tk6 revised assignment4
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assignment 4TRANSCRIPT
UNIVERSITAS INDONESIA
ASSIGNMENT 4
HEALTH, SAFETY AND ENVIRONMENT (HSE)
LNG REGASIFICATION PLANT USING AMMONIA
RANKINE POWER CYCLE AS THE COLD UTILIZATION
GROUP 6
Andreas Kurniawan (1106052940)
Fildzah Khalishah Alhadar (1106021433)
Ichwan Sangiaji Rangga Syakirrullah (1106019924)
Muhammad Nur Tsani Rizka (1106008170)
Rahmita Diansari (1106013151)
CHEMICAL ENGINEERING DEPARTMENT
ENGINEERING FACULTY
UNIVERSITAS INDONESIA
DEPOK, 2014
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TABLE OF CONTENT
TABLE OF CONTENT ........................................................................................ i
LIST OF FIGURES ............................................................................................. ii LIST OF TABLES.............................................................................................. iii
EXECUTIVE SUMMARY ................................................................................. iv CHAPTER 1 HEALTH, SAFETY, AND ENVIROMENTAL MANAGEMENT 1
1.1 Health and Environmental Safety Aspect ....................................................... 1 1.1.1 Hazard Identification and Risk Assessment (HIRA) .................................... 3
1.1.2 Hazard Identification (HAZID) ................................................................... 5 1.1.3 Hazard and Operability Study (HAZOP) ..................................................... 8
1.2 HSE Management ........................................................................................ 21 1.2.1 Operational Details ................................................................................... 21
1.2.2 Personal Protection Equipment.................................................................. 27 1.3 Emergency Action Plant............................................................................... 29
1.4 Waste Management .................................................................................... 31 1.4.2 Gas ........................................................................................................... 33
1.5 Plant Control Design .................................................................................... 34 PLANT LAYOUT ............................................................................................. 42
2.1 Plant Location .............................................................................................. 42 2.2 Area Plant Layout ........................................................................................ 42 2.2.1 2D and 3D Plant Layout .......................................................................... 43
CHAPTER 3 CONCLUSION ............................................................................ 50 REFERENCES .................................................................................................. 51
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LIST OF FIGURES
Figure 1.1 Interactions of Human Factors ........................................................... 1
Figure 1.2 Escape Route ................................................................................... 31
Figure 1.3 Water Cooling Waste Management .................................................. 32
Figure 2.1 Cilegon Industrial Area ..................................................................... 30
Figure 2.2 Full View of Regasification Plant in 2D from Up View .................... 32
Figure 2.3 Office Area of Regasification Plant in 2D Picture ............................. 33
Figure 2.4 Process Area of Regasification Plant in 2D Picture .......................... 34
Figure 2.5 Inside Look of Process Area of Regasification Plant in 2D Picture .... 35
Figure 2.6 Up View of Regasification Plant in 3D Picture .................................. 36
Figure 2.7 Front View of Regasification Plant in 3D Picture ............................. 37
Figure 2.8 Office Area View of Regasification Plant in 3D Picture .................... 38
Figure 2.9 Process Area View of Regasification Plant in 3D Picture .................. 49
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LIST OF TABLES
Table 1.1 Criteria in the Assessment of the Level of Risk to the Human Factor .. 3
Table 1.2 Parameter in Calculation of Likelihood ............................................... 4
Table 1.3 Frequency Criteria in Risk Assessment ................................................ 4
Table 1.4 Parameter in Calculation of Severity ................................................... 4
Table 1.5 Parameter in Taking into Level of Possible Danger ............................ 5
Table 1.6 Hazard Identification and Risk Assesment (HIRA) ............................... 6
Table 1.7 Parameter in Taking into Danger Effect ............................................... 8
Table 1.8 Hazard Identification (HAZID) .......................................................... 9
Table 1.9 Guide Words and the Meaning ........................................................... 10
Table 1.10 Type of Problems Indication ........................................................... 11
Table 1.11 HAZOP Sheet for Recondenser ........................................................ 13
Table 1.12 HAZOP Sheet for Storage Tank. ..................................................... 13
Table 1.13 HAZOP Sheet for Pump. ................................................................. 14
Table 1.14 HAZOP Sheet for Compressor ....................................................... 15
Table 1.15 HAZOP Sheet for Heat Exchanger ................................................... 16
Table 1.16 HAZOP Sheet for Reactor. .............................................................. 16
Table 1.17 HAZOP Sheet for Cooler.. ............................................................... 17
Table 1.18 HAZOP Sheet for Evaporator .......................................................... 18
Table 1.19 HAZOP Sheet for Turbine. ............................................................... 18
Table 1.20 HAZOP Sheet for Generator ............................................................ 19
Table 1.21 HAZOP Sheet for Loading Arm ....................................................... 19
Table 1.22 Type of Personal Proterctive Equipment with its Use ...................... 26
Table 1.23 LNG Storage Tank Control Tabulation ............................................ 34
Table 1.24 BOG and Air Compressor Control Tabulation ................................ 35
Table 1.25 Gas Turbine Control Tabulation ...................................................... 36
Table 1.26 Recondenser Control Tabulation ...................................................... 37
Table 1.27 Evaporator Control Tabulation ....................................................... 38
Table 1.28 Combustor Control Tabulation ........................................................ 39
Table 1.29 Water Cooler Control Tabulation ..................................................... 40
Table 1.30 Mixer Control Tabulation ............................................................... 41
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EXECUTIVE SUMMARY
Health, Safety, and Environment Aspect is a good aspect that we should
consider. Health, safety, and environment program is a standard for industries
around the world including in Indonesia in order to protect the rights of labor and
protect the environment from damage of waste produces by industries. The work
at the plant is a risky job. The possibility of accidents is greater than work in an
office. Human factor brings a potential risk if we correlate it with the case in
working in LNG Regasification Plant. To avoid the danger of necessary control
components with potential risks such as human factors and equipment also
materials, we need to have a risk management system.
There are three risks management that we use in this evaluation. It is
HIRA, HAZID, and HAZOP. HIRA (Hazard Identification and Risk Assessment)
is a hazard identification and risk study to define the problem and how to manage
the Hazard In daily activities and special of operation process and Industries
production. HAZID is a hazard identification based on place and location of
activity. In determining HAZID, There are several steps that must be done are.
The locations that are identified as hazardous location are storage tank,
regasification unit, neighborhood around the plant, and combustor Unit. The
HAZOP (Hazard and Operability Study) method is technique used to identify the
hazards on process facilities and prepare the system safety of potential hazards
occurring in the operation.
In this assignment, we also evaluate the start up and shut down procedure.
Our regasification plant is not a complicated plant that needs many aspects that
we should see. Another important is evaluating waste management, we have two
waste such as liquid and gas. The liquid is cooling water and gas is flue gas.
As we already determine before, our regasification plant will build in
Cilegon, Banten. This power plant is divided into several area. The main one is
the process area where the natural gas and power are produced. The main first is
the regasification process, where the LNG will regasify to become the natural gas.
The second is the ammonia cycle, where the ammonia is heated before going to
the regasification plant. The third is gas power plant area, where the air that will
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be used to heat the ammonia is produced. In this part, the air will be heated using
the combustor with the natural gas from boil-off gas as the fuel. In this process
part, there are control room and also metering station. The total area that we need
to build our plant included process section and office section is 57.64 hectares.
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CHAPTER 1
HEALTH, SAFETY, AND ENVIROMENTAL MANAGEMENT
1.1 Health and Environmental Safety Aspect
Human factor is a science that focuses on how humans interact with the
environment in their workplace. It examines the workplace factors that influence
the decisions and actions of workers. No one goes to work intending to be injured.
The decisions and actions that workers take make sense to them at the time given
their goals, knowledge and focus of attention. The human factors approach to an
investigation asks why a worker's decision or action made sense to that worker at
the time.
Figure 1.1 Interaction of Human Factors
(Source: UK HSE Government)
Human factor brings a potential risk if we correlate it with the case in
working in mine mouth power plant from coal gasification. To avoid the danger of
necessary control components with potential risks such as human factors and
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equipment also materials, we need to have a risk management system. Risk
management system is a management process carried out with the intention of
minimizing the risk or the extent possible to avoid the risk altogether. Risk
management system requires the application of the hierarchy of control measure
against the risk of a hazard, with the following steps:
Elimination (eliminating the hazard)
Substitution (use raw materials more secure)
Engineering (redesign existing processes to make it more secure)
Administrative control (changing methods or procedures work in a more
secure)
Personal Protective Equipment (using the appropriate protective
equipment to isolate the body from harm)
Risk management aims to prevent the occurrence of safety accidents. A
particular effort is needed to reduce or eliminate potential risks. Safety is a series
of efforts to be done to prevent accidents in the work process and to improve the
working environment for all employees securely in order to achieve the goals set.
The work at the plant is a risky job. The possibility of accidents is greater
than work in an office. Not to mention an unhealthy environment for the flying
material and the air is not clean. Risk itself has a definition, which is a condition
where there is a possibility of an accident or occupational disease because of the
presence of a hazard. Risk management need tools and backup facilities to prevent
or overcome danger that occurs in plants. The tools are necessary including
personal protection equipment for employees. Here is the description of personal
protection equipment that should be suited for every worker who works directly in
the plant area.
Health, safety, and environment program is a standard for industries
around the world including in Indonesia in order to protect the rights of labor and
protect the environment from damage of waste produces by industries. Good
safety and health will enhance the secure and work passion of the employee or
labor particularly. In order to apply good HSE program, so in this plant is applied
some policies regarding to health, safety, and environment. Hazard analysis can
divided into three parts:
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HIRA (Hazard Identification and Risk Assessment)
HAZID (Hazard Identification)
HAZOP (Hazard and Operability Study)
1.1.1 Hazard Identification and Risk Assessment (HIRA)
HIRA (Hazard Identification and Risk Assessment) is a hazard
identification and risk study to define the problem and how to manage the Hazard
In daily activities and special of operation process and Industries production. In
HIRA Analysis contain some step that must be followed. They are:
Process of sorting to be sub process that more specific
Hazard potential identification in every sub process
Determine risk that may be happened (severity and likelihood)
Determine the preventive ways and recommendation of risk
Conclusion of hazard potential and risk which is solved for every
activities
Conclusion for all of working
In HIRA analysis, it is identified of hazard potential and risk with
calculate the level of risk, recommendation, and final risk. Risk is combination of
severity and likelihood. This is Risk can be described by this formula:
Likelihood of risk is consist of high, medium, and low. Severity is constant
variable and also consist of high, medium, and low effect. Level of severity and
likelihood is variant, they can 3 or more (also can 8 depend on agreement from the
companies). This table below show a parameter to calculate a likelihood and
calculate a severity.
Table 1.1 Criteria in the Assessment of the Level of Risk of Damage to the Human Factor
Level of Damage Number of People who Died
Moderate 0
Serious 1-2
Major 2-3
Catastrophic 3-4
Disastrous >4
(Source: GS EP SAF 041)
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Table 1.2 Parameter in Calculation of Likelihood
Parameter High Medium Low
Frequency of
hazard
Every the job is
working
Once in 10 until
100
Once during the job is
working
Frequency of
hazard effect
Almost the job is
working
Once in 10 until
100 Once in 100 or more
Reliability of work
Without
experience,not
ever doing the job
before
Less experience
Well experience, have
good skill and often
doing that job
(Source: GS EP SAF 041)
Table 1.3 Frequency Criteria in Risk Assessment
Frequency Definition for Qualitative Assessment Frequency (/year)
Likely Occur several times during the plant lifetime > 10-2
Unlikely Occur once every 10-20 on some similar plant for 20 to 30
years of plant lifetime 10
-2 – 10
-3
Very
unlikely
There is a one time per year per 1000 units
There is one every 100 to 200 similar plant in the
world over the past 20 to 30 years of plant life
Ever happened in the company, but corrective action
has been taken
10-3
– 10-4
Extremely
unlikely
Ever happened in the industry, but corrective action has
been taken 10
-4 – 10
-5
Remote
The incident is physically possible but never or rarely
occurred during the period of 20-30 years for a large
number of field
< 10-5
(Source: GS EP SAF 041)
Table 1.4 Parameter in Calculation of Severity
Parameter High Medium Low
Human
Resource
Death, physical
defect, Physical dis-
function, harmful.
Medium harm,
The body still
doing the job
Low harm
Asset
High damage in
equipment,
production is stopped
Damage which is
caused decreasing
of production
level
Low damage, no
production effect
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Table 1.4 Parameter in Calculation of Severity (con’t)
Parameter High Medium Low
Protection
Equipment
Protection equipment
is not at environment
flammable chemical
Minimum
Protection
equipment
Protection
equipment is
available enough
and installation is
well isolated
Available of
evacuation time More than one minute
Between 1-30
minutes
More than 30
minutes
(Source: GS EP SAF 041)
From the above steps, it can be withdrawn risk to the activity in this plant,
where the risk is the result of the frequency of hazards with existing activities and
consequences listed in the following matrix (table 1.6 in next page)
1.1.2 Hazard Identification (HAZID)
HAZID is a hazard identification based on place and location of activity. In
determining HAZID, There are several steps that must be done are. All aspects of
industrial and plants installations are:
Data installation information industry (PFD, P & ID, Layout,
meteorological data, social data cultural community, event records)
Location (operation facilities and support facilities)
Risk (Human resources, aset, image)
Hazards Potential (fire and huge explosions, drowning, environmental
pollution)
Table 1.5 Parameter in Taking into Level of Possible Danger
Frequency
of hazards
Most Likely Unlikely
More than 10 in 10
years
1-10 times in 10
years
Less than once in 10
years
(Source: GS EP SAF 041)
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Table 1.6 Hazard Identification and Risk Assesment (HIRA)
Type of
Activities Potency of Hazard Hazard Effect Severity Likelihood
Prevention and
Countermeasures
Final
Risk
Unloading
LNG
LNG (in liquid phase) leakage Permanent injuries,
cold body burn H L
- Use PP
- Follow SOP M
LNG ship hit the dock, reacts
with water and caused detonation
Cold body burn,
permanent injuries,
death
H L - Use PPE
- Follow SOP M
Explosion because LNG (in gas
phase) leakage/spills Body burn, death H L
- Check the condition of the pipe
before and after unloading
- Use PPE
M
Triggering fires Permanent injuries,
death H L
- Adheres to applicable SOP
- Provides adequate fire safety M
Operational
and
Maintenance
Activity
LNG (in liquid phase) leakage in
storage tank and LNG Vaporizer
Permanent injuries,
cold body burn H L
- Use PP
- Follow SOP M
Boil Off Gas Leakage in BOG
Handling
Explosion, Body
burn, Permanent
injuries, death
H L - Use PP
- Follow SOP M
Ammonia Leakage in Ammonia
Rankine Power Cycle Cold-Body Burn H L
- Use PP
- Follow SOP M
Sound Disturbance from
Compressor, turbine and generatir Ear-obstruction, deaf M H
- Use PP
- Follow SOP H
Gas leakage in piping facilities Permanent injuries,
death H L
- Use PP
- Follow SOP M
Explosion caused by high
pressure in combustor
Permanent injuries,
death H L
- Use PP
- Follow SOP M
Temperature distubance around
combustor
Skin iritations, body
burn M M
- Use PP
- Follow SOP M
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Table 1.6 Hazard Identification and Risk Assesment (HIRA) (con’t)
Type of
Activities Potency of Hazard Hazard Effect Severity Likelihood Risk
Prevention and
Countermeasures
Final
Risk
Checking
electrical
installation
Electric shock
Non-permanent
injuries M M M
-Use Personal Protective
Equipment (PPE)
- Use gloves
- Adheres to applicable Standard
Operating Procedure
- Employ skilled labor
M
Death H M M M
In case of fire/ explosion due to
short circuit
Permanent
injuries, death H M M M
Falling from height during
installation
Dysfunctions of
the body and
death
H M M
- Use safety belts
- Use PPE
- Adheres to applicable SOP
M
Checking
water utilities Dropped because of slip road
Broken bones,
dysfunction of
the body, and
death
H M M Use safety helmets and safety
shoes M
Checking
Equipment
Installation
Hit a piece of tool
Non-permanent
injuries M M M
- Use PPE
- Follow SOP
- Employ skilled labor
M
Dysfunctions of
the body and
death
H M M M
Working at
office Ergonomic hazard
Stress and health
problem which
lead to lower
productivity
L M M Redesign office to support
productivity L
(Source: Author’s Internal Data)
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Table 1.7 Parameter in Taking into Danger Effect
PARAMETER MINOR MAJOR SEVERE
Human resources There is no accident The accident was
not fatal
The accident was
fatal
Asset Loss below US$
100’000
Loss US$ 100.000
until 1.000.000
Loss over US$
1.000.000
Environment no damage to the
environment
Minor damage to
the environment
Major damage to
the environment
(Source: GS EP SAF 041)
The HAZID analysis for LNG Regasification and Power Unit Plant is
attached below (table 1.8 on next page)
1.1.3 Hazard and Operability Study (HAZOP)
The HAZOP (Hazard and Operability Study) method is technique used to
identify the hazards on process facilities and prepare the system safety of potential
hazards occurring in the operation. Even those who are not familiar with the
hazards analysis process will often have heard of the term HAZOP, even if they
are not really sure what it means.
It has happened when the Process Safety Management (PSM) regulations
in the United States were being promulgated in the early 1990s it was not
unknown for a plant manager to say, "I know what PSM is, it's HAZOPs!" In fact
the HAZOP method is just one of the many types of Process Hazards Analysis
(PHA) techniques that are available, and PHAs are just one element of a PSM
program. Nevertheless, these managers were somewhat justified in what they said
because they knew that, unless they could identify the hazards on their facilities,
they could not reduce risk. The goals of HAZOP are to figure out:
The potential hazards, especially the most dangerous ones for human being and
environment
Some various operability problems in each process because of some deviations
toward the design intent in plant, both active one or about to begin one.
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Table 1.8 Hazard Identification (HAZID)
Location Description Cause Potential Danger Danger Effect Possibility Prevention
Unloading Unit To unload the LNG
from LNG ship
Leaking on joint pipe from
unloading arm and ship
Cold Damage,
Flesh will be torn Major Unlikely
Cross Check every
detail and use coverall
Storage Tank
Unit
To storage liquid
LNG
Natural factors, such as
weather (hot temperature),
corrosion factor
The lack of
durability of the
tank, Cold Damage
Major Likely Routine maintenance
BOG Handling To reliquefy the Boil
Off Gas Compressor's Motor Sound Pollution Minor Most Using Earplug
Vaporizer Unit To vaporize the LNG Extreme Low temperature,
Leakage
Cold Damage,
Flesh will be torn Major Unlikely
Procurement of
instrumentation, routine
maintenance, using
coverall
Ammonia
Cycle
The cycle of
ammonia as a
working fluid (pump
and expander)
Leaking on pipe or equipment Cold Damage,
Flesh will be torn Major Unlikely
Procurement of
instrumentation, routine
maintenance, using
coverall
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Location Description Cause Potential Danger Danger Effect Possibility Prevention
Gas Turbine To burn the methane
as a power plant Too High Pressure
Fire Explosion and
flame Major Unlikely
Procurement of
instrumentation, routine
maintenance, using
coverall
Electric Grid
Place where
Electricity is
produced and
transferred
High Voltage Explosion, Electric
Shock Major Likely
Construct fence to
prevent people enter the
area
(Source: Author’s Internal Data)
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Furthermore, both regulators and legal advisors generally support the use
of the HAZOP technique because of its reputation and because it is so thorough.
The use of the HAZOP technique is very defensible if a company is challenged
regarding its safety performance, particularly in a legal dispute. As a result of its
widespread use and acceptance, large numbers of process safety practitioners are
now trained in the use of the HAZOP method, and many of those are also trained
as leaders/facilitators. Furthermore, a substantial HAZOP infrastructure has
developed. Many consulting companies offer HAZOP facilitation services
special-purpose software.
A HAZOP is organized by dividing the unit to be analyzed into nodes. A
node represents a section of the process where a significant process change takes
place. For example, a node might cover the transfer of material from one vessel to
another through a pump. In this case the process change is the increase in pressure
and flow that occurs across the node. Another node might include an overhead air-
cooler on a distillation column. Here temperature and phase are the process
variables that change. The HAZOP team would systematically examine a
proposed process design by asking questions using guidewords representing
deviations from the intended parameters of the process which can be seen in table
below:
Table 1.9 Guide Words and the Meaning
Guide Words Meaning
No or None The negation of the intention (e.g.: no flow)
More A quantitative increase (e.g.: high pressure)
Less A quantitative decrease (e.g.: low pressure)
As Well As In addition to (e.g.: impurity)
Part Of A qualitative decrease (e.g.: only one of two components present)
Reverse The opposite of the intention (e.g.: back flow)
Other Than Complete substitution (e.g.: wrong material)
(Source: GS EP SAF 041)
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Table 1.10 Type of Problems Indication
Deviation Typical Problems
No Flow Blockage, pump failure, suction vessel empty, vapor lock, control
failure, etc.
Reverse Flow Pump failure, pump reversed, over pressurization, etc.
More Temp
More Press Blockage, loss of control, reaction, explosion, valve closed, etc.
Less Flow Pump failure, leak, partial blockage, sediment, cavitation, etc.
Less Temp
Less Press Heat loss, vaporization, leak, imbalance of input and output, etc.
As Well As Presence of contaminants, e.g.: water, air, lubrication oil, etc.
(Source: GS EP SAF 041)
Although the strength of the HAZOP method lies in its clear organization,
it is important not to allow the analysis to become too rigid. If the team finds that
it is talking about "Reverse Flow" even though the current guideword is "High
Flow", the leader should probably let the discussion continue. If he or she were to
postpone the discussion until the "right" guideword, the current thinking and
creativity may be lost. On the other hand, the leader must also keep the discussion
focused on the issue at hand, and should prevent too many digressions.
1. Select a node, define its purpose and determine the process safe limits.
2. Select a process guideword.
3. Identify the hazards and their causes using the deviation guidewords.
4. Determine how the hazard is "announced", i.e., how the operator knows a
safe limit has been exceeded.
5. Estimate the consequences (safety, environmental, economic) of each
identified hazard.
6. Identify the safeguards.
7. Estimate the frequency of occurrence of the hazard.
8. Risk rank the hazard, with and without safeguards.
9. Develop findings and potential recommendations.
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10. Move on to the next process guideword, or to the next node if the guideword
discussion is complete.
Some mistakes might happen in assessing HAZOP are:
1. Failing to establish a "safe" environment for team members.
2. Consequences of events not carried to conclusion.
3. Taking unwarranted credit for
4. Too little credit given for safeguards
5. Making recommendations as specific as possible
6. Poor recording of HAZOPS
7. Failure to HAZOP start-up and shut-down procedures
8. Poorly up-dated P&IDs
9. A HAZOP is performed in lieu of properly executed design reviews
10. Wrong technique for system being.
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Table 1.11 HAZOP Sheet for Recondenser
Recondenser (Single Outlet Vessel)
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. More Flow rate The flow inlet is
too low
The pressure will
be very high
Rechecking
inspection/maintenance
regime done by
engineers to prevent
any problems
Set up the flow rate
inlet of air Engineer
(Source: Author’s Internal Data)
Table 1.12 HAZOP Sheet for Storage Tank.
LNG Storage Tank
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Level
The amount of
LNG put into the
storage tank is too
few
The composition
will run out
earlier before they
come into Y-
junction
Rechecking
inspection/maintenance
regime done by engineers to
prevent any problems
By designing the
weigh tank with
alarm for low level
occurring
Engineer
2. More Level
The amount of
LNG put into the
storage tank is too
many
The composition
will be over
capacity
Rechecking
inspection/maintenance
regime done by engineers to
prevent any problems
By designing the
weigh tank with
alarm for high level
occurring
Engineer
(Source: Author’s Internal Data)
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Table 1.13 HAZOP Sheet for Pump.
Pump
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Level The flow inlet is too
low then there will also
be air coming in to the
pump and operator
error
Pump failure and
cavitation occurs
Rechecking
inspection/maintenance
regime done by engineers to
prevent any problems
By designing the level
alarm system and installing
gas detector
Engineer
2. Less Flow
rate
The blockage by solid
or gaseous and pump
motor power is too low
Supply of liquid flow
to the next process to
be hampered and
therefore contributes to
the flow of the
subsequent processes,
and can make a rapid
deterioration
Rechecking
inspection/maintenance
regime done by engineers to
prevent any problems
Control/monitoring
regularly,
cleaning/maintenance
periodically of pumps,
installing flow indicator
that is connected directly to
the pump
Engineer
3. More Flow
rate
Pump motor power is
too high and excessive
impeller performance
Pump to quickly
corrode and become
damaged , the
electricity consumed is
also higher for the
pump motor
Rechecking
inspection/maintenance
regime done by engineers to
prevent any problems
Control/monitor it regularly Engineer
(Source: Author’s Internal Data)
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Table 1.14 HAZOP Sheet for Compressor
Compressor
No.
Deviation
Cause Consequences Safeguards Action Required
Action
Assigned
to
Guide
Word Parameter
1. Less Flow rate The blockage by
solid or liquid and
compressor motor
power is too low
Supply of vapour flow
to the next process to
be hampered and
therefore contributes to
the flow of the
subsequent processes,
and can make a rapid
deterioration
Rechecking
inspection/maintenance
regime done by
engineers to prevent
any problems
Control/monitoring
regularly,
cleaning/maintenance
periodically of
compressors,
installing flow
indicator that is
connected directly to
the compressor
Engineer
2. More Flow rate Compressor
impeller power is
too high and
excessive impeller
performance
Compressor to quickly
corrode and become
damaged , the
electricity consumed is
also higher for the
compressor impeller
Rechecking
inspection/maintenance
regime done by
engineers to prevent
any problems
Control/monitor it
regularly
Engineer
(Source: Author’s Internal Data)
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Table 1.15 HAZOP Sheet for Heat Exchanger.
LNG Evaporator
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Flow rate Flow is
too low
The heat transfer will be
not effective
Rechecking inspection/maintenance
regime will be suitable toward the
specification
Set up and
control/monitoring
of flow rate
Engineer
2. More Temperature Flow is
too
high
The error in
equipment.Flash failure
will happen in vaporizer
Rechecking inspection/maintenance
regime will be suitable toward the
specification
Set up and
control/monitoring
of feed temperature
Engineer
(Source: Author’s Internal Data)
Table 1.16 HAZOP Sheet for Reactor.
Combustor
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Temperature Heat losses to the
environment and
temperature is low
The heat
transfer will be
not effective
Rechecking inspection/maintenance
regime will be suitable toward the
specification
Set up and
control/monitoring
of flow rate
Engineer
2. More Temperature Flow is too high The error in
equipment
Rechecking inspection/maintenance
regime will be suitable toward the
specification
Set up and
control/monitoring
of feed
temperature
Engineer
(Source: Author’s Internal Data)
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Table 1.17 HAZOP Sheet for Cooler.
Cooler
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Temperature Cooling fluid
temperature or the
temperature of the
cooled fluid or
both are too low
The process of
heat exchange
(cooling) become
ineffective and
inefficient
Rechecking
inspection/maintenance
regime will be suitable
toward the
specification
Set up air
temperature in
accordance with
proper operating
conditions and the
temperature cooled
fluid to
control/monitoring
periodically
Engineer
2. More Temperature Cooling fluid
temperature or the
temperature of the
cooled fluid or
both are too high
The process of
heat exchange
(cooling) become
ineffective and
inefficient
Rechecking
inspection/maintenance
regime will be suitable
toward the
specification
Set up air
temperature in
accordance with
proper operating
conditions and the
temperature cooled
fluid to
control/monitoring
periodically
Engineer
(Source: Author’s Internal Data)
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Table 1.18 HAZOP Sheet for Evaporator.
Ammonia Evaporator
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Flow rate Flow is too
low
The heat transfer
will be not
effective
Rechecking
inspection/maintenance regime
will be suitable toward the
specification
Set up and
control/monitoring
of flow rate
Engineer
2. More Temperature Flow is too
high
The error in
equipment
Rechecking
inspection/maintenance regime
will be suitable toward the
specification
Set up and
control/monitoring
of feed temperature
Engineer
(Source: Author’s Internal Data)
Table 1.19 HAZOP Sheet for Turbine.
Turbine
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Rpm of rotor The rpm of
rotor is too
low
The power
generated is low
Rechecking
inspection/maintenance
regime will be suitable toward
the specification
Control/monitoring
periodically of
pressure
Engineer
(Source: Author’s Internal Data)
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Table 1.20 HAZOP Sheet for Generator.
Generator
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Speed of rotor The speed of rotor
is too low
The electricity
can’t be generated
Rechecking
inspection/maintenance
regime will be suitable
toward the
specification
Periodically
maintenance of
generator
Engineer
(Source: Author’s Internal Data)
Table 1.21 HAZOP Sheet for Loading Arm
Loading Arm
No. Deviation
Cause Consequences Safeguards Action Required Action
Assigned to Guide Word Parameter
1. Less Accuracy slot
in Barge
LNG leak to the
environment
LNG spoils out the
system and the
flow rate to the
storage tank
decreases
Rechecking
inspection/maintenance
regime will be suitable
toward the
specification
Periodically
maintenance of
Loading Arm
Engineer
(Source: Author’s Internal Data)
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1.2 HSE Management
1.2.1 Operational Details
1.2.1.1 Precondition
Before starting the regasification system in this plant, the major utilities
such as power supply (combuster which is produced heat to actuate the gas
turbine), instrument air, nitrogen, water as working fluid, will be made
operational.
All lines and equipment will be flushed, cleaned and de-watered. Lines
which have been identified for chemical cleaning would be cleaned as per
approved procedures. After cleaning and dewatering, necessary leak and tightness
testing of plant flanges, joints, manholes etc. will be done. Before initiating plant
start-up, all plant piping and equipment should be nitrogen purged to make the
plant air free. It should be ensured that all temporary start-up strainers are
installed at their appropriate locations prior to clean-up runs. These temporary
strainers should be removed after clean-up runs are completed.
All instruments such as level transmitters, level gauge, pressure
transmitters etc. would be installed. The following major checks should be
performed before initiating start-up:
a. All piping and instruments are installed as per the P&IDs. The plant would
have been inserted with nitrogen and holding a pressure no less than 7~10
psig.
b. Ensure functionality of the control valves, controllers, emergency
shutdown system, etc.
c. Complete functional testing of all rotating equipment as per the supplier
instruction manuals.
d. Ensure that relief valves are installed with upstream and downstream
isolation valves locked open for the duty valve and upstream isolation
valve locked close for spare valve.
e. Ensure that the blow down valves is closed and their respective upstream
and downstream isolation valves are locked open.
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f. Ensure that all other manual valves are in their appropriate position for
start-up.
Once these steps are completed, the regasification system is ready for first
start-up. To start up this regasification plant, involves the following step:
a. Open Gate Valve to distribute the LNG to storage tank.
b. Make sure valve V-01 and V-02 are closed before warm up the equipment.
c. Open Relief Valve V-08, open V-04 to flows the Boil Off Gas (BOG) to
recondenser.
d. Warm up the pump, which used to flows ammonia as working fluid to
ammonia evaporator
e. Open all valve in the system, ammonia rankine cycle and LNG main line
For utility systems that we need to be done in precondition phase is: (in this
following explanation)
a. Air Instrument System
The availability of instrument air must be check before the process is
running. Air instrument (compressor) is used for the units that make
pneumatic control.
b. Storage and distribution of water
Water that has been sent from the pipe is kept in the water storage before it
distribute to the interstage cooler. The maximum allowable temperature of
water in the storage is 55oC. If the level in the storage is so high, valve in
this storage is close and in the same time, water is transported to the other
water storage using pump.
1.2.1.2 Start-up Procedure
The successful long term performance of the regasification LNG and cold
utilization depends on operation and maintenance of the system. This includes the
initial plant start-up and operational start-ups and shut-downs. Preventing the
problems not only a matter of system design but also a matter of proper
commissioning and operation. Before beginning to start-up the upstream process
facilities, should be commissioned and ready for operation.
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1. Initial Start Up-Pre Start Up Check and Commissioning
Before starting up systems, make sure that the whole pretreatment
section is working in accordance with the specifications. If the
pretreatment involved changing of the chemical characteristics of raw
material, then a full analysis must be made. Commissioning will involve
bringing into operation LNG regasification plant process a time and cold
utilization until full operation is established. Once full operation is
established, the output of the plant will be progressively brought to full
capacity to ensure all system are functioning and able to operate at
maximum output.
Initial commissioning activities will involve testing power
generation facilities using gas turbine, cold utilization of ammonia rankine
cycle, and will occur up to one year before planned start-up of the plant.
This will require the feed LNG tank to have been commissioned and ready
for service. Pre-Start Up Checklist:
All piping and instrument are completed as per P&ID.
Instrument calibration is verified
All instruments such as level transmitters, level gauges, pressure
transmitters etc. must be installed.
All piping and equipment is compatible with design pressure
All piping and equipment is protected against corrosion
Planned instrumentation is installed and operative
Pumps are ready for operation: aligned, lubricated, proper rotation
All plant piping and equipment should be Nitrogen purged to make the
plant air free.
Within the plant all lines and equipment must be flushed, cleaned and
dewatered.
Ensure functionally control valves, switching valves, controllers,
emergency shutdown system, etc.
Ensure manual valves are in proper positions.
Complete functional testing all rotating equipment
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Ensure that the relief valves are installed with upstream and
downstream isolation valves locked open for the duty valve and
upstream isolation valve locked close for spare valve.
Ensure that the blow down valves are closed and their respective
upstream and downstream isolation valves are locked open.
Verify that all temporary start-up strainers are installed at their
appropriate locations.
Major utilities such as power supply, instrument air, nitrogen,
ammonia, cooling water, drains etc. must be operational. Within the
plant all lines and equipment must be flushed, cleaned and de-watered.
Necessary leak and tightness testing flanges, joints, manholes etc. must
also be completed prior to start-up. Before initiating plant start-up, all
plant piping and equipment should be nitrogen purged to make the
plant air free.
As part of the pre start up activities, it requires degreasing as any dirt, oil
and greasy material left in the piping and equipment will contaminate raw
material solution and lead to foaming problems during operation. The
degreasing and rinsing operation are essential during first start-up of the
plant and normally would not be required for subsequent plant restart.
Once rinsing and draining is complete, reaction treatment should be made
air free through nitrogen purge. When the system has been made air free
and established, raw material transporting and filling circulation should be
started.
2. Start Up Sequence
Following steps shall form part of plant start-up:
Ensure the tank storage of the LNG unit system maintance for the
insulation and circulation for LNG. The system for boil off gas
recovery set up.
Unloading the LNG will require to maintain the level of LNG in the
tank because the pump in the tank must be fill before start up so the
pump will suction the LNG.
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Ensure that the pipe is perfect installed especially the natural gas
pipeline.
Ensure the Ammonia rankine power cycle unit, the make up stream
ammonia will be prepare to mixer to start up the cycle.
Prepare the gust turbine power plant cycle unit by start up the air
compressor but close the flow control air valve inlet. The air
compressor start up one by one then open the valve and intake the fuel
gas to the combustor and start up the combustor. The superheated gas
will be through gas turbine and go to ammonia evaporator.
Start up the make up steam ammonia through mixer and circulation
line. The ammonia will through ammonia pump and go to the
ammonia evaporator. The ammonia liquid will become gas and
through the gas turbine to the LNG evaporator.
Start up the pump in the storage tank so the LNG will be through the
recondenser unit and pump to the LNG evaporator, then maintain the
pipeline system and control the ration for fuel gas to combustor.
Monitoring all the control system.
1.2.1.3 Normal Operation Procedure
In this plant, after the startup processes are succesfully being run, a normal
operation procedures should be performed in sequence to maintain an optimum
regasification of LNG and electricity production.
1. When loading from LNG carrier to LNG storage tank(V-101, V-102), we
need to control the liquid level and pressure level. The circulation system
require to maintain the temperature and phase of LNG itself. Control of
level of LNG must be so the LNG pump will suction the liquid to avoid
the air on the pump.
2. Boil off gas will be go through the valve through the compressor (K-101)
and the pumped LNG (subcooled LNG) will meet the boil off gas in the
recondenser and make the boil off gas become the liquid again. We must
maintain flow and level in absorption column. The level so the pump after
condenser still through by liquid.
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3. LNG will pump to LNG evaporator, we maintain the LNG evaporator by
contorl the outlet temperature and the flow of working fluid which is
ammonia gas. The temperature outlet must be control so we can be sure all
LNG will be become the natural gas through to pipeline and guel gas
circulation.
4. Combustor will require the air and fuel gas intake with certain ration. To
maintain this we need analyzer control and temperature control from outlet
the temperature of superheated gas. Water cooler on air compressor have
to working to maintain the rising temperature of the compressor.
5. The ammonia liquid will intake from the make up stream through the
mixer, the make up stream controled by the sytem so the flow of ammonia
in rankine cycle still steady as the working fluid.
1.2.1.4 Shut-Down Procedure
The safety shutdown system to stop the operation of this plant is based on
the following principles:
1. Means are to be provided to indicate the parameters causing shutdown.
2. Upon activation of the safety shutdown system, alarms are to be given at
the normal control position and at the local control position.
3. In the event where shutdown by the safety shutdown system is activated
the restart should not occur automatically, unless & after the system is
reset.
4. The safety shutdown system is to be supplied by two sources of power.
5. Means are to be provided to evacuate NG remaining in the system after a
shutdown.
Then, this following words will explain a process shutdown for each unit
is explained as follow:
a. Regasification LNG Unit
A process shutdown of the regasification unit results in the following:
1. Closure all the Natural gas through the pipeline
2. Turn off the LNG pump
3. Amonia exhaust from gas turbin-II cant be condensed
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4. Turn off all switch STHE and combuster
5. Turn off the LNG evaporator and mixer.
b. Gas Turbine Power Plant Unit
A process shutdown of the amine unit results in the following:
1. Closure of air and fuel gas flow to combustor.
2. Turn off all switch of air compressor
3. Turn off all switch gas turbine
1.2.2 Personal Protection Equipment
Equipment protection for employees is the main standard for a company to
protect its employees. Personal protective equipment can be divided into:
a. General equipment: personal protective equipment as a minimum
requirement to enter the plant, the safety helmet, mask, and safety shoes
b. Special equipment: Personal Protective Equipment (PPE) is used in
accordance with the needs of employees in the workplace each based on
hazard and risk. For example: safety goggles, welding goggles, respirator,
mask, ear protection, gloves, earplugs, and so on.
This following table will show type of PPE and the function for our body and type
of hazard that can be prevent by this PPE.
Table 1.22 Type of Personal Proterctive Equipment with its Use
Part of Body Hazard Protection Option Note
Eyes
Chemical or metal
splash, dust,
projectiles, gas and
vapour, radiation
Safety spectacles,
goggles, face
screens, faceshields,
visors
Make sure the eye protection
chosen has the right combination
of impact/dust/splash/molten
metal eye protection for the task
and fits the user properly
Head and
Neck
Impact from falling or
flying objects, risk of
head bumping, hair
getting tangled in
machinery, chemical
drips or splash,
climate or
temperature
Industrial safety
helmets, bump caps,
hairnets and
firefighters' helmets
Some safety helmets incorporate
or can be fitted with specially-
designed eye or hearing
protection
Don't forget neck protection, eg
scarves for use during welding
Replace head protection if it is
damaged
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Table 1.22 Type of Personal Proterctive Equipment with its Use (con’t)
Part of Body Hazard Protection Option Note
Ear
Noise – a combination
of sound level and
duration of exposure,
very high-level
sounds are a hazard
even with short
duration
Earplugs, earmuffs,
semi-insert/canal
caps
Provide the right hearing
protectors for the type of work,
and make sure workers know
how to fit them
Choose protectors that reduce
noise to an acceptable level,
while allowing for safety and
communication
Hand and
Arm
Abrasion, temperature
extremes, cuts and
punctures, impact,
chemicals, electric
shock, radiation,
vibration, biological
agents and prolonged
immersion in water
Gloves, gloves with
a cuff, gauntlets and
sleeving that covers
part or all of the arm
Avoid gloves when operating
machines such as bench drills
where the gloves might get
caught
Some materials are quickly
penetrated by chemicals – take
care in selection, see HSE’s skin
at work website
Barrier creams are unreliable and
are no substitute for proper PPE
Wearing gloves for long periods
can make the skin hot and
sweaty, leading to skin
problems. Using separate cotton
inner gloves can help prevent
this
Feet and Legs
Wet, hot and cold
conditions,
electrostatic build-up,
slipping, cuts and
punctures, falling
objects, heavy loads,
metal and chemical
splash, vehicles
Safety boots and
shoes with
protective toecaps
and penetration-
resistant, mid-sole
wellington boots and
specific footwear, eg
foundry boots and
chainsaw boots
Footwear can have a variety of
sole patterns and materials to
help prevent slips in different
conditions, including oil- or
chemical-resistant soles. It can
also be anti-static, electrically
conductive or thermally
insulating
Appropriate footwear should be
selected for the risks identified
Lungs
Oxygen-deficient
atmospheres, dusts,
gases and vapours
Respiratory
protective equipment
(RPE)
The right type of respirator filter
must be used as each is effective
for only a limited range of
substances
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Table 1.21 Type of Personal Proterctive Equipment with its Use
Part of Body Hazard Protection Option Note
Lungs
Oxygen-deficient
atmospheres, dusts,
gases and vapours
Respiratory
protective equipment
(RPE)
Filters have only a limited life.
Where there is a shortage of
oxygen or any danger of losing
consciousness due to exposure to
high levels of harmful fumes,
only use breathing apparatus –
never use a filtering cartridge
You will need to use breathing
apparatus in a confined space or
if there is a chance of an oxygen
deficiency in the work area
Whole Body
Heat, chemical or
metal splash, spray
from pressure leaks or
spray guns,
contaminated dust,
impact or penetration.
Conventional or
disposable overalls,
boiler suits, aprons,
chemical suits
The choice of materials includes
flame-retardant, anti-static, chain
mail, chemically impermeable,
and high-visibility
Don't forget other protection,
like safety harnesses or life
jackets
(Source: UK HSE Government)
Based on the information on the data above, the workers on regasification
plant will be using this following PPE:
Table 1.22 PPE for Regasification Plant’s Worker
No Part of Body Protector
1 Eyes Safety Glasses
2 Head and Neck Industrial Safety Helmet
3 Ear Ear-plug
4 Hand and Arm Gloves with a Cuff
5 Feet and Leg Safety Shoes
6 Lungs -
7 Whole Body Conventional Cover All
(Source: UK HSE Government)
1.3 Emergency Action Plant
An emergency action plan (EAP) is a written document required by
particular OSHA standards. The purpose of an EAP is to facilitate and organize
employer and employee actions during workplace emergencies. Well developed
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emergency plans and proper employee training (such that employees understand
their roles and responsibilities within the plan) will result in fewer and less severe
employee injuries and less structural damage to the facility during emergencies. A
poorly prepared plan, likely will lead to a disorganized evacuation or emergency
response, resulting in confusion, injury, and property damage.
Putting together a comprehensive emergency action plan that deals with
those issues specific to your worksite is not difficult. It involves taking what was
learned from your workplace evaluation and describing how employees will
respond to different types of emergencies, taking into account your specific
worksite layout, structural features, and emergency systems. At a minimum, the
plan must include but is not limited to the following elements:
1. Means of reporting fires and other emergencies
Preferred procedures for reporting emergencies such as dialing 911, or an
internal emergency number, or pulling a manual fire alarm are examples of
emergency reporting procedures, but there are many other possibilities.
2. Evacuation Procedures and emergency escape route assignments
An evacuation policy, procedures, and escape route assignments so
employees understand who is authorized to order an evacuation, under what
conditions an evacuation would be necessary, how to evacuate, and what routes to
take. Exit diagrams are typically used to identify the escape routes to be followed
by employees from each specific facility location. Evacuation procedures also
often describe actions employees should take before and while evacuating such as
shutting windows, turning off equipment, and closing doors behind them.
Sometimes a critical decision may need to be made when planning - whether or
not employees should fight a small fire with a portable fire extinguisher or simply
evacuate. Portable fire extinguishers may be integrated into the emergency action
plan.
3. Procedures to account for all employees after an emergency evacuation has been
completed
Procedures need to account for employees after the evacuation to ensure that
everyone got out. This might include procedures for designated employees to
sweep areas, checking offices and rest rooms, before being the last to leave a
workplace or conducting a roll call in the assembly area. Many employers
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designate an "evacuation warden" to assist others in an evacuation and to account
for personnel.
Figure 1.2 Escape Route
(source: Author’s Internal Data)
1.4 Waste Management
Environment is one of our priority to do our plant design. Waste
management is an important aspect that we should consider. We should identify
our waste and then know how to treat and throw it to the environment. Waste that
will be produced from our plant will be divided into two part, liquid and gas.
1.4.1 Liquid
Cooling water is the only one liquid waste from our plant. Cooling water
that is used for cooling some process in a heat exchanger will be changed in
temperature. There is no other aspect of this waste that we should worry about.
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The temperature of cooling water will be around 50oC. The cooling water that will
be just threw away to the environment or back to the sea will damage the sea
environment and could kill the biota. So, we should decide what kind of waste
water treatment that will be used in our plant.
There are various ways to treat waste water. They are sedimentation tank,
Sedimentation Lake, and the new biological treatment. The waste treatment that is
mention above is different to our problem. The idea was that we need a wide
surface contact in order to cool down the temperature of the water. A simple way
is maybe just using the wide lake to be the place to cool the water by the wind.
Another idea is using some artificial river to flow the water through then it will be
cooled down by using the wind another natural way.
After doing the scoring and analyze it, we will do water treatment by
flowing it through the artificial river that then will be flowed into the sea. This
method is a natural way and economic way.
Figure 1.3 Water Cooling Waste Management
(source: Author’s Internal Data)
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1.4.2 Gas
Flue gas as is the only gas waste that we have. Flue gas is a waste from the
gas turbine that is used to roll the turbine and heat the ammonia. Flue gas
composition is a little unburned methane, a little carbon monoxide, and carbon
dioxide. The composition of this flue gas is not dangerous to our environment.
There is no problem also in temperature aspect. The temperature of flue gas that is
threw to the environment is near the ambient temperature.
1.4.2 Gas
Flue gas as is the only gas waste that we have. Flue gas is a waste from the
gas turbine that is used to roll the turbine and heat the ammonia. Flue gas
composition is a little unburned methane, a little carbon monoxide, and carbon
dioxide. The composition of this flue gas is not dangerous to our environment.
There is no problem also in temperature aspect. The temperature of flue gas that is
threw to the environment is near the ambient temperature.
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1.5 Plant Control Design
Table 1.23 LNG Storage Tank Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter Controller Alarm Function Control Procedure
StorageTank
(V-101/V-
102)
Output
Pressure
Pressure control
outlet valve
Pressure Indicator
Control (PIC -
101/102)
-
Controlling the
pressure of tank
and also control
the volume of
boil off gas that
created in tank
When the pressure outlet flow from tank
is hingher (5%) than each initial flow
condition, the pressure transmitter will
give an electric signal to PIC and then
transfer that signal into a pneumatic
signal to pressure outlet valve to increase
the flow of gas to the compressor until
the condition become normal condition.
Liquid Level Flow control
Outlet valve
Level Indicator
Control (LIC -
101/102)
-
Controling the
level of the
LNG in storage
tank so the tank
not lower than
1/3 tank to
maintain
submerged
pump in the tank
When tank level is reach the minimum
level which is 1/3 of tank height, the
level indicator transmitter will give an
electric signal to the level indicator
control. Then the level indicator control
will give a electric signal to the flow
control valve at the outlet line. Thus this
valve will change its opening to be
decrease then the normal one (set 50%
from its normal opening).
(Source: Author’s Internal Data)
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Table 1.24 BOG and Air Compressor Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter Controller Alarm Function Control Procedure
Compressor
(K-101/
201/202/
203/204/205)
Pressure
Outlet
Pressure
control outlet
valve (anti-
surge valve)
Pressure Indicator Control
(PIC-
103/109/111/113/115/117)
-
Controlling
the inlet
feed flow to
compressor
is not more
or less.
When the pressure outlet flow from
compressor is lower (about 5%) than each
initial flow condition, the pressure
transmitter will give an electric signal to
PIC and then transfer that signal into a
pneumatic signal to open the anti-surge
valve higher so the flow of recycle gas
will be more to increase the flow to
compressor until the condition become
normal condition. And if the pressure
outlet flow is higher from its initial flow
condition, the control procedure is likely
the same when it is lower than the initial
condition, but, the final action is lower
opening of the valve until the condition
become steady normal condition.
(Source: Author’s Internal Data)
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Table 1.25 Gas Turbine Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter
Controller Alarm Function Control Procedure
Gas Turbine
(T-101/301)
Pressure
Outlet
Pressure control
inlet valve
Pressure Indicator
Control (PIC-107/
121)
-
Controlling the
inlet feed flow
to turbine is not
more or less.
When the pressure outlet flow from
turbine is lower (about 5%) than each
initial flow condition, the pressure
transmitter will give an electric signal to
PIC and then transfer that signal into a
pneumatic signal to open the pressure
control inlet valve higher until the
condition become normal condition. And
if the pressure outlet flow is higher from
its initial flow condition, the control
procedure is likely the same when it is
lower than the initial condition, but, the
final action is to open the pressure
control inlet valve lower until the
condition become steady normal
condition.
(Source: Author’s Internal Data)
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Table 1.26 Recondenser Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter
Controller Alarm Function Control Procedure
Recondenser
(Absorption
Column) (C-
101)
Liquid Level Flow control
inlet valve
Level Indicator
Control (LIC -
104)
-
Controling the
level of the
liquid in column
so the height not
lower than 1/3
column to
maintain pump
after the column
When column level is reach the
minimum level which is 1/3 of tank
height, the level indicator transmitter will
give an electric signal to the level
indicator control. Then the level indicator
control will give a electric signal to the
flow control valve at the inlet line. Thus
this valve will change its opening to be
increase then the normal one (set 50%
from its normal opening).
(Source: Author’s Internal Data)
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Table 1.27 Evaporator Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter Controller Alarm Function Control Procedure
Evaporator /
Heat
Exchanger
(E-101/301)
Temperature
Outlet
Flow control
inlet hot fluid
valve
Temperature
Indicator Control
(TIC- 105/108)
-
Controling the
temperature’s
products of the
material that
evaporize by
evaporator.
When the temperature higher than set
point of the temperature, the temperature
transmitter will be send electric signal to
temperature indicator control to make the
opening in flow control valve at inlet hot
fluid will lower than make the flow of
hot fluid will be decrease until the
temperature is come back to the normal
temperature that we set. If the
temperature of product is lower, the
transmitter will send to indicator so it can
control the opening valve higher so make
the flow of hot fluid increase.
(Source: Author’s Internal Data)
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Table 1.28 Combustor Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter Controller Alarm Function Control Procedure
Combustor
(R-101)
Composition
of Product
Flow control of
air inlet valve
Analyzer
Indicator Control
(AIC-119)
-
To
maintain
the inlet
ratio of air
and fuel
gas for
combustion
reaction.
By analyze the composition of product, we can know if
the ratio of air and fuel gas same as the normal condition.
If this reaction, the air will be 20% excess (20% excess
of oxygen). If the methane in the product still higher than
the analyzer transmitter will send electric signal to
analyzer indicator to control the opening of flow control
valve of air inlet higher to increase the flow of air until
the ratio become as we set before, otherwise the valve
opening will be lower and the flow of air will be
decrease until the normal ration
Temperature
of
Superheated
Gas
Flow control of
fuel gas inlet
valve
Temperature
Indicator Control
(TIC -120)
-
To control
the
temperature
of outlet
gas product
of
combustor
When the temperature higher than set point of the
temperature, the temperature transmitter will be send
electric signal to temperature indicator control to make
the opening in flow control valve at inlet fuel gas will
lower than make the flow of fuel gas will be decrease
until the temperature is come back to the normal
temperature that we set. If the temperature of product is
lower, the transmitter will send to indicator so it can
control the opening valve higher so make the flow of fuel
gas increase.
(Source: Author’s Internal Data)
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Table 1.29 Water Cooler Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter Controller Alarm Function Control Procedure
Cooler (E-
201/204)
Temperature
Outlet
Flow control
inlet water valve
Temperature
Indicator Control
(TIC-
110/112/114/116)
-
Controling the
temperature
outlet to
maintain the
temperature of
compressor not
very high and
the temperature
of air inlet not
very low
When the temperature higher than set
point of the temperatur, the temperature
transmitter will be send electric signal to
temperature indicator control to make the
opening in flow control valve at inlet
water will higher than make the flow of
water will be increase until the
temperature is come back to the normal
temperature that we set. If the
temperature of product is lower, the
transmitter will send to indicator so it can
control the opening valve lower so make
the flow of water decrease until the
temperature back to normal condition.
(Source: Author’s Internal Data)
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Table 1.30 Mixer Control Tabulation
Process
equipment
Controlled
Parameter
Controlling
Parameter Controller Alarm Function Control Procedure
Mixer (M-
301) Flow Outlet
Flow control
inlet make up
ammonia valve
Flow Indicator
Control (TIC-
106)
-
Controlling the
flow of the
ammonia fluid
as the working
fluid in Rankine
cycle so the
flow will not
more or less
When flow after mixer lower than each
initial flow condition, the flow
transmitter will give an electric signal to
FIC then FIC will transfer that signal into
a electric signal to flow control valve.
Valve will give an opening until the
condition become normal condition. This
make the ammonia will be added to
mixer by stream of make up ammonia
inlet until the flow of ammonia liquid is
back to normal. Otherwise, if the inlet
flow is higher from its initial flow
condition, the final action from control
valve is that it will close until the
condition become steady normal conditio
which make the make up ammonia
stream stopped.
(Source: Author’s Internal Data)
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CHAPTER 2
PLANT LAYOUT
2.1 Plant Location
As we already determine before, our regasification plant will build in
Cilegon, Banten. the location was chosen by consider the industries that require
natural gas supply to be around Cilegon, and also the raw material, the LNG itself,
can be distributed using ship from Bontang, Kalimantan. Besides that, this plant
will consider the safety, ease of distribution equipment, utilities, land availability,
environmental, and ease of marketing. So, we decided that Cilegon is the most
suitable location for our regasification plant.
Figure 2.1 Cilegon Industrial Area
(Source: Google Earth)
2.2 Area Plant Layout
This power plant is divided into several area. The main one is the process
area where the natural gas and power are produced. The main first is the
regasification process, where the LNG will regasify to become the natural gas.
The second is the ammonia cycle, where the ammonia is heated before going to
the regasification plant. The third is gas power plant area, where the air that will
be used to heat the ammonia is produced. In this part, the air will be heated using
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the combustor with the natural gas from boil-off gas as the fuel. In this process
part, there are control room and also metering station.
Besides the process area, there are the other area in this plant, which are
the LNG storage tank, where the LNG will be cycling from the jetty and back into
jetty. The unloading facilities will be built from the sea to the land. In this plant,
there is the utility plant, where the seawater that will be used in water cooler to
cooling the air that will be compress. There is flare outside the process area.
In the other side of this plant, there are the supporting area and building,
such as the security post, main office, mosque, sport facility, clinic, canteen,
laboratories, fire station, and also the assembly point and parking area.
We also consider the position of equipment and the building with the HSE
aspect. LNG storage is located far from other equipment especially human. The
equipment that produces heat, is located far from LNG storage such as the heat
exchangers, combustor, and flare. Between the office and the process area is the
artificial river to block the effect of heat and other effect of accident, and also to
transport the water back to the sea. About the pipeline, we connected the
equipment with that. The arrangement of pipeline based on sense of engineering.
The layout of our plant can be seen in the next part. The total area that we need to
build our plant included process section and office section is 57.64 hectares.
2.2.1 2D and 3D Plant Layout
In this sub-chapter we will show you 2D and 3D configuration or pictures
of our regasification plant. Those picture are shown on next page.
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Figure 2.2 Full View of Regasification Plant in 2D from Up View
(Source: Author’s Internal Data)
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Figure 2.3 Office Area of Regasification Plant in 2D Picture
(Source: Author’s Internal Data)
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Figure 2.4 Process Area of Regasification Plant in 2D Picture
(Source: Author’s Internal Data)
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Figure 2.5 Inside Look of Process Area of Regasification Plant in 2D Picture
(Source: Author’s Internal Data)
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Figure 2.6 Full View of Regasification Plant in 3D Picture
(Source: Author’s Internal Data)
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Figure 2.7 Office Area View of Regasification Plant in 3D Picture
(Source: Author’s Internal Data)
Figure 2.8 Process Area View of Regasification Plant in 3D Picture
(Source: Author’s Internal Data)
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CHAPTER 3
CONCLUSION
Based on explanation above, we can conclude this main point of this
assignment below:
1. Human factor brings a potential risk if we correlate it with the case in working
in LNG Regasification Plant.
2. Risk management aims to prevent the occurrence of safety accidents
3. Hazard analysis that we use is HIRA, HAZID, and HAZOP.
4. The locations that are identified as hazardous location are storage tank,
regasification unit, neighborhood around the plant, and combustor Unit.
5. Another important is evaluating waste management and our plant has two
waste such as liquid and gas. The liquid waste is cooling water and gas waste
is flue gas.
6. We also should consider operational detail such as start up and shut down.
7. The total area that we need to build our plant included process section and
office section is 57.64 hectares.
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