tk6 revised assignment4

UNIVERSITAS INDONESIA

ASSIGNMENT 4

HEALTH, SAFETY AND ENVIRONMENT (HSE)

LNG REGASIFICATION PLANT USING AMMONIA

RANKINE POWER CYCLE AS THE COLD UTILIZATION

GROUP 6

Andreas Kurniawan (1106052940)

Fildzah Khalishah Alhadar (1106021433)

Ichwan Sangiaji Rangga Syakirrullah (1106019924)

Muhammad Nur Tsani Rizka (1106008170)

Rahmita Diansari (1106013151)

CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY

UNIVERSITAS INDONESIA

DEPOK, 2014

i Universitas Indonesia

TABLE OF CONTENT

TABLE OF CONTENT ........................................................................................ i

LIST OF FIGURES ............................................................................................. ii LIST OF TABLES.............................................................................................. iii

EXECUTIVE SUMMARY ................................................................................. iv CHAPTER 1 HEALTH, SAFETY, AND ENVIROMENTAL MANAGEMENT 1

1.1 Health and Environmental Safety Aspect ....................................................... 1 1.1.1 Hazard Identification and Risk Assessment (HIRA) .................................... 3

1.1.2 Hazard Identification (HAZID) ................................................................... 5 1.1.3 Hazard and Operability Study (HAZOP) ..................................................... 8

1.2 HSE Management ........................................................................................ 21 1.2.1 Operational Details ................................................................................... 21

1.2.2 Personal Protection Equipment.................................................................. 27 1.3 Emergency Action Plant............................................................................... 29

1.4 Waste Management .................................................................................... 31 1.4.2 Gas ........................................................................................................... 33

1.5 Plant Control Design .................................................................................... 34 PLANT LAYOUT ............................................................................................. 42

2.1 Plant Location .............................................................................................. 42 2.2 Area Plant Layout ........................................................................................ 42 2.2.1 2D and 3D Plant Layout .......................................................................... 43

CHAPTER 3 CONCLUSION ............................................................................ 50 REFERENCES .................................................................................................. 51

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LIST OF FIGURES

Figure 1.1 Interactions of Human Factors ........................................................... 1

Figure 1.2 Escape Route ................................................................................... 31

Figure 1.3 Water Cooling Waste Management .................................................. 32

Figure 2.1 Cilegon Industrial Area ..................................................................... 30

Figure 2.2 Full View of Regasification Plant in 2D from Up View .................... 32

Figure 2.3 Office Area of Regasification Plant in 2D Picture ............................. 33

Figure 2.4 Process Area of Regasification Plant in 2D Picture .......................... 34

Figure 2.5 Inside Look of Process Area of Regasification Plant in 2D Picture .... 35

Figure 2.6 Up View of Regasification Plant in 3D Picture .................................. 36

Figure 2.7 Front View of Regasification Plant in 3D Picture ............................. 37

Figure 2.8 Office Area View of Regasification Plant in 3D Picture .................... 38

Figure 2.9 Process Area View of Regasification Plant in 3D Picture .................. 49

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LIST OF TABLES

Table 1.1 Criteria in the Assessment of the Level of Risk to the Human Factor .. 3

Table 1.2 Parameter in Calculation of Likelihood ............................................... 4

Table 1.3 Frequency Criteria in Risk Assessment ................................................ 4

Table 1.4 Parameter in Calculation of Severity ................................................... 4

Table 1.5 Parameter in Taking into Level of Possible Danger ............................ 5

Table 1.6 Hazard Identification and Risk Assesment (HIRA) ............................... 6

Table 1.7 Parameter in Taking into Danger Effect ............................................... 8

Table 1.8 Hazard Identification (HAZID) .......................................................... 9

Table 1.9 Guide Words and the Meaning ........................................................... 10

Table 1.10 Type of Problems Indication ........................................................... 11

Table 1.11 HAZOP Sheet for Recondenser ........................................................ 13

Table 1.12 HAZOP Sheet for Storage Tank. ..................................................... 13

Table 1.13 HAZOP Sheet for Pump. ................................................................. 14

Table 1.14 HAZOP Sheet for Compressor ....................................................... 15

Table 1.15 HAZOP Sheet for Heat Exchanger ................................................... 16

Table 1.16 HAZOP Sheet for Reactor. .............................................................. 16

Table 1.17 HAZOP Sheet for Cooler.. ............................................................... 17

Table 1.18 HAZOP Sheet for Evaporator .......................................................... 18

Table 1.19 HAZOP Sheet for Turbine. ............................................................... 18

Table 1.20 HAZOP Sheet for Generator ............................................................ 19

Table 1.21 HAZOP Sheet for Loading Arm ....................................................... 19

Table 1.22 Type of Personal Proterctive Equipment with its Use ...................... 26

Table 1.23 LNG Storage Tank Control Tabulation ............................................ 34

Table 1.24 BOG and Air Compressor Control Tabulation ................................ 35

Table 1.25 Gas Turbine Control Tabulation ...................................................... 36

Table 1.26 Recondenser Control Tabulation ...................................................... 37

Table 1.27 Evaporator Control Tabulation ....................................................... 38

Table 1.28 Combustor Control Tabulation ........................................................ 39

Table 1.29 Water Cooler Control Tabulation ..................................................... 40

Table 1.30 Mixer Control Tabulation ............................................................... 41

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EXECUTIVE SUMMARY

Health, Safety, and Environment Aspect is a good aspect that we should

consider. Health, safety, and environment program is a standard for industries

around the world including in Indonesia in order to protect the rights of labor and

protect the environment from damage of waste produces by industries. The work

at the plant is a risky job. The possibility of accidents is greater than work in an

office. Human factor brings a potential risk if we correlate it with the case in

working in LNG Regasification Plant. To avoid the danger of necessary control

components with potential risks such as human factors and equipment also

materials, we need to have a risk management system.

There are three risks management that we use in this evaluation. It is

HIRA, HAZID, and HAZOP. HIRA (Hazard Identification and Risk Assessment)

is a hazard identification and risk study to define the problem and how to manage

the Hazard In daily activities and special of operation process and Industries

production. HAZID is a hazard identification based on place and location of

activity. In determining HAZID, There are several steps that must be done are.

The locations that are identified as hazardous location are storage tank,

regasification unit, neighborhood around the plant, and combustor Unit. The

HAZOP (Hazard and Operability Study) method is technique used to identify the

hazards on process facilities and prepare the system safety of potential hazards

occurring in the operation.

In this assignment, we also evaluate the start up and shut down procedure.

Our regasification plant is not a complicated plant that needs many aspects that

we should see. Another important is evaluating waste management, we have two

waste such as liquid and gas. The liquid is cooling water and gas is flue gas.

As we already determine before, our regasification plant will build in

Cilegon, Banten. This power plant is divided into several area. The main one is

the process area where the natural gas and power are produced. The main first is

the regasification process, where the LNG will regasify to become the natural gas.

The second is the ammonia cycle, where the ammonia is heated before going to

the regasification plant. The third is gas power plant area, where the air that will

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be used to heat the ammonia is produced. In this part, the air will be heated using

the combustor with the natural gas from boil-off gas as the fuel. In this process

part, there are control room and also metering station. The total area that we need

to build our plant included process section and office section is 57.64 hectares.

1 Universitas Indonesia

CHAPTER 1

HEALTH, SAFETY, AND ENVIROMENTAL MANAGEMENT

1.1 Health and Environmental Safety Aspect

Human factor is a science that focuses on how humans interact with the

environment in their workplace. It examines the workplace factors that influence

the decisions and actions of workers. No one goes to work intending to be injured.

The decisions and actions that workers take make sense to them at the time given

their goals, knowledge and focus of attention. The human factors approach to an

investigation asks why a worker's decision or action made sense to that worker at

the time.

Figure 1.1 Interaction of Human Factors

(Source: UK HSE Government)

Human factor brings a potential risk if we correlate it with the case in

working in mine mouth power plant from coal gasification. To avoid the danger of

necessary control components with potential risks such as human factors and

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equipment also materials, we need to have a risk management system. Risk

management system is a management process carried out with the intention of

minimizing the risk or the extent possible to avoid the risk altogether. Risk

management system requires the application of the hierarchy of control measure

against the risk of a hazard, with the following steps:

Elimination (eliminating the hazard)

Substitution (use raw materials more secure)

Engineering (redesign existing processes to make it more secure)

Administrative control (changing methods or procedures work in a more

secure)

Personal Protective Equipment (using the appropriate protective

equipment to isolate the body from harm)

Risk management aims to prevent the occurrence of safety accidents. A

particular effort is needed to reduce or eliminate potential risks. Safety is a series

of efforts to be done to prevent accidents in the work process and to improve the

working environment for all employees securely in order to achieve the goals set.

The work at the plant is a risky job. The possibility of accidents is greater

than work in an office. Not to mention an unhealthy environment for the flying

material and the air is not clean. Risk itself has a definition, which is a condition

where there is a possibility of an accident or occupational disease because of the

presence of a hazard. Risk management need tools and backup facilities to prevent

or overcome danger that occurs in plants. The tools are necessary including

personal protection equipment for employees. Here is the description of personal

protection equipment that should be suited for every worker who works directly in

the plant area.

Health, safety, and environment program is a standard for industries

around the world including in Indonesia in order to protect the rights of labor and

protect the environment from damage of waste produces by industries. Good

safety and health will enhance the secure and work passion of the employee or

labor particularly. In order to apply good HSE program, so in this plant is applied

some policies regarding to health, safety, and environment. Hazard analysis can

divided into three parts:

3


HIRA (Hazard Identification and Risk Assessment)

HAZID (Hazard Identification)

HAZOP (Hazard and Operability Study)

1.1.1 Hazard Identification and Risk Assessment (HIRA)

HIRA (Hazard Identification and Risk Assessment) is a hazard

identification and risk study to define the problem and how to manage the Hazard

In daily activities and special of operation process and Industries production. In

HIRA Analysis contain some step that must be followed. They are:

Process of sorting to be sub process that more specific

Hazard potential identification in every sub process

Determine risk that may be happened (severity and likelihood)

Determine the preventive ways and recommendation of risk

Conclusion of hazard potential and risk which is solved for every

activities

Conclusion for all of working

In HIRA analysis, it is identified of hazard potential and risk with

calculate the level of risk, recommendation, and final risk. Risk is combination of

severity and likelihood. This is Risk can be described by this formula:

Likelihood of risk is consist of high, medium, and low. Severity is constant

variable and also consist of high, medium, and low effect. Level of severity and

likelihood is variant, they can 3 or more (also can 8 depend on agreement from the

companies). This table below show a parameter to calculate a likelihood and

calculate a severity.

Table 1.1 Criteria in the Assessment of the Level of Risk of Damage to the Human Factor

Level of Damage Number of People who Died

Moderate 0

Serious 1-2

Major 2-3

Catastrophic 3-4

Disastrous >4

(Source: GS EP SAF 041)

4


Table 1.2 Parameter in Calculation of Likelihood

Parameter High Medium Low

Frequency of

hazard

Every the job is

working

Once in 10 until

100

Once during the job is

working

Frequency of

hazard effect

Almost the job is

working

Once in 10 until

100 Once in 100 or more

Reliability of work

Without

experience,not

ever doing the job

before

Less experience

Well experience, have

good skill and often

doing that job


Table 1.3 Frequency Criteria in Risk Assessment

Frequency Definition for Qualitative Assessment Frequency (/year)

Likely Occur several times during the plant lifetime > 10-2

Unlikely Occur once every 10-20 on some similar plant for 20 to 30

years of plant lifetime 10

-2 – 10

-3

Very

unlikely

There is a one time per year per 1000 units

There is one every 100 to 200 similar plant in the

world over the past 20 to 30 years of plant life

Ever happened in the company, but corrective action

has been taken

10-3

– 10-4

Extremely

unlikely

Ever happened in the industry, but corrective action has

been taken 10

-4 – 10

-5

Remote

The incident is physically possible but never or rarely

occurred during the period of 20-30 years for a large

number of field

< 10-5


Table 1.4 Parameter in Calculation of Severity


Human

Resource

Death, physical

defect, Physical dis-

function, harmful.

Medium harm,

The body still

doing the job

Low harm

Asset

High damage in

equipment,

production is stopped

Damage which is

caused decreasing

of production

level

Low damage, no

production effect

5


Table 1.4 Parameter in Calculation of Severity (con’t)


Protection

Equipment

Protection equipment

is not at environment

flammable chemical

Minimum

Protection

equipment

Protection

equipment is

available enough

and installation is

well isolated

Available of

evacuation time More than one minute

Between 1-30

minutes

More than 30

minutes


From the above steps, it can be withdrawn risk to the activity in this plant,

where the risk is the result of the frequency of hazards with existing activities and

consequences listed in the following matrix (table 1.6 in next page)

1.1.2 Hazard Identification (HAZID)

HAZID is a hazard identification based on place and location of activity. In

determining HAZID, There are several steps that must be done are. All aspects of

industrial and plants installations are:

Data installation information industry (PFD, P & ID, Layout,

meteorological data, social data cultural community, event records)

Location (operation facilities and support facilities)

Risk (Human resources, aset, image)

Hazards Potential (fire and huge explosions, drowning, environmental

pollution)

Table 1.5 Parameter in Taking into Level of Possible Danger

Frequency

of hazards

Most Likely Unlikely

More than 10 in 10

years

1-10 times in 10

years

Less than once in 10

years


6


Table 1.6 Hazard Identification and Risk Assesment (HIRA)

Type of

Activities Potency of Hazard Hazard Effect Severity Likelihood

Prevention and

Countermeasures

Final

Risk

Unloading

LNG

LNG (in liquid phase) leakage Permanent injuries,

cold body burn H L

- Use PP

- Follow SOP M

LNG ship hit the dock, reacts

with water and caused detonation

Cold body burn,

permanent injuries,

death

H L - Use PPE

- Follow SOP M

Explosion because LNG (in gas

phase) leakage/spills Body burn, death H L

- Check the condition of the pipe

before and after unloading

- Use PPE

M

Triggering fires Permanent injuries,

death H L

- Adheres to applicable SOP

- Provides adequate fire safety M

Operational

and

Maintenance

Activity

LNG (in liquid phase) leakage in

storage tank and LNG Vaporizer

Permanent injuries,

cold body burn H L

- Use PP

- Follow SOP M

Boil Off Gas Leakage in BOG

Handling

Explosion, Body

burn, Permanent

injuries, death

H L - Use PP

- Follow SOP M

Ammonia Leakage in Ammonia

Rankine Power Cycle Cold-Body Burn H L

- Use PP

- Follow SOP M

Sound Disturbance from

Compressor, turbine and generatir Ear-obstruction, deaf M H

- Use PP

- Follow SOP H

Gas leakage in piping facilities Permanent injuries,

death H L

- Use PP

- Follow SOP M

Explosion caused by high

pressure in combustor

Permanent injuries,

death H L

- Use PP

- Follow SOP M

Temperature distubance around

combustor

Skin iritations, body

burn M M

- Use PP

- Follow SOP M

7


Table 1.6 Hazard Identification and Risk Assesment (HIRA) (con’t)

Type of

Activities Potency of Hazard Hazard Effect Severity Likelihood Risk

Prevention and

Countermeasures

Final

Risk

Checking

electrical

installation

Electric shock

Non-permanent

injuries M M M

-Use Personal Protective

Equipment (PPE)

- Use gloves

- Adheres to applicable Standard

Operating Procedure

- Employ skilled labor

M

Death H M M M

In case of fire/ explosion due to

short circuit

Permanent

injuries, death H M M M

Falling from height during

installation

Dysfunctions of

the body and

death

H M M

- Use safety belts

- Use PPE

- Adheres to applicable SOP

M

Checking

water utilities Dropped because of slip road

Broken bones,

dysfunction of

the body, and

death

H M M Use safety helmets and safety

shoes M

Checking

Equipment

Installation

Hit a piece of tool

Non-permanent

injuries M M M

- Use PPE

- Follow SOP

- Employ skilled labor

M

Dysfunctions of

the body and

death

H M M M

Working at

office Ergonomic hazard

Stress and health

problem which

lead to lower

productivity

L M M Redesign office to support

productivity L

(Source: Author’s Internal Data)

8


Table 1.7 Parameter in Taking into Danger Effect

PARAMETER MINOR MAJOR SEVERE

Human resources There is no accident The accident was

not fatal

The accident was

fatal

Asset Loss below US$

100’000

Loss US$ 100.000

until 1.000.000

Loss over US$

1.000.000

Environment no damage to the

environment

Minor damage to

the environment

Major damage to

the environment


The HAZID analysis for LNG Regasification and Power Unit Plant is

attached below (table 1.8 on next page)

1.1.3 Hazard and Operability Study (HAZOP)

The HAZOP (Hazard and Operability Study) method is technique used to

identify the hazards on process facilities and prepare the system safety of potential

hazards occurring in the operation. Even those who are not familiar with the

hazards analysis process will often have heard of the term HAZOP, even if they

are not really sure what it means.

It has happened when the Process Safety Management (PSM) regulations

in the United States were being promulgated in the early 1990s it was not

unknown for a plant manager to say, "I know what PSM is, it's HAZOPs!" In fact

the HAZOP method is just one of the many types of Process Hazards Analysis

(PHA) techniques that are available, and PHAs are just one element of a PSM

program. Nevertheless, these managers were somewhat justified in what they said

because they knew that, unless they could identify the hazards on their facilities,

they could not reduce risk. The goals of HAZOP are to figure out:

The potential hazards, especially the most dangerous ones for human being and

environment

Some various operability problems in each process because of some deviations

toward the design intent in plant, both active one or about to begin one.

9


Table 1.8 Hazard Identification (HAZID)

Location Description Cause Potential Danger Danger Effect Possibility Prevention

Unloading Unit To unload the LNG

from LNG ship

Leaking on joint pipe from

unloading arm and ship

Cold Damage,

Flesh will be torn Major Unlikely

Cross Check every

detail and use coverall

Storage Tank

Unit

To storage liquid

LNG

Natural factors, such as

weather (hot temperature),

corrosion factor

The lack of

durability of the

tank, Cold Damage

Major Likely Routine maintenance

BOG Handling To reliquefy the Boil

Off Gas Compressor's Motor Sound Pollution Minor Most Using Earplug

Vaporizer Unit To vaporize the LNG Extreme Low temperature,

Leakage

Cold Damage,


Procurement of

instrumentation, routine

maintenance, using

coverall

Ammonia

Cycle

The cycle of

ammonia as a

working fluid (pump

and expander)

Leaking on pipe or equipment Cold Damage,


Procurement of


maintenance, using

coverall

10


Location Description Cause Potential Danger Danger Effect Possibility Prevention

Gas Turbine To burn the methane

as a power plant Too High Pressure

Fire Explosion and

flame Major Unlikely

Procurement of


maintenance, using

coverall

Electric Grid

Place where

Electricity is

produced and

transferred

High Voltage Explosion, Electric

Shock Major Likely

Construct fence to

prevent people enter the

area


11


Furthermore, both regulators and legal advisors generally support the use

of the HAZOP technique because of its reputation and because it is so thorough.

The use of the HAZOP technique is very defensible if a company is challenged

regarding its safety performance, particularly in a legal dispute. As a result of its

widespread use and acceptance, large numbers of process safety practitioners are

now trained in the use of the HAZOP method, and many of those are also trained

as leaders/facilitators. Furthermore, a substantial HAZOP infrastructure has

developed. Many consulting companies offer HAZOP facilitation services

special-purpose software.

A HAZOP is organized by dividing the unit to be analyzed into nodes. A

node represents a section of the process where a significant process change takes

place. For example, a node might cover the transfer of material from one vessel to

another through a pump. In this case the process change is the increase in pressure

and flow that occurs across the node. Another node might include an overhead air-

cooler on a distillation column. Here temperature and phase are the process

variables that change. The HAZOP team would systematically examine a

proposed process design by asking questions using guidewords representing

deviations from the intended parameters of the process which can be seen in table

below:

Table 1.9 Guide Words and the Meaning

Guide Words Meaning

No or None The negation of the intention (e.g.: no flow)

More A quantitative increase (e.g.: high pressure)

Less A quantitative decrease (e.g.: low pressure)

As Well As In addition to (e.g.: impurity)

Part Of A qualitative decrease (e.g.: only one of two components present)

Reverse The opposite of the intention (e.g.: back flow)

Other Than Complete substitution (e.g.: wrong material)


12


Table 1.10 Type of Problems Indication

Deviation Typical Problems

No Flow Blockage, pump failure, suction vessel empty, vapor lock, control

failure, etc.

Reverse Flow Pump failure, pump reversed, over pressurization, etc.

More Temp

More Press Blockage, loss of control, reaction, explosion, valve closed, etc.

Less Flow Pump failure, leak, partial blockage, sediment, cavitation, etc.

Less Temp

Less Press Heat loss, vaporization, leak, imbalance of input and output, etc.

As Well As Presence of contaminants, e.g.: water, air, lubrication oil, etc.


Although the strength of the HAZOP method lies in its clear organization,

it is important not to allow the analysis to become too rigid. If the team finds that

it is talking about "Reverse Flow" even though the current guideword is "High

Flow", the leader should probably let the discussion continue. If he or she were to

postpone the discussion until the "right" guideword, the current thinking and

creativity may be lost. On the other hand, the leader must also keep the discussion

focused on the issue at hand, and should prevent too many digressions.

1. Select a node, define its purpose and determine the process safe limits.

2. Select a process guideword.

3. Identify the hazards and their causes using the deviation guidewords.

4. Determine how the hazard is "announced", i.e., how the operator knows a

safe limit has been exceeded.

5. Estimate the consequences (safety, environmental, economic) of each

identified hazard.

6. Identify the safeguards.

7. Estimate the frequency of occurrence of the hazard.

8. Risk rank the hazard, with and without safeguards.

9. Develop findings and potential recommendations.

13


10. Move on to the next process guideword, or to the next node if the guideword

discussion is complete.

Some mistakes might happen in assessing HAZOP are:

1. Failing to establish a "safe" environment for team members.

2. Consequences of events not carried to conclusion.

3. Taking unwarranted credit for

4. Too little credit given for safeguards

5. Making recommendations as specific as possible

6. Poor recording of HAZOPS

7. Failure to HAZOP start-up and shut-down procedures

8. Poorly up-dated P&IDs

9. A HAZOP is performed in lieu of properly executed design reviews

10. Wrong technique for system being.

14


Table 1.11 HAZOP Sheet for Recondenser

Recondenser (Single Outlet Vessel)

No. Deviation

Cause Consequences Safeguards Action Required Action

Assigned to Guide Word Parameter

1. More Flow rate The flow inlet is

too low

The pressure will

be very high

Rechecking

inspection/maintenance

regime done by

engineers to prevent

any problems

Set up the flow rate

inlet of air Engineer


Table 1.12 HAZOP Sheet for Storage Tank.

LNG Storage Tank

No. Deviation



1. Less Level

The amount of

LNG put into the

storage tank is too

few

The composition

will run out

earlier before they

come into Y-

junction

Rechecking


regime done by engineers to

prevent any problems

By designing the

weigh tank with

alarm for low level

occurring

Engineer

2. More Level

The amount of

LNG put into the

storage tank is too

many

The composition

will be over

capacity

Rechecking




By designing the

weigh tank with

alarm for high level

occurring

Engineer


15


Table 1.13 HAZOP Sheet for Pump.

Pump

No. Deviation



1. Less Level The flow inlet is too

low then there will also

be air coming in to the

pump and operator

error

Pump failure and

cavitation occurs

Rechecking




By designing the level

alarm system and installing

gas detector

Engineer

2. Less Flow

rate

The blockage by solid

or gaseous and pump

motor power is too low

Supply of liquid flow

to the next process to

be hampered and

therefore contributes to

the flow of the

subsequent processes,

and can make a rapid

deterioration

Rechecking




Control/monitoring

regularly,

cleaning/maintenance

periodically of pumps,

installing flow indicator

that is connected directly to

the pump

Engineer

3. More Flow

rate

Pump motor power is

too high and excessive

impeller performance

Pump to quickly

corrode and become

damaged , the

electricity consumed is

also higher for the

pump motor

Rechecking




Control/monitor it regularly Engineer


16


Table 1.14 HAZOP Sheet for Compressor

Compressor

No.

Deviation

Cause Consequences Safeguards Action Required

Action

Assigned

to

Guide

Word Parameter

1. Less Flow rate The blockage by

solid or liquid and

compressor motor

power is too low

Supply of vapour flow

to the next process to

be hampered and

therefore contributes to

the flow of the

subsequent processes,

and can make a rapid

deterioration

Rechecking


regime done by


any problems

Control/monitoring

regularly,

cleaning/maintenance

periodically of

compressors,

installing flow

indicator that is

connected directly to

the compressor

Engineer

2. More Flow rate Compressor

impeller power is

too high and

excessive impeller

performance

Compressor to quickly

corrode and become

damaged , the

electricity consumed is

also higher for the

compressor impeller

Rechecking


regime done by


any problems

Control/monitor it

regularly

Engineer


17


Table 1.15 HAZOP Sheet for Heat Exchanger.

LNG Evaporator

No. Deviation



1. Less Flow rate Flow is

too low

The heat transfer will be

not effective

Rechecking inspection/maintenance

regime will be suitable toward the

specification

Set up and

control/monitoring

of flow rate

Engineer

2. More Temperature Flow is

too

high

The error in

equipment.Flash failure

will happen in vaporizer



specification

Set up and

control/monitoring

of feed temperature

Engineer


Table 1.16 HAZOP Sheet for Reactor.

Combustor

No. Deviation



1. Less Temperature Heat losses to the

environment and

temperature is low

The heat

transfer will be

not effective



specification

Set up and

control/monitoring

of flow rate

Engineer

2. More Temperature Flow is too high The error in

equipment



specification

Set up and

control/monitoring

of feed

temperature

Engineer


18


Table 1.17 HAZOP Sheet for Cooler.

Cooler

No. Deviation



1. Less Temperature Cooling fluid

temperature or the

temperature of the

cooled fluid or

both are too low

The process of

heat exchange

(cooling) become

ineffective and

inefficient

Rechecking


regime will be suitable

toward the

specification

Set up air

temperature in

accordance with

proper operating

conditions and the

temperature cooled

fluid to

control/monitoring

periodically

Engineer

2. More Temperature Cooling fluid

temperature or the

temperature of the

cooled fluid or

both are too high

The process of

heat exchange

(cooling) become

ineffective and

inefficient

Rechecking



toward the

specification

Set up air

temperature in

accordance with

proper operating

conditions and the

temperature cooled

fluid to

control/monitoring

periodically

Engineer


19


Table 1.18 HAZOP Sheet for Evaporator.

Ammonia Evaporator

No. Deviation



1. Less Flow rate Flow is too

low

The heat transfer

will be not

effective

Rechecking

inspection/maintenance regime

will be suitable toward the

specification

Set up and

control/monitoring

of flow rate

Engineer

2. More Temperature Flow is too

high

The error in

equipment

Rechecking

inspection/maintenance regime

will be suitable toward the

specification

Set up and

control/monitoring

of feed temperature

Engineer


Table 1.19 HAZOP Sheet for Turbine.

Turbine

No. Deviation



1. Less Rpm of rotor The rpm of

rotor is too

low

The power

generated is low

Rechecking


regime will be suitable toward

the specification

Control/monitoring

periodically of

pressure

Engineer


20


Table 1.20 HAZOP Sheet for Generator.

Generator

No. Deviation



1. Less Speed of rotor The speed of rotor

is too low

The electricity

can’t be generated

Rechecking



toward the

specification

Periodically

maintenance of

generator

Engineer


Table 1.21 HAZOP Sheet for Loading Arm

Loading Arm

No. Deviation



1. Less Accuracy slot

in Barge

LNG leak to the

environment

LNG spoils out the

system and the

flow rate to the

storage tank

decreases

Rechecking



toward the

specification

Periodically

maintenance of

Loading Arm

Engineer


21


1.2 HSE Management

1.2.1 Operational Details

1.2.1.1 Precondition

Before starting the regasification system in this plant, the major utilities

such as power supply (combuster which is produced heat to actuate the gas

turbine), instrument air, nitrogen, water as working fluid, will be made

operational.

All lines and equipment will be flushed, cleaned and de-watered. Lines

which have been identified for chemical cleaning would be cleaned as per

approved procedures. After cleaning and dewatering, necessary leak and tightness

testing of plant flanges, joints, manholes etc. will be done. Before initiating plant

start-up, all plant piping and equipment should be nitrogen purged to make the

plant air free. It should be ensured that all temporary start-up strainers are

installed at their appropriate locations prior to clean-up runs. These temporary

strainers should be removed after clean-up runs are completed.

All instruments such as level transmitters, level gauge, pressure

transmitters etc. would be installed. The following major checks should be

performed before initiating start-up:

a. All piping and instruments are installed as per the P&IDs. The plant would

have been inserted with nitrogen and holding a pressure no less than 7~10

psig.

b. Ensure functionality of the control valves, controllers, emergency

shutdown system, etc.

c. Complete functional testing of all rotating equipment as per the supplier

instruction manuals.

d. Ensure that relief valves are installed with upstream and downstream

isolation valves locked open for the duty valve and upstream isolation

valve locked close for spare valve.

e. Ensure that the blow down valves is closed and their respective upstream

and downstream isolation valves are locked open.

22


f. Ensure that all other manual valves are in their appropriate position for

start-up.

Once these steps are completed, the regasification system is ready for first

start-up. To start up this regasification plant, involves the following step:

a. Open Gate Valve to distribute the LNG to storage tank.

b. Make sure valve V-01 and V-02 are closed before warm up the equipment.

c. Open Relief Valve V-08, open V-04 to flows the Boil Off Gas (BOG) to

recondenser.

d. Warm up the pump, which used to flows ammonia as working fluid to

ammonia evaporator

e. Open all valve in the system, ammonia rankine cycle and LNG main line

For utility systems that we need to be done in precondition phase is: (in this

following explanation)

a. Air Instrument System

The availability of instrument air must be check before the process is

running. Air instrument (compressor) is used for the units that make

pneumatic control.

b. Storage and distribution of water

Water that has been sent from the pipe is kept in the water storage before it

distribute to the interstage cooler. The maximum allowable temperature of

water in the storage is 55oC. If the level in the storage is so high, valve in

this storage is close and in the same time, water is transported to the other

water storage using pump.

1.2.1.2 Start-up Procedure

The successful long term performance of the regasification LNG and cold

utilization depends on operation and maintenance of the system. This includes the

initial plant start-up and operational start-ups and shut-downs. Preventing the

problems not only a matter of system design but also a matter of proper

commissioning and operation. Before beginning to start-up the upstream process

facilities, should be commissioned and ready for operation.

23


1. Initial Start Up-Pre Start Up Check and Commissioning

Before starting up systems, make sure that the whole pretreatment

section is working in accordance with the specifications. If the

pretreatment involved changing of the chemical characteristics of raw

material, then a full analysis must be made. Commissioning will involve

bringing into operation LNG regasification plant process a time and cold

utilization until full operation is established. Once full operation is

established, the output of the plant will be progressively brought to full

capacity to ensure all system are functioning and able to operate at

maximum output.

Initial commissioning activities will involve testing power

generation facilities using gas turbine, cold utilization of ammonia rankine

cycle, and will occur up to one year before planned start-up of the plant.

This will require the feed LNG tank to have been commissioned and ready

for service. Pre-Start Up Checklist:

All piping and instrument are completed as per P&ID.

Instrument calibration is verified

All instruments such as level transmitters, level gauges, pressure

transmitters etc. must be installed.

All piping and equipment is compatible with design pressure

All piping and equipment is protected against corrosion

Planned instrumentation is installed and operative

Pumps are ready for operation: aligned, lubricated, proper rotation

All plant piping and equipment should be Nitrogen purged to make the

plant air free.

Within the plant all lines and equipment must be flushed, cleaned and

dewatered.

Ensure functionally control valves, switching valves, controllers,

emergency shutdown system, etc.

Ensure manual valves are in proper positions.

Complete functional testing all rotating equipment

24


Ensure that the relief valves are installed with upstream and

downstream isolation valves locked open for the duty valve and

upstream isolation valve locked close for spare valve.

Ensure that the blow down valves are closed and their respective

upstream and downstream isolation valves are locked open.

Verify that all temporary start-up strainers are installed at their

appropriate locations.

Major utilities such as power supply, instrument air, nitrogen,

ammonia, cooling water, drains etc. must be operational. Within the

plant all lines and equipment must be flushed, cleaned and de-watered.

Necessary leak and tightness testing flanges, joints, manholes etc. must

also be completed prior to start-up. Before initiating plant start-up, all

plant piping and equipment should be nitrogen purged to make the

plant air free.

As part of the pre start up activities, it requires degreasing as any dirt, oil

and greasy material left in the piping and equipment will contaminate raw

material solution and lead to foaming problems during operation. The

degreasing and rinsing operation are essential during first start-up of the

plant and normally would not be required for subsequent plant restart.

Once rinsing and draining is complete, reaction treatment should be made

air free through nitrogen purge. When the system has been made air free

and established, raw material transporting and filling circulation should be

started.

2. Start Up Sequence

Following steps shall form part of plant start-up:

Ensure the tank storage of the LNG unit system maintance for the

insulation and circulation for LNG. The system for boil off gas

recovery set up.

Unloading the LNG will require to maintain the level of LNG in the

tank because the pump in the tank must be fill before start up so the

pump will suction the LNG.

25


Ensure that the pipe is perfect installed especially the natural gas

pipeline.

Ensure the Ammonia rankine power cycle unit, the make up stream

ammonia will be prepare to mixer to start up the cycle.

Prepare the gust turbine power plant cycle unit by start up the air

compressor but close the flow control air valve inlet. The air

compressor start up one by one then open the valve and intake the fuel

gas to the combustor and start up the combustor. The superheated gas

will be through gas turbine and go to ammonia evaporator.

Start up the make up steam ammonia through mixer and circulation

line. The ammonia will through ammonia pump and go to the

ammonia evaporator. The ammonia liquid will become gas and

through the gas turbine to the LNG evaporator.

Start up the pump in the storage tank so the LNG will be through the

recondenser unit and pump to the LNG evaporator, then maintain the

pipeline system and control the ration for fuel gas to combustor.

Monitoring all the control system.

1.2.1.3 Normal Operation Procedure

In this plant, after the startup processes are succesfully being run, a normal

operation procedures should be performed in sequence to maintain an optimum

regasification of LNG and electricity production.

1. When loading from LNG carrier to LNG storage tank(V-101, V-102), we

need to control the liquid level and pressure level. The circulation system

require to maintain the temperature and phase of LNG itself. Control of

level of LNG must be so the LNG pump will suction the liquid to avoid

the air on the pump.

2. Boil off gas will be go through the valve through the compressor (K-101)

and the pumped LNG (subcooled LNG) will meet the boil off gas in the

recondenser and make the boil off gas become the liquid again. We must

maintain flow and level in absorption column. The level so the pump after

condenser still through by liquid.

26


3. LNG will pump to LNG evaporator, we maintain the LNG evaporator by

contorl the outlet temperature and the flow of working fluid which is

ammonia gas. The temperature outlet must be control so we can be sure all

LNG will be become the natural gas through to pipeline and guel gas

circulation.

4. Combustor will require the air and fuel gas intake with certain ration. To

maintain this we need analyzer control and temperature control from outlet

the temperature of superheated gas. Water cooler on air compressor have

to working to maintain the rising temperature of the compressor.

5. The ammonia liquid will intake from the make up stream through the

mixer, the make up stream controled by the sytem so the flow of ammonia

in rankine cycle still steady as the working fluid.

1.2.1.4 Shut-Down Procedure

The safety shutdown system to stop the operation of this plant is based on

the following principles:

1. Means are to be provided to indicate the parameters causing shutdown.

2. Upon activation of the safety shutdown system, alarms are to be given at

the normal control position and at the local control position.

3. In the event where shutdown by the safety shutdown system is activated

the restart should not occur automatically, unless & after the system is

reset.

4. The safety shutdown system is to be supplied by two sources of power.

5. Means are to be provided to evacuate NG remaining in the system after a

shutdown.

Then, this following words will explain a process shutdown for each unit

is explained as follow:

a. Regasification LNG Unit

A process shutdown of the regasification unit results in the following:

1. Closure all the Natural gas through the pipeline

2. Turn off the LNG pump

3. Amonia exhaust from gas turbin-II cant be condensed

27


4. Turn off all switch STHE and combuster

5. Turn off the LNG evaporator and mixer.

b. Gas Turbine Power Plant Unit

A process shutdown of the amine unit results in the following:

1. Closure of air and fuel gas flow to combustor.

2. Turn off all switch of air compressor

3. Turn off all switch gas turbine

1.2.2 Personal Protection Equipment

Equipment protection for employees is the main standard for a company to

protect its employees. Personal protective equipment can be divided into:

a. General equipment: personal protective equipment as a minimum

requirement to enter the plant, the safety helmet, mask, and safety shoes

b. Special equipment: Personal Protective Equipment (PPE) is used in

accordance with the needs of employees in the workplace each based on

hazard and risk. For example: safety goggles, welding goggles, respirator,

mask, ear protection, gloves, earplugs, and so on.

This following table will show type of PPE and the function for our body and type

of hazard that can be prevent by this PPE.

Table 1.22 Type of Personal Proterctive Equipment with its Use

Part of Body Hazard Protection Option Note

Eyes

Chemical or metal

splash, dust,

projectiles, gas and

vapour, radiation

Safety spectacles,

goggles, face

screens, faceshields,

visors

Make sure the eye protection

chosen has the right combination

of impact/dust/splash/molten

metal eye protection for the task

and fits the user properly

Head and

Neck

Impact from falling or

flying objects, risk of

head bumping, hair

getting tangled in

machinery, chemical

drips or splash,

climate or

temperature

Industrial safety

helmets, bump caps,

hairnets and

firefighters' helmets

Some safety helmets incorporate

or can be fitted with specially-

designed eye or hearing

protection

Don't forget neck protection, eg

scarves for use during welding

Replace head protection if it is

damaged

28


Table 1.22 Type of Personal Proterctive Equipment with its Use (con’t)


Ear

Noise – a combination

of sound level and

duration of exposure,

very high-level

sounds are a hazard

even with short

duration

Earplugs, earmuffs,

semi-insert/canal

caps

Provide the right hearing

protectors for the type of work,

and make sure workers know

how to fit them

Choose protectors that reduce

noise to an acceptable level,

while allowing for safety and

communication

Hand and

Arm

Abrasion, temperature

extremes, cuts and

punctures, impact,

chemicals, electric

shock, radiation,

vibration, biological

agents and prolonged

immersion in water

Gloves, gloves with

a cuff, gauntlets and

sleeving that covers

part or all of the arm

Avoid gloves when operating

machines such as bench drills

where the gloves might get

caught

Some materials are quickly

penetrated by chemicals – take

care in selection, see HSE’s skin

at work website

Barrier creams are unreliable and

are no substitute for proper PPE

Wearing gloves for long periods

can make the skin hot and

sweaty, leading to skin

problems. Using separate cotton

inner gloves can help prevent

this

Feet and Legs

Wet, hot and cold

conditions,

electrostatic build-up,

slipping, cuts and

punctures, falling

objects, heavy loads,

metal and chemical

splash, vehicles

Safety boots and

shoes with

protective toecaps

and penetration-

resistant, mid-sole

wellington boots and

specific footwear, eg

foundry boots and

chainsaw boots

Footwear can have a variety of

sole patterns and materials to

help prevent slips in different

conditions, including oil- or

chemical-resistant soles. It can

also be anti-static, electrically

conductive or thermally

insulating

Appropriate footwear should be

selected for the risks identified

Lungs

Oxygen-deficient

atmospheres, dusts,

gases and vapours

Respiratory

protective equipment

(RPE)

The right type of respirator filter

must be used as each is effective

for only a limited range of

substances

http://www.hse.gov.uk/skin/




29


Table 1.21 Type of Personal Proterctive Equipment with its Use


Lungs

Oxygen-deficient

atmospheres, dusts,

gases and vapours

Respiratory

protective equipment

(RPE)

Filters have only a limited life.

Where there is a shortage of

oxygen or any danger of losing

consciousness due to exposure to

high levels of harmful fumes,

only use breathing apparatus –

never use a filtering cartridge

You will need to use breathing

apparatus in a confined space or

if there is a chance of an oxygen

deficiency in the work area

Whole Body

Heat, chemical or

metal splash, spray

from pressure leaks or

spray guns,

contaminated dust,

impact or penetration.

Conventional or

disposable overalls,

boiler suits, aprons,

chemical suits

The choice of materials includes

flame-retardant, anti-static, chain

mail, chemically impermeable,

and high-visibility

Don't forget other protection,

like safety harnesses or life

jackets


Based on the information on the data above, the workers on regasification

plant will be using this following PPE:

Table 1.22 PPE for Regasification Plant’s Worker

No Part of Body Protector

1 Eyes Safety Glasses

2 Head and Neck Industrial Safety Helmet

3 Ear Ear-plug

4 Hand and Arm Gloves with a Cuff

5 Feet and Leg Safety Shoes

6 Lungs -

7 Whole Body Conventional Cover All


1.3 Emergency Action Plant

An emergency action plan (EAP) is a written document required by

particular OSHA standards. The purpose of an EAP is to facilitate and organize

employer and employee actions during workplace emergencies. Well developed

30


emergency plans and proper employee training (such that employees understand

their roles and responsibilities within the plan) will result in fewer and less severe

employee injuries and less structural damage to the facility during emergencies. A

poorly prepared plan, likely will lead to a disorganized evacuation or emergency

response, resulting in confusion, injury, and property damage.

Putting together a comprehensive emergency action plan that deals with

those issues specific to your worksite is not difficult. It involves taking what was

learned from your workplace evaluation and describing how employees will

respond to different types of emergencies, taking into account your specific

worksite layout, structural features, and emergency systems. At a minimum, the

plan must include but is not limited to the following elements:

1. Means of reporting fires and other emergencies

Preferred procedures for reporting emergencies such as dialing 911, or an

internal emergency number, or pulling a manual fire alarm are examples of

emergency reporting procedures, but there are many other possibilities.

2. Evacuation Procedures and emergency escape route assignments

An evacuation policy, procedures, and escape route assignments so

employees understand who is authorized to order an evacuation, under what

conditions an evacuation would be necessary, how to evacuate, and what routes to

take. Exit diagrams are typically used to identify the escape routes to be followed

by employees from each specific facility location. Evacuation procedures also

often describe actions employees should take before and while evacuating such as

shutting windows, turning off equipment, and closing doors behind them.

Sometimes a critical decision may need to be made when planning - whether or

not employees should fight a small fire with a portable fire extinguisher or simply

evacuate. Portable fire extinguishers may be integrated into the emergency action

plan.

3. Procedures to account for all employees after an emergency evacuation has been

completed

Procedures need to account for employees after the evacuation to ensure that

everyone got out. This might include procedures for designated employees to

sweep areas, checking offices and rest rooms, before being the last to leave a

workplace or conducting a roll call in the assembly area. Many employers

31


designate an "evacuation warden" to assist others in an evacuation and to account

for personnel.

Figure 1.2 Escape Route

(source: Author’s Internal Data)

1.4 Waste Management

Environment is one of our priority to do our plant design. Waste

management is an important aspect that we should consider. We should identify

our waste and then know how to treat and throw it to the environment. Waste that

will be produced from our plant will be divided into two part, liquid and gas.

1.4.1 Liquid

Cooling water is the only one liquid waste from our plant. Cooling water

that is used for cooling some process in a heat exchanger will be changed in

temperature. There is no other aspect of this waste that we should worry about.

32


The temperature of cooling water will be around 50oC. The cooling water that will

be just threw away to the environment or back to the sea will damage the sea

environment and could kill the biota. So, we should decide what kind of waste

water treatment that will be used in our plant.

There are various ways to treat waste water. They are sedimentation tank,

Sedimentation Lake, and the new biological treatment. The waste treatment that is

mention above is different to our problem. The idea was that we need a wide

surface contact in order to cool down the temperature of the water. A simple way

is maybe just using the wide lake to be the place to cool the water by the wind.

Another idea is using some artificial river to flow the water through then it will be

cooled down by using the wind another natural way.

After doing the scoring and analyze it, we will do water treatment by

flowing it through the artificial river that then will be flowed into the sea. This

method is a natural way and economic way.

Figure 1.3 Water Cooling Waste Management

(source: Author’s Internal Data)

33


1.4.2 Gas

Flue gas as is the only gas waste that we have. Flue gas is a waste from the

gas turbine that is used to roll the turbine and heat the ammonia. Flue gas

composition is a little unburned methane, a little carbon monoxide, and carbon

dioxide. The composition of this flue gas is not dangerous to our environment.

There is no problem also in temperature aspect. The temperature of flue gas that is

threw to the environment is near the ambient temperature.

1.4.2 Gas

Flue gas as is the only gas waste that we have. Flue gas is a waste from the

gas turbine that is used to roll the turbine and heat the ammonia. Flue gas

composition is a little unburned methane, a little carbon monoxide, and carbon

dioxide. The composition of this flue gas is not dangerous to our environment.

There is no problem also in temperature aspect. The temperature of flue gas that is

threw to the environment is near the ambient temperature.

34


1.5 Plant Control Design

Table 1.23 LNG Storage Tank Control Tabulation

Process

equipment

Controlled

Parameter

Controlling

Parameter Controller Alarm Function Control Procedure

StorageTank

(V-101/V-

102)

Output

Pressure

Pressure control

outlet valve

Pressure Indicator

Control (PIC -

101/102)

-

Controlling the

pressure of tank

and also control

the volume of

boil off gas that

created in tank

When the pressure outlet flow from tank

is hingher (5%) than each initial flow

condition, the pressure transmitter will

give an electric signal to PIC and then

transfer that signal into a pneumatic

signal to pressure outlet valve to increase

the flow of gas to the compressor until

the condition become normal condition.

Liquid Level Flow control

Outlet valve

Level Indicator

Control (LIC -

101/102)

-

Controling the

level of the

LNG in storage

tank so the tank

not lower than

1/3 tank to

maintain

submerged

pump in the tank

When tank level is reach the minimum

level which is 1/3 of tank height, the

level indicator transmitter will give an

electric signal to the level indicator

control. Then the level indicator control

will give a electric signal to the flow

control valve at the outlet line. Thus this

valve will change its opening to be

decrease then the normal one (set 50%

from its normal opening).


35


Table 1.24 BOG and Air Compressor Control Tabulation

Process

equipment

Controlled

Parameter

Controlling


Compressor

(K-101/

201/202/

203/204/205)

Pressure

Outlet

Pressure

control outlet

valve (anti-

surge valve)

Pressure Indicator Control

(PIC-

103/109/111/113/115/117)

-

Controlling

the inlet

feed flow to

compressor

is not more

or less.

When the pressure outlet flow from

compressor is lower (about 5%) than each

initial flow condition, the pressure

transmitter will give an electric signal to

PIC and then transfer that signal into a

pneumatic signal to open the anti-surge

valve higher so the flow of recycle gas

will be more to increase the flow to

compressor until the condition become

normal condition. And if the pressure

outlet flow is higher from its initial flow

condition, the control procedure is likely

the same when it is lower than the initial

condition, but, the final action is lower

opening of the valve until the condition

become steady normal condition.


36


Table 1.25 Gas Turbine Control Tabulation

Process

equipment

Controlled

Parameter

Controlling

Parameter

Controller Alarm Function Control Procedure

Gas Turbine

(T-101/301)

Pressure

Outlet

Pressure control

inlet valve

Pressure Indicator

Control (PIC-107/

121)

-

Controlling the

inlet feed flow

to turbine is not

more or less.

When the pressure outlet flow from

turbine is lower (about 5%) than each

initial flow condition, the pressure


PIC and then transfer that signal into a

pneumatic signal to open the pressure

control inlet valve higher until the

condition become normal condition. And

if the pressure outlet flow is higher from

its initial flow condition, the control

procedure is likely the same when it is

lower than the initial condition, but, the

final action is to open the pressure

control inlet valve lower until the

condition become steady normal

condition.


37


Table 1.26 Recondenser Control Tabulation

Process

equipment

Controlled

Parameter

Controlling

Parameter

Controller Alarm Function Control Procedure

Recondenser

(Absorption

Column) (C-

101)

Liquid Level Flow control

inlet valve

Level Indicator

Control (LIC -

104)

-

Controling the

level of the

liquid in column

so the height not

lower than 1/3

column to

maintain pump

after the column

When column level is reach the

minimum level which is 1/3 of tank

height, the level indicator transmitter will

give an electric signal to the level

indicator control. Then the level indicator

control will give a electric signal to the

flow control valve at the inlet line. Thus

this valve will change its opening to be

increase then the normal one (set 50%

from its normal opening).


38


Table 1.27 Evaporator Control Tabulation

Process

equipment

Controlled

Parameter

Controlling


Evaporator /

Heat

Exchanger

(E-101/301)

Temperature

Outlet

Flow control

inlet hot fluid

valve

Temperature

Indicator Control

(TIC- 105/108)

-

Controling the

temperature’s

products of the

material that

evaporize by

evaporator.

When the temperature higher than set

point of the temperature, the temperature

transmitter will be send electric signal to

temperature indicator control to make the

opening in flow control valve at inlet hot

fluid will lower than make the flow of

hot fluid will be decrease until the

temperature is come back to the normal

temperature that we set. If the

temperature of product is lower, the

transmitter will send to indicator so it can

control the opening valve higher so make

the flow of hot fluid increase.


39


Table 1.28 Combustor Control Tabulation

Process

equipment

Controlled

Parameter

Controlling


Combustor

(R-101)

Composition

of Product

Flow control of

air inlet valve

Analyzer

Indicator Control

(AIC-119)

-

To

maintain

the inlet

ratio of air

and fuel

gas for

combustion

reaction.

By analyze the composition of product, we can know if

the ratio of air and fuel gas same as the normal condition.

If this reaction, the air will be 20% excess (20% excess

of oxygen). If the methane in the product still higher than

the analyzer transmitter will send electric signal to

analyzer indicator to control the opening of flow control

valve of air inlet higher to increase the flow of air until

the ratio become as we set before, otherwise the valve

opening will be lower and the flow of air will be

decrease until the normal ration

Temperature

of

Superheated

Gas

Flow control of

fuel gas inlet

valve

Temperature

Indicator Control

(TIC -120)

-

To control

the

temperature

of outlet

gas product

of

combustor

When the temperature higher than set point of the

temperature, the temperature transmitter will be send

electric signal to temperature indicator control to make

the opening in flow control valve at inlet fuel gas will

lower than make the flow of fuel gas will be decrease

until the temperature is come back to the normal

temperature that we set. If the temperature of product is

lower, the transmitter will send to indicator so it can

control the opening valve higher so make the flow of fuel

gas increase.


40


Table 1.29 Water Cooler Control Tabulation

Process

equipment

Controlled

Parameter

Controlling


Cooler (E-

201/204)

Temperature

Outlet

Flow control

inlet water valve

Temperature

Indicator Control

(TIC-

110/112/114/116)

-

Controling the

temperature

outlet to

maintain the

temperature of

compressor not

very high and

the temperature

of air inlet not

very low

When the temperature higher than set

point of the temperatur, the temperature

transmitter will be send electric signal to

temperature indicator control to make the

opening in flow control valve at inlet

water will higher than make the flow of

water will be increase until the

temperature is come back to the normal

temperature that we set. If the

temperature of product is lower, the

transmitter will send to indicator so it can

control the opening valve lower so make

the flow of water decrease until the

temperature back to normal condition.


41


Table 1.30 Mixer Control Tabulation

Process

equipment

Controlled

Parameter

Controlling


Mixer (M-

301) Flow Outlet

Flow control

inlet make up

ammonia valve

Flow Indicator

Control (TIC-

106)

-

Controlling the

flow of the

ammonia fluid

as the working

fluid in Rankine

cycle so the

flow will not

more or less

When flow after mixer lower than each

initial flow condition, the flow


FIC then FIC will transfer that signal into

a electric signal to flow control valve.

Valve will give an opening until the

condition become normal condition. This

make the ammonia will be added to

mixer by stream of make up ammonia

inlet until the flow of ammonia liquid is

back to normal. Otherwise, if the inlet

flow is higher from its initial flow

condition, the final action from control

valve is that it will close until the

condition become steady normal conditio

which make the make up ammonia

stream stopped.



CHAPTER 2

PLANT LAYOUT

2.1 Plant Location

As we already determine before, our regasification plant will build in

Cilegon, Banten. the location was chosen by consider the industries that require

natural gas supply to be around Cilegon, and also the raw material, the LNG itself,

can be distributed using ship from Bontang, Kalimantan. Besides that, this plant

will consider the safety, ease of distribution equipment, utilities, land availability,

environmental, and ease of marketing. So, we decided that Cilegon is the most

suitable location for our regasification plant.

Figure 2.1 Cilegon Industrial Area

(Source: Google Earth)

2.2 Area Plant Layout

This power plant is divided into several area. The main one is the process

area where the natural gas and power are produced. The main first is the

regasification process, where the LNG will regasify to become the natural gas.

The second is the ammonia cycle, where the ammonia is heated before going to

the regasification plant. The third is gas power plant area, where the air that will

be used to heat the ammonia is produced. In this part, the air will be heated using

43


the combustor with the natural gas from boil-off gas as the fuel. In this process

part, there are control room and also metering station.

Besides the process area, there are the other area in this plant, which are

the LNG storage tank, where the LNG will be cycling from the jetty and back into

jetty. The unloading facilities will be built from the sea to the land. In this plant,

there is the utility plant, where the seawater that will be used in water cooler to

cooling the air that will be compress. There is flare outside the process area.

In the other side of this plant, there are the supporting area and building,

such as the security post, main office, mosque, sport facility, clinic, canteen,

laboratories, fire station, and also the assembly point and parking area.

We also consider the position of equipment and the building with the HSE

aspect. LNG storage is located far from other equipment especially human. The

equipment that produces heat, is located far from LNG storage such as the heat

exchangers, combustor, and flare. Between the office and the process area is the

artificial river to block the effect of heat and other effect of accident, and also to

transport the water back to the sea. About the pipeline, we connected the

equipment with that. The arrangement of pipeline based on sense of engineering.

The layout of our plant can be seen in the next part. The total area that we need to

build our plant included process section and office section is 57.64 hectares.

2.2.1 2D and 3D Plant Layout

In this sub-chapter we will show you 2D and 3D configuration or pictures

of our regasification plant. Those picture are shown on next page.

44


Figure 2.2 Full View of Regasification Plant in 2D from Up View


45


Figure 2.3 Office Area of Regasification Plant in 2D Picture


46


Figure 2.4 Process Area of Regasification Plant in 2D Picture


47


Figure 2.5 Inside Look of Process Area of Regasification Plant in 2D Picture


48


Figure 2.6 Full View of Regasification Plant in 3D Picture


49


Figure 2.7 Office Area View of Regasification Plant in 3D Picture


Figure 2.8 Process Area View of Regasification Plant in 3D Picture



CHAPTER 3

CONCLUSION

Based on explanation above, we can conclude this main point of this

assignment below:

1. Human factor brings a potential risk if we correlate it with the case in working

in LNG Regasification Plant.

2. Risk management aims to prevent the occurrence of safety accidents

3. Hazard analysis that we use is HIRA, HAZID, and HAZOP.

4. The locations that are identified as hazardous location are storage tank,

regasification unit, neighborhood around the plant, and combustor Unit.

5. Another important is evaluating waste management and our plant has two

waste such as liquid and gas. The liquid waste is cooling water and gas waste

is flue gas.

6. We also should consider operational detail such as start up and shut down.

7. The total area that we need to build our plant included process section and

office section is 57.64 hectares.


REFERENCES

Brownell, Lloyd E and Edwin H. Young. 1959. Process Equipment Design. John

Wiley & Sons, inc.

Dispenza C, Dispenza G, La Rocca V, Panno G. 2009. Exergy recovery in

regasification facilities – cold utilization: a modular unit. Applied

Thermal Engineering; 29:3595–608

Elsentrout, B., Wintercom, S., & Weber, B. 2006. Study Focuses on Six LNG

Regasification Systems. Engineering Forum.

G. Speigth, James. 1980. Chemical And Process Design Handbook. New York :

McGraw-Hill.

Grenier, M. R. 1971. La Centrale d’Oxygene de Fos-sur-Mer. Proceedings of the

XIII Congress of the International Institute of Refrigeration: Washington,

D.C.

Kataoka, H., Fujisawa, S., & Inoue A. 1970. Utilization of LNG Cold for the

Production of Liquid Oxygen and Liquid Nitrogen. Proceedings of the

Second International Conference and Exhibition on LNG: Paris.

Kobayashi, Yoshikazu. 2010. Natural Gas Situation and LNG Supply/Demand

Trends in Asia-Pacific and Atlantic Markets.

Liu, Y., & Guo, K. 2011. “A novel cryogenic power cycle for LNG cold energy

recovery. Energy 36, 2828-2833.

Manning, P. 2012. LNG Prices Could Deflate on New Fields. Accessed on

http://www.smh.com.au/business/lng-prices-could-deflate-on-new-fields-

20121219-2bn73.html, at: September, 18th 2014. Australia: The Sydnes

Morning Herald.

Perry, Robert H. 1999. Perry’s Chemical Engineers’ Handbook. McGraw-Hill

Companies, Inc.

Picutti, E. 1970. The LNG Terminal at La Spezia. Proceedings of the Second

International Conference and Exhibition on LNG: Paris.

Rigola, M. 1970. Recovery of Cold in a Heavy LNG. Proceedings of the Second

International Conference and Exhibition on LNG: Paris.

Robin, Smith. Chemical Process Design and Integration. 2nd

Edition. Centre of

Process Integration, University of Manchester, UK.

Zafri, M. 2013. Cold Energy Utilization from LNG Regasification. Malaysia:

Universiti Teknologi Petronas.

tk6 revised assignment4

Documents

plant location

d plant layout

area plant layout

hse management

emergency action plant

plant control design

enviromental management

water cooling waste