-XV-1455) via a manual override facility,
mounted on the valve
Flow control valve (69-FV-1453) which regulates the flow of sodium
hypochlorite dosing to sea water can be operated by flow controller in UCP
manually
Dilution blowers, dosing pumps and transformer rectifiers can be operated
manually by selecting local mode at RCU in the field
Manual operation of each Transformer/Rectifier (6932-RC-101A/6932-RC-101B)
can be done via local start/stop push buttons (69-HSOA-1470/69-HSCA-1470), by
selecting manual button (69-HSR-1470) mounted on the front panel of each T/R.
5.12 CHEMICAL INJECTION SYSTEM

5.12.1 Complex Product Injection Package (6834-A-09)

Fill the Complex Product Tank, 68-T-18 with Complex Product Chemical.

WARNING: REVIEW THE COMPLEX PRODUCT MSDS AND ENSURE THAT


APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING THE
CHEMICAL.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 225 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

1. Ensure that the Complex Product Inhibitor Tank, 68-T-18 is clean and dry for
charging chemicals.
2. Line up the Complex Product Unloading Pump (6834-P-42) (Pneumatic driven) with
chemical Tote Tank through the pump suction line and open isolation valve on the
suction line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Complex Product Unloading
Pump (6834-P-42) and start filling the tank. Check all connections and confirm that
there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level, 68-LALL-1316 and the low-level alarm, 68-LAL-1317 are reset at their
respective set point.
7. Fill the tank up to its maximum operating level, stop the chemical unloading pump
(6834-P-42) by closing the plant air isolation valve and close the isolation valve on
the fill line. Close the isolation valve on the pump suction line.
8. Open the Complex Product Injection Pump, 68-P-41A/B manual suction valve and
fill the pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Complex Product Injection Pump, 68-P-41A/B to 10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.12.2 Oxygen Scavenger Injection Package (6834-A-09)

Fill the Oxygen Scavenger Storage Tank, 6834-T-17 with Oxygen Scavenger Chemical.

WARNING: REVIEW THE OXYGEN SCAVENGER MSDS AND ENSURE


THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE
HANDLING THE CHEMICAL.

1. Ensure that the Oxygen Scavenger Storage Tank, 6834-T-17 is clean and dry for
charging chemicals.
2. Line up the Oxygen Scavenger Unloading Pump (6834-P-40) (Pneumatic driven) with
chemical Tote Tank through the pump suction line and open isolation valve on the
suction line.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 226 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Oxygen Scavenger Transfer
Pump (6834-P-40) and start filling the tank. Check all connections and confirm that
there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 68-LALL-1314 and the low-level alarm, 68-LAL-1315 are reset at their
respective set point.
7. Fill the tank up to its maximum operating level, stop the chemical unloading pump
(6834-P-42) by closing the plant air isolation valve and close the isolation valve on
the fill line. Close the isolation valve on the pump suction line.
8. Open the Oxygen Scavenger Injection Pump, 68-P-39A/B manual suction valve and
fill the pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Oxygen Scavenger Injection Pump, 68-P-39A/B to
10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.12.3 Biocide Injection Package (6932-A-06)

Filling the Biocide Tank, 6932-T-04 with Biocide Chemical

WARNING: REVIEW THE BIOCIDE MSDS AND ENSURE THAT


APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING
ANY CHEMICAL.

1. Ensure that the Biocide Tank, 6932-T-04 is clean and dry for charging chemicals.
2. Line up the Biocide Unloading Pump (6932-P-08) (Pneumatic driven) with chemical
Tote Tank through the pump suction line and open isolation valve on the suction
line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Biocide Unloading Pump
(6932-P-08) by opening the plant air isolation valve to the pump and start filling
the tank. Check all connections and confirm that there is no leakage.
5. Line up instruments for operation.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 227 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 69-LALL-1329 and the low-level alarm, 69-LAL-1328 are reset at their
respective set point.
7. Fill the tank up to its maximum operating level, stop the Biocide Unloading Pump
(6932-P-08) by closing the plant air isolation valve and close the isolation valve on
the fill line. Close the isolation valve on the pump suction line.
8. Open the Biocide Injection Pump, 6932-P-07A/B manual suction valves and fill the
pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Biocide Injection Pump, 6932-P-07A/B to 10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.12.4 Scale Inhibitor Injection Package (6932-A-07)

Filling the Scale Inhibitor Tank 6932-T-05 with Scale Inhibitor Chemical

WARNING: REVIEW THE SCALE INHIBITOR MSDS AND ENSURE THAT


APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY
CHEMICAL.

1. Ensure that the Scale Inhibitor Tank, 6932-T-05 is clean and dry for charging
chemicals.
2. Line up the Scale Inhibitor Unloading Pump (6932-P-10) (Pneumatic driven) with
chemical Tote Tank through the pump suction line and open isolation valve on the
suction line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Scale Inhibitor Transfer
Pump (6932-P-10) by opening the plant air isolation valve to the pump and start
filling the tank. Check all connections and confirm that there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 69-LALL-1331 and the low-level alarm, 69-LAL-1330 are reset at their
respective set points.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 228 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

7. Fill the tank up to its maximum operating level, stop the Scale Inhibitor Unloading
Pump (6932-P-10) by closing the plant air isolation valve and close the isolation
valve on the fill line. Close the isolation valve on the pump suction line.
8. Open the Scale Inhibitor Injection Pump, 6932-P-09A/B manual suction valves and
fill the pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Scale Inhibitor Injection Pump, 6932-P-09A/B to 10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.12.5 Catalyst Injection Package (9101-A-01)

Filling the Catalyst Tank 9101-T-09 with Aquisulf Catalyst Chemical

WARNING: REVIEW THE CATALYST MSDS AND ENSURE THAT


APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY
CHEMICAL.

1. Ensure that the Catalyst Tank, 9101-T-01 is clean and dry for charging chemicals.
2. Line up the Catalyst Unloading Pump (9101-P-12) (Pneumatic driven) with chemical
Tote Tank through the pump suction line and open isolation valve on the suction
line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Catalyst Unloading Pump
(9101-P-12) by opening the plant air isolation valve to the pump and start filling
the tank. Check all connections and confirm that there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 91-LALL-1128 and the low-level alarm, 91-LAL-1127 are reset at their
respective set points.
7. Fill the tank up to its maximum operating level, stop the chemical transfer pump
(9101-P-12) by closing the plant air isolation valve and close the isolation valve on
the fill line. Close the isolation valve on the pump suction line.
8. Open the Catalyst Injection Pump, 9101-P-11A/B suction isolation valves and fill
the pumps.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 229 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Catalyst Injection Pump, 9101-P-11A/B to 10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.12.6 Antifoam Injection Package (9103-A-11)

Fill the Antifoam Tank, 9103-T-12 with Antifoam Chemical

WARNING: REVIEW THE ANTIFOAM MSDS AND ENSURE THAT


APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY
CHEMICAL.

1. Ensure that the Antifoam Tank, 9103-T-12 is clean and dry for charging chemicals.
2. Line up the Antifoam Unloading Pump (9103-P-19) (Pneumatic driven) with
chemical Tote Tank through the pump suction line and open isolation valve on the
suction line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Antifoam Unloading Pump
(9103-P-19) by opening the plant air isolation valve to the pump and start filling
the tank. Check all connections and confirm that there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 91-LALL-1520 and the low-level alarm, 91-LAL-1521 are reset at their
respective set points.
7. Fill the tank up to its maximum operating level, stop the Antifoam Unloading Pump
(9103-P-19) by closing the plant air isolation valve and close the isolation valve on
the fill line. Close the isolation valve on the pump suction line.
8. Open the Antifoam Injection Pump, 9103-P-16A/B suction valves and fill the
pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Antifoam Injection Pump, 9103-P-16A/B to 10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 230 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.12.7 Corrosion Inhibitor Injection Package (9103-A-12)

Filling the Corrosion Inhibitor Tank, 9103-T-13 with Corrosion Inhibitor Chemical.

WARNING: REVIEW THE CORROSION INHIBITOR MSDS AND ENSURE


THAT APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE
HANDLING ANY CHEMICAL.

1. Ensure that the Corrosion Inhibitor Tank, 9103-T-13 is clean and dry for charging
chemicals.
2. Line up the Corrosion Inhibitor Unloading Pump (9103-P-102) (Pneumatic driven)
with chemical Tote Tank through the pump suction line and open isolation valve on
the suction line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Corrosion Inhibitor Unloading
Pump (9103-P-102) by opening the plant air isolation valve to the pump and start
filling the tank. Check all connections and confirm that there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 91-LALL-1522 and the low-level alarm, 91-LAL-1523 are reset at their
respective set points.
7. Fill the tank up to its maximum operating level, stop the Corrosion Inhibitor
Unloading Pump (9103-P-102) by closing the plant air isolation valve and close the
isolation valve on the fill line. Close the isolation valve on the pump suction line.
8. Open the Corrosion Inhibitor Injection Pump, 9103-P-101A/B suction valves and fill
the pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Corrosion Inhibitor Injection Pump, 9103-P-101A/B to
10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 231 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.12.8 Caustic Injection Package (9103-A-13)

Filling the Caustic Storage Tank, 9103-T-14 with Caustic

WARNING: REVIEW THE CAUSTIC MSDS AND ENSURE THAT


APPROPRIATE SAFETY MEASURES ARE TAKEN BEFORE HANDLING ANY
CHEMICAL.

1. Ensure that the Caustic Storage Tank, 9103-T-14 is clean and dry for charging
chemicals.
2. Line up the Caustic Unloading Pump (9103-P-104) (Pneumatic driven) with chemical
Tote Tank through the pump suction line and open isolation valve on the suction
line.
3. Check plant air pressure and line up air to the unloading pump.
4. Open the isolation valve on the tank fill line and start Caustic Unloading Pump
(9103-P-104) by opening the plant air isolation valve to the pump and start filling
the tank. Check all connections and confirm that there is no leakage.
5. Vent the instruments and line up for operation.
6. Monitor the level from the ICSS as the level increases. Ensure that the low low
level trip, 91-LALL-1524 and the low-level alarm, 91-LAL-1525 are reset at their
respective set points.
7. Fill the tank up to its maximum operating level, stop the Caustic Unloading Pump
(9103-P-104) by closing the plant air isolation valve and close the isolation valve on
the fill line. Close the isolation valve on the pump suction line.
8. Open the Caustic Injection Pump, 9103-P-103A/B manual suction valves and fill the
pumps.
9. Open pump discharge valve and close valve at injection point and upstream drain
valve.
10. Set the stroke adjuster of the Caustic Injection Pump, 9103-P-103A/B to 10%.
11. Start the pump and check for flow at the injection point drain valve. Then stop the
pump.
12. The system is now ready for start-up. The manual stroke is later adjusted to the
desired injection rate based on the actual chemical requirement at the injection
points.
5.13 DEMINERALIZED WATER SYSTEM

5.13.1 Demineralized Water Unit Start-up

Demineralized Water Unit (2 trains) is designed for automatic operation via unit
control panel which contains Siemens S7-400 PLC. All the alarms, indications and
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 232 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

status signals generated within the package are transmitted from package UCP to DCS
through serial link (modbus through TCP/IP).

The list of switches used in the operation of DM water package is tabulated below:

Tag No.
Sl. # Service
Train-A Train-B
1. 68-HS-1840 A 68-HS-1840 B Auto/Man/Off selector-Auto
2. 68-HS-1841 A 68-HS-1841 B Auto/Man/Off selector-Manual
3. 68-HS-1843 A 68-HS-1843 B Auto/Man/Off selector-off
4. 68-HS-1842 A 68-HS-1842 B Step advance push button
5. 68-HSOA-1845 A 68-HSOA-1845B Remote start from DCS
6. 68-HSCA-1845 A 68-HSCA-1845B Remote stop from DCS

The list of ON/OFF valves is tabulated below:

Tag No.
Sl. # Service
Train-A Train-B
1. 68-XV-1825 68-XV-1840 Cation Exchanger Inlet
2. 68- XV-1831 68-XV-1846 Cation Exchanger outlet
3. 68-XV-1833 68-XV-1848 Anion Exchanger inlet
4. 68-XV-1838 68-XV-1852 Anion Exchanger outlet
5. 68- XV-1856 68-XV-1855 DM Water common header inlet
6. 68-XV-1832 68-XV-1847 AE-1825 pH Analyzer inlet
7. 68-XV-1839 68-XV-1853 AE-1826 Conductivity Analyzer inlet
8. 68-XV-1830 68-XV-1844 HCL drain to pit
9. 68-XV-1837 68-XV-1851 NaOH drain to pit
10. 68-XV-1828 68-XV-1843 DM+HCL inlet to cationic exchanger
DM+ NaOH inlet to anionic
11. 68-XV-1835 68-XV-1854
exchanger
Regeneration inlet to cationic
12. 68-XV-1829 68-XV-1845
exchanger
Regeneration inlet to anionic
13. 68-XV-1836 68-XV-1850
exchanger
14. 68-XV-1826 68-XV-1841 Recycle water to cation exchanger
Cation exchanger to neutralization
15. 68-XV-1827 68-XV-1842
pit
Anion exchanger to neutralization
16. 68-XV-1834 68-XV-1849
pit
17. 68-XV-1857 Neutralization pump discharge
18. 68-XV-1858 Neutralization pump recycle
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 233 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The list of Pumps is tabulated below:

Tag No.
Sl. # Service
Train-A Train-B
1. 6834-P-37A 6834-P-37B Recycling pump
2. 6834-P-34A/B/C NaOH dosing pump
3. 6834-P-35A/B/C HCL dosing pump
4. 6834-P-36A/B Regeneration pump
5. 6834-P-38A/B Neutralization pump

The operational status of the package is indicated by the following signals:

Tag No.
Sl. # Service
Train-A Train-B
1. 68-XL-1840A 68-XL-1840B Package working in auto mode
2. 68-XL-1841A 68-XL-1841B Package working in manual mode
3. 68-XL-1843A 68-XL-1843B Package is in offline
4. 68-XL-1850A 68-XL-1850B service phase
5. 68-XL-1851A 68-XL-1851B waiting regeneration phase
Acid regeneration/caustic
6. 68-XL-1852A 68-XL-1852B
regeneration
7. 68-XL-1853A 68-XL-1853B Acid slow rinse/caustic slow rinse
8. 68-XL-1854A 68-XL-1854B caustic slow rinse
9. 68-XL-1855A 68-XL-1855B Final rinse with recirculation
10. 68-XL-1856A 68-XL-1856B Waiting ready phase
11. 68-XL-1857A 68-XL-1857B Pre-service phase
12. 68-UA-1844 Irregular valves/pumps position
13. 68-XL-1858 Neutralization
14. 68-XL-1859 Effluent discharge
15. 68-XL-1860 Neutralization recirculation
16. 68-XL-1861 Neutralization standby

Startup of the Demineralized Water System

1. Put the AUTO/MANUAL/OFF selector in UCP in MANUAL position for Train-A


(68-HS-1841A).
2. Put the AUTO/MANUAL/OFF selector in UCP in MANUAL position for Train-B
(68-HS-1841B).
3. Put the LOR selector of all the pumps in Remote and select the duty and standby
pumps in UCP and put them in auto.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 234 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4. Put the Train-A in SERVICE mode (Phase No. 1) by pressing the Step Advance
push button 68-HS-1842A in the UCP once.
5. Ensure that the following valves are open in TrainA:
a. 68-XV-1825
b. 68-XV-1831
c. 68-XV-1833
d. 68-XV-1854
e. 68-XV-1830
f. 68-XV-1837
g. 68-XV-1832

6. Now Train A is on line.


7. Put Train B in WAITING READY mode (Phase No. 7) by pressing the Step Advance
push button 68-HS-1842B in the UCP.
8. Ensure that the following valves in Train-B are open:
a. 68-XV-1844
b. 68-XV-1851

9. Ensure that drinking water is available in the existing Drinking Water Storage Tanks
6834-T-01A/B.
10. Open the isolation valve from the existing Drinking water storage tank 6834-T-01A
to the new Drinking Water Pumps 6834-P-23A/B slowly and fill up the suction lines
of the pumps.
11. Prime the Drinking Water Pumps 6834-P-23A/B by opening the casing vents and
releasing air.
12. Put the LOR switch of the Drinking Water Pump 6834-P-23A in LOCAL position.
13. Start the Drinking Water Pump 6834-P-23A on recirculation, gradually open the
discharge valve and slowly pressurize the Demineralized Water Unit Train A.
14. Ensure 68-LCV-1827 is lined up and it is fully open on manual.
15. Ensure the Demineralized Water Storage Tank 6834-T-08 water level is raising.
16. When the level is 30% in the storage tank, take 68-LCV-1827 in auto with a set
point of 70%.
17. After stabilising the unit, put the AUTO/MANUAL/OFF selector in UCP in AUTO for
both A & B trains.
18. Prime the Recycling and Regeneration pumps.
19. Prepare HCl (33%) and Caustic solutions (50%).
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 235 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.13.2 Demineralized Water Unit Sequence

A. Phase No. 1: Service

1. Ensure that when put in service the following XVs of Train-A are open:
a. 68-XV-1825: Cation Exchanger I/L

b. 68-XV-1831: Cation Exchanger O/L

c. 68-XV-1833: Anion Exchanger I/L

d. 68-XV-1838: Anion Exchanger O/L

e. 68-XV-1856: Demin. Water common header I/L

f. 68-XV-1832: AE-1825 pH Analyzer I/L

g. 68-XV-1839: AE-1826 Conductivity Analyzer I/L

h. 68-XV-1830: HCl drain line

i. 68-XV-1837: NaOH drain line

2. Ensure that 68-FIC-1825 is on line and the flow rate through the train is 7 m3/hr.
3. Ensure that Train A is in line for a through put of 168 m3 (=24 hours @ 7 m3/hr)
measured by the flow totaliser 68-FQI-1825 or until the high conductivity 68-AAH-
1829 measured by the Analyzer 68-AI-1829.
4. Ensure that Train A is transferred to Phase No. 2 Waiting Regeneration mode
after step 3.
5. Ensure that the high conductivity alarm is ON if 68-AAH-1829 is ON for 5 minutes.
6. Ensure that this service phase is terminated if 68-AAH-1829 is ON for additional 30
minutes.
B. Phase No. 2: Waiting Regeneration

1. Ensure that the following XVs are open in this phase:


a. 68-XV-1830

b. 68-XV-1837

2. Ensure that the following conditions do not exist:


a. Acid Level Low (68-LAL-1825)

b. Caustic Level Low (68-LAL-1827)

3. Ensure that the following alarms are not present:


a. Irregular valve position alarm 68-UA-1844
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 236 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

b. Both Regeneration Pumps unavailable

c. Dosing Pumps unavailable

4. Ensure that this phase duration is 2 minutes.


C. Phase No. 3: Acid Regeneration/Caustic Regeneration

1. Ensure that the following XVs are open:


a. 68-XV-1829

b. 68-XV-1828

c. 68-XV-1827

d. 68-XV-1836

e. 68-XV-1835

f. 68-XV-1834

2. Ensure that Acid Dosing Pump 6834-P-35A/B/C is started and dosing 174 litres/
hour of acid for regeneration.
3. Ensure that Caustic Dosing Pump 6834-P-34A/B/C is started and dosing 126 litres/
hour of caustic for regeneration.
4. Ensure that Regeneration Pump 6834-P-36 A/B is started and supplies 1173 litres/
hour of dilution water for acid regeneration and 2300 litres/hour of dilution water
for caustic regeneration.
5. Ensure that the following control valves are in line to control the dilution water to
the acid and caustic dosing systems:
a. 68-FIC-1835 in auto with a set point of 2175 litres/hour

b. 68-FIC-1836 in auto with a set point of 1000 litres/hour

6. Ensure that the Neutralisation Pit Pump 6834-P-38 A/B starts when the level in the
Neutralisation Pit rises to high level 68-LAH-1831.
7. Ensure that the duration of this regeneration phase is 25 minutes.
D. Phase No. 4: Acid Slow Rinse/Caustic Slow Rinse

1. Ensure that the following XVs are open:


a. 68-XV-1830

b. 68-XV-1837

c. 68-XV-1827

d. 68-XV-1836
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 237 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

e. 68-XV-1835

f. 68-XV-1834

g. 68-XV-1828

h. 68-XV-1829

2. Ensure that the Regeneration Pump 6834-P-36 A/B is started and supplies 1000
litres/hour to the Cationic Exchanger 6834-S-21A and 2175 litres/hour to the
Anionic Exchanger 6834-S-22A for rinsing.
3. Ensure that the controllers 68-FIC-1835 and 68-FIC-1836 are inline.
4. Ensure that the rinsing duration is 54 minutes.
E. Phase No. 5: Caustic Slow Rinse

1. Ensure that the following XVs are open:


a. 68-XV-1837

b. 68-XV-1836

c. 68-XV-1835

d. 68-XV-1834

2. Ensure that the Regeneration Pump 6834-P-36 A/B is started and supplies 2175
litres/hour to the Anionic Exchanger 6834-S-22A for rinsing.
3. Ensure that the controller 68-FIC-1835 is online.
4. Ensure that the rinsing duration is 29 minutes.
F. Phase No. 6: Final Rinse with Recirculation

1. Ensure that the following XVs are open:


a. 68-XV-1831

b. 68-XV-1833

c. 68-XV-1826

d. 68-XV-1839

2. Ensure that the Recirculation Pump 6834-P-37 A is started and recirculates


10 m3/hour water through the cationic and anionic exchangers
3. Ensure that the rinsing duration is 30 minutes.
4. Ensure that after 30 minutes of rinsing, 68-AAH-826 alarm is OFF.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 238 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5. Ensure that if the alarm 68-AAH-826 is ON after 30 minutes of recirculation, the


Regeneration Failure alarm starts and the final rinse with recirculation phase
continues until 68-AAH-826 is OFF.
G. Phase No. 7: Waiting Ready

Ensure that the following XVs are open:

a. 68-XV-1830

b. 68-XV-1837

H. Phase No. 8: Pre-service Recirculation

1. Ensure that the following XVs are open:


a. 68-XV-1831

b. 68-XV-1833

c. 68-XV-1826

d. 68-XV-1839

e. 68-XV-1838

f. 68-XV-1830

g. 68-XV-1837

2. Ensure that the Recirculation Pump 6834-P-37 A is started and circulates 10 m3/hr
water through the system.
3. Ensure that the duration of this phase is 10 minutes.
4. Ensure that the high conductivity 68-AAH-1826 alarm is not present at the end of
the duration of this phase.
5. Ensure that if the alarm 68-AAH-1826 is present, then the Pre-service circulation
continues till the alarm is cancelled.
5.13.3 Neutralization Pit

The waste water generated during regeneration of the Demineralized Plant is


collected in the Neutralization Pit (6834-T-014). Once the level reaches the required
level, ensure the following 4 Phases to pump out the effluent.

A. Phase No. P1: Waiting Ready

1. Check of conditions for recirculation.


2. Check the level 68-LT-1831/68-LT-1830 in Neutralization Pit 6834-A-01.
3. Ensure duration of this phase is 1 minute.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 239 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4. Activation of level alarm 68-LAH-1831 in pit leads to phase No. P2. Recirculation
B. Phase No. P2: Recirculation

1. Ensure that the Neutralization Pit Pump 6834-P-38 A/B starts at 68-LAH-1831.
2. Ensure that 68-XV-1858 is open.
3. Ensure that 68-XV-1857 is closed.
4. Ensure the duration of this phase is 15 minutes.
5. At the end of re-circulation time if pH is within range, then discharge phase 4
starts.
C. Phase No. P3: Neutralization

1. Ensure that the Neutralization Pit Pump 6834-P-38 A/B starts at LAH-1831.
2. Ensure that 68-XV-1858 is open.
3. Ensure that 68-AAH-1831 (pH is more than 9) starts Acid Dosing Pumps 6834-P-35C.
4. Ensure that 68-AAL-1831 (pH is less than 6) starts Caustic Dosing Pumps 6834-P-
34C.
5. Activation of low low alarm 68-LALL-1830 in neutralization pit trips the
neutralization, acid and caustic dosing pumps.
D. Phase No. P4: Effluents Discharge

1. Ensure that the Neutralization Pit Pump 6834-P-38 A/B starts discharging effluents
when pH analyzer 68-AI-1831 is in the range (pH: 6-9) for more than 5 minutes.
2. Ensure that 68-XV-1857 is open.
3. Ensure that the Neutralization Pit Pump 6834-P-38 A/B stops at low level alarm
level of the pit 68-LAL-1831.
4. By simulating 68-LALL-1830 check the trip signal of Neutralization Pit Pump 6834-
P-38 A/B in MCC.
Operator can abort Manual Step-by-Step mode and continue operating in Automatic
Mode by simply putting the AUTO/MAN/OFF selectors in AUTO position. The sequence
will continue operating from last selected phase during Step-by-Step mode.

Details of ON/OFF valve positions against the respective phase are tabulated below:

Neutralization -
Tag No. Demineralization - Phase Number
Phase Number
Train A Train B 1 2 3 4 5 6 7 8 1 2 3 4
68-XV-1825 68-XV-1840 O C C C C C C C
68- XV-1831 68-XV-1846 O C C C C O C O
68-XV-1833 68-XV-1848 O C C C C O C O
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 240 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Neutralization -
Tag No. Demineralization - Phase Number
Phase Number
Train A Train B 1 2 3 4 5 6 7 8 1 2 3 4
68-XV-1838 68-XV-1852 O C C C C O C O
68- XV-1856 68-XV-1855 O C C C C C C C
68-XV-1832 68-XV-1847 O C C C C C C C
68-XV-1839 68-XV-1853 O C C C C O C O
68-XV-1830 68-XV-1844 O O C O O O O O
68-XV-1837 68-XV-1851 O O C O O O O O
68-XV-1828 68-XV-1843 C C O O C C C C
68-XV-1835 68-XV-1854 C C O O O C C C
68-XV-1829 68-XV-1845 C C O O C C C C
68-XV-1836 68-XV-1850 C C O O O C C C
68-XV-1826 68-XV-1841 C C C C C O C O
68-XV-1827 68-XV-1842 C C O O O C C C
68-XV-1834 68-XV-1849 C C O O O C C C
68-XV-1857 C C C C C C C C C C C O
68-XV-1858 C C C C C C C C C O O C

Details of pump status against the respective phase are tabulated below:

Neutralization -
Pump Tag No. Demineralization - Phase Number
Phase Number
Train A Train B 1 2 3 4 5 6 7 8 1 2 3 4
6834-P-37A 6834-P-37B ON ON ON
6834-P-34A
ON
6834-P-34B
ON
6834-P-34C
6834-P-35A
ON
6834-P-35B
ON
6834-P-35C
6834-P-36A
ON ON ON
6834-P-36B
6834-P-38A
ON ON ON
6834-P-38B
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 241 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.14 BOILER FEED WATER DEAERATOR SYSTEM

5.14.1 Lining up of Steam Condensate Flash Drum 6834-V-05

1. Open the 2 drum vent isolation valve to atmosphere.


2. Open the 2 drain valve from the Steam Condensate Flash Drum 6834-V-05.
3. Open the 12 Condensate Distribution Header isolation valves at battery limit and
near the Steam Condensate Flash Drum 6834-V-05 slowly and introduce
condensate from condensate distribution header and warm up the Steam
Condensate Flash Drum 6834-V-05.
4. Ensure enough time is given for the warming up of the drum and then open the
condensate header isolation valves fully.
5. Close the 2 drain valve from the Steam Condensate Flash Drum 6834-V-05.
6. Ensure that low low level trip 68-LALL-1309 is cancelled when the water level is
rising.
7. Ensure that low level alarm 68-LAL-1301 is cancelled when the level is rising in the
drum.
8. Ensure that the level in the drum is rising by checking the level transmitter 68-LT-
1301/1308/68-LG-1303.
9. When the level is around 50%, close the condensate inlet isolation valve near the
drum.
10. Open the Deaerator Feed Pumps 6834-P-20A/B suction isolation valves and the
common suction line isolation valve and warm up the pumps by opening the casing
vent isolation valves.
11. Prime the pumps by opening the casing vent isolation valves and releasing air.
12. Ensure that the Deaerator Package 6834-A-08 inlet isolation valves from the
Deaerator Feed Pumps 6834-P-20A/B discharge is closed.
13. Open the Steam Condensate Coolers fans 6834-E-02A/B/C inlet and outlet
isolation valves.
14. Line up condensate from Steam Condensate Cooler 6834-E-02 to Steam
Condensate Flash Drum 6834-V-05 isolation valve.
15. Open the discharge valve of Deaerator Feed Pump 6834-P-20A.
16. Open the minimum flow control valve 68-FV-1301 in manual by 50% and the
upstream and downstream isolation valves.
17. Ensure that the temperature control valve 68-TV-1301 is manually closed.
18. Start Deaerator Feed Pump 6834-P-20A from the local panel.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 242 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

19. Now the Deaerator Feed Pump 6834-P-20A is circulating water back to the Steam
Condensate Flash Drum 6834-V-05 through the Steam Condensate Cooler 6834-E-02.
20. Line up temperature control valve 68-TV-1301 upstream and downstream isolation
valves and take 68-TV-1301 in AUTO with a set point of 102C.
21. Line up Demineralised Water from Demineralised Water Feed Pumps 6834-P-24A/B
by opening the upstream and downstream isolation valves of 68-LV-1301.
22. Take 68-LV-1301 in AUTO with a set point of 50%.
5.14.2 Lining up of BFW Deaerator Package 6834-A-08

1. Open the 2 Deaerator Column vent isolation valve to atmosphere.


2. Open the 3 drain valve from the Deaerator Storage Vessel 6834-A-08.
3. Reset ESD and ensure the Deaerator inlet ON-OFF valve 68-XV-1301 opens.
4. Line up 68-LV-1302 upstream and downstream isolation valve.
5. Open 68-LV-1302 manually by 10%.
6. Warm up the Deaerator Storage Vessel and the Deaerator Column with the
condensate from Deaerator Feed Pumps.
7. After allowing sufficient time for the warming up of Deaerator, close the 3 drain
valve from the drum.
8. Now the level in the drum starts to rise.
9. Ensure that the low low level trip 68-LALL-1310 in the drum is cancelled when the
level rises.
10. Ensure that the low level alarm 68-LAL-1310 is cancelled when the level rises.
11. When the level reaches 50%, put 68-LIC-1302 in AUTO with a set point of 50%.
12. Line up LP saturated steam by opening the upstream and downstream isolation
valves of 68-PV-1304.
13. Put 68-PV-1304 in AUTO with a set point of 1.21 bara.
14. Drain condensate from the Deaerator if required to maintain the level at 50%.
15. Start Boiler Feed Water Pump 6834-P-22A and recirculate the condensate to the
Deaerator through the minimum flow line.
16. Start O2 Scavenging Injection from the Chemical Injection Package 6834-A-09 as
per section 5.12.2 and line up to the Deaerator at a rate of 0.55 l/hr.
17. Take a sample from the Sample cooler 68-SC-1004 at the suction of the Boiler
Feed Water Pump 6834-P-22A and analyse for dissolved Oxygen.
18. If O2 and CO2 in the sample are less than 5 parts per billion then the Boiler Feed
Water is ready for lining up to the steam generation units.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 243 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

5.15 STEAM GENERATION PACKAGE START-UP

5.15.1 Checks for Start-up

First of all it is necessary to be sure that all lines up to boiler package battery
limit (including water, steam, compressed air, fuel gas etc.) have been completely
and properly cleaned to eliminate from internal side of lines, any possible
presence of impurities/oxides, debris, rust and scales. This is very important for
the first time start-up of the Boiler subsequent to a long shutdown and there is a
reasonable doubt about possible accumulation of deposits on line internal parts
In the case boiler start-up is subsequent to a long boiler shutdown (for instance:
for maintenance, inspection or repair purposes), the Operator visual inspection
should be extended to internal and external parts and it should cover at least the
following essential points:
Check of cleaning of all involved piping by means of appropriate fluids so that
piping is internally free from scale and impurities. Operator must always take
care to achieve an ideal clean tube condition, in order to avoid any obstruction
to the instruments, valves and fittings that could seriously jeopardize the
boiler/plant functionality and operation. This visual inspection should be
extended till to check the drains and to see if the fluid is discharged without
any obstruction and free from scales or other impurities;
Water gauge passages and other boiler mounting openings are clear
Manhole doors are in position with good gaskets and satisfactorily tightened

All Boiler and Economizer valves and fittings are operated and checked
Combustion chamber and flue gas circuits are checked for cleanliness with
refractory brickwork in good condition and expansion allowances are clear

All valves and fittings installed on remaining lines (such as instrument air,
cooling water, fuel lines and so on) are proven clear and in working order
All installed instrumentation are in good and working conditions
Before start-up of the steam generator, it should be verified that all the
auxiliary equipments are in proper working condition and all the control
devices have been positively tested
Critical checks for start-up of Boiler:
Verify the proper functioning of the level gauge (Boiler). If necessary level
gauge drains are to be operated and the level gauge is checked. Ensure that
water comes out of the level gauge drains and that upstream piping is not
blocked by impurities. In case of doubt and if necessary remove the drain
valves and clear the upstream piping of blockages

Verify that all the Boiler and Economizer drains are closed
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 244 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Verify that main steam stop valve and relevant by-pass valves are completely
closed
Verify the proper operation of all the control and block valves
Verify that all equipment inspection doors are properly closed
Verify that feed water is available with proper quality
5.15.2 Water Filling

Before the Boiler start-up operation, boiler has to be filled with water up to
the operating level
Feed water must always be introduced slowly into the boiler. The filling water
flow rate depends on the water temperature.
In general 20C is the minimum recommended value of the feed water
temperature. If this value is higher than 40C, the steam generator should be
filled very slowly in order to prevent stress on the boiler components
(particularly on drums)
Before starting boiler filling, all vent valves (both manual and actuated) shall
be fully opened
Ensure that the manual start-up vent valves GV-5045 & GV-5046 are fully open
Boiler and Economizer drains shall be opened (in order to check their proper
operation). Boiler and Economizer drain valves shall be closed after few
minutes

All the vent valves are to be kept open. This is to vent out air pockets inside
steam generator tubes to atmosphere
When water exits from the Economizer vent, the relevant Economizer vent
manual valve has to be closed.

Keep 68-PIC-1819 in Manual Mode and Open 68-PV-1524 fully (MV=100%).


Open the start-up vent 68-PV-1523 fully in Manual Mode.

Confirm that the LP Steam Outlet 68-MOV-1522 is in closed position.


Ensure that the BFW Pumps 6834-P-22 A/B/C are running.
Ensure that the BFW inlet 68-XV-1522 & 68-XV-1524 are open.
Ensure that complex product Injection package is started as per section 5.12.1
and complex product is dosed at a rate of 1.87 l/hr to the BFW.
Gradually open the 68-LV-1522 in Manual Mode and fill the downstream line.

Gradually open the valve GV-5013 and fill the Boiler Steam Drum 6848-V-02A
with DM water.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 245 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fill the Boiler gradually and open the drain lines one by one for flushing.
Close all the drain valves after ensuring sediment free water from Boiler.

Monitor the level in the Steam Drum.


Check for water leakages if any.

Raise the Steam Drum Water level up to normal level.


Confirm that the all drain valves are closed properly.

Water filling is completed when drum level is at about 50 mm below the


normal water level (NWL) so that there is enough volume for expansion during
subsequent water heating when burner is lighted.
Note: Achieving of drum level is a necessary and mandatory pre-condition for boiler
start-up operation. Normal Water Level is located +50 mm above Steam Drum centre line.

5.15.3 Fuel Gas Line-up

1. Ensure that the main fuel gas line and the pilot fuel gas line are purged with
nitrogen and are under nitrogen pressure.
2. Ensure that the fuel gas lines are leak tested.
3. Ensure that the vent and drain valves in the fuel gas lines are closed.
4. Ensure that fuel gas inlet filter 6848-S-01A elements are available and boxed up.
5. Ensure that the fuel gas inlet 68-XV-1302 is open.
6. Slowly open the isolation valve upstream of 68-XV-1302 and pressurise the line.
Check the pressure increase through 68-PG-1314.
7. Open the isolation valve BV-5167 and slowly pressurise the downstream lines.
8. Open 68-PCV-1522 in Manual Mode slowly and pressurise the Main Fuel Gas Line.
9. Open the Block valve BV-5190 and slowly pressurise the Pilot Fuel Gas line.
10. Check for any gas leakages.
5.15.4 FD Fan Start-up

1. Confirm that necessary lubricants/grease is filled as per specifications.


2. Confirm that the Cooling water is lined-up and the water flows through the Sight
Flow Glass (SFG).
3. Ensure that the Inlet damper is fully open.
4. Keep the LOR selector Switch in Local mode.
5. Rotate the shaft, half turn, by hand to ensure free rotation of the Fan.
6. Confirm that the FD Fan 6848-K-02A is ready to start.
7. Inform to the substation.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 246 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

8. Start the FD Fan by pressing START push button.


9. Ensure that there is no abnormal noise and vibration
5.15.5 Burner Start-up

Burner management system (BMS):

The burner operation is performed in fully automatic through Burner management


system (BMS).

The BMS performs the following basic functions:


1. Continuous check of all valves and dampers of combustion systems
2. Pre-firing cycle.
3. Light-off cycle of burner.
4. Boiler Stop cycle.
5. ESD-Master fuel trip.
6. Post firing purge.
Steam generation unit-Burner start-up:

Note: Tags considered in this document are all related to BOILER A.

Steam generation unit Local panel details (6848A02A-LP-003) are tabulated below:

Sl. # Tag No. Description


1. 68-HSO-1526 Burner start
2. 68-HSC-1527 Burner stop
3. 68-HS-1528 Reset button
4. 68-HS-1524 Emergency shutdown
5. 68-HSR-1529 Local/Remote selector
6. 68-HS-1530 Lamp test button
7. 68-XL-1541 Burner firing lamp
8. 68-XL-1542 Burner shutdown lamp

Control valve/ON-OFF valve details are tabulated below:

Sl. # Tag No. Description


1. 68-XV-1528 Main gas shut off valve-1
2. 68-XV-1529 Main gas shut off valve-2
3. 68-XV-1530 Main gas vent valve
4. 68-XV-1531 Pilot gas shut off valve-1
5. 68-XV-1532 Pilot gas shut off valve-2
6. 68-XV-1533 Pilot gas vent valve
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 247 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Sl. # Tag No. Description


7. 68-FV-1525 Fuel gas control valve
8. 68-FV-1524 Flue gas recirculation damper
9. 68-FV-1526 Combustion air damper

Burner start can be done from HMI, Local panel and DCS.

DCS start is active only in remote mode and start on HMI or local panel is active in
local mode.

Burner Consent to Start:

The start of the burner is allowed only if all the following consents are set:

Burner is OFF
Combustion Air fan (6848-K-02A) is running
Flue gas recirculation fan (6848-K-03A) is running (If enabled)
Below mentioned burner Shutdowns are not present

Sl. # Tag No./Alarm Description


1. 68-PAHH-1528A/B/C Combustion chamber pressure high-high
2. 68-LALL-1523A/B/C Boiler level low-low
3. 68-LAHH-1523A/B/C Boiler level high-high
4. 68-PAHH-1522A/B/C Saturated steam pressure high-high
5. 68-PALL-1525A/B/C Upstream burner gas pressure low-low
6. 68-PAHH-1526A/B/C Downstream burner gas pressure high-high
7. 68-FALL-1526B/C/D Combustion air flow low-low
8. 68-FAHH-1525B/C/D Natural gas flow High-High
9. 68-PALL-1527A/B/C Instrument air pressure low-low
10. 68-HS-1523 ESD from boiler control panel
11. 68-HS-1524 ESD from boiler local control panel
12. 68-HS-1525 Emergency shutdown
13. 68-ZI-1548 Forced draft fan not running
14. 68-XS-1327 Emergency shutdown from ESD
Burner main, pilot shutoff and vent valves
15. NA
discrepancies

1. The burner can be started only manually by the operator from LCP or DCS. The
following permissives for burner start-up are to be satisfied.
a. The burner is off. The burner is not already STARTING or ON.

b. Burner shutdown alarms are not present.


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 248 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

c. Combustion Air Fan 6848-K-02A is running.

d. Flue Gas Recirculation Fan 6848-K-03A is running. (If flue gas recirculation
control is enabled).

2. Select LOCAL in the Local Burner Panel.


3. Press the START push button HSO-1526 from the Local Burner Panel.
4. Set the minimum opening for the air flow control damper 68-FV-1526 from the LBP
for purge.
5. Ensure that the air purge is done for 5 minutes.
6. After air purge is done ensure that the damper FV-1526 opening is decreased to the
burner light off threshold.
7. If flue gas recirculation controller is enabled, set the opening for the flue gas
recirculation damper FV-1524.
8. Ensure that the flue gas recirculation damper 68-FV-1524 is open.
9. Ensure that the flue gas recirculation purge is done for 1 minute.
10. After flue gas purge is done ensure that the damper 68-FV-1524 is decreased to the
burner light off threshold.
11. After 2 seconds of the PURGE VALID signal given by BMS, ensure that the burner
ignition transformer is powered.
12. After 2 seconds of powering of the transformer, ensure the burner igniter vent
valve 68-XV-1533 is closed and opens the burner igniter shut-off valves 68-XV-1531
and 68-XV-1532.
13. Ensure that after 5 seconds, the burner ignition transformer is powered off.
14. Ensure that the flame is detected by the flame scanner 68-BE-1523.
15. If flame is detected, ensure Pilot On indication is available in LBP.
16. If the flame scanner 68-BE-1523 does not detect the flame, ensure that the burner
restart is attempted automatically after 1 minute without purging the combustion
chamber again.
Note: The system can try the restart for 3 times. If flame is not detected again,
the shutdown of the burner is started and purge valid signal is reset.

17. When the pilot ignition is successful, ensure that the main burner vent valve 68-XV-
1530 is closed and the main shut-off valves 68-XV-1528 and 68-XV-1529 are opened.
18. After 5 seconds for flame stabilization, the pilot vent valve 68-XV-1533 is opened
and the pilot shut off valves 68-XV-1531 and 68-XV-1532 are closed.
19. Ensure that the flame scanners 68-BE-1522A & 68-BE-1522B detect flame.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/212
Doc. No.: 2970-0-22-0001 Page: 249 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 26 - Burner Management Sequence for Steam Generation Package


EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 250 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

5.15.6 Boiler Normal Start-up

1. Raise the furnace Temperature gradually as per the Vendor IOM.


2. Operate the Boiler as per the Vendor IOM.
3. When the Drum Pressure reaches 1.5 barg (Hot) tighten the Drums bolts/nuts.
4. Steam Trap line-up:

Ensure that the steam flow through the trap bypass line.
Open the steam trap down steam valve.
Open the steam trap upstream valve.
Close the bypass valve.
5. Observe and monitor the parameters:
Fuel Gas Flow/Pressure
Combustion Air flow
Furnace Pressure

FD Fan Discharge Pressure


Drum Level/Pressure

Main Steam line Pressure


6. Check for Boilers expansions, if any.
7. Ensure that the Main Steam line distribution headers, all vents and drains are
opened.
8. Check the furnace for flue gas leakages, if any.
9. Gradually increase the Drum pressure by throttling the start-up vent valve 68-PV-1523.
10. Ensure that the Drum level is maintained.
11. Gradually raise the air flow and fuel gas flow to increase the Drum pressure.
12. Check and confirm that the expansion of the Boiler at various locations is as per
the design values.
13. Collect the Boiler water sample periodically and analyse the sample in lab for oil
traces.
14. When the Drum Pressure reaches 5 barg, gradually open the Main Steam line
MOV-1522 and crack open the downstream isolation valve to warm up the main
steam line Header.
15. Line up all the steam traps along the main header and open the drain valves fully
in the steam traps and drain all the condensate from the header.

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 251 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

16. Keep open the traps drain valves till superheated steam comes out of the drain
lines.
17. When the superheated steam is noticed close the steam trap drain valves one by
one and line up the steam traps to the condensate header.
18. Ensure that the condensate header is already warmed up.
19. When the steam header is warmed up, close all the drains and vents and open the
MOV-1522 downstream isolation valve fully and charge the header.
20. Gradually increase the header pressure to the normal operating pressure.
21. Take all the controls in auto.
22. Open the continuous blow down valve and give blow down as necessary.
23. Line up Complex Product Injection pump 6834-P-41A/B and start dosing the
chemical as per requirement.
5.15.7 Start-up from Cold Condition (Manual Mode)

Start-up from cold condition refers to the boiler that is being started at atmospheric
pressure and ambient temperature.

While starting the Boiler on Cold conditions, the following also has to be verified:

Economizer manual vent valves are closed


Boiler and Economizer manual drain valves are closed

Desuperheater 6848-X-03A Boiler Feed water control valve 68-TV-1522 is closed as


it is not necessary to use the Desuperheater 6848-X-03A during initial start-up as
the first steam produced is still cold
Motorized main steam stop valve and relevant motorized by-pass valve are
completely closed.
Before lighting any burner the Forced Draft Fan 6848-K-02A and the Flue Gas
Recirculation Fan 6848-K-03A are to be started in order to allow the system to be
ready to initiate the boiler purging and also the fuel gas lines leakage test.

Provided that all detailed sequences and controls as described in BMS Controls are
satisfied, it is necessary to wait for a sufficient time to completely purge all boiler
flue gas passages.

Light up the first burner according to the operating sequence described on BMS
controls.

The boiler thermal heat input introduced through the burner must be maintained at
boiler minimum load.

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 252 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

When saturated steam starts to exit from vents installed on the saturated steam line
(this means that boiler pressure is slightly higher than atmospheric pressure) the vent
valve installed on the saturated steam line to be closed to increase the Boiler
pressure.

During start-up, the boiler pressurisation curve (that is, saturated pressure and
saturated temperature vs. time) shown in the following figure Boiler start-up curve
to be followed for pressurisation.

To follow the burner should be operated at minimum allowable firing rate and if
necessary the burner should be shut down and subsequently (after purging time)
started up.

Note: Faster start-up can cause serious damages to boiler. In order to comply with
boiler pressurisation limit curve shown on following figure the burner can be lighted
off/lighted on, as long as necessary.

During boiler pressurisation, do not exceed the following limitations:

30C/h: from ambient temperature up to about 130C (2 barg steam pressure)


55C/h: from 2 barg steam pressure till to MCR operating pressure
During the boiler heating ramp, when adequate steam pressure is reached the burner
load/fuel heat input can be increased from its minimum, but in any case the boiler
pressurisation curve shall be correctly followed.

When adequate steam flow rate is reached, the Boiler Feed Water to Desuperheater
6848-X-03A is lined up.

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 253 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

Fig. 27 - Burner Management Sequence for Steam Generation Package

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 254 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

5.15.8 Start-up from Hot Condition

If the steam generator is in hot" condition (that is, the boiler is close to the value of
operating pressure/temperature, condition that practically occurs immediately after
or a few hours after a boiler trip) the following conditions often exist:

Main steam stop valve 68-MOV-1522 and its by-pass valve are closed
Actuated start-up vent valve 68-PV-1523 is closed
Before starting the boiler again, Operator shall check the existing differential pressure
between Steam Drum 6848-V-02A pressure and steam header downstream of main
steam stop valve pressure. When the two pressures are equalised then steam from
Steam Drum can be lined up to the header.

After opening the actuated start-up steam vent valve the burner is started at minimum
firing conditions. The Boiler pressure slowly increases. When the pressure increases
above the header pressure, the produced steam from Steam Drum can be lined up to
the steam network through the motorised main steam shut off valve 68-MOV-1522.

If the steam network grid pressure is higher than the boiler pressure, the motorised
steam shut off valve 68-MOV-1522 should remain closed.

In case steam network grid pressure is lower than the Boiler pressure and main stop
valve is closed, then the bypass valve is crack opened to pressurise the network grid.

At the end of this pressurisation activity, when the network grid pressure is equal or a
little bit lower than boiler pressure (approx 0,5 bar), the motorised main steam stop
valve shall be fully opened by Operator. After that, the actuated start-up vent valve
shall be gradually closed.

During this transfer, the firing rate shall be maintained constant. Then the firing ramp
can be started.

It is strongly recommended during boiler ramping, do not exceed the following


limitations:

55C/h: from 2 barg steam pressure to MCR operating pressure


5.15.9 Going On Line

Once the Boiler has reached the operating pressure, the main shut off steam valve
can be opened completely (provided that downstream steam network grid is
warmed up and ready to take the boiler steam). The start-up vent valve can now
be closed.
When this transfer is completed and the alignment between Steam Generator and
steam network grid line has been stabilised, the Boiler load can be increased from
minimum load.

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 255 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

When the Boiler is stabilized, the Steam Pressure Controller 68-PIC-1819 can be
put in AUTO.
The Steam Pressure Controller 68-PIC-1819 varies the firing rate of the fuel gas
according to the pressure set point.
The entire system should be kept under close surveillance until full load operating
conditions are achieved. There is always the possibility of a defect in the safety
cut outs.
The operation of burner and the flame pattern shall be closely monitored during
start-up phase.
Two scanners are installed on each burner so to reveal the flame presence. The
flame pattern must be checked directly on field by Operator through the
peepholes installed on each burner and in the rear furnace wall.

The flame pattern shall be set in order to have a good flame, without furnace
tube impingement and achieving minimum unburned emissions (basically CO
content on flue gases).
Operator shall verify that the combustion takes place correctly, monitoring the
flame pattern.
5.16 LEAK CHECKING OF SYSTEMS

Leak checking of process systems to be done after maintenance of equipment or break


open of piping flanges for repair/maintenance works.

Preparation:

Ensure that the following activities are completed:

Relevant Work Permit have been filled up and signed


The system is reinstated as per P&IDs
Pressurising manifold with suitable PSV and pressure gauge will be used.
Leak Check:

Leak check shall be done as below:

Isolate the process system, using the available block valves


Close all vent and drains
Prepare a list of flanges and other critical locations to be checked.
Connect an air hose preferably from the plant air header or otherwise from a
temporary compressor discharge manifold through temporary hoses.

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 256 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

Pressurise the system step by step and hold the pressure at 25%, 50%, 75% and
operating pressure and carry out a thorough leak check of all the listed flanges
and other systems using tape and soap solution. Attend to leaks, if any after
depressurisation.
Repeat the above procedure till there is no leak identified
Hold the pressure for 30 minutes and record the pressure loss. If the pressure loss
is less than 0.05 bar/hr, the system will be considered to be leak free.
5.17 PURGING

Purging of process lines and equipments with Nitrogen is to be carried out prior to
introduction of acid gases into the process system. Process System and piping which
contains acid gases are Nitrogen purged using an approved inerting procedure.

A. Pre-requisite for Nitrogen Purging


1. Verify portable radios are available for communication.
2. Verify that all-loose materials and tools have been cleaned up prior to nitrogen
purging.
3. Obtain Oxygen monitors for testing Oxygen concentration during purging.
4. Verify that all personnel are appropriately equipped with required PPEs including
hard hats, goggles, earplugs and gas monitoring equipment.
5. Prior to initiating purge, a toolbox talk shall be held for the personnel regarding
the purging and the hazards of Nitrogen gas.
B. Preparation
1. Risk assessment shall be done prior to purging of each system.
2. System shall be marked and identified in the P&ID. Also the point used for purging
will be marked in P&ID.
3. The PI and PGs in the system will be used for monitoring the system pressure.
4. Pressure test with nitrogen is carried along with the nitrogen purging.
5. Depressurisation points shall be chosen such that the whole system is
depressurised and no pressure is trapped downstream of check valves.
C. Purging Procedure for Vessels & Equipment
1. Purging of Process Systems is critical for a safe start-up of the facility.
2. Purging is accomplished by using Nitrogen.
3. While carrying out the vessels and equipment purging ensure vents and pressure
taps such as gauge glass, level control bridles, spare pumps, etc., are properly
purged. Purging and testing should be continued until Oxygen content is less than
2%. A sample is taken in each case from the system being purged at the purge

/
EPIC for Gas Sweetening Facilities Project
(GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 257 of 517
TITLE: OPERATION AND MAINTENANCE
MANUAL
/212

pressure and passed through an Oxygen monitor, which reads directly in percent
Oxygen.
4. Consider each line and piece of equipment to assure complete purging of air.
Purge interconnecting piping systematically to avoid leaving air pockets in these
systems. Ensure that all appropriate valves are open or closed as required.
Particular attention should be given to block the valves located at the upstream of
relief valves.
5. If proper tapings are not available, arrange necessary flanged nipples to fix
Nitrogen hose or to make purge outlet.

/
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 258 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

SECTION VI START-UP OF PLANT


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 259 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6.1 GENERAL

The start-up procedure of the SRU depends on the exact situation of the unit at any
particular point of time. The various cases are:

Start-up after a major turnaround shutdown


Start-up after an emergency shutdown, where the unit is ready to be taken on
stream immediately
When starting the unit after a shutdown, only the relevant procedures are followed
depending on the status of the various sections of the unit and nature of jobs carried
out. All safety precautions as per the safety rules and regulations are followed while
taking over and starting up of any equipment or section of the unit. There are
standard procedures to be followed as per the QP safety manuals for inspection,
followed by accepting/deblinding any equipment before taking in line.

Smooth start-up will depend to a larger degree on how well the unit is checked prior
to start-up. In a major turnaround shutdown, all vessel internals are inspected, and if
there are any modifications to be carried out, it is completed and the vessels boxed
up. All safety items should be checked before, during and after start-up to ensure safe
and stable operation.

During start-up, the operating conditions of each unit must be adjusted to bring the
product specifications in line with the design values. During the period of off-spec
product it should be vented to flare system as far as possible to meet the required
specification. Prior planning of various start-up activities can eliminate delay and
improve the safety of personnel and equipment.

6.2 START-UP SEQUENCE

It will be necessary to start-up all or section of the plant after shutting down plant for
various reasons viz.; mechanical repair, repair of critical equipments/pipeline leaks,
utilities failure or any operating problem.

The process plants are to be started in the following sequence:

1. Incinerator

2. Acid Gas Enrichment Unit

3. Sulphur Recovery Unit

4. Tail Gas Treatment Unit


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 260 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6.3 START-UP OF PROCESS

6.3.1 Start-up of Incinerator 9101-F-14

Start-up of the Incinerator involves the following activities:

1. Purging of the system and pilot ignition


2. Main burner ignition, heat-up and introduction of Tail gases.
6.3.1.1 Purging Of the System and Pilot Ignition

a. Pre-requisites

1. Air inlets, burner and incinerator/stack passages are in good condition and free of
foreign material.
2. All personnel have been evacuated from the Incinerator, duct work, associated
equipment and all access and inspection doors closed and sealed.
3. Blower VFDs are operated through full range to check the blower response.
4. All safety shut off valves in fuel gas lines are closed.
5. Fuel system vents are open and venting properly to atmosphere. Lines are
properly drained and cleared of condensate.
6. A complete functional check of the safety interlocks has been made after any
overhaul or other significant maintenance.
7. The area is clear of obvious safety hazards and flammable gases are not present in
the area.
8. All lines have been blown down with plant air to ensure they are free of debris
that might plug metering orifices and burner tips.
9. Utilities (fuel gas, instrument air and plant air) are established and initial
operational checks performed on the elements in each line.
10. Burner elements and pilot are in their proper position in accordance with
specifications shown in the burner assembly and pilot drawings.
11. Power has been supplied to control systems and to safety interlocks.
12. Meters or gauges indicating fuel header pressure to the unit are functional.
13. Ensure that the following Pressure self regulating valves are set according to the
instrument data sheets.
Pilot gas supply PCV-1155 set at 0.7 barg
Pilot air supply PCV-1164 set at 0.7 barg
14. Isolation valves for all pressure gauges and pressure transmitters are open and
their respective bleed valves are closed.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 261 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

15. Purge air has been established for the sight ports and flame scanners. Flame
scanners have clear lenses and the scanner isolation ball valves are open.
b. Local Control Panel

Incinerator is equipped with a Local Control Panel 9101-F-14-LP-001. This panel is used
for the start-up of the Incinerator System. The LCP is supplied with the following
indications:

Tag No. Description Colour


91-XL-1173 System Ready for Purge Green
91-XL-1174 Purge in Progress Green
91-XL-1175 Purge Complete Green
91-XL-1176 Pilot Flame On Green
91-XL-1177 Main Burner On Green
91-XA-1178 Common Alarm Red
91-XL-1180 BE-1155A Flame Detected Green
91-XL-1181 BE-1155B Flame Detected Green
91-XL-1182 BE-1155C Flame Detected Green
91-HS-1162 Reset Black
91-HS-1163 Start Purge Black
91-HS-1164 Start Pilot Black
91-HS-1165 Start Burner Black
91-HS-1166 Normal Stop Black
91-HS-1167 Emergency Shutdown Red Mushroom Head
91-HS-1168 Lamp Test Black

Control valve and ON-OFF valve details are tabulated below:

Sl. # Tag No. Description


1. 91-XV-1155 Fuel gas upstream block valve
2. 91-XV-1156 Fuel gas vent valve
3. 91-XV-1157 Fuel gas downstream block valve
4. 91-XV-1158 Pilot gas upstream block valve
5. 91-XV-1159 Pilot gas vent valve
6. 91-XV-1160 Pilot gas downstream block valve
7. 91-XV-1161 Instrument air block valve
8. 91-XV-1162 Pilot air block valve
9. 91-FV-1155 Fuel gas control valve
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 262 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Prior to the start-up of the Incinerator ensure the following:

BMS (PLC-UCP) is powered up

Signal 91-XS-1170 to force fuel gas flow rate controller 91-FIC-1155 to 0% output is
present.
Signal 91-XS-1171 to force combustion air flow rate controller 91-FIC-1156 to 100%
output is absent.
Fuel gas control valve 91-FV-1155 at minimum stop position.
Fuel gas upstream (91-XV-1155) and downstream (91-XV-1157) is closed.
Fuel gas vent valve (91-XV-1156) is opened.
Pilot gas upstream (91-XV-1158) and downstream (91-XV-1160) is closed.
Pilot gas vent valve (91-XV-1159) is opened.
Instrument air block valve (91-XV-1161) is closed.
Pilot air block valve (91-XV-1162) is closed.
Note: Press lamp test switch 91-HS-1168 on the local panel and ensure all the lamps
are working.

c. Purge Cycle

Prior to the ignition of any burner it is important to purge the Incinerator with fresh
air which will sweep away any combustible that may have accumulated in the system.

Start-up of Blowers:

Select Local on the local/remote selector switch 9101-RCU-KM-12A/B

Force VFD (9101-K-12A/B) to minimum speed from the DCS


Press motor start switch in 9101-RCU-KM-12A/B
Open the O/L damper
1. Ensure the following BMS Shutdown alarm conditions in Incinerator are normal:

Tag No. Description


91-XS-1185 Remote ESD signal
91-HS-1167 Local ESD (PB on LCP)
91-FALL-1156B Combustion Air flow low low alarm
91-PALL-1155 Fuel gas pressure low low alarm
91-PALL-1156 Fuel gas pressure low low alarm
91-PAHH-1156 Fuel gas pressure high high alarm
91-BSLL-1155 Flame fail (2oo3) alarm
91-TAHH-1160 Incinerator Temperature high high alarm
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 263 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Note: During start-up, the discrepancy alarms of BMS ON/OFF valves trips the
Incinerator.

2. Ensure that the following permissives to start the purge are available:

Tag No. Description Position/Status


91-BSL-1155A Flame Scanner Switch Not energized (No flame)
91-BSL-1155B Flame Scanner Switch Not energized (No flame)
91-BSL-1155C Flame Scanner Switch Not energized (No flame)
91-BSL-1156 Flame Rod Switch Not energized (No flame)
91-ZSL-1155 Fuel Gas Control valve Valve at low-fire position
91-ZSC-1155 Fuel Gas upstream block valve Valve closed
91-ZSO-1156 Fuel Gas vent valve Valve open
91-ZSC-1157 Fuel Gas downstream block valve Valve closed
91-ZSC-1158 Pilot Fuel Gas upstream block Valve closed
valve
91-ZSO-1159 Pilot Fuel Gas vent valve Valve open
91-ZSC-1160 Pilot Fuel Gas downstream block Valve closed
valve

3. If purge permissives are met, ensure that the System Ready for Purge lamp 91-XL-
1173 on LCP is lit.
4. Press START PURGE pushbutton 91-HS-1163 from LCP 9101-F14-LP-001.
5. Ensure that the force signal (91-XS-1171) to FIC-1156 is energized and forces the
flow controller FIC-1156 to manual mode with 100% output.
6. Ensure that the shut off valves 91-XV-1161 & 91-XV-1162 are opened and air is
supplied to the pilot and purge air to the flame scanners.
7. Ensure that the combustion air flow measured by 91-FT-1156C indicates a flow of
>45500 Sm3/hr.
8. Ensure that the PURGE IN PROGRESS lamp 91-XL-1174 on LCP is lit.
9. Ensure purging is completed in 5 minutes.
10. Ensure that PURGE COMPLETE lamp 91-XL-1175 on the LCP is lit.
11. At the end of 5 minutes, the forcing signal 91-XS-1171 is de-energised allowing
FIC-1156 to return to automatic mode, since no fuel gas is flowing to the burner at
this point the output to the VFD is at its minimum, 11106 Sm3/hr.
12. Ensure that this condition exists for another 5 minutes.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 264 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

d. Pilot Ignition

1. Ensure that there are no alarms present in the UCP (BMS).


2. Ensure that the above listed permissives are met.
3. Press START PILOT push button 91-HS-1164 from LCP.
4. Ensure that PURGE COMPLETE indication is no more present.
5. Ensure that the pilot vent valve 91-XV-1159 is closed.
6. Ensure that the pilot block valves 91-XV-1158 & 91-XV-1160 are opened after
receiving the CLOSE feedback 91-ZSC-1159 of the vent valve 91-XV-1159.
7. Ensure that the ignition transformer 91-XS-1183 is energised.
8. Ensure that after 10 seconds, ignition transformer 91-XS-1183 is de-energised.
9. Ensure that after 10 seconds, if pilot is ON, the flame is detected by the Pilot
Flame Rod 91-BE-1156.
10. Ensure that the PILOT FLAME ON lamp 91-XL-1176 on the LCP is lit.
11. Ensure that pilot stabilisation timer of 60 seconds is completed from UCP HMI.
12. If no pilot flame is detected by the flame rod, ensure that after 10 seconds, SRU
tail gas Incinerator is tripped.
13. Ensure that the COMMON ALARM lamp 91-XA-1178 is lit.
14. Check the DCS/UCP for the first out alarm condition.
15. Clear the alarm condition.
16. RESET the system by pressing the RESET push button 91-HS-1162 from LCP.
17. Restart the system from the beginning.
18. If a flame is detected by 91-BE-1156 at the end of the 10 second trial period, then
the second pilot flame stabilization timer will be started.
6.3.1.2 Main Burner Ignition, Heat-up and Introduction of Tail Gases

1. After pilot stabilisation timer of 60 seconds is completed, press START BURNER


pushbutton 91-HS-1165 on LCP 9101-F14-LP-001.
2. Ensure that fuel gas vent valve 91-XV-1156 is closed.
3. Ensure that the vent valve closing feedback is received from the limit switch
91-ZSC-1156.
4. Ensure that the fuel gas block valves 91-XV-1155 & 91-XV-1157 are opened.
5. Ensure that the burner fuel gas control valve 91-FV-1155 is at its minimum stop
position.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 265 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6. Ensure that in a 10 second trial for ignition period, the burner main flame is
detected by 2oo3 voting of flame scanners 91-BE-1155A, 91-BE-1155B & 91-BE-
1155C.
7. Ensure that the MAIN BURNER ON lamp 91-XA-1178 is lit in LCP.
8. If no pilot flame is detected by the flame scanners, ensure that after 10 seconds,
SRU tail gas Incinerator is tripped.
9. Ensure that the COMMON ALARM lamp 91-XA-1178 is lit.
10. Check the DCS/UCP for the first out alarm condition.
11. Clear the alarm condition.
12. RESET the system by pressing the RESET push button 91-HS-1162 from LCP.
13. Restart the system from the beginning.
14. Ensure that if the main flame is confirmed at the end of the main burner trial-for-
ignition period, then a 60 second low fire timer in the BMS is automatically
started.
15. Ensure at the end of the 60 second low fire period, the BMS stops sending the
forcing signal 91-XS-1170 to the DCS.
16. Increase slowly the set point of 91-TIC-1155 so that the temperature of the
incinerator does not rise faster than 50C per hour, until the normal operating
temperature of 817C is reached.
17. Ensure that at 817C the pilot is turned off.
18. Ensure that 91-XV-1158 & 91-XV-1160 are closed.
19. Ensure that 91-XV-1159 is opened.
20. Ensure that 91-XV-1162 is closed.
21. Ensure that there is a flow of 4.6 Sm3/hr. of purge cooling air through a restriction
orifice RO-1155 to the pilot around 91-XV-1162.
22. To introduce tail gases ensure that the system is in operation with no alarm
condition.
23. Ensure that the Incinerator temperature at 91-TE-1156 is greater than or equal to
817C.
24. Now the system is ready for introduction of tail gases.
25. The flow of waste gases can be started and stopped in any order. However the
waste gases should be introduced one at a time to the Incinerator.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 266 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Fig. 28 - Incinerator Burner Start-up Flow Chart


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 267 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6.3.2 Start-Up of Acid Gas Enrichment Unit

Pre-requisites

Preparation of Antifoam
Preparation of Corrosion Inhibitor

Preparation of Amine Solution


6.3.2.1 Preparation of Antifoam

1. Ensure that the Antifoam Injection Pumps 9103-P-16A/B and the Agitator 9103-M-
12 are energised in MCC.
2. Ensure that the Antifoam Storage Tank 9103-T-12 is cleaned internally.
3. Ensure that all the drain and vent valves in the package are closed.
4. Introduce minimum flow of Nitrogen to the Antifoam Storage Tank and read the
flow through the flow indicator 91-FI-1537.
5. Procure the Antifoam drums to the site and place it near the unloading pumps
9103-P-19A/B.
6. Connect the drums to the unloading pumps through flexible hose.
7. Start the unloading pumps and transfer antifoam to the tank.
8. Ensure that the low low level trip 91-LALL-1520 & low level alarm 91-LAL-1521 are
cancelled while making up the solution.
9. Ensure the level in the tank from 91-LG-1510 and 91-LT-1521 and ensure the tank
does not overflow.
10. Start agitator 9103-M-12 from the local panel to mix the solution thoroughly.
6.3.2.2 Lining up of Antifoam Injection Pumps 9103-P-16A/B

1. Ensure that the Antifoam Injection pumps 9103-P-16A/B suction strainer elements
are fixed and boxed up.
2. Ensure that the Antifoam Injection Pumps 9103-P-16A/B discharge PSVs 91-PSV-
1602/1603 are lined up.
3. Open the Antifoam Storage Tank outlet isolation valve to the injection pumps and
fill the lines with the antifoam solution.
4. Open the discharge isolation valve of the Antifoam Injection Pump 9103-P-16A.
5. Open the common discharge isolation valve of the Antifoam Injection Pumps 9103-
P-16A/B.
6. Select the LOR switch of the Antifoam Injection Pump 9103-P-16A in Local.
7. Start the Antifoam Injection Pump 9103-P-16A from local control station.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 268 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

8. Ensure that the Antifoam Injection Pump 9103-P-16A is developing pressure by


checking the discharge pressure transmitter 91-PT-1559.
9. Stop the pump and keep the Antifoam Injection Pump 9103-P-16A ready for
dosing.
10. Repeat the above procedure for Antifoam Injection Pump 9103-P-16B and keep it
ready.
11. Line up Antifoam to the Acid Gas Amine Absorber 9103-C-11 or Amine Regenerator
9103-C-12 as required.
6.3.2.3 Preparation of Corrosion Inhibitor

1. Ensure that the Corrosion Inhibitor Injection Pumps 9103-P-101A/B and the
Agitator 9103-M-13 are energised in MCC.
2. Ensure that the Corrosion Inhibitor Storage Tank 9103-T-13 is cleaned internally.
3. Ensure that all the drain and vent valves in the package are closed.
4. Transport the Corrosion Inhibitor drums to the site and place it near the unloading
pumps 9103-P-102.
5. Connect the drums to the unloading pumps through unloading hose.
6. Start the unloading pumps and transfer Corrosion Inhibitor to the tank.
7. Ensure that the low low level trip 91-LALL-1522 is cancelled while making up the
solution.
8. Ensure the level in the tank from 91-LG-1511 and 91-LT-1523 and ensure the tank
does not overflow.
9. Start agitator 9103-M-13 from the local panel to mix the solution thoroughly.
10. Keep the Corrosion Inhibitor Injection Pumps 9103-P-101A/B ready for dosing.
6.3.2.4 Lining up of Corrosion Inhibitor Injection Pumps 9103-P-101A/B

1. Ensure that the Corrosion Inhibitor Injection pumps 9103-P-101A/B suction strainer
elements are fixed and boxed up.
2. Ensure that the Corrosion Inhibitor Injection Pumps 9103-P-101A/B discharge PSVs
PSV-1504/1505 are lined up.
3. Open the Corrosion Inhibitor Storage Tank outlet isolation valve to the injection
pumps and fill the lines with the Corrosion Inhibitor solution.
4. Open the discharge isolation valve of the Corrosion Inhibitor Injection Pump 9103-
P-101A.
5. Open the common discharge isolation valve of the Corrosion Inhibitor Injection
Pumps 9103-P-101A/B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 269 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6. Put the stroke length of the Corrosion Inhibitor Injection Pump 9103-P-101A at
minimum position.
7. Keep the LOR switch of the Corrosion Inhibitor Injection Pump 9103-P-101A in
Local.
8. Start the Corrosion Inhibitor Injection Pump 9103-P-101A from local control
station.
9. Ensure that the Corrosion Inhibitor Injection Pump 9103-P-101A is developing
pressure by checking the discharge pressure transmitter 91-PT-1561.
10. Stop the pump and keep the Corrosion Inhibitor Injection Pump 9103-P-101A ready
for dosing.
11. Repeat the above procedure for Corrosion Inhibitor Injection Pump 9103-P-101B
and keep it ready.
12. Line up Corrosion Inhibitor to the Acid Gas Amine Absorber 9103-C-11 or Amine
Regenerator 9103-C-12 as required.
6.3.2.5 Filling Amine Surge Tank 9103-T-11 with Dow Ucarsol HS-103 (Amine Solution)

1. Ensure that the Amine Surge Tank 9103-T-11 internals are clean and the man ways
are boxed up.
2. Ensure that the following valves are closed.
a. Lean Amine from Lean Amine Trim Cooler 9103-E-15 to the Tank 9103-T-11.

b. Amine from Amine Filters 9103-S-11/12/13 to the Tank 9103-T-11.

c. DM Water line to the Tank 9103-T-11.

d. Lean Amine Pump 9103-P-13A/B minimum flow line isolation valves to the
Tank 9103-T-11.

e. Lean Amine from Tank 9103-T-11 to Lean Amine Pump 9103-P-13A/B isolation
valve.

f. Hydrocarbon skimming facility isolation valves.

g. PSV-1513/1517/1518 outlet header isolation valve to the Tank 9103-T-11.

3. Ensure that the drain and vent valves of the Tank 9103-T-11 are isolated.
4. Ensure that the Tank PVRV-1521/PVRV-1522 upstream isolation valves are lined up.
5. Ensure that the Amine Surge Tank 9103-T-11 is purged with Nitrogen.
6. Line up tank vent valve 91-PV-1526B upstream isolation valve and take the control
valve in Remote.
7. Take the pressure controller 91-PIC-1526 in Auto with a set point of 0.02 barg.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 270 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

8. Line up the Nitrogen supply line to the tank isolation valves and take the control
valve 91-PV-1526A in Remote.
9. Ensure that all the instruments in the Amine Surge Tank 9103-T-11 are lined up.
10. Receive the road tanker containing amine solution and place it near the Amine
Surge Tank 9103-T-11 filling station.
11. Connect a 2 flexible metallic hose to the road tanker unloading line.
12. Connect the other end of the flexible metallic hose to the suction of the Amine
Unloading Pump 9103-P-18.
13. Ensure that the amine unloading pump suction strainer element is in place.
14. Connect the discharge of the amine unloading pump 9103-P-18 to the loading line
2-9103-M-141-A189 of the Amine Surge Tank 9103-T-11 with a flexible metallic
hose.
15. Connect plant air to the pneumatic amine unloading pump 9103-P-18.
16. Ensure that the air vent valve (if any) of the pneumatic pump is open.
17. Open the amine loading line isolation valves of the Amine Surge Tank 9103-T-11.
18. Open the road tanker unloading line isolation valve slowly and fill the metallic
hose.
19. Start the Amine Unloading Pump 9103-P-18 by supplying plant air, and start to load
the amine into the Amine Surge Tank 9103-T-11.
20. Ensure that low low level trip 91-LT-1511 (1000 mm) is cancelled in ICSS.
21. Ensure that the low level alarm 91-LAL-1512 (1150 mm) is cancelled as the level
rises.
22. Monitor 91-LT-1512 and build the level up to 40% in the Amine Surge Tank 9103-T-11.
23. Stop pumping amine into the Amine Surge Tank 9103-T-11.
24. Close the tanker outlet valve and the Amine Surge Tank 9103-T-11 amine make up
line isolation valves.
25. Drain amine from all the transfer lines and the metallic hoses and remove the
metallic hoses.
26. Find the quantity of amine pumped into the Amine Surge Tank 9103-T-11.
27. If the added amine is 100% in concentration then DM water is to be added to dilute
the solution to 50%.
28. Open DM water make up to the Tank and fill DM water by observing the flow
through the flow gauge 91-FI-1529 in the DM water line equivalent to the Amine
quantity.
29. The concentration of the solution in the Tank now is 50%.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 271 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

30. Collect a sample of the Amine solution and send it to laboratory for analysing the
concentration.
31. When the sample concentration is given by the lab, necessary correction may be
carried out to make the concentration of 50% amine.
32. Now the amine solution at 50% concentration is ready to be transferred to the
AGEU and TGTU.
33. Ensure that the tank is blanketed by Nitrogen by checking through the pressure
transmitter 91-PT-1526.
6.3.2.6 Transfer of Amine from Amine Surge Tank 9103-T-11 to Acid Gas Amine
Absorber 9103-C-11

1. Ensure that the Amine absorption section is under nitrogen pressure.


2. Ensure that the drain and vent isolation valves are closed in the Lean Amine
Pumps 9103-P-13A/B suction and discharge lines.
3. Ensure that the H2S Analyzer 91-AI-1506 from Lean Amine Cooler 9103-E-14 outlet
line joining the suction of the Lean Amine Pump 9103-P-13A/B isolation valve is
closed.
4. Open the Amine Surge Tank 9103-T-11 outlet line to Lean Amine Pump 9103-P-
13A/B isolation valve and fill up the line with amine.
5. Open the suction isolation valves of the Lean Amine Pumps 9103-P-13A/B and fill
the pumps by opening the casing vent valves.
6. Ensure that the Lean Amine from the Lean Amine Pumps 9103-P-13A/B discharge
to the Tail Gas Amine Absorber 9103-C-12 is closed.
7. Ensure that the Lean Amine from the Lean Amine Pumps 9103-P-13A/B discharge
to the Lean Amine Filter 9103-S-11/12/13 isolation valve is closed.
8. Put the LOR switch position to Local position.
9. Ensure that the Lean Amine Pumps 9103-P-13A/B are energized.
10. Reset PSD (Process Shut Down) from ICSS.
11. Ensure that Lean amine to Acid Gas Amine Absorber 9103-C-11 inlet ON-OFF valve
91-XV-1504 is opened.
12. Line up Lean Amine to Acid Gas Amine Absorber 9103-C-11 flow controller
91-FV-1501 isolation valves and close the bypass valve. Close the control valve
91-FV-1501 fully in manual.
13. Ensure that all the drain valves in the lean amine line to the Acid Gas Amine
Absorber 9103-C-11 are closed.
14. Start the Lean Amine Pump 9103-P-13A on minimum flow from local control
station.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 272 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

15. Ensure that the minimum flow line isolation valves are opened and the control
valve 91-FV-1511 is lined up and the controller 91-FIC-1511 is in AUTO with a set
point of 300 m3/hr.
16. Check the discharge pressure is normal at 6.50 barg from the pressure gauge
91-PG-1522.
17. Slowly open the discharge valve of the pump and fill the discharge line.
18. Open the Lean amine to Acid Gas Amine Absorber 9103-C-11 isolation valve and fill
the downstream lines.
19. Open the flow control valve 91-FV-1501 slowly and start filling up the Acid Gas
Amine Absorber 9103-C-11 with the amine.
20. Ensure that the Acid Gas Rich Amine Pumps 9103-P-12 A/B suction isolation valves
are closed.
21. Ensure that the level is increasing in the Acid Gas Amine Absorber 9103-C-11 by
checking the level transmitter 91-LT-1505 & level gauge 91-LG-1505A/B/C/D.
22. Ensure that the low low level alarm 91-LALL-1516 is cancelled as the level rises.
23. Ensure that the low level alarm 91-LAL-1506 is cancelled is cancelled as the level
rises.
24. When the level reaches 100%, close the flow control valve 91-FV-1501 fully and
close the isolation valve at pump discharge which is going to the Acid Gas Amine
Absorber 9103-C-11.
6.3.2.7 Filling Lean Amine Filters 9103-S-11/12/13 with Lean Amine Solution

1. Ensure that the Lean Amine Pump 9103-P-13A is running on minimum flow.
2. Ensure that the drain and vent valves in the Lean Amine Filters 9103-S-11/12/13
are closed.
3. Ensure that Lean Amine Filter 9103-S-11 and Fines Filter 9103-S-13 elements are
fixed in the respective filter elements.
4. Ensure that the Activated carbon Filter 9103-S-12 is loaded with the media and
boxed up.
5. Ensure that the amine from Amine Sump Pump isolation valve is isolated near the
filters.
6. Ensure that the upstream and downstream isolation valves of the 91-PSV-1512 are
opened, the upstream isolation valve is closed for 91-PSV-1513 and the bypass
valve is closed for Lean Amine Filter 9103-S-11.
7. Ensure that the upstream and downstream isolation valves of the 91-PSV-1515 are
opened, the upstream isolation valve is closed for 91-PSV-1514 and the bypass
valve is closed for Activated Carbon Filter 9103-S-12.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 273 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

8. Ensure that the upstream and downstream isolation valves of the 91-PSV-1517 are
opened, the upstream isolation valve is closed for 91-PSV-1516 and the bypass
valve is closed for Fines Filter 9103-S-13.
9. Ensure all the instruments in the Lean Amine Filters are lined up.
10. Ensure that the bypass for the Activated Carbon Filter and Fines Filter is closed.
11. Open slowly the Lean Amine Pump 9103-P-13A/B discharge isolation valve to the
filters and fill up the lines.
12. Crack open the Lean Amine Filter 9103-S-11 vent valve at the top.
13. Line up the flow control valve 91-FV-1507 and slowly open 91-FV-1507 on manual.
14. Slowly fill up the Lean Amine Filter 9103-S-11 until all the nitrogen is displaced
through the vent and the amine just starts to overflow through the vent.
15. Close the vent valve at the top of the Lean Amine Filter 9103-S-11.
16. Crack open the vent valve at the top of the Activated Carbon Filter 9103-S-12.
17. Crack open the inlet isolation valve for the Activated Carbon Filter 9103-S-12 from
the Lean Amine Filter 9103-S-11.
18. Fill the vessel with amine by displacing nitrogen through the vent valve at the top.
19. When the amine just starts to overflow through the vent valve, close the valve
immediately.
20. Crack open the vent valve of the Fines Filter 9103-S-13 at the top.
21. Crack open the inlet isolation valve for the Fines Filter 9103-S-13 and start filling
the vessel with amine.
22. The nitrogen inside the vessel is displaced through the vent and when the amine
just starts to overflow through the vent immediately close the vent valve.
23. Open the outlet valve of the Fines Filter 9103-S-13 and fill the line up to the
Amine Surge Tank 9103-T-11.
6.3.2.8 Lining up of Lean Amine Filters 9103-S-11/12/13

1. Ensure that the Lean Amine Filter 9103-S-11, Activated Carbon Filter 9103-S-12
and Fines Filter 9103-S-13 are filled with the amine.
2. Open the Lean amine Filters outlet isolation valves and line up the amine to the
Amine Surge Tank 9103-T-11.
3. Take Lean Amine Filters inlet control valve 91-FV-1507 in manual and slowly open
the control valve so that the amine starts to flow through the amine filters.
4. Slowly open the control valve till the flow measured by 91-FT-1507 reaches
155.6 m3/hr.
5. Put the flow control valve 91-FV-1507 in auto with a set point of 155.6 m3/hr.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 274 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6. Check the pressure drop across the Lean Amine Filter 9103-S-11 and ensure that it
is less than 0.7 barg from 91-PDT-1517.
7. Check the pressure drop across the Activated Carbon Filter 9103-S-12 and ensure
that it is less than 0.7 barg from 91-PDT-1518.
8. Check the pressure drop across the Fines Filter 9103-S-13 and ensure that it is less
than 0.7 barg from 91-PDT-1519.
6.3.2.9 Transfer of Amine from Acid Gas Amine Absorber 9103-C-11 to the Amine
Regenerator 9103-C-12

1. Ensure that all the drain valves in the Rich amine line to the Lean/Rich Amine
Exchanger 9103-E-11A/B and to the Regenerator 9103-C-12 are closed.
2. Open the suction isolation valves of Acid Gas Rich Amine Pumps 9103-P-12A/B and
fill the suction lines.
3. Prime the pumps by opening the casing vent valves of the pumps and releasing
Nitrogen.
4. Put the switch position of the Acid Gas Rich Amine Pumps 9103-P-12A/B to
LOCAL position.
5. Ensure that the Acid Gas Rich Amine Pumps 9103-P-12A/B are energized.
6. Line up the Rich Amine Pump 9103-P-12A minimum flow control valve 91-FV-1508
and open it manually by 50%.
7. Start the Acid Gas Rich Amine Pump 9103-P-12A from local control station on
minimum flow.
8. Check the discharge pressure is normal at 7.50 barg from the pressure gauge
91-PG-1536.
9. Ensure that the pump is running without any abnormal noise and vibration.
10. Open the discharge valves of the pump slowly and fill the discharge line and
circulate the Rich Amine back to the Acid Gas Amine Absorber 9103-C-11 through
the minimum flow line control valve 91-FV-1508.
11. Open the Rich amine to Lean/Rich Exchanger inlet isolation valves 9103-E-11A/B
and fill the downstream lines and the exchanger.
12. Open the Lean Rich Exchanger outlet isolation valve and fill the downstream lines
up to 91-FV-1520.
13. Take the flow control valve 91-FV-1520 in manual and open the control valve
slowly and start taking level in Amine Regenerator 9103-C-12.
14. Ensure that the level is increasing in the Amine Regenerator 9103-C-12 by
checking the level transmitter 91-LT-1510 and level gauge 91-1506A/B.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 275 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

15. Ensure that the Amine Regenerator 9103-C-12 low low level alarm 91-LALL-1517 is
cancelled as the level rises.
16. Ensure that the Amine Regenerator 9103-C-12 low level alarm 91-LAL-1510 is
cancelled as level increases.
17. When the level reaches 50%, close the flow control valve 91-FV-1520 fully and stop
the Rich Amine Pump 9103-P-12A from the local control station.
18. Check the level in the Acid Gas Amine Absorber 9103-C-11 and ensure that it does
not drop below 50%.
19. If the level drops below 50% in the Acid Gas Amine Absorber 9103-C-11, stop the
Acid Gas Rich Amine Pump 9103-P-12A immediately.
20. Start the Lean Amine Pump 9103-P-13A and fill the Acid Gas Amine Absorber
9103-C-11 as mentioned previously.
6.3.2.10 Filling up of Lean Amine Section with Amine

1. Ensure that the drain and vent valves of the Hot Lean Amine Pumps 9103-P-17A/B,
lean amine side of the Lean/Rich Exchanger 9103-E-11A/B, Lean Amine Cooler
9103-E-14 and Lean Amine Trim Cooler 9103-E-15 are closed.
2. Ensure that the Amine Regenerator 9103-C-12 is filled with amine upto 50% level.
Check the level in 91-LT-1510 and also cross check with 91-LG-1506A/B.
3. Open the Hot Lean Amine Pumps 9103-P-17A/B suction isolation valves slowly and
fill the lines and the pumps with amine by opening the casing vent valves of the
pumps and by releasing Nitrogen.
4. Ensure that the Hot Lean Amine Pumps 9103-P-17A/B are energized in MCC.
5. Put the LOR switch of the Hot Lean Amine Pumps 9103-P-17A/B to LOCAL at
local control station.
6. Ensure that the minimum flow line of the Hot Lean Amine Pumps 9103-P-17A/B is
lined up and the flow control valve 91-FV-1512 is opened by 20% on manual.
7. Start the Hot Lean Amine Pump 9103-P-17A from local control station.
8. Ensure that the Hot Lean Amine Pump 9103-P-17A discharge pressure is normal at
6.80 barg.
9. Ensure that the Hot Lean Amine Pump 9103-P-17A is pumping amine back to the
Amine Regenerator 9103-C-12 through the minimum flow control valve 91-FV-1512.
10. Put the minimum flow control valve 91-FV-1512 in Auto with a set point of
250 m3/hr.
11. Ensure that the Hot Lean Amine Pumps 9103-P-17A/B discharge ON-OFF valve
91-XV-1507 is opened.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 276 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

12. Open the Hot Lean Amine Pump 9103-P-17A discharge isolation valve slowly and
fill the Lean/Rich Exchanger 9103-E-11A/B inlet strainer and the lean amine side
of the Lean/Rich Exchanger 9103-E-11A/B.
13. Open the Lean/Rich Amine Exchanger 9103-E-11A/B outlet isolation valve and fill
the outlet lines.
14. Open the Lean Amine Cooler 9103-E-14 inlet isolation valves and start filling the
Exchanger.
15. Open the high point vent in the Lean Amine Cooler 9103-E-14 and release
Nitrogen.
16. Close the vent valve when the amine just starts to come out of the vent valve.
17. Open the outlet isolation valve of the Lean Amine Cooler 9103-E-14 and fill the
outlet lines.
18. Ensure that the Amine line from the Lean Amine Cooler 9103-E-14 outlet to the
Analyzer AT-1506 isolation valve is closed.
19. Open the Lean Amine Trim Cooler 9103-E-15 inlet isolation valve and fill the
Cooler with amine.
20. Ensure that the Lean Amine Trim Cooler 9103-E-15 bypass control valve 91-TV-
1509 is closed.
21. Open the high point vent in the Lean Amine Trim Cooler 9103-E-15 and release
Nitrogen.
22. Close the high point vent isolation valve when the amine just starts to overflow.
23. Open the outlet isolation valve of the Lean Amine Trim Cooler 9103-E-15 and fill
the outlet lines.
24. Check the level in the Amine Regenerator 9103-C-12 through the 91-LT-1510. If
the level is less than 30%, make up the level as previously mentioned to 50%.
25. Put 91-FV-1530 in Manual and open the control valve by 10% and line up the
amine to Amine Surge Tank 9103-T-11.
26. Open the Amine Surge Tank inlet isolation valve and line up lean amine to Amine
Surge Tank 9103-T-11.
27. Stop the Hot Lean Amine Pump 9103-P-17A from the local control station.
6.3.2.11 Establishing Amine Circulation in the System

1. Ensure that Amine Surge Tank 9103-T-11 is having more than 50% level. If not then
make up the tank from road tankers as mentioned previously.
2. Ensure that the Lean Amine Pump 9103-P-13A/B suction, discharge and minimum
flow lines are lined up.
3. Put the LOR switch of the Lean Amine Pump in Remote.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 277 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

4. Start the Lean Amine Pump 9103-P-13A from ICSS and put 9103-P-13B in AUTO.
5. Open the minimum flow control valve 91-FV-1511 in manual and adjust the valve
opening to ensure a minimum flow of 375 m3/Hr.
6. Now put the minimum flow control valve in auto with a set point of 375 m3/hr.
7. Reset Process Shutdown and ensure that the Acid Gas Amine Absorber 9103-C-11
inlet ON-OFF valve 91-XV-1504 is opened.
8. Open the Lean Amine Pump 9103-P-13A/B discharge valve to the Acid Gas Amine
Absorber 9103-C-11.
9. Open the Acid Gas Amine Absorber 9103-C-11 inlet flow control valve 91-FV-1501
in manual by 10%.
10. Ensure that the level in Acid Gas Amine Absorber 9103-C-11 is rising by checking
the level transmitter 91-LT-1505.
11. Ensure that the Acid Gas Rich Amine Pumps 9103-P-12A/B suction, discharge and
minimum flow isolation valves are lined up and the pumps are primed.
12. Put the Acid Gas Rich Amine Pumps 9103-P-12A/B LOR switch in Remote and
start the pump 9103-P-12A from ICSS and put the pump 9103-P-12B in AUTO.
13. Open the minimum flow control valve 91-FV-1508 in manual and adjust the valve
opening to get a flow of 375 m3/hr.
14. Take the minimum flow control valve 91-FV-1508 in Auto with a set point of
375 m3/hr.
15. Ensure that the Rich Amine to the Amine Regenerator 9103-C-12 isolation valves
are lined up.
16. Open the Amine Regenerator inlet control valve 91-FV-1520 to 10% in manual.
17. Ensure that the level in the Amine Regenerator started to rise through 91-LT-1510.
18. Ensure that the suction, discharge and the minimum flow lines are lined up.
19. Put the LOR switch of the Hot Lean Amine Pumps 9103-P-17A/B in Remote and
start the pump 9103-P-17A from ICSS and put the pump 9103-P-17B in AUTO.
20. Open the minimum flow control valve 91-FV-1512 in manual and adjust the control
valve opening to get a minimum flow of 250 m3/hr.
21. Put the control valve 91-FV-1512 in auto with a set point of 250 m3/hr.
22. Ensure that the Hot Lean Amine Pumps 9103-P-17A/B discharge ON-OFF valve
91-XV-1507 is open.
23. Line up the Hot Lean Amine Pumps discharge to the Lean/Rich Amine Exchanger
9103-E-11, Lean Amine Cooler 9103-E-14, Lean Amine Trim Cooler 9103-E-15 and
the Amine Surge Tank 9103-T-11.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 278 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

24. Slowly increase the flow rate from the Lean Amine Surge Tank 9103-T-11 to the
Acid Gas Amine Absorber 9103-C-11 by opening the control valve 91-FV-1501 to
487 m3/hr.
25. Ensure that the minimum flow control valve of the Lean Amine Pumps 9103-P-
13A/B is closed.
26. Correspondingly to maintain level in the Acid Gas Amine Absorber, open the flow
Control valve 91-FV-1520 manually till the level is maintaining. Now put the flow
control valve in auto with a set point of 487 m3/hr.
27. Ensure that the minimum flow control valve 91-FV-1508 of the Acid Gas Rich
Amine Pumps 9103-P-12A/B is closed.
28. To maintain the level in the Amine Regenerator 9103-C-12, open the flow control
valve 91-FV-1530 slowly till the level in the Regenerator is maintaining.
29. Put flow control valve 91-FV-1530 in auto with a set point of 487 m3/hr.
30. Ensure that the minimum flow control valve 91-FV-1512 of the Hot Lean Amine
Pumps 9103-P-17A/B is closed.
31. Open the Sea Cooling water inlet isolation valve of the Lean Amine Trim Cooler
9103-E-15 and fill the cooler.
32. Open the Sea Cooling water outlet isolation valve and establish the cooling water
flow.
33. Ensure that the temperature control valve 91-TV-1509 of the lean amine in the
Lean Amine Trim Cooler 9103-E-15 is closed.
34. Ensure that the temperature control valve 91-TV-1513 of the lean amine in the
Lean/Rich Exchanger 9103-E-11A/B is closed.
6.3.2.12 Lining up of Regenerator Overhead System

1. Ensure that the drain and vent isolation valves in the Regenerator overhead
system are closed.
2. Ensure that the Regenerator overhead 91-PSV-1508 isolation valves are lined up,
91-PSV-1509 upstream isolation valve is closed and the bypass valves are closed.
3. Ensure that the Regenerator Condenser Cooler 9103-E-12 inlet and outlet isolation
valves are lined up and the vent and drain valves are closed.
4. Ensure that the Regenerator Condenser Trim Cooler 9103-E-16 inlet and outlet
isolation valves are lined up and the vent and drain valves are closed.
5. Ensure that the Regenerator Reflux Drum 9103-V-12 drain and vent valves are
closed.
6. Ensure that the Regenerator Reflux Drum 9103-V-12 pressure control valves 91-PV-
1503A/B are lined up and they are in closed condition.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 279 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

7. Ensure that the Regenerator Reflux Drum 9103-V-12 acid gas to Acid Gas KO Drum
9101-V-04 line ON-OFF valve XV-1516 is open.
8. Put the Regenerator Reflux Drum 9103-V-12 pressure controller 91-PIC-1503 in
Auto with a set point of 1.0 barg and the pressure control valves 91-PV-1503A/B in
Remote.
9. Line up DM water to the Regenerator Reflux Drum 9103-V-12 by opening the flow
control valve 91-FV-1521 manually.
10. Check that the level in the Regenerator Reflux Drum 9103-V-12 is increasing by
checking the level gauge 91-LG-1502 and 91-LT-1506.
11. When the level in the Regenerator Reflux Drum 9103-V-12 is around 40% close the
DM water make up and the flow control valve 91-FV-1521.
12. Start the Regenerator Condenser Cooler fans 9103-EM-12AA/AB/AC/BA/BB/BC/
CA/CB/CC/DA/DB/DC.
13. Line up sea cooling water to the Regenerator Condenser Trim Cooler 9103-E-16 by
opening the inlet and outlet isolation valves.
14. Line up the Regenerator Condenser Trim Cooler 9103-E-16 temperature control
valve 91-TV-1509 and put it on Auto with a set point of 49C.
6.3.2.13 Lining up of Regenerator Reboiler 9103-E-13 System

1. Ensure that the Regenerator Reboiler 9103-E-13 is filled with amine solution by
checking the level gauge 91-LG-1503.
2. Open the drain valve upstream of Reboiler steam inlet ON-OFF valve 91-XV-1505
and drain all the condensate.
3. Warm up the steam line upstream of Reboiler steam inlet ON-OFF valve 91-XV-
1505 till there is full fledged steam coming out from the drain valve.
4. Close the drain valve. Open the drain valve downstream of the Reboiler steam
inlet ON-OFF valve 91-XV-1505 and drain all the condensate.
5. Reset Process shutdown and ensure that Reboiler steam inlet ON-OFF valve 91-XV-
1505 is open.
6. Open the bypass valves of the Reboiler Steam inlet flow control valve 91-FV-1503
and start warming up the steam lines and Reboiler tubes.
7. Ensure that Regenerator Reboiler Condensate Pot 9103-V-13 is also being warmed
up through the equalisation line.
8. Open the drain valve in the condensate outlet line of the Regenerator Reboiler
Condensate Pot 9103-V-13.
9. When all the condensate is drained and steam is coming out of the drain, close the
drain valve.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 280 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

10. Open the Reboiler condensate outlet line drain valve and drain all the condensate.
11. Warm up the Reboiler tubes till hot condensate comes out of the drain line.
12. Open the Reboiler steam inlet flow control valve 91-FV-1503 by 5% and heat the
Reboiler amine solution.
13. Close the drain line valve and allow the condensate level to be built up in the
Regenerator Reboiler Condensate Pot 9103-V-13.
14. Ensure that the level is building up in the Regenerator Reboiler Condensate Pot
9103-V-13 by checking the level gauge 91-LG-1504A/B.
15. Ensure that low level alarm 91-LAL-1508 is cancelled in the Pot.
16. Line up Regenerator Reboiler Condensate Pot 9103-V-13 condensate outlet line
level control valve 91-LV-1508 and put the controller in auto with a set point of
50%.
17. Ensure that the level in Regenerator Reboiler Condensate Pot 9103-V-13 is
maintained at 50%.
18. Gradually increase the opening of the steam inlet control valve 91-FV-1503 and
heat the amine solution at a rate of 25C/hr till the Regenerator bottom
temperature reaches 130C.
19. Put the Reboiler steam inlet flow controller 91-FIC-1503 in Remote and enter
the ratio of steam to rich amine at 118.5 in the ratio controller 91-HIC-1503 and
take the ratio controller in Auto.
20. Put the Regenerator top temperature controller 91-TIC-1510 in Auto with a set
point of 118C.
21. Line up the Regenerator Reflux Drum Pumps 9103-P-11A/B by opening the suction
and discharge valves and priming the pumps by opening the casing vent and
releasing Nitrogen.
22. Ensure that the Regenerator Reflux Drum Pumps 9103-P-11A/B discharge to the
Waste Water Degasser is isolated.
23. Ensure that the Regenerator Reflux Drum Pumps 9103-P-11A/B minimum flow line
control valve FV-1505 is lined up.
24. Put the minimum flow controller 91-FIC-1505 in Auto with a set point of 20 m3/hr.
25. Put the LOR switch of the Regenerator Reflux Drum Pumps 9103-P-11A/B in
Remote position.
26. Start the Regenerator Reflux Drum Pumps 9103-P-11A from the ICSS and put
9103-P-11B in AUTO.
27. Line up the reflux from the Regenerator Reflux Drum Pumps 9103-P-11A to the
Regenerator 9103-C-12 by lining up the control valve 91-FV-1531.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 281 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

28. Put the level controller 91-LIC-1506 of the Regenerator Reflux Drum 9103-V-12 in
Auto with a set point of 50%.
29. Put the reflux flow control valve 91-FV-1531 in remote mode.
30. Ensure that the top temperature of the Regenerator is being maintained at around
118C.
6.3.2.14 Lining up of Acid Gas to the Acid Gas Amine Absorber

1. Ensure that the vent and drain valves in the Acid Gas Coolers 9103-E-101A/B, Lean
Acid Gas KO Drum 9103-V-14, Acid Gas KO Drum Return Pumps 9103-P-14A/B are
closed.
2. Ensure that the sea cooling water to Acid Gas Coolers 9103-E-101A/B inlet filter
elements are fixed and boxed up.
3. Open the Sea Cooling water inlet and outlet isolation valves and line up sea
cooling water to Acid Gas Coolers 9103-E-101A/B.
4. Ensure that the 91-VRV-1577 upstream isolation valve is lined up in the sea cooling
water inlet of Acid Gas Coolers 9103-E-101A/B.
5. Ensure that the 91-VRV-1578 upstream isolation valve is lined up in the sea cooling
water outlet of Acid Gas Coolers 9103-E-101A/B.
6. Ensure that the 91-TSV-1501 upstream isolation valve is opened & 91-TSV-1502
upstream isolation valve is closed in the sea cooling water outlet of Acid Gas
Coolers 9103-E-101A/B.
7. Ensure that the 91-PSV-1501 in Lean Acid Gas KO Drum 9103-V-14 isolation valves
is opened, 91-PSV-1502 upstream isolation valves are closed and the bypass valves
are closed.
8. Reset Process shutdown from ICSS.
9. Ensure that Acid Gas inlet ON-OFF valve 91-XV-1501 is opened to the Acid Gas
Cooler 9103-E-101A/B and the ON-OFF valve 91-XV-1502 to the Acid Gas Flare
Header is closed.
10. Open the isolation valves downstream of ON-OFF valve 91-XV-1502 and lock the
valves in open position.
11. Open the isolation valve upstream of ON-OFF valve 91-XV-1501 and lock the valve
in open position.
12. Line up pressure control valve 91-PV-1502 of the Acid Gas Amine Absorber 9103-C-
11 and take the pressure controller 91-PIC-1502 in Auto with a set point of
0.2 barg.
13. Ensure that the 91-PSV-1503 in Acid Gas Amine Absorber 9103-C-11 isolation valves
are lined up and the PSV-1504 upstream isolation valves are closed and the bypass
valves are closed.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 282 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

14. Inform AGRU 1 & 2 (Existing units) to line up Acid Gas to AGEU.
15. Open the isolation valves of the Acid Gas line to AGEU in the battery limit slowly
and admit acid gas into the Acid Gas Coolers 9103-E-101A/B.
16. Ensure that the temperature of the acid gas at the outlet of the acid gas coolers is
53C by checking the temperature indicator 91-TI-1501.
17. When there is an increase in the level of the Lean Acid Gas KO Drum which is read
from the LG-1501A/B & LT-1501, Line up Acid Gas KO Drum Return Pumps 9103-P-
14A/B.
18. Open the suction isolation valves of the Acid Gas KO Drum Return Pumps 9103-P-
14A/B and prime the pumps by opening the casing vents and releasing Nitrogen.
19. Reset process shutdown and ensure that the ON-OFF valve 91-XV-1503 in the pump
discharge is open.
20. Ensure that the pumps 9103-P-14A/B discharge to the Sour Water Stripper 6922-C-
01 is isolated.
21. Put the LOR switch of the pumps in Remote and start the pump 9103-P-14A from
ICSS and put pump 9103-P-14B in AUTO.
22. Open the pump discharge valves and then open LV-1501 gradually.
23. Put the Lean Acid Gas KO Drum level controller 91-LIC-1501in auto with a set point
of 50%.
24. Put the lean amine flow control valve 91-FV-1501 to the Acid Gas Amine Absorber
9103-C-11 in ratio control with the acid gas feed.
25. Check the Incinerator 9101-F-14 performance as acid gas is routed to it from the
Acid Gas Amine Absorber.
26. Open 91-PV-1503A in manual and route acid gases from Regenerator Reflux Drum
9103-V-12 to flare. Keep 91-PV-1503B closed in manual.
27. When the acid gases produced from Regenerator is stabilized, put the pressure
controller 91-PIC-1503 in Auto with a set point of 1.0 barg.
28. Check the differential pressure 91-PDT-1522 in the Acid Gas Amine Absorber and
91-PDT-1523 in the Amine Regenerator 9103-C-12. If the differential pressures
shows increasing trend then antifoam has to be dosed to amine feed to that
tower.
29. After stabilising the plant, inform NGL-1/2/4 to line up acid gases one by one.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 283 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

6.3.3 Start-Up of Sulphur Recovery Unit

The first start-up of the SRU following a major overhaul may be carried out
independent of the TGTU BSR Section. In this case the SRU tail gases will be routed to
the Incinerator and closed to the TGTU. The start-up of sulphur recovery unit involves
the following activities:

1. Confirm LP heating steam is in service to all sulphur lines, Sulphur Degassing Pit
9101-T-01/01B heating coils and trace heating lines.
2. Confirm acid gas shutdown valve 9103-XV-1516 from the upstream amine
Regenerator Reflux Drum 9103-V-12 to the Acid Gas KO Drum 9101-V-04 is closed.
3. Confirm that the SRU tail gas ON/OFF valve 91-XV-1097 from the Final Separator
9101-V-05 to the Incinerator 9101-F-14 is open.
4. Confirm that the SRU tail gas ON/OFF valve 9101-XV-1098 from Final Separator
9101-V-05 to the Tail Gas Treatment Unit is closed.
5. Introduce BFW to the SRU Reaction Furnace Boiler 9101-E-07 Steam Drum 9101-V-
07 and establish a normal operating water level in the vessel.
6. Introduce BFW through the BFW Preheater and establish normal operating levels in
the Last Condenser, Reaction Furnace Condenser 9101-E-01 and 1st Stage
Condenser 9101-E-02.
7. Now Reaction Furnace burner to be started to heat up the system.
6.3.3.1 Start-up of Reaction Furnace (9101-F-01) Burner

Reaction Furnace-BMS sequence

The burner management system of Reaction Furnace is incorporated in ESD system.

Reaction furnace LCP 9101-F-01LP-005 hand switches detail is tabulated below:

Sl. # Tag No. Description


1. 91-HS-1211 Start purge
2. 91-HS-1212 Start ignition
3. 91-HS-1213 Emergency shutdown
4. 91-HS-1214 Lamp test

Reaction Furnace 9101-F-01 hardwired auxiliary console hand switches detail is


tabulated below:

Sl. # Tag No. Description


1. 91-HS-1217 Acid gas ON/OFF
2. 91-HS-1218 Fuel gas ON/OFF
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 284 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

Reaction furnace LCP 9101-F-01LP-005 lamp indication detail is tabulated below:

Sl. # Tag No. Description


1. 91-XA-1211 Reaction furnace burner shutdown
2. 91-XL-1212 Ready for purge
3. 91-XL-1213 Purge ON
4. 91-XL-1214 Ready for ignition
5. 91-XL-1215 Ignition ON
6. 91-XL-1216 Fuel gas ON
7. 91-XL-1217 Acid gas ON
8. 91-BAL-1055A Flame-1 ON
9. 91-BAL-1055B Flame-2 ON

Reaction Furnace 9101-F-01 soft pushbutton details in DCS is tabulated below:

Sl. # Tag No. Description


1. 91-HS-1216 Quench steam valve 91-XV-1078 ON/OFF
2. 91-HS-1040 Quench steam valve 91-XV-1079 ON/OFF
3. 91-HS-1219 Nitrogen valve ON/OFF switch
4. 91-HS-1220 System reset
5. 91-HS-1017 Start-up bypass for 91-PALL-1025

Control valve/ON-OFF valve details are tabulated below:

Sl. # Tag No. Description


1. 91-XV-1048 Fuel gas shut-off valve-1
2. 91-XV-1099 Fuel gas shut-off valve-2
3. 91-XV-1100 Fuel gas vent valve
4. 91-FV-1009 Fuel gas flow control valve
5. 91-XV-1001 Acid gas shut-off valve
6. 91-XV-1102 Acid gas shut-off valve
7. 91-XV-1110 Nitrogen shut-off valve
8. 91-XV-1127 Nitrogen shut-off valve
9. 91-XV-1101 Main combustion air shut-off valve
10. 91-FV-1002 Combustion air control valve
11. 91-FV-1002B Secondary air control valve
12. 91-FV-1003 Make-up air control valve
13. 91-XV-1078 Quench steam ON/OFF valve
14. 91-XV-1079 Quench steam ON/OFF valve
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 285 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

The burner light-on is carried out in three steps:

i. System reset

ii. Pre-ignition purge

iii. Fuel gas burner light-on

i. System Reset

1. Check the following shutdown interlocks are absent in the ICSS:

Sl. # Tag No. Description


1. 91-HS-1012A Reaction furnace ESD pushbutton (CCR)
2. 91-HS-1213 Reaction furnace ESD pushbutton (LCP)
3. 65-XS-1008 AGR shutdown
4. 91-BSL-1055A/B Flame failure of reaction furnace (2oo2)
5. 65-HS-001 General plant shutdown activation (existing)
6. 65-XA-1001 Existing SRU shutdown
7. 91-TT-1050 Rupture pin failure
8. 65-XS-1024 Total power Shutdown
9. 65-PT-1003A/B/C Instrument air pressure low-low
10. 65-XS-1015 Steam pressure failure (low low pressure)
11. 91-HS-1011 Unit-91 general shutdown button
12. 91-XS-1901 Confirmed gas detection
13. 65-XS-1020 Fuel gas low-low pressure
14. 91-LT-1003 Acid gas KOD (9101-V-04) high-high level
15. 91-LT-1006 Steam drum (9101-V-07) low-low level
16. 91-LT-1009 RF condenser (9101-E-01) low-low level
17. 91-LT-1012 1st condenser (9101-E-02) low-low level
18. 91-PT-1025 Acid gas inlet low-low pressure
19. 91-XS-1063/1064 Blowers (9101-K-01A/B) are not running
20. 91-PT-1054A/B/C Air for acid gas burner high-high pressure
21. 91-FT-1140 Acid gas to reaction furnace low-low flow
22. 91-FT-1129 Process air to acid gas burner flow low-low
23. 91-FT-1130 Fuel gas to reaction furnace flow low-low

If the above conditions do not exist, the Reaction furnace BMS system can be reset.

When the BMS reset is pressed, following shutdown causes are automatically bypassed
during start-up:

a. 91-FT-1129 (Combustion Air low-low flow)


EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 286 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

b. 91-FT-1130 (Fuel gas to reaction furnace low-low)

c. 91-FT-1140 (Acid gas to reaction furnace low-low)

d. 91-BSL-1055A/B (Flame detector signal)

e. 91-PT-1025 (Acid gas I/L pressure low-low)

2. Start any one of Process Air Blower 9101-K-01A & 9101-K-01B.


3. The following conditions are to be satisfied for the pre-ignition purge:
a. No flame present 91-BSL-1055A/91-BSL-1055B.

b. Fuel Gas cut-in valve XV-1048 is in close position 91-ZSC-1048.

c. Fuel Gas cut in valve XV-1099 is in close position - 91-ZSC-1099.

d. Fuel Gas vent valve XV-1100 is in open position - 91-ZSO-1100.

e. Ensure READY FOR RESET (91-XL-1218) is lit in ICSS.

4. RESET the system by pressing the Soft switch 91-HS-1220 from DCS and ensure the
following:
a. Energizing of combustion air control valve SOV 91-FY-1002B and 91-FY-1002.

b. Process air flow controller 91-FIC-1002, 91-FIC-1002B to manual mode and


output at start position.

c. Fuel gas flow controller 91-FRC-1009 to manual mode and output at start
position.

d. READY FOR PURGE lamp (91-XL-1212) is lit on the local panel and also in
ICSS.

e. SYSTEM IN SHUTDOWN lamp 91-XA-1211 will extinguish on the LCP and ICSS.

ii. Pre-ignition Purge

1. Ensure the control valves for combustion air 91-FV-1002, fuel gas control valve
91-FV-1009 and steam valves are in start position at the ICSS and in field.
2. Press the start purge button 91-HS-1211 at the local control panel.
3. Ensure the SYSTEM READY FOR PURGE is unlit.
4. Ensure that the Nitrogen shutdown valve 91-XV-1127 for furnace purging and 91-
XV-1110 for flame scanner, sight glass purging are opened.
5. Ensure that main Process air shutdown valve 91-XV-1101 is closed.
6. Verify whether the PURGE ON lamp 91-XL-1213 is lit for 20 minutes (purge timer)
in the Local Control Panel.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 287 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

7. After the purge time is over, ensure that the PURGE ON lamp 91-XL-1213 is unlit
in the Local Control Panel.
8. Ensure that PURGE COMPLETE lamp 91-XL-1219 is lit on the ICSS.
9. Ensure the READY FOR IGNITION lamp 91-XL-1214 is lit on local panel.
10. Ensure that the Nitrogen cut-in valve 91-XV-1127 is closed.
iii. Fuel Gas Burner Light On

1. Ensure that the air inlets, burner and outlet passages are boxed up and free of
foreign material.
2. Ensure that all personnel have been evacuated from the reaction furnace area,
ductwork and associated equipment and all access and inspecting doors closed and
sealed.
3. Ensure that the Process Air Blower 9101-K-01A/B is running.
4. Ensure that all safety shut off valves are closed.
5. Ensure that the Fuel System vents are open and venting to atmosphere. Lines are
properly drained and cleared of condensate.
6. Ensure that a complete functional check of the safety interlocks has been made.
7. Ensure that the area is clear of obvious safety hazards and flammable gases are
not present in the area.
8. Ensure that all lines have been blown down with plant air to insure they are free
of debris that might plug metering orifices and burner tips.
9. Ensure that utilities like fuel gas, instrument air, nitrogen and plant air are
available and initial operational checks performed on the elements in each line.
10. Ensure that the burner elements are in their proper position.
11. Ensure that power has been supplied to control systems and to safety interlocks.
12. Ensure that the gauges indicating fuel header pressure to the unit are functional.
13. Ensure that the pressure self regulating valves are set according to the instrument
data sheets.
14. Ensure that the isolation valves for all the pressure gauges and pressure
transmitters are open and their respective bleed valves are closed. Valves are
sealed in position as indicated on P&IDs.
15. Ensure that the minimum purge period is satisfactorily completed.
16. Ensure that the control valves of the fuel gas 91-FV-1009, quench steam 91-XV-
1078, 91-XV-1079 and Combustion Air 91-FV-1002 are closed.
17. Ensure that the igniter is in the correct position and that the fuel gas gun is ready
for operation with fuel gas.
EPIC for Gas Sweetening Facilities Project (GSF)
at Mesaieed & Dukhan Rev.: 0
Part-1 SRU (Mesaieed) Date: 03/09/2012
Doc. No.: 2970-0-22-0001 Page: 288 of 517
TITLE: OPERATION AND MAINTENANCE MANUAL

18. Open the fuel gas control valve 91-FV-1009 and combustion air control valve
91-FV-1002B to the pre-determined position.
19. Press the START IGNITION push button 91-HS-1212 from the local control panel.
20. Ensure that READY FOR IGNITION lamp 91-XL-1214 is unlit.
21. Ensure that the igniters insert SOV 91-XY-1103 is energised.
22. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1103.
23. Ensure