Abu Dhabi Gas Liquefaction Company Ltd

Basic Maintenance Technician

Course

Module 8

Overview of ADGAS Operations

Part 2—Utilities

ADGAS Personnel & Training Division

 Personnel & Training Division Basic Maintenance Technician

Contents
Page No.

Terminology and Abbreviations ………………………..………. 3

List of Illustrations ………………………………………………… 5

6 Utilities ………………………………………………………………. 6

6.1 Introduction ………………………………..………………… 6

6.2 Trains I & II …………………………………………………… 8

6.2.1 Plants 11 & 12 – Nitrogen Plant………….……….. 8

6.2.2 Plant 31 – Steam Turbines ………………………… 11
6.2.3 Plant 31 – Boilers …………………………………… 13
6.2.4 Plant 32 – Jacket Water System ………………….. 15
6.2.5 Plant 35 – Air Compressors ………………………. 17
6.2.6 Plant 36 – Demineralisation & Water Storage …. 19
6.2.7 Plant 42 – Cooling Water & Chlorine ……………. 21
6.2.8 Plant 43 – Fire Water System ……………………... 23
6.2.9 Plant 80 – Gas Turbines …………………………… 26

6.3 Train III ………………………………………………………... 28

6.3.1 Plant 14 – Nitrogen …………………………………. 28

6.3.2 Plant 29 – Desalination and Demineralisation … 30
Part 1 – Desalination ……………………………….. 30
Part 2 – Demineralisation ………………………….. 32
6.3.3 Plant 37 – Reverse Osmosis – Desalination Unit
(MECO) …………..……………………………………. 34
6.3.4 Plant 38 – Sea Water & Jacket Water Cooling …. 37
Plant 38 – (Part 1) - Sea Water Cooling .………… 37
Plant 38 – (Part 2) - Jacket Water Cooling ……... 39
6.3.5 Plant 45 – Boilers …………………………………… 41
6.3.6 Plant 46 – Air Compressors ………………………. 43

Overview of Utilities/Rev. 1.0 Page 2 of 46

 Personnel & Training Division Basic Maintenance Technician

Pre-Requisite Completion of A.T.I. Maintenance Programme and ADGAS

Induction Course

Programme The Basic Maintenance Technician Course is the first phase of

Objectives the development programme intended specifically for the
maintenance developee.

On completion of the Course the developee will have acquired

an awareness of the equipment, terminology, and safety
requirements related to the ADGAS LNG plant and Maintenance
Training Workshops.

Module Objectives On completion of this module, the developee will be able to

demonstrate an awareness of the basic Utility Systems that are in
use on Das Island.

He will be able to correctly :

• Understand an overview of the Utilities that are

available on Das Island.

• Identify the Utilities; understand their basic function and

their location.

Methodology The above will be achieved through the following:

• Pre-test
• Post test
• Classroom instruction
• Site visits
• Tasks & exercises
• Audio visual support

Overview of Utilities/Rev. 1.0 Page 3 of 46

 Personnel & Training Division Basic Maintenance Technician

Abbreviations and Terminology

ADGAS Abu Dhabi Gas Liquefaction Company

ADMA – OPCO Abu Dhabi Marine Operating Company

CW Cooling Water

LNG Liquid Natural Gas

MCR Maximum Continuous Rating

N.S.I New Seawater Intake

NRV Non Return Valve

PCV Pressure Control Valve

ppm Parts per million

RO Reverse Osmosis

SH Steam High

SM Steam Medium

T/hr. Tons per hour

TDS Total Dissolved Solids

Anion A negatively charged ion. (An ion that is attached to the anode
in electrolysis)

Cation A positively charged ion. (An ion that is attached to the cathode
in electrolysis)

Coagulant Substance that enables a liquid to change into a semisolid mass

Cryogenic Very low temperature

Demineralisation The removal of minerals from a fluid

Desalination The removal of salt from sea water

Desiccant A drying agent (Improves drying effect)

Overview of Utilities/Rev. 1.0 Page 4 of 46

 Personnel & Training Division Basic Maintenance Technician

Hotwell Storage area at the bottom of the condenser containing hot water

Impulse Impact thrust

N2 Nitrogen

Osmotic Any process by which something is acquired by adsorption

Reverse Osmosis Reverse Osmosis is a membrane process that acts to remove

dissolved minerals, dissolved organic and biological organic and
colloidal matter from water

Stage Section

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 Personnel & Training Division Basic Maintenance Technician

List of Illustrations

Page No.

Figure 6.1 Utilities (Location) …………………………….….. 7

Figure 6.2.1 Nitrogen Plant 11 – Train I ……………………… 9

Figure 6.2.2 Steam Turbine (Simplified Steam Flow) ….…… 12

Figure 6.2.3 Boilers …………………………………………...… 14

Figure 6.2.4 Plant 32 Jacket Water System ……………….… 16

Figure 6.2.5 Air Compressors …………………………….…… 18

Figure 6.2.6 Plant 36 Demineralisation & Water …………..... 20

Figure 6.2.7 Cooling Water System ………………………...… 22

Figure 6.2.8 Fire Water System ……………………………..… 25

Figure 6.2.9 Gas Turbine (Process Air/Compressor Flow) … 27

Figure 6.3.1 Nitrogen Plant ………………………………..…… 29

Figure 6.3.2(a) Desalination Plant ………………………………... 31

Figure 6.3.2(b) Plant 29 Demineralisation Process …………….. 33

Figure 6.3.3 Reverse Osmosis Plant …………………………. 36

Figure 6.3.4(a) Sea Water Cooling ………………………………. 38

Figure 6.3.4(b) Jacket Water ……………………………………… 40

Figure 6.3.5 Boilers Water & Steam Simplified Flow ……….. 42

Figure 6.3.6 Compressors ……………………………………… 44

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 Personnel & Training Division Basic Maintenance Technician

6 Utilities

6.1 Introduction

In order that the Process Trains I, II & III function correctly, back up Utility Systems are
required.

The Utilities for Trains I and II are described initially. The descriptions of the Train III
Utilities follow. Cross-connections and shared usage is indicated in the text.

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 Personnel & Training Division Basic Maintenance Technician

Figure 6.1: Utilities (Location)

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 Personnel & Training Division Basic Maintenance Technician

6.2 Trains I and II

A brief process preview of the various Utilities installed on Das Island to support the
production of LNG within Trains I and II follows:

6.2.1 Plants 11 & 12 – Nitrogen Plant

Nitrogen gas is used for purging lines and vessels, and as a component of the main process
refrigerant. The nitrogen gas produced passes through a distribution system to utility points.
The three Nitrogen (N2) Plants produce the N2 gas by cooling air to cryogenic (very low)
temperatures. At these temperatures Nitrogen and Oxygen, separate. In the process some
liquid N2 is produced, which is stored to meet peak demands for gas that exceed the
production capabilities of the N2 plant.

Nitrogen gas from Plants 11 & 12 enters the distribution grid covering the ADGAS complex.
ADGAS are also able to export Nitrogen to the ADMA-OPCO plant area via a connection
located in the Plant 26 area.

Note: Nitrogen gas is non-toxic, but can be extremely hazardous because, in

certain conditions and locations, it can exclude air, and cause immediate
suffocation. In the case of a cold gas leak, or vessel rupture, the gas can
damage or destroy sensitive body areas like the lungs, eyes, throat and nose.

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 Personnel & Training Division Basic Maintenance Technician

ATMOS
PROCESS WATER
RETURN HS1033 VENT
VENT A9 TCV SL STM
268
L. OIL PPS'
11-G-101A/B L.OIL
A1 COOELRS N2
11-E-109A/B W ASTE FC 1031 O.F
1003 DRAIN GAS LINE
OIL TK SILENCER TIC 268
FT HV 1001 11-T-103 PIC 98
L. OIL
A21 A22 FILTER
11-T-104 LC
L.O. TO TURBINE EXP. TURB. TO PV
N2 11K-102 PC1032 REBOILER/ LC1032 98
A23 0-10 T COND.
0-12 PCV38 AIR 11-E-106
B8 VENT
0-11 N10

AIR FILTER
N3
TIC
N15 N11 LC
PCV A6 1029
66 B
N14 N13 A7
TV N8
1002 CHILLER PC1027A
PCV130
R9 R4 11-E-101 N2 HC1035
R5
PCV241 A13 CROSS OVER
R10 N6 N5
R8
COMPRESSED N15 N16 A2 A3
R2 R6 AIR FOR SEAL
LG N17
LC
AIR PRE AIR LIQ
11-E-108 COND A4 LIQ HC 11-E-104
KV 11-E-103 1028
FROM DISTILLATION
A9 HC 1033 COL.
R1 1013 11-C-102
FROM TURBINE
BLOWER
KV1011 KV1018 FROM PCV 91
FT 1021 T2
R3 KV 1016 A8 11-E-107
HE ATE R
FREON COMPRESSOR REGEN GAS
11-M-101 A5 REGEN GAS
S1

DEFROSTING
LINE ELEG END 11-C-103A
REGEN GAS
OUT- LET 11-C-103B
MASTER V/V PV
98
LIQUID
N2
AIR IN
KV 1014
ON STORAGE
SERVICE HEAT VESSEL
KV1017
N2 KV1012 REG EN PV
87
FREON
KV1015

C W.
WASTE GAS VENT
N2
VAPORISERS
11-E- 305 A

Figure 6.2.1: Nitrogen Plant 11 – Train I

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 Personnel & Training Division Basic Maintenance Technician

This Nitrogen plant consists of two identical streams in which dried Carbon Dioxide
free air at approximately eight barg is progressively cooled, part liquefied and separated
by distillation into high purity gaseous and liquid nitrogen. Oxygen rich liquid waste
gas is produced which is evaporated and expanded to atmospheric pressure providing
cooling for the incoming feed air. The liquid Nitrogen product is stored, and peak
demand is supplemented by evaporation of liquid from storage.

Now try EXERCISE - 1

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 Personnel & Training Division Basic Maintenance Technician

6.2.2 Plant 31 – Steam Turbine

Steam from Plant 31 Boilers (Refer 6.2.3) is used to drive two steam turbines, LG1 and
LG2 and are generally running continually, alongside LG5, which is a gas turbine.
(Refer 6.2.8, Plant 80 Gas Turbines). These turbines produce electricity for the plant.

There are two identical 17.5 MW steam turbine driven generators installed as part of the
power generation system. Each unit also supplies 122 T/hr. of steam to the SM
(Medium Temperature Steam) header. The generator has a proven test load capacity of
17.5 MW (under very high ambient temperature) with full extraction steam.

Each turbine is an impulse type with automatic steam extraction to the SM header. The
turbine has fourteen stages, the first two stages being the high-pressure side and the last
12 stages are low-pressure side. The extraction steam, at 34.5 barg, is routed from after
the second stage of the turbine.

SH (High Temperature), steam at 62.0 barg and 4400C drives the turbine. At a
maximum input of 188 tones of steam per hour, 122 tonnes of steam per hour is
extracted as pass out steam. The remaining 66 tonnes per hour is condensed in the
surface condenser. There are two condensate pumps, one steam driven and the other
motor driven. Each has a capacity of 77 tonnes per hour. They take suction from the
condenser hotwell and discharge through the condenser level controller to a condensate
tank.

Now try EXERCISE - 2

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 Personnel & Training Division Basic Maintenance Technician

SH STEAM 188 T/hr.

HEADER LINE LEGEND
STEAM
HOT WATER
EXTRACTION
STEAM CONTROL

STEAM CHEST

LOW PRESSURE
JOURNAL BEARING HIGH PRESSURE

ROTATING SHAFT

TURBINE JOURNAL BEARING

STATOR

66 T/hr.

VACUUM
CONDENSER

HOT WATER
(CONDENSATE)

122 T/hr. HOT WATER

SM PASSOUT STEAM

TO CONDENSATE
SYSTEM

Figure 6.2.2: Steam Turbine (Simplified Steam Flow)

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 Personnel & Training Division Basic Maintenance Technician

6.2.3 Plant 31 – Boilers

Steam is generated in four boilers and supplies superheated steam at 62.0 bar and
440°C. Each boiler is capable of generating 360 T/hr at maximum continuous rating
(MCR), or 388 T/hr peak rating, which can be maintained for up to 2 hours. The boilers
are of water tube boilers.

Steam pressures are stepped down to four levels to serve various needs. The major users
of SH (High Pressure), steam are as follows:

Feed Gas Compressor 106 T/hr each machine

Propane Compressor 125 T/hr each machine
MCR Compressor 163 T/hr each machine
Booster Compressor 16 T/hr each machine
*Utilities LG1 and LG2 188 T /hr each machine
*(Refer to 6.2.2 Steam Turbine)

The exhaust from the mechanical drive turbines supplies utility steam which is used for
heating and deaerating boiler feedwater and for sealing steam at the power turbines.

Excess steam in this header is released to atmosphere via a silencer and exhaust head
through two throttling control valves.

Now try EXERCISE - 3

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 Personnel & Training Division Basic Maintenance Technician

Figure 6.2.3: Boilers

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 Personnel & Training Division Basic Maintenance Technician

6.2.4 Plant 32 – Jacket Water System

Plant 32 refers to the closed circuit process fresh water system known as the Jacket
Water System.

Note: The use of seawater as a cooling medium in high temperature areas would
cause the generation of virulent chemical corrosion, and scaling in the system.
The use of the Jacket Water System in these situations avoids this.

The system operates in a closed loop, to and from a storage tank. The system supplies
cooling water for the compressors internal coolers, and product exchangers. Make up
water is provided from the Process Water System, which is supplied from the
desalinated water storage tanks via pumps.

The two main items of equipment are:

Circulating Pumps: There are two pumps generally running and one on auto standby.

Heat Exchangers: The exchangers use seawater to cool the jacket water.

The equipment is interconnected to provide various pump and heat exchanger

combinations. The compressors have internal coolers and product exchangers cooled
by Jacket Water. This required the expanding of the cooling system from two pumps
and two seawater/jacket water exchangers to four pumps and three exchangers.

Now try EXERCISE - 4

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 Personnel & Training Division Basic Maintenance Technician

32-LSL-92
FRESH WATER STORAGE TANK
32-D-1

32-LV-0090

PUMP PUMP PUMP PUMP

32-G-10A 32-G-10B 32-G-10C 32-G-10D

AUTO
START

EX DESAL PLANT

PSL-98

TO 35 KM 1C
COOLER COOLER COOLER
EIA EIB EIC

TO 35 V 4

TO PLANT-35 &
JACKET WATER SYSTEM

TI 0107 (22.1)

Figure 6.2.4: Plant 32 Jacket Water System

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 Personnel & Training Division Basic Maintenance Technician

6.2.5 Plant 35 – Air Compressors

Plant 35 supplies the Train I & II compressed air needs to Process, Utilities, Storex (Off
Plots) and Nitrogen Plants 11 and 12. It has cross connections to receive or supply air
to and from Train 3, Plant 46 (Refer 6.3.6).

Plant 35 consists of compressors, air receivers and humidriers.

Three main rotary type compressors are installed for the total air requirement. They are
symmetrical four stage intercooled compressors. 1A is driven by steam turbine and 1B
an electric motor. 1C is a three stage intercooled motor driven compressor. 1A & B are
rated at 6110 NM3/hr. and 1C rated at 7017NM3/hr.

An Emergency Air Compressor (1130 NM3/hr at 8.25 barg) is fitted, this is a two stage
reciprocating steam turbine driven compressor and supplies only the utilities instrument
air header through a dedicated non heating dry vent driven system. This compressor is
only used in an emergency.

Three air receivers for the main compressors feed into one common header. The
emergency air compressor feeds an air receiver, which supplies utilities instrument air
header only. The emergency air receiver is kept charged at system pressure at all times
through a bleed off line from the instrument air header via a NRV. There are three
main humidriers which are package units and supply moisture free air at an outlet dew
point better than 40°C to instrument and purge air headers. Each drier unit has two
desiccant packed towers. Each tower is in service for 4 hours, while the other tower is
regenerated.

Now try EXERCISE - 5

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 Personnel & Training Division Basic Maintenance Technician

TRIP
FS 2018
JACKET
INTER STAGE COOLERS WATER
SYSTEM

Y2004D Y2004C Y2004B Y2004A

0.281 0.078 0.204 0.178

HC2015
OVERIDE
MOTOR
H2006A
FC2019A START

H2009A
5480 STOP

MASTER PC
ATMOS
FOR CMP1B
BLOW OFF
VALVE PC0001A P0001B AIR FILTERS

8.04

COMP AIR TO SYSTEM

Figure 6.2.5: Air Compressors

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 Personnel & Training Division Basic Maintenance Technician

6.2.6 Plant 36 – Demineralisation & Water Storage

Three Demineralisation Units are fitted to treat desalinated water and contaminated
condensate to produce water of boiler feed quality. The units are held at standby at
present, as Train III water treatment facilities are sufficient for normal operation (Refer
6.3.2).

Mixed bed feed pumps pump water from the polishing section tanks through the
operating ion exchange (mixed bed unit) and passes to the Demineralised Water Storage
Tanks.

For regeneration in the mixed bed unit, the cation and anion resins are separated by a
controlled backwash water flow and then are regenerated simultaneously by dilute
caustic soda and hydrochloric acid solution.

Desalinated water is used as intermittent process water to Trains I and II process area,
pump seal flushing water in utilities, Jacket Water make-up, utility water for Train III
and Desalination water transfer to ADMA.

Now try EXERCISE - 6

Overview of– Utilities/Rev. 1.0 Page 20 of 46

 Personnel & Training Division Basic Maintenance Technician

DEMINERALISED WATER ZSL CLOSED

36-C-1A/B/C 9012
FROM DESAL. 36-D-3 MB UNITS
TANK POLISHING AT AT XV ZSH OPEN
XS
TANK 9012 9011 9012 9012
9013
ZL
AI AI 9012
9012 9011
XV S
OPEN/CLOSED
S 9013
A/S XS
29HY 9012
36-G-3 A/B 0010

29HIC
0010

DEMINERALISED WATER 31-D-2A/B

CROSSOVER
VALVE
AAHH
9012

FROM DESAL. TANKS

ASHH ASHH
G-301A/B MINIMUM FLOW XS AAHH
9012 9011 AS
9011 9011
29H S
PI PI PIC
FT 0310
9301 9302 PV 9011
9001 FV 9011 XV
FI 9001 TSHH 29XY XY OPEN ZSH
FY 9011
9001 9001
0010 0310 0300 9011
29TI TAHH
FIC 0010 CLOSED ZSL
36-G-301A 36-G-301B 0011
9001 29XL 9011
0310
H XI XL
0300 0300 9011
RESET LATCHED OPEN/CLOSED
UNIT-29
PLANT-36 DEMINERALISATION PLANT
DEMINERALISATION COMMON FACILITIES

Figure 6.2.6: Plant 36 Demineralisation & Water

Overview of Utilities/Rev. 1.0 Page 21 of 46

 Personnel & Training Division Basic Maintenance Technician

6.2.7 Plant 42 – Cooling Water & Chlorine

The cooling water seawater intake pumping station is designed to supply all present seawater
requirements together with some excess for possible future expansion. The Cooling Water
and Fire Main Systems (Refer 6.2.8) are completely separate and operate at different
pressures. Cooling water supplied is at 3.5 bar. Water is extracted from approximately 175
meters off shore and flows by gravity into the screening and pumping plants through 3
meters diameter inlet pipes buried in a trench on the seabed. The seawater enters the inlet
pipes via two riser units, which take water in at approximately 3 meters above the seabed and
4 meters below sea level. The low level ensures that surface oil and floating debris will not
be drawn into the system. There will also be less suspended sand and seaweed and a lower
water temperature than that on the sea surface.

Water from the submerged pipes enters a stilling basin through a diffuser. In the diffuser
structures, two circular intake pipes are divided into two rectangular inlets. This ensures an
even flow distribution to the screens. In the stilling basin, further settlement of suspended
sand should take place before the water passes into the screening units. There are four
screening units each consisting of a Bar Screen and a Travelling Band Fine Screen. The bar
screen is designed to remove seaweed and jelly fish and is provided with a raking system to
remove the debris. The travelling band screen removes fine materials a requirement for fire
fighting equipment to prevent blocking of nozzles etc.

The cooling water system consists of six electrically driven (11 kV, 2.5 Mw) single stage
pumps. These pumps are rated at 18,300 m3/hr. All pumps discharge via an isolation valve
into a 110" header. A chlorination system is provided to control biological growth in the
water systems. Hydrogen is removed from the system and the hypochlorite is pumped to the
intake of the screen and to the intake risers on the seabed. The dosing to the screen inlets is
on a continuous basis and the dosing to the risers is intermittent shock dosing.

Now try EXERCISE - 6

Overview of Utilities/Rev. 1.0 Page 22 of 46

 Personnel & Training Division Basic Maintenance Technician
S E A W A TER
SYSTEM

STAR T U P LINE
T O T RA IN -3
PCV
PLAN T CW2
601
J -1 5 42 C /R
ADMA B O O S TE R CW3
PUM PS
PLA N T
C W -1
32 J -0 8
J -5 0
JJ-0
.0 77 PLAN T
12
J-51

G EN ER A TE RS
B O IL O R S & A U X 'S

PLANTS PLA NT
11&35 36
FLUM E

PLANTS P LA N T PLANTS
P LA N T
1 1 5&6
5&6

PLAN T PLANTS PLAN T PLANTS

2 4/5/9 2 4/5/9

P LAN T
P LAN T 7
FURNACES 7 FURNACES

T O P LA N T 2 6 B O O S T E R P U M P S

TO PLANT 27 BOG + VRU COMPRESSORS

Figure 6.2.7: Cooling Water System

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 Personnel & Training Division Basic Maintenance Technician

6.2.8 Plant 43 – Fire Water System

This system provides water for firefighting. The system has 4 pumps of equal capacity
2 electric and 2 diesel driven; each header has one diesel pump, one electrically driven
pump (11 KV) and 2 jockey pumps each 3.3 KV capacity and 750 m3/hr).

The fire main header is provided with a pressure control at 15.4 barg via control valves.
In normal operation, both sides of the header will be in use with the central isolating
valve open, in this mode only one PCV will be in use. Each PCV is sized to take the
flow of one firewater pump. Normal operation with two headers in use and no demand
for water, the Fire Main header is maintained at about 13 barg by intermittent operation
of one of the jockey pumps.

To understand the operation assume the fire main header is at 12.5 barg with one jockey
pump running and the pressure slowly decaying. If the pressure falls to
12.0 barg, the second jockey pump starts. The header pressure rises and reaches
13 barg; control is activated stopping the second jockey pump. A small demand for
firewater will cause one jockey pump to run continuously and the other jockey pump to
cut in and out as required. All fire pumps may be started manually or automatically.

If there is additional demand for fire water with both jockey pumps running the pressure
in the header will fall. When the pressure has fallen to 10.5 barg control starts the large
firewater pumps in a preselected sequence in the automatic mode. There are six
possible sequences of automatic start up selected by six push buttons on the control
panel. When the pressure in the firewater header falls to 10.5 barg, the first firewater
pump is started automatically. If the pressure in the firewater header remains below
13.7 barg or a period of 5-10 seconds after the first pump is running or if the pressure is
still below 10.5 barg due to the first pump failing to start the second pump in the
selected sequence starts automatically.

Overview of Utilities/Rev. 1.0 Page 24 of 46

 Personnel & Training Division Basic Maintenance Technician

Should the pressure in the fire water header remain below 13.7 barg for a period of
5-10 seconds due to the failure of the 2nd pump to start then the 3rd pump in the
selected sequence will automatically start. With one or more firewater pumps running
the pressure in the discharge header controlled to 15.4 barg. The pressure will then be
reduced through Fire Pressure Reducing Stations down to 7.5 bar.

A similar sequential process starts as the demand diminishes. Because of its carbon
steel construction the ring firemain is kept pressurised with inhibited fresh water. Such
water can also be used for deluge nozzle testing purposes or fighting small fires. It is
supplied from storage tank 27-D-15. Maximum fresh fire fighting water availability is
800m3/hr.

The main firewater supply is seawater. This is supplied if required via the 48" NSI
supply line. The Production Manager/Head of Operations must give authority for the
use of NSI water. The worst fire situation, from a water demand point, is the collapse
of butane tank D404 concrete roof and its suspended deck followed by ignition of the
tank contents. Due to its location relative to the other storage tanks 10,000 m3/hr of
water will be required to cool surrounding structures. On detection of such a fire, the
fire panel control logic, would open specific deluge valves after a seven-minute delay.
At this time, all remaining tanks would have cooling water sprayed onto the roofs and
facing tank walls. Additionally water would be sprayed onto other appropriate
structures.

Now try EXERCISE - 8

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 Personnel & Training Division Basic Maintenance Technician

NOTE: ONLY 1 PCV IS REQUIRED TO BE IN SERVICE AT A TIME.

TO BASIN 12900 M 3 /Hr. 43-G-05B
TO BASIN EXPEC TED WATER FLOW R ATES TO BASIN ARE AS FOLLOWS:
43-G-05A a) CASE OF FIRE ON TANK 27-D-404 : 2800 M 3/Hr.
b) CASE OF F/F W ATER SUPPLY TO AD MA OPCO : 1550 M 3 /Hr.
INSTALLED 4 PUMPS AT 4300M 3/Hr. c) CASE OF F/F WATER SUPPLY TO EXISTING AD GAS FIR EM AIN : 3700 M 3/Hr.
M AX. 3 PU MPS OPERA TIN G

CO NT. B ELOW
2750 EX IST AD GAS PRESSURE BAR
AD MA-OPC O

18"

30"
48"
30"
MAIN SEAWATER

48"
18"
FIRE FIGHTING 2.0 F.F SYST EM M 3/Hr.
600 600 10100
SYSTEM
2 HOSE HY DRANT
FIRE W ATER PR S. TR AIN 3 TOWER ELEV.
JH JETTY HYDRANT
14" 4 HOSE HYDRANT
521
PCV 112
SUBSTATION OPERATING H YDR ANT
4.3
2101 K
60 200
PCV 305 PC V 306 DELUGE VALVE
BOG COMPR. 1640
TURBO TU RBO
HOUSE LNG
GEN. SET GEN. S ET 27-D-103
521 521 TOWER
10
SUPPLEME NTARY
FIRE SYSTE M COO LING G ENERAL
CON TROL BUILDING UTILITIES
FLA RES

4.3 TO LIQUID
X-OVER TO 406
AD MA-OPC O PC V 113 FLA RE 1640 1330
PCV 23 702 LN G BU TAN E
SYSTEM 27-D-106 27-D-403
TAN K 15 412
NC 10 10
TOWER
SW EET WATER
608 FIRE FIGH TING
PU MPS 2 x 100% 400M 3 /hr
TOW ER TOWER TOWER
27-V -101 2" 1660
LN G 1640
OUT DOOR E QUIP BU TAN E
TOW ER 27-D-105
27-D-404
10 10
TOWER 27-V-101 COMP. 3"
HOUSE

27-V -101 6"

IMPOUNDING
OUTDOOR EQUIP. DE CK MOU NTED
STATION

BASIN
1512 1330 M ON ITOR
PROPANE
SUB

PR OPANE
27-D-303 27-D-304 92
PROPANE PROPANE 2103-K
20-D-101 10 10 SU LPHUR LOADING
27-D-403 27-D-403 10 BERTH
608 2104-K
CONTROL

608
HOUSE

120 120 120 FAST FOA M 406

UNIT
FOA M DE CK MOU NTED
PROPANE PROPANE PRO PORTIO NER CON VEYOR
LNG M ON ITOR
27-D-403 27-D-403 67 TRA NSFER
20-D-102
PUMPS

SPR AY POINT
LPG

FOA M
12" NB SY STEM FLU SHING TO SEA INJE CTION U NIT
10
JH 406
608
JETTY HEAD
PR OD UC T BERTHS
PROPANE SUBSTATION 2 406
PROPANE PELLITISING PLANT
27-D-403 27-D-403 STO CK PILE
FOAM
608 GENERATOR
6" X 3" FIR E BOAT C ON N'S SYSTEM
X-OVER TO ADMA 10
SY STEM 550
SYSTEM CONT. ABOVE

Figure 6.2.8: Fire Water System

Overview of Utilities/Rev. 1.0 Page 26 of 46

 Personnel & Training Division Basic Maintenance Technician

6.2.9 Plant 80 – Gas Turbines

There are four Gas Turbine Generators all independent self-contained package units
[Three ADMA (Plant-80), one ADGAS (not Plant-80)]. Gas Turbine LG 5 (ADGAS)
which is not part of Plant-80 is rated at 17.5 MW. These turbines supplement the steam
turbines (refer 6.2.2) in supplying the LNG plant electricity requirement.
Note:
1. Gas Turbine LG 5 is located in ADGAS with LG 1 and LG 2 (Steam Turbines);
this Gas Turbine LG 5 is not part of Plant 80.
2. Gas Turbines GT 1, 2 and 3 (ADMA) are similarly rated 17.5 MW.
3. LG 5 is run on Fuel Gas only.
4. GT 1, 2 & 3 can be run on either Fuel Gas or Diesel.

Each unit is comprised of a main frame having four separate compartments:

1. The Control Cabin, housing the auxiliary switchgear, speedtronic controls, hand
and auto voltage regulator and field switch for generators.

2. The Accessory Compartment housing the diesel start engine, torque converter,
main and auxiliary oil pumps, oil relays and equipment.

3. The Compressor /Turbine Compartment housing the air compressor unit and
power turbine with load gear box.

4. The Alternator Compartment with the Generator with Air Coolers, field and
excitation equipment installed.

The base of the unit is used to house the oil coolers, lube oil storage and diesel fuel oil
storage tanks. An Air Plenum House contains air filtration equipment, fans and
emergency an air by-pass damper.

A Cooling Water Module contains a head tank unit incorporating fin fans and heat
exchangers. A skid unit containing two circulating water pumps is installed. LG 5 is an
ADGAS Gas Turbine 17.5 MW (refer Note 1 above), which supplies 3 phase, 50-Hertz
power at 11000 volts to a double bus bar main at the 11kv switchboard. The ADMA-
OPCO power station has three gas turbines all rated 17.5 MW.

Now try EXERCISE - 9

Overview of Utilities/Rev. 1.0 Page 27 of 46

 Personnel & Training Division Basic Maintenance Technician

AIR INLET

FUEL INPUT

COMBUSTION Gas

COOL AIR
CHAMBER Expansion

HOT GAS INPUT

VERY HOT GAS
HOT AIR
GENERATOR
ROTATING SHAFT

COMPRESSOR GAS TURBINE GEARBOX

EXCITER

Pressure Increase
STARTING DIESEL
Hot Exhaust
GEARBOX HOT AIR Gas

POWER
OUTPUT

EXHAUST TO ATMOSPHERE
Via WASTE HEAT BOILERS

Figure 6.2.9: Gas Turbine (Process Air/Compressor Flow Diagram)

Overview of Utilities/Rev. 1.0 Page 28 of 46

 Personnel & Training Division Basic Maintenance Technician

6.3 Train III

A brief process preview of the various Utilities installed on Das Island to support the
production of LNG, within Train III follows:

6.3.1 Plant 14 – Nitrogen

Plant-14 – The Nitrogen Plant is installed as part of Train III, LNG on Das Island. It
produces liquid Nitrogen delivered into two tanks to meet peak demand together with
Nitrogen gas. The Nitrogen gas produced passes to a distribution system that provides
nitrogen for purging and process use and to utilities points.

The Nitrogen plant consists of refrigeration section, absorber section, cold box, liquid
N2 storage area and liquid Nitrogen vaporisation. Air at approximately eight barg is
cooled at the refrigeration section and dried. Carbon Dioxide freed at the absorber
section, is progressively cooled, part liquefied and separated by distillation into high
purity gaseous and liquid Nitrogen in the cold box. An oxygen rich liquid waste is
produced which is evaporated and expanded to atmospheric pressure to provide cooling
for the incoming feed gas. The liquid Nitrogen product is stored in the storage area and
peak demand for purging and process is satisfied by evaporation of liquid from storage.

Now try EXERCISE - 10

Overview of Utilities/Rev. 1.0 Page 29 of 46

 Personnel & Training Division Basic Maintenance Technician

AIR PRESSURE 8.5 BARG.

CROSS OVER VALVE
FROM/TO
PLANT-35 RESTRICTED TO
PCV 3005 2000M3/HR
PLANT
46
ATMOSPHERIC VENT

VENT CHILLER UNIT

AIR LIQUID FREON COMP.
CONDENSER SEPERATOR
AIR DRIERS
MOL SIEVE

14-C-302B
14-C-302A

EVAPORATOR

N2
SYSTEM

THAW LIQUID
VALVES STORAGE
VESSELS
14-D-301
MAIN
E-304
EXCH
D-302
NORM. OP.
PRESS. 4.8 BARG
CAP.150M3
MAX. EACH

E-305 14-C-304 DISTILATION

REBOILER COLUMN
COND. OUTPUT 800M 3 GAS
OR
400M3 GAS & 60M 3 LIQUID/HR
AT -1720C, 4.8 BARG

EXPANSION
TURBINE
K-302

Figure 6.3.1: Nitrogen Plant

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 Personnel & Training Division Basic Maintenance Technician

6.3.2 Plant 29 – Desalination and Demineralisation

Part 1 – Desalination

The plant comprises three thermo-compression units for desalination of seawater. The
plant has a production capacity of 80 T/hr. There are three identical desalination units,
29V-401, 29V-501 and 29V-601. During the normal operation, two units will be
operated. In the case of an emergency, all the three units will be operated.

The plant is a thermo-compression, multi-effect falling film evaporator type with four
evaporator effects. The seawater is preheated, in a distillate condenser, before being
routed to the evaporators. In each, the water is sprayed onto a tube bundle where partial
evaporation occurs. The vapour produced is used as heating medium in the next
evaporator to produce further evaporation of the feed water. Vapour is condensed in the
distillate condenser compartment and joins with the condensate as the distillate product.
The brine from the is pumped to blowdown. The plant operates under a vacuum, pulled
by steam ejectors.

Overview of Utilities/Rev. 1.0 Page 31 of 46

 Personnel & Training Division Basic Maintenance Technician

29H-401 RINSE LINE

VACUUM
ATMOS EJECTOR V1
V1
29T-404A/B
FILTERS
VENT
HV-4002 COND
29H-402 EJECT
COND

FV- 4004
HOGGING
EJECTOR SCALE INHIBITOR

gSM STEAM ANTI - FOAM

TIT 4007
69 o C 65 oC 61 o C 56 o C
FV-4001 EJECTO
COMP TO C.W. RETURN
TV-4007 HEADER
f -0.70 -0.75 -0.8 -0.9
SL STEAM
c
SEA WATER INLET
LSHH 4005
V3 LSH 4004 LSH 4009 DE-CHLORINE INJECTION
V4 LSL 4002 LSL 4007
LSLL 4003 LSLL 4008

LINE LEGENDS
TI 4001 TI 4003 TI 4004 TI 4005
SEA WATER TV-4010 UV-4001A
V1 PRODUCT
STEAM COOLER REJECT WATER
CONDENSATE RETURN
PRODUCT TO
PRODUCT WATER DESAL. WATER
29G-403 LV-4006 UV-4001B TANKS
SPRAY WATER
DESUP. PUMP
AE CONDUCTIVITY
29G-402 29G-401 4001 ANALYSER
BRINE PUMP PRODUCT PUMP
h DEMIN
WATER TO C.W. RETURN
BRINE FROM
PRODUCT RUNDOWN HEADER
LV-4001

Figure 6.3.2(a): Desalination Plant

Overview of Utilities/Rev. 1.0 Page 32 of 46

 Personnel & Training Division Basic Maintenance Technician

Part 2 – Demineralisation

The demineralisation plant is installed to treat desalinated water and contaminated

condensate by ion exchange to produce high purity water suitable for boiler feed. The
plant comprising three mixed bed ion exchange vessels, an associated regeneration
system and neutralisation system is supplied. Three mixed bed polishers treat
desalinated water from the storage tanks. Desalinated water from storage tanks is
pumped by mixed bed feed pumps through the operating ion exchanger(s) and passes to
demineralised water tanks. For regeneration, cation and anion resins are separated by a
controlled backwash water flow and then are regenerated simultaneously by dilute
caustic soda and hydrochloric acid solution. The resins are finally rinsed and then re-
mixed by an upward airflow to complete the process. Wastewater generated by the
regeneration is collected in a neutralisation pit, neutralised by either caustic soda or
hydrochloric acid and discharged to waste.

Steam condensate from the hotwells of surface condensers is normally returned to the
condensate tanks. A conductivity meter is provided on the discharge line from each
surface condenser to watch the contamination degree of the steam condensate.

Now try EXERCISE - 11

Overview of Utilities/Rev. 1.0 Page 33 of 46

 Personnel & Training Division Basic Maintenance Technician

OPERATING DESCRIPTION - MIXED BED REGENERATION

Figure 6.3.2(b): Plant 29 Demineralisation Process

Overview of Utilities/Rev. 1.0 Page 34 of 46

 Personnel & Training Division Basic Maintenance Technician

6.3.3 Plant 37 – Reverse Osmosis–Desalination Unit (MECO)

The desalination (MECO Reverse Osmosis Unit) removes suspended and dissolved
solids from seawater and thus produces Potable Water for drinking. The product water
will contain 200 ppm total dissolved solids (TDS) when operated at the standard
operating conditions as per the specifications and data section. The conversion of salty
water to Potable Water takes place through a process called "Reverse Osmosis".
Reverse Osmosis is a membrane process that acts to remove dissolved minerals,
dissolved organic and biological organic and microscopic matter from water.

To understand Reverse Osmosis, consider natural osmosis. If pure water is separated

from a salt solution by a semi permeable membrane (i.e. passes water readily but retards
the flow of dissolved solids), natural osmosis will cause the pure water to pass through
the membrane from the pure water side to salt solution side, causing the salt solution to
become more dilute.

The natural driving force of this process is called the osmotic pressure. Reverse
Osmosis is a process in which the flow is reversed by the application of an external
pressure on the salt solution side. This pressure must be in excess of the system's
natural osmotic pressure. Only pure water will flow through the membrane from the
salt solution side to be collected on the pure waterside. The Reverse Osmosis
desalination system, process is as follows:

Overview of Utilities/Rev. 1.0 Page 35 of 46

 Personnel & Training Division Basic Maintenance Technician

There is a seawater feed control system, incorporating an inlet strainer, which maintains
a correct level in the seawater tank. The seawater tank is of dual chamber
configuration. The inlet side receives feed water from the feed control system. Upon
reaching a level above the internal retaining wall in the outlet chamber, the seawater is
pumped out by the seawater pump(s). The unit contains three seawater pumps, two for
operation and one for standby. This water is now feed water and is pumped at a
controlled rate through the media filters. Two backwash pumps one standby are
provided to flush out the media filters when required. Coagulant is injected into the
feed water by the coagulant chemical injection system (one for each reverse osmosis
system) causing particles of impurities to adhere for easier filtration. Four media filters
for initial feed water purification are fitted followed by cartridge filters, which remove
solids larger than 5 microns prior to the feedwater passing through the high-pressure
pump.

At this point in the process, the equipment separates into two separate RO Units. The
high-pressure pumps boosts the pressure of the feed water to the turbocharger feed inlet.
From the high-pressure pumps, a discharge accumulator reduces pump pulsation and
protects piping, instruments and other components from harmful vibrations. The high-
pressure water from the permeator reject stream powers the turbocharger. The power
generated by the turbine boosts the high-pressure pump discharge stream to the pressure
required to produce water in the permeators. Feed water flows into the permeators, to
the drawback tank. The drawback tank provides for storage of product water, which is
drawn back into the membranes to protect against dehydration due to osmosis after
shutdown. The product water finally flows into a single storage tank.

Now try EXERCISE – 12

Overview of Utilities/Rev. 1.0 Page 36 of 46

 Personnel & Training Division Basic Maintenance Technician

10" LINE FROM ADMA

SEA W ATER INLET

159 M 3 /HR NORMAL SODIUM BISULPHATE
CW FILTER 249 M 3 /HR BACKWA SH (TO OMIT CARBONATES)
V39 V40 DRAW BA CK
ACID TANK
PREMEATOR
V95 NO.1
V66
V41 SEA W ATER DRAW BA CK
ACC
TANK TANK
37-D-304 PREMEATOR
V67 NO.2
TUNE UP CON. V117
ACC
V14
V4 V1 TO W AS TE TO W AS TE V81
V11 V58 V62
V2 V74 V75
V15 V5 V12 V114 V115
V3 V59 V63
V13
V60 V64 ACID V83
37-G -322 (TO OMIT CARBONATES)
V112 CLEANING V84
COAGULANT PUMPS
V61 V65 SYS TEM
37-G -322A
V32
SUPER FLO CK 573 CARTRIDGE
FILTERS TO W AS TE SODIUM HYDROXIDE
V69
SODIUM PT A /B PUMP
BISULPHATE
PH CONTRO L

W ASH CLEA N
PUM P

PRODUCT
V16 V17 V21 V22 V26 V27 V31 V32 LG 2 TANK
37-D-303
280 M 3
W ASTE

M ULTIMED IA MULTIMED IA M ULTIMED IA M ULTIMED IA PRODUCT O UTLET

FILTER FILTER FILTER FILTER 1300 M 3 /DAY
NO.1 NO.2 NO.3 NO.4
V88 V90 35 o C, 2.75 BARG
V33 V86
V18 V23 V28 100 M 3 /HR

V19 V20 V24 V25 V29 V30 V34 V35 V89 V91
V87
100M 3 /HR

TO W AS TE

Figure 6.3.3: Reverse Osmosis Plant

Overview of Utilities/Rev. 1.0 Page 37 of 46

 Personnel & Training Division Basic Maintenance Technician

6.3.4 Plant 38 (Part 1 & 2) – Sea Water Cooling & Jacket Water Cooling

Plant 38 – (Part - 1) – Sea Water Cooling

Seawater is taken from the sea for plant cooling purposes through a pipe to the intake
basin. There are two identical seawater intake trains; each train consists of a Bar Screen
Unit and a Travelling Screen Unit. The Bar Screen with Rake and Travelling Screen
are provided to the intake basin in order to remove foreign materials from seawater.
Each intake has a design flow rate of 44,000m3 /s.

Debris collected at the Bar Screen is removed intermittently by means of motor driven
mechanical rake. Debris removed from the screen is disposed through a trash trench to
the Trash Container or by using the Trash Conveyer. Travelling Screens are located
between the Bar Screens and the pump pit. Travelling Screens are washed by seawater
supplied by Back Wash Booster Pump. Some seawater from the discharge of the
Cooling Water Pumps is supplied to the Back Wash Booster Pump. Pump chamber
dewatering pumps are installed in the pump chamber pit to send water to the sewer.

A travelling crane is installed for lifting the seawater pumps and motors, stop logs, bar
screens and travelling screens. There are three electric motor driven Cooling Water
Pumps. Each pump capacity is 22,000m3/hr. During normal operation, two pumps are
in service and one in stand by. At the pump discharge a common header is fitted, when
the header pressure decreases below 2.5 barg the stand-by pump will start
automatically. The Cooling Water System supplies seawater to the process coolers and
to other ancillary equipment. After passing through the equipment, the cooling water is
returned to the sea. The system design capacity of 44,000m3/h.

Now try EXERCISE - 13

Overview of Utilities/Rev. 1.0 Page 38 of 46

 Personnel & Training Division Basic Maintenance Technician

PLT 29 -401 PLT 29 -501 PLT 29 -601

CW TO PLT 38 JACKET
WATER COOLERS

CW TO DESAL UNITS PLT 29

CW SUPPLY TOPLT 45 BOILER AUX. 32" X/OVER

VALVE

100" HEADER
TRN 3 CW SUPPLY
T 1+T 2
BATTERY LIMIT
ISOL VALVE
38-G-301 38-G-302 38-G-303
BACKWASH
PUMPS
H V 201
321 A
302 BAND 302
A SCREENS B 321 B
HYP BUND
CLEANING
LINE

CW
WASTE
BAR
DBRRIS 301 301
SCREENS CW 2 PLT42
TO A B
ISOL VALVE

WASTE WASTE
BINS BINS
WASTE
BINS
T1+T2 CW OUTFALL

Figure 6.3.4(a): Sea Water Cooling

Overview of Utilities/Rev. 1.0 Page 39 of 46

 Personnel & Training Division Basic Maintenance Technician

Plant 38 – (Part - 2) – Jacket Water Cooling

The Jacket Cooling Water System supplies inhibited non-aggressive water (Fresh
Water) instead of seawater to coolers where the use of salt water would cause serious
problems due to corrosion or fouling passages. Jacket cooling water is a closed
3
circulation system with a design flow of 500m /h.

The Jacket Cooling Water System comprises, a Jacket Cooling Water Pump, Jacket
Cooling Water Cooler, Distribution system and Jacket Cooling Water Tank. The Jacket
Cooling Water System is a closed recirculating system. The supply of the water to the
storage tank is controlled. In the event of low liquid level in the storage tank, two low-
level alarms are installed.

There are two Jacket Water Pumps, one steam driven and one motor driven. In normal
operation, the steam turbine driven pump is running the motor driven pump on stand-
by. An automatic start of the stand-by pump is initiated by a low-low pressure signal,
on the pump discharge header. Set pressure 3.9 barg. The low-pressure signal also
energises a low-pressure alarm display. The pump is rated at 500m3/h.

Jacket Cooling Water Flows through a basket type Jacket Water Strainer and is cooled
at one of two Jacket Cooling Water Coolers. 100% spare capacity is provided. The
cooling medium of Jacket Cooling Water Cooler is seawater.

Now try EXERCISE - 14

Overview of Utilities/Rev. 1.0 Page 40 of 46

 Personnel & Training Division Basic Maintenance Technician

TI-0101
LC-0101
38-D-310
JACKET CW RETURN

FLUSHING WATER CORROSION INHIBITOR

38-E-310A

FC-0101 JACKET CW
PI-0107 SUPPLY
SEA WATER

DESAL. WATER
TI-0102
FOR BACK-UP
PI-0102 38-T-311

38-E-310B
A B

38-G-310A 38-G-310B
SEA WATER

SL HEADER SM HEADER

Figure 6.3.4(b): Jacket Water

Overview of Utilities/Rev. 1.0 Page 41 of 46

 Personnel & Training Division Basic Maintenance Technician

6.3.5 Plant 45 – Boilers

The two sets of boilers are sized to provide adequate capacity to supply steam for the
compressors and pump turbines, heaters and export steam requirement.

The normal demand steam load for each boiler is expected to be 70 – 75% of the
maximum continuous rating (470,000kg/hr x 2).

Each boiler is designed to operate at a peak steam-generating rate of 517,000 Kg per

hour, which can be continued for a maximum of 2 hours in 24 hours.

The boilers have a design pressure 62 barg and a superheater outlet temperature of 440
centigrade.

Each boiler is provided with two variable speed, forced draught fans, each capable of
supplying 100% of the combustion air requirement at MCR. One force draught fan for
each boiler is steam turbine driven. The other is electric motor driven to permit boiler
start-up when no steam is available.

Three feedwater pumps are provided for boilers, with each pump capable of supplying
at least 135% of the feedwater requirement of one boiler at MCR. Two steam turbine
driven pumps are driven by variable speed steam turbines and the third by an electric
motor. Two pumps are normally in operation with one motor driven in automatic
standby. Instrumentation is provided to allow any combination of two-pump operation
remaining pump is in stand-by. Each boiler is provided with nine fuel gas burners.
Provision is made for chemical cleaning of the boilers.

Now try EXERCISE - 15

Overview of Utilities/Rev. 1.0 Page 42 of 46

 Personnel & Training Division Basic Maintenance Technician

FO
6E-301A/B 6E -342 E X T - 303
6K T -30 2 6E -33 2
38D-301 6E -352 E X T - 301
42-D-1/2(EXIST IN G) FC H Y P O C H LO R ITE 6E -341 A TM
6E -351
FO 6E -331
WC FO 2E-31 7A /B-2E -389A /B ,2E -315A/B S T A CK
LC
3E-30 3-2GT-303A/B,2E3 12A/B
CV PUM P O U T F A LL
7C-3097K-301A/B,9E-38 3 FO
FI FI FI JA C K E T C O O LIN G 8E-30 1,9E-304,4E-305 GAS
W ATER 4E-30 6,4E-316,8C-322 AT
38G -306A /B 38G -304A/B 38G-321A/B 4E-30 8,5KT -301,5E -304
T R A IN -3 U S E R
38G -305A/B 5E-30 5,6E-303A /B,6E -305A /B SL STM
M
FI JAC K ET CW INH IBITO R P OT 6E-30 4A /B,5K T-301
M SL FI FO AT FO

45 F -501 ,6 01 38D -310

45 G -3 01 A /B /C
SEA
45 G T -30 1A /B 38E -310A /B
38G-301,302,303 LC FC
E X IS T IN G PC
SEA W AT ER
FO STRAINER
HS 38G -31 0A /B

A TM
SH/SM COND
8E-328 7E-307,308,309
U T IL IT Y W A T E R U TILITY W A TE R 310,311
T R A IN - 1 /2 FO LC
360-1A /B T O T RA IN -3 9E-301,3E-384
FT
3 6D -1 A/B A
D E M IN . W A T E R
SL STM P CV M IN .FLO W T R A IN -3
DESAL W ATER SL CO ND .
SM S TM LC 2E -32 1,318 ,3 11
FC 7E -30 5,304 ,3 03,30 2
29E-401 3 1D- 2A /B D E M IN . W A T E R
29E -402 36C-1A/B/C 2D-30 1,302 ,3 04,30 6
36-D-3 T R A IN -1/2 7D-30 1,6E-311
D E MIN .TK 8C -321
P O LISH TK 31G -7A/B
360-3A/B EM ERGENCY C/BLEED LC
HOT/COLD
36D -1C /0
CO NDENSATE
FC TRAIN-1/2 FC
29V-401 DESAL W ATER F1 8G-321A/B
501
WR

DESLINATIO N UNIT 3 1 D -1 A /B TO DEARATO R

601 T R A IN -1/2
C .C TK
31G-8A/B/C
TC ATM
C O N T AM IN A T E D
LC C O N DE N S A T E 8E-321
TC
TR A IN -1/2
36D -15
SL C
PC 29C-701D/E/F
29G-401 AC DESAL W ATER 4E -3 01, 4E -3 04, 4E-30 7
HC 3E -3 05, 5E -3 06
COLD CONDENSATE
29G -402 1E -3 11
2 9E -403 36G-301 A /B F1 TANK

FC
FC B C -322
45D-320 A
CW
3 20B

HP. BFW 45G -328 A /B /C FC

PC TO PIT NEUTRN LC HC
SH STM HEA DER
SH STM HEADER ATM LC
TC S B S TM
T R A IN -1 /2 LC
SH STM

45T-501 PHOSPHATE FC D E A RA TO R
45T -301A /B /C 4 5C -301A /B 8G -322A /B A
5 K T -3 0 1 45E-501
TC C O N T.C O N D
SM STM H EADER SM STM HEADER HC FC TC OIL
T R A IN -1 /2 C O LD C O N D. F R O M 6K T -301
ATM 30 2
BOILER
45T-302A /B /C FC S U S TM 30 3
4 5F-501/6 01 SBC FI A
S B S TM H E A D E R HC
F/G FO A TM
SU STM
SU STM CC
45T-302A/B/C LC

SL STM HEADER PC FI
SL STM H EADER 45C-501 ATM A IR
LC FC SCM /S CL /SCU
T R A IN -1 /2
LC FROM UIL. A RE A
45E -502
LC
H Y DR A ZIN E LC 45E -602
PC
S U STM H E AD E R FC 45C-32B
45C-502 45K-501/502 45G -301A /B /C A M ON IA
PC W HB /D E SUP . F W
7E -3 01 ,30 2,30 3,30 4
HP BFW 81 -30 2A/B , 81 -30 3, 81-3 81 45G -321A /B
FI
H P BF W 45G-303A/B W H 8/DE S U P . F W 81 -30 4,45 1-31 1A /B
45F-501, 45F-681
451-301A/B/C 45 T-30 2A /B/C, 4 51 -303 A/B/C

Figure 6.3.5: Boilers Water & Steam Simplified Flow

Overview of Utilities/Rev. 1.0 Page 43 of 46

 Personnel & Training Division Basic Maintenance Technician

6.3.6 Plant 46 – Air Compressors

This facility consists of two main sections, one is the air compressor section and the
other is the air dryer section. Clean dry air is required for instrumentation, the nitrogen
units and other utilities.

The air compressor section has three compressors and one air receiver. Each
compressor is centrifugal and has design capacity of 3,800 Nm3/H at 9.0 barg and 48°C,
which is capable of around 70% of the normal plant load of 5,460 Nm3/H at 48°C. Two
compressors are turbine driven, the other one is motor driven. Two of three air
compressors normally operate one on automatic stand-by operating when the supply
pressure falls to 8.5 barg. The discharge air from compressors passes to wet air receiver
after being cooled by aftercoolers. The discharge pressure of the air compressors is
regulated to 9.0 barg downstream of the aftercoolers by a pressure/surge control system.
The compressed air is cooled to 480C through the aftercoolers. From the wet air
receiver 2,060 Nm3/H of air is taken as feed by the nitrogen unit (Plant-14 Refer Para
6.3.1) and intermittent flow is taken by utility hose stations.

The utility air header is interconnected with Trains I & II for mutual support and its
capacity is 2,000 Nm3/H. After passing through the pre-filters, the airflow passes to air
dryers where water is absorbed from the feed air to give an outlet air of better than 40°C
dew point at atmospheric pressure. One air dryer normally operates. The air dryer
consists of two bed towers, one bed drying wet air while the other bed is regenerating.
The regeneration air is introduced into the regeneration system from the regeneration air
blower. It is then heated in the regeneration air heater, used to regenerate the air dryer
and then discharged to atmosphere. Discharge air from the dryer enters the instrument
air receivers. The instrument air receivers provide instrument air for approximately 10
minutes without air supply from upstream of the air dryers. The air from the instrument
air receivers enters the instrument air header and is distributed to the process and
utilities areas.

Now try EXERCISE - 16

Overview of Utilities/Rev. 1.0 Page 44 of 46

 Personnel & Training Division Basic Maintenance Technician

46-T-301D 46-T-301E 46-T-301F

SURGE SURGE SURGE

ACTIVATION ACTIVATION ACTIVATION

46-E-301D 46-E-301E 46-E-301F

PRES./SURGE PRES./SURGE PRES./SURGE
CONTROL CONTROL CONTROL

46-K-301D 46-K-301E 46-K-301F

S S

STOP/START STOP/START M

CONTROL CONTROL

SB STEAM SB STEAM
SM STEAM EXHAUST SM STEAM EXHAUST
SUPPLY SUPPLY
J/WATER SUPPLY J/WATER RETURN J/WATER SUPPLY J/WATER RETURN J/WATER SUPPLY J/WATER RETURN

Figure 6.3.6: Compressors

Overview of Utilities/Rev. 1.0 Page 45 of 46

 Personnel & Training Division Basic Maintenance Technician

Exercises

Overview of Utilities/Rev. 1.0 Page 46 of 46