Condensate Stabilization Unit (1)

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PT. Brown & Root Indonesia

Doc. No. 11-IOM-PS-1201 Rev. 6A

Project TLNG Author’s Org. KJP

KJP Doc. No. S-011-1283-001 Date 18-May-06 KJP Job Code J-3400-20-0000 Sheet 1 of 24

X Core Non-core Lifecycle Code A

For Information For Review For Approval X Released As-Built

Rev. Date Page Description Prep’d Chk’d App’d BP App’d

5A 3-Mar-06 All Issue for Approval Winanto Y.Kakutani Y.Kakutani

6A 18-May-06 All Issue for Release Winanto Y.Kakutani Y.Kakutani

3.8 MTPA TRAIN CAPACITYOperation Manual for Condensate Stabilization Unit

BPMIGAS

TANGGUH LNG

BP Berau Ltd.

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Doc. No. 11-IOM-PS-1201KJP Doc. No. S-011-1283-001 Rev. 6ASheet No. 2 of 23 Operation Manual for Condensate Stabilization Unit

BP Berau Ltd. Tangguh LNG Project

CONTENTS

1. Introduction.................................................................................................................................4 2. Basis of Design.............................................................................................................................4

2.1 General.........................................................................................................................................4 2.2 Design Margin .............................................................................................................................4 2.3 Design Condition.........................................................................................................................4 2.4 Special Equipment ......................................................................................................................5 2.4.1 CONDENSATE STABILIZER COLUMN (011-T-1001A/B) ............................................................. 5 2.4.2 CONDENSATE STABILIZER R EBOILER (011-E-1001A/B)............................................................ 5 2.4.3 CONDENSATE PRODUCT COOLER (011-E-1002) ........................................................................ 5 2.5 Process Description.....................................................................................................................5

3. Process Controls..........................................................................................................................6 3.1 Pressure........................................................................................................................................6 3.2 Temperature................................................................................................................................6 3.3 Level .............................................................................................................................................7

4. Preparation for initial start-up ..................................................................................................7 5. Normal Start-up Procedure .......................................................................................................8

5.1 General.........................................................................................................................................8 5.2 Start up of Condensate Stabilization Unit ................................................................................8 5.2.1 START UP OF STABILIZER R EBOILER (011-E-1001A/B)............................................................. 8 5.2.2 START UP OF CONDENSATE STABILIZER COLUMN (011-T-1001A/B)........................................ 9

6. Normal Operation.....................................................................................................................10 6.1 Condensate Stabilization Unit..................................................................................................10 6.2 Removing Accumulated Water on Trays................................................................................10

7. Normal Shutdown Procedure ..................................................................................................11 7.1 Condensate Stabilizer Switching Operation...........................................................................11 7.2 Condensate Product Cooler Shut down..................................................................................13

8. Emergency Shutdown Procedure ............................................................................................14

8.1 General.......................................................................................................................................14 8.2 Loss of Utilities ..........................................................................................................................14 8.2.1 POWER FAILURE ....................................................................................................................... 14 8.2.2 I NSTRUMENT AIR FAILURE ....................................................................................................... 14 8.2.3 STEAM FAILURE ....................................................................................................................... 14

9. Safety Procedure.......................................................................................................................14 9.1 General.......................................................................................................................................14 9.2 Emergency Fire Plan ................................................................................................................15 9.3 Fire Fighting and Protective Equipment ................................................................................15 9.4 Maintenance of Equipment and Housekeeping......................................................................16 9.5 Repair Work..............................................................................................................................16 9.6 Withdrawal of Samples ............................................................................................................17 9.7 Safe Handling of Volatile and Toxic Materials ......................................................................17 9.8 Respiratory Protection .............................................................................................................17 9.9 Breathing Apparatus (B. A.) ....................................................................................................18 9.9.1 N ITROGEN ................................................................................................................................ 18 9.9.2 CORROSIVE MATERIALS ........................................................................................................... 18

10. Isolation Procedure for Maintenance......................................................................................18 10.1 General ......................................................................................................................................18 10.2 Basic Procedures.......................................................................................................................19 10.2.1 TRAIN ISOLATION .................................................................................................................... 19 10.2.2 I NDIVIDUAL EQUIPMENT / SYSTEM ISOLATION ........................................................................ 19

Vertical Pressure Vessels (Column with Reboiler).......................................................................... 19 11. Maintenance Procedure............................................................................................................20

11.1 General ......................................................................................................................................20 11.1.1 R OUTINE /F IRST LINE / MAINTENANCE ...................................................................................... 20 11.1.2 BREAKDOWN MAINTENANCE .................................................................................................. 20 11.1.3 PLANNED PREVENTIVE MAINTENANCE ................................................................................... 20

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11.1.4 PREDICTIVE /CONDITION BASED MONITORING ........................................................................ 20 11.1.5 TURNAROUND /I NSPECTION MAINTENANCE ............................................................................ 20 11.2 Precautions prior to Maintenance...........................................................................................21 11.3 Preparation for Maintenance ..................................................................................................21 11.3.1 I NSTALLATION OF BLANK FLANGES OR SPADES ....................................................................... 21 11.3.2 STEAM PURGING PRIOR TO MAINTENANCE ............................................................................... 21 11.3.3 PURGING NITROGEN WITH AIR ................................................................................................. 22 11.4 Typical isolation method ..........................................................................................................22 11.4.1 VESSELS /DRUMS ...................................................................................................................... 22 11.4.2 SHELL AND TUBE TYPE HEAT EXCHANGERS ........................................................................... 22 11.4.3 CLOSE OUT ............................................................................................................................... 22

12. Attachment List.........................................................................................................................23

Attachment-1 Process Flow DiagramAttachment-2 P&IDsAttachment-3 Equipment Data Sheet (List only)Attachment-4 Instrument Alarm Set Point (List only)

Attachment-5 Cause and Effect Charts (List only)Attachment-6 Laboratory Sampling ScheduleAttachment-7 Material Safety Data Sheets (Later)

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1. INTRODUCTION

The purpose of the Condensate Stabilization Unit (Unit 011) is to stabilize hydrocarbon condensatefrom Onshore Receiving Facility (Unit 016) and Dehydration and Mercury Removal (Unit 031) tomeet the product specification, such as Reid Vapor Pressure (Max. 0.77 kg/cm [email protected]°C) and also

butane content (0.5 % liquid volume max.). Total 30 ton/h condensate is produced .

The Condensate Stabilization Unit is designed for two LNG trains capacity. The CondensateStabilization Unit consists of two columns and their associated equipment ( as spare) to prevent plantshutdown during maintenance of this unit.

Feed to the unit is condensate from ORF (Unit 016) and Dehydration and Mercury Removal Unit(Unit 031/032). Feed to the column is two-phase flow.

Condensate Stabilization Unit also produces flash gas with high methane content (75-%mol). The

flash gas from the overhead line of Stabilizer Column is sent to LP Fuel Gas System for furthertreatment.

Refer to Process Flow Diagrams Unit 011 Condensate Stabilization, drawings no:11-PFD-PS-1150/1151/1152/1153 (D-011-1223-101/102/103/104).

2. BASIS OF DESIGN

2.1 General

Please refer to S-900-1220-001 for general design data.

The Condensate Stabilization Unit is designed for two LNG Trains capacity.

The Condensate Stabilization (Unit 011) consists of:- Condensate Stabilizer Column (011-T-1001A/B)- Condensate Stabilizer Reboiler (011-E-1001A/B)- Condensate Product Cooler (011-E-1002)- Water Draw-off Drum (011-D-1002A/B)

2.2 Design Margin

Please refer to refer to S-099-1222-111 for design margin of Unit 011.

2.3 Design Condition

- Condensate source Hydrocarbon condensate from ORF includes dynamic slug of 1400 BPD (9.27m 3/h)

@ feed condition of 50 oC, 62.55 kg/cm 2A. Hydrocarbon condensate from Unit 031 and Unit 032, with design flow is 32 13

ton/h. All feed condition is two-phase flow.

- Product specification:The specifications of condensate product after Condensate Product Cooler are:

RVP @ 37.8 oC (100 oF) : 0.77 kg/cm 2A (10.95 psia) Max butane content : 0.5 %-liquid volume.

- Flow rate (one unit): Feed : 32,083 kg/h

Feed from Unit /31/032 : 13 ,017 kg/h

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Feed from ORF (Unit 016 w/o slug) : 12 ,716 kg/hSlug flow from Unit 016 : 6 ,350 kg/h (1400 BPD)

Condensate Product : 29,797 kg/h Overhead Flash Gas : 2,286 kg/h

- Operating Condition:Unit 011 is part of ORF liquid phase treatment. Unit 011 operating condition dependson ORF arrival feed gas condition as follows (Please refer to 16-IOM-PS-1201 Section2.3.1): There are four operating conditions that depend on ORF (Unit 016) feed gascondition:

50oC, 62.55 kg/cm 2A 26oC, 62.55 kg/cm 2A 74oC, 62.55 kg/cm 2A 26oC, 102.98 kg/cm 2A

The ORF feed gas condition of 50 oC, 62.55 kg/cm 2A is expected as normal operating

condition.

HC condensate product condition is maintained at 40 oC, 7.03 kg/cm 2A.

2.4 Special Equipment

Please refer to equipment data sheets for detail information.

2.4.1 Condensate Stabilizer Column (011-T-1001A/B)

No of equipment : 2

Type : Tray column (total 8 trays)

Capacity : 30 ton/h of condensate product

2.4.2 Condensate Stabilizer Reboiler (011-E-1001A/B)

No of equipment :2

TEMA Type : BKU (Kettle type)

Design Heat Duty : 3696 kW

2.4.3 Condensate Product Cooler (011-E-1002A/B)

No of equipment : 1*

Type : Forced draft

Cond. Prod. Temp. : 40 oC

Note:

*: 011-E-1002 consists of two tube bundles for easy maintenance.

2.5 Process Description

Hydrocarbon condensate from ORF (Unit 016), Dehydration and Mercury Removal (Unit 031) arecombined at upstream of Condensate Stabilizer Columns (011-T-1001A/B) branch point.

This combined feed, which is two-phase flow, is introduced to the top of 011-T-1001A (or011-T-1001B). Only one column will be operating at a time. Feed condensate is flowing to the

bottom trays and collected on the chimney tray. The total draw off nozzle (on chimney tray) directsall liquid to Stabilizer Reboiler, 011-E-1001A (or 011-E-1001B).

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In the Stabilizer Reboiler, liquid is heated and partially vaporized by HP saturated steam. The vapor isreturned back to the column under the chimney tray and passes back up the column. During passingthe trays, returned vapor is stripping the lighter components from the liquid flowing down thecolumn.

In the reboiler, the saturated liquid is in equilibrium with the vapor. The overflow liquid is returned back to the bottom of the column as condensate product.

The Stabilizer Columns (011-T-1001A/B) operate at 6 kg/cm 2G 7.03 kg/cm 2A under pressurecontrol. The hydrocarbon vapor from the top of the 011-T-1001A/B is sent to the LP Fuel Gas Systemwithout cooling since the temperature of this vapor is about 38 °C.

To meet the product specification, the temperature of the liquid hydrocarbon is controlled with aTC-FC cascade control of steam supply line.

The high pressure saturated steam (HPSAT) (38 kg/cm 2A) is utilized as a heating medium. HP SATis generated prior to Stabilizer Reboilers (011-E-1001A/B) entering. Boiler feed water is injected in011-DPH-1001 and mixed with superheated HP steam to produce high pressure saturated steam.

The steam condensate flow returned to HP Steam Condensate KO Drum (052-D-1104 and051-D-1104) on each LNG train. The returned steam condensate flow is maintained by individualLC-FC cascade control. During two LNG trains operation, the steam condensate flow to each train ismaintained evenly.

The stabilized condensate product from the bottom of 011-T-1001A/B flows to the CondensateProduct Cooler (011-E-1002) under level control to cool down its temperature to 40 oC. At the initialstage of Unit 011 start up, off-spec condensate product is expected. The condensate quality ismonitored by online RVP Analyzer 090-AI-1801. When RVP is high, it means off-speccondensate is produced, Tthe off-spec condensate product shall be routed to wet flare.

After the stabilized product condensate is cooled down to around 40°C by 011-E-1002, it is combinedwith the hydrocarbon condensate product from the Debutanizer bottom in the Fractionation Unit(Unit 041/042). The combined condensate product is sent to and stored in the Condensate Storage

Tank (076-TK-1001).Water accumulation is expected on tray during operation. Top section trays have higher possibility ofwater accumulation because of lower operating temperature. The accumulated water shall beremoved by using water draw off facilities (on the 3 top trays). The oily water to be collected in thewater draw off drums (011-D-1002A/B) shall be sent to Wet Flare KO Drum (086-D-1002).

3. PROCESS CONTROLS

Process controlling purpose is to maintain on-spec condensate production.

The parameters to be controlled during operation are:- Pressure

- Temperature

- Level

3.1 Pressure

The operating pressure of 011-T-1001A/B and 011-E-1001A/B is 6 kg/cm 2G 7.03 kg/cm 2A .011-PV-1201/1221, installed on overhead line, controls the operating pressure of CondensateStabilzer Column ( 011-T-1001A/B ), respectively. Feed forward pressure controlling is applied.

3.2 Temperature

Stabilizer bottom temperature to be maintained at around 207 oC to vaporize water and lighterhydrocarbon to reduce the HC condensate vapor pressure . HP saturated steam is used as heatingmedium. The TC (Column temperature)-FC (steam flow) cascades are selected to control Stabilizer

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Reboiler temperature by controlling steam supply to Stabilizer Reboiler. Split range controller isadopted applied because of wide operating range of heat duty.

011-FV-2710A/B, located on the HP steam supply line to Stabilizer Reboiler A (011-E-1001A),controls the various HP steam flow demand from turndown operation in one LNG train to slug

flow handling in two LNG trains operation. When the HP steam flow is less than 20% of designflowrate, 011-FV-2710B controls small amount of flowrate. When HP steam flowrate isbetween 20% and 100%, 011-FV-2710A control the steam flowrate, while 011-FV-2710B is infully open. 011-FV-2710A/B, located on the HP steam supply line to Stabilizer Reboiler B(011-E-1001B) is also used in the same manner as a completely spare stabilizer.

There are three locations (for each stabilizer) for temperature transmitter, which are:

- Stabilizer Tray #8 :011-TE-1471/1342

- Stabilizer vapor return line : 011-TE-1304/1334

- Stabilizer liquid return line : 011-TE-2710/1341

The criteria to select most sensitive temperature are as follow:

1. During Stabilizer Column start up, heat duty is increased in accordance with feed flowrate,therefore 011-TE TIC -1471/1342 to be selected.

2. During steady operation, 011-T IC-2710/1341 to be selected.

3. Urgently on spec production is required during Stabilizer Column upset condition,011-TI-1303/1333 or 011-TIC-1304/1334 to be selected.

The temperature transmitters selection shall use 011-HS-1501 for Condensate Stabilizer A and011-HS-1521 for Condensate Stabilzier B.

The HC condensate from Stabilizer Column (011-T-1001A/B) is cooled down to around 40 oCby Condensate Product Cooler (011-E-1002). The condensate product temperature ismonitored by 011-TI-9301. The lower temperature of HC condensate is safer for handling and

storage. Therefore all fin fan motors of Condensate Product Cooler (011-E-1002) should bealways in operation When temperature is higher than 50 oC, the operator has to investigate011-E-1002 to eliminate the high temperature cause.

3.3 Level

Stabilization unit has no pump to transfer condensate to Condensate sStorage t Tank (076-TK-1001).011-LV-1101 controls liquid level in 011-T-1001A/B. When level decrease to LLL, 011-LV-1001will close, to prevent vapor breakthrough to downstream facilities.

The liquid level in 011 D-1001A/B is controlled by LC-FC cascade control of 011-FV-1011A/B and011-FV-1031A/B respectively. The steam condensate flow distribution to LNG train is set by

011-HIC-1011 by adjusting “

” parameter . The “

” parameter shall be set as follow:- When two LNG trains operate, the set point shall be set to 0.5 to distribute steam

condensate evenly to both HP Steam Condensate Drums (051-D-1104 and 052-D-1104)

- When only LNG Train#1 operates, shall be set to 1.0.

- When only LNG Train#2 operates, shall be set to 0.0

4. PREPARATION FOR INITIAL START-UP

The Preparation for Initial Start-up is including the following steps:- Air Blowing Procedure

- Operational Tightness Test_ _ _ _ _

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- Inerting Operation

- Mechanical Run-in Procedure

- Safety Requirement

For the detail preparation for smooth initial start-up, R r efer to Commissioning Procedure(11-PRC-OP-1001).

5. NORMAL START-UP PROCEDURE

5.1 General

Check points are as follows:

(1) All equipment including instrument, etc. is ready for use.

(2) Electric power is available.

(3) All blinds or spectacle blinds except for Battery Limit have been placed in operation position.

(4) Ensure all vents, drains, and sample connections are closed.

(5) All safety equipment must be properly installed on site, calibrated and operable.

After all the above checkpoints have been checked, start-up can be proceeded. Start up check listshould be provided and signed by concerned operator.

5.2 Start up of Condensate Stabilization Unit

Unit 011 Condensate Stabilization Unit start up is proceeded before receives condensate from Unit016. The Stabilizer Reboiler (011-E-1001A or 011-E-1001B) and steam condensate line to HP SteamCondensate KO Drum (051-D-1104 or 052-D-1104) of each LNG Train have to be warmed up to

prevent line damage due to water hammering in the steam condensate lines. The start up of Unit 011is described below

5.2.1 Start up of Stabilizer Reboiler (011-E-1001A/B)

011-E-1001A Warming-up procedure.

Since at the initial start-up, Stabilizer ReboilerA (011-E-1001A) has no demand to be heated,very small amount of HP steam shall be introduced into Stabilizer Reboiler A (011-E-1001A) toprevent water hammering due to cold piping temperature from 011-FV-1011A (HP steamcondensate flow control valve) to Condensate Flash Drum (051-D-1104) and excessvaporization at Condensate Flash Drum (051-D-1104) due to large amount of vaporbreakthrough from 011-FV-1011A.

Reboiler has to be warmed up before receives condensate. 011-FV-2710A/B shall be in close position and bypassed. Open the 3” bypass line of 011-FV-1011A (or 011-FV-1031A) forsteam passing. Introduce steam through 4” bypass line of 011-FV-2710A/B at minimum flowto warm up the reboiler and condensate lines.

2.The LP steam will warm up the Stabilizer Reboiler. During initial start up of Stabilizer Reboiler,there is no demand (HC condensate) in the reboiler, therefore steam is not condensed and steamonly flows through the tube side. After passing Reboiler Condensate Drum, steam is delivered to051-D-1104.

Steam condensate line is wamed up during steam passing to 051-D-1104.

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The following are proposed procedure for Stabilzer Reboiler A warming-up.

a. Manipulate the set point of 011-FV-2710B in 011-FIC-2710. The very small HP steamflowrate (max 10% of normal flowrate) is introduced into Stabilizer Reboiler A(011-E-1001A).

b. Open 011-FV-1011A gradually at very small opening by manipulating the set point in011-FIC-1011A. Operator shall observe water hammering issue on the cold piping at thedownstream of 011-FV-1011A carefully. If water hammering is occurred, HP steamsupply and steam condensate flowrate shall be reduced.

a.Check the Stabilizer Reboiler temperature. When temperature reached the normal operatingtemperature, the condensate feed can be introduced into Stabilizer.

c. Once warm-up operation of HP steam condensate return line to Condensate Flash Drum(051-D-1104) is completed, the reboiler and associated piping temperature should bemaintained by manipulating the appropriate set point of 011-FV-2710B and011-FV-1011A until the feed is introduced to Condensate Stabilizer A (011-T-1001A).

5.2.2 Start up of Condensate Stabilizer Column (011-T-1001A/B)

Coordination with ORF Unit 016 is required during Condensate Stabilizer Column start up. Before HC condensate is introduced, the warm up operation of Condensate Stabilizer Reboiler (011-E-1001A) warming up has to be established (Sec. 5.2.1).

The following procedure is start up procedure for one stabilizer unit , with 011-T-1001A as anexample. .

(1) Confirm that the second standby stabilizer is well isolated before start up of first stabilizer.

Stabilizer is under nitrogen blanketing at slightly higher than atmospheric pressure.

(2) Confirm that pressure control valve ( 011-PV-1201 ) on overhead line of Stabilizer Column(011-T-1001A) and 011-LV-1101 are is in auto mode.

Set the overhead pressure control (011-PV-1201) to desired pressure setting (7.03 kg/cm 2A).

Confirm that stabilizer temperature control (TC-FC cascade) of 011-FV-2710A/B are turned toauto mode and close its bypass line.

Confirm that 011-FV-1011A is in auto mode and close its bypass line.

Line up the stabilizer overhead to wet flare by opening the 3” start up line (011-GF-1102) locateddownstream of 011-PV-1201.

Line up the stabilizer bottom to wet flare by opening 4” start up line (011-GH-1705) located

downstream of 011-LV-1101.(3) Turn on 011-E-1002 motor to cool down the condensate product. The number of operating

motor to be decided by referring to condensate product temperature (011-TI-9301).Normally, two motor fans are operating initially.

(3)(4) Confirm with Unit 016 that HC condensate from Condensate/Water Separator(016-D-1004 ) is ready to deliver and Stabilizer Reboiler (011-E-1001A) has been warmed up.

Turn 011-LV-1101 to auto mode.

Open the 12” LO valve (011-KIV-1001) on the main feed line (016-GH-1004) . Continuestabilizer condensate feeding into Stabilizer Column A (011-T-1001A) until the liquid reachesthe normal low liquid level . 011-LV-1101 located on downstream of 011-E-1002is operatedin auto mode .

(4)Turn on 011-E-1002 motor to cool down the condensate product. The number of operating motorto be decided by referring to condensate product temperature (011-TI-9301).

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(5) When temperature, pressure and level of 011-T-1001A are in normal condition, line up theoverhead gas product to LP fuel gas system. Open the block valve located downstream of011-USVE-2060 and then close gradually the 3” line to wet flare (011-GF-1102) .

(6) Check the condensate product specification by sampling check (011-SCA-1002) located

around 011-LV-1101 . When on-spec condensate is produced, line up the bottom product tocC ondensate s Storage t Tank (076-TK-1001) by open ing the block valve located downstream of011-USVE-2070 and close the 4” line to wet flare (011-GH-1705) .

6. NORMAL OPERATION

6.1 Condensate Stabilization Unit

Condensate s Stabilization u Unit (Unit 011) is designed for 4 operating conditions. Feed and productconditions depend on the ORF (Unit 016) feed condition. The condensate product quality is kepton-spec condensate under all operating condition.

The condensate source are form from ORF and Unit 031. The condensate from Unit 016 mainly isfrom 016-D-1004 which produces about 15 ton/h condensate. The max condensate flowrate (20ton/h) is at ORF feed condition of 26 oC and 62.55 kg/cm 2A.

The main condensate source from Unit 031 is 031-D-1001 (Dehydration Precooler Separator) withcondensate flowrate is 12.4 ton/h.

The quality of condensate product is monitored by using RVP analyzer (090-AI- 1801 ) located oninlet line of Condensate Storage Tank (076-TK-1001) . The condensate product is sent toCondensate Storage Tank (076-TK-1001). Off-spec condensate is sent to wet flare to preventcontamination of on-spec condensate in the storage tank.

The condensate stabilization unit produces flash gas with high methane content (about 70 %-mol).

This produced flash gas is sent to LP Fuel Gas System (Unit 063) for further treatment to produceadequate fuel gas. Methane content in the flash gas are shown on Table 6.1 :

Table 6.1 Methane content in the flash gas.

ORF Feed Condition Methane content(%-mol)

50oC;62.55 kg/cm 2A 7526oC;62.55 kg/cm 2A 6774oC;62.55 kg/cm 2A 74

26 oC;102.98 kg/cm 2A 70

6.2 Removing Accumulated Water on Trays

The feed condensate is consisting of small water content. During some operation period, possible ofwater accumulation on top trays section, due to lower operating temperature than water dew point.The stabilizer column is equipped with water draw off nozzle on top 3 trays (Tray#1, #2 and #3).

Water draw off is conduc ted periodically. Operator shall open one by one of the water draw off linesand refer to 011-LG-9101 , provided on Stabilizer Water Draw-off Drum A (011-D-1002A), (or011-LG-9151 , provided on Stabilizer Water Draw-off Drum B (011-D-1002B) ) to confirm ifwater is accumulated on top trays. During initial operation of Condensate Stabilizer Column(011-T-1001A), daily water draw off operation is required to check the water content untilCondensate Stabilization Unit operation is stable. During normal operation, weekly water

draw off operation is sufficient, because possibility of steam condensate and wateraccumulation on top trays is very small theoritically.

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Water is disposed to wet flare KO drum and finally water is treated in the water disposal system(CPI Separator 087-V-1001) , without further analysis. The purpose of water draw - of f is only tocheck and remove the accumulated water on trays. Water quality is not a concern.

Operating temperature of top tray section is low (around 38 oC). The isolation is not required during

water draw off operation.

7. NORMAL SHUTDOWN PROCEDURE

Condensate s Stabilizer c C olumn (011-T-1001A/B) , r R eboiler (011-E-1001A/B) , water draw offdrum (011-D-1002A/B) , and r R eboiler KO d Drum (011-D-1001A/B) shall be shut down at the sametime.

One complete spare (column, reboiler, water draw off drum and reboiler KO drum) is provided forcondensate stabilization unit to prevent total LNG plant shutdown during maintenance. The propersmooth switching operation shall be executed to keep on-spec condensate production.

7.1 Condensate Stabilizer Switching Operation

1. The assumption to be used are as follows:

- 011-T-1001A is in full operation.

- 011-T-1001B, which is under positive pressure with N 2 blanketing, is in stand by.

2. Set the overhead pressure control on 011-T-1001B (011-PV-1221) to normal operating pressuresetting (7.03 kg/cm 2A) and line up to Wet Flare by using the 3” venting line located downstream of011-PV-1221.

3. Establish the level in 011-T-1001B by cracking open the 2” bypass valve around the bottom product isolation valve. Introduce stabilized condensate from 011-T-1001A into 011-T-1001Bslowly until the liquid level in 011-T-1001B reaches normal liquid level. N 2 vapor in 011-T-1001Bwill be partly displaced and discharged to the wet flare during stabilized condensate transferringoperation.

4. When the liquid level in 011-T-1001B reach NLL, close the 2” bottom bypass line. HP saturatedsteam should not introduce to Stabilizer Reboiler, until all tubes are soaked in HC liquid.

5. Open Valve E fully and Valve F is cracked open (See Fig. 7.1 -1). When the liquid level in011-T-1001B increase to more than NLL, it ensured that liquid feed overflows the internal baffle ofStabilizer Reboiler.

6. Feed flowrate is increased by gradually opening globe valve F (See Fig. 7.1 -1). HP Steam flowrateis introduced, consequently the operating pressure in 011-T-1001B is increasing to normaloperating pressure of 7.03 kg/cm 2A.

Fig. 7.1-1 Opening Stabilizer B inlet bypass line.

C D

E F

A

B

LO

LC

GH-1001

From ORF To 011-T-1001A

GH-1004

Fully open Cracked open

To 011-T-1001B

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7. The main bottom liquid line of 011-T-1001B is still blocked. LC 4” valve on the overhead line(011-GF-1715) shall be opened to discharge the excess vapor to LP fuel gas system..

8. When reboiler temperature is normal, auto control in 011-T-1001B. Then, open the 6” block valveon the bottom product line allowing the levels in the two columns to be equalized.

9. Monitor the bottom temperature in 011-T-1001B to ensure the bottoms product is still on spec. Atthis time, both column levels will be controlled from 011-T-1001A level controller (011-LIC-1101A) .

10. After globe valve (Valve F) is fully open, the main feed valve (Valve B) to 011-T-1001B can beopened fully (See Fig. 7.1-2 ). At this time, both columns are sharing the load. Continue to monitor

both columns to ensure that temperatures and pressures shall remain at normal operating condition.

Fig. 7.1-2. Opening Stabilizer B inlet main line.

11. While main feed line valve (Valve A) to 011-T-1001A is still in fully open, open the bypass

block valve (Valve C) and then followed by globe valve (Valve D) fully open. (See Fig 7.1-3 )

Fig. 7.1-3. Opening Stabilizer A inlet bypass line.

12. Once the bypass valves in 011-T-1001A are fully open, using the key interlock system betweenthe block valves, Valve A and Valve B, on the main feed lines to Columns A&B. Close Valve Aon the main feed line to 011-T-1001A. This condition means that the feed flow could be changedto 011-T-1001B from 011-T-1001A. (See Fig 7.1-4 )

C D

E F

A

B

LO

LO

GH-1001


To 011-T-1001B

GH-1004

Fully open Fully open

C D

E F

A

B

LO

LO

GH-1001


To 011-T-1001B

GH-1004

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Fig. 7.1-4. Closing Stabilizer A inlet main line.

13. Gradually close the globe valve (Valve D) until fully closed and then close bypass block valve(Valve C) (See Fig. 7.1-5 ). Monitor the temperature in 011-T-1001A as the feed is removed.

Fig. 7.1-5. Closing Stabilizer A bypass globe valve of inlet line.

14. Valve C and Valve D are fully closed. Once the feed to 011-T-1001A is stopped , then change thelevel controller from 011-T-1001A to 011 T-1001B in 011-HS-1522. dDecrease the level in

both columns, by decreasing the set point of the level control in 011-T-1001B until the liquid in both columns reach low level.

Fig. 7.1-6 .Stabilizer B is ready for normal operating

15. The bottom line of 011-T-1001A is blocked and stop steam supply to Stabilzier Reboiler A(011-E-1001A). The condensate products in 011-T-1001A left until cool down. 011-T-1001A isisolated and then cooled condensate shall be drained out to wet flare KO drum through permanentHC liquid drain line. Vacuum conditions must be avoided during isolation and draining.

7.2 Condensate Product Cooler Shut down

Condensate product cooler (011-E-1002) consists of two tube bundles. On spec condensate can still be produced during shut down of one tube bundle.

C D

E F

A

B

LC

LO

GH-1001


To 011-T-1001B

GH-1004

C D

E

A

B

LC

LO

GH-1001


To 011-T-1001B

GH-1004

Close fully open to fully close

C D

E F

A

B

LC

LO

GH-1001


To 011-T-1001B

GH-1004

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Close the 3” block valves on inlet and then outlet of each tube bundle. Open the 2” line to wet flareand liquid drain to reduce the pressure before tube maintenance.

8. EMERGENCY SHUTDOWN PROCEDURE

8.1 General

This section describes the guidelines of shutdown procedure in case of emergencies. However, inemergencies, required actions by operators may vary because they depend on the actual situation atthe time of emergency. Therefore, it is most important for the operators to determine the cause ofemergency accurately and to understand the exact situation.

Unit 011 and 016 shutdown shall be proceeded at the same time, because Unit 011 is one of the liquidtreatment facility for ORF. Unit 011 shutdown is initiated by 016-HS-2000A. After isolationcompleted, Unit 011 can be depressurized by opening line to wet (located on 011-USVE-2060upstream).

Refer to Unit 016 Emergency Shutdown for unit isolation (Doc. No 16-IOM-PS-1201 Sec 8 )

8.2 Loss of Utilities

8.2.1 Power Failure

When a total power failure occurs and it is impossible to restore the power in a short time, shutdownthe whole plant.

Condensate product cooler (011-E-1002) will stop functioning. High temperature condensate of207 oC will be sent to condensate storage tank and possible damage on storage tank. The hightemperature condensate to be dispose d to wet flare.

8.2.2 Instrument Air Failure

When instrument air failure occurs, 011-PV-1201, 011-LV-1101,011-FV-1011A/B and011-FV-2710A/B will be closed.

Closing of 011-PV-1201 will lead to increase the stabilizer unit pressure. Closing of 011-LV-1101will increase the liquid level in the stabilizer column. 011-PSV-8001 protects stabilizer unit in anycase of pressure increasing.

When one of steam or steam condensate control valve is closed, there will be no steam supply to thereboiler. Off-spec condensate is produced.

8.2.3 Steam Failure

In case of steam failure, there will be no heat supply to reboiler. Lighter hydrocarbon and watercontent will be high, therefore off-spec condensate is produced. When steam failure occurs,condensate product shall be routed to wet flare.

9. SAFETY PROCEDURE

9.1 General

To prevent accidents it is of the utmost importance that all personnel be instructed properly of thefollowing subject:

- The leaks and responsibilities of the operators

- The methods to accomplish this in a safe manner_ _ _ _ _

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The following safety regulations cover operations of particular concern to the personnel responsiblefor the unit. They are intended to supplement any existing general plant safety regulations whichcover all units; reference should be made to the latter for all points not mentioned below. Mechanical

craftsmen working on their unit will be governed by their own departmental safety regulations, butthe operator should see that none of the following safety regulations are violated by mechanicalworkers.

In addition to specifically defined rules and practices, the exercise of good judgment by every personinvolved is essential to safe operation. An operator should be alert for any situation which might

present a personnel hazard. It should also be the responsibility of each person familiar with the plantto warn other workers who enter the plant of possible hazards they could encounter.

All personnel must know the location and use of safety shower, fire extinguisher, plant fire alarm, andmain isolation valves, fire hoses and hydrants, fire blankets, gas masks and respirators, and other

protective equipment such as hard hats, rubber gloves, etc.

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

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

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

Safety hats must be worn when outdoors.

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

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

Gas masks must have fresh cartridges installed after use.

9.2 Emergency Fire Plan

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

9.3 Fire Fighting and Protective Equipment

Fire hazard status throughout the plant shall be monitored on the Hazard Detection and MonitoringSystem (HDMS (F&G)) consoles in the main control room and fire and emergency station.

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Upon fire detection, suitable fire fighting agents such as water, foam, dry chemical and inert gas shall be used to control and/or extinguish a fire, and cool down equipment exposed by a fire or a heatradiation.

For the detail, refer to 82-SPE-HS-1540 (S-082-1241-019), “Operation Manual for Fire Protection

System” and the relevant drawings for fire protection system.

9.4 Maintenance of Equipment and Housekeeping

1. Operating equipment should be checked frequently for signs of leakage, overheating, orcorrosion, so that unsafe conditions may be corrected before they result in serious consequences.Unusual conditions should be reported at once.

2. Guard around moving shafts, coupling belts, etc., which have been removed for repairs of theequipment must be replaced when repair work is completed.

3. Tools, pieces of pipe etc., should never be left lying on platforms or railings of operationequipment where they can be knocked off and injure someone below.

4. Access to ladders and fire escapes must be kept clear. Waste material and refuse must be put in proper locations where they will not offer fire or stumbling hazards.

5. Liquid spills must be cleaned up immediately. Blanket gas leaks with steam and immediatelyreport leaks for repair.

6. In the event that electrical equipment does not function properly, notify the electrical departmentand stay clear of the equipment until the electrician arrives.

7. Gas cylinders should be stored so that they cannot fall over. Guard caps must remain in placeover the valves of cylinders, which are not in use.

8. Care should be taken when installing scaffolding to ensure that the wooden boards do notcontact hot equipment and that no part is allowed to impair free access on operational equipmente.g. ladders, stairways, walkways or valves. Scaffolding should be removed immediately oncompletion of the work in hand.

9. Switch pumps regularly when spares are provided. This will assure start the spare pump will beready when needed.

9.5 Repair Work

1. Mechanical work around and operating unit must be kept to a minimum, and the minimumnumber of men should be used.

2. No mechanical work on the equipment is to be done without a properly authorized work permit.3. Safety hats must be worn by all personnel in all areas at all times.

4.

No burning, welding, open fires, or other hot work shall be allowed in the area unless authorized by a work permit. Catch basins, manholes, and other sewer connections must be properly sealedoff to prevent the leakage of gases, which may ignite upon contact with an open flame.

5. No personnel shall enter a vessel for any purpose whatsoever until it has been adequately purged, blanked off, and then tested to ensure freedom from noxious or inflammable gases andan entry permit issued.

6. Lines operation at a low temperature might fracture if unduly stressed; therefore, do not physically strike these lines and avoid operation conditions, which would cause a water hammerto start.

7. Do not use light distillates such as gasoline or naphtha to clean machinery or for any othercleaning purposes.

8. Equipment should not be left open overnight. At the end of each day’s work blanks or spadesshould be installed to prevent entry of flammable materials due to valve let-by.

9. Welding cylinders should be removed from site to a designate safe area at the end of each

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working day.

9.6 Withdrawal of Samples

Samples shall be withdrawn from the unit only by authorized personnel.

Protective equipment, face masks or goggles, and suitable gloves must be worn for sampling. Acontainer must never be filled to the brim, in order to minimize risk of subsequent spillage.

When sampling any product liquids, gloves and goggles will be worn.

When sampling any material, gas or liquid, the sampling line must be flushed long enough to removedormant materials to insure that the sample obtained represents the current stream. Pass enough gasthrough the sample vessel to insure the displacement of the purge gas and to adjust the temperature ofthe sampler to that the composition is not distorted by condensation or flashing, etc.

When the sample composition is representative of the source material, it shall not be distorted byflash vaporization. Certain classes of samples may require inert atmospheres , cooling or specialcarrying devices. Wear approved personal safety equipment and exercise caution to avoid injuries.

When sample cooling is required, operator shall confirm cooling water is flowing properly beforetaking the sample.

9.7 Safe Handling of Volatile and Toxic Materials

The safety rules given below are for the protection of life and limb, and the prevention of propertyloss. It is expected that plant people will exercise common sense, alertness, and good judgment incarrying them out. If ever there is any doubt as to the safety aspect of a particular operation, consultyour supervisor immediately.

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

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

Secure a gas test certificate showing the gas condition of the vessel is safe for entry. Stand on the windward side of an operating from which gases escape. Provide proper ventilation. All personnel should become familiar with the accepted method of artificial respiration in order

to render assistance to any one overcome by gas, electric shock, or drowning.

If anyone is overcome by gas, his rescuer should:

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

When using a breathing apparatus, be sure that the mask fits the face properly. Test it by the approvedtest method.

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Wear the correct type of breathing apparatus, suited to the situation encountered.

9.9 Breathing Apparatus (B. A.)

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

The compressed air self-contained breathing apparatus has a self-contained air supply carried on the back of the user.

It is used principally in emergencies.

After use, always notify the proper department so that they can recharge the cylinders as soon as possible.

9.9.1 Nitrogen

N2 is an inert gas used for purging equipment or maintaining a positive pressure inert gas blanket on avessel.

N2 is neither poisonous nor flammable, but care must be exercised when working inside equipmentthat has been N 2 purged. Adequate ventilation must be provided and appropriate breathing deviceworn. To breathe an atmosphere high in N 2, could result in suffocation.

Before entering vessels that have been purged with N 2, a check must be made for proper oxygencontent prior to entry. Rapid vaporization of liquid nitrogen can cause severe burns on contact withthe skin.

9.9.2 Corrosive Materials

Whenever containers of corrosive chemicals such as caustic soda and sulfuric acid, are to be openedor emptied, always have a connected water hose handy to flush off and help absorb spilled materialand to reduce spread of toxic vapors.

10. ISOLATION PROCEDURE FOR MAINTENANCE

This section describes the isolation procedures to be taken prior to maintenance work based on thefollowing specification:Maintainability Philosophy (99-PHI-EM-0005)Availability and Sparing Philosophy (99-PHI-PS-0002)

10.1 General

It is necessary to isolate trains, items of equipment, or groups of equipment, in order to facilitateshutdown for maintenance, inspection, tie-ins, or loss prevention.

As the degree of hazard increases, the measure of protection required must be deeply considered. Thedegree of hazard is related to the system contents (e.g. flammability, toxicity etc.), pressure andtemperature. There are two main methods of isolation which can be used:

Positive isolation incorporating the use of spades/spectacle blinds or removable spools and blindflanges, where no leakage can be tolerated for safety and contamination reasons, e.g. for vessel entryor for creating safe construction areas within a plant.

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11. MAINTENANCE PROCEDURE

11.1 General

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

Type of maintenance is classified in the following categories.

11.1.1 Routine/First line/ Maintenance

Routine/First Line Maintenance is the daily on-line or off-line visual inspection, lubrication,calibration or minor adjustment of running and static equipment. In addition to the maintenance

personnel carrying out the above types of checks/adjustments, the operator shall perform thefollowing routine maintenance activities whilst carrying out his daily checks on the Plant, in order to

prevent any minor problems developing into major ones:

• Tightening gland followers on leaking valve packing.• Checking temperature and pressure gauges for broken glass faces.• Checking for correct oil levels in compressors, gearboxes, oil reservoirs.• Topping up low oil levels in the above equipment as required.• Cleaning pump filters and strainers.• Keeping equipment clean and tidy.• Checking leak from flange joints for air fin exchanger" (Note 1)

Note 1

Due to the inherent dynamics associated with in-service air fin exchangers over an extendedperiod, there exists the potential for increased leak frequencies, particularly at flange jointsdue to vibration.

11.1.2 Breakdown Maintenance

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

11.1.3 Planned Preventive MaintenancePlanned Preventive Maintenance will be carried out on a calendar or running hours basis. It will be

performed in accordance with the vendors’ recommended frequencies.

11.1.4 Predictive/Condition Based Monitoring

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

11.1.5

Turnaround /Inspection MaintenanceTurnaround/Inspection Maintenance will be carried out at approximately 3 yearly intervals, andusually entails a complete Plant or Train shutdown. It is utilized to perform testing and resetting of

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safety valves, and inspections and repairs of equipment that cannot be shutdown or removed duringProduction.

11.2 Precautions prior to Maintenance

This section covers precautions prior to start maintenance work for a whole or a part of the plant.

• All work must be carried out within the requirements of company Safety & EnvironmentalPolicies and Procedures. Prepare all known Work Permits, these must reflect safety issues.Obtain relevant permit to work before starting work.

• Inform Operations of the work content of this preventive maintenance procedure and how it willaffect them.

• All rotating equipment is to be considered energized until proven isolated.• All vessels must be isolated, drained and vented.• Cordon the work area, to prevent unauthorized access.• Prior to commencement of this work ensure that moving/rotating/power generating/energy

storing equipment has been isolated in accordance with the relevant permit to work and lock-out /tag-out requirements.

• Physically isolate vessels. Only standard blank flanges and spades should be used. No personshould enter a vessel unless all directly connected sources of utilities fluids have been positivelyisolated from the vessel. Entry means total body entry or any part of the body.

• Operations should check for oxygen, taking samples at several representative places, with a portable analyzer to check for oxygen deficiency.

• Prior to commencement of this work it is recommended that the crew will be briefed on what isrequired and what hazards there are. The crew will be reminded of the location of safety showers,first-aid boxes and telephones.

11.3 Preparation for Maintenance

The outline of the work sequence begins as below.• Shutdown of the unit operation• Installation of isolating blank flanges or spades• Replacement with nitrogen for entry into the equipment, if required

Purge with nitrogen and once hydrocarbon content is less than 0.5%, purge with air to atmosphereto achieve 20% oxygen content.

11.3.1 Installation of blank flanges or spades

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

The space to be inserted by a temporary blind flange shall be provided between bank isolation

flanges.

11.3.2 Steam purging prior to maintenance

Steam is potentially dangerous and can cause severe burns. It can also lead to mechanicaldamage if not properly handled.

The measures outline below must be observed:

• Fence (using scaffolds or rope) shall be provided to prevent workers from accidentaltouching or getting in contact with the heated system.

• Operator shall always wear adequate clothes in working (Safety glove, long sleeve shirt,

etc).• To be clearly marked with hazard notices and kept free of personnel.

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• Any combustible material (plastics, paper, woods etc.) must be removed from the heatedsystem to prevent possible external fire.

• Steam is hazardous service, due to not only temperature and pressure considerations, butalso cause of possible mechanical damage by liquid vaporization or water hammering,

when steam is fed into cold service. Therefore, introduction of steam must be done slowlyand carefully.

• Safety Awareness Program to be implemented by Safety team before the steam outcommences. It should focus on the danger of steam line and heated system, burns etc.

• Toolbox shall be provided in field for required activities and safety measures.

11.3.211.3.3 Purging nitrogen with air

Replacement of nitrogen gas with air and safety test for equipment must be performed prior to permitting entry.

(1) Connect temporary air hoses at the appropriate location with utility air or instrument air ifrequired.

(2) Open the top vent valves and drain off valves to atmosphere of the equipment.

(3) Introduce air to displace/purge nitrogen gas to atmosphere.

(4) Continue to purge until oxygen contents are higher than 20% at all point.

11.4 Typical isolation method

11.4.1 Vessels/Drums

• Erect scaffold for access as required.•

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

11.4.2 Shell and Tube Type Heat Exchangers

• Erect scaffold for access as required.• Operations to close down the system and depressurize.• Mechanical to swing spectacle inlet and outlet spectacle blinds.• Operations to air purge and check for oxygen level.• Mechanical to open as required.• Mechanical to clean.

11.4.3 Close out

• Ensure the equipment is left in a safe condition.• Remove all tools and debris, clean local area.• Note any faults found and comments.• Raise a work request if any major corrective work is identified or the performance standards are

not met during the above maintenance.• Sign off permit to work and inform area authority of equipment status.

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12. ATTACHMENT LIST

Attachment-1 Process Flow Diagram

11-PFD-PS-1150 11-PFD-PS-1151

11-PFD-PS-1152

Attachment-2 P&IDs

11-PID-PS-1151

11-PID-PS-1152

11-PID-PS-1153

Attachment-3 Equipment Data Sheet (List only)

11-EDS-VM-1251 (EDS for 011-T-1001A/B)

11-EDS-VM-1261 (EDS for 011-D-1001A/B)

11-EDS-VM-1261 (EDS for 011-D-1002A/B)

11-EDS-EX-1301 (EDS for 011-E-1001A/B)

11-EDS-EX-1302 (EDS for 011-E-1002)

Attachment-4 Instrument Alarm Set Point (List only)

11-SPE-CS-1754

Attachment-5 Cause and Effect Charts (List only)

11-LOG-PS-1150

Attachment-6 Laboratory Sampling Schedule

Attachment-7 Material Safety Data Sheets (Later)

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Documents

Condensate Stabilization Unit (1)