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JIHAR Stage 3 Project

HPC Contract No.: HPC/08-06
Petrofac Job No.: JI-191

TRAINING COURSE MATERIAL MODULE M16

GAS TREATMENT PLANT

EMERGENCY SHUTDOWN PROCEDURE

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TABLE OF CONTENTS

1 EMERGENCY SHUTDOWN PROCEDURE.........................................................3

1.1 Emergency shutdown ESD-1 (Level 1)....................................3
1.2 Emergency Shutdown – ESD2 ( Level 2)..................................8
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1 EMERGENCY SHUTDOWN PROCEDURE

Emergency shutdown is caused either due to a Level-1 ESD or Level-2

ESD. ESD Levels for this plant is split into the following sub levels

• ESD-1: Complete plant isolation of GTP. Upon initiation of ESD 1

shutdown, Complete Blowdown shall be initiated by operator through a

hardwired pushbutton (HS-2970-09) on the ESD matrix panel in the GTP

control room.

• ESD-2: Complete isolation of a process unit. Upon initiation of ESD

2 shutdown

Blowdown (if applicable) shall be initiated by the operator through the

hardwired pushbutton on the ESD matrix panel in the GTP control room

for a particular unit.

The details of each level is described below .

1.1 Emergency shutdown ESD-1 (Level 1)

There are two scenarios of shutdown in ESD-1.

Automatic shutdown:

Emergency shutdown can be initiated automatically based on the

following signals:

• Instrument air failure

• Flare ko drum level high high

• Total power failure

• Confirmed fire & gas detection in GTG area(Fire zone 14)

• Confirmed fire & gas detection in Fire zone15 (Telecom

tower,MCC, Control room)

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• Confirmed fire & gas detection in oil storage area(Fire zone

10) Manual Shutdown:

Emergency shutdown can be initiated manually by pressing any of the

push buttons indicated below :

• HS-2970-01 at Jihar GTP control room

• HS-2970-02 at Jihar GTP gas plant gate

• HS-2970-03 at Jihar GTP process area

• HS-2970-04 at Jihar GTP oil tank farm area

The schematic representation of ESD-1 is as follows :

Complete plant can be depressurised through a sequential blowdown by

initiating a push button HS-2970-09. The sequential blowdown is required to

limit the flaring with the design capacity of flare.

The overall sequential blow down system is as follows :

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The overall blowdown time is estimated to be about 3 hours to depressurise

the complete plant.

The figure below indicates the overall blowdown time .

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JIHAR GTP STAGGERED BLOWDOWN SEQUENCE ( ADIABATIC CASE)

Blowdown Rate MMSCFD

200

1. Demethansier Overhead Vapour Loop

180 2.Recycle compressor Loop ( 3 loops)
5
3. Sales gas compressor Loop
2,3,4
4. De-Ethansier loop
160
5. HP Gas Loop

140
1

120

100

80

60

40

20

0
0 20 40 60 80 100 120 140 160 180
Time (min)

As indicated above there are 5 blowdown zones . Each blowdown zone

is provided with a push button to depressurise that particular system.

The details of each blowdown zone and the push button numbers are

listed below in the Table.

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Blowdown Blowdown Hand

RO Tag
Sequence. Vessel description Valve tag Switch
No. No. Tag No.
No.
Turbo expander ( EXP-2501)
Demethaniser Column (T-2501)
Demethaniser Auxiliary Reboiler shell side (E-2505)
Demethanizer Reboiler shell side (E-2501)
Demethanizer Reflux Sub-cooler shell and tube (E-2504) HS-2500-
1 RO-2501-08 XV-2501-16
Demethanizer Reflux Pump (P-2501A/B) 04
Fluid-2 and 3 of Gas / Gas Exchanger (E-2502)
Gas Recompressor Suction Drum (V-2502)
Turbo expander and Recompressor (EXP-2501 and C-2501)
Deethaniser Overhead compressor discharge to Sales gas
compressor suction ( C-2503)
Recycle Compressor 1st stage KO Drum (V-2301),
2A Recycle Compressor condensate pumps (P-2301 A/B) RO-2301-01 XV-2301-03
Recycle Compressor -1st stage (C-2301) suction
Recycle Compressor -1st stage (C-2301) discharge
Recycle Compressor inter stage Cooler (A-2301)
2B XV-2302-05 HS-2300-02
Recycle Compressor 2nd stage KO Drum (V-2302), RO-2302-02
nd
Recycle Compressor- 2 stage (C-2302) suction
nd
Recycle Compressor- 2 stage (C-2302) discharge
2C RO-2302-01 XV-2302-02
Recycle Compressor inter stage Cooler (A-2302)
Sales gas compressor discharge ( C-2502 A/B/C)
3 Sales Gas Cooler (A-2501) RO-2501-06 XV-2501-12 HS-2500-02
Sales Gas Metering Skid (X-2590)
Deethaniser Column (T-2511)
Deethaniser Reboiler shell side (E-2511)
Deethaniser Overhead Receiver (V-2511)
4 RO-2511-01 XV-2511-06 HS-2500-05
Deethaniser Overhead Condenser tube side (E-2507)
Deethaniser Reflux Pump (P-2511A/B)
Deethaniser Overhead compressor suction ( C-2503)
HP separator ( V-2101)
Test Separator ( V-2102)
HP gas cooler (A-2101)
Demethaniser Reboiler (E-2501)
Gas Cooler ( E-2401)
Molecular sieve inlet separator ( V-2401)
5 RO-2502-03 XV-2502-05 HS-2500-03
Molecular sieve inlet filter coalescer (F-2401)
Dehydration inlet heater ( E-2402)
Molecular sieve dryer ( V-2402 A/B/C)
Dry gas filter (F-2402 A/B)
Fluid-1 Gas Gas exchanger (E-2502)
Low temperature Separator ( V-2501)
RO-2601- XV-2601- HS-2600-
6 LPG Bullets ( V-2601 A/B/C/D) ( * )
01/02/03/04 03/06/09/12 02/03/04/05

( *) Only one LPG bullet will be depressurized at a time. Blow down sequence no.6 ( LPG bullets) is not part
of the overall sequential blow down
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1.2 Emergency Shutdown – ESD2 ( Level 2)

ESD-2 shall be automatically initiated upon receiving confirmed fire /gas in

the unit or package and can also be manually executed by ESD-2

Pushbutton in Control room for Process unit or local pushbutton for package

unit.

The schematic representation of the ESD-2 loop is as

:

On ESD-2, operator is authorized to press any one push button for blow

down of respective loop. On initiation of one push button, other push

button shall be inhibited for the delay time specified.

Time delay for the blow down push buttons is as indicated in the table
Sr .No Description Hand Switch Tag No. Time
below:
Delay, min

1 De-Methaniser Overhead Vapour Loop HS-2500-04 & HS- 80

& De- Ethaniser Loop 2500-05

2 HP Gas Loop HS-2500-03 110

3 Sales Gas Compressor Loop HS-2500-02 30

On confirmed fire in fire zone FZ-08, both push buttons HS-2500-04 & HS-

2500-05 shall be initiated simultaneously.

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On confirmed fire only in fire zone FZ-09, push button HS-2500-05 shall only

be initiated.

Delay timer is not required for initiating Recycle compressor loop (HS-2300-

02) push button. Recycle compressor loop can be initiated along with any

one of the blow down loops specified in Table above.

During ESD-2 blowdown of plant, operator shall not initiate LPG bullets

blowdown. Blowdown valves for LPG bullets are provided only for

depressurization during maintenance. Fire case is not envisaged for LPG

bullets since LPG bullets are mounded.

If operator decides to initiate ESD-1 after ESD-2 initiation, the blow down

initiated on ESD-2 has to be aborted.

Refer to ESD C&E document no JI-191-IN-18-2970-10020 for cause & effects

due to ESD Level-1 & 2.

On Confirmed F&G detection in Fire zone 01 to 09 , the following units are

automatically shutdown on ESD2 :

Unit 2000 / 2100 / 2200 / 2300 / 2400 / 2500 / 2860 /

2880

On Confirmed F&G detection in Fire zone 11, Unit 2600 is shutdown on

ESD2 .

On Confirmed F&G detection in Fire zone 13, Unit 2700 is shutdown on

ESD2 .

On confirmed fire detection in Fire zone 17, Unit 2960 is shutdown on

ESD2
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Additionally the following units can be shutdown manually through push

buttons

o Unit 2300 - By PB , HS-2300-01

o Unit 2500 – By PB , HS-2500-01

o Unit 2600 – By PB, HS-2600-01

o Unit 2700 – By PB, HS-2700-01