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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
CONTENTS
SECTION I INTRODUCTION
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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
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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
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:
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.
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.
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2.3.1 MDEA
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
First-Aid Measures
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.
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3.1 PROCESS
The following facilities are part of the Sulphur Recovery Upgrade Project:
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.
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.
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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.
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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).
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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 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 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.
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).
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LV-1305
FV-1314
XV-1331
FV-1304
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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.
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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)
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.
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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
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)
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 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.
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.
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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
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
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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 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.
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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).
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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.
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PV-1523
TV-1522
XV-1527
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PV-1301A
Suction Header
E-19
6236-V-05
XV-1302 PV-1301B
XV-1303 PV-1302
To Flare Header
Backup Supply Fuel Gas
from 30" Existing Line
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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.
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XV 1312
Pressurised drain from
PV 1307
9102-P-12A/B
LV-1325 M Water for Startup
Waste
Water
Stripper Stripper Overheads
FV 1314
6922-C-01 Circulation Pumps
6922-P-11 A/B
TV 1327
LV 1327 LP
Sour Stripped Condensate
Water Exchanger
Stripped Water Pumps
6922-E-01
6922-P-10A/B
Stripped Water to
M Observation Sump
6922-X-04
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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.
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.
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LO
6 Lit. Capacity
Air Vessel
NC
LC
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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
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
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
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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
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
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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).
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.
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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.
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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.
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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.
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.
Acid gas amine absorber top pressure control valve 91-PV-1502 opens on instrument air
failure.
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
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.
High high level alarm (91-LAHH-1504) in Acid Gas Amine Absorber bottom activates
the ESD Level-2 shutdown
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Low low level alarm (91-LALL-1516) in Acid Gas Amine Absorber bottom trips the
Acid Gas Rich Amine Pumps (9103-P-12A/B)
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.
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
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.
Hot lean amine bypass control valve 91-TV-1513 locks on instrument air failure.
91-PIC-1539 opens the Nitrogen control valve 91-PV-1539 on falling pressure in the
Regenerator over head to Regenerator Condenser Cooler.
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Amine Regenerator 9103-C-12 top pressure nitrogen control valve 91-PV-1539 opens on
instrument air failure.
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.
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.
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.
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.
High high vibration alarm of each fan trips the respective fan motors.
The temperature controller adjusts the bypass control valve 91-TV-1502 and maintains
the Regenerator Condenser Trim Cooler outlet temperature 91-TT-1502.
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.
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
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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
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.
The above drawing shows the split range operation of 91-PV-1503A & 91-PV-1503B.
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ESD valve 91-XV-1516 located at the acid gas to Acid Gas KO Drum control valve
downstream
Output of the controller 91-FIC-1505 controls the pump minimum flow control valve
91-FV-1505.
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:
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
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.
Reboiler condensate control valve 91-LV-1508 will close on instrument air failure.
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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)
High high vibration alarm of each fan trips the respective fan motors.
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.
Lean amine cooler bypass control valve 91-TV-1509 closes on instrument air failure.
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.
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
Output of the controller 91-FIC-1511 throttles the pump minimum flow control valve
91-FV-1511.
Control Loop:
Low low flow (91-FALL-1515) alarm set at 300 m3/hr trips the Lean Amine Pumps
9103-P-13A/B.
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.
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The below drawing shows the split range operation of 91-PV-1527A & 91-PV-1527B:
Control Loop:
Lean Amine Pumps (9103-P-13A/B) discharge flow to Lean Amine Filter (9103-S-11) is
controlled by 91-FIC-1507.
Lean Amine Pumps 9103-P-13A/B flow control valve 91-FV-1507 to filter closes on
instrument air failure.
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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
Steam Ejector
Equipment Tag No. 9101-X-03
3
Capacity, Nm /hr 500
Design Temperature, C 185
Differential Pressure, bar 0.1
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.
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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:
This reaction produces a high enough temperature to trigger the Claus reaction
thermally:
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.
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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).
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:
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.
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).
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.
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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.
The schematic diagram for 1st stage auxiliary burner temperature control is shown
below:
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
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.
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
The schematic diagram for 2nd stage auxiliary burner temperature control is shown
below:
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
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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.
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
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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
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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
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 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 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 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
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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.
The regulation of the combustion air blower valves is implemented on the CCC Anti-
surge controller.
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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
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.
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.
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.
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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.
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
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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
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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.
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.
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.
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).
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.
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).
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).
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.
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.
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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.
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.
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
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
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.
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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.
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.
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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.
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.
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
Slave >
FT FIC SP FY
1156A 1156 1156C
Combustion Air Fan PV
MV High Selector
FY-1156A
VFD
9101-K-12A
FY-1156B
VFD
9101-K-12B
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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
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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
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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
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.
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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.
A. Loading/Unloading
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.
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.
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.
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).
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.
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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.
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.
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.
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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.
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69-PIC-1307 opens the nitrogen control valve 69-PV-1307 on falling pressure in the
Waste Water Degasser.
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
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
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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.
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.
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.
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.
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.
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.
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 Controller 69-TIC-1327 directly regulates the boiler feed water flow via
69-TV-1327 located at the inlet of De-super heater.
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.
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.
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High high vibration alarm of each fan trips the respective fan motors
4.7.2.1 Introduction
LP Fuel Gas is required for New Steam Generation Boiler Packages 6848-A-02A/B/C.
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-
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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.
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.
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.
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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.
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.
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A tie in to the existing NGL-3/4 seawater supply system is also provided to supply
seawater from the new seawater pumps.
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.
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 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).
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.
Sea cooling water drain control valve 69-PV-1306 opens on instrument air failure
4.9 ELECTROCHLORINATION PACKAGE
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
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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
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 Bund
Material of Construction GRP
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.
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 &
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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.
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,
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.
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.
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:
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.
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
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
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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.
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.
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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.
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.
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).
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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.
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.
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
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).
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.
Output of the controllers 68-FIC-1835 and 68-FIC-1836 directly commands the control
valve 68-FV-1835 and 68-FV-1836, respectively.
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.
3. Regeneration Pumps
4. Recirculation Pumps
5. Neutralization Pumps
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.
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.
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
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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.
In the event of a non ESD trip of the operating pump, the standby pump will start
automatically.
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 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.
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.
There are two sets of Chemical Injection Pumps (each comprising two electric motor
driven gear pumps) provided for each chemical as follows;
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).
In the event of a non ESD trip of the operating pump, the standby pump will start
automatically.
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.
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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.
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.
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.
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 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.
68-PIC-1304 opens the steam control valve 68-PV-1304 on falling pressure in the
Deaerator.
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
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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
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Stack
Type Self Supporting
Height/Top Dia/Bottom Dia, m 30/1/2
CS (Rated for High Temp.
Material
Service)
Thickness, mm, (min.) 5
Auxiliary Steam Boiler Package is essentially constituted by: Three water tube
Clajtub type saturated steam boilers.
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.
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.
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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
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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):
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
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.
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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
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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.
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
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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.
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.
The external insulation panels are enclosed in a cladding, made of painted aluminium,
properly spaced and fixed through screws to allow an easy removal.
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
The steam generator body is mounted on a steel base-frame, which supports it with a
uniform load distribution.
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.
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
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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.
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.
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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)
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.
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
Each Steam Generator is provided with one Phosphate chemical dosing unit, whose
purpose is to inject Phosphate into boiler Steam Drum 6848-V-02A.
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
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
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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.
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).
The boiler level control is performed with single or three elements philosophy.
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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.
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 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.
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
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
Where
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.
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
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
Where
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.
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.
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).
Operating Alarm
Controller Control Loop Unit
Set Point Low High
68-AIC-1522 Oxygen analyzer controller % XX 2.2 6.7
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.
Operating Alarm
Controller Control Loop Unit
Set Point Low High
Flue gas damper position
68-ZIC-1524 % XX NA NA
controller
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Flue gas flow control valve 68-FV-1524 to boiler locks at the position on instrument air
failure.
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.
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
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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%.
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.
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
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ON/OFF MOV1522
Each boiler contains a MOV which feeds the steam to the header
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).
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:
Hot standby mode is active and the boiler level is lower than a closure threshold
value
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The valve is opened automatically when all the following conditions are satisfied:
Hot standby mode is active
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.
LP steam header pressure low low pressure 2oo3 (68-PALL-1303A/B/C) alarm set
at 4 barg initiates the following:
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.
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):
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:
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
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.
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
The Corrosion Inhibitor Pumps 9103-P-101A/B are having discharge pulsation dampner
and calibration pots at the suction line.
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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:
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.
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The Complex Product Injection Pumps 6834-P-41A/B are having discharge pulsation
dampner and calibration pots at the suction line.
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.
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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:
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.
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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 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:
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
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 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).
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
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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
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.
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.
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
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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:
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.
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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.
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.
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:
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
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ESD-0, ESD-1, ESD-2 shutdown signals activates the tripping of both the Catalyst
Injection Pumps 9101-P-11A/B.
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5.1 GENERAL
For Start-up of the SRU Upgrade Facilities the pre-requisites are given below:
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
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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
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 lean gas from 6103-K-01A/B and the LP Fuel Gas KO
Drum 6236-V-05
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Interconnection between the existing fuel gas line upstream of 65-XV-001 and the
LP Fuel Gas KO Drum 6236-V-05
2. Nitrogen System
6. Flare System
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:
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.
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
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).
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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.
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.
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
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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.
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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
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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.
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
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
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.
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At the initial start for the availability of the dryer, the position of valves is as follows:
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
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:
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.
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:
Ensure that the vent and drain valves are closed in the header.
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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.
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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.
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.
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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.
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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. 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.
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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.
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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
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
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
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
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.
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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.
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The start-up procedure for the Sea Cooling Water Pumps 6932-P-04A/B is given below:
1. Rotate the pump shaft by hand to make sure that the pump rotates freely and the
impellers are correctly positioned
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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
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.
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Before starting the package, ensure the following emergency shutdown causes are
normal/healthy:
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).
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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
Fill the Complex Product Tank, 68-T-18 with Complex Product Chemical.
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.
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.
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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)
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.
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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
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.
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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)
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.
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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)
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.
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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.
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.
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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
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
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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
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
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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
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
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
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%).
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1. Ensure that when put in service the following XVs of Train-A are open:
a. 68-XV-1825: Cation Exchanger I/L
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
b. 68-XV-1837
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
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
b. 68-XV-1837
c. 68-XV-1827
d. 68-XV-1836
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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
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
b. 68-XV-1833
c. 68-XV-1826
d. 68-XV-1839
a. 68-XV-1830
b. 68-XV-1837
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
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
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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
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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
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
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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.
Gradually open the valve GV-5013 and fill the Boiler Steam Drum 6848-V-02A
with DM water.
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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.
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
Steam generation unit Local panel details (6848A02A-LP-003) are tabulated below:
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.
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
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.
d. Flue Gas Recirculation Fan 6848-K-03A is running. (If flue gas recirculation
control is enabled).
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.
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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
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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:
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.
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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.
When adequate steam flow rate is reached, the Boiler Feed Water to Desuperheater
6848-X-03A is lined up.
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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.
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.
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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
Preparation:
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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.
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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.
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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:
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.
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.
1. Incinerator
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.
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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:
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:
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:
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.
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d. Pilot Ignition
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.
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Pre-requisites
Preparation of Antifoam
Preparation of Corrosion Inhibitor
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.
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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.
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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.
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.
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.
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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%.
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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
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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
i. System reset
i. System Reset
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:
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.
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.
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.
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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.
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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 the Process air shutdown valve 91-XV-1101 is opened.
24. Ensure fuel gas bleed valve 91-XV-1100 is closed and fuel gas shutdown valves
91-XV-1048 and 91-XV-1099 are opened.
25. Ensure that the igniter transformer is energised for 10 seconds and sparking
begins.
26. Ensure that the igniter transformer is de-energised and igniter retracts
automatically (91-ZSO-1103) after 10 seconds of ignition timer.
27. If flame is detected then ensure that the FLAME ON lamps (91-BAL-1055A,
91-BAL-1055B) are lit on the local control panel.
28. Permit is provided to open the steam quench shutdown valve 91-XV-1078 and
91-XV-1079 from ICSS soft switches.
29. Permit is provided to open the acid gas shutdown valve 91-XV-1102.
30. Ensure that the FUEL GAS ON lamp 91-XL-1216, 91-XL-1216A is lit in the Local
Control Panel and ICSS respectively.
31. Open the instrument air purge valve to sight glasses, flame scanners and nozzles.
32. Ensure that the Nitrogen purge valve to sight glasses, flame scanners and nozzles
is closed.
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Start
A B
1. Take fuel gas controller 91-FIC-1009 in manual and slowly increase the fuel gas to
Reaction Furnace.
2. Take the combustion air controller 91-FIC-1002/91-FIC-1002B in manual and
increase the combustion air to the Reaction Furnace.
3. Proceed to heat up the Reaction Furnace at 50C/hr
Note
1) If the converters have been filled with catalyst following the units pre-
commissioning refractory dry out phase, then for the first start-up of the unit,
the rate of temperature increase of the process air must be initially controlled
to slowly heat up the converters at 10-15C/hr to 90C to ensure any free
water and moisture is removed in the converters catalyst beds. In this case the
introduction of BFW to the steam generators will be delayed until the
converters catalyst beds are first heated through to 90C.
2) As the SRU process gas system and the SRU converters does not contain sulphur
compounds at this time, firing of fuel gas in the Reaction Furnace burner may
be carried out in excess air conditions.
The burner management system of 1st Stage Auxiliary Burner is incorporated in ESD
system.
1st stage auxiliary burner LCP 9101-F-102 LP-006 hand switches detail is tabulated
below:
Sl. # Tag No. Description
1. 91-HS-1226 Start burner
2. 91-HS-1227 Stop burner
3. 91-HS-1228 Lamp test
1st stage auxiliary burner 9101-F-02 hardwired aux console hand switches detail is
tabulated below:
1st stage auxiliary burner LCP 9101-F-102LP-006 lamp indication detail is tabulated
below:
System Reset to be done by activating the soft push button 91-HS-1225 in DCS.
i. System Reset
i. System Reset
2. When the BMS reset is pressed, following shutdown causes are automatically
bypassed during start-up (start-up override)
a. 91-FT-1133 (Combustion Air low-low flow)
3. Ensure that any one of Process Air Blower 9101-K-01A & 9101-K-01B is started and
running.
4. If the above conditions are satisfied then ensure 1st STAGE BURNER READY FOR
RESET (91-XL-1232) is lit in ICSS.
5. RESET the system by pressing the Soft switch 91-HS-1225 from ICSS and ensure the
following:
a. Energizing of fuel gas control valve SOV 91-FY-1020.
c. Fuel gas flow controller 91-FIC-1020 to manual mode and output at start
position.
d. READY FOR IGNITION lamp 91-XL-1227 and 91-XL-1227A is lit on the local
panel and also in ICSS respectively.
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1. Ensure that the air inlets, burner and outlet passages are boxed up and free of
foreign material.
2. Ensure that all safety shut off valves are closed.
3. Ensure that the Fuel System vents are open and venting to atmosphere. Lines are
properly drained and cleared of condensate.
4. Ensure that a complete functional check of the safety interlocks has been made.
5. Ensure that the area is clear of obvious safety hazards and flammable gases are
not present in the area.
6. 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.
7. Ensure that utilities like fuel gas, instrument air, plant air and nitrogen are
available and initial operational checks performed on the elements in each line.
8. Ensure that the burner elements are in their proper position.
9. Ensure that power has been supplied to control systems and to safety interlocks.
10. Ensure that the gauges indicating fuel header pressure to the unit are functional.
11. Ensure that the pressure self regulating valves are set according to the instrument
data sheets.
12. 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.
13. Ensure that the minimum purge period is satisfactorily completed.
14. Ensure that the control valves of the fuel gas 91-FV-1020, quench steam and
Combustion Air 91-FV-1018 are closed.
15. Ensure that the igniter is in the correct position and that the fuel gas gun is ready
for operation with fuel gas.
16. Open the fuel gas control valve 91-FV-1020 and Process air control valve 91-FV-
1018 to the pre-determined position.
17. Press the START IGNITION push button 91-HS-1226 from the local control panel.
18. Ensure that READY FOR IGNITION lamp 91-XL-1227 is unlit on the local control
panel and 91-XL-1227A is unlit on the ICSS.
19. Ensure IGNITION ON 91-XL-1288A lamp lit in ICSS and 91-XL-1228 lamp in Local
panel.
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20. Ensure Ist STAGE BURNER IN SHUTDOWN 91-XA-1126 lamp extinguished in Local
panel and 91-XA-1126A lamp extinguished in ICSS.
21. Ensure combustion air control valve SOV 91-FY-1018 energized.
22. Ensure Combustion air flow controller 91-FIC-1018 and fuel gas controller 91-FIC-
1020 to manual mode and output forced to start position at 10%
23. Ensure that the igniters insert SOV 91-XY-1234 is energised.
24. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1234.
25. Ensure fuel gas bleed valve 91-XV-1132 is closed and fuel gas shutdown valves
91-XV-1028 and 91-XV-1131 are opened.
26. Ensure that the igniter transformer is energised for 10 seconds and sparking
begins.
27. Ensure that the igniter transformer is de-energised and Igniter retracts
automatically (91-ZSO-1234) after 10 seconds ignition timer.
28. If flame is detected then ensure that the FLAME ON lamp 91-BAL-1003A, 91-BAL-
1003B) are lit on the local control panel.
29. Permit is provided to open the steam quench valve.
30. Permit is provided to open the acid gas control valve 91-FV-1019.
31. Ensure that the FUEL GAS ON lamp 91-XL-1229 is lit in the Local Control Panel.
32. Ensure combustion air controller 91-FIC-1018 and fuel gas controller 91-FIC-1020
force signal removed.
33. Ensure that the FUEL GAS ON lamp 91-XL-1229A is lit in ICSS.
34. Open the instrument air purge valve to sight glasses, flame scanners and nozzles is
opened.
35. Ensure that the Nitrogen purge valve to sight glasses, flame scanners and nozzles
is closed.
36. Take the fuel gas controller 91-FIC-1020 in manual and slowly increase the fuel
gas to the burner.
37. Take the combustion air controller 91-FIC-1018 in manual and increase the air to
the burner.
38. Slowly open the fuel gas and combustion air and increase the 1st Stage Converter
inlet temperature to 230C.
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The burner management system of 2nd Stage Auxiliary Burner is incorporated in ESD
system.
2nd Stage Auxiliary Burner LCP 9101-F103LP-007 hand switches detail is tabulated below:
2nd Stage Auxiliary Burner hardwired aux console hand switches detail is tabulated below:
2nd Stage Auxiliary Burner LCP 9101 F103LP-007 lamp indication detail is tabulated below:
i. System reset
i. System Reset
2. When the BMS reset is pressed, following shutdown causes are automatically
bypassed during start-up (start-up override)
a. 91-FT-1136 (Combustion Air low-low flow)
3. Ensure that any one of Process Air Blower 9101-K-01A & 9101-K-01B is running.
4. If the above conditions are satisfied then Ensure 2nd STAGE BURNER READY FOR
RESET (91-XL-1197) is lit in ICSS.
5. RESET the system by pressing the Soft switch 91-HS-1194 from ICSS and ensure
the following:
a. Energizing of fuel gas control valve SOV 91-FY-1027.
b. Combustion air flow controller 91-FIC-1025 to manual mode and output at start
position.
c. Fuel gas flow controller 91-FIC-1027 to manual mode and output at start
position.
d. READY FOR IGNITION lamp 91-XL-1192 and 91-XL-1192A is lit on the local
panel and ICSS respectively.
1. Ensure that the air inlets, burner and outlet passages are boxed up and free of
foreign material.
2. Ensure that all safety shut off valves are closed.
3. Ensure that the Fuel System vents are open and venting to atmosphere. Lines are
properly drained and cleared of condensate.
4. Ensure that a complete functional check of the safety interlocks has been made.
5. Ensure that the area is clear of obvious safety hazards and flammable gases are
not present in the area.
6. 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.
7. 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.
8. Ensure that the burner elements are in their proper position.
9. Ensure that power has been supplied to control systems and to safety interlocks.
10. Ensure that the gauges indicating fuel header pressure to the unit are functional.
11. Ensure that the pressure self regulating valves are set according to the instrument
data sheets.
12. 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.
13. Ensure that the control valves of the fuel gas 91-FV-1027, quench steam and
Combustion air 91-FV-1025 are closed.
14. Ensure that the igniter is in the correct position and that the fuel gas gun is ready
for operation with fuel gas.
15. Open the fuel gas control valve 91-FV-1027 and combustion air control valve 91-
FV-1025 to the pre-determined position.
16. Press the START IGNITION push button 91-HS-1195 from the local control panel.
17. Ensure that READY FOR IGNITION lamp 91-XL-1192, 91-XL-1192A is unlit on the
local control panel and ICSS respectively.
18. Ensure IGNITION ON lamp 91-XL-1193A, 91-XL-1193 lamp lit in ICSS and Local
panel respectively.
19. Ensure 2nd STAGE BURNER IN SHUTDOWN lamp 91-XA-1191 and 91-XA-1191A
extinguished in Local panel and ICSS respectively.
20. Ensure combustion air control valve SOV 91-FY-1025 energized.
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21. Ensure Combustion air flow controller 91-FIC-1025 and fuel gas controller 91-FIC-
1027 forced to manual mode and output forced to start position at 10%.
22. Ensure that the igniters insert SOV 91-XY-1199 is energised.
23. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1199.
24. Ensure fuel gas bleed valve 91-XV-1134 is closed and fuel gas shutdown valves 91-
XV-1031 and 91-XV-1133 are opened.
25. Ensure that the igniter transformer is energised for 10 seconds and sparking
begins.
26. Ensure that the igniter transformer is de-energised and Igniter retracts
automatically (91-ZSO-1199) after 10 seconds ignition timer.
27. If flame is detected then ensure that the FLAME ON lamps (91-BAL-1004A, 91-
BAL-1004B) are lit on the LCP and ICSS.
28. Permit is provided to open the steam quench valve.
29. Permit is provided to open the acid gas control valve 91-FV-1026.
30. Ensure that the FUEL GAS ON lamp 91-XL-1194 is lit in the Local Control Panel.
31. Ensure that the FUEL GAS ON lamp 91-XL-1194A is lit in ICSS.
32. Ensure combustion air controller 91-FIC1025 and fuel gas controller 91-FIC-1027
force signals removed.
33. Open the instrument air purge valve to sight glasses, flame scanners and nozzles.
34. Ensure that the Nitrogen purge valve to sight glasses, flame scanners and nozzles
is closed.
35. Slowly increase the fuel gas to the burner by keeping the Fuel gas flow controller
91-FIC-1027 in manual.
36. Slowly increase the combustion air to the burner by keeping the Combustion air
flow controller 91-FIC-1025 in manual.
37. Slowly open the fuel gas and combustion air and increase the 2nd Stage Converter
inlet temperature to 230C.
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1. When the Reaction Furnace temperature is >1250C set the Reaction Furnace
burner control system to slightly sub-stoichiometric firing conditions with steam
being injected as noted above to prevent the formation of carbon.
2. Acid gas may now be introduced to the SRU Reaction Furnace burner provided the
following points are first confirmed:
The SRU converters catalyst beds are at their normal operating temperatures
of 230 and 210C, respectively
The SRU Reaction Furnace burner is operating on fuel gas in slightly sub-
stoichiometric firing conditions with steam injection to fuel gas and process
air lines
There is sufficient acid gas available from the upstream Amine Regenerator, at
a stable flow rate of and at/or above the minimum design flow required for
the SRU to operate satisfactorily.
3. Confirm that the acid gas system has been purged with nitrogen.
4. Using a utility water hose connected to the Acid Gas KO Drum utility connection,
introduce water to establish a low level of water in the Acid Gas KO Drum 9101-V-04.
5. Using MS steam from the SRU Reaction Furnace Boiler 9101-E-07, continue
increasing the Acid Gas Pre-heater 9101-E-06 outlet temperature at 50C/hr to
210C.
6. Confirm available acid gas flow is at or above the minimum turndown required of
5935 kg/hr, (2349 m3/hr) for the SRU to operate.
6.3.3.6 Reaction Furnace Acid Gas Burner Light-On
8. Ensure the minimum air flow rate while switching between fuel gas and acid gas.
9. As soon as a flow of acid gas is introduced to the Reaction Furnace burner,
commence reducing fuel gas flow to the burner.
10. When fuel gas flow has stopped, isolate fuel gas line by closing fuel gas shutdown
valves.
11. Stop steam injection to the fuel gas and process air lines to the Reaction Furnace
burner.
12. Set all controllers in automatic mode.
13. Remove the override from the acid gas low flow trip.
14. Acid Gas is now to be introduced to the 1st and 2nd Stage Auxiliary Burners
6.3.3.7 1st Stage Auxiliary Burner Acid Gas Burner Light-On
1. When the SRU operation has stabilised, commission the tail gas analyser and set in
automatic with the trim air control valve to maintain a H2S:SO2 of 2.0:1.0.
2. Following a period of approximately 30-60 minutes after the introduction of acid
gases to the SRU Reaction Furnace Burner, commence checking of the SRU
condensers, sultraps for liquid sulphur.
3. If the sultraps have not been pre-filled with flake or powdered sulphur then the
following procedure should be adopted to fill the sultraps with liquid sulphur.
Note: It is necessary to use a respirator or fresh air breathing apparatus to ensure
complete operator safety during this operation.
Slowly open each of the condensers sulphur outlet drain valves and observe
through the open sultrap inspection door
When opening a sultrap if acid gas vapour appears, usually as a white smoky
gas, this will indicate that no liquid sulphur has collected behind the isolation
valve. The sultrap should be closed immediately in this case and only opened
again after about 10 minutes. If only a bluish haze with little pressure behind
it shows from the sultrap, this indicates that the sultrap is filling with liquid
sulphur and the condensers sulphur outlet valve can be left open.
Check the sultrap inspection door at regular intervals until sulphur is seen to
flow from each seal
When sulphur is seen at the condensers sulphur outlet valve may now be left
open to allow the sulphur to flow freely
Repeat this exercise until sulphur is seen to flow from all three seals
Note: It may take a considerable period of time, possibly several hours before
sulphur is seen to flow from the third condenser.
6.3.4.1 Pre-requisites
1. Ensure that the suction and discharge isolation valves of the Cooling Water
Circulation Pumps 9102-P-12A/B are closed.
2. Ensure that the Cooling Water Circulation Pumps 9102-P-12A/B suction to the
Waste Water Degasser 6922-V-07 isolation valves are closed.
3. Open the DM water make up to the suction of the Cooling Water Circulation Pumps
9102-P-12A/B and increase level in the top section of the Desuperheater/Contact
Condenser 9102-C-11.
4. When the level in the Desuperheater/Contact Condenser 9102-C-11 top section
reaches 50% which is noted through the 91-LG-1302/91-LT-1305, close the DM
water make up to the pumps suction.
5. Take the flow control valve 91-FV-1307 in auto with a set point of 197 m3/hr.
6. Ensure that the flow control valve 91-FV-1305 is closed fully on manual and the
upstream and downstream isolation valves are closed.
7. Start Cooling Water Circulation Pump 9102-P-12A from ICSS and circulate the
water in the Desuperheater/Contact Condenser 9102-C-11 top chimney tray.
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8. Select Cooling Water Circulation Pump 9102-P-12B in AUTO from ICSS and open
the suction and discharge isolation valves and prime the pump.
9. Line up 91-LV-1307 to top up Desuperheater/Contact Condenser 9102-C-11 bottom
section.
10. Open 91-LV-1307 manually and top up Desuperheater/Contact Condenser 9102-C-11
bottom section.
11. Open the DM water make up to the suction of the Cooling Water Circulation Pumps
9102-P-12A/B to maintain the level at 50% at top section.
12. Check the level in the Desuperheater/Contact Condenser 9102-C-11 bottom by
checking 91-LG-1303A/B & 91-LT-1307.
13. When the level in the Desuperheater/Contact Condenser 9102-C-11 bottom
reaches 50%, close the DM water make up to the pump suction and put the level
control valve 91-LV-1307 in auto with a set point of 50%.
14. Take the flow control valve FV-1314 in auto with a set point of 199 m3/hr.
15. Start Desuperheater Circulation Pump 9102-P-11A from ICSS and start circulating
the water.
16. Ensure that the Desuperheater Circulation Pump 9102-P-11B is taken in AUTO from
ICSS and the suction and discharge isolation valves are opened and primed.
17. Line up pH analyzer 91-AT-1302 in the suction of the Desuperheater Circulation
Pumps 9102-P-11A/B.
III. Lining up of Caustic Solution Injection Pumps 9103-P-103A/B
1. Ensure that the Caustic Solution Injection pumps 9103-P-103A/B suction strainer
elements are fixed and boxed up.
2. Ensure that the Caustic Solution Injection Pumps 9103-P-103A/B discharge PSVs
PSV-1606/1607 are lined up.
3. Open the Caustic Storage Tank outlet isolation valve to the injection pumps and
fill the lines with the Caustic Solution.
4. Open the suction isolation valves of the injection pumps.
5. Open the discharge isolation valve of the Caustic Injection Pump 9103-P-103A.
6. Put the LOR switch of the Caustic Injection Pump 9103-P-103A in Local.
7. Start the Caustic Solution Injection Pump 9103-P-103A from LCP.
8. Put the stroke length of the Caustic Solution Injection Pump 9103-P-103A at 10%.
9. Ensure that the Caustic Solution Injection Pump 9103-P-103A is developing
pressure by checking the discharge pressure transmitter 91-PT-1563.
10. Open the drain valve near the dosing point and ensure that the line is clear.
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11. Line up Caustic Solution to the Desuperheater Circulation Pump suction till a pH of
9.0 to 10.0 is achieved in the circulating solution.
IV. Calibration of Caustic Injection Pumps
1. Ensure that the instrument air from instrument air header to the Reducing Gas
Generator 9102-F-11 isolation valve is closed.
2. Ensure that the spectacle blind is in open position downstream of the isolation
valve of the instrument air from instrument air header to the Reducing Gas
Generator 9102-F-11.
3. Ensure that the fuel gas from fuel gas distribution to Reducing Gas Generator
9102-F-11 isolation valve is closed.
4. Ensure that the spectacle blind is in open position downstream of the isolation valve
of the fuel gas from fuel gas distribution to Reducing Gas Generator 9102-F-11.
5. Ensure that the steam from steam distribution to Reducing Gas Generator 9102-F-11
isolation valve is closed.
6. Ensure that the spectacle blind is in open position downstream of the isolation
valve of the steam from steam distribution to Reducing Gas Generator 9102-F-11.
7. Ensure that the combustion air from combustion air blower 9102-K-11A/B to
Reducing Gas Generator 9102-F-11 isolation valve is closed.
8. Ensure that the spectacle blind is in open position downstream of the isolation
valve of the combustion air from combustion air blower 9102-K-11A/B to Reducing
Gas Generator 9102-F-11.
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9. Ensure that the Nitrogen from Nitrogen distribution header to Reducing Gas
Generator 9102-F-11 isolation valve is closed.
10. Ensure that the spectacle blind is in open position downstream of the isolation
valve of the Nitrogen from Nitrogen distribution header to Reducing Gas Generator
9102-F-11.
11. Ensure that the drain and vent valves in the Reducing Gas Generator 9102-F-11
section is closed.
12. Ensure that all the instruments in Reducing Gas Generator 9102-F-11,
Hydrogenation Reactor 9102-V-11, Reactor Effluent Cooler 9102-E-11 are lined up.
13. Ensure that the Reactor Effluent Cooler 9102-E-11 atmospheric steam vent
isolation valves are open.
14. Ensure that the Reactor Effluent Cooler 9102-E-11 vents and drains isolation valves
are closed.
15. Ensure that the SRU tail gas valve to the TGTU 91-XV-1098 is closed at SRU.
6.3.4.3 Lining up of Reactor Effluent Cooler 9102-E-11
10. Open the isolation valve of the start-up bypass line near the Reducing Gas
Generator 9102-F-11.
11. Introduce Nitrogen through the hose to the Reducing Gas Generator via the
process gas inlet line.
12. Ensure that the start-up pressure control valve PIC-1308 opening to control the
excess Nitrogen gases to the Incinerator from Desuperheater/Contact Condenser
9102-C-11. Close the nitrogen valve.
13. Open the Start-up Gas Steam Ejector 9102-X-11 process gas inlet and outlet
isolation valves.
14. Open the Boiler Feed Water to Reactor Effluent Cooler 9102-E-11 isolation valves.
15. Open the level control valve 91-LV-1302 in manual and introduce Boiler Feed
Water to the Reactor Effluent Cooler 9102-E-11.
16. Slowly increase the level in the Reactor Effluent Cooler 9102-E-11.
17. When the level in the Reactor Effluent Cooler 9102-E-11 is around 85%, take the
level control valve LV-1302 in Auto with a set point of 80%.
6.3.4.4 Circulating Nitrogen through TGTU
Start
A
Note A & Note B
Nitrogen SDV-XV-1307,
XV-1301 open Y
BAL-1301, BAL-1302, BAL-1303 ON
A
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Burner Light On
i. System reset
i. System Reset
If the above conditions are not exists, then the RGG BMS system can be reset.
a. Instrument air must be available and the seal air low low pressure 91-PALL-
1460 is reset.
d. The auxiliary lube oil pump 91-P-13A is started and running and the low low
lube oil pressure 91-PI-1459 is reset.
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Blower Start-up
a. Ensure that blower ready to start indication is available in the Local Control
Panel.
b. Switch ON the electrical heater for the Lube Oil tank 91-E-15AA.
c. Ensure that the temperature of the Lube oil is increasing by checking 91-TI-1463.
d. When the temperature reaches 45C ensure that the heater is cut off
automatically.
e. Ensure that when the temperature reaches 40C, the heater is cut in
automatically.
g. Ensure that the Auxiliary Oil Pump 91-P-13A develops a discharge pressure of
5.50 barg.
h. Line up the instrument air to the seal system of the blower and ensure that the
low low seal air pressure 91-PALL-1460 is reset by 91-HS-1471.
i. Select Local from the Local Control Panel 9102K11A-LP-003 selector switch
91-HS-1452.
l. Ensure that the Lube Oil Cooler duty fan is started and running.
m. Ensure that the air filter inlet inertial fan is started and running.
p. After 17 minutes ensure that the Auxiliary Oil Pump 91-P-13A is stopped and the
Blower load function is enabled.
q. Load the Blower from the Local Control Panel selector switch 91-HS-1455.
t. Ensure that the combustion air flow control valve 91-FV-1304, Fuel Gas flow
control valve FV-1311 and quench steam flow control valve FV-1310 are closed.
u. RESET the system by pressing the pushbutton 91-HS-1400 from the local control
panel.
1. Verify whether the System ready for purge lamp 91-XL-1401 is lit after RESET at
Local Control Panel.
2. Ensure that the Nitrogen shutdown valve 91-XV-1307 for furnace purging and
91-XV-1301 for flame scanner, sight glass purging are opened.
3. Ensure that main combustion air shutdown valve 91-XV-1306 & instrument air
valve 91-XV-1302 (for flame scanner, sight glass purging) are closed.
4. Open the Nitrogen line isolation valve slowly and set a flow rate of 125 m3/hr read
by 91-FT-1308.
5. Press Purge Start Pushbutton 91-HS-1401 from the Local Control Panel.
6. Ensure that the Purge On lamp 91-XL-1402 is lit in the Local Control Panel.
7. Set the purge timer at 7.5 minutes.
8. Verify whether the Purge On lamp 91-XL-1402 is lit for 7.5 minutes in the Local
Control Panel.
9. After the purge time is over, ensure that the Purge On lamp 91-XL-1402 is unlit
in the Local Control Panel.
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10. Ensure that Purge Complete lamp 91-XL-1403 is lit on the Local Control Panel.
11. Ensure that the Nitrogen cut-in valve 91-XV-1307 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 RGG area, ductwork and
associated equipment and all access and inspecting doors closed and sealed.
3. Ensure that the Combustion Air Blower 9102-K-11A/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 2 steam drum vent isolation valves of the reactor effluent cooler
are open.
16. Ensure that the Reactor Effluent Cooler is filled with boiler feed water and the
level is being maintained at 80%.
17. Ensure that the minimum purge period is satisfactorily completed.
18. Ensure that the control valves of the fuel gas - 91-FV-1311, quench steam 91-FV-
1310 and Combustion Air 91-FV-1304 are closed.
19. Ensure that the igniter is in the correct position and that the fuel gas gun is ready
for operation with fuel gas.
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20. Ensure that the Purge Complete lamp 91-XL-1403 is lit in the local control panel.
21. Open the fuel gas control valve 91-FV-1311 from ICSS to the pre-determined
position signalled by the lamp 91-FZAL-1311 at the local control panel.
22. Open the combustion air control valve 91-FV-1304.
23. Press the Burner Start push button 91-HS-1402 from the local control panel.
24. Ensure that Purge Complete lamp 91-XL-1403 is unlit.
25. Ensure that the igniter insert SOV is energised.
26. Ensure that the igniter insertion is proved by limit switch 91-ZSC-1400.
27. Ensure that the igniter transformer is energised for 10 seconds and sparking
begins.
28. Ensure that the combustion air shutdown valve 91-XV-1306 is opened.
29. Ensure that the fuel gas bleed valve 91-XV-1308 is closed.
30. Ensure that the fuel gas shutdown valves 91-XV-1303 and 1304 are opened.
31. Ensure that the igniter transformer is de-energised and Igniter retracts
automatically (91-ZSO-1400) after 10 seconds ignition timer.
32. If flame is detected then ensure that the FLAME ON lamps (91-BAL-1301, 91-BAL-
1302, 91-BAL-1303) are lit.
33. Ensure that the fuel gas control valve correct start-up position lamp 91-FZSL-1311
is unlit.
Note: Permit is provided to open the steam quench shutdown valve 91-XV-1305
from ICSS soft switch 91-HS-1406
34. Permit is provided to open the tail gas shutdown valve 91-XV-1098 from ICSS soft
switch 91-HS-1052A.
35. Ensure that the FUEL GAS ON lamp 91-XL-1404 is lit in the Local Control Panel.
36. Ensure that the FUEL GAS ON lamp 91-XL-1410 is lit in ICSS.
37. Ensure that the instrument air purge valve 91-XV-1302 to sight glasses, flame
scanners and nozzles is opened.
38. Ensure that the Nitrogen purge valve 91-XV-1301 to sight glasses, flame scanners
and nozzles is closed.
6.3.4.6 Hydrogenation Reactor Catalyst Sulphiding
3. When RGG outlet and Hydrogenation Reactor inlet temperature is 200C and the
Hydrogenation Reactor is heated through to >120C, introduce LP steam to the
RGG by opening the steam inlet control valve 91-FV-1310.
4. Set the steam flow in a ratio of 2:1 by weight to fuel gas in 91-HIC-1311.
5. Boiler feed water in the Reactor Effluent Cooler 9102-E-11 are heated by the
effluent gases from the Hydrogenation Reactor 9102-V-11 and steam will start
coming out of the drum vent.
6. Slowly close the drum vent and increase the pressure in the drum to the LP steam
header pressure of 5.0 barg which is read by the drum pressure gauge 91-PT-1309.
7. When the drum pressure reaches 5.0 barg, open the steam outlet isolation valve
connecting to the header and close the drum vent fully at the same time.
8. When the Hydrogenation Reactor has heated through to 200C the sulphiding of
the catalyst should be started.
9. Check the temperature transmitters in the catalyst bed 91-TT-1303/1306/1308/
1309/1318/1319/1320/1321/1322 from ICSS.
10. All the temperature points should be around 200C.
11. Line up the isolation valves of the Acid Gas sulphiding line from Regenerator
Reflux Drum 9103-V-12 to the Hydrogenation Reactor 9102-V-11.
12. Open the Acid Gas sulphiding line control valve 91-HV-1301 slowly and introduce
acid gases to the Hydrogenation Reactor 9102-V-11.
13. Introduce acid gases for 1% - 2% volume of H2S initially in the process gases.
Note: The reaction of H2S in the Hydrogenation Reactor catalyst is exothermic.
For every 1% volume of H2S entering the reactor a catalyst temperature increase
of approximately 15C can be expected.
16. As soon as amine acid gas is introduced into the Hydrogenation Reactor inlet line
start sampling the reactors inlet and outlet process gas.
17. A hand held Drager tube type sampling system is suggested where an immediate
read out of H2S in % or ppm can be seen.
18. Continue sampling reactor outlet gas at one hour intervals.
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19. When the Hydrogenation Reactor has been fully sulphided, the reactor outlet gas
H2S concentration will equal the inlet gas H2S concentration.
20. Maintain the reactor catalyst bed temperature at 390C with the H2S rich amine
acid gas flow to the reactor for a minimum of 4 hours to ensure the catalyst is
fully sulphided.
21. Stop the flow of the H2S rich amine acid gas to the inlet of the Hydrogenation
Reactor by closing the isolation valves near the Hydrogenation Reactor inlet line
and the Regenerator Reflux Drum.
22. Depressurise the line through the drain line given upstream of the check valve.
23. Connect a Nitrogen hose to the acid gas line and purge the line through the drain
line to acid gas flare.
24. Close the control valve 91-HV-1301 in the acid gas line.
25. Reverse the spectacle blinds to close position at both the ends of the acid gas
line.
26. Reduce the reactor inlet temperature to 290C by slowly reducing the firing.
27. Sulphiding of the reactor catalyst is now complete and the TGTU is now ready to
receive and process SRU tail gases.
6.3.4.7 Lining up of Tail Gases to the TGTU
1. Confirm that the SRU is operating at near to its minimum design acid gas feed
rate.
2. When the SRU operation has stabilised commission the tail gas analyzer 91-AT-1001.
3. Set a H2S:SO2 ratio of 4.0:1.0 in the controller 91-ARC-1001.
4. Open the Reactor Effluent Cooler 9102-E-11 outlet ON-OFF valve 91-XV-1331 to
the Incinerator 9101-F-14.
5. Close the Reactor Effluent Cooler 9102-E-11 outlet ON-OFF valve 91-XV-1332 to
the Desuperheater/Contact Condenser 9102-C-11.
6. Open the manual isolation valve in the Desuperheater/Contact Condenser 9102-C-11
gas outlet to the Tail Gas Amine Absorber 9102-C-12.
7. Simultaneously open the SRU tail gas ON-OFF valve 91-XV-1098 to the TGTU and
close the ON-OFF valve 91-XV-1097 to the Incinerator 9101-F-14.
8. Slowly open the downstream isolation valve of the ON-OFF valve 91-XV-1098 and
start the tail gas flow to the Reducing Gas Generator.
9. Close the LP steam supply isolation valve to the Start-up Gas Steam Ejector
9102-X-11.
10. Close the process gas inlet isolation valve to the Start-up Gas Steam Ejector
9102-X-11 and outlet valve from the Start-up Gas Steam Ejector 9102-X-11.
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11. Close BSR section start-up vent gas pressure control valve 91-PV-1308 and manual
isolation valves.
12. Close Nitrogen supply to the RGG process gas inlet line.
13. Observe Hydrogenation Reactor operation, catalyst temperature will increase as
exothermic reactions take place in the reactors catalyst.
6.3.4.8 Lining up of TGTU Wet Section
1. Ensure that the DCC 9102-C-11 process outlet gas isolation valve to the Tail Gas
Amine Absorber 9102-C-11 is open.
2. Ensure that DCC top chimney tray level is made up and the Cooling Water
Circulation Pump 9102-P-12A/B is running circulating water back to the DCC top
section.
3. Ensure that sea cooling water is lined up to the Contact Condenser Trim Cooler
9102-E-13A/B.
4. Ensure that the Contact Condenser Cooler 9102-E-12 fans are started and running.
5. Ensure that the DCC bottom Desuperheater section water level is made up and the
Desuperheater Circulation Pump 9102-P-11A/B is started and circulating water to
the Desuperheater bottom 9102-C-11.
6. Ensure that the desuperheater circulating water pH is maintained in the range of
9.0-10.0.
7. Line up lean amine to the Tail Gas Amine Absorber 9102-C-12 by opening all the
isolation valves from the Lean Amine Pumps 9103-P-13A/B discharge.
8. Reset process shutdown and ensure that lean amine to Tail Gas Amine Absorber
9102-C-12 inlet ON-OFF valve 91-XV-1310 is opened.
9. Open the lean amine flow control valve 91-FV-1301 slowly and establish a flow of
lean amine to the Tail Gas Amine Absorber 9102-C-12. Put the control valve 91-FV-
1301 in auto with a set point of 110 m3/hr.
10. Ensure that the low low level alarm 91-LALL-1301 in the Tail Gas Amine Absorber
9102-C-12 is cancelled.
11. Check the level transmitter 91-LT-1308 and ensure that the level is increasing in
the Tail Gas Amine Absorber 9102-C-12.
12. When the level reaches to about 50% in the Tail Gas Amine Absorber 9102-C-12,
line up the Tail Gas Rich Amine Pumps 9102-P-16A/B by opening the suction and
discharge isolation valves.
13. Keep the Tail Gas Rich Amine Pumps 9102-P-16A/B discharge control valves 91-FV-
1325 & 91-FV-1303 in closed condition.
14. Fill up the Tail Gas Rich Amine Pumps 9102-P-16A/B casing, by opening the casing
vent valve and releasing Nitrogen.
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15. Put the LOR switch of the Tail Gas Rich Amine Pumps 9102-P-16A/B in Remote.
16. Reset the process shutdown and ensure that the Tail Gas Rich Amine Pumps
9102-P-16A/B discharge ON-OFF valve 91-XV-1309 is opened.
17. Start the Tail Gas Rich Amine Pump 9102-P-16A from ICSS. Put the Tail Gas Rich
Amine Pump 9102-P-16B in AUTO from ICSS.
18. Open the minimum flow control valve 91-FV-1303 in manual and establish a flow
rate of 31.25 m3/hr. Put the controller 91-FIC-1303 in AUTO with a set point of
31.25 m3/hr.
19. Take the level controller 91-LIC-1308 in AUTO with a set point of 50%.
20. Take the flow controller 91-FIC-1325 in REMOTE and ensure the level of the Tail
Gas Amine Absorber is maintained at 50%.
21. Ensure that the level in the Acid Gas Amine Absorber 9103-C-11 is maintained due
to the lining up of the rich amine from Tail Gas Amine Absorber 9102-C-12.
22. Ensure that the SRU is in stable operation and the acid gas feed to the SRU at or
above the minimum design flow rate.
23. Ensure that the TGTU Hydrogenation Reactor is in a stable operation.
24. Open the Reactor Effluent Cooler process gas outlet valve 91-XV-1322 to the DCC
and the close the process gas outlet valve 91-XV-1331 to the Incinerator 9101-F-14
through the hand switch 91-HS-1303A from the ICSS.
25. Check the Tail Gas Amine Absorber 9102-C-12 outlet vent gas line H2 and H2S
analysers 91-AI-1301 in ICSS. The H2 analyser should show a minimum of 1.5%
excess H2 in the vent gases.
26. Closely observe the Incinerators operation as the unit stops incineration of the
H2S rich process gases from the Reactor Effluent Cooler and commences
incineration of the very dilute in H2S rich vent gases from the Tail Gas Amine
Absorber.
27. Ensure that the DCC cooling water circulation level control valve 91-LV-1305 is
taken in auto with a set point of 50%.
28. Ensure that the DCC Desuperheater top up water control valve 91-LV-1307 is taken
in auto with a set point of 50%.
29. Ensure that the level in the Contact Condenser is always maintained at 50% by
making up with DM water if needed.
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1. Check the flow of acid gases from Regenerator Reflux Drum 9103-V-12 to Acid Gas
KO Drum 9101-V-04 of SRU is above the minimum turndown required of
5935 kg/hr, for the SRU to operate.
2. Gradually increase the flow from Regenerator Reflux Drum 9103-V-12 to Acid Gas
KO Drum 9101-V-04 of SRU.
3. Ensure the Acid Gas Pre-heater 9101-E-06 outlet temperature is maintained at
200C.
4. Adjust the process air flow to the Reaction furnace accordingly.
5. Ensure that the Process Air pre-heater 9101-E-05 outlet temperature is maintained
at 200C.
6. Ensure that steam drum 9101-V-07 level is maintained.
7. Ensure that 1st Stage Converter 9101-V-01 inlet temperature is maintained at
230C.
8. Ensure that 2nd Stage Converter 9101-V-02 inlet temperature is maintained at
210C.
9. Ensure that the level in the Sulphur Degassing Pit 9101-T-01 is maintained.
10. Ensure that the tail gases from the SRU to the TGTU have gradually increased due
to the load increase in the SRU.
11. Ensure that the combustion air flow to the Reducing gas Generator has increased
accordingly.
12. Ensure that the Hydrogenation Reactor 9102-V-11 inlet temperature and outlet
temperature are maintained at 290C and 320C.
13. Ensure that the BFW level is maintained in the Reactor Effluent Cooler 9102-E-11.
14. Ensure that the Tail Gas Amine Absorber level, pressure and temperature
parameters are maintained.
15. Ensure that the Incinerator is at its normal operating temperature of 817C.
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The absorption of H2S by the Methyl Di Ethanol Amine (MDEA) in the Acid Gas Amine
Absorber 9103-C-11 is a function of the following:
The flow and distribution of MDEA falling down the Acid Gas Amine Absorber tower
through the upward flow of process gases
The temperature of the lean MDEA entering the Acid Gas Amine Absorber 9103-C-11.
The concentration and condition of the lean MDEA entering the Acid Gas Amine
Absorber 9103-C-11
Monitoring of the amine unit will include the following:
Regularly check the following vessels and towers level gauges and compare with
DCS indicated levels:
Regularly check the function of the following level transmitters and alarms to
confirm correct operation:
Confirm that the following pumps are operating satisfactorily. Periodically run
each spare pump and check the operation:
Confirm that the following air cooler fans are operating satisfactorily. Periodically
run each spare fan and check the operation:
Maintain lean amine flows to the amine absorbers at the correct flows for efficient
absorption of H2S in the towers.
Regularly test the concentration of the lean amine. Add fresh amine if the
strength is <50%. A low strength or weak solution will result in the inefficient
absorption of H2S in the absorber with the possibility of slippage of off
specification treated gas. This will be detected by the treated gas analyser
91-AI-1501 showing a higher than normal concentration of H2S and other sulphur
species in the absorber effluent vent gases to the Incinerator 9101-F-14 resulting
in an increase of SO2 emissions to atmosphere from the Incinerator Stack 9101-X-
01. Increasing the amine solution strength should correct this problem. An initial
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correction may be possible by increasing the circulating flow of the amine solution
above its normal design flow rate until the strength of the solution can be
corrected.
Regularly check the H2S/H2 analyzer 91-AT-1501 for normal operation.
Regularly check that the nitrogen blanketing systems to the Amine Surge Tank
9103-T-11 and to the Amine Sump 9103-V-10 are operating; failure of a blanketing
gas system and the ingress of air will result in the degradation of the amine and
the production of sludge in the system.
Maintain the Amine Surge Tank 9103-T-11 at minimum level, 20-30%, so that space
is available in the tank to store amine from the system at times when the unit is
shutdown for inspection.
Replace water losses by adding condensate to the Amine Surge Tank 9103-T-11.
Monitor the Acid Gas Amine Absorber 9103-C-11 differential pressure indicator and
Amine Regenerator 9103-C-13 differential pressure indicator as given below. A
gradual increase in pressure differential in a tower over a period of time will
indicate fouling, whilst an increase in pressure differential over a short period will
indicate foaming or flooding of the tower. In this case antifoam should be injected
into an injection point before the problem tower and the amine circulation flow
should be temporarily reduced to reduce the liquid/vapour loadings across the
towers packed sections.
Monitor the amine filters beds differential pressure indicators as given below.
When a filter pressure differential pressure reaches an advised number (high
alarm), remove the filter from service to replace its filtration medium/cleaning.
If corrosion is detected in the amine system then inject Corrosion Inhibitor into
one or more of the injection points to protect the system.
Normal Operating Parameters - AGEU
The operation and monitoring of the SRU includes the following activities:
Regularly check Acid Gas KO Drum 9101-V-04 level gauge 91-LG-1001 and compare
with DCS indicated level 91-LI-1001
Check for excessive liquid carryover from the upstream AGEU Amine Regenerator
9103-C-12
Do not drain sour water to the open sewer from low point drains due to the toxic
nature of the H2S saturated water and gas in the KO drums.
b. H2S:SO2 Ratio Control
The most important control variable in the operation of a SRU is the H2S:SO2 ratio in
the tail gas at the outlet of the SRU Final Separator 9101-V-05. The following points
should be noted:
If the Tail Gas Analyser 91-ARC-1001 should be temporarily out of service, sample
the tail gas and analyse for H2S:SO2. Analysis of the tail gas may be carried out
crudely by Drager tube or by chemical lab analysis.
Maintain the Tail Gas Analyser 91-ARC-1001 in good working order to ensure the
SRU is operating at its maximum efficiency for conversion of H2S to liquid sulphur
in the SRU converters (9101-V-01 & 9101-V-02) and have the correct ratio of H2S
and SO2 gases for the TGTU.
The main air to acid gas ratio controller 91-HIC-1001 point is adjusted as necessary
to change the main process air flow control valve position. The Tail Gas Analyser
91-ARC-1001 will control the trim air to fine tune the air required by the process
to achieve the desired H2S:SO2 ratio in tail gases. When the TGTU is in service with
the SRU then the SRU tail gases H2S:SO2 ratio should be 4.0:1.0. If the SRU is in
service without the TGTU then the tail gases H2S:SO2 ratio should be 2.0:1.0. If the
composition of the acid gas should change then the analyser may drive the trim air
control valve 91-FV-1003 fully open or fully closed; in this case a small adjustment
will have to be made to the main air to acid gas ratio controller to increase or
decrease the total air to allow the Tail Gas Analyser to bring the trim air control
valve 91-FV-1003 back onto control.
The control room operator responsible for the amine unit must inform the SRU
control room operator of impending changes in acid gas flow rates and/or upset
operating conditions in these units that will affect the operation of the SRU and
TGTU.
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c. Controllers Operation
To ensure good control of the processes at all times the following should be noted:
When the acid gas flow is steady, and the SRU is on automatic, set all controllers
for maximum speed and accuracy of response with control stability. A sudden
reduction in acid gas feed without the accompanied change in air rate could result
in high temperatures in the SRU converters (9101-V-01 & 9101-V-02) catalyst beds;
whilst a sudden increase in acid gas feed without the corresponding increase in air
rate will result in an increase in the amount of acid gas in the SRU tail gas and
increased load on the TGTU Desuperheater/Contact Condenser 9102-C-11 and
possibly the Incinerator 9101-F-14.
An increase in H2S concentration and decrease of SO2 in the SRU tail gas to the
TGTU will cause a decrease in temperature rise across the Hydrogenation Reactor
9102-V-11, whilst an increase in SO2 and decrease of H2S concentration in the SRU
tail gas to the TGTU will cause an increase in temperature rise across the
Hydrogenation Reactor 9102-V-11.
The SRU Tail Gas Analyser 91-ARC-1001 should be set to a maximum possible speed
and response in order not to cause the SRU tail gas compositions of H2S and SO2 to
vary too widely.
Steam Generators BFW level controllers should be set to maintain the water levels
at their recommended levels. A swinging water level may cause water to be
carried over into the steam system which will cause downstream problems with
process units operations.
d. Reaction Furnace Monitoring:
The following points should be noted to ensure good reaction furnace operation:
Keep close surveillance of the temperatures at the inlet of SRU 1st Stage Converter
9101-V-01 and 2nd Stage Converter 9101-V-02. Keep these temperatures at
230/210C to avoid liquid sulphur deposition on the catalyst.
Sulphur deposition in a SRU 1st Stage Converter 9101-V-01 and 2nd Stage Converter
9101-V-02 catalysts is indicated by a progressive catalyst bed temperature drop
starting at the top and continuing downward. If this is noted, increase the
corresponding converter inlet temperature by adjusting the upstream auxiliary
burner outlet temperature to carry out a rejuvenation of the converters catalyst.
Over long periods of operation a decrease in the activity of a SRU 1st Stage
Converter 9101-V-01 and 2nd Stage Converter 9101-V-02 catalysts will be seen. The
reaction of the H2S and SO2 in the process gas combining to form sulphur vapour is
seen by the exothermic reaction in the converters. As the converters catalysts age
this exothermic temperature rise reaction will be seen to move further down the
converters catalyst bed. The temperature rise across the first converter will
decrease whilst the temperature increase across the second converter will
increase.
An increased pressure drop across the SRU, seen by an increased pressure on the
Reaction Furnace 9101-F-01 process air inlet line pressure indicator 91-PI-1054
A/B/C, could indicate the deposition of soot/carbon deposits on the converters
catalysts. Soot and carbon deposits are the result of operating the SRU at start-up
or during a hot inert gas sweep with insufficient process air or steam injection to
the fuel gas in the Reaction Furnace 9101-F-01 burner or the result of excess
hydrocarbons in the acid feed gases to the SRU.
SRU converters 1st Stage Converter 9101-V-01 and 2nd Stage Converter 9101-V-02
catalyst deterioration can be partially reversed by carrying out a catalyst
rejuvenation exercise. Failure of signs of improved catalyst activity following a
series of rejuvenations will require the catalyst to be sulphur stripped.
Note that soot/carbon deactivation can only be corrected by removal of the
contaminated top layers of catalyst from the reactors and replenishment with new.
The following points should be carried out to ensure good operation of the Steam
Generators:
Regularly check the levels (as given below) of the SRU Reaction Furnace Boiler
9101-E-07 Steam Drum 9101-V-07, Reaction Furnace Condenser 9101-E-01, 1st
Stage Condenser 9101-E-02 and Last Condenser 9101-E-04. These levels can vary
on load change, especially during start-up, but will normally present no problem
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unless there is evidence of water carryover in the steam systems. In that case,
gradually lower the steam generators level by operating the intermittent blow
down. Blowing down too quickly could result in the start of a cycling level in the
steam generator by an over compensating level controller.
Keep a record of the analysis of the treated Boiler Feed Water that enters the
unit. Also maintain a record of the analysis of each Steam Generator Boiler Feed
Water. These samples are drawn from the vessels continuous blow down lines
through the sample coolers.
Maintain total dissolved solids, TDS, in the boiler water to below 3000 ppm for the
LP Steam Generators and 1500 ppm for the SRU Reaction Furnace Boiler 9101-E-07.
Control the TDS in each Steam Generator by the setting of the continuous blow
down valve.
The operation and monitoring of the TGTU includes the following activities:
Periodically, e.g. every 3 months, sample the reactor outlet process gas and
analyse for SO2.
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The following points should be carried out to ensure good operation of the
De superheater Contact Condenser 9102-C-11 tower:
Regularly check the Desuperheater circulating water for colour. The water colour
will change from brown to dark brown to black over time as it becomes
contaminated by traces of SO2 which pass out of the Hydrogenation Reactor
9102-V-11 into the Desuperheater Contact Condenser 9102-C-11. Should a sudden
breakthrough of SO2 from the Hydrogenation Reactor 9102-V-11 occur then a rapid
change of the circulating water colour will take place, accompanied by a low pH.
Should a sudden breakthrough of SO2 occur due to an upset in the SRU, and if the
upset condition is likely to take some time to correct, then it is advised that the
Desuperheater Contact Condenser 9102-C-11/Tail Gas Amine Absorber 9102-C-12,
i.e. the TGTU wet section, are temporarily taken off line to minimise any low pH
corrosion of the Desuperheater Contact Condenser 9102-C-11 and possible
degradation to the Tail Gas Amine Absorber 9102-C-12 circulating amine.
Periodically change out the Desuperheater circulating water by manually bleeding
off to the spent caustic system. Water from the top cooling section of the
Desuperheater Contact Condenser 9102-C-11 automatically replenish the towers
bottom Desuperheater section level.
Monitor the Desuperheater Contact Condenser 9102-C-11 tower packed sections
differential pressure indicators 91-PDI-1323/1324. An increase in differential
pressure >0.04 barg could indicate packing fouling or flooding whilst a decrease in
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pressure could indicate low circulation water flow and/or poor distribution across
the packing.
c. Tail Gas Amine Absorber 9102-C-12
The absorption of H2S by the Methyl Di Ethanol Amine (MDEA) in the Tail Gas Amine
Absorber 9102-C-12 is a function of the following:
The flow and distribution of MDEA falling down the Tail Gas Amine Absorber
9102-C-12 tower through the upward flow of process gases
The temperature of the lean MDEA entering the Tail Gas Amine Absorber
9102-C-12
The concentration and condition of the lean MDEA entering the Tail Gas Amine
Absorber 9102-C-12
Monitoring of the amine unit will include the following:
Regularly check the following Tail Gas Amine Absorber 9102-C-12 level gauges and
compare with DCS indicated levels:
Regularly check the function of the following level transmitters and alarms as
given below to confirm correct operation:
Maintain lean amine flow (91-FIC-1301) to the amine absorber at the correct flow
for efficient absorption of H2S in the towers.
Maintain amine and gas temperatures as given below.
Pressure,
Flow Temp. C
bar(a)
Amine flow to Tail Gas Amine Absorber 9102-C-12 4.69 45
Process gas flow to Acid Gas Amine Absorber
1.19 41
9102-C-12
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Regularly test the concentration of the lean amine. Add fresh amine if the
strength is <50%.
Regularly check the healthiness of the H2S/H2 analyser 91-AI-1301 for normal
operation.
Monitor the Tail Gas Amine Absorber 9102-C-12 differential pressure indicator
9102-PDI-1327. A gradual increase in pressure differential in a tower over a period
of time will indicate fouling, whilst an increase in pressure differential over a
short period will indicate foaming or flooding of the tower. In this case antifoam
should be injected into an injection point and the amine circulation flow should be
temporarily reduced to reduce the liquid/vapour loadings across the towers
packed sections.
Normal Operating Parameters - TGTU
Alarm and trip values for the Combustion Air Blower 9102-K-11A/B to be
monitored are tabulated below:
7.1.4 Instrumentation
The following actions should be carried out to ensure that all instrumentation is
operating satisfactorily:
The SRU Reaction Furnace 9101-F-01 burner instruments and peep sight nozzles
are purged by instrument air during normal operation and by nitrogen at times of
unit shutdown. In all cases it is important to ensure the purge flows are in
operation to ensure the process tapping points do not block with corrosion
products and/or sulphur deposits. A daily check should be made to ensure that
these purges are taking place, failure or an incorrect purge flow to an instrument
or peep sight nozzle will result in the blockage of the tapping point or nozzle with
sulphur vapours.
Set up a preventative maintenance programme to regularly check critical
instrumentation. It is advised that all instrumentation which initiates a unit
shutdown should be checked every three months. Monitoring instruments such as
Tail Gas Analysers, H2/H2S and pH analysers should be checked weekly.
7.1.5 Process On-Stream Analysis and Testing
The good operation of the AGEU, SRU and TGTU can be maintained by close
observation of a number of analysers. The SRU tail gas H2S/SO2 analyser and the TGTU
Tail Gas Amine Absorber vent gas H2/H2S analysers. The information seen on these
analysers will inform the operator of the condition of the SRU and TGTU processes as
follows:
The SRU tail gas analyser is the most important analyser within the SRU/TGTU.
Failure of this analyser to control the correct volume of trim air to the SRU
Reaction Furnace burner will result, in the event that there is a change in
composition of the acid feed gas, in an abnormal ratio of H2S and SO2 passing from
the SRU and into the TGTU. The consequences of high H2S concentrations in the
SRU tail gases will result in a reduction in the reactions taking place in the TGTU
Hydrogenation Reactor (reduced delta temperature across reactor) and potential
overloading of the tail gas amine absorber amine solution ability to absorb the
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higher than normal loading of H2S gases from the process gases. This will result in
H2S slippage in the Tail Gas Amine Absorbers vent gases to the Incinerator and
possibly an increase of SO2 to atmosphere via the Incinerator stack. The
consequences of high SO2 concentrations in the SRU tail gas will result in higher
than normal temperatures in the TGTU Hydrogenation Reactor (increased delta
temperature across reactor) and the possible breakthrough of SO2 to the DCC
tower and Tail Gas Amine Absorber. Severe SO2 breakthrough will result in
excessive corrosion of the DCC and Tail Gas Amine Absorber and degradation of
the circulating amine solution
The Tail Gas Amine Absorber process vent gas outlet H2/H2S analyser may be used
as a guide to the operation of the SRU Reaction Furnace burner stoichiometry. A
reduction in the H2 and H2S contents of the Tail Gas Amine Absorber vent gases
will indicate that the SRU Reaction Furnace is off ratio producing a higher than
normal concentration of SO2 in its tail gases; i.e. too much process air. This
process change may be confirmed by an increase in the delta temperature across
the Hydrogenation Reactor catalyst bed. If the H2 and H2S contents of the Tail Gas
Amine Absorber outlet vent gas should increase then the SRU is off ratio producing
too much H2S in its tail gas; i.e. too little process air. This process change may be
confirmed by a decrease in the delta temperature across the Hydrogenation
Reactors catalyst bed. In both cases an increase of SO2 to atmosphere via the
Incinerator stack will occur
The pH analyser employed in the DCC Desuperheater circulating water stream will
indicate a low pH when any SO2 breakthrough occurs from the upstream
Hydrogenation Reactor. To avoid corrosion of the equipment the desuperheating
circulating water pH must always be alkaline, ideally in the 9.0 10.0 range. In
the event of a sudden reduction of the contact condensers desuperheating
circulating water pH, due to a breakthrough of SO2 from the Hydrogenation
Reactor, the process gas flow from the Reactor Effluent Cooler to the contact
condenser should be temporarily redirected to the Incinerator until the process
upset has been corrected
Regular testing of the lean amine solution must be carried out to determine
solution strength and H2S loading. If the solution strength is <40% then add fresh
amine to the system via the amine surge tank fill connection. If the lean amine
arriving at the Acid Gas Amine Absorber and the Tail Gas Amine Absorber is only
semi lean, i.e. part loaded with H2S, then it is not being fully regenerated in the
Amine Regenerator and operating corrections are required at the Regenerator
The following is a suggested program for the analysis of the AGEU, SRU and TGTU gas
and liquid streams. This program may be modified following operating experience of
the units:
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Daily:
Twice Weekly:
All the process variables are controlled by monitoring Oxygen and SOX/NOX
contents in the flue gas from stack. The excess Oxygen, SOX and NOX are
continuously monitored by 91-AT-1051, 91-AT-1052 and 91-AT-1053, respectively.
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TITLE: OPERATION AND MAINTENANCE MANUAL
Following are the main parameters in the Incinerator which are to be monitored
for normal operation of Incinerator:
Normal Operating Parameters Tail Gas Incinerator
7.2 UTILITIES
The following are the important parameters to be monitored for steady operation of
Instrument Air System:
Check discharge pressure (68-PI-1402) of lube oil pump and ensure the
pressure is not less than 1.5 barg
Ensure that the differential pressure (68-PDI-1403) across Lube Oil Filter is not
more than 0.5 barg
3. Monitoring of Compressor
Monitor and ensure the compressor outlet pressure (68-PT-1406) is maintained
around 8.0 barg
Monitor and ensure the compressor outlet temperature (68-TI-1405) is
maintained around 55C
Monitor compressor air intake pressure (68-PDI-1401) and ensure the pressure
is under limit
Monitor Compressor 1st Stage and 2nd stage outlet temperatures (68-TI-1401
and 68-TI-1404) and ensure it is maintained below 250C
Monitor Main Motor winding temperatures and ensure the temperatures are
below 125C
Monitor Main motor bearing temperatures (68-TI-1410 & 68-TI-1411) are below
100C
Monitor inter cooler & after cooler air fans are running normal
Ensure loading and unloading of compressor is functioning normal
Ensure changeover of compressor after every 24 hrs
Ensure proper working of water level indicators in inter and after cooler
separators and ensure the proper working of automatic drain valves
Required
Tag No. Description
Value Unit
68-LI-1401 Lube oil sump level 60 %
68-PI-1402 Compressor Lube oil pressure 1.5 barg
68-TI-1402 Lube oil temperature 65 C
68-PDI-1403 DP across lube oil filter 1.5 barg
68-TI-1401 LP stage outlet transmitter 250 C
68-TI-1403 HP stage inlet temperature transmitter 65 C
HP stage outlet temperature
68-TI-1404 250 C
transmitter
Compressor outlet temperature
68-TI-1405 55C C
transmitter
68-PI-1406 Compressor outlet pressure transmitter 8 barg
68-PIC-1310 Instrument air at header pressure 7.8 barg
Plant air flow to plant air distribution
68-PI-1311 7.85 barg
System
Alarm and trip values of main parameters in Instrument air compressor are tabulated
below:
Alarm
Tag No. Description Unit
LL L H HH
68-PDI-1401 Compressor air inlet pressure bar(g) -0.065 -0.070 NA NA
68-PI-1406 Compressor outlet pressure bar(g) NA NA 14 16
68-PI-1402 Compressor Oil pressure bar(g) 1 1.2 NA NA
68-PDI-1403 Compressor Oil filter DP bar(g) NA NA 0.9 1.0
68-TI-1401 LP stage outlet temperature C NA NA 255 260
68-TI-1402 Compressor oil temperature C NA NA 70 75
68-TI-1403 HP stage inlet temperature C NA NA 70 80
68-TI-1404 HP stage outlet temperature C NA NA 255 260
68-TI-1405 Compressor outlet temp. C NA NA 70 80
68-TI-1406 Main motor winding temp. C NA NA NA 155
68-TI-1407 Main motor winding temp. C NA NA NA 155
68-TI-1408 Main motor winding temp. C NA NA NA 155
68-TI-1410 Main motor DE bearing temp. C NA NA NA 115
Main motor NDE bearing
68-TI-1411 C NA NA NA 115
temp.
68-TI-1412 Main motor winding temp. C NA NA NA 155
68-TI-1413 Main motor winding temp. C NA NA NA 155
68-TI-1414 Main motor winding temp. C NA NA NA 155
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TITLE: OPERATION AND MAINTENANCE MANUAL
4. Monitoring of Dryer
Monitor Dryer Inlet filter differential pressure 68-PDI-1407and ensure that it is
<0.3 bar
Monitor Dryer outlet filter differential pressure 68-PDI-1410and ensure that it
is <0.3 bar
Monitor Dryer outlet Dew point analyzer 68-AI-1401 reading and ensure that it
is< (-) 40C
Monitor Dryer outlet pressure in 68-PG-1412
Monitor drying and regeneration sequence are working properly
Details of alarm values of main parameters in the dryer system are tabulated below:
Low High
Sl. # Tag No. Description Unit
Alarm Alarm
1. 68-PDI-1407 Inlet filter Diff. pressure bar NA 0.36
2. 68-PDI-1410 Outlet filter Diff. pressure bar NA 0.36
3. 68-PI-1408 Vessel A pressure bar 3.5 0.7
4. 68-PI-1409 Vessel B pressure bar 3.5 0.7
5. 68-AI-1401 Dew point C NA -40
6. 68-TI-1409 Inlet temperature C 1C 60
Note: 68-PI-1408/68-PI-1409 low alarm is active only during the drying cycle and 68-PI-
1408/68-PI-1409 high alarm is active only during regeneration cycle.
The following are the important parameters to be monitored for steady operation of
Effluent & Waste Water Treatment System:
Regularly check the level being maintained in the Waste Water Degasser 6922-V-07
by comparing the indicated level 69-LT-1301 with the level gauge 69-LG-1302
Routinely check the smooth running of the Waste Water Degasser Pumps
6922-P-08A/B.
Check the differential pressure 69-PDI-1320 across the Sour Water Filter
6922-S-06. If it reaches 1.0 barg, then the filter elements are to be cleaned.
Regularly check the Sour Water Stripper 6922-C-01 pressure is maintained at
1.0 barg through 69-PT-1315
Regularly check the Sour Water Stripper 6922-C-01 top trays differential pressure
69-PDI-1321
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Regularly check the Sour Water Stripper 6922-C-01 bottom trays differential
pressure 69-PDI-1322
Check the Sour Water Stripper 6922-C-01 top temperature is maintained at 82C
through 69-TI-1322
Check the bottom temperature of the Sour Water Stripper 6922-C-01 is maintained
at 126C through 69-TI-1313
The Sour Water Stripper 6922-C-01 bottom level has to be maintained around 50%.
Check the level through 69-LI-1306 and compare with the level gauge 69-LG-1306.
Regularly check the smooth running of the Stripped Water Pumps 6922-P-10A/B.
Routinely check the smooth running of the Stripper Overheads Circulation Pumps
6922-P-11A/B.
Check the temperature of the LP steam is being maintained at 148C through
69-TI-1327
Regularly check the temperature of the Sour Water Stripper Reboiler outlet vapour
temperature is being maintained at 126C through 69-TI-1314
Check the level of the Reboiler Condensate Drum is maintained at around 50%
through 69-LI-1327
Normal operating parameters:
Required
Tag No. Description
Value Unit
69-LIC-1301 Waste Water Degasser 6922-V-07 level 60 %
69-PIC-1307 Waste Water Degasser 6922-V-07 pressure 1 barg
69-FIC-1314 Sour water to sour water stripper flow 8.72 m3/hr
69-PDI-1320 DP across Sour Water Filter 6922-S-06 1 barg
69-PIC-1315 Sour Water Stripper 6922-C-01 1 barg
69-PDI-1321 Sour Water Stripper 6922-C-01 tray top DP <0.15 barg
69-PDI-1322 Sour Water Stripper 6922-C-01 tray bottom DP <0.15 barg
69-TI-1322 Sour Water Stripper 6922-C-01 top temperature 82 C
69-TI-1313 Sour Water Stripper 6922-C-01 bottom temperature 126 C
69-LIC-1306 Sour Water Stripper 6922-C-01 bottom level 50 %
69-TIC-1327 Temperature of the LP steam 148 C
Sour Water Stripper Re-boiler outlet vapour C
69-TI-1314 126
temperature
69-LI-1327 Re-boiler Condensate Drum level 50 C
69-LIC-1325 Sour Water Stripper top level 50 %
69-FIC-1316 CW to Stripper Overhead Cooler 13.6 m3/hr
69-FIC-1315 LP steam flow to the Stripper Re-boiler 2154 Kg/hr
69-TIC-1315 Stripper overheads cooler to sour water 55 C
69-FIC-1317 Stripped Water Cooler outlet flow 8 m3/hr
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Regularly check the Fuel Gas KOD 6236-V-05 level gauge 62-LG-1301 and compare
with DCS indicated level 62-LI-1301.
Fuel Gas KOD 6236-V-05 level in 62-LG-1301 and 62-LI-1301is to be maintained
below 50%
Routine checks to be made in the Fuel gas system to identify any leaks with the
portable gas detectors and to be recorded
Fuel Gas KOD 6236-V-05 is to be checked for condensate collection and to be
drained free of condensate
Routine sampling of the Fuel gas to be done and the quality has to be cross
checked with the Laboratory
Consumption of fuel gas has to be monitored and mass balance study has to be
carried out to find any abnormal loss
Required
Tag No. Description
Value Unit
62-PIC-1301 Fuel Gas KOD 6236-V-05 pressure 7 barg
62-PIC-1302 Fuel Gas KOD 6236-V-05 pressure 7 barg
62-PIC-1303 Fuel Gas KOD 6236-V-05 pressure 7 barg
62-PDI-1305 Fuel Gas KOD 6236-V-05 DP 0.02 barg
62-LI-1301 Fuel Gas KOD 6236-V-05 level 55 %
For normal operation of sea cooling water system following monitoring is required:
Monitor the flow trend of the 69-FI-1301. In case of any increase or decrease in
consumption, analyse the cause and take the corrective measures
Ensure the sea cooling water pumps (6932-P04A/B) discharge pressure
(69-PI-1301/69-PI-1303) is maintained around 5 barg
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Periodic checking of the discharge headers has to be carried out for any leak
Ensure the vibrations 69-VI-1301/69-VI-1302 of sea cooling water pumps
(6932-P04A/B) are below 12 mm/s
Ensure the thrust bearing temperatures 69-TI-1331A/69-TI-1338A of Sea Cooling
Water Pump (6932-P04A/B) bearings are below 85C
Ensure the motor winding temperatures of Sea Cooling Water Pump (6932-P04A/B)
are below 135C
Ensure the pump DE/NDE bearing temperatures of Sea Cooling Water Pump
(6932-P04A/B) are below 110C
Sea Cooling Water system normal operating parameters with values is tabulated
below:
Required
Tag No. Description
Value Unit
69-FI-1301 Sea Cooling Water Pumps common discharge 1500 m3/hr
69-PI-1301 Sea Cooling Water Pump-A discharge pressure 5 barg
69-PI-1303 Sea Cooling Water Pump-B discharge pressure 5 barg
69-VI-1301 Sea Cooling Water Pump-A vibration <12 mm/s
69-VI-1302 Sea Cooling Water Pump-B vibration <12 mm/s
Sea Cooling Water Pump-A thrust bearing
69-TI-1331A <85 C
temperature
Sea Cooling Water Pump-B thrust bearing
69-TI-1338A <85 C
temperature
Maintain the sea water pressure to the electrolyser around 4barg by monitoring
the pressure gauge 69-PG-1451.
Maintain the Electrolyser outlet temperatures are below 42C by monitoring the
temperature indications 69-TI-1452 (6932-G01A) and 69-TI-1453 (6932-G01B)
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TITLE: OPERATION AND MAINTENANCE MANUAL
Confirm that the new Drinking Water Feed Pumps 6834-P-23A/B are operating
satisfactory with sufficient level in Potable Water Storage Tank 6834-T-01 A/B and
providing potable water to De-mineralized Water Package 6834-A-07.
Confirm that the following pumps are operating satisfactory. Periodically run each
spare pump to prove its operation.
Check for the inventories of the chemicals like sulphuric acid & NaOH regularly
and arrange for the specified quantity of chemicals storage drums to avoid
shortage of chemicals at any time.
Monitor the differential pressure across the Cationic Exchangers Bed 6834-S-21A/B
by reading the 68-PDI-1826/68-PDI-1829 and ensure that it is less than XX barg.
Monitor the differential pressure across the Anionic Exchangers Bed 6834-S-22A/B
by reading the 68-PDI-1827/68-PDI-1831 and ensure that it is less than XX barg.
Routine sampling of HCI Storage Tank 6834-T-16 to be carried out to check the
concentration (33%) using the sampler 68-SC-1840.
Close co-ordination between the units is to be maintained for monitoring the
levels in the HCI Storage Tank during transfer of acid. Initial and final tank levels
have to be recorded for tank and loss of acid if any during transfer. Investigation
has to be done in case of abnormal values and the root cause has to be identified
and attended.
Check and monitor the HCI Storage Tank 6834-T-16 level in 68-LG-1825 and
68-LI-1825.
Close co-ordination between the units is to be maintained for monitoring the
levels in the NaOH Storage Tank 6834-T-15 during transfer of NaOH. Initial and
final tank levels have to be recorded for tank and loss of NaOH if any during
transfer. Investigation has to be done in case of abnormal values and the root
cause has to be identified and attended.
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TITLE: OPERATION AND MAINTENANCE MANUAL
Routine sampling of NaOH Storage Tank 6834-T-15 to be carried out to check the
concentration (25%) using the sampler 68-SC-1841.
Check and monitor the NaOH Storage Tank 6834-T-15 level in 68-LG-1826 and
68-LI-1826.
Check and monitor the following normal operating parameters:
a. DM Water Storage Tank 6834-T-08 level 68-LIC-1305 (5200 mm)
b. Check that no resin is flowing over into the drain header trench as a result of
incorrect action when a train is started up.
b. Whenever working on the chemical system H2SO4 & NaOH make sure that
appropriate protective equipment is used
b. Check the level of resin bed in the Cationic/Anionic Beds, if necessary, make
up the difference. Do remember that resin swells, and that after regeneration
both cation and anionic resins are at their maximum expansion
Alarm and trip values main parameters in DM Water Package are tabulated below:
Limit Values
Tag No. Service Unit
L H LL HH
68-LI-1825 Acid storage tank level % NA NA XX NA
68-LI-1826 Acid storage tank level % XX XX NA NA
68-LI-1827 Caustic storage tank level % NA NA XX NA
68-LI-1828 Caustic storage tank level % XX XX NA NA
68-LI-1830 Neutralisation Pit level % NA NA XX NA
68-LI-1831 Neutralising Pit level % XX XX NA NA
68-LI-1305 DMW storage Tank level % XX XX NA NA
68-AI-1829 Outlet DMW conductivity s NA NA NA XX
68-AI-1830 Outlet DM Water silica Sio2 NA NA NA XX
68-AI-1826 Train-A Anionic Exchangers s NA XX NA NA
outlet conductivity
68-AI-1828 Train-B Anionic Exchangers s NA XX NA NA
outlet conductivity
68-FI-1826 Train-A Recycle pump flow m3/hr XX XX NA NA
3
68-FI-1837 Train-A Recycle pump flow m /hr NA NA XX NA
3
68-FI-1829 Train B Recycle pump Flow m /hr XX XX NA NA
3
68-FI-1838 Train-B Recycle pump flow m /hr NA NA XX NA
3
68-FI-1830 DM water package outlet m /hr NA NA XX NA
flow
68-FI-1828 DM water package outlet m3/hr XX XX NA NA
flow
68-FI-1825 Train-A Cationic exchanger m3/hr XX XX NA NA
inlet flow
68-FI-1827 Train-B Cationic exchangers m3/hr XX XX NA NA
inlet flow
68-PDI-1825 Train-A Cationic exchangers barg NA XX NA NA
bed differential pressure
68-PDI-1826 Train-A Resin trap barg NA XX NA NA
differential pressure
68-PDI-1828 Train-A Anionic exchangers barg NA XX NA NA
Bed differential pressure
68-PDI-1827 Train-A Anionic exchanger barg NA XX NA NA
Resin trap differential
pressure
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Limit Values
Tag No. Service Unit
L H LL HH
68-PDI-1830 Train-B Cationic exchangers barg NA XX NA NA
differential pressure
68-PDI-1829 Train-B Resin Trap barg NA XX NA NA
differential pressure
68-PDI-1832 Train-B Anionic exchangers barg NA XX NA NA
differential pressure
68-PI-1825 6834-P-35A diaphragm barg NA XX NA NA
failure
68-PI-1826 6834-P-35B diaphragm barg NA XX NA NA
failure
68-PI-1827 6834-P-35C diaphragm barg NA XX NA NA
failure
68-PI-1828 6834-P-34A diaphragm barg NA XX NA NA
failure
68-PI-1829 6834-P-34B diaphragm barg NA XX NA NA
failure
68-PI-1830 6834-P-34C diaphragm barg NA XX NA NA
failure
68-AI-1831 Neutralisation pump pH XX XX NA NA
discharge pH
68-FI-1831 Neutralisation pump m3/hr XX XX NA NA
discharge flow
68-FI-1835 Static Mixer inlet DM Water m3/hr XX XX NA NA
flow
68-AI-1832 Static Mixer-A outlet s XX XX NA NA
conductivity
68-AI-1833 Static Mixer-B outlet s XX XX NA NA
conductivity
68-FI-1836 Static Mixer inlet DM Water m3/hr XX XX NA NA
flow
68-AI-1833 Static mixer outlet s XX XX NA NA
conductivity
Ensure the Steam Condensate Flash Drum pressure is maintained around 0.1 barg
by monitoring the 68-PG-1308.
Routine analysis of Boiler Feed Water from De-aerator Vessel 6834-A-08 should be
carried out and confirm that the Oxygen content is <0.007 ppm wt.
Check the inventories of the chemicals like Oxygen Scavenger and complex
product regularly and arrange for the road Tankers to avoid shortage of chemicals
at any time.
Required
Tag No. Description
Value Unit
68-PG-1308 Steam condensate flash drum pressure 0.1 barg
68-LI-1301 Steam condensate flash drum level 50 %
De-aerator feed pumps 6834-P-20A/B
68-FIC-1301 83 m3/hr
flow
68-PIC-1304 De-aerator top pressure 0.2 Barg
68-LIC-1302 De-aerator level 50 %
68-FI-1309 LP saturated steam flow 180 Kg/hr
68-PI-1307 BFW pumps 6834-P-22A/B/C pressure 20.8 barg
Steam Condensate Flash Drum
68-TIC-1301 102 C
temperature
During normal operation of the boiler, attention should be paid to the proper
operation of all the ancillaries and equipment in service.
Safe and reliable operation of the steam generator depends on routine monitoring of
the control and safety systems.
Controls and checks must be done continuously, also if the system is operated
automatically.
In fact variations in the selected and settled parameters can result in worsening of the
auxiliary power consumption and/or boiler efficiency, or sometimes can indicate a risk
of possible damage.
For example, the increasing of the boiler flue gas exit temperature can indicate
possible carbon fouling deposition on tube surfaces or improper flame position or miss-
adjustment of the air-fuel ratio.
Water level variations in the boiler take place in case of rapid increase or decrease in
steam output, so the proper water level in the steam drum must be maintained.
Boiler water level is maintained by the level controller 91-LIC-1522 (set at 50%).
Monitor the Boiler water level by the level gauges 91-LG-1522 & 91-LG-1523 during
normal operation.
Regularly cross check the DCS indicated level with level gauge.
The Boiler Feed Water should be carefully treated and monitored during boiler
operation as it is essential to assure boiler integrity. It is important that plant
operators always maintain the quality of Boiler feed Water as given below.
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The Steam Generator is provided with one sampling system, that allows to analyse the
quality of the Boiler Feed Water.
The Boiler Feed Water Conductivity is maintained by acting on the CBD control valve,
whose position determines the conductivity of the Boiler Feed Water.
In order to get quality Boiler Feed Water, the following actions to be taken:
Establish a strict control of Feed Water and Boiler Water parameters through a
routine sampling and subsequent chemical analysis of the samples at least one for
each working shift (8 hours) or more frequently. Record each analysis result to
easily check all data comparing them with boiler load and injection amounts of
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chemical additives. This database allows also to check immediately any possible
data variation and consequently to take the necessary remedial actions.
Feed water quality: Maintain Feed Water quality continuously by acting on
Continuous Blow Down. Generally the CBD flow rate, during a good and regular
boiler operation, should be about 1% of boiler MCR (the most economic and best
operation should be based on a target of 0.5%). However, in case of need, the CBD
flow rate can be temporarily increased by 2-3%.
Operation at high CBD flow rates clearly indicates that boiler water quality is not
under control and that necessary remedial action must be taken.
Chemicals dosing injection: Operator must check that chemical dosing system is
available and that all chemicals are injected at the required rate and
concentration in the Feed Water and in Boiler Feed Water.
Attention: For water chemical conditioning, its absolutely forbidden to use strong
alkali compounds, with particular reference to those containing caustic soda (Sodium
Hydroxide) and caustic potash (Potassium Hydroxide). Its allowed to use volatile alkali
compounds, adequately dosed and in the recommended quantity and phosphate
treatment.
The CBD flow rate is automatically adjusted by the system according to the measured
value of boiler water conductivity.
The sampling system dedicated to steam generator is provided also with manual
sampling line for each sample that can be used to perform a complete analysis of the
feed/boiler water.
Note: When the boiler is in normal operation and in any cases when the boiler
water/steam pressure is higher than atmospheric pressure, no manual boiler pressure
part drain valves shall be opened.
The boiler water column and level glass indicator shall be periodically and very
carefully purged at least one time a week, so to limit sludge or sediment accumulation
in these devices.
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In fact all this kind of accumulated deposits could cause an erroneous indication of the
water level.
d. Flame Pattern
It is important to assure a good flame pattern in order to get a stable and safe
combustion, limiting possible impingement on furnace wall tubes or on burner throat
refractory and limiting also any possible flame pulsation.
A good combustion will allow achieving the expected boiler performance, both in
terms of steam production and flue gas emissions.
On the contrary improper flame pattern could result in carbon build-up on the external
tube surfaces that could reduce the thermal heat transfer, and consequently could
increase the flue gas temperatures at the stack, so creating an efficiency reduction.
Flame instability can cause some dangerous vibration phenomena and possible
unburned fuel zone accumulation into the furnace. This dangerous situation must be
absolutely avoided: in such case all the combustion system parameters must be
controlled again till to eliminate this disturbance.
Steam Generation unit normal operating parameters with values are tabulated below:
Required
Tag No. Description
Value Unit
68-LIC-1522 Boiler drum level 50 %
3
68-FIC-1522 Boiler Feed Water flow XXX m /hr
68-TIC-1522 SH steam temperature 163 C
68-TIC-1820 LP Steam header temperature XX C
68-PIC-1523A Boiler drum pressure 16.4 barg
68-FIC-1525 Fuel gas flow to boiler XXX Kg/hr
68-FIC-1526 Combustion air flow to boiler XXX Kg/hr
68-AIC-1522 Oxygen analyzer controller XXX %
68-ZIC-1524 Flue gas damper position controller XXX %
68-PIC-1523B Steam pressure vent 17.4 barg
68-PIC-1306 LP steam header pressure 5 barg
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8.1 GENERAL
SRU
TGTU
8.2 TAIL GAS INCINERATOR RESTART
After the Tail Gas Incinerator ESD shutdown is activated, the unit is restarted as
follows:
Confirm the root cause of the Incinerator shutdown and rectify the same
problem. Reset the ESD by pressing 65-HS-4001R for ESD-0, 65-HS-001R for
ESD-1 and 65-HS-1192 for ESD-2/3/4
Check and confirm the availability of utilities for operation.
Start Incinerator as per procedure described in section 6.3.1
8.3 ACID GAS ENRICHMENT UNIT RESTART
After an emergency shutdown of AGEU, the unit is still with liquid levels in Acid Gas
Amine Absorber column bottoms, Amine Surge Tank, Amine Regenerator and Amine
Regenerator Reflux Drum.
Confirm the root cause of the Acid Gas Enrichment Unit shutdown and rectify the
same problem. Reset the ESD by pressing 65-HS-4001R for ESD-0, 65-HS-001R for
ESD-1 and 65-HS-1192 for ESD-2/3/4
Confirm that all the utility services are available and all rotating equipments are
ready for operation
Confirm that the downstream units are ready to receive the acid gas
All instrumentation is confirmed as reading correctly on the DCS, against local
instrumentation and local gauges
All shut-down devices have been tested
Confirm Tail Gas Incinerator is in line
After an emergency shutdown of SRU, the unit is still with liquid levels in Reaction
Furnace Boiler 9101-E-07, Reaction Furnace Condenser 9101-E-01, 1st Stage Condenser
9101-E-02 and Last Condenser 9101-E-04.
Confirm the root cause of the SRU shutdown and rectify the same problem.
Reset the ESD by pressing 65-HS-4001R for ESD-0, 65-HS-001R for ESD-1 and
65-HS-1192 for ESD-2/3/4
Confirm that all the utility services are available and all rotating equipments
are ready for operation
Confirm that the downstream units are ready to receive the tail gas
All instrumentation is confirmed as reading correctly on the DCS, against local
instrumentation and local gauges
All shut-down devices have been tested
The restart is done considering that SRU converters 1st Stage Converter 9101-V-01 & 2nd
Stage Converter 9101-V-02 contain sulphur compounds. To ensure that during this
start-up, there is no ignition of any Sulphur compounds within the unit, the Reaction
furnace burner is operated at slightly sub-stoichiometric firing condition.
Start SRU as per the procedure described in section 6.3.3.
After the TGTU unit ESD is activated, the unit is still with liquid levels in Reactor
Effluent Cooler 9102-E-11 and Desuperheater/Contact Condenser 9102-C-11 top and
bottom sections.
Confirm the root cause of the TGTU shutdown and rectify the same problem.
Reset the ESD by pressing 65-HS-4001R for ESD-0, 65-HS-001R for ESD-1 and
65-HS-1192 for ESD-2/3/4.
Confirm that all the utility services are available and all rotating equipments
are ready for operation
Confirm that the downstream units are ready to receive the tail gas
All instrumentation is confirmed as reading correctly on the DCS, against local
instrumentation and local gauges
All shut-down devices have been tested
The Hydrogenation Reactor catalyst is in sulphided state so sulphiding of the catalyst is
not required. The start-up is carried out considering that unit contains Sulphur
compounds and ensure that during this start-up there is no ignition of any Sulphur
compounds within the unit; the RGG burner is operated at slightly sub-stoichiometric
firing conditions from the start of ignition in the RGG.
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9.1 PROCESS
9.1.1 Incinerator
9.2 UTILITIES
a. Air Compressor
b. Air Dryer
The shutdown of the AGEU, SRU, TGTU and the Incinerator is explained below. The
shutdown of the Incinerator will only take place following the shutdown of the AGEU,
SRU and the TGTU.
The planned shutdown of the process units take place in the following sequence:
TGTU
SRU
AGEU
Incinerator
The shutdown of the TGTU wet section, the DCC and Tail Gas Amine Absorber tower,
may take place before or after acid feed gases are removed and replaced with fuel gas
in the SRU Reaction Furnace burner.
It is advised to stop the flow of SRU tail gas to the TGTU wet section before acid feed
gas is removed from the SRU Reaction Furnace burner, rather than after the burner is
operating on fuel gas; this action will minimise the possibility of an upset condition
during the acid gas to fuel gas change over in the SRU Reaction Furnace burner, that
could result in high concentrations of SO2 in the process gas causing corrosion of
equipment in the TGTU wet section and degradation of the amine solution in the Tail
Gas Amine Absorber.
Shutdown of the TGTU DCC and absorber tower will proceed as follows:
Open Reactor Effluent Cooler process outlet gas valve 91-XV-1331 to route
Hydrogenation section process gases to the Incinerator
Close Reactor Effluent Cooler process outlet gas valve 91-XV-1332 to the DCC
tower
Continue DCC Desuperheater and cooling waters circulations until column has
cooled to near ambient temperatures, then stop pumps
Continue circulation of lean amine to the Tail Gas Amine Absorber for a period of
time, e.g. 30 minutes, to ensure all rich amine solution has been removed to the
Amine Regenerator for regeneration, then stop lean amine flow to the Tail Gas
Amine Absorber and stop the Tail Gas Rich Amine Pump
Before stopping the DCC tower top section cooling water pump, pump all possible
water from the top chimney tray to the Effluent Water Treatment
Pump out the bottom Desuperheater section of the DCC to the spent caustic
system
Through the condensate line to the cooling water pumps suction line, introduce
condensate to establish a level in the contact condenser tower top chimney tray
cooling section
Start a Cooling Water Recirculation Pump 9102-P-12A/B to establish water
circulation through the Contact Condenser Cooler to the top of the DCC tower
Open the DCC bottom level control valve 91-LV-1307 to transfer condensate from
the top cooling water system to establish a condensate level in the bottom of the
tower. Continue adding condensate via the Cooling Water Recirculation Pumps
suction line to maintain a water level in the top chimney tray
When a water level is established in the bottom of the DCC, start a Desuperheater
Circulation Pump 9102-P-11A/B and start circulation around the bottom of the
tower
Again pump out the bottom Desuperheater section to the spent caustic system
Sample the water whilst it is being pumped out to the spent caustic system, if the
pH of the water is near to the pH of condensate, then the Desuperheater section
has been flushed clean. Repeat filling and circulating the Desuperheater section if
further flushing is required
When flushed clean, drain any remaining water in the top cooling water and
bottom Desuperheating sections of the DCC tower to the drains system
After water washing, final cleaning and gas freeing of the DCC tower should be
carried out by steaming. The DCC process gas outlet valve to the Tail Gas Amine
Absorber is first closed and LP steam is introduced into the tower via its utility
connection.
The DCC tower is initially steamed to flare, via the towers PSV open bypass line,
and then to atmosphere before the steam is stopped, and air allowed to enter the
equipment. Steam out of the tower should be for a minimum of 4 hours to flare
followed by a minimum of 4 hours to atmosphere.
If the Tail Gas Amine Absorber is to be opened for inspection then:
Restart a Tail Gas Rich Amine Pump 9102-P-16A/B and pump out all amine from
the bottom of the Tail Gas Amine Absorber to the Acid Gas Amine Absorber
After water washing, final cleaning and gas freeing of the Tail Gas Amine Absorber
should be carried out by steaming. LP steam is introduced into the tower via its
utility connection and steamed to the Incinerator for a minimum of 8 hours
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Note: The Incinerator must be in operation when steam out of the Tail Gas Amine
Absorber is taking place.
Stop the Sour gas from Effluent and Waste Water Treatment Unit by closing 69-PV-
1315A and open 69-PV-1315B to LP Acid Gas Flare.
Open SRU tail gas outlet valve 91-XV-1097 to route tail gas directly to the
Incinerator
Close SRU tail gas outlet valve 91-XV-1098 to the TGTU
Simultaneously while the SRU tail gas valve to the TGTU is being closed; shutdown
the RGG burner via the RGG manual shutdown switch 91-HS-1403.
Confirm that the action of the shutdown switch has closed or opened the following
RGG shutdown valves:
Nitrogen valve 91-XV-1307 to the RGG process air line is opened (valve will
remain open for ~15 minutes)
Nitrogen valve 91-XV-1301 to the RGG instrument nozzles is opened (valve will
remain open for ~15 minutes)
Instrument air valve 91-XV-1302 to the RGG instrument nozzles is closed
After a set time of 15 minutes, confirm that the nitrogen purge valves to the RGG
process air line 91-XV-1307 and to the RGG instrument nozzles 91-XV-1301 have
closed.
Close manual valves in the RGG process air, instrument air, fuel gas and LP steam
lines to the RGG.
The TGTU BSR section and hydrogenation reactor may then be left to cool
naturally until a re-start is required.
Observe the Reactor Effluent Cooler steam side pressure after unit shutdown and
open the vessels steam side vent valve when steam side pressure falls to
<1.0 barg to avoid a vacuum being formed in the vessel.
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If time permits, prior to reducing acid feed gas to the SRU it is advised that the
SRU converters catalyst beds undergo a rejuvenation exercise, refer to Section
12.4.5.
Reduce acid gas feed to the SRU Reaction Furnace to the unit minimum design
flow of 6628 kg/hr, (2169 am3/hr)
When acid gas feed flows to the SRU reaction furnace burner are at the units
minimum:
Switch trim air controller 91-FIC-1003 to manual mode and close trim air control
valve.
Confirm the stoichiometric air requirements for the fuel gas
Confirming the fuel gas shutdown valves are open, in manual operating mode,
slowly open fuel gas control valve 91-FV-1009 to introduce fuel gas to the SRU
Reaction Furnace burner to replace the acid gas.
Observe adjustment of the process air flow as fuel gas flow to the Reaction
Furnace burner increases.
Simultaneously whilst increasing fuel gas flow 91-FT-1009, decrease acid gas flow
91-FI-1001 to the reaction furnace burner to ensure the fuel gas is being burned at
slightly substoichiometric firing conditions.
Simultaneously switch 1st Stage Auxiliary Burner and 2nd Stage Auxiliary Burner
from acid gas to fuel gas
When acid gas flow has stopped close manual valve in acid gas line to Reaction
Furnace burner.
Close MS steam to the Acid Gas Pre-heater
Observe adjustment of the process air as fuel gas flow to the Reaction Furnace
burner increases and acid gas flow decreases.
Introduce LP steam to the fuel gas line through 91-XV-1079 to prevent soot being
formed at sub-stoichiometric firing conditions. Set steam controller to control the
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steam flow at a ratio to natural gas of 1:1 (by wt). Before opening steam valves
ensure steam lines are fully drained of condensate.
Introduce LP steam to the burner process air line through 91-XV-1078 to moderate
the furnace temperature and prevent overheating of the furnace refractory. Note
that the furnace temperature will dictate the amount of steam used, too much
steam could result in interference of the burners flame detectors sensing the
flame resulting in a burner trip. Before opening steam valves ensure steam lines
are fully drained of condensate.
Continue operating the SRU Reaction Furnace burner in slightly sub-stoichiometric
firing conditions to produce a hot inert flow of combustion gas through the unit to
sweep all possible sulphur from the SRU converters catalyst beds. Continue this
operation until the flow of sulphur is seen to have stopped from all sulphur
condenser seals.
When all possible sulphur has been removed from the SRU converters, if the intent
is not to open the SRU to carry out maintenance, then shutdown the unit via its
emergency stop switch.
If the SRU is not to be opened for a maintenance overhaul then a catalyst sulphur
stripping exercise is not required and the shutdown of the unit can proceed as follows:
After a set time of 15 minutes, confirm that the nitrogen purge valves to the
Reaction Furnace process air line and to the Reaction Furnace burner instrument
nozzles have closed
Close manual valves in the process air, instrument air, fuel gas, acid gas and LP
steam lines to the reaction furnace
Observe all steam generators steam side pressures after unit shutdown. When
pressures have decayed to <1.0 barg on the steam side of the WHB, condensers
and reactor effluent cooler, open atmospheric vents to prevent a vacuum being
formed in the vessels
The SRU may then be left to cool naturally until a re-start is required
If the intent is to open the unit to carry out an internal inspection and
maintenance then a sulphur stripping/regeneration exercise will first have to be
carried out to remove all hazardous sulphur compounds from the unit, refer to
Section 12.4.6
10.1.3 Acid Gas Enrichment Unit Shutdown
Inform NGL-1, 2 & 3 to slowly reduce the acid gas feed to AGEU to the unit
turndown flow of 12241 kg/hr
When the acid gas feed is at the turndown flow:
Close the acid gas feed to amine absorber by closing the inlet block valve
Close the treated gas outlet from Acid Gas Amine Absorber 9103-C-11 to
Incinerator pressure control valve 91-PV-1502 and the upstream and downstream
isolation valves.
The amine solution is to be circulated until the solution is completely
regenerated. Take samples from Amine Regenerator bottom and confirm.
When the solution is completely regenerated, slowly close the LP Steam to
Regenerator Reboiler 9103-E-13 by closing the inlet flow control valve 91-FV-1503.
Close the condensate outlet from Regenerator Reboiler Condensate Pot 9103-V-13
and open the pot vent to avoid pulling vacuum when the pressure is reduced.
Stop the Regenerator Reflux drum pumps 9103-P-11A/B when the level in the
Regenerator Reflux Drum 9103-V-12 reaches low and close the discharge isolation
valves.
Open 91-PV-1539 to supply nitrogen to the Amine Regenerator.
Continue MDEA circulation till the solution is cooled down.
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Slowly reduce the amine circulation rate and stop the Lean Amine Pumps 9103-P-
13A/B.
Stop Rich Amine Pumps 9103-P-12A/B and Hot Lean Amine Pumps 9103-P-17A/B
after transferring the solution to the Amine Surge Tank 9103-T-11.
Stop Regenerator Condenser Cooler 9103-E-12 fans and Lean Amine Cooler 9103-E-
14 fans.
Drain the MDEA solution from Acid Gas Amine Absorber 9103-C-11 through the Acid
Gas Rich Amine Pumps casing drain to the Amine Sump 9103-V-10 and transfer the
solution from the Amine Sump to the Amine Surge Tank 9103-T-11
Drain the Lean/Rich Amine Exchanger 9103-E-11A/B by opening the drains on the
Lean and Rich amine side to the Amine Sump 9103-V-10 and transfer the solution
from the Amine Sump to the Amine Surge Tank 9103-T-11
Drain the Amine Regenerator 9103-C-12 through the Hot Lean Amine Pumps 9103-
P-17A/B casing drain to the Amine Sump 9103-V-10 and transfer the solution from
the Amine Sump to the Amine Surge Tank 9103-T-11
Drain the solution from the Regenerator Condenser Cooler 9103-E-12 and
Regenerator Condenser Trim Cooler 9103-E-16 by draining through the upstream
and downstream drain valves of 91-TV-1502 to the Amine Sump 9103-V-10 and
transfer the solution from the Amine Sump to the Amine Surge Tank 9103-T-11
Drain the Regenerator Reboiler through the vessel drains to the Amine Sump
9103-V-10 and transfer the solution from the Amine Sump to the Amine Surge Tank
9103-T-11
Drain the Lean Amine Cooler and Lean Amine Trim Cooler through the drains to
the Amine Sump 9103-V-10 and transfer the solution from the Amine Sump to the
Amine Surge Tank 9103-T-11
Drain the Lean Amine Filters through the drains to the Amine Sump 9103-V-10 and
transfer the solution from the Amine Sump to the Amine Surge Tank 9103-T-11
Depressurise the system by opening the vents to flare
Steam out of the unit has to be carried out for vessel entry
10.1.4 Incinerator Shutdown
The Incinerator will only be shutdown following the shutdown of the TGTU, SRU and
AGEU. The shutdown of the unit may proceed as follows:
Confirm that all process gases from the upstream AGEU, SRU and TGTU have stopped
and that the following process gas valves to the incinerator are isolated:
Treated vent gas line from the Acid Gas Amine Absorber is blind isolated
Treated vent gas line from the Tail Gas Amine Absorber is blind isolated
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Blind isolate the unit for in readiness for opening and inspection
10.2 UTILITIES
Before stopping the boiler increase the blow down rate to remove as much
sediments as possible
Reduce the boiler load to 75%
Reduce the boiler load to 20%, by taking all boiler controls in manual
Start to open the start-up vent valve 68-PV-1523 until the steam drum pressure
begins to decrease
Close the 68-MOV-1522 to stop the steam supply to the header
Stop the burner by pressing the normal stop push button 68-HSC-1527 in local
boiler panel
Following are the sequence in BMS when burner stop pushbutton is pressed:
BMS sets the air purge request and post purge in progress signal
Combustion air flow damper (68-FV-1526) will be opened to threshold limit
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When Drum Pressure reaches 1.5- 2.0 barg, open the saturated steam vent valves
Cool down the unit naturally until the ambient temperature is reached
Drain the Boiler with the drum vent valves in open position
Isolate the other utility pipelines
Follow the same sequence for stopping of another running boiler.
During Planned Shutdown of Boiler Feed Water system, the scheduled maintenance
activity on Deaerator, Boiler Feed Water Pumps, chemical Injection Pumps and the
auxiliary equipment can be carried out as per company maintenance schedule. Other
maintenance activity that may be carried out includes checking of PSV and calibration
of instruments, etc.
Jobs like Deaerator Internal work, equipment overhauls will be planned in long
Shutdown. But in case if the Deaerator internal work is not planned during long
Shutdowns, preservation procedures as per the company procedure has to be followed.
Get clearance from all process units before taking the shutdown of the Boiler Feed
Water System.
Ensure steam generation units are stopped, before taking shutdown of boiler feed
Water system.
Following steps are to be followed for shutdown of Boiler Feed Water System:
Stop Oxygen Scavenger injection to Deaerator package 6834-A-08
Stop the boiler feed water Pumps 6834-P-22 A/B/C and close the pump suction &
discharge valves.
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Isolate the steam condensate from Steam Condensate Coolers 6834-E-02 by taking
68-TIC-1301 in manual and close the control valve 68-TV-1301
Ensure Deaerator Feed Pumps recirculation flow controller 68-FIC-1301 is in
manual and the steam condensate to flash drum minimum flow control valve
68-FV-1301 is fully closed.
Stop all the running Steam Condensate Cooler Fans 6834-E-02.
10.2.3 DM water package Shutdown
Jobs like Resin replacement, Equipment overhauls will be planned in this Long
Shutdown. But in case if the resin replacement is not planned during Long Shutdowns,
Preservation procedures as per the vendor has to be followed. For details of these
preservation procedures refer the Vendor Operation and Maintenance Manual.
To stop the DM water train, place the respective AUTO/MAN/OFF selector in OFF
position.
When OFF mode is selected, all valves involved in the respective sequence is closed,
phase duration timers are stopped at the current status, and the sequence is freeze
in the current phase, with all outputs inhibited.
The procedure for normal shutdown of DM Water Package unit is given below:
1. Get clearance from all process units before taking the shutdown of the DM Water
System.
3. If the regeneration is in progress in one of the train continue regeneration and stop
the train after the completion of regeneration by placing the respective AUTO/
MAN/OFF selector in OFF position.
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4. Select the train which is in online to manual, use the step advance button to start
the regeneration and after completion of regeneration, stop the train by placing
the respective AUTO/MAN/OFF selector in OFF position.
6. If the Resins are to be preserved for a long time, follow the Preservation
procedures as given in the Vendors Manual.
7. Based on the requirement, isolate and hand over the equipments as per the
equipment hand over procedure.
If the Antifoam Storage Tank has to be handed over for maintenance, then the
tank level has to be reduced to the level possible before stopping the Injection
pumps. The tank has to be drained fully to the drain pit and washed thoroughly
with water.
b. Caustic Injection Package 9103-A-13
Drain the Caustic from the lines and the pumps to the drain pit and flush the lines
with water and deenergise the pumps if required for any maintenance.
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If the Caustic Storage Tank has to be handed over for maintenance, then the tank
level has to be reduced to the level possible before stopping the Injection pumps.
The tank has to be drained fully to the drain pit and washed thoroughly with
water.
c. Corrosion Inhibitor Injection Package 9103-A-12
Close the isolation valve at the Corrosion Inhibitor Storage Tank outlet to the
suction of the pumps
Close the suction and discharge isolation valves of the Corrosion Inhibitor Injection
Pumps
Close the Corrosion Inhibitor injection line isolation valve at the injection point
Drain the Corrosion Inhibitor from the lines and the pumps to the drain pit and
flush the lines with water and deenergise the pumps if required for any
maintenance.
If the Corrosion Inhibitor Storage Tank has to be handed over for maintenance,
then the tank level has to be reduced to the level possible before stopping the
Injection pumps. The tank has to be drained fully to the drain pit and washed
thoroughly with water.
d. Complex Product Injection Package 6834-A-09
Close the Oxygen Scavenger injection line isolation valve at the injection point
Drain the Oxygen Scavenger from the lines and the pumps to the drain pit and
flush the lines with water and deenergise the pumps if required for any
maintenance.
If the Oxygen Scavenger Storage Tank has to be handed over for maintenance,
then the tank level has to be reduced to the level possible before stopping the
Injection pumps. The tank has to be drained fully to the drain pit and washed
thoroughly with water.
f. Biocide Injection Package 6932-A-06
Close the suction and discharge isolation valves of the Scale Inhibitor Injection
Pumps
Close the Scale Inhibitor injection line isolation valve at the injection point
Drain the Scale Inhibitor from the lines and the pumps to the drain pit and flush
the lines with water and deenergise the pumps if required for any maintenance.
If the Scale Inhibitor Storage Tank has to be handed over for maintenance, then
the tank level has to be reduced to the level possible before stopping the Injection
pumps. The tank has to be drained fully to the drain pit and washed thoroughly
with water.
h. Catalyst Injection Package 9101-A-01
The shutdown of the Sea Cooling Water Pumps 6932-P-04A/B will proceed as follows:
Ensure that there is no requirement for fuel gas from the New Steam Boiler
Package 6848-A-02A/B/C
Ensure that the Boiler Package 6848-A-02A/B/C fuel gas inlet XVs 68-XV-1302,
68-XV-1303 & 68-XV-1304 and the isolation valves are closed
Isolate the backup fuel gas supply from 6103-K-01A/B by closing the isolation
valves of 62-PV-1301B
Isolate the backup fuel gas supply from 30 existing line by closing the isolation
valves of 62-PV-1302
Close the fuel gas supply from first stage Booster Compressor 6701-K-10/20/30 by
closing the isolation valves of 62-PV-1301A
Open 62-PV-1303 to LP Flare Header and depressurise the system
Open the drain valves of the LP Fuel gas KO Drum and drain the liquids to the LP
Flare Header
Purge the Fuel gas system with nitrogen to reduce the HC content to 0% LEL and
depressurise the system
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Reverse to close the spectacle blinds on the fuel gas lines from Booster
Compressor 6701-K-10/20/30 upstream of 62-XV-1301, spectacle blind on the back
up fuel gas supply from 6103-K-01A/B upstream of 62-XV-1302 and spectacle blind
on the back up fuel gas supply from 30 existing line upstream of 62-XV-1303
Reverse to close the spectacle blinds on the fuel gas lines to the New Steam Boiler
Package 6848-A-02A/B/C upstream of XV-1302/XV-1303/XV-1304
The fuel gas system is to be preserved under nitrogen till maintenance activities
are taken up.
10.2.8 Effluent & Waste Water Unit Shutdown
The Effluent & Waste Water Unit shutdown is carried out in the following steps:
Slowly reduce the waste water feed to the Waste Water Degasser 6922-V-07 and
stop the flow from the upstream units
Close 69-PV-1315A and open 69-PV-1315B and send the sour gas from Sour Water
Stripper to LP Acid Gas Flare Header
Gradually reduce the level in the Waste Water Degasser 6922-V-07 by pumping the
waste water to the Sour Water Stripper.
Stop Waste Water Degasser Pumps 6922-08A/B
Close the Reboiler Condensate Drum 6922-V-09 level control valve 69-LV-1327 and
open vent in the drum when the pressure reaches 1.0 barg
Reduce the level in the Sour Water Stripper 6922-C-01 and stop the Stripped Water
Pump 6922-P-10 A/B when the level is low
Stop the Stripper Overheads Cooler 6922-E-03 fans and the Stripped Water Cooler
6922-E-02 fans
Close 69-PV-1307 and stop the nitrogen supply to the Waste Water Degasser
6922-V-07
Drain the Waste Water Degasser 6922-V-07 to the waste water distribution header
through the Waste Water Degasser Pumps 6922-P-08A/B casing drains
Drain the Sour Water Filter 6922-S-06 to the waste water distribution header
Drain the Sour/Stripped Water Exchanger 6922-E-01 to the waste water
distribution header
Drain the Sour Water Stripper 6922-C-01 to the waste water distribution header
through the bottom drain
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Drain the Stripped Water Pumps 6922-P-10A/B to the waste water distribution
header through the casing drain
Drain the Stripper Overhead Circulation Pumps 6922-P-11A/B to the waste water
distribution header through the casing drain
Drain the Sour Water Stripper Reboiler 6922-E-04A/B to the waste water
distribution header through the low point drain
Drain the Stripper Overheads Cooler 6922-E-03 and Stripped Water Cooler 6922-E-
02 to the waste water distribution header through the low point drain
Depressurise the system to LP Acid Gas Flare Header
Steam out of the system is necessary to carry out maintenance activities.
10.2.9 Instrument air Shutdown
The Instrument Air Compressor is normally kept in Remote-Auto mode during normal
operation. Hence, depending on the demand of instrument air, the Compressor will get
stopped automatically.
Auto Stop
In Remote mode, if the Compressor runs unloaded for a period of time (maximum 20
minutes idling delay), the Compressor gets stopped. The Compressor will restart only
when the air is required.
A compressor can be taken for planned shutdown after ensuring the healthiness of
Stand-by Compressor
In remote mode compressor can be stopped by the operator from ICSS/UCP. In local
mode Compressor can be stopped by pressing the STOP pushbutton in Local Control
Panel.
The following steps to be followed for stopping the Compressor 6837-K-02A from LCP:
4. After 10 seconds main motor and the fan cooler motors will be stopped.
Note: Follow the above steps for shutdown of Instrument Air Compressor 6837-K-02B.
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The Dryer Package can be taken planned shutdown for carrying out the scheduled
maintenance activities like cleaning of Filters, replacement of desiccant, calibration of
instruments, servicing of ON-OFF valves may be carried out as per QP maintenance
schedule.
The following steps are to be followed for shutdown of the Instrument Air Dryer
Package (Train A) and release for maintenance:
11.1 GENERAL
The ESD System is designed to achieve the following objectives listed in order of
priority:
In case of activation of any one unit ESD, the activated ESD performs the other unit
shutdown, according to the sequence given in Cause & Effect Matrix & P&ID.
ESD level-0 shutdown is a total plant shutdown which includes a number of related
level 3 unit/sub unit/zones which can also be shutdown on an individual basis with
depressurization.
This is the lowest level of shutdown, without depressurization and involves shutdown
of an individual piece of equipment or a zone, which is immediately affected by an
upset condition, but not affecting other equipment or zones.
ESD Zones
Process:
11.2 PROCESS
Acid gas from Regenerator Reflux Drum ON/OFF valve 91-XV-1516 to SRU closes
Regenerator Reboiler steam valve 91-XV-1505 closes
Tail Gas Rich Amine Pumps 9102-P-16A/B trips
Lean amine to Tail Gas Amine Absorber valve 91-XV-1310 closes
Tail gas rich amine valve from Tail Gas Rich Amine Pump discharge 91-XV-1309
closes
Lean Amine Pumps 9103-P-13A/B trips
Amine sump pump 9103-P-15 trips
Acid gas drain outlet valve 91-XV-1109 from pipe separator closes.
Flammable gas detection alarm (68-XS-03-1802) from utility boiler area (LER-6)
Flammable gas detection alarm (66-XS-03-1802) from LER-6
Acid gas drain outlet valve 91-XV-1109 from pipe separator closes.
Regenerator condenser cooler fans trip
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Instrument air pressure low low (2oo3) alarm 68-PALL-1312 (SRU Upgrade)
Steam Generator Package shutdown signal 68-XS-1580/68-XS-1680/68-XS-1780
Existing SRU shutdown signal 65-XA-1001 from ESD system at LER-4
Low low flow alarm (91-FALL-1515) from Lean Amine Pumps (9103-P-13A/B)
discharge
Following are the effects of ESD Level 2 Shutdowns in AGEU:
Operator Permissive is available for operating Acid gas ON/OFF valve 91-XV-1502
to flare
Acid gas ON/OFF valve 91-XV-1501 to 9103-E-101 closes
Acid Gas KO Drum Return Pumps 9103-P-14A/B trips
Liquid from Acid Gas KO Drum Return Pump ON/OFF valve 91-XV-1503 closes
Acid Gas Rich Amine Pump 9103-P-12A/B trips
Lean amine valve 91-XV-1504 to acid gas amine absorber closes
Hot Lean Amine Pumps 9103-P-17A/B trips
Hot lean amine valve 91-XV-1507 to Lean/Rich Exchanger closes
Regenerator Reflux Drum Pumps 9103-P-11A/B trips
DM water valve 91-XV-1517 to Regenerator Reflux Drum closes
Acid gas from Regenerator Reflux Drum ON/OFF valve 91-XV-1516 to SRU closes
Following are the effects of ESD Level 3 Shutdown in AGEU & Amine section:
Acid gas drain outlet valve 91-XV-1109 from Pipe Separator closes.
Following are the ESD Level 4 Shutdowns (equipment wise) in AGEU & Amine section:
High high level alarm 91-LAHH-1502 in Lean Acid Gas KO Drum (9103-V-14) closes
the acid gas block valve 91-XV-1501 to Acid Gas Coolers
Low low level alarm 91-LALL-1503 in lean acid gas KO drum (9103-V-14) closes the
liquid block valve 91-XV-1503 from lean acid KO drum
Acid Gas Amine Absorber (9103-C-11)
Low low level alarm 91-LALL-1516 in Acid Gas Amine Absorber bottom trips the
Acid Gas Rich Amine Pumps 9103-P-12A/B
Low low rich amine flow alarm 91-FALL-1510 in Acid Gas Amine Absorber trips the
Acid Gas Rich Amine Pumps 9103-P-12A/B
Amine Regenerator
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 valve 91-XV-1507 to
Lean Rich Exchanger
Low low hot lean amine flow alarm 91-FALL-1509 trips the Hot Lean Amine Pumps
9103-P-17A/B and closes the hot lean amine valve 91-XV-1507 to Lean Rich
Exchanger
Regenerator Reflux Drum
Low low level alarm 91-LALL-1518 in Regenerator Reflux Drum trips the
regenerator reflux drum pumps 9103-P-11A/B
High high level alarm (91-LAHH-1507) in Regenerator Reflux Drum closes the DM
water block valve 91-XV-1517
Low low flow alarm (91-FALL-1506) trips the Regenerator Reflux Pumps 9103-P-
11A/B
Tail Gas Absorber
High high level alarm (91-LAHH-1310) in Tail Gas 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 Absorber bottom trips the Tail Gas
Absorber Bottom Pumps (9102-P-16A/B) and closes the Tail Gas Rich Amine
On/OFF valve 91-XV-1309
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Low low flow alarm (91-FALL-1305) in Tail Gas Rich Amine Pump discharge trips
the Tail Gas Absorber Bottom Pumps (9102-P-16A/B) and closes the tail gas rich
amine On/OFF valve 91-XV-1309
Amine Surge Tank
Low low level alarm (91-LALL-1511) in Amine Surge Tank trips the lean amine
pump (9103-P-13A/B)
Low low level alarm (91-LALL-1513) in Amine Sump trips the amine sump pump
(9103-P-15)
Pipe Separator
Low low level alarm (91-LALL-1054) closes the acid gas outlet valve 91-XV-1109 in the
Pipe Separator
Lean amine coolers 9103-E-14AA to 9103-E-14JC trips due to high high vibration alarms
sensed by their respective cooler fan vibration probes.
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High high temperature alarm (91-TAHH-1589) in Acid Gas Rich Amine Pump motor
drive NDE bearing, trips the acid gas rich amine pump 9103-P-12A.
High high temperature alarm (91-TAHH-1593) in Acid Gas Rich Amine Pump motor
drive NDE bearing, trips the acid gas rich amine pump 9103-P-12B.
High high temperature alarm (91-TAHH-1597) in Hot Lean Amine Pump motor drive
NDE bearing, trips the acid gas rich amine pump 9103-P-17A.
High high temperature alarm (91-TAHH-1601) in Hot Lean Amine Pump motor drive
NDE bearing, trips the acid gas rich amine pump 9103-P-17B.
11.2.2 Sulphur Recovery Unit
Following are the causes which initiates ESD level-1 shutdown in existing SRU:
Above mentioned ESD level-1 shutdown causes opens the following valves in existing
SRU:
Fuel gas to atmosphere from 1st Stage Auxiliary Burner valve 91-XV-1132
Fuel gas to atmosphere from 2nd Stage Auxiliary Burner valve 91-XV-1134
Fuel gas to atmosphere from Reaction Furnace valve 91-XV-1100
Note:
1. Steam supply valve 91-XV-1045 to Ejector 9101-X-02 and Steam supply valve 91-XV-
1092 to Ejector 9101-X-03 is closed only on the following ESD level-1 causes:
Following is the only cause which initiates ESD level-2 shutdowns in existing SRU:
Above mentioned ESD level-2 shutdown cause closes the following valves in existing
SRU:
Above mentioned ESD level -2 shutdown cause opens the following valves in existing
SRU:
Fuel gas to atmosphere from 1st Stage Auxiliary Burner valve 91-XV-1132
Fuel gas to atmosphere from 2nd Stage Auxiliary Burner valve 91-XV-1134
Fuel gas to atmosphere from reaction furnace valve 91-XV-1100 Nitrogen valve
91-XV-1127 to Reaction Furnace instruments
LP steam in air valve 91-XV-1076 to acid gas burner
LP steam ON/OFF valve 91-XV-1079 to acid gas gun
Tail gas valve 91-XV-1097 to Incinerator
Above mentioned ESD level -2 shutdown causes trips the following in existing SRU:
Following are the causes which initiates ESD level-3 shutdowns in existing SRU:
Air for acid gas burner pressure high high alarm 91-PAHH-1054A/B/C
Acid gas to reaction furnace flow low low alarm 91-FALL-1140
Combustion air to acid gas burner flow low low alarm 91-FALL-1129
Fuel gas to reaction furnace flow low low alarm 91-FALL-1130
Above mentioned ESD level-3 shutdown causes opens the following valves in existing
SRU:
Fuel gas to atmosphere from 1st Stage Auxiliary Burner valve 91-XV-1132
Fuel gas to atmosphere from 2nd Stage Auxiliary Burner valve 91-XV-1134
Fuel gas to atmosphere from Reaction Furnace valve 91-XV-1100
Following are the causes in SRU 1st Stage Auxiliary Burner which initiates ESD Level 4
Shutdown:
Activation of 1st Stage Auxiliary Burner stop pushbutton 91-HS-1227 from LCP
Combustion air flow to 1st Stage Auxiliary Burner low low alarm 91-FALL-1133
Acid gas flow to 1st Stage Auxiliary Burner low low alarm 91-FALL-1134
Fuel gas flow to 1st Stage Auxiliary Burner low low alarm 91-FALL-1135
Flame failure alarm 91-BALL-1003A/B in 1st Stage Auxiliary Burner
Effects of ESD Level 4 Shutdown in SRU-1st stage auxiliary burner:
1st Stage Auxiliary Burner fuel gas to atmosphere valve 91-XV-1132 opens
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Following are the causes in SRU 2nd Stage Auxiliary Burner which initiates ESD Level 4
Shutdown:
Activation of 2nd Stage Auxiliary Burner stop pushbutton 91-HS-1196 from LCP
Combustion air flow to 2nd Stage Auxiliary Burner low low alarm 91-FALL-1136
Acid gas flow to 2nd Stage Auxiliary Burner low low alarm 91-FALL-1137
Fuel gas flow to 2nd Stage Auxiliary Burner low low alarm 91-FALL-1138
Flame failure alarm 91-BALL-1004A/B in 2nd Stage Auxiliary Burner
Effects of ESD Level 4 Shutdown in SRU 2nd stage auxiliary burner:
Following are the causes in SRU which initiates ESD Level 4 Shutdown in Sulphur pit
9101-T-01:
Following are the causes in SRU which initiates ESD Level 4 Shutdown in New Sulphur
Pit 9101-T-01B:
Effects of ESD Level 4 Shutdown in SRU New Sulphur Pit 9101-T-01B area:
High high level alarm 91-LAHH-1003 alarm in Acid Gas KO Drum 9101-V-04 closes the
following valves:
Fuel gas to atmosphere from 1st Stage Auxiliary Burner valve 91-XV-1132
Fuel gas to atmosphere from 2nd Stage Auxiliary Burner valve 91-XV-1134
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Low low level alarm 91-LALL-1015 alarm in Sulphur Degassing Unit 9101-T-01 trips
the following:
Sulphur Degassing Pumps 9101-P-03A/B
Sulphur Product Pumps 9101-P-04A/B
Low low level alarm 91-LALL-1017 alarm in Sulphur Storage Tank 9101-T-02 trips
the Sulphur Tank Pumps 9101-P-15A/B.
Low low level alarm 91-LALL-1052 alarm in Sulphur Degassing Unit 9101-T-01B
trips the following:
Sulphur Degassing Pumps 9101-P-09A/B
High high pressure alarm 91-PAHH-1055 in Final Separator 9101-V-05 opens the tail
gas valve 91-XV-1097 to Incinerator and closes the tail gas valve 91-XV-1098 to
RGG.
Gas detected alarm 91-XS-1902(91-GF-1001 to 91-GF-1003) in air intake of 9101-K-
01A trips the Combustion Blower 9101-K-01A.
Gas detected alarm 91-XS-1903 (91-GF-1004 to 91-GF-1006) in air intake of
9101-K-01B trips the Combustion Blower 9101-K-01B.
Inter trips
RGG shutdown signals 91-XS-1350 to existing SRU unit opens the tail gas valve 91-XV-
1097 to Incinerator and closes the tail gas valve 91-XV-1098 to RGG
Acid gas inlet valve 91-XV-1001 to Acid Gas KO Drum 9101-V-04 close
Combustion air discharge valve 91-XV-1046 to Pre-Heater 9101-E-05 close
Fuel gas to 1st Stage Auxiliary Burner valve 91-XV-1028 close
Fuel gas to 1st Stage Auxiliary Burner valve 91-XV-1131 close
Fuel gas to atmosphere from 1st Stage Auxiliary Burner valve 91-XV-1132 open
Fuel gas to atmosphere from 2nd Stage Auxiliary Burner valve 91-XV-1134 open
RGG (9102-F-11)
Hydrogenation Reactor (9102-V-11)
Reactor Effluent Cooler (9102-E-11)
High high level alarm (91-LAHH-1504) in Acid Gas Amine Absorber bottom
(9103-C-11)
High high level alarm (91-LAHH-1509) in Amine Regenerator bottom (9103-C-12)
Contact Condenser:
11.2.4 Incinerator
UCP checks all trip and alarm condition for healthy status before start-up and during
operation. Alarm conditions are flagged on display of UCP but the Incinerator remains
running. Trip conditions initiate a shutdown and a reset is required before the unit is
available.
Following are the causes that initiates the Incinerator trip action in UCP:
Local ESD pushbutton (91-HS-1167) and remote ESD signal (91-XS-1185) shutdown the
blowers directly.
Also above mentioned causes in UCP initiates ESD Level-2 trip signal to 91-XS-1186 to
plant ESD system.
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11.3 UTILITIES
Flammable gas detection alarm (68-XS-03-1802) from Utility boiler area (LER-6)
Flammable gas detection alarm (66-XS-03-1802) from LER-6
Flammable gas detection alarm (66-XS-01-1802) from New Substation area
All the above mentioned ESD Level-1 causes directly trips all the running Steam
Generation Packages (6848-A02A/B/C) through UCP.
All the above mentioned ESD Level-2 causes directly trips all the running Steam
Generation Packages (6848-A02A/B/C) through UCP.
Activation of Manual Shutdown pushbutton 68-HS-1580 from CCR console trips the
Steam Generation Package6848-A02A.
Activation of Manual Shutdown pushbutton 68-HS-1680 from CCR console trips the
Steam Generation Package6848-A02B.
Activation of Manual Shutdown pushbutton 68-HS-1780 from CCR console trips the
Steam Generation Package6848-A02B.
Main LP steam header pressure low low alarm 68-PALL-1303A/B/C and De-aerator
level low low alarm 68-LALL-1310 trips all the running Steam Generation Packages
(6848-A02A/B/C) through UCP.
11.3.1.5 Steam Generator Package Trip through UCP Causes
Close main burner shut-off valve 68-XV-1528 & open vent valve 68 XV-1530
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1. Main LP steam header pressure low low alarm 68-PALL-1303A/B/C and de-aerator
level low low alarm 68-LALL-1310 causes the following effects in heating system:
Boiler 6848-A-02A fuel gas ON/OFF valve 68-XV-1302 close
Boiler 6848-A-02A fuel gas ON/OFF valve 68-XV-1303 close
Boiler 6848-A-02A fuel gas ON/OFF valve 68-XV-1304 close
De aerator feed pumps (68-P-20A/B) trip
Low low level alarm 68-LALL-006 in existing Drinking Water Storage Tank 6834-T-
01A trips the Drinking Water Pumps 6834-P-23A/B.
Low low level alarm 68-LALL-007 in existing Drinking Water Storage Tank 6834-T-
01B trips the Drinking Water Pumps 6834-P-23A/B.
Low low level alarm 68-LALL-1307 in DMW storage tank 6834-T-08 trips the DMW
Water Feed Pumps 6834-P-24A/B.
High high level alarm 68-LAHH-1306 in DMW storage tank 6834-T-08 trips the DMW
package.
Steam Condensate Flash Drum
Low low level alarm 68-LALL-1309 in Steam Condensate Flash Drum 6834-V-05 trips
the De-aerator Water Feed Pumps 6834-P-20A/B.
High high level alarm 68-LAHH-1308 in Steam Condensate Flash Drum 6834-V-05
trips the DMW Water Feed Pumps 6834-P-24A/B.
BFW De-aerator Package
High high level alarm 68-LAHH-1312 in BFW De-aerator Package 6834-A-08 closes the
De-aerator inlet ESD valve 68-XV-1301.
Low low Level alarm 68-LALL-1825 in Acid Storage Tank 6834-T-16 trips the Acid
Dosing Pump 6834-P-35A/B/C in DM water package
Low low Level alarm 68-LALL-1827 in Caustic Storage Tank 6834-T-15 trips the
Caustic Dosing Pump 6834-P-34A/B/C in DM water package
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Low low Level alarm 68-LALL-1830 in Neutralisation Pit 6834-A-01 trips the
Neutralisation Pump 6834-P-38A/B in DM water package
Low low Level 68-LALL-1307 in De-mineralized Water Storage Tank 6834 T-08 trips
the following in DM water package:
Regeneration Pumps 6834-P-36A/B
DM Package flow low low alarm 68-FALL-1830 trips recycling Pump 6834-P-37A/B.
Following are the effects of ESD Level 0 Shutdowns in chemical injection system:
Complex Product
Low low level alarm (68-LALL-1316) in Complex Product Tank trips the Complex Product
Injection Pumps (6834-P-41A/B) and Complex Product Tank Agitator (6834-M-04)
Oxygen Scavenger
Low low level alarm (68-LALL-1315) in Oxygen Scavenger Tank 6834-T17 trips the
Oxygen Scavenger Injection Pumps (6834-P-39A/B) and Oxygen Scavenger Product Tank
Agitator (6834-M-03)
Corrosion Inhibitor
Low low level alarm (91-LALL-1522) in Corrosion Inhibitor Tank 9103-T-13 trips the
Corrosion Inhibitor Pumps (9103-P-101A/B) and Corrosion Inhibitor Tank Agitator
(9103-M-13)
Caustic Injection
Low low level alarm (91-LALL-1524) in Caustic Injection Tank 9103-T-14 trips the Caustic
Injection Pumps (9103-P-103A/B) and Caustic Injection Tank Agitator (9103-M-14)
Antifoam Injection
Low low level alarm (91-LALL-1520) in Antifoam Injection Tank 9103-T-12 trips the
Antifoam Injection Pumps (9103-P-16A/B) and Antifoam Injection Tank Agitator
(9103-M-12)
Catalyst Injection
Low low level alarm (91-LALL-1128) in Catalyst Injection Tank 9101-T-901 trips the
Antifoam Injection Pumps (9103-P-16A/B)
Following are the ESD-4 shutdowns (equipment wise) in Chemical Injection Package:
Complex Product
Low low level alarm (68-LALL-1316) in complex product tank trips the Complex
Product Pumps (6834-P-41A/B)
Low low level alarm (68-LALL-1315) in Oxygen Scavenger Tank 6834-T17 trips the
Oxygen Scavenger Injection Pumps (6834-P-39A/B)
High high diaphragm pressure alarm (68-PAHH-1324) in Oxygen Scavenger Injection
Pump 6834-P-39A trips the pump
Low low level alarm (91-LALL-1522) in Corrosion Inhibitor Tank 9103-T-13 trips the
corrosion inhibitor pumps (9103-P-101A/B)
Low low level alarm (91-LALL-1524) in Caustic Injection Tank 9103-T-14 trips the
caustic injection pumps (9103-P-103A/B)
High high diaphragm pressure alarm (91-PAHH-1567) in Caustic Injection Pump
9103-P-103A trips the pump
High high diaphragm pressure alarm (91-PAHH-1568) in Caustic Injection Pump
9103-P-103B trips the pump
Antifoam Injection
Low low level alarm (91-LALL-1520) in Antifoam Injection Tank 9103-T-12 trips the
Antifoam Injection Pumps (9103-P-16A/B)
High high diaphragm pressure alarm (91-PAHH-1565) in Antifoam Injection Pump
(9103-P-16A trips the pump
High high diaphragm pressure alarm (91-PAHH-1566) in Antifoam Injection Pump
9103-P-16B trips the pump
Catalyst Injection
Low low level alarm (91-LALL-1128) in Catalyst Injection Tank 9101-T-901 trips the
Antifoam Injection Pumps (9103-P-16A/B)
Following are the ESD-4 shutdowns (equipment wise) in Sea Cooling Water System:
High high vibration alarm (69-VSHH-1301) in Sea Cooling water Pump 6932-P-
04A trips the sea cooling water pump 6932-P-04A
High high vibration alarm (69-VSHH-1302) in Sea Cooling Water Pump 6932-P-
04B trips the sea cooling water pump 6932-P-04B
Sea Cooling Water Pumps 6932-P-04A/B trip signals (69-XZA-1311/69-XZA-1322) trips
the following packages:
Following are the effects of ESD Level 0 Shutdowns in Fuel Gas System:
Fuel gas from 1st Stage Booster Compressor ON/OFF valve 62-XV-1301 close
Fuel gas from 6103-K-01A/B ON/OFF valve 62-XV-1302 close
Fuel gas from 30 existing main line inlet ON/OFF valve 62-XV-1303 close
11.3.7.2 ESD Level 1 Shutdown in Fuel Gas System
Fuel gas from 1st Stage Booster Compressor ON/OFF valve 62-XV-1301 close
ESD level2 is activated by high high fuel gas header pressure alarm 62-PAHH-1304 and
following are the effects of level-2 shutdown:
Fuel gas from 1st Stage Booster Compressor ON/OFF valve 62-XV-1301 close
Fuel gas from 6103-K-01A/B ON/OFF valve 62-XV-1302 close
Fuel gas from 30 existing main line inlet ON/OFF valve 62-XV-1303 close
11.3.8 Effluent Waste Water System
Following are the effects of ESD Level 0 Shutdown in Effluent Waste Water System:
High high level alarm 91-LAHH-1504 in Acid Gas Amine Absorber bottom
9103-C-11
High high level alarm 91-LAHH-1509 in Amine Regenerator bottom 9103-C-12
Following are the ESD-4 shutdowns (equipment wise) in effluent waste water system:
Low low level alarm 69-LALL-1311 in Waste Water Degasser 6922-V-07 trips the
Waste Water Degasser Pumps (6922-P-08A/B)
High high level alarm 69-LAHH-1311 in Waste Water Degasser 6922-V-07 closes the
waste water degasser inlet valve 69-XV-1312, LP fuel gas supply valve 69-XV-1315
and sour water to Waste Water Degasser valve 91-XV-1575.
High high pressure alarm 69-PAHH-1311 in Waste Water Degasser 6922-V-07
Sour Water Stripper
Low low level alarm 69-LALL-1315 in Sour Water Stripper 6922-C-01 trips the
Stripper overhead Circulation Pumps 6922-P-11A/B
Low low level alarm 69-LALL-1316 in Sour Water Stripper 6922-C-01 bottom
section trips the Stripper Water Pumps (6922-P-10A/B) and closes the Sour Water
Stripper outlet ON/OFF valve 69-XV-1339
High high level alarm 69-LAHH-1316 in Sour Water Stripper 6922-C-01 bottom
section trips Waste Water Degasser Pumps 6922-P-08A/B and closes the 6922-V-07
outlet ON/OFF valve 69-XV-1316
Stripper Overheads Cooler
UCP checks all trip and alarm condition for healthy status before start-up and during
operation. Alarm conditions are flagged on display of UCP but the compressor remains
running. Trip conditions initiate a compressor shutdown and a reset is required before
the unit is available.
While every emergency situation must be handled individually, depending upon the
existing conditions when the emergency originates. The following recommended
procedures provide sequences of major steps which must be taken for the most likely
emergency situations.
The extent to which the plant has to be shut down depends on the specific emergency.
In any emergency, determine the extent of the emergency condition, and decide how
to cope with it. Then proceed with one of the following actions as warranted by the
emergency:
Handle the emergency as a localized condition without shutting down the rest of
the plant. For example, in case of a faulty control valve. Block in and bypass the
malfunctioning item until repairs can be made.
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Shut down the unit using the normal shutdown procedure described in Section
10.2.
Shut down the unit using the emergency procedures given below for a specific
emergency.
11.4.1 LP Steam Failure
Consequence
Generally, steam failure is for long duration. Due to loss of LP steam, the stripping of
the amine solution in Amine Regenerator, Reducing Gas Generator, BFW Preheater
9101-E-08, Sulphur Degassing Pit 9101-T-01B, Sour Water Stripper Reboiler and Steam
tracing of fuel gas lines are affected. The lack of steam to AGEU Regenerator Reboiler
produce off spec gas to Sulphur Recovery Unit, it affects the sulphur quality which is
produced by Sulphur Recovery Unit. So, the off spec gas is lined up to acid gas flare.
When the temperature reaches below Sulphur melting temperature, solid formation
occurs inside Sulphur transfer lines. Hence, the SRU unit shutdown is necessary until
steam flow reaches normal flow of plant running.
Action
Shutdown AGEU, SRU and TGTU unit due as the LP steam is not available for
Reboilers, Preheating and heat tracing.
Isolate sulphur transfer lines and drain all the sulphur to collection area.
11.4.2 Sea Cooling Water Failure
Consequence
In the event of Sea Cooling Water failure, there is no cooling water supply to
coolers and condensers.
Consequence
In case, the instrument air supply to SRU upgrade is stopped, all the control valves
position is kept on fail safe position as per the position indicated in P&ID. If the
instrument air is not immediately restored, the SRU Upgrade units must be shut down.
Action
Shut down the AGEU, SRU, TGTU and Incinerator units as instrument air supply to SRU
is not available for operating control valves and ESD valves.
In case of power failure, all pumps and compressors are stopped due to loss of power.
Only UPS power is available for DCS, F&G panel and emergency light. Generally, the
power failure affects all the units.
Consequence
The plant has to be shut down as:
Power failure trips all the pumps, blowers, compressors and air cooler fans.
Action
Shut down all the units of SRU Upgrade facilities due to unavailability of feed for
running the plant.
In the general boiler feed water failure, all the Steam Generators, SRU Reaction
Furnace Boiler, Reaction Furnace Condensers, 1st Stage Condenser and Reaction
Effluent Cooler in TGTU initiates shutdown to respective unit, due to loss of boiler
feed water.
Consequence
The plant has to be shut down as:
SRU Upgrade Reaction Furnace Boiler & Last condenser and TGTU unit Reactor Effluent
Cooler tubes will be damaged due to loss of boiler feed water.
Action
Shutdown the AGEU, SRU and TGTU units as the boiler feed water is not available for
recovering heat from the above equipment.
Consequence
Steam Generation from the Boilers is affected
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Complete burning of Sulphur and hydrocarbon compound are not possible when
Incinerator temperature is less than normal operating temperature.
Hydrogenation reaction rate is reduced due to low temperature in RGG.
Action
Shutdown AGEU, SRU, TGTU and Incinerator units of SRU units as fuel gas is not
available.
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12.1 GENERAL
Maintenance is an activity which helps to keep the plant and equipments in running
condition for a longer period of time. It is the work performed on an equipment,
vessel, column or piping to preserve it in as near to its original condition as is practical
and to realize its normal life expectancy.
Types of Maintenance
b. Shutdown Maintenance
Shutdown maintenance consists of those activities that can be carried out only during
the shutdown of the plant/equipments. In order to ensure that a process plant
continues to run at peak efficiency, it is prudent to do shutdown maintenance for huge
sections of the plant at specific intervals. During this shutdown period, the plant is
stopped, cleaning and repairing of equipments is carried out and then the plant is
started back. The plant has to be carefully and safely shutdown for this activity. For
handing over to maintenance the plant has to be depressurised, drained of liquids,
purged with nitrogen, steaming out is carried out if necessary, chemicals disposed of
safely. Refer sectionX for safe shutdown and handing over of the plant for
maintenance.
12.2.1 Process
Regular inspection and maintenance of the rotary equipment pays rich dividends.
Potentially hazardous situations can be avoided and costly delays in production can be
minimized. QP standard maintenance schedules and procedures shall be followed for
the regular maintenance of the mechanical equipment (blowers, pumps, etc.)
electrical equipment and instruments. Refer to the vendor O & M manuals for detailed
maintenance procedures of package equipment (Instrument Air Compressors, Electrical
Equipment, etc.).
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a. Centrifugal Pumps
Equipment Description Acid Gas KO Drum Return Pump 9103-P-14A/B,
Acid Gas Rich Amine Pumps 9103-P-12A/B,
Hot Lean Amine Pumps 9103-P-17A/B,
Regenerator Reflux Drum Pumps 9103-P-11A/B,
Lean Amine Pumps 9103-P-13A/B,
Amine Sump Pump 9103-P-15
b. Vessels
Equipment Description Lean Acid Gas KO Drum 9103-V-14
Regenerator Reflux Drum 9103-V-12
Regenerator Reboiler Condensate Pot 9103-V-13
Amine Sump 9103-V-10
Amine Sump Filter 9103-S-14
c. Filter
d. Columns
Acid Gas Amine Absorber 9103-C-11
Equipment Description
Amine Regenerator 9103-C-12
e. Heat Exchanger
Acid Gas Coolers 9103-E-101A/B
Regenerator Reboiler 9103-E-13
Equipment Description Lean/Rich Amine Exchangers 9103-E-11A/B
Regenerator Condenser Trim Cooler 9103-E-16
Lean Amine Trim Cooler 9103-E-15
f. Tank
Equipment Description Amine Surge Tank 9103-T-11
g. Air Coolers
Equipment Description Regenerator Condenser Cooler 9103-E-12
Lean Amine Cooler 9103-E-14
a. Blower
Equipment Description Process Air Blowers 9101-K-01A/B
b. Vessels
Acid Gas KO Drum 9101-V-04
Equipment Description HP Condensate Drum 91014-V-06
Final Separator 9101-V-05
c. Pumps
Equipment Description Acid Water Pump 9101-P-01A/B,
Sulphur Product Pumps 9101-P-10A/B
Sulphur Degassing Pumps 9101-P-09A/B
Sulphur Tank Pumps 9101-P-15A/B
Catalyst Metering Pumps 9101-P-11A/B
Sulphur Product Pumps 9101-P-10A/B
Sulphur Degassing Pumps 9101-P-09A/B
d. Boiler
Equipment Description Reaction Furnace Boiler 9101-E-07
e. Heat Exchanger
Process Air Preheater 9101-E-05
Acid Gas Preheater 9101-E-06
Reaction Furnace Condenser 9101-E-01
Equipment Description
1st Stage Condenser 9101-E-02
Last Condenser 9101-E-04
BFW Preheater 9101-E-08
f. Combustion Chamber
Reaction Furnace 9101-F-01
Equipment Description 1st Stage Auxiliary Burner 9101-F-02
2nd Stage Auxiliary Burner 9101-F-03
g. Reactor
1st Stage Converter 9101-V-01
Equipment Description
2nd Stage Converter 9101-V-02
h. Tank
Equipment Description Catalyst Tank 9101-T-03/09
Sulphur Degassing Pit 9101-T-01/01B
a. Blowers
Equipment Description Combustion Air Blowers 9102-K-11A/B
b. Combustion Chamber
Equipment Description Reducing Gas Generator 9102-F-11
c. Reactor
d. Boiler
Equipment Description Reactor Effluent Cooler 9102-E-11
e. Heat Exchanger
Equipment Description Contact Condenser Trim Cooler 9102-E-13A/B
f. Pumps
Equipment Description Cooling Water Circulation Pump 9102-P-12A/B
Desuperheater Circulation Pumps 9102-P-11A/B
Tail Gas Rich Amine Pumps 9102-P-16A/B
g. Air Coolers
Equipment Description Contact Condenser Cooler 9102-E-12
h. Columns
Desuperheater/Contact Condenser 9102-C-11
Equipment Description
Tail Gas Amine Absorber 9102-C-12
i. Filter
Equipment Description Wash Water Filter 9102-S-15
a. Combustion Chamber
Equipment Description Incinerator 9101-F-14
Activity Area Activity Description Frequency
Check all joints/flanges/gaskets for
Joints/ Operator
Leakage any leakage. Report to maintenance
Flanges Rounds
for any leakage.
Check entire skid for loose nuts &
Loose All bolts, cable trays & earthing wire. Operator
Component Components Report to maintenance any Rounds
abnormality.
Carry out logging of key parameters As per QP
Logging Incinerator
required schedule
b. Blowers
Equipment Description Incinerator Air Blowers 9101-K-12A/B
12.2.2 UTILITIES
Maintenance Frequency
Description Comments
Daily Weekly Monthly Annually
Complete overall visual
Overall inspection to be sure all
Visual equipment is operating & X
Inspection safety systems are in
place.
Leakage Look for and report any
X
Assessment system leakage
Monitor operation for run
Compressor time and temperature
X
Operation variance from trended
norms
Dryers should be observed
Dryers X
for proper function
Make sure proper
Compressor
ventilation is available for X
Ventilation
compressor inlet
Condensate Drain condensate from
X
Drains tanks, legs, and/or traps
Verify operating
Operating
temperature is per X
Temperature
manufacturer specification
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Maintenance Frequency
Description Comments
Daily Weekly Monthly Annually
Verify all pressure relief
Pressure
valves are functioning X
Relief Valves
properly
Air
All air consumer devices
Consuming
need to be inspected on a X
Device
regular basis for leakage
Check
Clean out debris and check
Drain Traps X
operation
The following maintenance procedures are applicable to the all the chemical injection
systems listed below.
a. Vessels
Waste Water Degasser 6922-V-07
Equipment Description Sour Water Stripper Reboiler 6922-E-04
Reboiler Condensate Drum 6922-V-09
b. Columns
Equipment Description Sour Water Stripper 6922-C-01
c. Heat Exchanger
d. Filter
e. Pumps
f. Air Coolers
a. Filters
b. Electrolyser
Electrolyser 6932-G-01A/B
Equipment Description Degassing Tank 6932-T-02
Acid Wash Tank 6932-T-03
c. Tanks
d. Blowers
e. Pumps
a. Pumps
Regeneration Pumps 6834-P-36A/B
Recycling Pumps 6834-P-37A/B
Neutralisation Pit Pumps 6834-P-38A/B
Equipment Description
HCl Injection Pumps 6834-P-35A/B/C
NaOH Injection Pumps 6834-P-34A/B/C
Demineralized Water Feed Pumps 6834-P-24A/B
b. Tanks
Equipment Description Demineralised Water Storage Tank 6834-T-08
HCl Storage Tank 6834-T-16
NaOH Storage Tank 6834-T-15
Neutralisation Pit 6834-A-01
c. Vessels
Cation Exchangers 6834-S-21A/B
Equipment Description
Anion Exchangers 6834-S-22A/B
a. Pumps
b. Vessels
Steam Condensate Flash Drum 6834-V-05
Equipment Description
BFW Deaerator Package 6834-A-08
c. Air Coolers
a. Fans
FD Fan 6848-K-02A
Equipment Description
Flue Gas Recirculation Fan 6848-K-03A
b. Drums
Equipment Description Steam Drum 6848-V-02A
c. Combustion Chamber
Equipment Description Steam Generation System
2. Hydrogenation Reactor
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a. Catalyst loading
This operation is carried out taking precautions highlighted hereafter:
Note: The catalyst is a sophisticated product and should be handled carefully,
avoiding any hazardous loss.
Before loading, it is recommended to check that all reactors are dry, clean and
that all internals are in the proper place and installed as recommended in the
various drawings and process data sheets
Covers must be installed at the top of each reactor on temporary structures to
protect against rain
Loading of catalyst shall not be done during a period of rain or of great level of
humidity
b. Preliminary operations
When the reaction section drying out is complete and nitrogen has been replaced
by air, the reactors can be opened for inspection of the internals. All damaged
internal parts must be replaced or repaired
If needed, the reactors will be brushed and vacuum cleaned before catalyst
loading starts
Catalyst loading will be interrupted in case of rain or snow, or efficient protection
must be set in place
c. Equipment and personnel
The list below is based on the following assumption: catalyst loading will be carried
out with one crane.
One telescopic crane capable of lifting about 3 tons, 5 meters above the reactor
upper manhole (see Fig. 33)
One forklift to handle the catalyst drum pallets
Stationary hopper equipped with 8 to 10" nozzles to be installed on the reactor
upper manhole (see Fig. 38)
Two mobile hoppers, each having a capacity of about 5 to 6 catalyst drums (see
Fig. 37)
One structure (scaffolding and timbers) to unload the drums into the mobile
hoppers (see Fig. 35)
One safety harness, rope ladders, portable oxygen analyzer, low voltage lighting,
dust masks, air masks, goggles, plastic sheets to protect drums and reactor in case
of rain
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One team of 4 riggers at ground level for catalyst handling and loading into
the mobile hoppers
One team of 6 fitters for vessels opening closing and for catalyst loading,
One sock loading operator inside the reactor.
Note: These personnel shall be permanently present during the loading operation. The
total number of personnel will be obtained by multiplying by the number of shifts, if
the loading takes place on 24 hours basis.
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Check that the quality of the catalyst and the amount available are as specified.
The following guideline for the reactor loading assumes a single catalyst bed. It
also assumes that the internals have been, first inspected in position and then
dismantled to speed up the loading process. When there is only one catalyst bed,
internals (except the bottom collector) would be installed and inspected after the
catalyst loading.
Refer to the loading drawing for the various heights of catalyst and alumina layers
etc., and to the detail drawings for the installation of the internals. Inside the
reactor measures will be taken from the welding line. Manufacturer's vessels
measurements are generally shown from tangent lines.
Make the necessary adjustment. Materialize the various levels with chalk marks on
the reactor wall.
Before loading catalyst ensure that operators have available wooden boards upon
which to stand when inside the reactor, to spread their weight and avoid crushing
of catalyst with the feet. Ensure also that the boards are counted into the reactor
and from time to time during loading and as they are taken out of the reactor.
Boards left in the reactor will interfere with pressure drop and flow distribution.
The reactor to be loaded should be placed under a reverse air flow to remove any
dust generated during the loading process, out of the reactor. Ideally, the dust
should be collected in bag filters installed at the outlet man-way.
Lift down the required volume of inert support balls, or active supports as
appropriate, and build up the bottom layer. Carefully level the surface, before
loading catalyst
Start loading the catalyst bed according to the loading diagram. The person
inside the reactor shall build a level of catalyst as uniformly as possible
During the catalyst loading a sample shall be taken in each drum/big bag in
order to prepare a composite sample of the reactor load.
when the upper level of the catalyst bed is reached stop loading the catalyst
and carefully level the surface
Add the layer of or hold down balls on top of the active catalyst if
required.
Note: Vendor does recommend loading inert ceramic balls to hold down the active
catalyst if no deflector is installed in the vessel, and/or if the active catalyst bed
height is lower than 90 cm.
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If deflector is installed and if the catalyst bed height is comprised in between 0.9 and
1 m, Vendor advises to load ceramic balls, when the height difference in between the
deflector and the top of the active catalyst is lower than 1 m.
According to what Vendor commonly sees, hold down ceramic balls can be avoided if a
deflector is installed and if the active catalyst bed height is larger than 1 m. Loading
hold down balls may also be avoided if a deflector is installed and if the active catalyst
bed height is comprised in between 0.9 and 1m, providing that the height difference in
between the deflector and the top of the active catalyst is larger than 1 m.
e. Leak test
After closure of the reactor and prior to catalyst activation, leak tests will be
conducted.
f. Catalyst Handling
The SRU first and second Claus converters are part filled with alumina and titanium
dioxide catalysts, the titanium dioxide catalyst being located in the bottom of the
converter with the alumina on top. The titanium dioxide catalyst is supported on the
ceramic balls support material.
The TGTU hydrogenation reactor contains a special CoMo catalyst which is supported
on ceramic balls support material. A layer of ceramic balls material is also located on
the top of the catalyst to protect the catalyst from refractory dust and debris that
may be carried forward from the upstream SRU.
All catalysts and ceramic ball support material will be delivered to site in either one
tonne big bags or 220 litre drums. Until the time of loading into a converter/reactor
all catalyst should be kept in a covered heated warehouse to ensure no contamination
from rain, sand, dust or low temperature damage can occur.
a. SRU Converters
Provided the acid feed gases being processed in the SRU compositions are near to
design then the converters catalysts can be expected to operate satisfactorily for a
minimum of three years before replacement is necessary.
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Catalyst life can be prolonged by maintaining a low hydrocarbon content in the acid
gas feed, by preventing carryover of amine solutions to the SRU, by ensuring that
ammonia salts are not being formed in the process, by avoiding emergency shutdown
conditions during which the catalyst beds may be exposed to high temperatures caused
by burning sulphur, and by operating care to avoid water condensation on the catalyst.
The first catalyst bed generally accounts for most of the conversion. Therefore, the
life expectancy of the second bed will almost always exceed that of the first. A shift
of the primary activity from the first to second bed is a reliable indication that the
first bed requires attention.
The best measure of a SRU converters catalyst activity is the percentage of H2S
conversion to sulphur obtained in normal operation. This activity will decrease over a
period of time, depending on the quality of acid gas feed used and the care with which
the SRU is operated. Normally a loss of activity will be seen in the first converter with
the point of reaction and temperature increase, moving down the catalyst bed. The
activity of the catalyst is observed by watching the temperature change across the
converter bed. Good activity is observed when a significant temperature increase is
seen in the top/upper portion of the catalyst bed. Record the bed temperature
differentials at the initial start-up, during, and at the end of a run as a reference for
operation of the unit. A permanent decrease in temperature differential usually
indicates catalyst deactivation. Normally, this is an accumulation of carbon, sulphates,
or other contaminants on the bed. An indication of sulphate formation in the catalyst
is by the increased concentrations of COS, CS2 and CO in the treated gas from the
upstream amine absorbers. Some catalyst activity may be restored by carrying out the
catalyst management procedures.
Since catalyst life expectancy cannot be predicted accurately in advance for any given
SRU, it is a good practice to maintain a full replacement supply of catalyst for the
converters of one SRU in the refinery warehouse, or be able to acquire the catalyst
quickly from the catalyst supplier should a replacement charge of catalyst be
required.
After sufficient data has been accumulated on the catalysts conversion performance,
it is generally advisable to replace all or part of the catalyst on a regular time
schedule.
Similarly to the SRU converters catalysts the TGTU Hydrogenation Reactor catalyst
activity is observed by watching the temperature change across the reactor bed. Good
activity is observed when a significant temperature change occurs in the top/upper
portion of the catalyst bed. Also records of the catalyst bed temperature differentials
should be taken at the initial start-up, during, and at the end of a run as a reference
for operation of the unit.
Although the Hydrogenation Reactor catalyst is not likely to be fouled and deactivated
by contaminants as the SRU converters catalysts may be it is advised to maintain a full
replacement supply of catalyst for one TGTU Hydrogenation Reactor in the refinery
warehouse or be able to acquire the catalyst quickly from the catalyst supplier should
a replacement charge of catalyst be required. Some catalyst activity may be restored
by carrying out the catalyst management procedures.
When preparing to inspect and/or replace a SRU or TGTU reactors catalyst the
SRU/TGTU must first follow the normal shutdown and sulphur stripping and
regeneration procedures.
Following the shutdown of the unit no vessel should be entered until it has been
cooled and all process gas utility streams to the SRU/TGTU have been isolated. Prior
to entry to a converter/reactor the vessel must be tested to determine if it is free of
noxious gases. Even when a satisfactory oxygen reading is recorded in the vessel it is
advised that persons entering the vessel should be supplied with an air mask and a
safety belt and that a safety attendant/standby person is continually stationed outside
the vessel to monitor the person(s) in the vessel.
a. Catalyst Sampling
When a SRU converter or the TGTU hydrogenation reactor is first opened it is advised
that samples of the catalysts are taken and sent to the catalyst supplier for analysis.
Samples should be taken from various levels in the beds.
b. Catalyst Inspection
The inspection of the catalyst will determine if part, or the complete, catalyst bed is
to be replaced because of catalyst contamination, fusion with other products, loss of
granular size or evidence of reduced activity.
c. Catalyst Replacement
Catalyst replacement alternatives are described in the following sub-sections:
If installed, carefully remove any top layer of ceramic balls followed by the catalyst
and catalyst support layer ceramic balls.
Replace the catalyst support ceramic balls in the bottom of the vessel.
Screen the catalyst that was removed, discard the fines and reserve the usable portion.
Add enough new catalyst to compensate for the amount discarded and spread this in
an even layer over the catalyst support ceramic balls.
Add the screened used catalyst to bring the bed to full depth.
Inspect the physical condition of the new catalyst to determine if screening is required
to remove fines. Do not screen unless necessary and avoid excessive handling.
If only the top section of catalyst in a converter has to be replaced then this layer is
normally removed by hand through the converters top manways; alternatively if care is
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taken, then the catalyst may be removed through the converters top manways by
means of the vacuum method.
If the catalyst is not to be reused then vacuum method is advised as this method
minimises the unloading time and does not require the opening of the converters side
manways.
h. Catalyst Disposal
Regenerated alumina catalyst may be disposed of to a land fill site. Titanium dioxide
and hydrogenation catalysts should be disposed of via a catalyst reclamation company.
At the end of the life of each catalyst it is advised that the supplier is consulted
regarding its disposal.
To improve converters catalyst activity a rejuvenation of the catalyst is carried out with
the SRU and TGTU in normal operation processing acid feed gas. If no improvement in
conversion is seen, a sulphur stripping procedure will then be necessary.
Prior to sulphur stripping, the catalyst beds and the SRU will contain potentially
hazardous and contaminating materials such as H2S, SO2, sulphur and other sulphurous
compounds. The object of the sulphur stripping exercise is to remove these
contaminants under controlled conditions.
At the conclusion of the sulphur stripping operations the catalyst should be clean and
the plant should be free of harmful gases and deposits.
A sulphur stripping operation will also be carried out before the plant is opened for
any maintenance work, where there is a possibility of air entering the system, which
could cause the ignition of any sulphurous compounds in the catalysts or process gas
stream side of the unit.
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Sulphur stripping is carried out with the SRU Reaction Furnace burner operating on
fuel gas only, initially at stoichiometric firing conditions.
Sulphur stripping should only be carried out for the requirements stated above, since
the operation can be potentially hazardous to both catalyst and equipment.
The activity of the catalyst is observed by watching the temperature change across the
reactor bed. Good activity is observed when a significant change occurs in the upper
portion of the bed. A decrease in activity will be seen by the point of start of
temperature increase moving down the catalyst bed. A permanent decrease in
temperature differential usually indicates catalyst deactivation. Normally, this is an
accumulation of carbon, sulphates or other contaminants on the catalyst bed.
Sulphation of the catalyst will be increased if concentrations of COS, CS2 and CO in
the acid feed gas increase.
Oxidation of the Hydrogenation Reactor catalyst will restore some activity. Oxidation
must be carried out prior to the TGTU being opened for maintenance and inspection.
Prior to unit restart the catalyst will require sulphiding.
A catalyst rejuvenation is carried out whilst the SRU and TGTU are in normal operation
processing acid gas.
To carry out this exercise the TGTU is first taken out of service and the SRU tail gas
routed directly to the Incinerator.
The procedure for sulphur stripping the SRU converters catalyst may be broken down
into three sub-procedures:
With process air and fuel gas controllers in manual operating mode, very slowly
increase process air flow to the Reaction Furnace burner by adjustments to
process air controller.
Maintain the auxiliary burners temperature outlet controllers in automatic
operating mode throughout the sulphur stripping operation set at their normal
operating temperatures of 230C and 210C.
Every few minutes increase process air flow in very small increments until there is
evidence of burning of sulphur compounds within the SRU. Note that the trim air
control valve may be used to allow a fine control of excess process air is achieved.
Observe all temperature points across the SRU.
The first sign of the burning of sulphur compounds in the SRU should be seen by a
temperature increase in the top layer of catalyst in the first converter. A
temperature increase may also be seen in the Reaction Furnace Condenser process
gas outlet or 1st Stage Condenser process gas outlet as sulphur compounds in these
sections commence burning.
Hold the process air flow at its present flow when a temperature front is seen in
the first converter.
Note the flows of fuel gas and process air.
Closely observe the converters catalyst bed temperatures, if temperatures
approach 400C, reduce the amount of process air to the Reaction Furnace
burner.
Note: Under no circumstances should converter catalyst temperatures exceed 425C
(or other temperature advised by the catalyst supplier).
flow to the reaction furnace burner to consume the excess oxygen in the process
gases and halt the temperature increase in the area of burning.
III. Cool Down
Cool down will commence immediately after sulphur stripping of the converters
catalyst is completed as follows:
Start increasing process air flow to the Reaction Furnace burner whilst holding fuel
gas flow constant. The Reaction Furnace temperature will slowly fall.
With process air at a fairly high flow, start lowering process temperatures by
reducing fuel gas flow to the Reaction Furnace burner.
If the SRU and TGTU are to be opened for inspection and maintenance at the same
time then the sulphur stripping of the SRU converters and the oxidation of the TGTU
Hydrogenation Reactor may be carried out in the same operation. In this case the
oxidation of the Hydrogenation Reactor catalyst would be carried out in series with
the sulphur stripping of the SRU converters catalyst as described in Section 12.4.7-I
If the TGTU is to be opened for inspection and maintenance independently of the SRU
then the TGTU Hydrogenation Reactor oxidation is carried out as a stand alone
procedure as described in Section 12.4.7-II
I. TGTU Hydrogenation Reactor Catalyst Oxidation (In series with the SRU
converters sulphur stripping operation):
Oxidation of the Hydrogenation Reactor in series with the sulphur stripping of the SRU
converters will proceed as follows:
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When the catalyst oxidation is complete as seen by the temperature front having
passed through the Hydrogenation Reactor catalyst bed the fuel gas flow to the
SRU Reaction Furnace burner is slowly decreased, leaving the process air flow
unchanged so allowing an excess of oxygen in the process gases passing through
the SRU converters and TGTU Hydrogenation Reactor.
Maintain close observation of all temperature points across the SRU converters and
the TGTU Hydrogenation Reactor for any secondary burning. If secondary burning
is seen then increase fuel gas flow to the SRU Reaction Furnace burner to consume
the excess oxygen in the process gases and halt the temperature increase in the
area of burning.
Following oxidation of the Hydrogenation Reactor catalyst, the TGTU
hydrogenation section is cooled down with the SRU.
Reduce RGG outlet temperatures at approx. 50C/hr to cool the Hydrogenation
Reactor catalyst. Note that the RGG process air to fuel gas ratio may now be
adjusted so that the RGG burner is operating in excess air conditions.
When ~100C is seen in the Hydrogenation Reactor catalyst, via the shutdown
switch, stop the RGG.
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Confirm that the action of the shutdown switch has closed or opened the following
RGG shutdown valves:
Nitrogen valve to the RGG combustion air line, open (valve will remain open
for ~15 minutes)
Nitrogen valve to the RGG instrument nozzles, open
Close manual valves in the RGG combustion air, instrument air, fuel gas and LP
steam lines to the RGG.
The TGTU Hydrogenation Reactor may now be opened for inspection and maintenance.
In the event that the TGTU is taken out of service independently of the SRU and has to
be opened for inspection and maintenance then all sulphur compounds in the
Hydrogenation Reactor catalyst must be first removed by regeneration of the catalyst.
This is achieved by recycling nitrogen gases around the RGG, Hydrogenation Reactor,
Reactor Effluent Cooler and the DCC tower by means of the start-up gas steam ejector
and by adjusting the amount of excess air to the RGG burner to burn off all sulphur
compounds on the Hydrogenation Reactor catalyst. This procedure should be carried
out immediately after the TGTU is shutdown when the Hydrogenation Reactor catalyst
is still near its normal operating temperature.
Shutdown the TGTU as described in Section 10.1.1 leaving the DCC top and bottom
circulating waters in service and a BFW level in the Reactor Effluent Cooler
Confirm that the SRU tail gas valve to the TGTU is closed
Confirm that the process gas valve from the Reactor Effluent Cooler to the DCC is
open
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Close the DCC process gas outlet valve to the Tail Gas Amine Absorber
Open manual valve in gas recycle line from the DCC outlet process gas line to the
RGG inlet line
Set vent gas pressure control valve from the DCC vent gas outlet line to the
Incinerator at 0.25 barg
Introduce a flow of nitrogen into the RGG inlet line
Observe the start-up pressure control valve opening to control the excess nitrogen
gases to the Incinerator
Open start-up gas steam ejector process gas inlet and outlet manual valves
Open LP steam to the start-up gas steam ejector to start circulating nitrogen gases
around the TGTU BSR section. Nitrogen gases will flow through and around the
RGG, Hydrogenation Reactor, Reactor Effluent Cooler and DCC with excess gases
being vented to the Incinerator via the recycle gas pressure control valve.
Ignite the RGG burner on fuel gas at normal slightly sub-stoichiometric firing
conditions and set RGG outlet temperature controller set point at 250C.
Open LP steam shutdown valve to the RGG and introduce steam to the RGG fuel
gas line to suppress the formation of carbon and soot at stoichiometric firing
conditions. Set the steam flow in a ratio of 2:1 (by wt) to fuel gas.
Notes:
1. As the Hydrogenation Reactor now contains sulphur compounds the RGG burner
must be operated at its normal, slightly sub-soichiometric, firing conditions.
2. If the Hydrogenation Reactor catalyst has cooled then slowly raise temperatures at
50C/hr to 250C.
Slowly adjust the RGG combustion air to fuel gas ratio controller to allow a small
excess of combustion air at the RGG burner.
Observe all temperature points across the Hydrogenation Reactor
The first sign of the burning of sulphur compounds in the Hydrogenation Reactor
should be seen by a temperature increase in the top layer of catalyst.
Hold the RGG excess combustion air conditions when a temperature front is seen
in the Hydrogenation Reactor. Note the flow of combustion air and fuel gas.
Closely observe the Hydrogenation Reactors catalyst temperatures, if
temperatures approach 400C, adjust the RGG combustion air to fuel gas ratio
controller to reduce the flow of combustion air to the RGG.
Note: Under no circumstances should catalyst temperatures exceed 425C (or other
temperature advised by the catalyst supplier).
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When the temperature front has moved through the Hydrogenation Reactor
catalyst, over a period of approx. two hours, gradually adjust the RGG combustion
air to fuel gas ratio controller to increase excess air flow and an excess of oxygen
to appear in the recycle process gas stream.
Closely observe all temperature points across the Hydrogenation Reactor for any
secondary burning of sulphur compounds. If secondary burning is seen,
immediately reset the RGG combustion air to fuel gas ratio controller to reduce
excess combustion air flow to the RGG to reduce the excess oxygen in the recycle
gas and halt the temperature increase in the area of burning within the
Hydrogenation Reactor catalyst bed.
Proceed to cool down the Hydrogenation Reactor as follows:
Start reducing the RGG outlet temperature controller set point at 50C/hr to cool
the Hydrogenation Reactor
Slowly adjust the RGG combustion air to fuel gas ratio controller to increase
excess combustion air flow to the RGG
When the RGG outlet temperature is 200C, close LP steam to the RGG fuel gas
line
Continue reducing RGG outlet temperature controller set point until ~100C is
seen in the hydrogenation reactor catalyst bed
Stop fuel gas to the RGG burner leaving combustion air flow to cool the
Hydrogenation Reactor to combustion air temperature
Close nitrogen to the RGG process gas inlet line
LP steam, closed
Close LP steam to the start-up gas steam ejector
Close process gas inlet valve to and outlet valve from the start-up steam gas
ejector
Close BSR section start-up vent gas pressure control valve and manual valve
Observe the Reactor Effluent Cooler steam generator steam side pressure after
unit shutdown. When pressure has decreased to <1.0 barg on the steam side of the
vessel, open atmospheric vent to prevent a vacuum being formed in the vessel.
The TGTU hydrogenation reactor catalyst regeneration procedure is now complete.
The following text is a guide only to the sulphiding of the hydrogenation reactor
catalyst. The catalyst manufacturer/supplier should advise the catalyst temperature
required at the start of sulphiding operations and the rate of temperature increase
and any temperature hold periods etc. during the operation.
Prior to the start of sulphiding operations, the SRU reaction furnace burner and the
RGG burner will be operating on fuel gas, and SRU tail gases will be routed through the
TGTU BSR section. TGTU process gases will be routed to the Incinerator from the
outlet of the Reactor Effluent Cooler and will be valve isolated to the contact
condenser.
Confirm that the SRU Reaction Furnace burner is operating on fuel gas at slightly
sub-stoichiometric firing conditions.
Confirm that the RGG burner is operating on fuel gas at slightly sub-stoichiometric
firing conditions.
Confirm that the Hydrogenation Reactor catalyst bed is fully heated through to a
temperature of 200C.
Using the acid gas sulphiding line from the Regenerator Reflux Drum 9103-V-12 to
the Hydrogenation Reactor inlet line, slowly open manual valve at the
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Hydrogenation Reactor to introduce a small flow of H2S acid gas into the
Hydrogenation Reactor. Aim initially for 1% - 2% vol. of H2S in process gases.
Notes:
As soon as acid gases are introduced into the Hydrogenation Reactor inlet line
start sampling the reactors inlet and outlet process gas
Note: A hand-held Drager tube type sampling system is suggested where an immediate
read out of H2S concentration in % or ppm can be seen.
At one hour intervals, continue sampling the reactor outlet gas until the H2S
concentration in process gases are stable; then increase the RGG outlet
temperature at 25C/hr to 390C, or other advised temperature.
Note: Closely observe all temperature points across the Hydrogenation Reactor. If
temperatures approach 400C reduce and/or temporarily stop acid gas flow to the
reactor. Under no circumstances should the reactor catalyst exceed 425C as damage
to the catalyst will occur.
Hold the reactor catalyst bed temperature at 390C with the H2S rich acid gas flow
passing through the reactor for a minimum of 4 hours to ensure the catalyst is
fully sulphided.
Following the 4 hours hold period, stop the flow of the H2S rich acid gas to the
inlet of the Hydrogenation Reactor.
Via the double block valves vent point valve, nitrogen purge the acid gas
sulphiding line to the Hydrogenation Reactor and then back to the SRU acid gas
feed line; then valve and blind isolate the line.
Reduce reactor inlet temperature to 240C
Sulphiding of the hydrogenation reactor is now complete and amine acid feed gas may
be introduced to the SRU.
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6. Close the drain valve fully after draining the spent oil
7. After draining the spent oil remove the oil drums to the designated place
11. After thorough cleaning of the inside of the tank close the top man way
12. Bring the new lube oil drums near to the tank
15. If any oil is spilled in the drain pan it has to be collected and disposed of in the
same way as mentioned above.
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13.1 PFD/P&ID
13.5 MSDS
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