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Doc. No.

350-IOM-PS-1202 TLNG Authors Org. Date Sheet

Rev. KJP

6B

TANGGUH LNG
BPMIGAS

Project
KJP Doc. No. BP Berau Ltd. KJP Job Code

S-350-1283-002 J-3400-20-0000

15 Nov, 06 1 of 19

3.8 MTPA TRAIN CAPACITY Operation Manual for GPFSB and Potable Water System

Core
For Information

Non-core
For Review For Approval
X

Lifecycle Code
Released As-Built

Rev. 5A

Date 20Feb06

Page all All All

Description For Approval (Integration issue with S-350-1283-001) Released (Separation issue from S-350-1283-001) Released

Prepd T.Bessho T.Bessho K. Irwan

Chkd M.Ditto Y.Kakutani Y.Kakutani

Appd M.Ditto Y.Kakutani Y.Kakutani

BP Appd

6A 20 June 06 6B 15 Nov 06

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PT. Brown & Root Indonesia

BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 2 of 191919

CONTENTS 1. Introduction.................................................................................................................................4 2. Basis of Design.............................................................................................................................6 2.1 General ..........................................................................................................................................6 2.1.1 PERMANENT POTABLE WATER SYSTEM..................................................................................... 6 2.1.2 EQUIPMENT FOR TEMPORARY POTABLE WATER SYSTEM ......................................................... 6 2.2 Process Description .......................................................................................................................6 3. Preparation for Initial Start-up .................................................................................................6 4. Initial Start-up Procedure ..........................................................................................................7 4.1 General.........................................................................................................................................7 4.2 Permanent Potable Water System.............................................................................................7 4.3 Temporary Potable Water System ............................................................................................7 4.3.1.1 Potable Water Initial Filling by Temporary Facilities (Month 17) ................................ 7 4.3.1.2 Potable Water Distribution by Temporary Facilities (Month 17) .................................. 7 5. Normal Operation.......................................................................................................................7 5.1 Permanent Potable Water System.............................................................................................7 5.2 Temporary Potable Water System ............................................................................................7 5.3 Operating Variables....................................................................................................................8 6. Quality control ............................................................................................................................8 6.1.1 PERMANENT POTABLE WATER SYSTEM..................................................................................... 8 6.1.2 TEMPORARY POTABLE WATER SYSTEM .................................................................................... 8 7. Normal Shutdown Procedure ....................................................................................................9 7.1 General.........................................................................................................................................9 7.2 Normal Shutdown .......................................................................................................................9 7.2.1 PERMANENT POTABLE WATER SYSTEM..................................................................................... 9 7.2.2 TEMPORARY POTABLE WATER SYSTEM .................................................................................... 9 8. Emergency Shutdown Procedure ..............................................................................................9 8.1 General.........................................................................................................................................9 8.2 Power Failure ............................................................................................................................10 8.3 Instrument Air Failure .............................................................................................................10 8.4 Fires/Serious Leakage...............................................................................................................10 9. Safety Procedure .......................................................................................................................10 9.1 General.......................................................................................................................................10 9.2 Emergency Fire Plan ................................................................................................................11 9.3 Fire Fighting and Protective Equipment ................................................................................12 9.4 Maintenance of Equipment and Housekeeping......................................................................12 9.5 Repair Work..............................................................................................................................12 9.6 Withdrawal of Samples ............................................................................................................13 9.7 Safe Handling of Volatile and Toxic Materials ......................................................................13 9.8 Respiratory Protection .............................................................................................................13 9.9 Breathing Apparatus (B. A.) ....................................................................................................14 10. Isolation Procedure for Maintenance......................................................................................14 10.1 General ......................................................................................................................................15 10.2 Basic Procedures.......................................................................................................................15 10.2.1 INDIVIDUAL EQUIPMENT / SYSTEM ISOLATION........................................................................ 15 10.2.1.1 Tank ............................................................................................................................. 15 10.2.1.2 Pumps........................................................................................................................... 16 11. Maintenance Procedure............................................................................................................17 11.1 General ......................................................................................................................................17 11.1.1 ROUTINE/FIRST LINE/ MAINTENANCE ...................................................................................... 17 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 17 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 17 11.1.4 PREDICTIVE/CONDITION BASED MONITORING ........................................................................ 17 11.1.5 TURNAROUND /INSPECTION MAINTENANCE ............................................................................ 18 11.2 Precautions Prior to Maintenance...........................................................................................18 11.3 Preparation for Maintenance ..................................................................................................18

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 3 of 191919

11.3.1 INSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 18 11.3.2 REPLACEMENT OF NITROGEN WITH AIR .................................................................................. 19 11.4 Typical Isolation Method .........................................................................................................19 11.4.1 TANKS ...................................................................................................................................... 19 11.4.2 CLOSE OUT ............................................................................................................................... 19 12. Attachment List.........................................................................................................................19

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 4 of 191919

1.

INTRODUCTION GPFSB consists of the following systems defined in System Definition List 900-PRC-OP-1903 (S-900-1710-004003) and temporary facilities as mentioned in taking over procedure of GPFSB 900-PRC-OP-1910 (S-900-1710-101) and Combo Dock ready for use (S-900-1710-001). 3501-D5 3502-D5 3503-D5 9010A-D5 9030A-D5 9040A-D5 9040B-D5 9040C-D5 9040D-D5 9040E-D5 9040F-D5 9040G-D5 9040H-D5 9040I-D5 9040J-D5 9040K-D5 9040M-D5 9040N-D5 9040S-D5 9041X-D5 9080A-D5 GPFSB Diesel Storage/Transfer System GPFSB Fire water system GPFSB Potable water system Civil General-GPFSB Structure General-GPFSB Office Block-GPFSB Warehouse-GPFSB Palletized Material Storage-GPFSB Chemical Storage-GPFSB Covered Washdown & Inspection Rack-GPFSB Covered Casing Storage-GPFSB Toilet Block-GPFSB 5-Bay Workshop-GPFSB Machine Shop-GPFSB Vehicle Workshop-GPFSB Explosive Storage-GPFSB Guard House-GPFSB Security Post-2-GPFSB Substation-GPFSB Watch Tower-GPFSB Electrical General-GPFSB

This manual mainly describes the operation of Temporary Potable Water System, but not Permanent Potable Water System. The operation manual for fire water system in GPFSB is described in 82-IOM-HS-1540 (S-082-1241-019) separately. The operation manual for Diesel Oil Storage/Transfer System is described in 350-IOM-PS-1201 (S-350-1283-001) separately. The referenced operation manuals for the other systems listed above, which are related to Infrastructure for building, civil and electricity, are summarized on the table of Manual List for GPFSB in Attachment-5. The brief explanation and sketches with overall scheme for potable water system in GPFSB are provided below. There are 2 (two) operations phases, i.e. 1st one is Month 17 which is period for taking over of GPFSB and ready for use of Combo Dock, and 2nd one is the period after all facilities are completed (plant acceptance)-which scheduled in Month 47. In Month 17, some of the facilities are not yet available. In Month 48, the operation will be supported by completion of full facilities.

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 5 of 191919

POTABLE WATER In Normal operation after plant acceptance, Potable water in GPFSB (Unit 350) is supplied from Potable Water System (unit 64) by Desalinated water Pumps (064-P-1001A/B) in Utility Facilities in LNG Plant. Please refer to below sketch for overall potable water storage/transfer system with complete facilities.

Unit 350 GPFSB

Each User

Unit 064 Potable Water System

064-TK-1002
USER USER USER

064-P-1001A/B
USER

USER

Fig 1.1. Overall Potable Water Storage/Transfer System with Complete Facilities

The facilities in GPFSB (Unit 350) shall be turned over to Company by schedule Month 17 (early phase) and potable water should be supplied to all buildings and workshop, because operators start to work since schedule Month 17. Although the permanent potable water header and each distribution line have been established, potable water from Unit-64 cannot be transferred because the potable water storage tank, transfer pump, and associated pipeline are still under construction. Therefore, a temporary potable water tank and a transfer pump shall be installed in GPFSB since schedule Month 17. Please refer to the below sketch, for potable water storage/transfer with temporary facility.
Each User

Unit 350 GPFSB


Temporary water tank

Unit 064 Potable Water System

Temporary transfer pump

064-TK-1002
USER USER USER USER USER

064-P-1001A/B
Legends Already installed/constructed Not yet available, under construction Battery Limit Boundary

Fig 1.2. Potable Water Storage/Transfer System with Temporary Facility

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 6 of 191919

2. 2.1

BASIS OF DESIGN General Potable water is supplied for drinking purpose as well as for such uses as safety showers and eye wash stations, change room showers, toilets, food preparation etc.

2.1.1

Permanent Potable Water System See Operation Manual for Seawater/Water System 64-IOM-PS-1201 (S-064-1283-001).

2.1.2

Equipment for Temporary Potable Water System Before completion of potable water system (U-064), temporary water tank and pump are used. (1) Temporary potable water tank Nominal Capacity: Rated flow: Pump head 300 m3 7.2m3/h 45 m (2) Temporary potable water pump

2.2

Process Description Potable water is distributed to users in GPFSB area such as; - Palletized material storage building (350-B-1003), - Toilet building (350-B-1007), - Drilling camp, - Office block (350-B-1001), - Covered washdown and inspection rack (350-B-1005), - Workshop building (350-B-1008), - Machine shop (350-B-1009), - Ware house (350-B-1002), - Vehicle workshop (350-B-1010) - Chemical storage (350-B-1004)

3.

PREPARATION FOR INITIAL START-UP Refer to Commissioning Manual for GPFSB (350-PRC-OP-1001) (S-350-1730-001).

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 7 of 191919

4. 4.1

INITIAL START-UP PROCEDURE General In normal operation after plant acceptance, potable water is supplied from Potable Water System (U-064) by Desalinated Water Pump (064-P-1001). A temporary potable water tank and a transfer pump shall be installed in GPFSB since schedule Month 17 because the Potable Water System is still under construction.

4.2

Permanent Potable Water System See Operation Manual for Seawater/Water System 64-IOM-PS-1283-1201 (S-064-1283-001).

4.3

Temporary Potable Water System Temporary potable water to be used in GPFSB is supplied from potable water produced for construction.

4.3.1.1

Potable Water Initial Filling by Temporary Facilities (Month 17) (1) In substitution for permanent potable water storage tank, a temporary storage tank is provided by contractor. Before filling this tank, make sure that the tank is ready to fill with water by mechanical cleaning, leak check in the shell side or body of tank, and visual inspection of damaged parts. (2) After completion of tank preparation work, fill water to the tank via hose connection from water tanker truck.

4.3.1.2

Potable Water Distribution by Temporary Facilities (Month 17) (1) Prepare the suction line from tank to temporary pump. Make sure that related instruments, block valves and strainer have already been provided. (2) Prepare the discharge line from pump to 2 spare connecting nozzle on the potable water. (3) Start temporary pump by the field hand switch, after all line has been completely prepared. (4) Monitor pressure gauge at the discharge to ensure that pump performance are meet the pumps specification. Check the potable water should be delivered to each building, workshop and office respectively with required flowrate.

5. 5.1

NORMAL OPERATION Permanent Potable Water System See Operation Manual for Seawater/Water System 64-IOM-PS-1201 (S-064-1283-001).

5.2

Temporary Potable Water System Temporary potable water pump is continuously operated, but operator needs to monitor temporary water tank level daily.

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 8 of 191919

Water in the tank is also used as fire water which min required volume is 228m3 (114m3/h 2 hours). When water tank level is below 228m3, operator needs to fill the tank. Filling operation is described in section 4.3.1.1.

5.3

Operating Variables (1) Permanent Potable Water System See Operation Manual for Seawater/Water System 64-IOM-PS-1201 (S-064-1283-001). (2) Temporary Potable Water System Operator needs to monitor temporary water tank level daily.

6. 6.1.1

QUALITY CONTROL Permanent Potable Water System See Operation Manual for Seawater/Water System 64-IOM-PS-1201 (S-064-1283-001).

6.1.2

Temporary Potable Water System Temporary potable water in GPFSB shall be supplied from the potable water produced for construction, which quality has been checked to meet the specification by WHO in the following parameters: (1) TDS (=Total Dissolved Solid) (2) Turbidity (3) Conductivity (4) Residual Chlorine (5) pH max 1000 ppm max 5 NTU max 1,400 S/c less than 0.2 ppm 6.0 8.5

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 9 of 191919

7. 7.1

NORMAL SHUTDOWN PROCEDURE General Shut-downs can be classified into normal shut-down and emergency shut-down. A normal shut-down is a scheduled shut-down, while an emergency shut-down is an unscheduled shut-down due to a failure or accident. The emergency shut-down procedures are shown in Section 8. When shutting down a unit, it is most important to avoid large and/or rapid fluctuations in flows and pressures in order to protect the equipment and recover without causing any adverse effects on the unit. Further, measures must be considered to avoid hazards to human beings and damage to facilities. The shut-down schedule must be reviewed and discussed and all operators must be notified of it in advance.

7.2 7.2.1

Normal Shutdown Permanent Potable Water System See Operation Manual for Seawater/Water System 64-IOM-PS-1201 (S-064-1283-001).

7.2.2

Temporary Potable Water System The normal shutdown is only expected for temporary potable water pump maintenance. Stop temporary potable water pump and close the inlet and outlet pump isolation valve.

8. 8.1

EMERGENCY SHUTDOWN PROCEDURE General (1) An emergency can be caused by the failure of an essential utility supply (power, instrument air, etc.), mechanical failure, a serious leak or fire. In these cases a partial or complete shut-down must be carried out quickly without damaging equipment. (2) A partial failure of a utility may necessitate close monitoring of operating conditions without enforcing an immediate shut-down. (3) At all times the safety of personnel is the first priority consideration. (4) Operators must judge the conditions of an emergency correctly in order to take the first necessary action in an actual emergency, and then appropriate action must be taken according to the changes in the conditions. (5) If a failure is likely to continue for a considerable time, the unit must be shut-down according to normal shut-down procedure after taking the initial necessary action. (6) No Emergency Shutdown System is provided because Unit 350 pumps and valves are operated manually.

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 10 of 191919

8.2

Power Failure See Operation Manual for Seawater/Water System 64-IOM-PS-1201 (S-064-1283-001).

8.3

Instrument Air Failure Instrument air failure does not cause an emergency situation because all valves for Unit 350 are opened and closed manually and instrument air is not used for operation.

8.4

Fires/Serious Leakage The required action will differ depending on the location/extent of the leak fire. In general cases, the following steps must be taken. (1) Stop hot work being carried out around the area. Notify the fire safety department about the situation. (2) Stop all work and evacuate personnel in the affected area. (3) Shut-down any related pumps. (4) Isolate equipment and piping affected by the leak fire, if possible pressure build up should be taken into consideration. (5) Switch off power sources if required.

It is of the most importance to detect the source of the fire/leak and to stop the supply of flammable materials.

9. 9.1

SAFETY PROCEDURE General To prevent accidents it is of the utmost importance that all personnel be instructed properly of the following subject: - The leaks and responsibilities of the operators - The methods to accomplish this in a safe manner

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The following safety regulations cover operations of particular concern to the personnel responsible for the unit. They are intended to supplement any existing general plant safety regulations which cover all units; reference should be made to the latter for all points not mentioned below. Mechanical craftsmen working on their unit will be governed by their own departmental safety regulations, but the operator should see that none of the following safety regulations are violated by mechanical workers.

BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 11 of 191919

In addition to specifically defined rules and practices, the exercise of good judgment by every person involved is essential to safe operation. An operator should be alert for any situation which might present a personnel hazard. It should also be the responsibility of each person familiar with the plant to warn other workers who enter the plant of possible hazards they could encounter.

All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, and main isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other protective equipment such as hard hats, rubber gloves, etc.

Soda acid or foam type extinguisher must not be used on fire around electrical equipment because the water solution will conduct electricity and may aggravate the difficulty or result in the electrocution of personnel.

Carbon dioxide or dry powder extinguisher may be used safety on electrical fires.

Gas masks or breathing apparatus must be worn whenever dangerous fumes are encountered.

Safety hats must be worn when outdoors.

Gloves and goggles or face shields should be worn where dangerous or hot vapor or liquid is encountered, and are recommended for use while samples are being withdrawn and solutions made up.

Fire extinguishers must be recharged immediately after use. All stream and water hose equipment must be put back in place after use. Access to such equipment must not be obstructed.

Gas masks must have fresh cartridges installed after use.

9.2

Emergency Fire Plan The fire protection system of the plant is designed to prevent fire occurrence, control fire escalation, or extinguish fire within short period of time, assuming there will be no outside fire fighting assistance, with only one major fire at a time.

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 12 of 191919

9.3

Fire Fighting and Protective Equipment Fire hazard status throughout the plant shall be monitored on the Hazard Detection and Monitoring System (HDMS (F&G)) consoles in the main control room and fire and emergency station. Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heat radiation. For the detail, refer to 82-SPEIOM-HS-1540 (S-082-1241-019), Operation Manual for Fire Protection System and the relevant drawings for fire protection system.

9.4

Maintenance of Equipment and Housekeeping 1. Operating equipment should be checked frequently for signs of leakage, overheating, or corrosion, so that unsafe conditions may be corrected before they result in serious consequences. Unusual conditions should be reported at once. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of the equipment must be replaced when repair work is completed. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operation equipment where they can be knocked off and injure someone below. Access to ladders and fire escapes must be kept clear. Waste material and refuse must be put in proper locations where they will not offer fire or stumbling hazards. Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediately report leaks for repair. In the event that electrical equipment does not function properly, notify the electrical department and stay clear of the equipment until the electrician arrives. Gas cylinders should be stored so that they cannot fall over. Guard caps must remain in place over the valves of cylinders, which are not in use. Care should be taken when installing scaffolding to ensure that the wooden boards do not contact hot equipment and that no part is allowed to impair free access on operational equipment e.g. ladders, stairways, walkways or valves. Scaffolding should be removed immediately on completion of the work in hand. Switch pumps regularly when spares are provided. This will assure start the spare pump will be ready when needed.

2. 3. 4. 5. 6. 7. 8.

9.

9.5

Repair Work 1. 2. 3. 4. Mechanical work around and operating unit must be kept to a minimum, and the minimum number of men should be used. No mechanical work on the equipment is to be done without a properly authorized work permit. Safety hats must be worn by all personnel in all areas at all times. No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized by a work permit. Catch basins, manholes, and other sewer connections must be properly sealed off to prevent the leakage of gases, which may ignite upon contact with an open flame. No personnel shall enter a vessel for any purpose whatsoever until it has been adequately

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 13 of 191919

6.

7. 8. 9.

purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases and an entry permit issued. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not physically strike these lines and avoid operation conditions, which would cause a water hammer to start. Do not use light distillates such as gasoline or naphtha to clean machinery or for any other cleaning purposes. Equipment should not be left open overnight. At the end of each days work blanks or spades should be installed to prevent entry of flammable materials due to valve let-by. Welding cylinders should be removed from site to a designate safe area at the end of each working day.

9.6

Withdrawal of Samples Samples shall be withdrawn from the unit only by authorized personnel. Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. A container must never be filled to the brim, in order to minimize risk of subsequent spillage. When sampling any product liquids, gloves and goggles will be worn. When sampling any material, gas or liquid, the sampling line must be flushed long enough to remove dormant materials to insure that the sample obtained represents the current stream. Pass enough gas through the sample vessel to insure the displacement of the purge gas and to adjust the temperature of the sampler to that the composition is not distorted by condensation or flashing, etc.

When the sample composition is representative of the source material, it shall not be distorted by flash vaporization. Certain classes of samples may require inert atmospheres , cooling or special carrying devices. Wear approved personal safety equipment and exercise caution to avoid injuries. When sample cooling is required, operator shall confirm cooling water is flowing properly before taking the sample.

9.7

Safe Handling of Volatile and Toxic Materials The safety rules given below are for the protection of life and limb, and the prevention of property loss. It is expected that plant people will exercise common sense, alertness, and good judgment in carrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consult your supervisor immediately.

9.8

Respiratory Protection Most plant gases, other than air, are harmful to human beings if inhaled in certain concentration. Toxic gases may be classified as either asphyxiating or irritating. Asphyxiating gases may cause death by replacing the air in the lungs or by reaction with the oxygen carried in the blood; examples are hydrogen sulfide carbon monoxide, and smoke. Irritating gases may cause injury or death not only

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 14 of 191919

by asphyxiating but also by burns internal and external/ examples are chlorine and sulfur dioxide. To guard against the inhalation of harmful gases:

Secure a gas test certificate showing the gas condition of the vessel is safe for entry. Stand on the windward side of an operating from which gases escape. Provide proper ventilation. All personnel should become familiar with the accepted method of artificial respiration in order to render assistance to any one overcome by gas, electric shock, or drowning.

If anyone is overcome by gas, his rescuer should:

Never attempt a rescue unless an assistant is standing by. Protect himself before attempting a rescue by wearing breathing apparatus. Get the victim to fresh air as soon as possible. Give artificial respiration and send his assistant to call for medical aid.

When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approved test method. Wear the correct type of breathing apparatus, suited to the situation encountered.

9.9

Breathing Apparatus (B. A.) There are four types of breathing apparatus in general plant service. They are the canister type masks, the fresh air hose line B. A., the compressed air self-contained B. A. and the compressed air line trolley B. A.

The compressed air self-contained breathing apparatus has a self-contained air supply carried on the back of the user. It is used principally in emergencies. After use, always notify the proper department so that they can recharge the cylinders as soon as possible.

10.

ISOLATION PROCEDURE FOR MAINTENANCE This section describes the isolation procedures to be taken prior to maintenance work based on the following specification: Maintainability Philosophy (99-PHI-EM-0005) (S-099-1222-005). Availability and Sparing Philosophy (99-PHI-PS-0002) (S-099-1222-002).

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 15 of 191919

10.1

General It is necessary to isolate trains, items of equipment, or groups of equipment, in order to facilitate shutdown for maintenance, inspection, tie-ins, or loss prevention. As the degree of hazard increases, the measure of protection required must be deeply considered. The degree of hazard is related to the system contents (e.g. flammability, toxicity etc.), pressure and temperature. There are two main methods of isolation which can be used: Positive isolation incorporating the use of spades/spectacle blinds or removable spools and blind flanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entry or for creating safe construction areas within a plant. Valved isolation for less critical duties than those requiring positive isolation, e.g. for control valve maintenance. Valved isolation will also be required to enable positive isolation to be installed or removed without the need for a complete plant shutdown.

10.2

Basic Procedures The basic ideas for method of isolation are shown below. The details will be developed by Owner when actual isolation work will be required. The selection of type of isolation valve and blind/removable spools shall be in accordance with the applicable piping and material specifications. This section considers train or system requiring isolation followed by individual equipment isolation requirements. Sketches below are provided as an aid to develop actual planning for maintenance work.

10.2.1

Individual Equipment / System Isolation

10.2.1.1 Tank All tanks where manned entry may be required are provided with temporary blind arrangements on every process inlet and outlet nozzles. Relief valve inlet lines from pressure vessels are normally positively isolated from the vessel by removing the relief valve and blinding the inlet line end. A typical arrangement is shown on Figure 10.2.1.

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 16 of 191919

Figure 10.2.1 Tank

MIN FLOW LINE OVERFLOW

INLET LINE

OUTLET LINE

DRAIN

TANK

10.2.1.2 Pumps Normally valved isolation method is applied for isolation of pump suction and discharge lines. If required from the maintenance work nature, blinds will be provided. Refer to Figure 10.2.2.

Figure 10.2.2 Pumps

OUTLET LINE INLET LINE

Y or T TYPE SUCTION STRAINER

PUMP

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Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 17 of 191919

11. 11.1

MAINTENANCE PROCEDURE General

INSTRUMENT AIR SYSTEM HAS NITROGEN BACKUP. NEVER USE INSTRUMENT AIR FOR BREATHING APPARATUS.

Type of maintenance is classified in the following categories.

11.1.1

Routine/First line/ Maintenance Routine/First Line Maintenance is the daily on-line or off-line visual inspection, lubrication, calibration or minor adjustment of running and static equipment. In addition to the maintenance personnel carrying out the above types of checks/adjustments, the operator shall perform the following routine maintenance activities whilst carrying out his daily checks on the Plant, in order to prevent any minor problems developing into major ones:

Tightening gland followers on leaking valve packing. Checking temperature and pressure gauges for broken glass faces. Checking for correct oil levels in compressors, gearboxes, oil reservoirs. Topping up low oil levels in the above equipment as required. Cleaning pump filters and strainers. Keeping equipment clean and tidy.

11.1.2

Breakdown Maintenance For Breakdown Maintenance, there will be no scheduled checks or servicing. Corrective repairs will be carried out on failure of the Plant or equipment.

11.1.3

Planned Preventive Maintenance Planned Preventive Maintenance will be carried out on a calendar or running hours basis. It will be performed in accordance with the vendors recommended frequencies.

11.1.4

Predictive/Condition Based Monitoring Predictive/Condition based maintenance is the most efficient planning option. It uses direct observations and instrument readings for the monitoring of the actual condition of the Plant and equipment, and can trend and forecast when maintenance activities are due to take place.

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BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 18 of 191919

11.1.5

Turnaround /Inspection Maintenance Turnaround/Inspection Maintenance will be carried out at approximately 3 yearly intervals, and usually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting of safety valves, and inspections and repairs of equipment that cannot be shutdown or removed during Production.

11.2

Precautions Prior to Maintenance

This section covers precautions prior to start maintenance work for a whole or a part of the plant.
All work must be carried out within the requirements of company Safety & Environmental Policies and Procedures. Prepare all known Work Permits, these must reflect safety issues. Obtain relevant permit to work before starting work. Inform Operations of the work content of this preventive maintenance procedure and how it will affect them. All rotating equipment is to be considered energized until proven isolated. All vessels must be isolated, drained and vented. Cordon the work area, to prevent unauthorized access. Prior to commencement of this work ensure that moving/rotating/power generating/energy storing equipment has been isolated in accordance with the relevant permit to work and lock-out / tag-out requirements. Physically isolate vessels. Only standard blank flanges and spades should be used. No person should enter a vessel unless all directly connected sources of utilities fluids have been positively isolated from the vessel. Entry means total body entry or any part of the body. Operations should check for oxygen, taking samples at several representative places, with a portable analyzer to check for oxygen deficiency. Prior to commencement of this work it is recommended that the crew will be briefed on what is required and what hazards there are. The crew will be reminded of the location of safety showers, first-aid boxes and telephones. 11.3 Preparation for Maintenance

The outline of the work sequence begins as below.


Shutdown of the unit operation Installation of isolating blank flanges or spades Replacement with air for entry into the equipment, if required

11.3.1

Installation of blank flanges or spades Isolating blank flanges or spades must be installed at locations as required.

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OV 15-N -2006

BP Berau Ltd. Tangguh LNG Project


Operation Manual for GPFSB and Potable Water System

Doc. No. 350-IOM-PS-1202 KJP Doc. No. S-350-1283-002 Rev. 6B Sheet No. 19 of 191919

11.3.2

Replacement of Nitrogen with Air Replacement of nitrogen gas with air and safety test for equipment must be performed prior to permitting entry. (1) (2) (3) (4) Connect temporary air hoses at the appropriate location with utility air or instrument air if required. Open the top vent valves and drain off valves to atmosphere of the equipment. Introduce air to displace/purge nitrogen gas to atmosphere. Continue to purge until oxygen contents are higher than 20% at all point.

11.4

Typical Isolation Method

11.4.1

Tanks
Erect scaffold for access as required. Operations to close down the system, depressurize and nitrogen purge. Mechanical to spade inlet and outlet nozzles of said equipment. Mechanical to open drum. Operations to air purge and check for oxygen level. Operations to clean. One person to enter another to stand by on watch.

11.4.2

Close out
Ensure the equipment is left in a safe condition. Remove all tools and debris, clean local area. Note any faults found and comments. Raise a work request if any major corrective work is identified or the performance standards are not met during the above maintenance. Sign off permit to work and inform area authority of equipment status.

12.

ATTACHMENT LIST None (Refer to 350-IOM-PS-1201 (S-350-1283-001))

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