JOB STUDY PROJECT NO: 75803

Nitrogen Cartridge Refilling Facilities on

Fire Training Ground
1. Background
The nitrogen cartridge refilling facilities on the fire training ground has been operated for more
than 20 years. This facilities provide equipments used for filling fire extinguishers cartridge with
pressurized nitrogen. The pressurized nitrogen is used to release the chemical compound that
breaks the combination of fire triangle. Because this nitrogen filling facilities are considered as
pressurized equipments, a request for engineering service (RES) is issued to study whether it
needs pressure safety device or not.

2. Discussion
General Description of the Facilities
Most of fire extinguishers that are usually found in the PT. Badak NGL community and plant
area are cartridge operated type fire extinguisher. The cartridge is filled with pressurized
nitrogen. If the fire extinguisher has already been used, the nitrogen cartridge need to be refilled.
The refilling process is conducted in the refilling facilities on the fire training ground. The
nitrogen comes from Plant 39, it is then compressed to fill the cartridge in three different types of
pressure, 1600 psi, 1800 psi, and 2400 psi. The facilities in this study refer to the compressor,
compressor’s discharge piping system, and the instrumentations.

Figure 1. The Nitrogen Cartridge

The discharge piping from the compressor is divided into two lines. One line is used to refill the
1600 psi and 1800 psi nitrogen cartridge, and the other is used to refill the 2500 psi nitrogen
cartridge.
The following part of Piping and Instrumentation Diagram (P&ID) shows the cartridge refilling
facilities.

Figure 2. P&ID Plant 33 Fire Training Ground

As shown above, on the 2500 psi filling valve manifold, there are already PSV 227 and 228
installed. But, those PSVs have never been operated since the set pressure is 1600 psi. So that
this system has no safety device(s) against overpressure.

Cause of Overpressure Possibility

The cartridge refilling process is done by continuously filling the cartridge by nitrogen up to the
expected operating pressure which usually takes up to 6 hours to achieve. It depends on the
operator response to keep this facilities not subjected to overpressure. There is high possibility of
overpressure because of this human factor.

The Rules and Regulations

Beside the overpressure possibility, ASME B31.3 states that provision shall be made to safely
contain or relieve any pressure to which the piping may be subjected. Indonesian government
also states that:
1. MPR 1930 pasal 226
"Pesawat-pesawat harus dilengkapi dengan alat-alat yang dapat menghindarkan
bahwa tekanan dalam pesawat itu tidak terlalu tinggi".
 2. PP No. 11 tahun 1979, Bab VI pasal15
"Kompresor, pompa, bejana tekan dan pipa penyalur harus dipasang alat-alat
pengaman yang selalu bekerja dengan baik diatas batas tekanan kerja aman yang
telah ditentukan untuk peralatan tersebut.

The Set Pressure

Assuming the system is designed in a careful and proper manner based on codes and standards, it
can be stated that the system allows working pressure up to 3200 psi based on the compressor
maximum working pressure. So that, the set pressure can be determined at any point bellow 3200
psi but does not bellow the cartridge operating pressure. The following data are the cartridges
specification :
• First Manifold services :

Nitrogen Cartridge : ANSUL DOT 3AA 2400 175+
Working Pressure : 2400, operated at 2418 psi (170 kg/cm2)
• Second Manifold services :

Nitrogen Cartridge : ANSUL LT-10-R DOT 3E 1800
Working Pressure : 1800 psi, operated at 1600 psi

Nitrogen Cartridge : ANSUL LT-20-R DOT 3A 2100
Working Pressure : 2100 psi, operated at 1800 psi
Based on the expected operating pressure of the cartridge, Facilities Engineering Section
proposes the PSV’s set pressure as below:
1. Set pressure of 2575 psi used at the first manifold.
2. Set pressure of 1800 psi used at the second manifold.

The Piping Material

There are several pipe material used in this facilities. To eliminate the possibility of galvanic
corrosion, it is recommended to replace the existing piping system with the uniform one. The PT.
Badak NGL General Specification states that piping class CB2B could be used for nitrogen
service.

3. Summary
The nitrogen cartridge refilling facilities has no safety device against overpressure. To avoid
overburst when filling the nitrogen cartridge, pressure safety valves need to be installed.

4. Recommendation
For safe operation, Facilities Engineering Section proposes the following recommendation:
a. replace the existing PSV 227 and 228 with PSV with 2575 psi set pressure.
b. install additional PSV with set pressure 1800 psi on the 2nd filling manifold.
c. To eliminate the possibility of galvanic corrosion, it is recommended to replace the
existing piping system with the uniform one.
Reference :
1. General Spec PT. Badak Volume III B.1.1 Piping
2. ASME - B31.3 Process Piping
3. API 520 - Sizing, Selection, and Inst of Pressure-Relieving Devices
4. API 521 - Guide for Pressure-Relieving and Depressuring Systems
5. Crosby® Pressure Relief Valve Engineering Handbook
Attachment :
Proposed Pressure Relief Valves :

For the first filling valve manifold

Set Pressure : 2575 psi

Fluid|Fluid State Nitrogen Gas

Required Capacity W 72.75 lb/hr
Molecular Weight M 28.02
Operating Pressure 2400 psig
Set Pressure 2575 psi
Effective Coefficient of Discharge K 0.975
Operating Temperature | Relieve Temperature T 79.74 ⁰C
Back Pressure 14.7 psia
% Allowable Overpressure 10
Relieving Pressure P1 2847.2 psia
Compressibility Factor Z 1
Ratio of Specific Heat 1.4
Coeff. Determined from Ratio of Spec. Heat C 356
Capacity Corr. Factor Due to Back Press. Kb 1
2
Calc. Area A 0.0004 in
Selected Area A 0.1104 in2
Orifice Designation D
Proposed Pressure Relief Valves :

For the first filling valve manifold

Set Pressure : 1800 psi

Fluid|Fluid State Nitrogen Gas

Required Capacity W 72.75 lb/hr
Molecular Weight M 28.02
Operating Pressure 1600 1800 psig
Set Pressure 1800 psi
Effective Coefficient of Discharge K 0.975
Operating Temperature | Relieve Temperature T 79.74 ⁰C
Back Pressure 14.7 psia
% Allowable Overpressure 10
Relieving Pressure P1 1994.7 psia
Compressibility Factor Z 1
Ratio of Specific Heat 1.4
Coeff. Determined from Ratio of Spec. Heat C 356
Capacity Corr. Factor Due to Back Press. Kb 1
2
Calc. Area A 0.0005 in
Selected Area A 0.1104 in2
Orifice Designation D
Attachment
The Nitrogen Cartridges Refilling Facilities

The Compressor

The first filling valve manifold

The second filling valve manifold

The Cartridges