PROCESS ENGINEERING
DOCUMENT NO.
OPERATION AND CONTROL
PHILOSOPHY
FMLP-LNG-GTL-DED-PROBSDG-002
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OWNER
:
PT. LIKUID NUSANTARA GAS
CONTRACTOR
:
PT GT LADANG TEKNIK
PROJECT NAME
:
DED FOR MINI LNG PLANT
LOCATION
:
PASURUAN INDUSTRIAL ESTATE REMBANG
CONTRACT NO.
:
002/SPK-LNG/QS-MEPI/XII/2023
0
29 Feb 2024
Issued for Construction
NGA
AI
UT
B
11 Jan 2024
Issued for Approval
NGA
AI
UT
A
02 Jan 2024
Issued for Review
NGA
AI
UT
PREPARE
REVIEW
APPROVED
REV
DATE
DESCRIPTION
PT GT LADANG TEKNIK
REVIEW
APPROVED
PT. LIKUID
NUSANTARA GAS
DED FOR MINI LNG PLANT
DOCUMENT NO.
OPERATION AND CONTROL
PHILOSOPY
FMLP-LNG-GTL-DED-PROBSDG-002
REVISION
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REVISION CONTROL SHEET
REV
DATE
PAGE
A
02 Jan 2024
All
First Issuance.
B
11 Jan 2024
8
Updated Capacity LNG Loading Pump to 40 m3/h.
11
Updated Diesel Fuel System.
12
Updated Water Treatment Plant.
All
Issued for Construction.
0
29 Feb 2024
DESCRIPTION
DED FOR MINI LNG PLANT
DOCUMENT NO.
FMLP-LNG-GTL-DED-PROBSDG-002
OPERATION AND CONTROL
PHILOSOPY
REVISION
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TABLE OF CONTENT
1.
2.
3.
4.
5.
GENERAL ........................................................................................................................... 4
OBJECTIVE ........................................................................................................................ 4
DEFINITION AND ABBREVIATION .................................................................................... 4
3.1 Definition ................................................................................................................... 4
3.2 Abbreviation .............................................................................................................. 5
PROCESS DESCRIPTION .................................................................................................. 5
OPERATION AND CONTROL PHILOSOPY ....................................................................... 6
5.1 Natural Gas Pipeline and Metering .......................................................................... 6
5.2 Amine System ........................................................................................................... 7
5.3 Dehydration System (ZPTS) ..................................................................................... 7
5.4 Liquefaction System (Cryobox) ............................................................................... 8
5.5 LNG Storage Tank .................................................................................................... 8
5.6 LNG Loading Pump .................................................................................................. 8
5.7 LNG Filling Pump (VGL Bottle) ................................................................................ 9
5.8 LNG Filling Station ................................................................................................... 9
5.9 VGL Filling Station .................................................................................................... 9
5.10 Vent Stack ............................................................................................................... 10
5.11 Instrument Air System............................................................................................ 10
5.12 Fire Water System .................................................................................................. 11
5.13 Diesel Fuel System ................................................................................................. 11
5.14 Utility Water System ............................................................................................... 11
DED FOR MINI LNG PLANT
DOCUMENT NO.
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1.
OPERATION AND CONTROL
PHILOSOPY
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GENERAL
PT. Likuid Nusantara Gas (PT LNG) plan to build Mini LNG Plant. The Plant capacity is 2.5
MMSCFD with a future capacity of 5.0 MMSCFD. The Plant is design to process natural gas
by separating the impurities and liquify it into LNG. The plant also have 40 ft Isotank filling
station and also have VGL filling station.
The plant located in Pasuruan Industrial Estate Rembang, East Java. The plant location is
stated in picture below.
Picture 1.1 Mini LNG Plant Location
2.
OBJECTIVE
This document is developed as Operation and Control Philosophy for Mini LNG Plant
Pasuruan owned by PT Likuid Nusantara Gas.
3.
DEFINITION AND ABBREVIATION
3.1
Definition
OWNER
: PT LIKUID NUSANTARA GAS
PROJECT NAME
: MINI LNG PLANT PASURUAN
CONSULTANT
: PT GT LADANG TEKNIK
CONTRACTOR
: The party that appointed by PT LNG to execute and to
complete procurement and construction works.
VENDOR
: The party which supply materials, equipment, technical
document/ drawing, and service to perform the duties by
PT LNG or Contractor.
DED FOR MINI LNG PLANT
DOCUMENT NO.
FMLP-LNG-GTL-DED-PROBSDG-002
OPERATION AND CONTROL
PHILOSOPY
MIGAS
REVISION
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: The Indonesians government agency responsible for
issuing operating and management permits for Oil and
Gas facilities.
PT PGS
: PT Penta Gas Solusi, Technology Provider that supply
Mini LNG Plant main process.
Certification Agency
3.2
4.
: Third Party Inspection Agency as MIGAS representative.
Abbreviation
CO2
: Carbon Dioxide
DEG
: Diesel Engine Generator
H2S
: Hydrogen Sulfide
LNG
: Liquefied Natural Gas
MEA
: Monoethanolamine
PSV
: Pressure Safety Valve
RO
: Reverse Osmosis
VGL
: Vertical Gas Liquid
PROCESS DESCRIPTION
PT. Likuid Nusantara Gas (PT LNG) will build Mini LNG Plant in Pasuruan, East Java. The
capacity shall be 2.5 MMSCFD with future expansion plans to 5 MMSCFD. Natural gas to be
converted into LNG will be supply by two company that is PT Isar Gas (ISAR) and Husky-CNOOC
Madura Limited (HCML). Gas from ISAR and HCML is transferred via transmission line owned
by PT Pertamina Gas (Pertagas). PT LNG shall connect to Future Connection at Pertagas facility
near PT LNG area. PT LNG shall build 4 inch pipeline to transfer natural gas to the LNG Plant.
Prior entering the Mini LNG Plant, natural gas shall be measured using Metering System. The
Metering system shall be ISAR’s Metering and HCML’s Metering. The gas pipeline contains
impurities such as CO2, H2S, and solid particles which needs to be removed prior to entering the
Liquefaction System.
After measured in Metering System, the gas shall enter gas sweetening process called Amine
System, to remove CO2 and H2S. Amine system shall capture CO2 and H2S using MEA solution
in Absorber Column by contacting the Gas with the MEA solution that called Lean MEA. MEA
solution that absorbed CO2 and H2S shall be called rich MEA. The rich MEA solution is
regenerated and recycled to Absorber Column. A small make up of MEA solution is expected to
ensure the concentration and quality of the solution meet the requirement.
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The sweet natural gas then enters to Dehydration System called ZPTS. ZPTS shall reduce water
content in the sweet natural gas because it can cause blockage in Liquefaction System. ZPTS
shall use Molecular Sieves as medium to adsorb water. Molecular Sieves are also can be used
to capture Mercury in the gas. The Molecular Sieves are contained in 2 vessels of dehydration
unit which runs one in operation and another in regeneration.
After completing the dehydration process, the gas shall be liquefied in Cryo Box. Cryo Box use
Propane as refrigerant to liquefy the clean natural gas. There will be 3 Cryo Boxes to be used to
liquefy the gas for 2.5 MMSCD and additional 2 Cryo Boxes for future expansion to 5.0 MMSCFD.
The liquid natural gas is now stored in storage tanks which uses iso-tanks. There are 2 iso-tanks
which are each dedicated for iso-tank filling system and VGL filling system. The LNG in iso-tank
for filling system is pumped to boost the pressure to a loading bay. At this loading bay, the LNG
is loaded to the mobile iso-tanks. In case the pump does not operate due to maintenance or other
problem, the loading bay takes the LNG directly from the storage tank. The LNG in iso-tank for
VGL system is pumped using LNG Pumps with 2x100% capacity.
Any BOG created during the operation is sent back to Cryo Box for re-liquefaction.
Utility systems to ensure a smooth liquefaction plant are supplied in the LNG Plant. Water utility
system takes the raw water supplied and stored in a raw water tank. The water is distributed by
water distributed pumps to water utility tank, to a water treatment facility which then the water is
used for boiler and make up solution for processing area, to fire water system, and to other areas
that required water. Instrument air system supply the compressed air used in the plant.
The plant also has equipment to cope with emergency situation. A cold vent stack system is used
to release the gas to safe area in case of overpressure or another emergency situation. A fire
fighting system such as fire pumps and fire hydrants are also available for any fire emergency
case.
5.
OPERATION AND CONTROL PHILOSOPY
5.1
Natural Gas Pipeline and Metering
PT LNG shall connect to 12 Inch Future Connection at Pertagas facility near PT LNG area. PT
LNG shall build 4 Inch pipeline to transfer natural gas to the LNG Plant. At tie-in point, there will
be Pressure Transmitter dan Temperature Transmitter to monitor Natural Gas operating
condition that enter PT LNG facility. At pipeline tie-in point will also be equipped with check valve
to prevent back flow to the Pertagas Facility. This gas flows at a pressure of 34.5 Barg at
temperature around 32oC.
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The pipeline shall be equipped with Insulation Flange to divide the above ground and
underground pipeline. In case of emergency such as over pressure is detected by the
transmitter, a shutdown valve is designed to close automatically to protect the equipment
downstream. A PSV is also available in case of emergency to vent the gas to cold vent system.
Custody Metering system shall be Orifice type. Metering system is design 2x100% as
redundancy. Each metering shall be equipped with Flow Computer to calculate the gas
entering the system. Metering also equipped with three pen recorders (pressure, temperature
and flow). Metering also completes with Flow Conditioner to prevent turbulence prior entering
the metering that result in an error in the reading.
5.2
Amine System
After measured in Metering System, the gas shall enter gas sweetening process called Amine
System, to remove CO2 and H2S. Gas that contains CO2 and H2S often called sour gas. In Amine
System sour gas will enter Absorber Column from the bottom, and MEA shall be entered from
the top, this MEA called Lean MEA. When sour gas and MEA contacted, MEA shall absorb
CO2 and H2S from the gas. The MEA that contains CO2 and H2S shall be called Rich MEA. Rich
MEA then shall enter Stripper column, and then heat up using steam. When temperature is high
enough MEA shall release the CO2 and H2S, Then MEA shall be transferred again to Absorber
Column as Lean MEA. The waste gas shall be vented to safe area.
The downstream of amine system is equipped with a shutdown valve in case a pressure
transmitter detects an overpressure which also protects the equipment downstream of amine
system.
5.3
Dehydration System (ZPTS)
The dehydration system (ZPTS) removes other impurities but mainly is water and humidity in
the gas. This water content tends to be a problem in the liquefaction system. ZPTS shall use
Molecular Sieves as medium to adsorb water. ZPTS shall consist of 2 (two) Adsorption column
minimum to ensure the system can run continuously. First column shall operate as adsorber and
second column shall operate as regenerator to recover its molecular sieves. To prevent the
molecular sieve damage by others impurities, ZPTS equipped with prefilter. Also, to prevent
molecular sieve dust carry over to Cryobox After Filter shall be also installed.
Any emergency in this package, a venting line is utilized to sent the gas to the cold vent system
for discharge.
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5.4
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Liquefaction System (Cryobox)
The liquefaction system (Cryobox) utilizes cryogenic refrigeration to bring the gas to its liquid
state. 3 Cryobox shall be installed to meet the capacity 2.5 MMSCFD and additional 2 Cryo
Boxes for future expansion to 5.0 MMSCFD. Cryoboxes shall use Propane as refrigerant.
Inside Cryobox, the natural gas is condensed into liquid form by reducing its temperature to
approximately -144 – -140 oC at pressure ±3 Barg.
Cryobox shall be equipped with gas reliquification system that reliquefy BOG that generated
in others system.
Cryobox also complete with Mass Flow Meter, to monitor LNG produce in the system. In case
of emergency, PSV shall be installed in the package to send the gas to the venting system.
5.5
LNG Storage Tank
The LNG storage tank is uses two horizontal iso-tank 60 ft with capacity 60 m3, one tank is
used dedicated for the unloading process to the Iso-tank (Truck) and one tank is used
dedicated for filling VGL. The LNG storage tank has a level indicator to monitor the liquid
level in the vessel. This indicator tells when the filling pump to stop in case of Low Level in
the storage tank. It also has a pressure indicator to let the operator maintain the pressure in
the tank. In case of low pressure, a certain amount of LNG is vaporized using the built-in
vaporizer, whereas in case of high pressure, the BOG is sent back to the cryobox. However,
in case of overpressure, a PSV is available to release the BOG to the cold vent.
5.6
LNG Loading Pump
LNG Loading Pump is designed to transfer LNG to Iso-tank truck from LNG storage tank.
The pump is intalled 1x100% with flowrate 40 m3/h. LNG Loading Pump is connected to
Variable Speed Drive (VSD) to control the flowrate. VSD will control the flowrate through the
rotation speed. VSD will allow operator to set capacity value of pump within operating range
provided by pump manufacturer or control using PLC. LNG Loading Pump is equipped with
Y strainer at suction to minimize the debris carry over to pump. Also, check valve is intalled
at pump’s downstream to prevent backflow which can damage the pump. LNG Loading Pump
is equipped with PT for LL setting, PT for HH setting. PT for LL shall protect the pump from
cavitation. PT for HH shall protect discharge line from over pressure
SDV shall be installed to protect the downstream equipment from over pressure. SDV also
shall protect for overfill in Iso-tank.
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LNG Filling Pump (VGL Bottle)
LNG Filling Pump is intalled 2x100% with flowrate 5,6 m3/h. VGL Transfer Pump is connected
to Variable Speed Drive (VSD) to control the flowrate. VSD will control the flowrate through
the rotation speed. VSD will allow operator to set capacity value of pump within operating
range provided by pump manufacturer or control using PLC. LNG Filling Pump is equipped
with Y strainer at suction to minimize the debris carry over to pump. Also, check valve is
intalled at pump’s downstream to prevent backflow which can damage the pump. LNG Filling
Pump is equipped with PT for LL setting, PT for HH setting. PT for LL shall protect the pump
from cavitation. PT for HH shall protect discharge line from over pressure.
SDV also shall be installed to protect the downstream equipment from over pressure.
5.8
LNG Filling Station
LNG Loading Pump is design to transfer LNG to Isotank at Filling Station. There will be 2
loading bay that will have 2 connections for LNG and 2 connections for BOG. This 2 Loading
Bay can serve 2 trucks at the same time.
Filling Station shall be design to serve iso-tank with capacity 40 m3 (40 ft). The iso-tank also
has a grounding system to avoid any electric static during the operation.
Filling station is received LNG from LNG Transfer Pump. When the LNG Transfer Pump are
tripped, LNG transfer shall be done to Isotank directly from Cryobox.
Filling Isotank shall be done manually. To start transferring, operator must be standby at
Isotank area. After all required connection and inspection already done the transfer sequence
can be start. Operator shall start LNG Transfer Pump using push button at Isotank Area.
Operator shall monitor LNG level inside Isotank. Once the level is full and pressure required
is achieved the pump shall be stopped. The BOG produce shall be sent back to the Cryobox.
5.9
VGL Filling Station
The VGL Filling Station is design to be filled using LNG Filling Pump. VGL Filling Station is
designed to fill 8 (eight) VGL at the same time. VGL capacity shall be 175 L each.
VGL filling shall be done manually. To start transferring, operator must be standby at VGL
Filling area. After all required connection and inspection already done the transfer sequence
can be start. Operator shall start LNG Filling Pump using push button. Operator shall monitor
the weight of VGL. Once the weight of VGL indicated full and pressure required is achieved
the pump shall be stopped. The pump shall not immediately stop, but the flowrate shall
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decrease until all VGL Filling Bay is stop operating. The BOG produce shall be sent back to
the Cryobox.
5.10 Vent Stack
In the case of emergency, the natural gas is fed to a Vent system. Vent Stack is designed to be
release point to environment. Vent Stack is design as efficient as possible to minimize noise and
maximize gas dispersion. Velocity gas that releases from the stack shall help gas dispersion in
environment. Vent Stack height shall be designed so nearby facility shall not affected by released
gas. All valve connected to vent system shall be normally open to allow sudden release as
emergency situation occurred.
5.11 Instrument Air System
Instrument air for pneumatic driver is supplied from Air Compressor Package. The Air
Compressor Package consist of 2 (two) Air Compressor with lead-lag operation mode, Air
Dryer and Air Receiver.
Air Compressor will compress the air to pressure 140 Psig. To cool down the compress air
near ambient temperature, Air Cooler is installed at discharge Air Compressor.
Air Dryer Package is installed at downstream Compressor to reduce dew point of compress
air to -15 oC minimum. The Air Dryer Package consists of Pre Filter, Air Dryer and After Filter.
The compress air will flow to Pre Filter first to remove particulate carried by the air. Then the
air will enter Dessicant Air Dyer to reduce water vapor composition. After that the dried air
will flow to Post Filter to remove Air Dyer particulate carried at drying process.
After drying process is complete the compressed-dried air will be stored at Air Receiver. Air
Receiver can store air for 15 minutes operation with range pressure from 140 Psig to 105
Psig. Air Receiver is also connected with Liquid Trap to prevent liquid built up in the vessel.
Air compressor is equipped with a function of loading and unloading. When the discharge
pressure reaches to the set point of unloading (cut-out pressure), the compressor shall be
unloaded. When the discharge pressure reaches the set point of loading (cut-in pressure),
the compressor shall be loaded. Motor for the air compressor package shall stop if the
pressure will not decrease to the set point of loading for a certain pre-determined period of
time after unloading. And when pressure drops to the set point of loading (cut-in pressure),
motor for the air compressor shall be started and loaded automatically.
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The two air compressors package shall be operated in lead-lag mode which shall be provided
with compressor package. In normal condition, one (1) compressor shall be operated as duty
(lead), and the other shall be standby (lag).
5.12 Fire Water System
Mini LNG Plant shall be equipped with Fire Water System. Fire Water system shall consist of
one (1) Fire Water tank, two (2) Diesel Engine Driven Fire Water Pump, one (1) Jockey Pump.
Fire Water system is designed for cooling purpose only. Water for fire fighting shall be using
fresh water.
Fire fighting in all area using Hydrant and only two (2) Hydrant can be operated at the same
time.
Fire Water Tank is used to supply fire water during emergency condition. The tank is design
to be atmospheric flat cone roof type. Level gauge shall be installed to monitor its water level.
Utility water shall be use as make up water if the level decrease. First filling shall use water
truck.
Fire Water Pump is design with discharge pressure of 8 Barg. Jockey Pump shall be used to
maintain pressure in Fire Water Ring at 7 Barg minimum. If the pressure drop at certain
condition, Fire Pump A shall be start automatically. Once started, fire pump cannot be stop
remotely. Operator have to stop it manually.
5.13 Diesel Fuel System
Diesel will be used as fuel oil for Emergency Diesel Generator and Fire Pumps. Diesel Fuel
will be supplied to the plant by supplier. Then, it will be stored at Diesel Daily Tank at
Emergency Diesel Generator and Diesel Fire Pumps.
5.14 Utility Water System
Utility water shall be used to provide service water to all consumers (utility stations, buildings,
etc.) in the plant. The water will be provided by PIER via a water pipeline and equipped with
flowmeter.
Utility water from PIER shall be stored inside Utility Water Tank with using 2x100% utility
water booster pump. Utility water from utility water tank is distribute using 2x100% utility water
pump with capacity 5 m3/h. This pump shall distribute water to fire water tank, utility water
tank (service water), water treatment plant.
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The fire water tank is designed to hold fire water tank and the level of the water should be
maintained at any time. A make up water is supplied to the tank to compensate the water lost
due to evaporation.
Utility water tank supplies water for daily human needs such as toilet and pantry. This water also
supplies to office, warehouse and B3 Storage areas. The tank is placed in an elevation thus the
water flows by gravity.
The water treatment plant processes raw water using ion exchange to remove of essentially all
inorganic salts to met quality of demin water. The demin water is used for processing purposes
such as for make up MEA solution and feed to the boiler.
The boiler is used as heating media for processing area. The demand from the steam comes
from the processing area to supply as heating source. The water in the boiler must be maintained
to prevent overheating and any other fire hazard.