OPERATING PHILOSOPHY

UNIT 122

FUEL GAS

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 CONTENTS
Page

1. INTRODUCTION............................................................................................................ 5
1.1 PURPOSE............................................................................................................................ 5
1.2 OVERVIEW........................................................................................................................... 5
1.3 UNIT INTERFACES.............................................................................................................. 5

2. PROCESS DESCRIPTION.............................................................................................6
2.1 BASIS OF DESIGN............................................................................................................... 6
2.1.1 GENERAL................................................................................................................. 6
2.1.2 PLANT CAPACITY.................................................................................................... 6
2.1.3 FEEDSTOCK CHARACTERISTICS.........................................................................8
2.1.4 PRODUCT SPECIFICATIONS..................................................................................9
2.2 PROCESS FLOW DESCRIPTION......................................................................................10
2.2.1 FUEL GAS FEED STREAMS..................................................................................10
2.2.2 HP FUEL GAS STREAMS......................................................................................10
2.2.3 LP FUEL GAS CONDITIONING..............................................................................11
2.3 PROCESS OPERATING VARIABLES................................................................................12
2.4 PROCESS CONTROL........................................................................................................ 13
2.4.1 UNIT CONTROLLERS SUMMARY.........................................................................13
2.4.2 HP FUEL GAS CONTROL......................................................................................13
2.4.3 LP FUEL GAS CONTROL.......................................................................................13

3. SAFETY INFORMATION..............................................................................................14
3.1 ALARMS............................................................................................................................. 14
3.2 RELIEF VALVES................................................................................................................. 15
3.3 SAFETY CONSIDERATIONS............................................................................................. 15

4. MAIN EQUIPMENT DATA............................................................................................16

4.1 DRUMS............................................................................................................................... 16

5. START-UP.................................................................................................................... 17
5.1 PRE-START PROCEDURES AND CHECKS......................................................................17
5.2 START-UP PROCEDURES AND CHECKS........................................................................18
5.2.1 INITIAL PRESSURISATION USING GAS FROM IGAT 3 NETWORK....................19
5.2.2 SWITCHOVER TO NORMAL FUEL GAS SUPPLY................................................19
5.2.3 START-UP OF FUEL GAS TRAIN B.......................................................................20
5.3 DIFFERENT START-UP MODES OR CONDITIONS..........................................................21
5.3.1 PHASE CROSSOVER OPERATION......................................................................21

6. NORMAL OPERATIONS..............................................................................................22
6.1 ROUTINE DUTIES AND CHECKS.....................................................................................22
6.2 ITEMS FOR SPECIAL ATTENTION....................................................................................23
6.2.1 FUEL GAS DRUMS................................................................................................ 23
6.3 OPERATING MODES......................................................................................................... 24

7. SHUTDOWN................................................................................................................ 25
7.1 EMERGENCY SHUTDOWN............................................................................................... 25
 7.2 PROCESS SHUTDOWN.................................................................................................... 25
7.3 NORMAL SHUTDOWN....................................................................................................... 25

8. REFERENCES............................................................................................................. 27
8.1 PROJECT / ENGINEERING DOCUMENTS.......................................................................27
8.2 VENDOR DOCUMENTS..................................................................................................... 27

9. DRAWINGS..................................................................................................................28
9.1 ENGINEERING DRAWINGS.............................................................................................. 28
9.2 VENDOR DRAWINGS........................................................................................................ 28

10. OTHER INFORMATION...............................................................................................29

1. INTRODUCTION

1.1 PURPOSE

The purpose of Unit 122 is to supply fuel gas to all consumers within the Phase 4 and 5 plant
facilities. Fuel gas is supplied at two pressures, HP fuel gas for gas turbines, flare stack
sweep gas and various other users, LP fuel gas for steam boilers and flare header sweep gas.

1.2 OVERVIEW

Two pressure levels of fuel gas are supplied within the onshore treatment complex, High
pressure (HP) and low pressure (LP) fuel gas. During normal operation, fuel gas is fed to the
fuel gas unit from the suction of the export gas compressors (unit 106). The fuel gas is
letdown to HP fuel gas operating pressure and is conditioned to produce HP fuel gas. Part of
the HP fuel gas is letdown and conditioned to produce LP fuel gas. Flash gas from the MDEA
Gas Sweetening Unit (Unit 101) and Ethane Treating Unit(Unit116) are fed to the Steam
Boilers and mixed with the LP fuel gas. Start-up/back-up fuel gas is imported from IGAT 3 gas
pipeline and letdown to the HP fuel gas system.

Two fuel gas trains are provided for fuel gas system. Each fuel gas train normally takes 50%
of the normal required fuel gas flow (2 x 50% fuel gas trains) at normal operating conditions in
the plant.

1.3 UNIT INTERFACES

Inlet Streams
Unit 106 Export Gas Compressor Suction Header
Unit 123 Instrument Air Supply
IGAT 3 Start-up/Back-up Gas Pipeline

Outlet Streams
Unit 120/106/108/140/142 HP Fuel Gas to Users
Unit 121/140 LP Fuel Gas to Users
Unit 109 Condensate to Sour Water Stripper Feed Drum
Unit 140 Vents and relief streams are vented HP/MP flare systems
Unit 140 HP Sweeping Gas to Flare Stack Phase 4/5
Unit 109/122 LP Sweeping Gas to Flare Headers Phase 4/5
2. PROCESS DESCRIPTION

2.1 BASIS OF DESIGN

2.1.1 GENERAL

The fuel gas unit is designed to feed all fuel gas requirements of the complex. The unit
consists of two trains, each fed by one phase. Normally one train is dedicated to one phase,
however, when one phase is down, it is possible to feed the other train with the opposing
phase. In this case crossovers are provided at the inlet to the unit as well as on the flare
headers of the unit (flares are dedicated to each phase). It should be noted that fuel gas
supply and distribution is common to both phases therefore no crossovers are required at the
outlet of the fuel gas unit.

2.1.2 PLANT CAPACITY

The major fuel gas users in the onshore treatment complex are:

HP Fuel Gas
 Gas Turbines of Generators 120-GT-101 A/B/C/D
 Gas Turbines of Export Gas Compressors 106-GT-101/201/301/401/501/601
 Sweeping gas for Flare stacks Unit 140, Unit 147 and Unit 149
 Fuel gas for SRU operation (incinerator, preheating, pilot etc.)
 Atomizing gas for HC Liquid Burn Pit

LP Fuel Gas
 Steam Boilers 121-B-101 A/B/C/D/E/F
 Sweeping gas for flare networks

The overall HP and LP fuel gas requirements for the above users are summarized on the
following table:

Type of Fuel Gas Consumption Rate (Nm3/h)

Fuel Gas Design case Summer case Winter case Turndown case Start-Up Case

HP Fuel Gas 90212 * 86189 * 84059 * 43446 * 44264 **

LP Fuel Gas 63589 * 41557 * 45715 * 28236 * 17369 **

Total : 153801 127746 129774 71682 61633 **

* Based on Normal Fuel gas.

** Based on Black Start-up gas.

Most of the LP fuel gas is produced by letdown of HP fuel gas, with supplement LP fuel gas
from Gas Treating Unit (Unit 101) and Ethane Treating Unit (Unit 116). The total supplement
of LP fuel gas from the Gas Treating Unit and Ethane Treating Unit are 6406 Nm3/h.

All equipment and associated line work have been designed for the possibility of
one phase operation, with the other phase being shut down for inspection.
Design flowrates for equipment in the fuel gas system are as follows:

HP Fuel Gas Drums 122-D-101 A/B

Based on winter flowrate of lean fuel gas:

 Design flowrate for a single drum = 76901 Nm3/h
 Total turndown flowrate for a single drum = 35841 Nm3/h
 Turndown ratio = about 2.15 to 1
The normal operating philosophy of the drums is 2 x 50%, each drum handling 50% of the
normal operating flow.
Each drum is sized to handle 50% of the design flow rate of the consumed LP & HP Fuel gas.
No design margin is provided

LP Fuel Gas Drums 122-D-102 A/B

Based on winter flowrate of lean fuel gas:

 Design flowrate for a single drum = 31795 Nm3/h
 Total turndown flowrate for a single drum = 14118 Nm3/h
 Turndown ratio = about 2.25 to 1
The normal operating philosophy of the drums is 2 x 50%, each drum handling 50% of the
normal operating flow.
Each drum is sized to handle 50% of the design flow rate of the consumed LP Fuel gas. No
design margin is provided
2.1.3 FEEDSTOCK CHARACTERISTICS

The following gases are identified as being the sources of fuel gas:

 High pressure gas from the suction header of Export Gas Compressors (unit 106) for use
as HP fuel gas

 Flashed hydrocarbon gas from the Gas Treating unit (unit 101) and Ethane Treating unit
(unit 116) for use as steam boilers fuel gas

 Export gas from IGAT 3 gas pipeline for use as start-up/back-up fuel gas.

Due to variation in operation, the composition of high-pressure gas tapped from the suction
header of the export gas compressors may vary. This will give effect to the heating value of
the fuel gas. Two high-pressure gas compositions are selected in order to cover the possible
range of heating value of the fuel gas:

Normal Fuel Gas

This fuel gas has a methane content of 93.3 mole % and lower ethane content of 1.97 mole
%, which occurs when the Ethane Treating Unit 116 is operating at its design capacity. The
gas is supplied at 32 barg and 50 °C. The molecular weight of the gas is 17.03 with a dew
point of -86.7 °C at this pressure.

C2 Reject Fuel Gas

This fuel gas has a methane content of 89.48 mole % and higher ethane content of 5.7 mole
%, which occurs when the recovered ethane in Unit 105 is rejected to Export Gas Compressor
in Unit 106. The gas is supplied at 32.1 barg and 49 °C with a molecular weight of 17.61 and
has a dew point of -73 °C at this pressure.

C2 reject and normal fuel gas is sweet and dry.

Most of the LP fuel gas is produced from the HP fuel gas.

The supplement LP fuel gas from the Gas Treating Unit 101 is wet and saturated with water.
It contains some carried-over MDEA and about 500 ppm vol. of H2S. It is supplied at a
maximum total flowrate of 5413 Nm3/h.

The supplement LP fuel gas from the Ethane Treating Unit 116 is wet and saturated with
water. It contains some carried-over DEA and about 500 ppm vol. of H2S. It is supplied at a
maximum total flowrate of 410 Nm3/h.
The start-up fuel gas imported from IGAT 3 gas pipeline is also a dry and sweet gas. The gas
is supplied at 90 barg and 55 °C.
 2.1.4 PRODUCT SPECIFICATIONS

Some properties of the produced HP fuel gas, LP fuel gas and IGAT 3 fuel are given as
follows:

Based on Normal Fuel Gas Based on Normal Fuel Gas

Based on C2 Reject Fuel Gas Start-up HP
(WINTER) (SUMMER)

Physical Properties HP Fuel Gas LP Fuel Gas HP Fuel Gas LP Fuel Gas HP Fuel Gas LP Fuel Gas Fuel Gas

Low heating value : kJ/kg 45696 45696 45689 45689 45548 45548 -
Gross heating value : kJ/kg 50721 50721 50715 50715 50505 50505 9000 kcal/nm3
3
Wobbe index (1) : MJ/Nm 51.58 51.58 51.57 51.57 52.22 52.22 -
Molecular weight 17.03 17.03 17.03 17.03 17.61 17.61 -

HC dew point : C°
-92.1 (Note 1) -106.3 (Note 2) -92.3 (Note 1) -106.5 (Note 2) -79.5 (Note 1) -97.6 (Note 2) -10  5 (Note 3)
°
Water dew point : C -190.3 (Note 1) -195 (Note 2) -190.3 (Note 1) -193.3 (Note 2) -190.4 (Note 1) -193.5 (Note 2) -10 (Note 4)

Notes: 1. At 21 barg
2. At 5.5 barg
3. At 55 barg
4. At 44 barg
2.2 PROCESS FLOW DESCRIPTION

Refer to: Utility Flow Diagram No. 2017-122-0020-0001, included in Section 9.

2.2.1 FUEL GAS FEED STREAMS

Normal Supply

During normal operation, HP fuel gas is fed from the two gas headers (one connection per
header), connecting the Treated Gas Compressor of Unit 105 to the suction of Export Gas
Compressors of Unit 106. The two fuel gas lines route the high pressure gas to the fuel gas
system at 32 barg and 50 °C. At the battery limit of fuel gas system, each gas line feeds one
fuel gas train. Both fuel gas trains are identical therefore the operation of only one fuel gas
train is described here.

At the inlet of each fuel gas train, there are two pressure control valves arranged in parallel.
One control valve is in normal operation with the second valve as standby. Each valve takes
50% of the required total HP fuel gas flow (or flow to one fuel gas train). The pressure control
valves let down the HP fuel gas pressure to about 26 barg. By the Joule-Thompson effect,
the temperature of gas downstream of the valves drops to 46.7 °C. Three pressure
transmitters are provided, giving three pressure signals to the pressure control loop. A 2 out
of 3 voting system is adopted for pressure control. This is to enhance the reliability of the
pressure control loop in maintaining the supply pressure of HP fuel gas.

Alternative Supply

During start-up, when no gas is available from the gas headers, fuel gas is imported from the
IGAT 3 gas pipeline. The IGAT 3 gas has a pressure of 90 barg and a temperature of 55 °C.
This imported fuel gas is fed to a pressure control valve located on the start-up fuel gas line.
This control valve has no spare but equipped with by-pass. The letdown fuel gas is routed at
26 barg to either one of the fuel gas trains, downstream of inlet pressure control valves PV
0001A1/A2/B1/B2.

2.2.2 HP FUEL GAS STREAMS

The supply pressure of HP Fuel Gas (26 barg) to users complies with user requirements.
Additional intermediary equipment (such as Compressors) is therefore not required between
HP fuel gas supply and users.

After letdown at the inlet of the fuel gas unit, the HP fuel gas is routed to HP Fuel Gas Drum
122-D-101A. This drum takes 50% of the total HP fuel gas requirement. Any liquid that may
be present in the HP fuel gas is removed in this drum. The drum is equipped with a wire
mesh demister to capture fine droplets which avoids sending liquid into the fuel gas
distribution network. The liquid that is collected in the HP Fuel Gas Drum is sent under
intermittent on/off level control (LIC 0021A) to the utilities and offsite drain drum.
 The HP fuel gas produced is split into three portions:

 One portion of the HP fuel gas is used to produce LP fuel gas.

 One portion of the HP fuel gas is sent directly to the users such as gas turbines of Export
Gas Compressors and Generators. The HP fuel gas line from the second fuel gas train is
combined with the HP fuel gas line from the first fuel gas train into a single distribution
header outside the battery limit of fuel gas system. No steam or electrical tracing is
required for the fuel gas distribution headers.

 One portion of the HP fuel gas is routed to the flare stacks as sweeping gas.

2.2.3 LP FUEL GAS CONDITIONING

In order to produce the LP fuel gas, the HP fuel gas is letdown to 7.5 barg by two pressure
control valves arranged in parallel. One control valve is in normal operation and the second
valve is in standby. Each valve takes 50% of the total LP fuel gas requirement of the plant.
Three pressure transmitters are provided each sending a signal to the pressure controller. 2
out of 3 voting is adopted for pressure control to enhance the reliability of the pressure control
loop to maintain the supply pressure of LP fuel gas. The resulting LP fuel gas has a
temperature of 40.8 °C.

Normally, LP Fuel Gas Drums in both fuel gas trains are in operation. Each drum takes 50%
of the total required LP fuel gas flow. The drum is equipped with a wire mesh demister to
capture fine droplets which avoids sending liquid into the fuel gas distribution network. The
liquid that is collected in the LP Fuel Gas Drum is sent under intermittent on/off level control
(LIC 0031A) to off spec condensate tank.

The LP fuel gas from the second fuel gas train is combined with the LP fuel gas from the first
fuel gas train into a single distribution header outside the battery limit of fuel gas system. No
steam or electrical tracing is required for the fuel gas distribution headers.
2.3 PROCESS OPERATING VARIABLES

The control of the fuel gas system is simple and is based on maintaining the correct pressures
and temperatures of HP and LP fuel gas. In broad terms, a control valve in the feed line
regulates most fuel gas users.

Maintaining HP Fuel Gas Pressure

The pressure control loop PIC 0001A1/A2 maintains the HP fuel gas pressure in first fuel gas
train by regulating pressure control valves PV 0001A1 or PV 0010A2. For second fuel gas
train, PIC 0001B1/B2 maintains the HP fuel gas pressure by regulating pressure control
valves PV 0001B1 or PV 0001B2.

Selector HS 0001 is provided to select one signal from PYs 0001A/B for controlling relevant
PVs 0001A/B.

The pressure control loop PIC 0003 maintains the HP fuel gas pressure from IGAT 3 (during
start-up) by regulating pressure control valve PV 0003.

Maintaining LP Fuel Gas Pressure

The pressure control loop PIC 0031A1/A2 maintains the LP fuel gas pressure in first fuel gas
train by regulating pressure control valves PV 0031A1 or PV 0031A2. For second fuel gas
train, PIC 0031B1/B2 maintains the LP fuel gas pressure by regulating pressure control valves
PV 0031B1 or PV 0031B2.

Selector HS 0031 is provided to select one signal from PYs 0031A/B for controlling relevant
PVs 0031A/B.
2.4 PROCESS CONTROL

Refer to: Unit 122 System Flow Diagram and P&IDs, included in Section 9.

2.4.1 UNIT CONTROLLERS SUMMARY

The following instrument tag numbers begin with the prefix 1221, unless otherwise noted.

Tag No. Function / Location Set Point Action / Remarks

PIC 0001 Modulates
U-122 fuel gas unit inlet letdown 26 barg
A1/A2/B1/B2 PV 0001A1/A2/B1/B2
PIC 0003 IGAT 3 start-up/backup gas letdown 22.5 barg Modulates PV 0003
On/Off controller acting
LIC 0021A/B HP fuel gas drum level controllers 650 mm
on LV 0021A/B
PIC 0031 Modulates
HP/LP fuel gas letdown 7 barg
A1/A2/B1/B2 PV 0031A1/A2/B1/B2
On/Off controller acting
LIC 0031A/B LP fuel gas drum level controllers 650 mm
on LV 0031A/B

2.4.2 HP FUEL GAS CONTROL

HP fuel gas is normally controlled by letdown of Fuel gas from the export gas compressor
suction header, in two parallel pressure letdown valves (PV 0001A1/A2 for train A and PV
0001B1/B2 for train B). Each valve is sized for 100 % of the design flow of 1 fuel gas train.
The fuel gas system is also fed from the IGAT 3 network for providing fuel gas for start-up and
backup. Fuel gas from the IGAT 3 network is letdown in PV 0003 to fuel gas operating
pressure. The set point of IGAT 3 pressure controller is set slightly lower than that of the main
fuel gas supply pressure controller such that during normal operation, the fuel gas system is
fed from the export gas suction header. If the main fuel gas supply is interrupted, when the
fuel gas pressure decreases to the IGAT 3 pressure controller set pressure, PV 00 03 on IGAT
3 will open to back-up the fuel gas system.

2.4.3 LP FUEL GAS CONTROL

The pressure of the LP fuel gas system is controlled by a pressure controller operating two
control valves per train (PV 0031A1/A2 for train A and PV 0031B1/B2 for train B). Each
control valve is sized for 100 % of the design fuel gas requirement for one train.
3. SAFETY INFORMATION

3.1 ALARMS

Tag No. Function / Location Set Point Action / Remarks

Prefix 1221 HP Fuel Gas
PACH 0001A/B HP fuel gas high / low letdown 27 barg Alarm
PACL 0001A/B pressure 25.5 barg Alarm
PACH 0003 IGAT 3 fuel gas high / low letdown 27 barg Alarm
PACL 0003 pressure 25.5 barg Alarm
LACH 0021A/B HP fuel gas drum (122-D-101A/B) 1000 mm Alarm
LACL 0021A/B high / low level 300 mm Alarm
Prefix 1221 LP Fuel Gas
PACH 0031A/B HP/LP Fuel gas high / low letdown 7.5 barg Alarm
PACL 0031A/B pressure 6.5 barg Alarm
LACH 0031A/B LP fuel gas drum (122-D-102A/B) high 1000 mm Alarm
LACL 0031A/B / low level 300 mm Alarm
PAH 0032A/B LP fuel gas high / low supply pressure 7.5 barg Alarm
PAL 0032A/B 6.5 barg Alarm
3.2 RELIEF VALVES

Tag No. Equipment Protected / Location Set Point Remarks

Prefix 1221
PSV 0022A1/A2 HP fuel gas drums 122-D-101A/B 31.0 barg Relief to FC4
PSV 0022B1/B2 31.0 barg Relief to FC5
PSV 0032A1/A2 LP fuel gas drums 122-D-102A/B 8.5 barg Relief to FS4
PSV 0032B1/B2 8.5 barg Relief to FS5

3.3 SAFETY CONSIDERATIONS

The fuel gas trains are provided with a manual crossover at the inlet to the unit. This allows
each train to operate on either phase when one train or phase is down.

As each fuel gas train is dedicated to one phase, the flare headers for the fuel gas block are
also provided with a crossover.

Care must be taken to assure that when the crossover at the inlet to the fuel gas unit is open,
the flare header crossovers must also be open as no interlocks are provided on these
crossovers.
4. MAIN EQUIPMENT DATA

4.1 DRUMS

Item No. 122-D-101 A/B 122-D-102 A/B

Service HP Fuel Gas Drums LP Fuel Gas Drums
Type Vertical Vertical
Supplier / Manufacturer DAE KYUNG DAE KYUNG
Material CS + SS Internals CS + SS Internals
Fluid Fuel Gas Fuel Gas
Dimensions (ID x TL/TL) 1800 x 3000 mm 1400 x 2900
Capacity (Total / Working Volume) - -
Flowrate (Design / Normal) Nm3/h Nm3/h
Design Pressure 31 barg 8.5 barg
Operating Pressure 26 barg 7 barg
Design Temperature 85 C 85 °C
Operating Temperature 46.7 C 40.8 °C
Insulation No No
5. START-UP

Refer to the Fuel Gas Unit P&ID’s listed in section 9 of this manual.

The following systems are assumes to be available prior to start-up of the fuel gas system:
- Electricity Supply System (Diesel back-up generators in operation)
- Flare System including flare header sweeping with nitrogen (U-140)
- Instrument Air System (U-123)
- Nitrogen System for unit inerting and flare header sweeping (U-124)
- Fire & Gas and ESD Systems.

Initial Status

Start-up is considered from a state when the export gas is not available from the export gas
compressor suction (Unit 106) and the system is completely drained, depressurised, cold and
has been purged with inert gas. All SDVs and ESDVs are in the closed position.

5.1 PRE-START PROCEDURES AND CHECKS

The following procedure corresponds to start-up of fuel gas train A only (phase 4). Starting of
train B (phase 5) is described further on in this section. This procedure is the same when
staring train B first rather than train A.
All unit spectacle blinds should be in operating position as shown on the P&IDs.
Manual valves should be in operating position; relief valve and BDV-0022 block valves should
be locked open.
Start-up bypass on SDV-0004 manual block valve should be unlocked and open, start-up
bypass globe valve should remain closed.

Manually override the following signal:

 Pressure PT 0001A HP Fuel Gas Pressure.
5.2 START-UP PROCEDURES AND CHECKS

The start-up sequence described in this section is for detailed start-up after a maintenance or
operations shutdown.

 Set the SDV valves in the position as listed in the table below.

Table 5-1 SDV Initial Position List

Initial
Valve N° Service
Position
SDV 0002A Fuel Gas Unit Feed From Export Gas Compressor Suction Header Phase 4 Closed
SDV 0002B Fuel Gas Unit Feed From Export Gas Compressor Suction Header Phase 5 Closed
SDV 0004 Start-up Fuel Gas Feed to Fuel Gas Unit From IGAT 3 Network Closed
SDV 0007A HP Sweeping Gas to Phase 4 Flare Stacks Open
SDV 0007B HP Sweeping Gas to Phase 5 Flare Stacks Closed
SDV 0024A HP Fuel Gas to Distribution From Fuel Gas Train A Closed
SDV 0024B HP Fuel Gas to Distribution From Fuel Gas Train B Closed
SDV 0031A HP Fuel Gas to LP Fuel Gas Train A Open
SDV 0031B HP Fuel Gas to LP Fuel Gas Train B Open
SDV 0032A LP flare Gas to Distribution From Fuel Gas Train 1 Closed
SDV 0032B LP flare Gas to Distribution From Fuel Gas Train 2 Closed

 Manual valves on IGAT 3 Start-up gas to Train A should be open.

 Check that all control loops in fuel gas train A are operational with the exception of those
listed above in section 5.1.

 Set all ESDV valves to the closed position.

 Train B should be kept isolated.

5.2.1 INITIAL PRESSURISATION USING GAS FROM IGAT 3 NETWORK

 Open first 8” manual valve and adjacent 1” bypass globe valve around second 8” manual
valve, in coordination with IGAT 3 gas network operator. Once pressurisation is attained,
second 8” manual valve is opened.

 Before pressurisation using gas from IGAT 3, the globe valve on SDV 0004 start-up
bypass should be opened slightly to avoid too much pressure difference across the valve
(~90 barg upstream and ~1 barg downstream) which would make opening the valve
impossible.

 Open ESDV 0003 on IGAT 3 gas network to start purging the inert gas from the system.

 Open SDV 0004 start-up bypass globe valve using this valve to control the rate of purge
of the system.

 Open the relief valve bypasses on both HP and LP Fuel Gas Drums to purge the inert gas
in the system to flare.

 After purging the system with fuel gas, close the relief valve bypasses to allow the system
to pressurise.

 Pressurise fuel gas train A using the start-up bypass until the fuel gas system reaches LP
fuel gas pressure. At this stage PV 0031 A1/A2 on the LP fuel gas inlet will start to control
the LP fuel gas pressure.

 When LP fuel gas pressure is attained, open SDV 0004 on the main IGAT 3 inlet to
continue pressurisation of the HP fuel gas system. PV 00 03 on the IGAT 3 inlet will start
to close when the set pressure of its controller is attained.

 Close both the block valve and globe valve on the start-up bypass round SDV 00 04. The
block valve should be locked CSC.

 As there is no consumption of fuel gas, the HP and LP fuel gas pressure controllers PIC
0003 and PIC 0031A will close their respective valves once each system has attained its
set pressure.

 Train A of the fuel gas system is now pressurised and is ready to feed the fuel gas
distribution.

5.2.2 SWITCHOVER TO NORMAL FUEL GAS SUPPLY

IGAT 3 fuel gas is used to feed the plant requirements until export gas is available in the
export gas compressor suction header. When export gas is available, IGAT 3 supply is
replaced and put on stand-by to be used as fuel gas back up.

 When export gas is available, the piping upstream of pressure control valve manifold PV
0001A is pressurised by opening the manual start-up bypass around SDV 000 2A by
slightly opening the bypass globe valve and fully opening the bypass block valve. Open
ESDV 0001A. The piping is pressurised by adjusting the flow through the bypass globe
valve until the pressure has equalised upstream and downstream of SDV 000 2A (no
more flow).

 Once the piping has been pressurised upstream of PV 0001A1/A2, open SDV 0002A and
close both the block valve and globe valve on the start-up bypass round SDV 000 2A.
The block valve should be locked CSC.
  Feed to the fuel gas system from the export gas compressor suction header is started by
cancelling the manual override on PT 0001A HP fuel gas pressure. With PT 0001A in
operation, PV 0001A1/A2 will adjust the fuel gas flow from the main supply to maintain
the HP fuel gas set pressure. The IGAT 3 fuel gas supply will be shut-off automatically by
PV 0003 as the set point on PIC 0003 is lower than that of PIC 0001A. The IGAT 3 fuel
gas supply will remain on standby in case of loss of the main fuel gas supply.

5.2.3 START-UP OF FUEL GAS TRAIN B

When required, fuel gas train B is started up in the same way as train A. It is essential to
ensure that the unit is well purged to avoid feeding pockets of inerts to fuel gas users. The
presence of inerts in consumer fuel gas could trip the user if the inert content of the fuel gas is
too high.
5.3 DIFFERENT START-UP MODES OR CONDITIONS

5.3.1 PHASE CROSSOVER OPERATION

Each fuel gas train is initially dedicated to a phase (Train A to Phase 4, Train B to Phase 5).
However, if one Phase is down for any reason, a crossover at the inlet to the fuel gas unit
allows either train to feed the opposing phase (Train A to Phase 5, Train B to Phase 4).

A crossover is also provided on block 109/122 flare headers such that each fuel gas train is
connected to the Phase that it is being fed by. For example, if fuel gas train B is being fed by
Phase 4, Phase 5 being down for maintenance, fuel gas train B will also be connected to
Phase 4 flare via the flare header crossovers. The following combinations of fuel gas trains
and Phase operation can be defined:

Table 5-2 Phase Train Flare Connections

Phase Operation Train Operation Flare Connections

Train A to Phase 4 Flares
Phase 4 & Phase 5 Train A & Train B
Train B to Phase 5 Flares
Phase 4 Only Train A Train A to Phase 4 Flares
Phase 4 Only Train B Train B to Phase 4 Flares
Train A to Phase 4 Flares
Phase 4 Only Train A & Train B
Train B to Phase 4 Flares
Phase 5 Only Train A Train A to Phase 5 Flares
Phase 5 Only Train B Train B to Phase 5 Flares
Train A to Phase 5 Flares
Phase 5 Only Train A & Train B
Train B to Phase 5 Flares

WARNING
When starting up a fuel gas train, it is extremely important to ensure that the fuel gas
train(s) in operation are connected to the flares of the Phase that they are being fed by. No
mechanical or electronic interlocks are provided on the crossovers to eliminate the risk of
connecting a fuel gas train to a flare that is not in operation.
 6. NORMAL OPERATIONS

6.1 ROUTINE DUTIES AND CHECKS

The following is a list of items or conditions that should be monitored and recorded on a
regular basis:

Table 6-1 Routine Instrument Checklist

Measurement DCS Indicator Local Indicator

Prefix 1231 Fuel gas

IGAT 3 Fuel Gas Supply
IGAT 3 Flowrate 1221-FQI-0003
IGAT 3 HP Fuel Gas Pressure Controller 1221-PIC-0003
HP Fuel Gas Train A
Fuel Gas Inlet Flowrate 1221-FI-0001A
HP Fuel Gas Pressure Controller 1221-PIC-0001A1
122-D-101A Level Controller 1221-LIC-0021A 1221-LG-0021A
HP Fuel Gas to Users 1221-FQI-0024A
HP Fuel Gas Supply Temperature 1221-TI-0022A
LP Fuel Gas Train A
LP Fuel Gas Pressure Controller 1221-PIC-0031A1
122-D-102A Level Controller 1221-LIC-0032A 1221-LG-0032A
LP Fuel Gas to Users 1221-FQI-0032A
LP Fuel Gas Supply Pressure 1221-PG-0032A
HP Fuel Gas Train B
Fuel Gas Inlet Flowrate 1221-FI-0001B1
HP Fuel Gas Pressure Controller 1221-PIC-0001B1
122-D-101B Level Controller 1221-LIC-0021B 1221-LG-0021B
HP Fuel Gas to Users 1221-FQI-0024B
HP Fuel Gas Supply Temperature 1221-TI-0022B
LP Fuel Gas Train A
LP Fuel Gas Pressure Controller 1221-PIC-0031B1
122-D-102A Level Controller 1221-LIC-0032B 1221-LG-0032B
LP Fuel Gas to Users 1221-FQI-0032B
LP Fuel Gas Supply Pressure 1221-PG-0032B
6.2 ITEMS FOR SPECIAL ATTENTION

All the operating parameters of the Unit should be monitored carefully in order to ensure a
steady and satisfactory operation of the system. Nevertheless, the following operating
parameters for the equipment listed below are of a primary importance and a special attention
should be paid to them.

6.2.1 FUEL GAS DRUMS

Liquid level in fuel gas drums 122-D-101A/B and 122-D-102A/B must be checked regularly on
control room VDU and local level gauges to ensure that there is no liquid build-up.
6.3 OPERATING MODES

Unit 122 is designed for normal plant operation to feed all plant requirements using both fuel
gas trains. Nevertheless in case one fuel gas train is down for maintenance, the operational
fuel gas train can feed 1 phase of the plant including all utilities and other users common to
both phases and also allows for the start-up of a third export gas compressor.

The design of each fuel gas train allows the simultaneous operation of the following:

Table 6-2 One Phase Operation Full Gas Allowance

Fuel Gas User One Phase Fuel Gas Allowance

HP Fuel Gas
Gas Turbine Generators
Export Gas Compressors
Flare Stack Sweeping Gas
SRU (unit 108)
Atomising Gas for Burn Pit
Requirement to produce electricity for 1 phase operation
All four compressors in operation
Requirement for flares of one phase
Requirement for 1 phase in operation
Same requirement as for two phases

LP Fuel Gas
HP Steam Boilers Requirement to produce steam for 1 phase operation
Flare Header Sweeping Gas Requirement for flare headers of one phase
7. SHUTDOWN

7.1 EMERGENCY SHUTDOWN

Actions of different levels of emergency shutdown are reported in the Shutdown Logic
Diagram (SLD), 2017-122-0020-1001, included in Section 9.

The Emergency Shutdown is reflected as ESD1 (Level 1: Fire Zone and Emergency
Shutdown) in the SLD.

7.2 PROCESS SHUTDOWN

Actions of different sections of process shutdown are reported in the Shutdown Logic Diagram
(SLD), 2017-122-0020-1001, included in Section 9.

The Process Shutdown is reflected as Level 3 Shutdowns (SD3) in the SLD, and referred to
as equipment shutdown.

7.3 NORMAL SHUTDOWN

Normal Unit Shutdown has to be considered for planned shutdown, generally in case of
maintenance requirement for the Unit.

Important: The only time that both fuel gas trains can be shutdown is after total shutdown
of the plant.

The following normal shutdown procedure concerns the shutdown of fuel gas train A only.
Shutdown of the fuel gas train B is identical to that described below. Fuel gas from IGAT 3
remains available for back up to train B.

 Close manual block valves (on IGAT 3 fuel gas supply) to isolate the fuel gas train from all
sources of fuel gas feed to the HP section of the train.

 To isolate the LP section from all sources of fuel gas, close SDV 003 1A to isolate from the
HP/LP letdown.

 Isolate the HP and LP outlets from train A by closing SDV 0007A (flare stack sweeping
gas), SDV 0024A (HP fuel gas to users, train A) and SDV-0032A (LP fuel gas to users,
train A).

Caution
When shutting down train A and phase 4 flare stacks are still required, ensure that the
crossover between train A and train B flare stack sweeping gas is open before closing SDV-
0007A.

 Finish isolating the unit by closing the following ESDVs:

ESDV-0006 HP Fuel gas supply from Export Gas Compressor suction Header
 All other ESDVs must remain open to allow operation of train B and the rest of the plant.

 Before depressurising the fuel gas train to flare, use the pressure remaining in the system
to transfer any liquid that may be present in HP Fuel Gas Drum 122-D-101A and LP Fuel
Gas Drum 122-D-102A to the sour water stripper feed drum.

 Depressurise the train by opening the relief valve bypasses and vents to flare in both the
HP and LP sections.

Caution
Before depressurising the fuel gas train, make sure that the corresponding flare systems
are available, otherwise, use flare crossovers to connect to flare of the phase that is still in
operation.

 When the fuel gas train has been depressurised, purge the equipment and lines with
nitrogen.

 Isolate the train by putting spectacle blinds in closed position before starting any
maintenance on the unit.

When shutting down the whole unit (both trains), the unit is similarly isolated by SDVs and
ESDVs, depressurised, purged with nitrogen and isolated by turning spectacle blinds to their
closed position.

Caution
Flares must be available during all stages of fuel gas unit shutdown.
8. REFERENCES

8.1 PROJECT / ENGINEERING DOCUMENTS

DB-2017-122-P312-101 Process Design Basis for Unit 122

Fuel Gas System

8.2 VENDOR DOCUMENTS

No Vendor Documents are required to be included for this Unit.

9. DRAWINGS

The following drawings are included hereafter:

9.1 ENGINEERING DRAWINGS

Utility Flow Diagram

2017 122 0020 0001 HP and LP Fuel Gas Drums

P&I Diagrams
2017 122 0030 0101 Pressure Letdown Station and Sweeping Gas
2017 122 0030 0102 HP Fuel Gas Drums
2017 122 0030 0103 LP Fuel Gas Drums

Interconnection P&ID Diagrams

2017 160 0040 0006A Diesel Oil and Fuel Gas
2017 160 0040 0006B Diesel Oil and Fuel Gas
2017 160 0040 0006C Diesel Oil and Fuel Gas

Shutdown Logic Diagram

2017-122-0020-100 Fuel Gas

9.3 VENDOR DRAWINGS

No Vendor Drawings are required to be included for this Unit.

10. OTHER INFORMATION

No other information is presently required for this section, but it is available for holding copies
of any additional documents, which are relevant to the correct and safe operation of this
System.