090768.232 3.00 018 A e - A

Doc. No.:S090768.232-3.
00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Rev. A Page 1 of 111
LPG Train-4 Project

at
MAA Refinery
Contract CA/CSPD/0009
OPERATING MANUAL UNIT 232
NGL RECOVERY
AND
CONDENSATE STRIPPER SECTION
(S090768.232-3.00-018-A-E)
23. Nov.
A Issue For Approval J.M.Mun G.P.Moon B.J.Yi S.K.KIM
2012
REV. DATE DESCRIPTION ORIGINAL/ CHECKED CHECKED APPROVED
REVISED BY BY BY BY
LPG Train-4 Project at MAA Refinery

Contract CA/CSPD/0009
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OPERATING MANUAL
Job No.: 090768
UNIT 232
TABLE OF CONTENTS
1 OVERVIEW .......................................................................................... 6
1.1 OVERALL CONSIDERATIONS .............................................................................. 6
1.2 DESCRIPTION OF UNIT......................................................................................... 6
2 DESIGN BASIS.................................................................................... 8
2.1 GENERAL ............................................................................................................... 8
2.2 DESIGN CAPACITY................................................................................................ 8
2.3 FEED CONDITION .................................................................................................. 9
2.4 PRODUCT SPECIFICATIONS ................................................................................ 9
2.5 BATTERY LIMITS CONDITIONS FOR TREATING UNIT....................................... 9
3 PROCESS DESCRIPTION ................................................................ 10
3.1 PROCESS FLOW DIAGRAM ............................................................................... 10
3.2 PROCESS FLOW DESCRIPTION ........................................................................ 10
3.3 TURBO EXPANDER-RESIDUE GAS COMPRESSOR ........................................ 14
3.4 METHANOL INJECTION SKID ............................................................................ 14
4 DESCRIPTION OF UNIT CONTROL ................................................. 17
4.1 NGL RECOVERY SECTION ................................................................................. 17
4.1.1 NGL RECOVERY SECTION OVERVIEW ................................................. 17
4.2 CONDENSATE STRIPPER SECTION .................................................................. 22
4.2.1 CONDENSATE STRIPPER SECTION OVERVIEW .................................. 22
4.3 NORMAL OPERATION OF TURBO EXPANDER ................................................ 23
4.3.1 READY TO START SEQUENCE............................................................... 24
4.4 DCS INTERLOCK LOGIC..................................................................................... 23
5 TEMPORARY OPERATION .............................................................. 24
5.1 SCOPE .................................................................................................................. 25
5.2 CO2 FREEZE UP .................................................................................................. 25
5.3 J-T VALVE OPERATION....................................................................................... 25
6 PREPARATION OF COLD BOX FOR PRECOMMISSIONING ......... 26
6.1 EQUIPMENT INSPECTION .................................................................................. 26
6.2 PIPING INSPECTION ........................................................................................... 26
6.3 PRESSURE TESTING .......................................................................................... 27
6.4 FILLING THE COLD BOX WITH PERLITE .......................................................... 27
7 START-UP.......................................................................................... 29
7.1 OVERALL CONSIDERATIONS ............................................................................ 29
7.2 INITIAL START-UP ............................................................................................... 29
7.2.1 OVERVIEW ................................................................................................ 29
7.2.2 PRE-START PROCEDURES AND CHECKS ........................................... 30
7.3 PROCESS FOR START-UP .................................................................................. 30
7.3.1 START UP SEQUENCE FOR NGL RECOVERY SECTION. .................... 30
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7.3.2 INITIAL LP PRESSURIZATION ................................................................ 31

7.3.3 DRYING-OUT OPERATION ...................................................................... 32
7.3.4 HP / LP PRESSURIZATION ...................................................................... 36
7.3.5 COOLING DOWN ...................................................................................... 36
7.3.6 STARTING TURBO EXPANDER / RESIDUE GAS COMPRESSOR ........ 38
7.3.7 START UP PROCEDURE FOR CONDENSATE STRIPPER SECTION. .. 40
7.3.8 INITIAL START-UP CHART ...................................................................... 41
8 NORMAL START-UP ......................................................................... 45
8.1 SUMMARY ............................................................................................................ 45
8.2 FINAL PREPARATION ......................................................................................... 45
8.3 NORMAL START-UP PROCEDURE .................................................................... 46
9 SHUT-DOWN ..................................................................................... 47
9.1 SUMMARY OF SHUTDOWN ................................................................................ 47
9.2 NORMAL SHUTDOWN PROCEDURE ................................................................. 47
9.2.1 SHUTDOWN OF COLD BOX ................................................................. 48
9.2.2 SHUTDOWN SEQUENCE OF TURBO EXPANDER / RESIDUE GAS
COMPRESSOR ....................................................................................... 49
9.3 EMERGENCY SHUTDOWN ................................................................................. 50
9.3.1 SUMMARY .............................................................................................. 50
9.3.2 EMERGENCY SHUTDOWN PROCEDURE ........................................... 50
9.3.3 ANALYZING THE EMERGENCY SHUTDOWN...................................... 51
9.3.4 INITIATION OF EMERGENCY SHUTDOWN .......................................... 51
9.3.5 EMERGENCY SHUTDOWN SEQUENCE .............................................. 52
9.3.6 SYSTEM DEPRESSURIZING ................................................................. 52
9.4 UTILITY FAILURE................................................................................................. 53
10 SAFETY EQUIPMENT ....................................................................... 55
10.1 PRESSURE RELIEF DEVICE............................................................................... 55
10.2 ALARM AND TRIP SETTING ............................................................................... 55
11 COLD BOX ........................................................................................ 56
11.1 DESCRIPTION OF EQUIPMENT.......................................................................... 56
11.1.1 NOZZLE .................................................................................................. 56
11.1.2 HEADER ................................................................................................. 56
11.1.3 PORTS .................................................................................................... 56
11.1.4 DISTRIBUTOR FINS ............................................................................... 56
11.1.5 HEAT TRANSFER FINS ......................................................................... 56
11.1.6 PARTING SHEETS ................................................................................. 57
11.1.7 CAP SHEETS .......................................................................................... 57
11.1.8 SIDE AND END BARS ............................................................................ 57
11.1.9 SUPPORT ANGLES ............................................................................... 57
11.1.10 LIFTING LUGS ........................................................................................ 57
11.1.11 UNIT ........................................................................................................ 57
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11.2 INSTALLATION GUIDELINE ................................................................................ 58

11.2.1 LIFTING & HANDLING ........................................................................... 58
11.2.2 MOUNTING AND BRACING................................................................... 59
11.2.3 CONNECTION CONFIGURATIONS ....................................................... 59
11.2.4 FLANGED CONNECTIONS .................................................................... 59
11.2.5 TRANSITION JOINTS ............................................................................. 60
11.2.6 VENTING ................................................................................................. 60
11.2.7 TESTING ................................................................................................. 60
11.2.8 INSULATION ........................................................................................... 61
11.3 OPERATING, STARTUP, AND SHUTDOWN GUIDELINES ................................. 61
11.3.1 FOULING PROTECTION ........................................................................ 62
11.3.2 CORROSION PROTECTION .................................................................. 62
11.3.3 THERMAL STRESSES ........................................................................... 62
11.3.4 STARTUP ................................................................................................ 64
11.3.5 SHUTDOWN ........................................................................................... 65
11.3.6 MOTHBALLING ...................................................................................... 65
11.4 MAINTENANCE GUIDELINES ............................................................................. 65
11.4.1 GENERAL ............................................................................................... 65
11.4.2 LEAKS .................................................................................................... 66
11.4.3 LEAK INDICATORS ................................................................................ 66
11.4.4 TESTING FOR LEAKS ........................................................................... 66
11.4.5 BLOCKAGE ............................................................................................ 68
11.4.6 DERIMING, BACK FLUSHING, AND DRYING ....................................... 68
11.4.7 BACK FLOWING / RUPTURE DISK TECHNIQUES .............................. 69
11.4.8 REPAIRS AND SERVICE........................................................................ 70
12 TURBO EXPANDER / RESIDUE GAS COMPRESSOR(L-231-001/C-
232-001) ............................................................................................. 71
12.1 DESCRIPTION OF EQUIPMENT.......................................................................... 71
12.1.1 TURBO EXPANDER ............................................................................... 71
12.1.2 EXPANDER NOZZLE CONTROL ........................................................... 71
12.1.3 COMPRESSOR ....................................................................................... 71
12.1.4 BEARING CARTRIDGE .......................................................................... 71
12.1.5 QUICK CLOSING VALVE ....................................................................... 72
12.1.6 ANTI-SURGE VALVE .............................................................................. 72
12.1.7 AXIAL THRUST SYSTEM....................................................................... 73
12.1.8 AUXILIARIES SYSTEMS ........................................................................ 73
12.1.9 CONTROL INSTRUMENTS AND LOCAL CONTROL PANEL .............. 75
12.1.10 CONTROL PANELS FOR INSTALLATION IN CONTROL ROOM ......... 77
12.1.11 HAZARDOUS AREA PROTECTION ...................................................... 77
12.2 OPERATION OF EQUIPMENT ............................................................................. 78
12.2.1 START UP PREPARATION (PRE-COMMISSIONING) .......................... 78
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12.2.2 START UP (COMMISSIONING) .............................................................. 79

12.2.3 START-UP SEQUENCE .......................................................................... 83
12.2.4 STEADY STATE OPERATION ................................................................ 85
12.2.5 EXPANDER SHUT DOWN ...................................................................... 85
12.2.6 EMERGENCY SHUT DOWN .................................................................. 85
12.3 TROUBLE SHOOTING ......................................................................................... 86
12.3.1 PROCESS SYSTEM ............................................................................... 86
12.3.2 OIL SYSTEM ........................................................................................... 91
ATTACHMENT
1. Process Flow Diagram (PFDs)

2. Piping & Instrumentation Diagram (P&IDs)
3. Plot Plan
4. Equipment List
5. Equipment Data Sheet
6. Instrument data sheet
7. Utility Summary
8. Cause and Effect Diagram
9. Safeguarding Memorandum
10. Alarm and Trip Setting
11. Dynamic Simulation Study Report
12. Gas Detector Monitor Location Plan
13. Chemical & Catalyst Summary
14. Technical Data of TURBO EXPANDER (L-232-001) & RESIDUE GAS
COMPRESSOR (C-232-001)
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OPERATING MANUAL
Job No.: 090768
UNIT 232
1 OVERVIEW
1.1 Overall Considerations
This section of operating manual is for unit 232, which describes the NGL recovery
section and Condensate Stripper section of LPG Train - 4 Project at MAA Refinery,
Kuwait. While preparing this manual it is assumed that the operator is familiar with the
basics of process plant operation and the use of large rotating machinery. This
document will help the operator to understand characteristics and special features of the
unit.
This operating manual is a comprehensive guide for the operating personnel who will be
responsible for the operation of this unit and will help enable personnel to:
1. Operate this unit safely.
2. Operate this unit to specification and to optimal conditions.
3. Make objective operating judgments.
4. Be aware of specific requirements to ensure correct action is taken for start-up,

shutdown, emergencies and normal operation.
1.2 Description of Unit
The primary objective of the NGL Section is to produce the Feed for Deethaniser (Raw
NGL) by removing the methane from the feed gas by Natural Gas Liquefaction. The
design of the NGL section is based on the GSP (Gas Sub-cooled Process), which is a
Turbo Expander based open art cryogenic technology. The design of the NGL Recovery
Section is comprise the following systems:
Combined Reboiler Exchanger (E-232-001) and Feed Residue Gas Exchanger (E-232-
002)
Dry Feed Gas Chillers. (E-232-004A/B)
Chilled Feed Gas K.O Drum (V-232-003A/B)
Turbo Expander (L-232-001) / Residue Gas Compressor (C-232-001)
Demethaniser (V-232-001)
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Job No.: 090768
UNIT 232
Condensate Stripper (V-232-002)
Methanol Injection Skid
Compressed feed gas after H2O and Mercury removal from Dehydration section (Section
231), is routed to the NGL Recovery Section where the gas is processed to separate the
following product streams:
Residue Gas (Sent to Battery Limit)
Raw NGL (Sent to Deethaniser column)
Condensate Feed after H2O removal from Dehydration section (Section 231), is routed
to the Condensate Stripper, where condensate is treated to strip-off light ends and it
then sent to Deethaniser column for further fractionation.
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UNIT 232
2 DESIGN BASIS
2.1 General
The NGL Recovery Section (Unit 232) under LPG Train - 4 Project is designed to
separate mainly Residue Gas from the dried feed gas stream and to make Raw NGL
stream which is then sent to downstream units for further separation into Propane,
Butane, Pentane and KNG. Condensate coming from Condensate Feed Drum after
treating for moisture removal is coming to this unit for further treatment.
The design capacity of this unit is the capacity resulting from the processing of 805
MMSCFD of total feed gas to LPG-4.
2.2 Design Capacity
Total Six cases have been summarized for the design of the NGL Recovery Unit as
below with capacity resulting from the Feed Gas Flow rate handled by Feed Gas
Compressor Train A and B from the unit 231.
Table: 2.1
W/O With W/O With

Dorra Dorra Dorra Dorra Rich Lean
Summer Summer Winter Winter
NGL Section
Feed Gas Flow rate

805 805 805 805 785.8 805
(MMSCFD)
Residue Gas
636.2 672.3 619.0 661.0 558.9 679.0
(MMSCFD)
Raw NGL
788,030 653,961 847,077 699,615 1,158,555 618,629
(lb/hr)
Condensate Stripper Section
Dry Condensate Feed

461,770 537,182 467,614 541,938 514,076 541,854
(lb/hr)
Treated Condensate
387,694 491,888 411,690 501,110 426,752 501,019
(lb/hr)
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2.3 Feed Condition
The following tables 2.2 the Dry Feed Gas and Dry Condensate Feed Condition,
Table: 2.2
Temperature Pressure
F (C) Psig (barg)
Dry Feed Gas 101.3 (38.5) 1042 (71.8)
Dry Condensate 99.8 (37.7) 430 (29.6)
2.4 Product specifications
There is only one product from this NGL Recovery unit sent to LPG-4 battery limit, which
is Residue Gas and the Specifications are given as below,
H2S : 800 ppmv (Max.)
CO2 : 2 Mol% (Max.)
2.5 Battery Limits Conditions for Treating Unit
Incoming:
There is no process stream coming from LPG-4 B/L.
Outgoing:
1. Residue Gas Product
Table: 2.3
Stream Operating Condition

Temperature Pressure
F (C) psig (barg)
Residue Gas 100.4 (38) 438 (30.2)
Battery Limit pressure is referenced to the LPG-4 IBL battery limit.

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OPERATING MANUAL
Job No.: 090768
UNIT 232
3 PROCESS DESCRIPTION
3.1 Process Flow Diagram
Reference is made to the following PFD for the Unit 232,
090768.231-3.00-100-A-B
090768.232-3.00-101-A-B
090768.232-3.00-102-A-B
090768.231-3.00-151-A-B
090768.231-3.00-152-A-B
This Process Flow Diagram is included in Attachment 1 for the process description
mentioned below.
Under mentioned temperature values, refer to Case 3 W/O Dorra Winter Case for NGL
and Condensate Stripper section.
3.2 Process Flow Description
Gas Cooling and Expansion Section
Dry Feed Gas from Feed Gas Dehydration section which has moisture content below
0.1 ppmv and mercury content below 10 ng/Sm3, is first split into two streams under flow
ratio control. One stream is cooled down to 7F (-13.8C) in Combined Reboiler
Exchanger (E-232-001) by exchanging heat with Demethaniser column side Reboiler
stream and provides reboiling heat to the bottom of the Demethaniser (C-232-001). The
flow rate of this inlet feed gas split stream is controlled by the Demethaniser bottoms
temperature, thereby controlling the bottoms liquid product.
Second stream routed to Feed Residue Gas Exchanger (E-232-002), where it is cooled
down to 17.1F (-8.3C) by exchanging heat with different streams as mentioned below,
With residue gas stream flowing at -16.8F (-23.4C) coming from Demethaniser
Column (V-232-001) top through Demethaniser Reflux Subcooler (E-232-003).
With Ethane Product stream flowing at -16.8F (-27.1C) coming from Deethaniser
Overhead Receiver (V-233-006).
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At this operating temperature, portion of the hydrocarbon is condensed and both of the
stream is of two phase flow. This stream from Combined Reboiler Exchanger (E-232-
001) and Feed Residue Gas Exchanger (E-232-002) are again combined before it is
sent to Dry Feed Gas Chiller (E-232-004A/B) for further chilling. This Chiller is cooling
the feed gas up to the temperature -10F (-23.3C) by using chilling medium as LP
Propane Refrigerant from the Propane Refrigeration section (Unit 235).
This two-phase stream from the Dry Feed Gas Chiller (E-232-004A/B) enters to Chilled
Feed Gas KO Drum (V-232-003A/B). This vessel provides separation of the liquid
condensed from the chilled feed gas stream during the cooling steps previously
described. Condensed liquid phase from this vessel feeds to the Demethaniser Column
(V-232-001) under level control on the tray no.20, while the vapor phase is split into two
streams.
a. The first stream is routed to the expander end of the Turbo Expander / Residue Gas
Compressor (L-232-001/C-232-001), where it is work expanded from essentially the
NGL inlet pressure to the Demethaniser pressure. This expansion results in a power
to be used for recompressing the residue gas stream coming out from the
Demethaniser (V-232-001) overhead. This work-expanded stream then feeds the
Demethaniser (V-232-001) at the top of the tray section on tray no. 26.
b. The second stream from Chilled Feed Gas KO Drum (V-232-003A/B) flows through
the Demethaniser Reflux Sub-cooler (E-232-003) before entering the Demethaniser
column (V-232-001) at the top of packing bed as a reflux stream.
In Demethaniser Reflux Subcooler (E-232-003), the second gas stream from

Chilled Feed Gas KO Drum (V-232-003A/B) is condensed at -95.7F (-71C) by
exchanging heat with Demethaniser overhead gas at 101.9F (-74.4C). Condensed
hydrocarbons are flashed through a flow control valve FCV-2451 at -122.3F (-85.7C)
and sent to the top of Bed in Demethaniser Column (V-232-001) as a reflux, to improve
C2+ recovery efficiency and light products separation
Expansion Section
The main gas stream from Chilled Feed Gas KO Drum (V-232-003A/B) is fed to Turbo
Expander (L-232-001) that operates as driver of Residue Gas Compressor (C-232-001)
provided to export Residue Gas to existing header. After expansion at 412.3 psig (28.4
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UNIT 232
barg) and -70.5F (-57C), gas stream is fed to Demethaniser Column (V-232-001).
There is Joule-Thompson valve FCV 2403 to operate NGL Recovery unit without Turbo
Expander (L-232-001). However, process efficiency is reduced in J-T operation mode
due to low temperature drop through J-T valve than Turbo Expander (L-232-001).
Demethaniser and Reboiler Section
The Demethaniser (V-232-001) is a Tray and Packing column that releases all of
methane plus non-condensable gases from the top and C2+ product (Raw NGL) from
the bottom. Top section of Demethaniser (V-232-001) is consist of 2 Pall ring packing,
while bottom section is consist of 26 valve trays with Four pass. Demethaniser (V-232-
001), operating at 408.6 psig (28.2 barg) at the top and 411.6 psig (28.4 barg) is fed by
three streams as listed below,
- First is two phase streams from Demethaniser Reflux Subcooler (E-232-003) on the
top of packing bed as a Demethaniser Column reflux stream,
- Second is expanded and chilled stream from Turbo expander (L-232-001) on tray
no.26,
- Third stream is condensed and separated liquid from Chilled Feed Gas KO Drum (V-
232-003A/B) to tray no.20,
- And Forth is Condensate Stripper (V-232-002) overhead lighters on tray no.5.
Within the Demethaniser (V-232-001), the vapors flowing up the column are partially
condensed and rectified by the reflux streams feeding the top section of the column.
This creates a downward flow of ethane and heavier hydrocarbons toward the bottom of
the column. Meanwhile, in the lower section of the column, the Demethaniser Reboiler,
which is Combined Reboiler Exchanger (E-232-001), is partially vaporizing the liquids.
Demethaniser Reboiler (E-232-001) is utilizing two streams from the column. One
stream from tray no.10 which is top Reboiler feed stream and another is from tray no.5
which is bottom Reboiler feed stream. Reboiler returns stream are then sent back to the
column at one tray below the respective draw tray. A Demethaniser Trim Reboiler
(E-232-006) has been included to operate in parallel with the Combined Reboiler
Exchanger (E-232-001) to provide additional heat to the column during start-up and J-T
operations. The heat source for the Demethaniser Trim Reboiler (E-232-006) is LP
steam.
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The resulting vapors from the Demethaniser Reboiler streams flows upwards in the
Demethaniser (V-232-001), thereby stripping the methane and lighter components from
the hydrocarbon liquids flowing downward through the column. Sufficient vapors must be
generated to provide a Demethaniser bottoms liquid stream that will produce the
specification fractionated bottom streams of Raw NGL. The required heat input for
separation is supplied by Demethaniser Reboiler which are integrated in Combined
Reboiler Exchanger (E-232-001). Two side streams from different temperature level are
fed to the Combined Reboiler Exchanger (E-232-001) at -3.3F (-19.6C), 48.2F (9C),
respectively from the top. These streams are being heated by main feed gas to the NGL
Recovery section. The main stream from Demethaniser bottom (Raw NGL) is sent to
Deethaniser (V-233-001) under level control resetting a flow control valve FCV-2492
through Demethaniser Bottom Pump (P-232-001).
And the set point of FIC-2493A should be changed by operator in according to the
operation condition, how many pumps are operated, one or two.
Residue Gas Compressor Section
The overhead vapor stream from the Demethaniser (V-232-001) exits through a
demister pad and flows to the Demethaniser Reflux Subcooler (E-232-002) and as
discussed earlier this cold residue gas stream provides cooling to Feed Gas KO Drum
vapor. This residue gas is then flows through Feed Residue Gas Exchanger (E-232-002)
where it continues to provide cooling to the gas stream to NGL unit.
After it exits E-232-003 / E-232-002, the warm residue gas feeds the Compressor side of
the Turbo Expander / Residue Gas Compressor (L-232-001/ C-232-001). This warm gas
is compressed to 442.6 psig (30.5 barg) and is sent to existing Residue Gas network
under pressure control.
During the normal operation, the position of XV-2496 is close and pressure is regulated
by PCV-2492 and when the downstream pressure at B/L is increased and flow is not
flow to B/L, the manual valve, XV-2496 should be opened by operator.
During the normal operation, the bypass valve, XV-2463, position of Residue Gas
Compressor, C-232-001, is open and when Residue Gas Compressor, C-232-001 is
shutdown, J-T valve is operated by logic and the residue gas is transfered through
bypass valve, XV-2463.
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Condensate Stripper Section
Dry Condensate from Dehydration section is further processed in this section by

Condensate Stripper (V-232-002). Condensate Stripper is 20 valve tray double pass
column with bottom and side Reboiler facilites. Dry Condensate is fed to this column at
tray no. 10 which is coming from Condensate Dehydrator (V-231-012A/B). Condensate
here is treated to remove the lighter hydrocarbons from the condensate feed.
Condensate overhead stream at 107.7F (42.1C) stream is sent to Demethaniser (V-232-

001) under pressure controller to tray no.5.
Condensate stripper bottom product is cooled down to 183F (83.9C) in Condensate

Stripper Side Reboiler (E-232-007) by exchanging heat with Condensate Stripper Reboiler
side stream and sent to the Deethaniser (V-233-001) under Flow control cascaded with
level controller FCV-2512.
3.3 Turbo Expander-Residue Gas Compressor
For the detail description of Turbo Expander/Residue Gas Compressor (L-232-001/232-

C-001), refer to section, 12.1 DESCRIPTION OF EQUIPMENT
3.4 Methanol Injection Skid
To prevent hydrate formation, methanol injection is foreseen upstream of Combined

Reboiler Exchanger (E-232-001), Feed Reside Gas Exchanger (E-232-002) and
upstream of Demethaniser Reflux Subcooler (E-232-003).
Methanol injection system is composed by Methanol Storage Tank (ME-232-001-TK1),

and Methanol Injection Pumps (ME-232-001-P1A/B) (reciprocating type).
If pressure drop across the strainer around cold box is increased abnormally or rapidly,
operator shall start Methanol Injection Pump and open relevant block valves manually to
allow methanol is to be injected into the process side.
Methanol Injection Skid Package Vendor provided document shall be referred for further
detail.
Methanol injection pump has two head (HP & MP). There are seven (7) high pressure
injection points and nine (9) medium pressure injection points in this area.
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High pressure (HP) Methanol injection points are on the line listed as below,
- Feed gas to E-232-001
- Cold Feed inlet to E-232-004A/B
- Feed Gas inlet to E-232-002
- Demethaniser reflux to E-232-003
- Feed gas inlet to L-232-001
- Feed gas inlet to J-T valve FCV-2403
- Feed Condensate from V-232-003 to V-232-001
Medium Pressure (MP) Methanol injection points are on the line listed as below,
- Top Reboiler feed to E-232-001
- Bottom Reboiler feed to E-232-001
- Demethaniser overhead to E-232-003
- Ethane product to E-232-002
- Deethaniser overhead gas to E-233-001
- Treated Propane to E-234-001
- Treated Butane to E-234-007
- Wet Feed Gas to E-231-031
- Wet Feed Gas to E-231-032
All injection point will be operated by manual only when necessary as above and each
injection point is composed as below sketch drawing.
The opening hole of end of injection nozzle is 45 Deg angle and its open direction is
counter-current of process fluid to get maximum mixing effect. Double block valve, check
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valve and drain valves are provided for each injection point to avoid contamination of
methanol by process fluid and physical isolation.
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Job No.: 090768
UNIT 232
4 DESCRIPTION OF UNIT CONTROL
4.1 NGL Recovery Section
4.1.1 NGL Recovery Section Overview
The Feed gas from LPG-4 unit battery limit is first received by Feed gas separator and
then it is compressed by Feed gas compression Train A and B and fed to the dehydrator
section from which dehydrated feed gas is delivered to the NGL Recovery Section. The
flow is passed through the various cold box to cool down the temperature and pressure is
let down across the Turbo Expander (L-232-001) to Demethaniser (V-232-001) pressure.
The residue gas is then compressed by the Residue Gas Compressor (C-232-001) to the
high pressure fuel gas system pressure and sent to the OSBL. There are then two main
process pressure levels in the NGL Recovery section, the high pressure section up to the
expander inlet, and the low pressure section which is the Demethaniser column pressure
through to the expander booster compressor suction.
The ethane recovery increases if the inlet pressure is raised and decreases if the inlet
pressure is lowered. The ethane recovery increases if the Demethaniser pressure is
lowered and decreases if Demethaniser pressure is raised. The ethane recovery is
dependent upon the pressure ratio across the expander, so good pressure control is
essential to maximizing ethane recovery.
Another major control variable in NGL Recovery section is the heat input to the
Demethaniser Column (V-232-001) bottoms. The heat input is adjusted to control the
methane content in the Raw NGL product. More heat input here reduces ethane recovery
and lower heat input increases ethane recovery.
There is one flow control loops which has an impact on the ethane recovery. This is the
flow rates to the top reflux feeds on the Demethaniser column. The top feed results from
condensing and subcooling a portion of the Chilled Feed KO Drum vapor stream.
The flow rate for the reflux stream is operator set as a fraction of the inlet gas rate for the
train.
Increasing the reflux flow ratios above optimum will increase the horsepower requirements
and lower ethane recovery. Lowering the reflux flow rates below the optimum will lower
the power requirements but also lower the ethane recovery.
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Flow controls
FIC-2404 NGL Section Inlet Flow Rate (P&ID 232-021)
P&ID 232-021 shows an external set point to FIC-2404 from PIC-2306. PIC-2306 is
located on the Dry Feed Gas line at the downstream of the Mercury Guard Bed After Filter
(F-231-004A/B). If the pressure comes up above set point, the FIC-2404 flow set point is
increased and then it will adjust train throughput to hold inlet pressure constant.
The output signal from FIC-2404 is directed to a low select relay FY on P&ID 232-025.
Either the flow controller output signal or the expander speed controller SIC-5710 output
signal, whichever is lowest, is used to control the expander vanes.
The action of the FIC-2404 controller is to open the Turbo Expander (L-232-001) vanes if
train inlet flow is below set point and to close the vanes if it is above set point.
If the expander speed exceeds the set point of SIC-5710, the output signal from SIC-5710
will decrease to close the vanes and reduce the speed. The SIC-5710 signal will override
the signal from the FIC-2404 controller if it is lower than the FIC-2404 controller output.
FIC-2403 NGL Section Flow Rate (J-T Valve) (P&ID 232-021)
FIC-2403 flow controller is shown with FIC-2404 on P&ID 232-021. The set point for this
controller is set approximately 5% below the set point for FIC-2404 and the tuning
parameters for this controller are set to open the J-T valve, FCV-2403, rapidly when the
Turbo Expander (L-232-001)/ Residue Gas Compressor (C-232-001) trips. Normally, with
the expander in service, the output to the FCV-2403 valve will be zero because the actual
plant flow will be above the FIC-2403 set point. If the expander trips, the flow rate will drop
below set point and the FIC-2404 and FIC-2403 outputs will both increased. However, the
FIC-2404 controller output will have no effect on plant operation since the end device, the
Turbo Expander (L-232-001), is out of service. Only rapid opening of the FCV-2403 valve
via the output from the FIC-2403 controller will prevent the compressors from surging.
When the valve opens, and flow is established, the FIC-2403 set point can be reached
and flow through the train restored.
Note also that the plant is started up using the FIC-2403 controller, not the FIC-2404
controller. After the Turbo Expander (L-232-001) is started up, the FIC-2404 controller
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becomes the primary controller for the train throughput and the FIC-2403 controller output
becomes zero and the J-T valve closes.
FFIC-2451 Chilled Feed Gas KO Drum Vapor Reflux Flow Rate (P&ID 232-024)
Reflux for the Demethaniser (V-232-001) is provided by condensing and subcooling the
gas from the Chilled Feed Gas KO Drum (V-232-003A/B). This gas flow is measured by a
flow transmitter FT-2451. This signal is the process variable input to the FFIC-2451
controller, which controls the vapor flow by adjusting the output signal to FCV-2451, the
control valve in the subcooled liquid line from the Demethaniser Reflux Subcooler (E-232-
003) down to the top of the Demethaniser. The train inlet flow signal from FI-2404 is an
external set point input to the FFIC-2451 controller. The controller set point is operator set
as a fraction of the inlet gas flow rate. The control valve position is adjusted until the FT-
2451 flow rate is equal to the FI-2404 flow rate times the ratio set point fraction. For
example, with a train inlet rate of 805 MMSCFD and a ratio set point of 0.175, the valve
position will be adjusted until a flow rate of 140.9 MMSCFD is achieved. When the plant
inlet rate decreases, the reflux flow rate set point will decrease proportionally.
Pressure Controls
PIC-2306 Inlet Pressure Controller (P&ID 231-046)
The compressor speeds set the pressure levels for a given throughput of the NGL
Recovery Section. There is an elaborate pressure and speed control system associated
with the turbine packages that is outside the Engineering Contractors scope for this
instrumentation document. PIC-2306 provides an external set point signal to increase the
flow set point of FIC-2404 controllers in the NGL Recovery section. In effect, this total
system is on pressure control. If a compressor trips and the NGL Recovery section inlet
pressure drops, the expander nozzles are closed to keep the inlet pressure up. The NGL
Recovery Section throughput is then adjusted automatically to match the throughput of the
running compressors.
PIC-2492 Residue Gas Compressor Discharge Pressure Control (P&ID 232-027)
The Residue Gas Compressor (C-232-001) discharge pressure and so, Demethaniser
(V-232-001) column pressure normally floats on the high pressure fuel gas (HPFG)
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header pressure less whatever pressure increase is achieved by the Residue Gas
Compressor (C-232-001). If the residue gas compressor discharge pressure drops below
the PIC-2492 set point, PIC-2492 output begins closing PCV-2492 to increase the
Residue Gas Compressor (C-232-001) discharge pressure and effectively Demethaniser
(V-232-001) column pressure. This control function helps isolate the column pressure from
fluctuations in the high pressure sales gas header pressure. The set point for PIC-2492
will be slightly lower than the normal residue gas compressor discharge pressure so that
the PCV-2492 valve is normally wide open.
Temperature controls
TIC-2402 Demethaniser Bottoms Reboiler Return Temperature Control (P&IDs 232-021)
TT-2402 is located at the Demethaniser bottom reboiler return stream located at outlet of
Combined Reboiler Exchanger (E-232-001). This temperature is sensitive to the amount
of methane contained in the ethane product. The temperature will decrease if the methane
content is above set point and will increase if the methane content is below set point. The
output from the TIC-2402 controller is routed to the flow splitting valves FCV-2401 A/B via
controller FFIC-2402. These two valves control the flow split of inlet gas between the
reboiler loop and the gas/gas loop. The A valve will normally be wide open, with the
Demethaniser (V-232-001) bottom reboiler return temperature being controlled by
adjusting the position of the B valve. If more heat is needed, the B valve is opened. The
B valve strokes from full closed to full open on 50% output from the controller. Only if the
B valve is fully open will the controller start closing the A valve. The A valve will
eventually close down to the limit of its mechanical stop in order to reach the temperature
set point.
Table: 4.1
Valve FCV-2401A TCV-2401B

Operation Position (Gas/Gas) Position (Reboiler)
Close-Open Open-Close
TIC-2402 Output 0-50% 50-100%
0% Close Limit 100% Open
50% 100% Open 100% Open

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100% 100% Open Close Limit
Note that in order to minimize pressure drop the control valve signals are arranged so that
one valve is open at all times while the other is in control to maintain the desired
temperature. Also, the valve output signals have an output limit to prevent the valves from
fully closing.
The Demethaniser Trim Reboiler (E-232-006) is required for startup conditions or any time
the Turbo Expander (L-232-001) is out of service and NGL Recovery section is operating
with Turbo Expander bypass J-T valve in operation. Under these conditions the
Demethaniser Reboiler temperature will be controlled in manual. This will place both inlet
gas flow split valves in the open position to minimize pressure drop and maintains flow to
the cold boxes. The operator should control the flow of LP Steam with TI-2502 on the
Demethaniser Trim Reboiler (E-232-006) vapor return line to the Demethaniser (V-232-
001) by FCV-2501 to provide the required heat.
TIC-2433 Dry Feed Gas Chiller Outlet Temperature Control (P&IDs 232-023)
Temperature of the Dry Feed Gas coming out from the Dry Feed Gas Chiller
(E-232-004A/B) is controlled by TIC-2433 which is cascaded with level controller LIC-
2431/2433. Set point for the required temperature control is provided by external input by
operator, and to meet the outlet temperature to provided set point, level of the refrigerant
cooler is changed automatically to change required duty for the exchanger E-232-004A/B.
Level controls
LIC-2453 Chilled Feed Gas KO Drum Level Control (P&IDs 232-024)
Level of Chilled Feed KO Drum (V-232-003B) is controlled by level controller LIC-2453,

which sent the signal to LCV-2453. This flow controller is provided on the liquid line from
the Feed KO Drum (V-232-003A/B). In case of change in level of the receiver, this control
scheme make necessary change in the amount of Chilled Condensate liquid out of the
drum by making necessary change in the control valve LCV-2453 opening.
LIC-2473 Demethaniser Bottom Level Control (P&ID 232-026)
LIC-2473 in the P&ID 233-026 shows the level control of the Demethaniser (V-232-001)
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Column bottom. This level control is cascaded with flow control FIC-2492, which is located
on the Demethaniser (V-232-001) column bottom stream going to Deethaniser (V-233-
001) as a feed at the bottom pumps discharge, and upon change in the level of the
Demethaniser Column, this control scheme makes FCV-2492 to open or close in the
respective manner to keep the level at required set point.
4.2 Condensate Stripper Section
4.2.1 Condensate Stripper Section Overview
The condensate from the LPG-4 unit battery limit is first received by Condensate Feed
Drum. This condensate is then treated by Condensate Dehydrators (V-231-012A/B) to
remove the moisture content and is sent to this Condensate Stripper section. Condensate
Stripper (V-232-002) is 20 trays column with side and bottom Reboiler, to remove the light
ends from the condensate and send the feed to Deethaniser (V-232-001) for further
recovery.
Level Control
LIC-2516 Condensate Stripper Bottom Level Control (P&ID 232-029)
P&ID 232-029 shows the level control of the condensate stripper (V-232-002) bottom
going to Deethaniser (V-232-001) as feed inlet. This flow control is cascaded with flow
controller FIC-2512 of Condensate stripper bottom and is operate under normal level
control.
Pressure Controls
PIC-2513 Condensate Stripper Top Pressure Controller (P&ID 232-029)
The condensate stripper top pressure is controlled under pressure controller PIC-2513.
External set point is given to this controller for particular pressure of the column and
accordingly column top is sent to Demethaniser column under back pressure control.
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Temperature Controls
TIC-2515 Condensate Stripper Tower Temperature Controller (P&ID 232-029)
Temperature of the Condensate Stripper bottom is determined from the amount of

methane escaping in the column bottoms to the Deethaniser (V-233-001). In case of the
higher methane into bottom product, column bottom temperature has to be increased to
achieve the required fraction of methane. Under Condensate Stripper (V-232-002) column
temperature control system, the required temperature of Tray no. 3 of the Condensate
Stripper Column is automatically controlled by TIC-2515. The output from temperature
controller should be set value of Condensate Stripper Reboiler Condensate Pot (V-233-
004) level as a cascade control to the level controller LIC-2512. Required level of tray
temperature is controlled by changing the level of the condensate pots by operating
control valve LCV on the condensate outlet line, which makes change in the Column
Reboiler duty as shown in the P&ID control scheme.
In case of low temperature of Condensate Stripper by reduce of Side Reboiler duty due to
blocking of Condensate Stripper bottom flowrate, the low differential alarm, TDAL-2518,
the differential temperature between inlet and outlet of Condensate Stripper Reboiler will
be initiated to prevent the tray damage by level increasing.
4.3 Normal Operation of Turbo Expander
Expander adjustable nozzles (IGV) are controlled by LCP (Local Control Panel) during
start-up. After the start up sequence the nozzles will be controlled by DCS. The selection
Remote/Local is made on DCS.
In Local mode, IGV is controlled by pushing Increase/Decrease buttons on display at

LCP (232-HIC-5721A). This signal is sent to PLC and changes the reference signal (set
point) to the IP converter (232-FY-5716).
When turbine speed reaches the end of start-up sequence speed (refer to start-up
sequence of Turbo Expander describes in Start-up section), the DCS could switch in
remote mode. In this case the PLC applies the set point from the DCS (232-FY-5703).
In Remote mode, speed, IGV are controlled by expander suction pressure by PIC-2306
located at the downstream of Mercury Guard Bed After Filter (F-231-004A/B). Quick
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closing valve (232-XV-5721) is opened via the PLC when the all requirement for Ready to
start sequence (Refer to the follow section) is satisfied and start button on LCP is pushed.
Anti-surge valve (232-FCV-5723) is controlled via the anti-surge controller CCC, and can
be adjusted manually (only for higher flows).
4.3.1 Ready to start sequence
Before enabling the start of the turbo expander, the following operations or conditions
must be fulfilled.
Oil system flushing

Complete machine (Turbo expander / Residue gas compressor) inerting and drying
with nitrogen
Seal gas system starting by opening the seal gas inlet valve
Oil system starting
Expander and compressor casing pressurization
It is assumed that the whole process has been started and is now operated with the
J-T valve (232-FCV-2403) in steady conditions.
J-T valve is open: Compressor anti-surge valve open, turbine adjustable nozzles are
closed, quick closing valve is closed
Authorization from ESD
Authorization from PLC
4.4 DCS Interlock Logic
232-I-2473 , P-232-001A/B Auto-start by LAHH-2473 on V-232-001 (P&ID 232-026)
During the operation of Demethanizer BTM Pumps(P-232-001A/B/C), The stand-by

pump will start by LAHH-2473 on V-232-001, and for auto-start, the 1 bypass glove
valve of check valve on discharge line of P-232-001A/B/C should be opened to prevent
the cavitation of spare pump.
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5 TEMPORARY OPERATION
5.1 Scope
The scope of this section covers temporary operations for this unit which might occurs
under various operating stages of the plant.
5.2 CO2 Freeze Up
CO2 can form solid dry ice in the NGL Section Demethaniser column. CO2 freeze in the
Demethaniser (V-232-001) is signified by increased column pressure drops. The operating
pressure in the Demethaniser column should be increased which will increase the column
temperatures to stop CO2 freezing.
The impact of the above adjustments will lower the ethane recovery but can prevent a
plant trip while operating on high CO2 feed composition.
5.3 J-T Valve Operation
In the event of a Turbo Expander (L-232-001) trips, the NGL train will continue to operate
on the bypass J-T valve FCV-2403. In this case, the plant performance is reduced and the
ethane recovery will be lower.
The periodic main tenance and testing of JT valve should be performed to prevent the
potential NGL shutdown and operational upset condition as per the schedule.
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6 PREPARATION OF COLD BOX FOR PRECOMMISSIONING
For the details of Start-up, Operation and Maintenance, refer to vendor provided
document on Preparation of Equipment for Commissioning, Start-up, Operating
Instructions and Maintenance.
Note: All equipment of material SS316L in this Unit 232 shall be flushed and
cleaned only by steam condensate to prevent chlorine impact, during pre-
commissioning and commissioning activities.
6.1 Equipment Inspection
After the nitrogen pressure has been released from all process loops, an internal
inspection of the unit should be made. Prior to entering, several access doors should be
opened and the cold box allowed venting. Before entering the cold box, the cold box
atmosphere should be checked to ensure that is life supporting and not explosive. It is
recommended that the plant superintendent or safety officer provide written approval to
enter the cold box.
All internal equipment and piping should be visually inspected for damage.
6.2 Piping Inspection
To avoid presence of humidity inside the streams, the blind flanges must be remove
just before the final connection.
- Remove of all the temporary transport support and structure (inside and outside the
cold box)
- Ensure that flange faces are clean. Care should be exercised to protect the machined
face of the flange against scratches, dents, etc. which may reduce the effectiveness
of the gasket.
- Before installation of gaskets, ensure that flanges faces are parallel.
- The two mating surface of the flanges should be parallel to each other prior to
connection. Flange faces should be aligned to the design plane to within maximum
deviation, measured across the diameter of the flange mating face, and flange bolt
holes should be aligned to within a maximum offset of 3mm.
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6.3 Pressure Testing
If a pneumatic test is to be performed on site (for instance to check that the shipping has
not damage the piping and the pressure vessels), the following general procedure is
described, however testing procedure provided by cold box supplier shall be strictly
followed.
Successively pressurize each stream one after the other up to the design pressure,
starting with the stream at the highest pressure, then in decreasing order of pressure.
Each stream will be pressurized as follows:
Pressurize to 25% of the final pressure, hold for 1 minute.
Increase by successive step of 25% of the final pressure, holding for 1 minute after
each intermediate step, and for 5 minutes at the final test pressure.
The procedure is repeated for all the streams until they all reach their respective final
pressure values.
Beginning with the highest pressure stream, deflate successively in decreasing order
of pressure, each stream to its design pressure.
Confirm the external leak tightness with soap water.
6.4 Filling the cold box with perlite
First of all, remove all debris from the cold box. After connection of cold box piping to
process piping and shutting tight of dismounted manholes, and successful completion of
all tests of the plant, perlite may be poured into cold box.
The nitrogen purge system must be installed prior to insulation with perlite.
First check for absence of moisture within the cold box. The inner walls of the cold box
must be dry, as well as the surfaces of the heat exchangers, drums and pipes. If it is not
the case, apply a jet of dry air onto the wet surfaces.
The degree of humidity in the cold box should be in most equal to the degree of humidity
outside.
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Introduce perlite into the cold box by pouring down the contents of bags through the
manhole to be found on the roof of the cold box.
This is a hazardous operation as far as the health of the operators is concerned. Perlite
is a very fine powder which will form dust, and therefore operators must be provided with
masks to prevent inhalation.
The total empty volume of the cold box is known, therefore the total volume of perlite
introduced into the cold box must correspond to this volume, plus wastage during filling
operation. When the cold box has been filled, it is recommended that a 24 hours settling
period be allowed, following which a filling up operation is conducted again if necessary
(this is a check that may be undertaken at periodic plant maintenance shut-downs).
When it has been ascertained that the perlite has uniformly filled all the empty spaces
inside the cold box (volume of perlite used-up), the manhole is tightly fitted and fixed.
The safety valve is then to be installed according to vendor drawing.
Start-up the nitrogen purge system so as the nitrogen pressure inside the cold box is
around 10 mbar.
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7 START-UP
7.1 Overall Considerations
Different start-up procedures are to be considered which are listed as below,
Initial start-up procedure to be performed for the first start-up after mechanical
completion or when the system has been shut down and completely drained and
vented.
Normal start-up procedure to be performed when the system has been shut down but
maintained full of hydrocarbons.
Start-up procedure after short-term shut down (partial or total) of the system.
7.2 Initial Start-up
7.2.1 Overview
Operations will need to ensure that all equipment and systems are in proper working order
and that the complete unit is ready for operation. A log book should be started at this time
to record daily completion of checkout and pre-commissioning steps.
The entire unit must be cleaned, inspected, and tested and the inspections logged or
recorded. Many of the activities described in this section are performed only during the
initial startup, while selected items must also be performed when the unit is down for a
major overhaul or inspection.
Before attempting to startup the plant, external housekeeping should be performed; all
scaffolding, construction equipment, and refuse must be removed from the operating area.
Also foreign materials, grease, and oil must be removed from inside equipment and lines.
Foreign materials can damage equipment or foul process controls and valves. Cleaning
procedures in the following sections must be observed in removing these materials.
Pre-commissioning activities must be completed before the initial startup of the plant is
attempted. These instructions are intended to supplement manufacturer's information for
individual equipment and must never replace or supersede that information.
To prevent death or injury to personnel, never commission any system unless it has
been completely checked and deemed safe to commission. Ensure that the fire water
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system is in service and that all safety equipment is in its designated location. Check
that all fresh air-A-Breathing units are charged and functioning properly. Check all fire
extinguishers to ensure they are charged properlyDifferent start-up procedures are to be
considered which are listed as below,
7.2.2 Pre-start Procedures and Checks
1. Perform a general check whether all equipment are correctly installed.
2. Perform on all piping a general check for correct installation.
3. Ensure that Nitrogen, MP Steam for lube oil pump, Closed Cooling Water,
Instrument Air is available.
4. Ensure that Electrical Power is available.
5. Check that all equipment is clean and ready to be put in operation.
6. Check that all instruments have been put in service.
7. Ensure that Control systems (DCS, ESD) are ready.
8. Ensure that all safety valves have been tested and are installed on place.
9. Ensure that spectacle blinds are correctly installed as per P&IDs.
10. Dryer regeneration operation is completed.
11. Propane Refrigeration system have been put in service.
7.3 Process for Start-up
Once the unit is pre-commissioned and the utility systems associated are ready, then the
unit will be in the step of the commissioning to initial process startup. Prior to start-up, any
outstanding of the plant check out described previous section should be completed.
7.3.1 Start up Sequence for NGL Recovery section.

The NGL Recovery section shall be start up as per below listed sequence.
1) Initial LP Pressurization
2) Drying Operation
3) HP/LP Pressurization
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4) Cool down Operation
5) Stabilization
6) Turbo Expander (L-232-001) Start
7) Load-up
8) Stable Operation.
7.3.2 Initial LP Pressurization
Followings are Initial Start-Up Operation of NGL Section.
Before NGL start up, it shall be checked that feed gas compression plant operating at
normal pressures and the dehydration system functional and beds are fully regenerated.
The Residue Gas shall be routed to OSBL line during start-up operation or it shall be
diverted to HP Fuel gas header.
During initial start up of the system, all the operation should be done manually, and start
up in auto mode shall be strictly not followed as possible.
Check the following before pressurizing the NGL section.

Status Description Remarks
Check for NGL Section

XV-2401 is Open position.
30 block valve on upstream of
XV-2401 is close position and 2
bypass line across this block valve is
close position.
Methanol injection skid is ready for
operation and all methanol injection is ME-232-001
point is closed.
XV-2451, 2452, 2554, 2455 is open V-231-003A/B Liquid and
position. Vapor flow line.
XV-2461 is open position.
XV-5721 is in close position. Inlet throttling valve
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Turbo Expander & Residue Gas

Compressor is ready for operation.
XV-2462 is in close position and
C-232-001 Bypass open.
XV-2463 is in open position.
FCV-5721 is fully open position. Anti-surge valve of C-232-001
Condensate stripper isolated
XV-2472, XV-2473 and XV-2474 is
and Demethaniser bottom
closed.
isolated.
Top Reboiler liquid to E-232-
HCV-2402 is fully open position.
001
PCV-2492 and XV-2496 is fully
Residue gas to B/L.
closed.
PDI-2474 and PDI-2475 shows no Pressure drop of top bed and
alarm. Tray section in V-232-001.
Whole NGL Extraction unit should be pressurized at the same time.
Slowly open the 2 bypass globe valve on upstream of XV-2401, thus allowing flow
through Cold boxes.
Start flow through plant at a reduced rate using the J-T valve.
The whole NGL Section shall be pressurized near to normal operating pressure of
Demethaniser Column which is roughly 25 barg, which is LP Pressurization step and
keep at the same pressure until next step of drying is initiated.
7.3.3 Drying-out Operation
The system should be purged using dry gas from downstream of Dryer. The objective of
this purge is to remove any residual moisture and hydrocarbons, the presence of which
could result in freeze damage to the heat exchangers during operation. Dry out
operation should be carried out at the LP Pressure, which is already achieved in the LP
Pressurization step.
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Expected duration of the purge should depending on size, complexity and physical state
of the exchanger system. The purge exit should be monitored until consistent readings
of moisture content of less than 10 ppm are obtained.
It is difficult to remove the water from the heat exchangers at low velocities because of
poor flow distribution in the exchanger at low flow rates.
The inlet pressure of purge gas should be as low as possible and the temperature of
purge gas should be as high as allowed within exchanger design value during dry out so
that the temperature drop across a flow control valve will be low and the flowing
temperature will be as high as possible. Low pressure and warm temperature also help
increases the velocity of the gas through the equipment.
It is not difficult to remove all the free water from the Gas Exchanger or Reboiler with a
high enough flow rate. It is much more difficult to dry out the Demethaniser (V-232-001)
column because it is difficult to achieve a significant flow rate of dry out gas through this
equipment.
All low point drains should be blown periodically to remove free water that accumulates
in the low spots during dry out. Puddles of water will be moved throughout the system as
the gas flow is established. The column bottoms should be blown down periodically as
well to remove water that is moved in to the column from the exchanger and piping.
The dehydration system must be in service and the beds regenerated before dry out can
commence. A portable moisture analyzer can be used during the dry out period with
permanently installed analyzers.
Note that the moisture analyzer readings will never reach as low as a reading as needed
theoretically. Typically the lowest dew point reading one will see on the portable
analyzer will be 58F (50C). The reading may start out at +68F (+20C) and
gradually decrease as the water in the system is removed. When the reading stops
changing, the dry out flow path should be changed, for example from the expander
vapor path to the column bottoms path. When dry out of all paths are completed, then
cool down can be commenced.
Below, listed loops are the sub-loops for drying operation.

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1) From XV-2401 - E-232-002 - E-232-004 A/B - V-232-003.
2) From XV-2401 E-232-001 - E-232-004 A/B - V-232-003
3) V-232-003 L-232-001 bypass to V-232-001
4) V-232-003 - E-232-003 to V-232-001
5) V-232-003 liquid line to V-232-001
6) From XV-2401 to Demethaniser top Reboiler vapor to V-232-001
7) From XV-2401 to Demethaniser bottom Reboiler vapor to V-232-001
8) From V-232-001 E-232-003 E-232-002 C-232-001 Bypass To Flare.
During dry out circulation, maintain desired flow rates, maintain the maximum dry out
recirculation rate without creating a differential pressure drop across the J.T. valve. This
should be avoided because it will cool the dry out gas. If any liquids accumulate they
should be dumped to the closed blow down system.
Procedure
Description Remarks
1. Feed Gas Compressor C-231-001 in operation for initial dry-out
operation.
(1) Line-up the drying out circulation loop no.1 for NGL Section,
which is consist of sub-loop 1, 3 & 8.
(2) Confirm that gas dryer unit is in service 232-FCV-5721
Closed
(V-231-001 A/B/C/D/E)
(3) SET J.T. valve 232-FCV-2403 wide open manually.
(4) Block-in and depressure Turbo expander (L-232-001).
(5) Block- in and depressure Residue Gas Compressor
(C-232-001).
(6) Set to maintain system pressure by relieving excess gas to the
flare system. XV-2464 Open.
(7) Block-in feed from Condensate stripper system.
(8) Block-in Demethaniser bottom outlet line to Deethaniser.
(9) Being a first loop of dry out, it will take long time to dry the
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system. Dry out operation shall be continued until dry gas

shows the H2O below 10 ppm.
2. Drying of E-232-001,
(1) Line-up the drying out circulation loop no. 2, which is consist of
sub-loop 2, 3 & 8.
Target dew point
(2) Continue recirculation procedure until the Demethaniser 58F(50C) at
overhead gas shows dry. atm.Condition.
3. Drying of E-232-003,
sub-loop 2, 4 & 8.
Target dew point
(2) Continue recirculation procedure until the Demethaniser 58F(50C) at
overhead gas shows dry. atm.Condition.
4. Drying of liquid feed line.

(1) Line-up the drying out circulation loop no. 4, which is consist of 232-LCV-2453
sub-loop 2, 5 & 8. Open the level control valves from the Target dew point
bottom of V-232-003A/B to the Demethaniser. 58F(50C) at
(2) Continue the procedure until the outlet gas shows dry. atm. Condition.
5. Drying of Demethaniser reboiler lines.
(1) Line-up the drying out circulation loop no. 5, which is consist of Target dew point
sub-loop 6 & 8. Continue the procedure until the outlet gas 58F(50C) at
shows dry. atm. Condition.
sub-loop 7 & 8. Continue the procedure until the outlet gas
shows dry.
6. Drying of Demethaniser pump around lines
(1) Open the drain lines to the cold blowdown and vent lines to
the cold gas flare, installed on pump casing
(2) Open the suction valve, the minimum flow valve, and then the
discharge cool down by-pass valve to flow gas through each
line. Do not open these valves too much and create any
pressure in the pump casing.
7. Refrigeration system shall also be drying out during the dyring
out of NGL section.
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7.3.4 HP / LP Pressurization
Then next step followed by drying-out step is to pressurize the NGL section up to High
Pressure. High pressure loop is mentioned as below,
XV-2401 to E-232-001, E-232-002, E-232-004 A/B, V-232-003A/B, E-232-003, Line up

to J-T valve, line up to Demethaniser Reflux Control valve, line from bottom of Chilled
Feed Gas KO Drum (V-232-003A/B) to level control valve LCV-2453. Reflux Control
Valve, J-T Valve and LCV-2453 should be close position to isolate HP and LP system.
System of the NGL section which is downstream of the J-T Valve, LCV-2453 and Reflux
valve shall be remained under Low pressure, which is already established in LP
Pressurization. This also includes Demethaniser Reboiler loops and Demethaniser
overhead to E-232-003, E-232-002 to by pass of residue gas compressor to flare.
Slowly open the 2 bypass globe valve on upstream of XV-2401, thus allowing flow to NGL
section of HP loop and built the HP loop up to high pressure as defined for start-up.
Once the HP/LP loop is established, then preparation for cool down should be
commenced.
7.3.5 Cooling Down
Cool down procedure for NGL section will be carried out following the completion of
HP/LP Pressurization. The gas is cooled by actuating J-T valve. The cold temperature is
obtained downstream of the J-T valve due to the pressure drop across the J-T valve.
Cool-down of the heat exchanger is only permitted using gas (i.e., no liquid phase
present). A gradual drop in temperature is recommended, at the rate of 2 oC per minute,
to avoid thermal shocks that may provide mechanical failure in the heat exchangers or in
the piping.
The cooling medium gas should be introduced to all streams simultaneously to prevent
developing local thermal stresses. The medium when introduced to the system should
not have a temperature difference greater than 86oF (30oC) relative to the local metal
temperature.
A record of all relevant data should be kept for each individual start-up. This will be
required in the event of problems developing later in the life of the heat exchanger.
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Procedure
Description Remarks
1. Line up the long cool-down circulation loop.
(1) Line up of cold circulation loop shall be from XV-2401 to Set 232-PCV-2492
Residue gas header through E-232-002, E-232-004A/B, To start up set point
V-232-003, L-232-001 by pass (J-T Valve), Demethaniser, pressure.
E-232-003, E-232-002, Residue Gas Compressor Bypass and FCV-2401A Open.
PCV-2496. Now open slowly J/T Valve.
(2) The Demethaniser temperatures will start to drop.
2. Start V-232-003B Liquid to Demethaniser.

(1) As liquid levels build in the Chilled Feed Gas KO Drum 232-LIC-2453
(V-232-003B), the level controllers will have to be set manually
and liquid systems will start to inventory. Open LCV-2453.
(5) Try to maintain desired temperature drop in the Demethaniser 232-TI-2471
top. See the temperature drop and keep opening the J-T
Valve.
3. Starting Demethaniser Reboiler.
(1) As the liquid feed to the Demethaniser tower increases, level
will built up in the Demethaniser bottom then start the Reboiler FCV-2401B Open
manually.
and hence start the feed gas flow through E-232-001 by
opening FCV-2401B. Bottom pumps should be ready for start
as levels permit.
(2) Adjust the tower temperature levels, and flows to maintain the
desired bottom product specification.
(3) Now start the Demethaniser reflux flow through E-232-003 by
FCV-2451 Open.
opening FCV-2451 manually.
4. Start the LP Propane Refrigerant service to E-232-004A/B and
Ready to start P-232-001.
(1) After completing above steps now for further cooling down the Refrigeration
Service Start.
Demethaniser column, start opening LP Propane refrigerant
service to the Dry Feed Gas Chiller, by opening LCV-2431 /
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2433 .
(2) Now start to stabilize Demethaniser column, and as time
permits start P-232-001, and flow to Deethaniser.
5. Ready to start P-232-001.

(1) After completing above steps now stabilize Demethaniser P-232-001A/B/C
column and keep operating on J-T valve mode operation, Start
without Expander / Residue Gas Compressor and as time
permits start P-232-001, and flow to Deethaniser.
6. Increase the plant feed gas rate.
7.3.6 Starting Turbo Expander / Residue Gas Compressor
Purpose and Method
After cooling down by J-T valve is completed and the plant operation is stabilized, the
expander compressor can be started.
The purpose of starting the Turbo Expander (L-232-001) / Residue Gas Compressor
(C-232-001) is to lower the temperature of NGL to normal condition. The starting of
Turbo Expander / Residue Gas Compressor will considerably increase the recovery
rates of liquid products, compared with the J-T operation.
The start-up of the system shall only be performed after the following steps are
completed.
- Cooling down by J-T valve has already done.
- Pre-start-up inspection and the preparation of seal gas / lube oil system of the Turbo
Expander (L-232-001)/ Residue Gas Compressor (C-232-001).
- All utilities for the Turbo Expander / Residue Gas Compressor are available.
The switching from the J-T operation to the Turbo Expander (L-232-001) / Residue Gas
Compressor (C-232-001) shall be carried out using only from the local panel located on
the lube oil skid. Start from DCS shall be available.
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Procedure
The start up of the Turbo Expander shall be followed strictly as per procedure mentioned
in the operating manual provided by Turbo Expander (L-232-001) / Reside Gas
Compressor (C-232-001) Vendor, however the general start up procedure is mentioned
as below,
Push start button on LCP to open QCV (XV-5721)
J-T valve (FCV-2403) starts to close automatically
Anti-surge controller is activated
Increase IGVs opening on LCP to 1st Step speed During the first initial few seconds
of the start-up of the machine a trip multiply will be active on the vibration alarm set
point. This function is applied during start-up to allow the expander to pass through the
high vibration range (due to system resonance and other normal transient vibrations)
without alarm indication.
1st Step speed will be maintained automatically by the PLC for 20~30 minutes (for
bearing warm-up). Increase / Decrease button on the LCP will be inactive during this
period.
Increase IGVs opening on LCP to 2nd Step speed Be careful, during this phase
because operation range will cross a No-Dwell zone. This will generate an alarm.
Cross this No-Dwell zone by pushing the increase button on the LCP (staying 5
minutes in a No-Dwell zone will generate a trip of the turbo expander / compressor).
2nd Step speed will be maintained automatically by the PLC for few minutes (for bearing
warm-up). Increase / decrease button on the LCP will be inactive during this period.
Increase IGVs opening on LCP to Minimum operating speed. Once this speed has
been reached, expander speed can be controlled from DCS.
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7.3.7 Start up Procedure for Condensate Stripper section.
Below, listed is the detail procedure for initial start-up sequence for Condensate Stripper
Section,
DESCRIPTION REMARKS
(1) Line-Up
(a) Commission Condensate Stripper Reboiler (E-232-008)
Slowly open the block valve of LP Steam and warming up Top Press. 460 psig
the Reboiler.
232-LCV-2512 remains closed on manual just before
232-LIC-2512
starting introduces LP Steam to the Reboiler. Manual
(2) Start-up
(a) Start feed to V-232-002 from the filters F-231-012A/B and
check the feed quality.
(b) When feed starts to V-232-002, slowly open the block
valve HIC-2511 to HP fuel gas line, so that any non-
HIC under manual
condensable gas present in the system will be vented. mode.
(b) As the tower is inventoried, the pressure will increase and
PIC-2613 will automatically come on control at set
operating pressure.
(c) When a liquid level is established in tower bottom, slowly
open LIC-2512 and start heating up the reboiler. Slowly LIC-2512 in manual
increase the flow of steam until the temperature of Tray no. mode.
3 reaches to the normal operating pressure. Then place
these LIC on auto mode.
(d) Send the condensate stripper bottom product to
Deethaniser under level control as level is reached normal
in the tower bottom. Check the Condensate Stripper
bottoms purity by laboratory analysis.
(g) Monitor all operating conditions and adjust to obtain
stabilized condition and desired product yield quality.
(h) Once column is stabilized then the column overhead
HCV-2511 closed
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stream should taken to the Demethaniser column under and

PCV-2513 in
normal operating pressure.
manually.
7.3.8 Initial Start-up Chart
Line-Up for
LP Pressurization of NGL Section
Gas Dryers are

regenerated
Pressurize the unit up to

LP Pressure
Line-Up for
Drying-out Circulation
(Short Circulation Loop)
Start Introducing Dry Feed Gas

for drying operation
Establish Dry-Out
Circulation
Dry Feed Gas Lines
No
Dry
Yes
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Dry Demethaniser
Liquid Feed Lines
No
Dry
Yes
Dry Demethaniser
Reboilers Lines
No
Dry
Yes
Establish HP Pressurization
Circulation
Start HP Pressurization
HP / LP Pressurized
Loop ready
Start Cool down Operation

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Place J-T Valve on 232-FCV-2403

Manual Operation
Start Cool-down
Establish Gas Rate 50% of

Design through J-T Valve
Condensate Dryer Line-Up Liquid Feed

in Service Line to Demethaniser
Line-Up Demethaniser
Reboiler
Refrigeration
System in Service
Take E-232-004A/B in
232-TIC-2433
service
Line-up Condensate
Feed to Condensate
Stripper No
Demethaniser Top
Temperature 50F
Start Reboiler &
Stabilize the column
Yes
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Stabilize
Demethaniser
Controlled
Cool down
Place Expander
(232-L-001) in Service
Increase Inlet Feed

Gas Rate
Inlet Feed Gas: 50% of

Plant Design
No
Demethaniser
On-Spec.
Yes
Start Feed to
Deethaniser
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8 NORMAL START-UP
8.1 Summary
If the plant or unit needed to start after maintenance due to the trouble or overhaul, they
should be aware that the requirement described in previous sections must be fulfilled.
Normal startup procedure is described under the following operating situation:
A. When this unit is being started up in parallel with service unit, process gas is filled
within the unit but the pressure is near atmospheric and the temperature is almost
ambient due to the time passed after shutdown. This means the unit is to be started
without any welding work or unbolting work but with depressurization after shutdown.
B. All related systems are ready for startup or are in operation or are in operation.
Circulate propane refrigerant and start cool down the system as required to
meet the process requirements.
Upstream facility of Gas Dehydration Section is started and shall be in normal

operation.
C. All valves are kept at position after completing the normal shutdown.
8.2 Final Preparation
The final preparations are carried out just prior to startup, but may also be required
following major maintenance work,
All manual valves and control valves are closed and are only opened as required
during start-up.
Valve position before initial start up are listed as below,

o Isolation valves for local instrument open
o Inlet/outlet isolation valves for PSV in service open
o Inlet/outlet isolation valves for PSV of standby use inlet Car Seal Close
o Vent valves close
o Drain valves close
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o Control valves: manually closed in DCS system. Set controller at its

design set value for
normal operation.
o Shutdown valves: Set at its normal
position auto-controlled
by ESD system.
o Inlet valves for methanol Injection points close
o Inlet valves for sampling point close
o Isolation valves for existing Residue gas connection close
o All other block valves: Set open the same as in
normal operation.
All instrumentation has been calibrated and checked and is ready for use.
Instrumentation must be recalibrated and rechecked once hydrocarbons are admitted
to the Unit.
All alarm and emergency shutdown circuits have been commissioned and are ready
for use.
Unit blinds are in the operating position and signed off on the blind list.
Inform to all concerned about related process, utility and off-sites areas of the timing of
the start-up.
Check that common utility supplies are available and in operation i.e. water, instrument
air, nitrogen, steam, power generation, etc.
Close monitoring with other units must be maintained to ensure minimum upset to
upstream and downstream units during the start-up
8.3 Normal Start-up Procedure
Normal Start up procedure shall be followed as same as of the Initial Start up descried in
Section 8.2.
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9 SHUT-DOWN
9.1 Summary of Shutdown
It is expected that the units will normally be shutdown only for periodic inspection.
Since the shutdown involves advanced notice, this includes the adequate plan that
enables the units to be shutdown safely with the minimum loss of production.
In a normal full shutdown, it would be necessary to de-inventory, steam out, or purge all
the plant and equipment in order to prepare the units for maintenance.
The basic shutdown procedure is the reverse of the start-up activities.
- Reduce feed rates.
- Continue to rundown products while these remain on specification.
- Shutdown of Turbo Expander (L-232-001) / Residue Gas Compressor (C-232-001)

and take NGL Recovery unit in J-T Mode operation.
- Isolate unit with respect to feed to the unit and product run down.
- De-inventory the units to the flare.
9.2 Normal Shutdown Procedure
Normal shutdown is generally defined as a planned interruption of plant operations.

Reasons for a normal shutdown usually involve repair, maintenance or modification of
the facilities. Whatever the reasons for the normal shutdown of the Plant facilities, it
must be coordinated with upstream and downstream facilities to minimize the impact of
the shutdown on the operation of those units.
If the shutdown does not require entry, it is advantageous to leave hydrocarbon liquid
levels and system pressures intact to expedite startup. The evaluation and decision to
leave the liquid inventory, or to drain and inert the system is the decision of onsite
operating management.
The following procedure outlines the basic steps to be followed for an orderly shutdown
of the unit in accordance with the normal plant shutdown.
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Plant Shutdown Steps Activity in the Plant Activity in This Unit Shutdown
Reduce Flow Rate - Lower liquid inventory - Reduce the plant throughput
- Plant turndown 50% by 232- by controlling L-232-001
FIC-2404 (NGL inlet flow) speed
- Rundown product within
on-spec.
- NGL loop warm operation - Place J-T valve in operation

NGL Warm-up
- Total reflux on the and open slowly. The warm-
Deethaniser, Depropaniser up rate should be less than
- Refrigeration system 10C/hr.
Warm-up - Stop the Reboiler operation
- Rotating machinery stop - Stop P-232-001

Stop Plant Operation
- Depressurizing the unit to - Watch unit pressure down

De-inventory
the flare during depressurizing.
- When system pressure 5 to - Follow plant normal shutdown
10 bar liquid drain by procedure.
manual drain valves
- System pressure to zero
Purge - Nitrogen purge - Nitrogen purge
- Isolation & Inerting as - Isolation & Inerting as required

Isolation & Aerating
required
9.2.1 Shutdown of Cold box
The cautions applicable to start-up also apply to shutdown of the cold box. In particular,
all liquids must be drained, and the unit isolated in order to begin a derive procedure that
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achieves a gradual increase in temperature at the recommended rate of 3.6oF (2oC) per
minute (with maximum stream temperature of 149 oF (65oC), measured at a suitable
location on the heat exchangers, as follow: warm up the heat exchangers by a
continuous flow of dry nitrogen from the warm end until the cold end has reached the
same temperature a the inlet nitrogen.
Should the unit be taken out of service, for a longer period of time, or made accessible
for work, then flow dry nitrogen at ambient temperature to allow purging of all circuit.
Keep the assembly under slight positive pressure at all times to avoid ingress of air and
moisture.
The unit considered dry when the nitrogen dew point at the outlet of the purging circuit is
measured at less than -40 F (-40C).
9.2.2 Shutdown Sequence of Turbo Expander / Residue Gas Compressor
The expander stop shall be performed from the LCP or DCS.
The sequence is the following:
Manually close the turbine inlet guide vanes gradually until fully close. In the meantime
compressor anti-surge valve opens gradually as directed by the anti-surge controller
CCC.
Closing of the quick shut off valve.
Lube oil pump and seal gas should only be shut off in case of a turbine standstill of
more than 12 hours. Otherwise both systems should remain in operation.
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9.3 Emergency Shutdown
9.3.1 Summary
Emergency situations will occur unexpectedly and the best preparation is having a
thorough knowledge of the units, an anticipation of the most probable problems and their
solution, and a complete familiarization with all normal procedures. Emergency
conditions are usually caused by equipment failure, utility failure, mis-operation, and fire.
If it is necessary to bring the units off stream due to an emergency situation, the
procedures used for a normal shut down should be followed as closely as practical.
The Emergency Shutdown (ESD) system is provided to actuate the necessary actions
for the emergency situation. However it is the operators' responsibility to check whether
the ESD system operates properly when an emergency occurs.
In most emergencies, two phases of action are required. The first consists of immediate
actions necessary to cope with the situation, safeguard personnel, equipment and
various associated units. The second consists of recovery action by completing a full
emergency shutdown, reverting to a normal shutdown or restoring normal operation.
There will be occasions when mechanical or localized failure brings about shutdown of
an individual pump or instrument. In such cases, the shutdown may be of a temporary
nature and will not require a complete shutdown depending on the duration of such
localized failure.
9.3.2 Emergency Shutdown Procedure
The following actions apply as a general response to all emergency circumstances.
1) Reduce the feed rate, as necessary and shut off the feed gas at the inlet to the plant.
2) Isolate the product rundown lines as soon as possible to avoid off-specification

products being fed to storage or directly to the customers.
3) Make adjustments to the common utilities as the shutdown proceeds i.e. power
generation and propane refrigeration systems.
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4) Isolate as necessary at the intermediate Unit isolation valves. Depressurize the Units to
the flare system as necessary.
5) Shut down the NGL circulations and other chemical injections as necessary.
6) With the preceding actions, the Plant will be generally isolated, depressurized and the
temperatures reverting to ambient conditions. Generally the plant can be held in this
condition until the emergency situation has been removed, otherwise it will be
necessary to proceed with the Normal Shutdown Procedure.
9.3.3 Analyzing the Emergency Shutdown
Decision to Be Made
In the event of an emergency, the following decisions have to be made:
1) Determine the extent and the possible cause of the emergency condition.
2) Decide how to cope with the emergency
Continue to operate the Unit by blocking and bypassing the malfunctioning

equipment.
Shut down the Unit by following the normal Shutdown Procedure.
Shut down the Unit by following the Emergency Shutdown Procedure.
3) Notify other Units and interested parties of the impending shutdown
9.3.4 Initiation of Emergency Shutdown
The facility should be equipped with an emergency shutdown, ESD, system to deal with
life threatening and/or inner-plant major upset operating conditions. The ESD of the
plant is integrated into the over-all facility and result in either a total or partial shutdown
of the facility. The plant design should incorporate the appropriate draining and
depressurizing facilities, as required, to de-inventory the plant during a hazardous
situation to minimize the risk of injury to personnel or damage to the plant equipment.
Causes that initiate Plant Shutdown are as follow:

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- Plant Shutdown Button
- Instrument Air Pressure Low Low
- General Power Failure
Operator should consider initiating ESD-2600 and ESD-2700 if emergency situation is

not controlled properly in such cases:
- Confirmed fire signal from F&G panel over the bearable limit
- Confirmed high level gas concentration from F&G panel over bearable range
- Flare system becomes inactive such as over high level in the Knock out drum
The detailed interlock initiation and protection in Protective Instrument System is shown
Cause & Effect Diagram as Attachment 8.
9.3.5 Emergency Shutdown Sequence
The Expander emergency shutdown is performed via the local control panel or the ESD.
Closing of the quick shut off valve.
Closing of turbine inlet guide vanes, opening of compressor anti-surge valves as

directed by the anti-surge controller CCC.
9.3.6 System Depressurizing
Once ESD-2600 & ESD-2700 initiates, the NGL and Condensate Stripper section is in
the state of no longer operation via whole shutdown valves closed and the whole
machinery stopped. After Plant Shutdown is initiated, operator should consider
depressurizing unit or plant using depressurizing valves in the unit or adjacent unit.
In this unit, the Depressurization EDP valves are located at below listed location, and
shall be used for the Emergency Depressurization as necessary.
- 232-XV-2453 on the Chilled Feed Gas KO Drum (V-232-003A/B)
- 232-XV-2464 at Residue Gas Compressor

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- 232-XV-2471 on the top of Deethaniser Column (V-232-001)
- 232-XV-2431 on Dry feed gas chiller refrigerant side
- 232-XV-2511 at Condensate Stripper Top (V-232-002)
9.4 Utility Failure
Power Failure
In case of power failure, following situations will be happen.
All motor driven equipment such as Pumps will trip and Feed Gas will be stopped by
the action of the ESD system.
Turbo Expander (L-232-001) / Residue Gas Compressor (C-232-001) will trip.
Pressure will be increase in Demethaniser (V-232-001).
ESD-2600 & ESD-2700 will be activated to shutdown the NGL Recovery Section. This
will close XV-2401 / 2432 / 2433 / 2451 / 2452 / 2454 / 2455 / 2461 / 2462 / 2463 /
2472 / 2473 / 2474 / 2491 / 2497 / 2501 / 2502 / 2513 / 2514 / 2515 and FCV-2403.
Inlet Quick Closing Valve, XV-5721 will close and Anti-surge valve FCV-5723 will open.
Steam Failure
LP Steam is used for Condensate Stripper Reboiler (E-232-008) only in this unit. If LP
Steam fails, then it will stop the condensate stripper reboiler operation and thus the
condensate stripper.
Instrument Air Failure
Total failure of all IA failure will lead to following situation,

Relevant control valves & shutdown valves will be in fail position.
Turbo Expander (L-232-001) / Residue Gas Compressor (C-232-001) will trip.
ESD-2600 & ESD-2700 will be activated to shutdown the NGL Recovery Section. This
will close XV-2401 / 2432 / 2433 / 2451 / 2452 / 2454 / 2455 / 2461 / 2462 / 2463 /
2472 / 2473 / 2474 / 2491 / 2497 / 2501 / 2502 / 2513 / 2514 / 2515 and FCV-2403.
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Sea Cooling Water & CCCW Failure
Closed Circuit Cooling Water (CCCW) is used for Turbo Expander / Residue Gas
Compressor for below equipment:
CCCW for Lube Oil Coolers,
When cooling water fails, the following situation will happen.
Turbo Expander (L-232-001) / Residue Gas Compressor (C-232-001) will trip due to
loss of lube oil cooling leading to high high bearing temperature.
Mechanical Failure
If any leak from the equipment is detected, the operator should make decision to fix the
problem, if possible, or to shutdown the plant for safety. The critical pumps have standby
spares hence standby machine should be brought up and put in service, if provided.
Otherwise, decision should be made whether to continue or to interrupt the operation for
maintenance.
Expander Failure
When the trouble is occurred in Expander, Expander inlet Quick Closing valve
(XV-5721) shall be closed and then J-T valve FCV-2403 shall be opened to maintain the
system pressure, in other word, plant shall be shifted to J-T Mode operation.
Accordingly Demethaniser (V-232-001) Column operation should be adjusted to meet
the J-T mode operation.
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10 SAFETY EQUIPMENT
10.1 Pressure Relief Device
PSV are provided throughout the Unit in order to prevent mechanical failure of vessels
and pipework on failure of the normal control and operation. The ultimate protection of the
system is by means of safety valve.
Below is the list of the PSV with location, set point and discharge route for the unit 232.
and the study for relief case of PSV is described in SAFEGUARDING MEMORANDUM,
Attachment 9, .
Set Pressure Discharge

Tag Number PSV Location P&ID Number
(Psig) To
E-232-004A/B SHELL
PSV-2431A/B 232-023 1000 FLR
SIDE OUTLET
PSV-2451/2452 V-232-003A/B 232-024 1300 FLR
L-232-001
PSV-2461 232-025 550 FLR
DISCHARGE
V-232-001
PSV-2471/2472 232-026 520 FLR
TOP
PSV- P-232-001A/B/C
232-027 550 V-232-001
2491/2492/2493 SUCTION LINE
V-232-005
PSV-2501 232-028 430 ATM
BALANCE LINE
E-232-006
PSV-2502 232-028 550 FLR
TUBE SIDE OUTLET
V-232-002
PSV-2511/2512 232-029 530 FLR
TOP
V-232-004
PSV-2513 232-030 440 ATM
BALANCE LINE
E-232-001
PSV-8001 232-021 76 mmAq(g) ATM
BOX
E-232-003
PSV-8011 232-022 76 mmAq(g) ATM
BOX
10.2 Alarm and Trip Setting
Refer to Attachment 10 for Alarm and Trip Setting List.

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11 COLD BOX
11.1 DESCRIPTION OF EQUIPMENT
Chart plate-fin heat exchangers are constructed of aluminum. The basic manufacture
consists of layers of corrugated fins separated by parting sheets and sealed along the
edges with bars. The construction is furnace brazed to form the rigid heat exchanger block.
The rectangular plate-fin block created by the stack of layers is also referred to as
a core and is normally specified by its outside block dimensions of W (width)
times H (stack height) times L (length).
A heat exchanger s size, number of layers, type of fins, stacking arrangement, and
stream circuiting will vary depending on the application requirements. The basic
components of a brazed aluminium heat exchanger are as follows.
11.1.1 Nozzle
Nozzles are the pipe sections used to connect the heat exchanger headers to the
customer piping. The typical aluminum alloy used is 5083.
11.1.2 Header
Headers are the half-cylinders which provide the link between the nozzle and the core
block. The headers distribute the fluid between the nozzles and the ports of each
appropriate layer within the heat exchanger. The typical aluminum alloy used is 5083.
11.1.3 Ports
Ports are the openings in either the side bar or the end bar, located under the headers,
through which the fluids enter or leave individual layers.
11.1.4 Distributor Fins
Distributor fins distribute the fluid between the port and the heat transfer fins. The
distributor fin used adjacent to a port is called a port fin. The distributor fin used between a
port fin and a heat transfer fin is called a turning fin. The aluminum alloy used for all fins is
3003.
11.1.5 Heat Transfer Fins
Heat transfer fins provide an extended heat transfer surface. All fins, both heat transfer
and distributor, provide a connecting structure between the parting sheets, thereby
creating the essential structural and pressure holding integrity of the heat exchanger.
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11.1.6 Parting Sheets
Parting sheets contain the fluids within individual layers in the exchanger and also serve
as primary heat transfer surface. The aluminum alloy used is 3003.
11.1.7 Cap Sheets
Cap sheets serve as the outside parting sheet. Cap sheets are typically thicker than the
parting sheets and serve as the outer protective surface of the exchanger as well as a
land for weld attachment of the headers. The aluminum alloy used is 3003.
11.1.8 Side and End Bars
Side and end bars enclose individual layers and form the protective perimeter of the
exchanger. The bars are solid extruded sections to match standard layer heights. The
outside surface of the stack of side bars or end bars is commonly called the bar
column . The aluminium alloy used is 3003.
11.1.9 Support Angles
Support angles are typically 90 o extruded aluminium angles welded to the exchanger bar
face for the purpose of supporting or securing an exchanger in its installed position.
11.1.10 Lifting Lugs
Lifting lugs are lift attachment points strategically welded to the exchanger block or a
header/nozzle assembly for the specific purpose of lifting the exchanger into its installed
position.
11.1.11 Unit
The term unit is used in this manual for any heat exchanger assembly and
associated piping. The following defines the most common types of units:
A. Single Core Heat Exchanger
A single core exchanger is built from one furnace brazed core block.
B. Modular Heat Exchanger
A modular exchanger consists of two or more exchanger blocks welded together prior to
attaching the headers, to form a single piece exchanger. This form of construction is used
when the customer s heat exchange requirements exceed the maximum block size that
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can be furnace brazed. Modular construction eliminates the need for piping to interconnect
separate exchangers.
C. Multiple Heat Exchanger Assembly
A multiple exchanger assembly, often referred to as a battery , consists of two or
more exchangers piped or manifolded together into a single assembly with the individual
exchangers arranged either in a parallel, series, or combination parallel series
arrangement. Multiple exchanger assemblies are used when the customer s heat
transfer requirements are too large for either single piece or modular heat exchanger
construction.
D. Cold Box
A cold box consists of a carbon steel casing, usually rectangular in shape, which supports
and houses heat exchangers, piping, other related cryogenic equipment, and insulation
material in an inert atmosphere.
E. Core-in-Kettle
A Core-in-Kettle consists of a cylindrical pressure vessel, usually carbon or stainless steel,
which contains and supports one or more heat exchangers and associated piping
including transition joints. In operation, one fluid is piped through the exchanger and the
other partially fills the vessel and passes through open passages in the exchanger.
11.2 INSTALLATION GUIDELINE
11.2.1 Lifting & Handling
Lifting and handling instructions will be issued with all units. All handling must be
in accordance with the supplied instructions. Contact Chart prior to moving the unit
if the handling instructions are missing or additional information is required.
Failure to handle equipment properly could result in the unit being dropped or some
other equipment accident which could cause serious personal injury or death as
well as irreparable damage to the unit.
Confirm the weight, dimensions, and lift connection locations of the unit. Select the
appropriate hoisting machines, spreader bars, slings, shackles, and other material
handling tools in consideration of the height, weight, and the angle and direction of the
hoisting.
Care should be taken to avoid impacts to the unit. Rough or improper handling can cause
damage to the internal construction of the exchanger.
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11.2.2 Mounting and Bracing
The units are normally installed vertically with the warm end up. The drawings should be
examined thoroughly for any special installation requirements.
All shipping supports should be removed as shown on the drawings prior to making pipe
connections. Temporary shipping supports are normally identified with yellow paint.
Extreme care should be taken to keep all steel working torches and flame cutting tools at
a proper distance from the exchanger in order to prevent severe damage to brazed joints
and to the internal construction.
11.2.3 Connection Configurations
Failure to confirm the shipping valve is in the closed position prior to removal of the plug or
pressure gauge can result in the plug or gauge becoming a projectile and cause serious
personal injury or death.
Over-pressurization of a unit with slugged ends/flanged blinds not designed for pressure
testing could result in a rupture of the slugged ends/flanged ends and cause serious
11.2.4 Flanged Connections
Care should be exercised to protect the machined face of the flange against scratches,
dents, or other damage that would reduce the effectiveness of the gasket in making a
proper seal.
The two mating surfaces of the flanges should be parallel with each other prior to
connecting. Flange faces should be aligned to the design plane to within 0.06 inch/foot (5
mm/m) maximum, measured across the diameter of the flange mating surface, and flange
bolt holes should be aligned to within 0.12 inch (3 mm) maximum offset.
Connections should be made utilizing the procedure of gradually tightening diametrically
opposite bolt pairs and tightening the pairs in a sequence which most uniformly loads the
gasket. Stainless steel bolts and nuts should be used for the final field connection for
cryogenic service. Stainless steel washers should be used under the bolt heads or nuts on
the aluminum flange, and threads should be lubricated for proper torque wrench
applications.
Flanges are supplied with spades and mating flanges on all process connections in order
to maintain the cleanliness of the heat exchanger during connection to the site pipe-work
through plant hydro-testing and dry-out. Any debris or moisture from the site pipe-work
that enters the exchanger may affect the performance of the unit and can permanently
damage the unit. The spades shall only be removed and replaced with the spacer
provided when plant pipe-work is thoroughly dried and plant is ready for startup. Pipe-work
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can be welded to the mating flange after the unit is installed, provided that a vent is
provided on the spade for the pipe-work testing.
11.2.5 Transition Joints
Transition joints, including flange-reinforced styles, do not contain gaskets or other

serviceable parts. Do not attempt to disassemble transition joints. Servicing is not required.
11.2.6 Venting
External venting of inactive or dummy zones is required when specified on the drawing.
Inactive or dummy regions are normally designed to be self-venting and simply require
that the plastic shipping plugs be removed by the installing contractor just prior to
insulating and pressurizing any stream. This requirement is stated on the drawing and on
a tag attached to the unit.
Attaching a vent line to the inactive vent is not recommended. If a vent line is installed, the
following should be considered:
The vent line should be NPS or larger and extend outside the cold box or insulation.
A relief valve is required to protect the inactive zone against pressurization over 15
psig (1 barg).
The vent line should be maintained in an internally frost free condition to eliminate the
possibility of line blockage from freezing liquids.
Failure to limit the pressurization of inactive or dummy zones in the heat exchanger to a
maximum of 15 psig (1 Barg) could result in a rupture of the heat exchanger and cause
serious personal injury or death. Always follow the instructions on the drawing.
11.2.7 Testing
At no time may the test pressure exceed the value stated on the unit label or construction
drawing. Over-pressurization of the unit could result in a rupture and cause serious
Most codes require a pressure test of the piping system after the unit is installed. Residual
test liquid which may become trapped within the unit cannot be tolerated, since during
operation the liquid may freeze and cause serious damage and possible failure. Therefore
a pneumatic test is most often performed. The pneumatic proof test pressure shall comply
with the requirements of the applicable code, but shall not exceed the test pressure shown
on the drawing.
Each stream is to be isolated using blind flanges of the appropriate pressure rating. Never
rely on isolation being achieved by closing line valves. At least two pressure gauges are to
be fitted on each stream, one at the stream inlet and one at the outlet. A third gauge shall
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be fitted immediately downstream from the test fluid supply regulator. All gauges must be
properly calibrated and should be clearly visible from the test fluid supply location.
Appropriate safety precautions must be taken during pneumatic testing. The test fluid
supply and all personnel should be located a safe distance from the equipment being
tested. Failure to take appropriate safety precautions could result in serious personal
injury or death.
11.2.8 Insulation
Since brazed aluminum heat exchangers usually operate at cryogenic temperatures,

highly efficient insulation should be applied by the customer to minimize heat leak.
Insulation material is normally applied after the unit is installed at the job site. Inert
materials should be used for insulation. Insulation materials are not normally applied to the
unit prior to installation because insulation materials are easily damaged in transit, restrict
the use of shipping tie downs and supports, and would impair accessibility to the unit for
lifting, mounting, leak testing, and other installation preparations.
Typically, the unit is mounted inside a cold box which is insulated by filling with expanded
perlite granules according to the requirements of the engineering contractor.
Caution should always be exercised whenever welding or flame cutting near insulation
materials.
11.3 OPERATING, STARTUP, AND SHUTDOWN GUIDELINES
All operating pressures and temperatures must be within the limits specified on the
nameplate. Exceeding any of the maximum working pressures or the temperature limits
specified on the nameplate could result in a rupture of the unit and cause serious personal
injury or death.
Operating flow rates shall be within the specification limits for design or over-design flow
conditions. If higher flow rates are being considered, contact Chart for recommendations
regarding maximum velocities within the unit.
All process fluids entering the unit should be steady state flow. Precautions must be taken
to prevent transmission of vibration or fluid pulsation (emanating from pumps,
compressors, etc.) to the unit.
To prevent over-pressurization, it is the user s responsibility to install suitable pressure
relief devices for each stream. The settings of the devices must not be greater than the
stated maximum allowable working pressures.
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11.3.1 Fouling Protection
The presence of particulates in the operating fluids may not only lead to fouling of the unit
but may also cause erosion in the high velocity areas of the unit. If there is any potential
for particulates in any stream entering the unit, the fluid should be filtered with a 177
micron (80 Mesh Tyler Standard) screen, or finer, directly upstream. The user should
consider a dual filter system with sufficient valving to allow filters to be changed without
shut down.
11.3.2 Corrosion Protection
Corrosion due to water is generally a concern only when operating above the freezing
point of water, which may not necessarily be 32 oF (0 oC) due to water purity variations
and supercooling phenomena. It is recommended, however, that all process fluids have
moisture content less than 10 ppm. The pH value of process fluids should range between
4.5 and 8.5, and the presence of halides and heavy metal ions should be avoided.
Contact Chart to discuss specific conditions and corrosion concerns.
Under certain conditions, mercury can corrode aluminum. Caution, therefore, must be
used when handling mercury-containing fluids. Units may be successfully used with fluids
containing mercury, provided proper equipment design and operating procedures are
implemented. If mercury is suspected or anticipated, contact Chart about specific
conditions and the mercury tolerant features that are available. Mercury tolerant features
were not included for these units.
11.3.3 Thermal Stresses
As with any pressure vessel, stresses in each component of the unit must be maintained
within allowable limits during operation. Pressure loads, externally applied loads (e.g.
piping forces and moments) and thermally induced loads each produce stress in the
components. The resultant stress from these loadings must be controlled to prevent
component damage or failure.
A margin above the stress created by the mechanical (pressure and externally applied)
loads is available for thermally induced stresses which may occur in service. The
conditions that produce thermal stress must be controlled to maintain the thermal stresses
within this margin. These conditions are associated with transient or other unstable
operating conditions that create local metal temperature differences within the exchanger.
Brazed aluminum plate-fin exchangers are compact and highly effective heat transfer
devices. Unlike less effective exchangers, brazed aluminium plate-fin exchangers respond
rapidly to transient thermal inputs. The heat transfer surfaces (fins and parting sheets)
locally exposed to the thermal input will respond quickest to the thermal input. The
response of the structural support components (for example the end and side bars) will lag.
This difference in response rate produces local metal temperature differences within or
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between the components which provides one of the two elements necessary for thermal
stress. As a compact exchanger, the components are relatively close and rigidly attached
in all directions. This rigidity provides restraint to the expanding or contracting components,
which is the second element necessary to create thermal stress.
If the local metal temperature differences are large, the margin for thermal stress can be
exceeded and the resultant of the thermally induced stress and mechanical stress can
exceed the yield strength and possibly the ultimate strength of the material. Stresses
exceeding the material yield strength subject the exchanger to possible failure by fatigue
with repeated thermal cycles. Stresses at or above the ultimate strength subject the
exchanger to failure with only one thermal cycle.
Large local metal temperature differences are inherently unstable, particularly in metals
having high thermal conductivity such as aluminum. Therefore large local metal
temperature differences develop from and can only be supported or maintained in the
exchanger by instabilities inherent in the operating conditions (transient or cyclic thermal
or hydraulic inputs) or transients associated with start-up, shutdown or upset conditions.
Operational instabilities can result from unstable boiling within the exchanger or from
externally produced hydraulic fluctuations caused by poor control systems. Detrimental
transients associated with start-up, shutdown or upset conditions can result from improper
procedures.
To prevent component damage or failure during these service conditions the following is
recommended:
Limit pressure and external loads in the heat exchanger to those specified by Chart. As
with any piece of thermal equipment, the unit should be brought to or from operating or
derime conditions slowly. Limit the temperature difference between the inlet fluids and the
exchanger metal where the fluid enters to 50F (28C).
If the temperature difference between an inlet fluid and the exchanger metal has the
potential to exceed 50F (28C), the flow must be slowly introduced and carefully
increased in controlled increments up to full flow conditions. The rate of change in metal
temperature should not exceed 3.6F (2C) per minute as the flows are introduced and the
flow rates increased. This can be achieved by bringing the flows incrementally up to full
flow over a period in minutes not less than the maximum ITD in F 3.6F (maximum
ITD in C 2C). The maximum ITD (Initial Temperature Difference) is the maximum
difference between any of the entering streams or exchanger metal temperatures at the
time the flow is introduced.
For example, an exchanger at 80F with streams to be introduced at 100F and -80F has
a maximum ITD of 180F [100-(-80)]. The flows to this exchanger should be slowly
introduced and incrementally increased to full flow over a span of not less than 50 minutes
[180F 3.6F/min]. Likewise, an exchanger at 80F having streams to be introduced at
-100F and -190F, has a maximum ITD of 270F [80-(-190)]. The flows to this exchanger
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should be slowly introduced and incrementally increased to full flow over a span of not
less than 75 minutes (270F 3.6F/min).
Flow control is particularly critical when introducing liquid or two-phase streams. Liquid
and two-phase fluids have a tremendous capacity to rapidly change metal temperature in
the exchanger. The flow control is less critical when introducing the sensibly heating or
cooling vapors due to the limited capacity of the vapor to rapidly change metal
temperature in the exchanger. For this reason, cooling or warming of the exchanger to or
from operating conditions with a vapor prior to introducing a liquid stream is highly
recommended.
Review plant operations to identify operational conditions beyond normal start-up that
have the potential for thermal shock and develop procedures to prevent thermal shock
during these events (e.g. flow control). Typical conditions include cold and warm restart.
Cold restart is a condition where the unit is shutdown and allowed to cool due to resident
cold fluids. At restart the inlet warm streams could flow into a cold exchanger. Warm
restart is a condition where the unit is shutdown and allowed to warm due to the continued
flow of warm fluids. At restart the inlet cold streams could flow into a warm heat exchanger.
The potential of these and other similar conditions need to be considered when identifying
thermal shock events that can occur in the operation of the plant.
Exercise extreme care in applications where the fluid must be totally vaporized in the
exchanger and there is potential for unstable boiling. The relatively large temperature
differences associated with unstable boiling along with surging of the vaporizing fluid
within the exchanger can cause thermally induced cyclic fatigue failure. When unstable
boiling is suspected, consult Chart if the 50F (28C) maximum temperature difference
between the liquid and metal may be approached or exceeded.
Limit the cyclic temperature fluctuations of any stream to 3.6F (2C) per minute.
In instances where it is not possible to adhere to these guidelines, contact Chart to
discuss your specific operation.
11.3.4 Startup
Prior to startup, all connecting pipework and vessels must be thoroughly cleaned of all
particulate matter such as rust, scale, grit, and sand. The system is then to be purged
using a warm dry gas (dew point of 40 F ( 40 C) or lower) to remove any moisture
and hydrocarbons, presence of which could result in freeze damage to the unit during
operation. The purge exit should be monitored until consistent readings of moisture
content less than 10 ppm are obtained and no trace of hydrocarbons are evident. Purge of
the pipe-work shall be completed with the exchanger still isolated with the supplied spades.
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11.3.5 Shutdown
The same cautions applicable to startup also apply to shutdown. The thermal shock
guidelines outlined above must be followed.
11.3.6 Mothballing
Units being removed from service for an extended period of time should be dried and
pressurized prior to storage. A purge of at least eight hours with dry air or nitrogen is
recommended to dry the unit.
Following the drying operation, each stream should be pressurized with dry air or nitrogen
with a dew point of 40 F ( 40 C) or lower. This low dew point is recommended to
prevent galvanic corrosion if traces of rust or other foreign materials have entered the unit
during operation. The storage pressure should be the lesser of 15 psig (1 barg) or one-
third of the design pressure.
The pressure level in the unit should be checked periodically to assure there are no leaks.
In addition, the storage recommendations in Section 7 should also be followed.
11.4 MAINTENANCE GUIDELINES
11.4.1 General
Beyond the precautions for installation and operation already recommended in these
instructions, no periodic maintenance is required. It is recommended that a maintenance
log be kept to record normal operating procedures, plant upsets, shut downs, and any
operating conditions available.
Prior to the inspection, testing, or repairing of any unit, either in service or recently taken
from operations, the system must be safety checked and cleared prior to the admittance of
personnel for any service function.
Caution must be exercised with regard to the flammability, toxicity, explosion potential, or
pressure potential of any fluid or stream within, or in the proximity of, the unit. All
personnel involved with installation or maintenance of cold box assemblies should be
made aware of the dangers of suffocation, especially in nitrogen filled containers. No
personnel must be allowed in the cold box until the uniform level of oxygen in the box
atmosphere has reached a minimum of 19% by volume.
Failure to observe proper safety precautions in this regard could result in equipment
rupture, fires, toxic gas or fluid escape, suffocating gas atmospheres or other accidents
which could cause serious personal injury or death.
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11.4.2 Leaks
It is recommended that any leaking unit be repaired as soon as practical and that the
cause of the leak be identified and corrected. Prolonged operation may lead to further
damage of the unit if the cause is cyclical thermal or mechanical fatigue. Prolonged
operation of an externally leaking unit within a cold box may also lead to further damage
due to perlite erosion of the metal.
11.4.3 Leak Indicators
Internal leaks in a unit are generally indicated by a change in purity in any of the fluid
streams. External leaks may be determined by sight, smell, audible sounds of leaking fluid,
external gas monitoring equipment, or localized cold spots appearing on the external
insulation or cold box casing. External leaks in units within a cold box may also be
indicated by excessive venting through the breather valve.
11.4.4 Testing for Leaks
A. Pressure Decay Test

Pressurize a stream with dry air or nitrogen.
Do not exceed the maximum working pressure specified for each stream on the Chart
nameplate! Over-pressurization could result in a rupture of the unit and cause serious
A stream is considered leak free if it maintains the original pressure for over eight hours
with correction for temperature changes. Keep in mind that the pressure decay time test is
a function not only of the leak size but the test pressure, temperature, and unit size, as
well.
For units with large internal volumes, and/or for leak tests at pressures less than 50 psig
(3.5 Barg), leaks may take longer than eight hours to detect, depending upon the size of
the leak.
The unit temperature should be the same at the two pressure checks since any change in
temperature will change the air pressure in the unit. If it is impractical to make the two
pressure checks when the temperatures are the same, the following pressure correction
an be used:
P1 T2
P2 = ------------
T1
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Where
P = Absolute Pressure
T = Temperature (R or K)
1 = Initial Reading
2 = Final Reading
For individual recommendations, contact Chart.

B. Air-Soap Test (External Leaks)
If the stream does not maintain the original pressure during the decay test, above,
determine what kind of leak exists by repressurizing the stream and checking the exterior
of the unit with a soap bubble test.
If the unit passes this test, the leak is internal.
C. Nitrogen-Trace Gas Test (External or Internal Leaks)
The second method for checking the nature of a leak is the nitrogen-trace gas test.
Normally, the suspect stream is pressurized to 5 psig (0.3 Barg) with a trace gas or
nitrogen-trace gas mixture. The stream then is pressurized with nitrogen to 50 psig (3.5
Barg) or the maximum working pressure, whichever is lower.
A trace gas detector is used to sense the presence of the nitrogen-trace gas mixture. The
exterior of the unit should be checked and, if no leaks are detected on the unit exterior,
then the nozzles of the other streams should be checked. The presence of a trace gas in
the nozzle of another stream indicates an internal (cross pass type) leak between the two
streams involved.
Air-trace gas mixtures can be used in lieu of nitrogen-trace gas, but only with proper
precaution regarding the explosion potential of air-trace gas mixtures.
Never use air-freon mixtures containing freon in excess of 50% of the mixture by volume
as this mixture can explode under certain conditions of applied pressure and heat. Failure
to observe this rule could result in an accidental explosion and cause serious personal
injury or death.
In any trace gas testing, precautions should also be taken to prevent suffocation or
personnel in closed areas or vessels where trace gas could accumulate.
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The method used to locate the individual layer leak involves a soap test over each port of
the stream in question while air or nitrogen pressure is applied to the other stream. This
operation normally involves removal of the header and should only be performed by
authorized Chart service personnel.
11.4.5 Blockage
If the unit is fouled or plugged, several options are available to the user for cleaning the
unit. When the fouling is solid and coats the fins in the heat exchanger, the unit will
normally have to be cleaned by chemical removal through a series of deriming, back
flushing, and drying procedures (see applicable section below).
If the unit is fouled or plugged by hydrates and/or ice, a warm derime is required and
consideration given to other methods for hydrate suppression (see applicable section
below).
If the unit is fouled or plugged by particulate matter, back puffing procedures are usually
successful in cleaning the exchanger (see applicable section below).
The piping and instrumentation diagrams should be carefully reviewed at the plant design
phase to ensure adequate nozzles and valves on the piping are available to carry out any
of the above cleaning procedures that are anticipated.
11.4.6 Deriming, Back Flushing, and Drying
Deriming and back flushing involves the use of heat and/or solvents to remove hydrates,
heavy hydrocarbons, waxy materials, compressor oils, or other soluble matter which
freeze or collect in the unit. The presence of these materials is detected by an increase in
the stream pressure drop and/or loss of heat transfer performance.
When systems for injecting methanol during operation have not been provided, shut down
and purge the unit and allow it to warm and defrost itself by natural heat leak or by an
approved derime procedure. Normally, the combination of warming and back flushing with
a solvent rinse such as trichloroethane, toluene, propylene, or methanol is successful for
this purpose.
Prior to startup, purge and dry out the unit in accordance with the startup section.
If a water based solvent is used to derime or back flush, or if water accidentally gets
introduced into the exchanger, the unit must be completely dried before returning to
service in order to prevent plugging or rupture caused by freezing. Use dry air, nitrogen, or
other dry gas as the drying medium.
The derime, back flushing, or drying temperature should not exceed 150 F (65 C),
unless the maximum working temperature on the Chart nameplate is higher. Do not
exceed the maximum working temperature specified on the Chart nameplate.
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The derime, back flushing or drying media shall be non-corrosive to aluminum. Always
use clean fluids. If any vessels, piping, or temporary pipe sections are used during the
cleaning, it is important to clean them of pipe scale, dirt, weld slag, or any other foreign
material which could enter and plug the exchanger.
When liquid solvents are used for purposes of deriming or back flushing the unit, the
nozzle fluid velocity should not exceed 10 ft/sec (3 m/s) to prevent erosion inside the heat
exchanger. Liquid solvents or any cleaning fluids should always be circulated through the
unit in the reverse direction of normal operating flow.
Cleaning solvents should always be chosen with regard to the suspected fouling agent. If
the fouling agent is unknown, a sample of it should be chemically analyzed to determine
its composition.
If any special procedures are required to meet uncommon derime, back flushing or drying
conditions, contact Chart for further evaluation.
11.4.7 Back Flowing / Rupture Disk Techniques
When proper precautions are taken regarding filtering, many years of clean service can be
expected. However, when foreign material (pipe scale, perlite, desiccant, mole sieve, etc.)
is introduced into the heat exchanger itself, by accident or mis-operation, back flowing can
be an effective method for removing entrained particulates.
Since particulates normally cause blockages in the heat exchanger at the inlet ports and
distributors, flowing in the reverse direction of normal operating flow is required to prevent
pushing the particulates farther into the exchanger. The back flowing procedure involves
attaching a rupture disk to the inlet nozzle or flange of the stream to be cleaned and
pressurizing the stream with a dry gas up to the approved pressure described below.
It is the user s responsibility to take the appropriate safety precautions regarding
personnel, clearing the test area, and the suitability of the supports and bracing to
withstand the reaction forces developed when the rupture disk bursts.
Extreme caution should be exercised as the rupture of the disk and the release of gas can
result in a rapid discharge of gas and flying debris which could cause serious personal
injury or death.
The plugged stream is slowly filled with dry air or nitrogen until the rupture disk bursts. The
sudden release of gas will help dislodge particulate matter. This back flowing procedure
should be repeated five (5) to ten (10) times, or until the amount of particulate removed
becomes minimal and the discharge cloud is clear.
Extreme caution must be exercised so as not to exceed the maximum working pressure of
the stream on the Chart nameplate, or 100 psig (7 Barg), whichever is less. Failure to limit
pressurization to these limits could result in a rupture of the heat exchange and cause
serious personal injury or death.
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If the maximum allowable pressure is reached and the rupture disk has not burst, the
stream should not be depressurized and a new rupture disk installed.
11.4.8 Repairs and Service
If a leak is detected, Chart should be notified for repair recommendations. Chart is well
qualified and staffed to perform field or factory service and repair on this type of
equipment.
Refer to the serial number shown on the unit nameplate when contacting Chart.
All ASME repairs must be certified by an R stamp and must be in accordance with
the Chart Heat Exchangers Quality Assurance Policy, the National Board Inspection Code,
and the ASME Code or any local jurisdictional requirements.
Repair to the unit should be made only authorized Chart personnel. The Chart Warranty
will be voided if repairs made to the unit during the warranty period are made by
unauthorized service personnel. Improper welding or brazing procedures on the
exchanger block can damage the braze joints. Repairs not made in accordance with
ASME procedure, and identified by the R stamp on the Chart nameplate, will
invalidate the National Board registration of the unit.
Improperly repaired units may not be suitable to withstand the nameplate maximum
working pressure ratings.
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12 TURBO EXPANDER / RESIDUE GAS COMPRESSOR(L-231-001/C-232-001)
12.1 DESCRIPTION OF EQUIPMENT
The complete turbo expander-booster system consists of two skids: one skid for the
machine and theother skid for the lube oil system. The skids are interconnected by a skid-
bridge to enable exact positioning of the two skids on the foundation for proper
prefabricated interconnecting piping installation.
The sub-systems for seal gas, oil supply, draining and venting, controls for monitoring and
safe operation, start-up panel, local gauge boards, etc., are integrated and assembled on
the two skids.
12.1.1 Turbo expander
The expansion turbine is of the radial inflow type with advanced aerodynamic design
maximising the isentropic efficiency. The machine is of a proven cartridge concept which
allows a quick replacement of the machinery capsule including rotating parts without
interference with expander process pipes.
12.1.2 Expander nozzle control
A system of vanes (adjustable nozzles) is located around the expander wheel and is used
to control the process gas flow by changing the flow area.
The nozzle vanes offer a simple construction, with shock free deceleration and provide the
widest possible flow range.
Vanes are pivoted around one of its mounting bolts in clockwise and counter-clockwise
directions
This adjustment is done by means of a lever system operated by a pneumatic actuator
with Positioner (PY 5716).
12.1.3 Compressor
A 3D high efficiency compressor wheel is utilized as a loading device, recovering the

mechanical energy from the expander.
A vane diffuser ensures optimum efficiency and head flow characteristic.
12.1.4 Bearing cartridge
A rigid shaft is supported by two tilting pad bearings in the bearing carrier. The bearing
carrier also includes the labyrinth seals and supports the expander nozzle assembly and
booster diffuser. The wheel to shaft connection is by means of a Hirth radial spur tooth
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coupling and tightening bolt. The assembly of the bearing carrier with nozzle assembly,
diffuser and shrouds is called plug in unit. The plug in unit to be preferably kept as spare.
12.1.5 Quick closing valve
In case of critical conditions that may lead to turbine or compressor damage (such as
expander overspeed), the unit has to be shut-down and isolated from the process in
emergency. This is performed by the quick closing valve (XV 5721) which is provided at
the inlet of the expander.
This valve is pneumatically operated, spring loaded and shall be mounted upstream of the
expander inlet.
The fail safe position of the valve is closed. The closing time from the fully open to the fully
closed position should be 1 second or less whereas the opening takes a minimum time of
10 seconds to prevent heavy pressure shock on closed expander inlet guide vanes
12.1.6 Anti-surge valve
The control system is composed by the following elements:

- An anti-surge valve (FCV 5723)
- A measurement of differential pressure of the compressor
- A measurement of an orifice differential pressure (to reflect the compressor inlet
volume flow).
Schematic of general principle:
Basically, the anti-surge system is using the values of DPcompressor and DPorifice to
determine the surge area
The control strategy is to avoid that the compressor operates to the left-hand side of the
surge line.
A proportional-integral controller (PI controller) shall be used to control the surge valve.
Its a generic control loop feedback mechanism widely used in industrial control systems.
A PI controller attempts to correct the error between a measured process variable and a
desired set point by calculating and then outputting a corrective action that can adjust the
process accordingly, based upon two parameters (proportional and integral).
During operation, the controller reads the process value (PV), it subtracts this
measurement from the set point value (SP) to determine the error (e). It then uses the
error to calculate a correction and control the surge valve (the "action") so that this
correction will remove the error from the process value (PV).
Set point calculation: SP= (DP compressor x (1/tan )) + offset C
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Note: The angle ( ) and offsets (C and C ) will be defined by Cryostar according to
Anti-surge instrumentation characteristics after FAT & Bench test and validated during
Commissioning phase.
Principle:
- When PV is higher SP, the controller shall close the surge valve to try to reduce PV
(normal condition).
- When PV is lower SP, the controller must be open surge valve to increase PV (surge
protection).
In case the controller is not fast enough (valve reaction too slow, poor piping configuration
of anti surge loop or a fast flow decrease) the flow may decrease far below the SP and
could eventually reach the surge line. To avoid this there is a safety line between the
CTRL Line and the Surge Line.
When the operating point reaches the safety line, the proportional-integral function shall
be by-passed and the controller shall require immediately the full opening of the surge
valve until the
operating point is back to the right-hand side of the CRTL Line.
12.1.7 Axial thrust system
The axial thrust force is a result of a pressure loads on the expander and the compressor
wheel. A too high differential force behind the two wheels can damage the bearings and
thus the turbo expander.
To control and to minimize the axial thrust, a control valve (PDCV 5708) is installed on a
line connecting the compressor back wheel to the compressor inlet.
Axial thrust measurement is done by measuring oil pressure on each axial bearing (PIT-
5708A/B). Each value is sent to the PLC, which will calculate a differential pressure
between the bearings and then send a signal to the control valve to regulate this
differential pressure.
12.1.8 Auxiliaries systems
12.1.8.1 Seal gas system

The whole machine is totally encapsulated. To prevent leakage to the atmosphere no
rotating seals are installed. The purpose of the seal gas system is to prevent the process
flow from freezing and entering the magnetic bearings and to avoid untreated
hydrocarbons to enter the bearing cavity. In order to do so, the seal gas pressure must be
higher than the expander labyrinth reference pressure.
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This pressure is controlled by the control valve (XV 5701) within the skid and injected
between the impellers and the bearings on expander side.
12.1.8.2 Lube oil system
The lube oil system is a pressurised closed circuit, following the API 614 design and
execution rules.
To draw the lube oil from the pressurized reservoir to the bearings, two screw pumps (C-
232- 001-P1A & C-232-001-P1B) are available. During normal operation only one pump
(main pump) is running whereas the other one (auxiliary pump) is used in case of main
pump failure.
Two pressure safety valves (PSV 5735A & PSV 5735B), set to 232 psig, are installed at
each pump discharge in case of over-pressure in lube oil circuit.
At pumps discharge, the lube oil is cooled-down via a temperature regulation loop
consisting on a shell & tube heat exchanger (C-232-001-E1A & C-232-001-E1B), a 3-way
automatic control valve (TCV 5739), a temperature transmitter (TT 5741) at filter outlet.
It is to be noted that in the shell & tube heat exchanger, oil circulates inside the shell
whereas the coolant (water) circulates inside the tubes.
After cooling, the lube oil is also filtered through a duplex filter (C-232-001-F1A & C-232-
001-F1B) which can be switched during operation with the transfer valve. The clogging of
the filter is continuously monitored by a differential pressure transmitter (PDIT 5740) which
activates an alarm in case of too high pressure.
The pump discharge pressure is controlled by a pressure regulation loop to maintain a
constant differential pressure across the machine bearings. The loop consists on a
pressure control valve (PCV 5745), a differential pressure transmitter (PDIT 5743). In
function of the signal of the PDIT 5743, the UCP adjusts the position of the valve PCV
5745 via the valve positioner PY 5745. The valve PCV 5745 is connected upstream the
coolers.
Note: the three other pressure transmitters (PDIT 5744A / B / C) located beside PDIT
5743 are dedicated for trip signal in case of very low pressure.
In case of lube oil low pressure alarm, a 220 liters accumulator (C-232-001-V3) will
maintain the pressure above the low low trip during 6 seconds in order to allow stand-by
pump starting.
In case of lube oil low low pressure trip, the accumulator will lubricate the bearings during
10 seconds to allow a safe cost down of the machine.
The pressurized lube oil return line from the bearing cartridge to the reservoir closes the
pressurized loop.
During start-up and normal operation, the oil temperature in the tank shall not be below
15C.
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So, when necessary the lube oil is heated with an electrical oil heater (C-232-001-H1)
immersed under the oil level in the tank. The oil temperature is continuously measured by
the temperature transmitter (TT 5729) and sent to the UCP. If the temperature is below
15C, then the UCP sends a start signal to the MCC to switch-on the heater. As soon as
the temperature reaches 37C, the UCP sends a stop signal to the MCC to switch-off the
heater. In case of heater over-heating, a safety thermostat (TSHH 5730) sends a stop
signal to the UCP to cutoff the power from MCC.
In case of oil heater trip, the safety thermostat shall be manually reset to start again the
temperature regulation.
12.1.8.3 Drain system
Expander and compressor bearing casings are connected to an integrated drain system
which allows the machine to be purged manually.
12.1.8.4 Instrument air line
On the turbine skid, pneumatic equipment is installed.
In this case, instrument air will be supplied by the customer.
The instrument air shall be filtered and exempt of dust particles and oil concentration
(customer scope).
12.1.9 Control instruments and local control panel
The system mainly includes monitoring instruments and transmitters for bearing
temperature control, shaft speed, vibration control, various pressure, and differential
pressure and temperature readings.
Instruments are mainly located on the local gauge boards as shown on gauge boards and
local panel drawings
The system includes temperature and pressure transmitters, nozzle position feedback (ZT
5716),
QCV limit switches (ZSH 2721 / ZSL 5721), (optional: anti-surge valve position feedback
(ZT 5723)).
The following indications and switches are on local panel (Switch box) :
- Process ready XA 5770
- Ready to start XA 5771
- Oil pump master A/B HS 5759
- Oil pump switching manu/auto HS 5773
- Common trip XA 5772
- Filling pump fault XA 5761
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- Oil heater fault XA 5763

- Oil pump A fault XA 5765
- Oil pump B fault XA 5767
- Common alarm XA 5759
- Filling pump on XA 5760
- Oil heater on XA 5762
- Oil pump A on XA 5764
- Oil pump B on XA 5766
- Turbine on XA 5778
- Filling pump start HS 5760
- Oil heater start HS 5762
- Oil pump A start HS 5764
- Oil pump B start HS 5766
- Turbine start HS 5768
- Filling pump stop HS 5761
- Oil heater stop HS 5763
- Oil pump A stop HS 5765
- Oil pump B stop HS 5767
- Turbine stop HS 5769
- Stop horn HS 5770
- Reset HS 5771
- Seal gas start HS 5779
- Seal gas stop HS 5780
- Test lamp HS 5772
- Emergency stop HS 5758
Note for Local Control Panel : The contact is necessary to cut the power before the first
pressurization of the LCP. In case of depressurization (or pressurization failure), the main
power supply will stay activate and there will be an alarm.
12.1.9.1 Speed protection

The Turbo expander is equipped with four speed detectors :
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Three detectors (SE5709A, SE5709B, SE5709C) are in 2oo3 mode. In case of overspeed
and underspeed they give a trip signal to ESD.
SE5710 is connected to the ST5710 transmitter, which sends an alarm to the PLC, in case
of high speed.
12.1.9.2 No dwell zone
The No-dwell zone is speed range within which the machines shall not be operated in
order to avoid potential mechanical damage due to resonance phenomenon.
To prevent any problem:
- An alarm is activated when the machine operates more than 1 minute in the no dwell
zone
- A trip occurs if the machine operates more than 5 minutes in the no dwell zone.
12.1.9.3 Vibration measurement analysis
The vibration system monitors signals coming from vibration transmitter / probes and/or
accelerometer transmitter / probes placed into axial and radial bearings to detect any high
vibration conditions on the machine.
12.1.10 Control panels for installation in control room
The PLC control system is contained in free standing control panels for installation in a
control equipment room located in safe area. The vibration monitoring system is also
included in the control panels.
12.1.11 Hazardous area protection
As the machine is operated in a hazardous area, all necessary precautions are taken, e.g.
all instruments etc. are selected according to the required area classification.
The machine itself is hermetically encapsulated and the windings are situated in an
oxygen-free (i.e. inert) gas atmosphere. Therefore the safe machine operation is not
assured by certification requirements but by strict adherence to the maintenance and
operation procedures.
All internals of any part of a hydrocarbon process system must be purged by inert gas
prior to filling with the process gas for pressurisation, in order to avoid hazardous gas
pockets of an oxygen/hydrocarbon mixture. The same is done with the expander unit as -
in this context -there is no difference between a process pipe, heat- exchanger, pressure
vessel, - or an expander.
After installation and maintenance, purging of the internals is compulsory and must be
checked / confirmed and signed by authorized person.
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12.2 OPERATION OF EQUIPMENT
12.2.1 Start up preparation (pre-commissioning)
12.2.1.1 Details of checks and controls

A. Check the foundation and the anchor bolts.
B. Check that the entire installation is completely cleaned. It is necessary to have clean
piping before start-up (prior to flanging up to the new equipment)
C. The unit piping and controls shall be checked in accordance with the piping and
instrument diagrams.
a. Inlet strainer shall be installed :
On expander inlet line upstream the quick closing valve (XV 5721)
On compressor Inlet line
b. Check all interconnection piping between the two skids (flexible hose position)
c. Check all piping and electrical connections.
d. Check that all valves, controllers and switches are in their proper positions.
e. All vents & drains not permanently piped shall be plugged with solid pipe plug of
similar material.
D. Check process piping for excessive forces and moments.(Customer Doc. No.: VP-18-
103-001-C-232-001-C-003) and Alignment procedure.- this can be done by checking
displacement after single piping disconnection or by checking machine movement
after disconnection from skid.
Note: Piping supports/spring hangers shall be adjusted accordingly when the system is
in service at operating temperature.
E. Check that all skid junction boxes are correctly connected to the control cabinets as
indicated in the wiring schematics Document (Customer Doc. No.: VP-18-103-001-C-
232-001-SK-023), in section VIII. Electrical schematics.
F. Check that all instrumentation has been calibrated and functionally tested.
For instruments details see Instrument data sheet, document (Customer Doc. No.: VP-
18-103-001-C-232-001-D-002),
Caution:
Follow all Ex-classified zone rules as given by applicable standards and plant
operational rules.
The Ex-certification of the power electrical equipment is collected in the Quality control
data book, Document (Customer Doc. No.: VP-18-103-001-C-232-001-P-023A).
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G. Check the operation of the control system according to the logic diagram, Document
(Customer Doc. No.: VP-18-103-001-C-232-001-SK-024),.
a. Check that all control loops have been functionally tested and all control valves work
properly.
b. Check that the modbus communication between DCS and control cabinet is
operational
H. Check the control system alarm and trip values according to the set point list. See
Document (Customer Doc. No.: VP-18-103-001-C-232-001-C-005)
I. Check that all power supplies are at correct voltage correctly connected to all power
consumers as indicated in the electrical load list, Document (Customer Doc. No.: VP-
18-103-001-C-232-001-SK-031).
J. Disassemble pump couplings. Check voltage/frequency indicated on the nameplate
and perform motors electrical wiring. Check that the delta/star connection is properly
performed. Make
a quick start of the motor to check that shaft rotation is the same that pump rotation.
Reassemble the coupling
Caution:
- Incorrect direction of rotation will damage the lube oil pumps
- During the rotation check without lube oil filling, do not operate the motors longer
than few seconds only
- Follow all Ex-classified zone rules as given by applicable standards and plant
operational rules.
K. Check the seal gas system and instrument air systems to be operational.
L. Prior to start up of the seal gas system, the entire machine, lube oil and seal gas
system needs to be inertized and dried with inert gas.
Note, insufficiently dried process system may lead to expander nozzle clogging and
seizure and also to expander wheel rubs.
12.2.2 Start up (commissioning)
12.2.2.1 Start-up philosophy

The commissioning before start-up consists on the following steps which must be adhered
as per the sequence listed below:
A. Lube oil flushing
B. Inertization and drying with Nitrogen
C. Seal gas starting
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D. Oil system starting

E. Pressurization
F. Draining
12.2.2.2 Lube oil flushing
The flushing of the lube oil system has to be done preferably in atmospheric conditions.
To perform the flushing proceeds as follows:
A. Open the valve V5M to connect oil tank at atmospheric pressure
B. Fill the lube oil tank with oil as specified in Lubricant list and
C. Clean lube oil system from spilled oil if necessary, to identify any leakage during the
flushing.
D. Charge the oil accumulators with nitrogen at:
25 bar(g) if ambient temperature is 20C
23 bar(g) if ambient temperature is -3C
28.1 bar(g) if ambient temperature is 55C
Note : Charging shall be done when the system is not running, depressurized, and
vent valve from the accumulator shall be opened (and closed again after charging has
been done).
E. Open the valve V5V and close the spectacle blind just before the oil bearing inlet in
order to by-pass the Expander bearings.
F. Operate the lube oil heater, if the oil temperature is below pump start interlock
temperature
G. Open vent valves from coolers and filters.
H. Open the pressure equalization valves on the oil cooler and the oil filter.
I. Open the vent valves from the pump casings (main and stand-by) and rotate the
coupling. When some oil comes out, close the vent valves. This is in order not to
damage the mechanical seals.
J. Start main lube oil pump and the lube oil will flush back to oil tank.
K. Adjust the oil pressure to 10 bar (measured by transmitter PDIT 5743) by slightly
closing the valve V 5V.
L. Check that oil is passing through the flow gauge FG 9 at bearing cartridge outlet.
M. Check the flow gauges on the vent lines from coolers (FG 5737) and filters (FG 5740).
As soon as oil is going through the flow gauges close the vent valves.
N. Switch over oil filter and oil cooler.
O. Refill oil as required due to the oil coolers and system filling
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P. Check operation of stand-by pump by opening the valve V 7F. After 5 minutes of
operation close the valve V 7F.
Q. Flush the machine for some 12 hours (during the flushing hit few times the oil piping
after the double oil filter by wooden bar). During this 12 hours check the oil system for
oil leakage.
R. During running check all relevant oil system data to be in accordance with set point list
S. Stop the oil pump.
T. Check the pump suction strainers and the dual oil filter for cleanliness
U. Close the valve V5M
V. Close the valve V 5V and open the spectacle blind just before the oil bearing inlet.
The complete unit can be declared now ready for inertization and drying.
12.2.2.3 Inertization and drying with Nitrogen
Prior to start the seal gas system, the entire lube oil and seal gas systems shall be
inertized and dried with inert gas in order to prevent formation of hazardous gas pockets
mixture made of oxygen/hydrocarbon gases.
The only recommended method to inert the Expander/Compressor and its lube oil system
is to proceed by successive cycles of pressurization / depressurization. The purpose of
this method is to purge all cavities, also piping dead ends in order to prevent formation of
hazardous gas pockets made of oxygen/hydrocarbon mix.
The cycles of pressurization / depressurization shall be repeated as long as the required
oxygen concentration has not been reached.
Purging by scavenging is not recommended as the dead area will not be purged in this
way. (Scavenging consists on filling the machine with Nitrogen at low pressure to force
process gas out of the unit, without pressurization/depressurization cycles).
Note :
After the inertization and drying, the machines and the entire system can be kept dry
by pressurization with inert gas atmosphere during long non operational stand by periods.
Insufficient dried process system may lead to expander nozzle clogging and seizure
and also to expander wheel rubs.
Inertization & drying shall be mandatory achieved before the first start-up of the
machine, or if the machine has been completely depressurized for maintenance.
12.2.2.4 Seal gas starting
To start the seal gas, the following actions shall be done:
Check if all internal valves are in the required position as indicated in the P&ID.
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Check if seal gas heater control panel is energized.

Open the seal gas supply valve XV-5701 from the LCP.
Seal gas heater will start automatically based on temperature set point measured with
the TT-5706.
The seal gas outlet pressure of the pressure control valve PDCV-5704 will be
automatically controlled by the PLC, based on pressure differential transmitters PDIT-
5704 value.
At this stage the expander/compressor is completely isolated from the process and
considered as a closed circuit. As soon as the seal gas valve is opened, the pressure in
the complete unit will start to rise. If the pressure into the machine (measured by
transmitters PIT-5715A / PIT-5715B / PIT-5725) reaches the JT valve outlet pressure, the
main process isolation valves at Expander inlet / outlet and compressor inlet / outlet shall
be opened.
12.2.2.5 Oil system starting
The lube oil system can be started only if the Seal Gas is in operation.
To perform the start-up, proceed as follows:
Check the oil accumulator bladder charging pressure.
Start the oil heater from the LCP or the PLC, if the oil temperature is below pump start-
up interlock.
Check if the pressure equalization valves on the oil coolers and the oil filters are open.
Start main lube oil pump* from the LCP.
Vent the filters and the coolers back to the oil tank.
Switchover filters and coolers.
Check all relevant oil system data and piping for leaks.
If no alarm and no leakage have been found, the machine can be declared ready for
pressurization.
The pump shall be correctly vented and filled with oil before starting. See oil pump
operating and maintenance manual for more detail.
12.2.2.6 Pressurization
The expander casing, bearing carrier, compressor casing and lube oil tank shall be
pressurized by process gas.
The entire package unit shall be pressurized at the JT valve outlet pressure value. The
pressure inside the unit is measured with the transmitters PIT-5715A / PIT-5715B / PIT-
5725.
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UNIT 232
Depending on the installation of the main process isolation valves and the sizes of
process piping, the time needed to pressurize the complete unit can vary. If the JT outlet
pressure has not been reached after the lube oil system starting phase, the 2 inches by-
pass valves from expander outlet and compressor
inlet main isolation process valves can be opened. This will accelerate the pressurization
phase.
However, care shall be taken by opening these 2 inches valves simultaneously in order
not to have too much differential pressure between expander and compressor wheels (to
prevent big axial loads).
As soon as the Expander / Compressor reaches the JT valve outlet pressure, the main
process isolation valves at Expander inlet / outlet and compressor inlet / outlet shall be
opened.
12.2.2.7 Draining
Prior to start the machine, the Expander and the Compressor casings shall be drained of
any condensates:
Open valve V9C at CP6 connection.
Open shortly valve V9A at Expander casing drain.
Open shortly valve V9B at compressor casing drain.
Close valve V9C at CP6 connection.
Note : The machine can be restarted without draining if the plant has been kept isolated
from the atmosphere and if the re-starting is done within 24h (maximum) of a shutdown.
12.2.3 Start-up sequence
The following operation can be started only if the entire procedure described previously
has been completed
Start-up of the Expander/Compressor is only available from the Local Control Panel
located on the skid.
Before to start the Expander/Compressor, it is assumed that the following conditions are
fulfilled :
The whole process has been started and is now operating with the JT valve in
steady state conditions.
Anti-surge valve FCV-5723 shall be open, Expander IGVs shall be closed,
Quick Closing Valve XV-5721 shall be closed.
Permissive to start from ESD.
Permissive to start from PLC (no alarm and no trip).
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Permissive to start from the DCS.

The main process isolation valves at Expander inlet/outlet and Compressor
inlet/outlet are open.
A. Push start button on Local Control Panel to open QCV.

B. Anti-surge controller is activated.
C. The UCP will automatically increase IGVs opening to the 1st Step Speed (2000 rpm).
D. 1st Step Speed will be maintained automatically by the UCP for 30 minutes (for
bearing warm-up). Increase / decrease button on the LCP will be inactive during this
period. Check also the following parameters during this warm-up step:
Seal gas differential pressure PDIT-5794
Lube oil differential pressure PDIT-5743
Bearings temperature TE-5711/5712/5713/5714
Bearings vibration VXE/VXY-5717 and VXE/VXY-5719
Oil mist separator differential pressure PDIT-5734
E. The UCP will automatically increase IGVs opening to the 2nd Step Speed(4400
rpm). During this phase you will cross a No-Dwell zone. Staying 1 minute in this No-
Dwell zone will generate an alarm, and 5 minutes will generate a trip.
F. 2nd Step Speed will be maintained automatically by the UCP for 30 minutes (for
bearing warm-up). Increase / decrease button on the LCP will be inactive during this
period.
G. Once this second warm-up step has been finished, expander speed is controlled from
the DCS.
Notes:
During all this speed ramping, the JT valve shall take care of the Expander suction
header pressure. Once the minimum operating speed has been reached, the suction
pressure control shall be transferred from the JT to the Expander.
During the first 15 seconds of the start-up of the machine a trip multiply will be
active on the vibration alarm setpoint. This function is applied during start-up to allow
the expander to pass through the high vibration range (due to system resonance and
other normal transient vibrations) without alarm indication.
During warming steps, the bearing cartridge temperature stabilization is required
to avoid too fast shaft elongation in cold housing, what may cause axial bearings
damage.
No dwell zone will be between 3300 to 4000 rpm.
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
12.2.4 Steady state operation
The flow through the expanders may be adjusted by changing the position of the
adjustable nozzles. The signal shall be transmitted from DCS to PLC via hard wire.
12.2.5 Expander shut down
The normal shut down shall be done from the local control panel or the DCS.
The following are the normal shut down steps:
A. Manually close the turbine inlet guide vanes gradually until fully close. In the meantime
compressor anti-surge valve opens gradually as directed by the anti-surge controller
CCC.
B. Closing of the quick shut off valve
C. Oil pump and seal gas should only be shut off in case of a turbine standstill of more
than 12 hours.
Otherwise both systems should remain in operation.
12.2.6 Emergency shut down
The expander emergency shutdown is performed via the Local control panel or the ESD.
The following are the emergency shut down steps:
A. Closing of the quick shut off valve.
B. Closing of turbine inlet guide vanes, opening of compressor anti-surge valve as
directed by the anti-surge controller CCC.
If desired after the trip, the turbine can be isolated by process block valves and be
maintained
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
12.3 TROUBLE SHOOTING
12.3.1 Process system
12.3.1.1 Speed
Speed transmitter (ST-5710)::
Alarm / Default Causes Required action
Trip level description
Alarm (SALL) Speed is below Acceleration during Increase acceleration rate during
(SE5709 A/B/C) expander minimum start-up too low start-up
speed Process flow rate to Check process conditions
low Check JT opening
Speed detection Check the complete loop of the
system failure speed detection
Value displayed on Wiring of the instru- Check if you have a wire break of
the transmitter is ment this instrument
erroneous Faulty calibration of Check and adjust, if necessary,
the transmitter the calibration of the instrument
according to the set point list
Default on the Check the analog input card
analog input card
Trip Check expander flow set point
Overspeed Process
(SAHH / SAH) value
(SE 5709 A/B/C) Value displayed on Check if you have a wire break of
Wiring of the instru-
the transmitter is this instrument
ment
erroneous
Faulty calibration of Check and adjust, if necessary,
analog input card
12.3.1.2 Displacement
Vibration transmitter (VXT 5719 / VYT 5719 / VXT 5717 / VYT 5717):
Alarm (VXAH) & Radial Rotor unbalance Dismount bearings and check all
Trip (VXAHH) displacement level mechanical parts during next
measured on the maintenance stop
shaft is too high Dismount bearings and check all
mechanical parts immediately
Vibration probe Check mounting of the vibration
installation default probe (tightening, clearance
shaft/probe) during next
maintenance stop
Check mounting of the vibration
probe (tightening, clearance
shaft/probe) immediately
Surge phenomenon Check if ASV loop is working
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
correctly
Process conditions Check flow and pressure
instability variations
Value displayed on Wiring of the Check if you have a wire break of
the transmitter is instrument this instrument
erroneous
analog input card
12.3.1.3 Pressure
Differential pressure transmitter (PDIT 5720) on expander inlet filter:
Alarm (PDAH1 & Differential Filter high clogging Maintenance is needed: strainer to
PDAH2) pressure is too high be cleaned or changed
immediately
analog input card
Differential pressure transmitter (PDIT 5724) on compressor inlet filter:

Alarm (PDAH1 & Differential Filter high clogging Maintenance is needed: strainer to
PDAH2) pressure is too high be cleaned or changed
immediately

erroneous

analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Differential pressure transmitter (PDIT 5704/PDIT 5705A/B/C) on seal gas supply :

Alarm (PDAL) or Seal gas pressure PDCV 5704 Failure Check PDCV setup and correct
Trip (PDALL) is not high enough action of the actuator
compare to
reference pressure Seal gas doesnt
arrive to the cavity
pressure:
- Obstructed - Dismantle tubing and check if it is
not obstructed
- Filter high - Check seal gas filter cartridge
clogging and change it if necessary.
- Check valve - Check position and proper

failure operation of the check valve
-Manual valve closed
-Manual valve -Check that manual valve is
closed opened/closed as indicated on
P&ID
erroneous
analog input card
Differential pressure transmitter (PDIT 5703) on seal gas filter :

Alarm (PDAH) Filter differential Filter high clogging 1) Switch to the second filter
pressure is too 2) During the next maintenance
high. stop, the filter cartridge must be
changed.
Seal gas flow is too Check setting of the PDCV

high according to the set point list
During the next maintenance stop,
check the wear of the labyrinths

analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
12.3.1.4 Temperature
Temperature transmitter (TT5706 / TT5707A/B/C) on seal gas inlet
Alarm (TAL) Seal gas The heater doesnt Check the regulation of the heater
& temperature at operate correctly and its correct operation
Trip (TALL) cavity inlet is too
low. Seal gas flow is too Check if flow rate is in accordance
high with operating flow range
Seal gas inlet Customer must check the seal gas
temperature is too inlet temperature
low
erroneous
analog input card
Temperature element (TE 5711A / 5711B / 5711C) on Expander axial bearing:

Alarm (TAH) Temperature on Oil temperature too Check cooling water temperature
& bearing (expander high
Trip (TAHH) side) is too high Check oil temperature supply at
TT 5741
Axial load too high Check process conditions
Check PDCV 5708 (axial trust

valve)

erroneous
analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Temperature element (TE 5712A & TE 5712B) on Expander radial bearing:

Alarm (TAH) Temperature on Oil temperature too Check cooling water temperature
& bearing (expander high
Trip (TAHH) side) is too high
Check oil temperature supply at
TT 5741
Axial load too high Check process conditions
Check PDCV 5708 (axial trust

valve)

erroneous

analog input card
Temperature transmitter (TT 5702 A/B) on seal gas heater:

Alarm (TAHH) Over-temperature Low seal gas flow Cut the power on seal gas heater
on the seal gas
heater heating Inlet gas Customer must control the inlet
element temperature is too gas temperature
high
erroneous

analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
12.3.2 Oil system
12.3.2.1 Pressure
Differential pressure transmitter (PDIT-5734) on oil mist separator :
Alarm (PDAH) Differential Seal gas flow is too Check that seal gas differential
pressure on oil mist high pressure is 0.5 bar (PDIT 5704)
separator is too
high Filter clogging Stop the machine and replace the
cartridge of the mist eliminator
erroneous

analog input card
Differential pressure transmitter (PDIT-5743) on Lube oil supply:

Alarm (PAL) Differential Pump discharge Check pressure discharge on PIT
pressure on lube oil pressure is too low 5735 A/B
supply is too low
Filter clogging Replace the filter cartridge
PCV 5745 Check regulation loop of the

malfunction PCV 5745

erroneous

analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Differential pressure transmitter (PDIT-5744A/B/C) on Lube oil supply:

Trip (PALL) Differential Pump discharge Check pressure discharge on PIT
pressure on lube oil pressure is too low 5735 A/B
supply is too low
Filter clogging Replace the filter cartridge
PCV 5745 Check regulation loop of the PCV

malfunction 5745

erroneous
analog input card
Differential pressure transmitter (PDIT-5740) on Lube oil filter:

Alarm (PDAH) Filter differential Filter high 1) Switch to the second filter
pressure is too clogging 2) During the next maintenance
high stop, the filter cartridge must be
changed.
analog input card
Differential pressure transmitter (LT 5727) on Lube oil tank level:

Alarm Differential Oil level too high Drain the oil tank by using valve
(PAH / PAL) pressure on lube oil V5B
tank level is too
Oil level too low Adjust oil level by using the filling
high
pump C-232-001-P2

analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Pressure transmitter (PIT 5735A / PIT 5735B) on Lube oil pressure downstream pump:
Alarm (PAH) Discharge Obstruction in the Check the oil circuit after pump:
pressure of the oil circuit after check valve position manual
standby pump is standby pump valve position Lube oil cooler
too high Filter (for clogging)
erroneous
analog input card
12.3.2.2 Temperature
Temperature transmitter (TT 5741) on lube oil supply:

Alarm (TAH) Lube oil TCV 5739 - Check valve and actuator
temperature is too malfunction - Adjust the setting of the TCV if
high necessary
Oil cooler - Check that oil cooler is on line

malfunction - Check cooling water temperature
Oil temperature in Check temperature, vibrations on

oil tank is too high bearings.
12.3.2.3 Viscosity
Viscosity transmitter (VT 5748) on lube oil supply:
Alarm High oil viscosity Oil temperature too Oil must be heated
(TAH / TAL) low
Low oil viscosity Oil temperature too See TT 5741
high
analog input card
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
ATTACHMENT
No. Description Refer to
Dwg. No. 090768.232-3.00-301/302-A-B
Process Flow Diagram
1 Dwg. No. 090768.231-3.00-
(PFDs)
300/351/352-A-B
Piping & Instrumentation Diagram Dwg. No. 090768.232-3.00-021~031-A-
2
(P&IDs) B
3 Plot Plan Dwg No. 090768.231-3.00-901-A-A
4 Equipment List Doc. No. S090768.231-3.01-001-A-E
5 Equipment Data Sheet Doc. No. refer to attachment
6 Utility Summary Doc. No. S090768.231-3.01-011-A-E
7 Instrument Data Sheet Doc. No. refer to attachment
8 Cause and Effect Diagram Doc. No. S090768.231-3.00-016-A-E
9 Safeguarding Memorandum Doc. No. S090768.231-3.00-013-A-E
10 Alarm and Trip Setting Doc. No. S090768.231-3.01-004-A-E
11 Dynamic Simulation Study Report Doc. No. S090768.231-3.01-005-A-E
12 Gas Detector Monitor Location Plan Dwg. 090768.231-3.70-321-A-B
13 Chemical & Catalyst Summary Doc. No. S090768.231-3.00-012-A-E

Technical Data of TURBO
14 EXPANDER (L-232-001) & RESIDUE Doc. No. refer to attachment -
GAS COMPRESSOR (C-232-001)
Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Attachment #1
Process Flow Diagram (PFDs)
- Dwg No. 090768.231-3.00-300-A-B

- Dwg. No. 090768.232-3.00-301-A-B
- Dwg. No. 090768.232-3.00-302-A-B
- Dwg No. 090768.231-3.00-351-A-B
- Dwg No. 090768.231-3.00-352-A-B
(To be Attached Later)

Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Attachment #2
Piping & Instrumentation Diagram (P&IDs)
DWG_No Drawing_Title
090768.231-3.00-001-A-B P & ID FOR DRAWING LIST
090768.231-3.00-002-A-B P & ID FOR EQUIPMENT INDEX
090768.231-3.00-003-A-B P & ID FOR GENERAL NOTES SYMBOLS AND LEGEND (1/5)
090768.231-3.00-004-B-B P & ID FOR GENERAL NOTES SYMBOLS AND LEGEND (3/5)
090768.231-3.00-007-A-B P & ID FOR CUSTODY METER DETAIL (1/2)
090768.231-3.00-008-A-B P & ID FOR CUSTODY METER DETAIL (2/2)
090768.231-3.00-009-A-B P & ID FOR VENT AND DRAIN DETAIL
090768.232-3.00-021-A-B P & ID FOR COMBINED REBOILER EXCHANGER
090768.232-3.00-022-A-B P & ID FOR RESIDUE GAS EXCHANGER / REFLUX SUBCOOLER
090768.232-3.00-023-A-B P & ID FOR DRY FEED GAS CHILLER
090768.232-3.00-024-A-B P & ID FOR CHILLED FEED GAS K.O. DRUM
090768.232-3.00-025-A-B P & ID FOR TURBO EXPANDER AND COMPRESSOR
090768.232-3.00-026-A-B P & ID FOR DEMETHANISER
090768.232-3.00-027-A-B P & ID FOR DEMETHANISER BOTTOM PUMPS
090768.232-3.00-028-A-B P & ID FOR DEBUTANISER TRIM REBOILER
090768.232-3.00-029-A-B P & ID FOR CONDENSATE STRIPPER

Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
090768.232-3.00-030-A-B P & ID FOR CONDENSATE STRIPPER REBOILER
090768.232-3.00-031-A-B P & ID FOR METHANOL INJECTION PACKAGE
P & ID FOR TURBO EXPANDER (L-232-001) & RESIDUE GAS

090768.232-3.00-032-A-B
COMPRESSOR (C-232-001) ANCILLARIES

Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Attachment #3
Plot Plan
- Dwg No. 090768.231-3.00-901-A-A

Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL
Job No.: 090768
UNIT 232
Attachment #4
Equipment List
- Doc. No. S090768.231-3.01-001-A-E

Doc. No.:S090768.232-3.00-018-A-E
OPERATING MANUAL Job No.: 090768
UNIT 232
Page 100 of
Rev. A
111
Attachment #5
Equipment Data Sheet
Item No. Doc_No Document_Title
* Tower
V-232-001 S090768.232-3.51-001-A-E PROCESS DATA SHEET FOR DEMETHANISER
PROCESS DATA SHEET FOR CONDENSATE

V-232-002 S090768.232-3.51-002-A-E
STRIPPER
* Vessel
PROCESS DATA SHEET FOR CHILLED FEED GAS
V-232-003A/B S090768.232-3.51-003-A-E
K.O.DRUM
V-232-004 S090768.232-3.51-004-A-E
STRIPPER REBOILER CONDENSATE POT
PROCESS DATA SHEET FOR DEMETHANISER
V-232-005 S090768.232-3.51-005-A-E
REBOILER CONDENSATE POT
* Heat Exchanger
PROCESS DATA SHEET FOR DRY FEED GAS
E-232-004A~B S090768.232-3.53-004-A-E
CHILLER
E-232-006 S090768.232-3.53-006-A-E
TRIM REBOILER
E-232-007 S090768.232-3.53-007-A-E
STRIPPER SIDE REBOILER
E-232-008 S090768.232-3.53-008-A-E
STRIPPER REBOILER
* Cold Box & Core Kettle H/E

PROCESS DATA SHEET FOR COMBINED
E-232-001 S090768.232-3.53-001-A-E
REBOILER EXCHANGER
PROCESS DATA SHEET FOR FEED-RESIDUE GAS
E-232-002 S090768.232-3.53-002-A-E
EXCHANGER
PROCESS DATA SHEET FOR DEMETHANISE
E-232-003 S090768.232-3.53-003-A-E
REFLUX SUBCOOLER
Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 101 of
Rev. A
111
* Compressor, GT & ST
PROCESS DATA SHEET FOR RESIDUE GAS
C-232-001 S090768.232-3.58-101-A-E
COMPRESSOR
L-232-001 S090768.232-3.58-101-B-E PROCESS DATA SHEET FOR TURBO EXPANDER
* Pump
P-232-001A/B/C S090768.232-3.58-001-A-E
BOTTOM PUMP
* Package Items
PROCESS DATA SHEET FOR METHANOL
ME-232-001 S090768.232-3.59-001-A-E
INJECTION PACKAGE

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 102 of
Rev. A
111
Attachment #6
Instrument data sheet
Doc_No Document_Title
* INSTRUMENT PROCESS DATA SHEET *

INSTRUMENT PROCESS DATA SHEET FOR CONTROL VALVE (UNIT
S090768.232-3.72-001-A-E
232)
S090768.231-3.72-002-A-E INSTRUMENT PROCESS DATA SHEET FOR SEQUENCE VALVE
S090768.231-3.72-002-B-E INSTRUMENT PROCESS DATA SHEET FOR HIPPS VALVE
INSTRUMENT PROCESS DATA SHEET FOR ON-OFF VALVE (UNIT

S090768.232-3.72-002-C-E
232)
INSTRUMENT PROCESS DATA SHEET FOR SPECIAL CONTROL
S090768.231-3.72-008-A-E
VALVE
S090768.231-3.72-028-A-E INSTRUMENT PROCESS DATA SHEET ANALYZER
INSTRUMENT PROCESS DATA SHEET SAFETY RELIFE VALVE (UNIT

S090768.232-3.72-003-A-E
232)
INSTRUMENT PROCESS DATA SHEET ORIFICE PLATE(231 ~ 238
S090768.231-3.72-004-A-D
UNIT)
INSTRUMENT PROCESS DATA SHEET ULTRASONIC
S090768.231-3.72-004-B-D
FLOWMETER(231 ~ 238 UNIT)
INSTRUMENT PROCESS DATA SHEET VORTEX FLOWMETER (231 ~
S090768.231-3.72-004-C-D
238 UNIT)
INSTRUMENT PROCESS DATA SHEET PRESSURE TRANMITTER
S090768.231-3.72-005-A-D
(231 ~ 238 UNIT)
INSTRUMENT PROCESS DATA SHEET DIFF. PRESSURE
S090768.231-3.72-005-B-D
TRANSMETER (231 ~ 238 UNIT)
INSTRUMENT PROCESS DATA SHEET TEMPERATURE
S090768.231-3.72-006-A-D
TRANSMITTER (231 ~ 238 UNIT)
INSTRUMENT PROCESS DATA SHEET LEVEL TRANSMITTER (231 ~
S090768.231-3.72-007-A-D
238 UNIT)
INSTRUMENT PROCESS DATA SHEET RESTRICTION ORIFICE (231 ~
S090768.231-3.72-029-A-D
238 UNIT)
S090768.237-3.72-004-A-D INSTRUMENT PROCESS DATA SHEET ROTAMETER (231 ~ 238 UNIT)
* METERING SKID PROCESS DATA SHEET *

S090768.232-3.72-019-A-E METERING SKID FOR RESIDUE GAS PRODUCT(232-MT-2111)
Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 103 of
Rev. A
111

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 104 of
Rev. A
111
Attachment #7
Utility Summary
- Doc. No. S090768.231-3.01-001-A-E

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 105 of
Rev. A
111
Attachment #8
Cause and Effect Diagram

- Doc. No. S090768.231-3.00-016-A-E

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 106 of
Rev. A
111
Attachment # 9
Safeguarding Memorandum
- Doc. No. S090768.231-3.00-013-A-E

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 107 of
Rev. A
111
Attachment #10
Alarm and Trip Setting

- Doc. No. S090768.231-3.00-016-A-E

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 108 of
Rev. A
111
Attachment #11
Dynamic Simulation Study Report
- Doc. No. S090768.231-3.01-005-A-E

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 109 of
Rev. A
111
Attachment #12
Gas Detector Monitor Location Plan
- Dwg. 090768.231-3.70-321-A-B

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 110 of
Rev. A
111
Attachment #13
Chemical & Catalyst Summary

- Doc. No. S090768.231-3.00-012-A-E

Doc. No.:S090768.232-3.00-018-A-E
UNIT 232
Page 111 of
Rev. A
111
Attachment #14
Technical Data of TURBO EXPANDER (L-232-001) &

RESIDUE GAS COMPRESSOR (C-232-001)
- Data Sheet
- P&ID
- Control Narrative
- Performance Curve

090768.232 3.00 018 A e - A

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LPG Train-4 Project

OPERATING MANUAL UNIT 232

LPG Train-4 Project at MAA Refinery

7.3.2 INITIAL LP PRESSURIZATION ................................................................ 31

11.2 INSTALLATION GUIDELINE ................................................................................ 58

12.2.2 START UP (COMMISSIONING) .............................................................. 79

1. Process Flow Diagram (PFDs)

1.1 Overall Considerations

1. Operate this unit safely.

2. Operate this unit to specification and to optimal conditions.

3. Make objective operating judgments.

4. Be aware of specific requirements to ensure correct action is taken for start-up,

1.2 Description of Unit

Dry Feed Gas Chillers. (E-232-004A/B)

Chilled Feed Gas K.O Drum (V-232-003A/B)

Turbo Expander (L-232-001) / Residue Gas Compressor (C-232-001)

Condensate Stripper (V-232-002)

Methanol Injection Skid

Residue Gas (Sent to Battery Limit)

Raw NGL (Sent to Deethaniser column)

2.2 Design Capacity

W/O With W/O With

Feed Gas Flow rate

Condensate Stripper Section

Dry Condensate Feed

2.3 Feed Condition

2.4 Product specifications

H2S : 800 ppmv (Max.)

CO2 : 2 Mol% (Max.)

2.5 Battery Limits Conditions for Treating Unit

Stream Operating Condition

Battery Limit pressure is referenced to the LPG-4 IBL battery limit.

3.1 Process Flow Diagram

Reference is made to the following PFD for the Unit 232,

3.2 Process Flow Description

Gas Cooling and Expansion Section

In Demethaniser Reflux Subcooler (E-232-003), the second gas stream from

Demethaniser and Reboiler Section

- And Forth is Condensate Stripper (V-232-002) overhead lighters on tray no.5.

Residue Gas Compressor Section

Condensate Stripper Section

Dry Condensate from Dehydration section is further processed in this section by

Condensate overhead stream at 107.7F (42.1C) stream is sent to Demethaniser (V-232-

Condensate stripper bottom product is cooled down to 183F (83.9C) in Condensate

3.3 Turbo Expander-Residue Gas Compressor

For the detail description of Turbo Expander/Residue Gas Compressor (L-232-001/232-

3.4 Methanol Injection Skid

To prevent hydrate formation, methanol injection is foreseen upstream of Combined

Methanol injection system is composed by Methanol Storage Tank (ME-232-001-TK1),

- Feed gas to E-232-001

- Cold Feed inlet to E-232-004A/B

- Feed Gas inlet to E-232-002

- Demethaniser reflux to E-232-003

- Feed gas inlet to L-232-001

- Feed gas inlet to J-T valve FCV-2403

- Feed Condensate from V-232-003 to V-232-001

- Top Reboiler feed to E-232-001

- Bottom Reboiler feed to E-232-001

- Demethaniser overhead to E-232-003

- Ethane product to E-232-002

- Deethaniser overhead gas to E-233-001

- Treated Propane to E-234-001