LNG Ship Operating Philosophy

OPERATING PHILOSOPHY


TABLE OF CONTENTS

OPERATING PHILOSOPHY 1.

2.

INTRODUCTION ......................................... .............................................................. .......................................... .......................................... .......................................... ........................... ......

4

1.1. BACKGROUND ........................................................................................................................................ 1.2. RU OPERATIONAL PHILOSOPHY ....................................... .................................................................................. .......................................................................... ............................... 1.2.1. Scope......................................................................................................................................... Scope ......................................................................................................................................... 1.2.2. Objectives.................................................................................................................................. Objectives .................................................................................................................................. 1.3. RU OVERVIEW, SPECIFICATIONS AND UTILITIES SYSTEM .................................................................................. 1.3.1. Overview ................................................................................................................................... Overview ................................................................................................................................... 1.3.2. LNG Buffer Tanks Buffer Tanks ...................................... ................................................................................ ................................................................................. ....................................... 1.3.3. Gas Pressure and Temperature and Temperature at Delivery at Delivery Point Point ....................................................................... ....................................................................... 1.3.4. Utility Systems Utility Systems ........................................ .................................................................................. ................................................................................... ......................................... 1.4. ABBREVIATIONS......................................................................................................................................

4 4 4 4 4 4 4 5 5 5

BASIS OF PHILOSOPHY ...................................... ............................................................ ........................................... .......................................... ........................................ ................... 7

2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 3.

HEALTH ..................................... .............................................................................. ................................................................................... .................................................................. ........................ SAFETY ...................................... ............................................................................... ................................................................................... .................................................................. ........................ ENVIRONMENT ....................................................................................................................................... EMERGENCY EQUIPMENT ........................................ ................................................................................. ................................................................................. ........................................ PERSONAL PROTECTIVE EQUIPMENT ........................................................................................................... EMERGENCY RESPONSE PLAN ................................... ............................................................................. ................................................................................. .......................................

7 7 7 8 8 8

STAFFING, COMPETENCY, DEVELOPMENT AND TRAINING ........................................ ........................................................... ............................ ......... 9

3.1. 3.2.

STAFFING ........................................... ................................................................................... .................................................................................. ........................................................... ................. 9 COMPETENCY, DEVELOPMENT AND TRAINING ............................................................................................... 9

4.

LNG BUFFER TANK OPERATING PHILOSOPHY..................... PHILOSOPHY.......................................... .......................................... ........................................ ....................... .... 10

5.

LNG TRANSFER PHILOSOPHY................... PHILOSOPHY ........................................ .......................................... .......................................... .......................................... ............................ ....... 10

5.1. LNG TRANSFER OPERATIONS ................................... ............................................................................. ............................................................................... ..................................... 5.1.1. LNG Transfer – Transfer – General General Requirements Requirements ..................................................................................... 5.1.2. LNG Flow Rates.................................. Flow Rates............................................................................ .................................................................................. ............................................ .... 5.1.3. Vapour Return Vapour Return ........................................ .................................................................................. ................................................................................. ....................................... 5.1.4. Accidental Cargo Accidental Cargo Release................................. Release.......................................................................... ........................................................................ ............................... 5.1.5. Metering Requirements ........................................................................................................... 5.1.6. Completion of Cargo of Cargo Transfer .................................................................................................. .................................................................................................. 5.2. PARCEL SIZE/OFFLOADING RATE ...................................... ................................................................................. ........................................................................ ............................. 5.3. BOIL OFF GAS ......................................................................................................................................

10 10 10 10 11 11 11 11 11

6.

REGASIFICATION OPERATION PHILOSOPHY.................... PHILOSOPHY ....................................... ........................................ .......................................... ............................ ....... 12

7.

GAS DISTRIBUTION SYSTEM OPERATION PHILOSOPHY ........................................ ............................................................. ............................... .......... 12

7.1. 7.2. 8.

12 12

RELIEF AND VENT SYSTEM OPERATION PHILOSOPHY................... PHILOSOPHY........................................ .......................................... .................................. ............. 13

8.1. 8.2. 8.3. 8.4. 9.

OVERVIEW .......................................................................................................................................... GAS METERING ....................................................................................................................................

OVERVIEW .......................................................................................................................................... RELIEF CONTINGENCIES .................................... ............................................................................ .................................................................................. .............................................. .... BLOWDOWN........................................................................................................................................ MANUAL DRAINS AND VENTS ................................... ............................................................................. ............................................................................... .....................................

13 13 13 14

CONTROL AND SHUTDOWN OPERATION PHILOSOPHY ........................................ ............................................................. ............................... .......... 15

9.1.

SHUTDOWN.........................................................................................................................................

15

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9.1.1. Hierarchy ................................................................................................................................. 9.1.2. Total RU Shutdown.................................................................................................................. 9.1.3. Regasification Process Shutdown ............................................................................................ 9.1.4. Unit Shutdown......................................................................................................................... 9.2. REGASIFICATION PROCESS CONTROL ......................................................................................................... 9.2.1. General .................................................................................................................................... 9.2.2. LNG Pumps .............................................................................................................................. 9.2.3. LNG Vaporiser Control Requirements....................................................................................... 9.3. START‐UP AND RESTART ......................................................................................................................... 10.

AUTOMATION, INSTRUMENTATION AND COMMUNICATIONS PHILOSOPHY................................... 17

10.1. SYSTEM REQUIREMENTS......................................................................................................................... 10.1.1. Overall Instrumentation and Control Philosophy ..................................................................... 10.1.2. Systems Interface .................................................................................................................... 10.1.3. Control Room and Human Machine Interface.......................................................................... 10.2. PCS SPECIFIC DESIGN REQUIREMENTS....................................................................................................... 10.2.1. PCS Architecture ...................................................................................................................... 10.2.2. Functional Requirements ......................................................................................................... 10.2.3. Data Communication............................................................................................................... 10.2.4. Tank Level Measuring Instrumentation ................................................................................... 10.3. COMMUNICATIONS PHILOSOPHY .............................................................................................................. 10.3.1. Telephone System.................................................................................................................... 10.3.2. IT Network ............................................................................................................................... 10.3.3. Public Address and General Alarm System............................................................................... 10.3.4. Close Circuit TV and Security System........................................................................................ 10.3.5. Meteorological System ............................................................................................................ 10.3.6. Radio Equipment Room ........................................................................................................... 11.

12.1. 12.2. 12.3. 12.4. 12.5. 12.6. 12.7. 12.8. 12.9.

17 17 18 19 19 19 20 21 21 22 22 22 22 23 23 23

MISCELLANEOUS OPERATIONAL PHILOSOPHIES ............................................................................. 24

11.1. SIMULTANEOUS OPERATIONS .................................................................................................................. 11.2. MATERIALS HANDLING/ACCESSIBILITY/DROPPED OBJECT PROTECTION ............................................................ 11.2.1. Materials Handling .................................................................................................................. 11.2.2. Accessibility ............................................................................................................................. 11.2.3. Impact Protection .................................................................................................................... 11.3. GENERAL HOUSEKEEPING ....................................................................................................................... 12.

15 15 15 15 16 16 16 16 16

24 24 24 24 25 25

MAINTENANCE PHILOSOPHIES....................................................................................................... 26

OBJECTIVES ......................................................................................................................................... SERVICING........................................................................................................................................... MAINTENANCE MANAGEMENT ................................................................................................................ FRONTLINE MAINTENANCE ..................................................................................................................... MAJOR SHUTDOWNS............................................................................................................................. CONDITION MONITORING, TESTING AND INSPECTION ................................................................................... CERTIFICATION ..................................................................................................................................... SPARES HOLDING.................................................................................................................................. PERMIT TO WORK/WORK ORDERS ...........................................................................................................

26 26 26 27 27 27 27 28 28

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1. INTRODUCTION 1.1.

Background PT. Pelindo Energi Logistik (PT. PEL) as a subsidiary of PT. Pelindo III, which engaged in provision of energy and electricity, have been collaborated with PT. Indonesia Power in LNG Receiving Terminal Project, for supplying gas to the Dual Fuel Engine Power Plant in Pesanggaran, Bali.

1.2.

RU Operational Philos ophy

1.2.1. Scope This document outlines the operational philosophy for the Regasification Unit (RU). It is anticipated that this document shall be updated and re-issued on an “as-required” basis throughout the development of this project.

1.2.2. Objectives The objectives of this operations philosophy are to ensure: a. Health, Safety and environment (HSE) objectives are achieved; b. Technical and mechanical integrity are maintained; c. Life cycle economics are optimised; d. Legal compliance; e. To provide an overall vision of how the RU shall be operated. This document also presents the key operational requirements to be incorporated into the design of the RU. Operational requirements are set out in general terms; the detailing of which shall be undertaken in the development of the Basis of Design (BOD) document.

1.3.

RU Overview, Specifi cation s and Utili ties System

1.3.1. Overview The Regasification Unit development consists of the following: a. LNG pumps from buffer tank to vaporizer b. LNG vaporisation units. c. Gas Heater and metering system

1.3.2. LNG Buf fer Tanks The LNG buffer tanks shall operate at slightly above atmospheric pressure and approximately -160°C, refer to BOD for actual value. The buffer tanks shall share a common boil-off gas (BOG) handling system.

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The RU can supply gas to Power Plant minimum for 3 hours when the FSU fail to supply LNG.

1.3.3. Gas Pressure and Temperature at Deliv ery Point The vaporised gas shall be delivered to the pipeline inlet under pressure and temperature control. The inlet pressure to the pipeline is set by the end user pressure requirements and is detailed in the BOD.

1.3.4. Utili ty Syst ems The key utility systems for the RU and their main functions are as follow (optional) : a. Compressed air systems: for the supply of two types of compressed air: i. Plant air, compressed undried air, for air driven tools and other equipment; ii. Instrument air, compressed dry air, for control and shutdown instrumentation, panel purging; b. HVAC system for pressurised spaces; c. Firewater system, which shall comply with marine as well as offshore safety practices; d. Service water system for the distribution of seawater throughout the RU as service water where required; e. Fuel gas system used for the disposal of boil-off gases; f. Emergency Power generation and distribution system onboard the RU; 1.4.

Abbreviations The abbreviations summarised in Table 1.1 are used throughout this report. Table 1.1: Abbreviations Abbr eviati on

Defini ti on

AAV

Ambient Air Vaporisers

ALARP

As Low As Reasonably Practical

API

American Petroleum Institute

BA

Breathing Apparatus

BOD

Basis of Design

BOG

Boil-Off Gas

CBTA

Competency Based Training and Assessment

CCR

Central Control Room

CCTV

Closed Circuit Television

CFC

Chlorofluorocarbon

COMPANY

PT. Pelindo Energi Logistik

CONTRACTOR

LNG Regasification Unit Contractor

dBA

Decibel-A weighted scale

ESD

Emergency Shutdown

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EWS

Engineering Work Stations

FGS

Fire and Gas System

RU

Floating Regasification Unit

FVO

First Valve On

HSE

Health, Safety and Environment

I/O

Input/Output

ICCS

Integrated Control and Safety System

IFV

Intermediate Fluid Vaporiser

IG

Inert Gas

IGC

IMO Gas Code

IGG

Inert Gas Generator

IMO

International Maritime Organisation

kPag

Kilo-Pascal gauge

LAN

Local Area Network

LNG

Liquefied Natural Gas

LNGC

Liquefied Natural Gas Carrier

MARVS

Maximum Allowable Relief Valve Setting

MIS

Management Information System

mmscfd

Millions standard cubic feet per day

mmtpa

Millions Tonne Per Annum

OPEX

Operating Expenses

ORF

Onshore Receiving Facility

OWS

Operator Work Stations

PAGA

Public Address and General Alarm

PCS

Process Control System

PFP

Passive Fire Protection

PMCS

Process Monitoring and Control System

PMS

Power Management System

PPE

Personal Protective Equipment

PS

Process Shutdown

RAM

Reliability, Availability and Maintainability Study

RER

Radio Equipment Room

SART

Search and Rescue Radar Transponder

SIS

Safety Instrumented System

SOPEP

Shipboard Oil Pollution Emergency Plans

SRT

Storage and Regasification Terminal

STCW

Standards of Training, Certification and Watchkeeping

STV

Shell and Tube Vaporisers

TCP/IP

Transmission Control Protocol/Internet Protocol

TS

Total Shutdown

UCP

Unit control Panels

UPS

Uninterruptible Power Supply

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2. 2.1.

BA SIS OF PHILOSOPHY Health Health hazards shall be identified (such as chemicals, toxic material, noise and heat etc) and appropriate means incorporated into the design to minimise the risk to personnel from these hazards. A database of all hazardous materials shall be established during the detailed design phase of this project. This database shall include Material Safety Data Sheets (MSDS) for all chemicals to be used on the RU, and shall be available electronically and in hard copy. A separate safety management system for handling/storing and treating exposure to hazardous materials/chemicals shall be developed during the detailed design phase of this project. A person qualified to act as a paramedic shall be present on the RU at all times. Asbestos or materials containing asbestos, tar-coal epoxy coatings and heavy metals shall not be used in the design of or during the operation of the RU. Personnel shall not be subjected to passive smoking.

2.2.

Safety The design and operation of the RU shall conform to the requirements of the relevant local laws and regulation and applicable codes and standards. The safety in design philosophy shall be one of identification of potential hazards under normal perceived operating circumstances and designing to reduce the risk from these hazards to ALARP (As Low As Reasonably Practica l).

2.3.

Environment The RU shall meet the local regulation and company requirements in relation to environmental management. An environmental management plan shall be developed during detailed design phase of this project, which shall outline any conditions imposed by local regulators in relation to environmental management. A design and operating philosophy of energy conservation shall be pursued where practical. The use of halon’s or ozone depleting chlorofluorocarbon (CFCs) is prohibited. Alternatives shall be used which have less effect on the environment (ozone layer). Flare system is the preferred method to dispose of process vent gases on the RU. However, if cold venting is proposed then CONTRACTOR shall undertake dispersion modeling of the vent gases to verify that the system shall meet all safety requirements. Operational flaring/venting shall be minimised. The operational design approach of the RU shall be to limit flaring/venting to ALARP.

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Monitoring of effluents (gaseous and liquid) discharged to the environment shall be conducted to provide an overall inventory of pollutant discharges.

2.4.

Emergency Equipm ent The RU shall be equipped with all necessary emergency equipment: a) Fire fighting equipment (such as monitors, hose reels etc.); b) First aid room, fully equipped and within accommodation module; c) Safety showers, eye wash, first aid kits; and d) Breathing apparatus (BA) sets.

2.5.

Personal Protect ive Equipm ent Staff shall be supplied with personal protective equipment (PPE) to enable safe operation and maintenance of the RU.

2.6.

Emergency Response Plan An Emergency Response Plan shall be developed for the RU. This plan shall address all credible events and shall cover: a. An emergency including, but not necessarily limited to gas release, fire, explosion, vessel collision; b. Medical emergency response; c. Hurricane plan; and d. Environmental emergency. Emergency response simulation exercises shall be carried out and shall be defined within the HSE Plan. A twice a year a simulation exercise shall be conducted which shall involve the RU and the Emergency Management Team.

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3. 3.1.

STAFFING, COMPETENCY, DEVELOPMENT AND TRAINING Staffing Staffing numbers shall be sufficient to provide for all routine operations and maintenance such that technical integrity is assured and overall gas export availability is optimised. For contract labour involved in specialised operational and maintenance activities, appropriate remuneration rates and conditions shall apply. For the current functional engineering phase, RU normal operational staffing shall include, but not limited to, the following personnel/disciplines: a. Regasification/production superintendent/Site Manager b. Regasification/production operators and technicians: Note the numbers of personnel noted above are indicative.

3.2.

Competency , Development and Training A Competency Based Training and Assessment (CBTA) system shall be established as part of the management system. The CBTA system shall ensure that individuals are trained in all safety and production critical activities and they shall be objectively assessed to be competent to perform the necessary tasks. Where appropriate the CBTA system shall also include proficiency in English. General cultural awareness training shall be provided where this is required. The CBTA system shall be designed and implemented to assure competency of operations personnel prior to RU startup. Staff development shall be continuously addressed so that the workforce skills base is broadened with the objective of leading to an improvement in operating efficiency and safety. This shall be carried out as part of an annual appraisal process.

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4.

LNG BUFFER TANK OPERATING PHILOSOPHY The LNG buffer tanks shall be operated in accordance with IGC code and applicable codes, laws and regulations. The detailed LNG buffer tank operational procedures are to be developed during the detailed design phase of this project. Buffer tank is to be inspected per annum. CONTRACTOR shall provide inspection procedures, specifications, and acceptance criteria in accordance with applicable codes, standards, laws and regulations.

5. 5.1.

LNG TRANSFER PHILOSOPHY LNG Transfer Operations

5.1.1. LNG Transfer – General Requir ements Throughout cargo transfer operations, the LNGC /FSU and the RU should station a responsible person at the designated control rooms. The manifold area on the RU is constantly monitored by CCTV's with the monitors placed in the CCR. In addition, on the LNGC, throughout the cargo transfer, a responsible person equipped with a portable radio should be stationed at or near the cargo pump controls to take action as required. LNG transfer should begin at a slow rate to enable the RU to check that the pipeline system is correctly set. The transfer rate should be reduced when the RU’s tanks are reaching their filling limits. Towards the end of transfer and at other critical periods, visual contact should be established between responsible officers on both ships. This should be in addition to portable radio communication.

5.1.2. LNG Flow Rates Before starting cargo transfer, the LNGC/FSU must be informed by the RU of the flow rates required for the different phases of the cargo operation. If variations in transfer rate become necessary, the RU should advise the LNGC/FSU accordingly. The agreed transfer rate shall not exceed the recommended flow rates for the loading arms in use. During cargo transfer, the maximum transfer rate should be kept consistent with the receiving ship’s receiving capacity.

5.1.3. Vapour Return The vapour return connection limits the need for vapour release to the atmosphere, and may improve the transfer rates as well. A vapour return connection is mandatory for the RU.

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5.1.4. Acc idental Cargo Release Any leakage or spillage should be reported immediately to the officer in charge who should stop the cargo transfer.

5.1.5. Meterin g Requirements It is considered necessary to install a dedicated LNG loading metering system on the RU. The custody transfer content from the LNGC/FSU to the RU shall be established by ullage.

5.1.6. Completi on of Cargo Transfer After completion of cargo t ransfer the following operations shall be carried out: a. Purging requirements to be complied with SIGTTO guidelines (LNG operational practice); b. Loading arm or cryogenic hose disconnected, taking precautions to ensure that no liquid is left in the cargo transfer system. The pressure in the system should be released through an appropriate device; c. Cargo manifolds securely blanked; d. Authorities informed of completion of cargo transfer and the anticipated time of unmooring;

5.2.

Parcel Size/Offlo ading Rate LNG offloading frequency and parcel size shall be analysed over the design life of the project in order to optimise the economies of the project. In reviewing this aspect of the RU’s design, safety considerations shall be taken into account (such as impact on safety of more frequent, but smaller parcels).

5.3.

Boi l Off Gas Boil off gas (BOG) results from the storage and loading of LNG. LNG stored in the tanks shall boil off due to heat leakage, while loading shall generate additional BOG due to a reduction in vapour space. The BOG from the RU LNG buffer tanks shall be sent to the BOG compressors. The LP compressed boil off gas shall be used as fuel gas for power generators or reinjected into the LNG at the suction of the LNG booster pumps. During LNG loading from an LNGC/FSU, the BOG may also be transferred to the LNGC/FSU via the vapour return line. Only under adverse circumstances shall BOG be sent to the flare system or tank vents for disposal.

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6.

REGASIFICATION OPERATION PHILOSOPHY The LNG regasification process shall consist of the following equipment items as a minimum: a. LNG pumps from buffer tank to vaporizer b. LNG vaporisation units. c. Gas Heater and metering system Refer to the regasification plant functional specification. The LNG is provided from buffer tank to the vaporization unit at a minimum pressure of 12 barg and temperature of -160°C. The design and arrangement of the pumps and vaporization units depends on the technology selection LNG buffer tank shall have its own LNG pumps to deliver LNG to the regasification plant. The LNG pumps are rated to 100-m³/h minimum and 12 barg discharge pressure to feed into the vaporizer. The LNG pump’s rating shall be confirmed during detailed design phase of the project. The pumping system shall typically consist of minimal 1 duty pumps and 1 standby pump. The number of LNG pumps required shall be determined during detailed design phase of this project.

7.

GAS DISTRIBUTION SYSTEM OPERATION PHILOSOPHY

7.1. Overview The gas export system receives the LNG vapour from the vaporization trains. The gas is metered in preparation for injection into the pipeline to the Power Plant. Analysis of the export gas, such as composition, calorific value and Wobbe index, shall not be performed on the RU. Odorisation of the gas is not required under the current project scope, though this may be subject to change during the detailed design phase of the project. The gas export system will also provide a take-off to allow gas to be returned to the buffer tanks to maintain tank pressurisation.

7.2. Gas Meterin g Gas metering is expected to be of custody-transfer accuracy. In addition, the gas meters shall form part of the pipeline inventory management and leak detection system. The gas metering system shall also form part of the topsides control and shutdown system in detecting low gas export temperatures, preventing liquid LNG entering the pipeline.

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8.

RELIEF AND VENT SYSTEM OPERATION PHILOSOPHY

8.1. Overview A relief and vent system is required to dispose of process vapours and liquids in the event of an emergency. The flare and vent systems shall comply with API STD 521 and shall be separate from the LNG buffer tank vents. Vapours are captured in the flare headers and sent to the flare drum. Liquids are captured by a closed drain system and routed to the flare drum for recovery and disposal. The flare drum has an internal electric heater to help with the disposal of cold liquids. Vapour from the flare drum shall be sent to the flare gas heater before flowing to the elevated flare tip for disposal. The flare gas heater is intended to prevent low temperature gases entering the flare system.

8.2.

Relief Conti ngenci es Relief contingencies shall be addressed in more detail as part of the relief and blowdown philosophies to be developed during detail design phase of the project. At this stage the major relief events shall be: a. A blocked discharge of the LNG vaporisers, equivalent to the maximum production capacity of the RU; b. Vaporizer failure. Additional relief events are expected to be blocked discharge of the BOG compression system.

8.3. Blowdown Blowdown and release of gas and liquid to the flare system is not expected to be a common occurrence. The process shall be designed to retain all fluids within the equipment under all operating conditions. Blowdown is expected to occur mainly due to events external to the process e.g. fire and gas alarm, maintenance etc. Blowdown shall be constrained to hydrocarbon bearing equipment such as vaporisers, LNG pumps, BOG compression and gas export. Emergency blowdown shall comply with the requirements of API STD 521 and sent to the flare system for disposal. Blowdown of liquid sources shall be minimised; blowdown of vapour streams is preferred.

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8.4.

Manual Drains and Vents The process area will be serviced by at least 3 drains systems: open drains, closed drains and cryogenic drains. The open drains system will collect all liquid discharges from equipment via tundishes. The open drains system is expected to tie into the RU’s slops system for disposal. Deluge and rainwater will shall be able to be routed and disposed of via this route, but in general would be discharged directly overboard. The closed drains system will collect all pressurised liquids, such as equipment drains, for equipment that operates at ambient temperatures. The closed drains system will connect into the LP flare drum. The cryogenic drains system will collect all pressurised low temperature liquids from equipment drains. The cryogenic drains system will connect to the LP flare drum at a location separate to the closed drain tie-in to prevent ice/wax formation. Process and equipment vents will be connected to the LP and HP flare headers as appropriate for the disposal of all vapours.

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9. 9.1.

CONTROL AND SHUTDOWN OPERATION PHILOSOPHY Shutdown

9.1.1. Hierarchy The RU shall be in accordance with the safety philosophy document. The RU shall have two separate programmable shutdown systems as follow: a. Fire and Gas System (FGS): detects gas, flame, heat and smoke, operates warning sirens and lamps and electrically isolates power systems and batteries as well as initiating the release of fire fighting systems; b. Safety Instrumented System (SIS): detects process parameter excursions outside normal control band and settings; c. Loading arm or cryogenic hoses emergency release safety system; d. Fully integrated with the jetty FGS or SIS system

9.1.2. Total RU Shutdo wn A Total Shutdown (TS, ESD 1) is the highest level of shutdown and shall result in total shutdown of the RU in preparation for abandonment. An ESD 1 shall be initiated by activation of the ESD 1 pushbuttons or confirmed gas, fire or smoke in safe areas such as the accommodation module or electrical/instrument room. Activation of an ESD 1 shall shutdown the FGS, SIS and the Process Control System (PCS), shutdown the engine room, living quarter’s module, the emergency generator and the communications.

9.1.3. Regasif icati on Process Shutdo wn A Regasification Process Shutdown (PS, ESD 2) shall cause a shutdown of the various process systems within the Regasification process area and initiate a blowdown of these systems. An ESD 2 shall be initiated by activation of the ESD 2 pushbuttons or by high importance process shutdowns such as low-low temperature in the vapour line from the LNG vaporisers.

9.1.4. Unit Shutd own A unit shutdown (US) is caused by less critical deviations such as low-low flow at the LNG pump, where the only action is to shutdown the pump. For a unit shutdown, the specific unit, or train of units (e.g. LNG pump and LNG vaporiser) shall be shutdown.

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9.2. Regasification Process Control 9.2.1. General Control of the operation of the processing facilities on the RU is by a Process Control System (PCS). The intent of the control functions shall be to maintain stable operations as well as minimise process excursions to avoid initiation of shutdowns. The SIS sends information to the PCS and initiates pre-alarms in the PCS. Particular attention needs to be paid to the continued gassing of the cryogenic process equipment under shutdown conditions. On a process shutdown, the residual LNG will continue to vaporise in the LNG pumps, header and heat exchangers and this vapour should be sent primarily to pipeline or the BOG system rather than to the flare system.

9.2.2. LNG Pump s The LNG Pumps shall transfer LNG from the LNG buffer tank to the LNG vaporizer. A flow meter located downstream of the pump shall indicate the flow through the pump. A recycle flow control valve driven by flow controller at the pump discharge shall keep the pump operating above its minimum continuous stable flow during low flow operation. The pumps shall be stopped when any of the following is activated:

9.2.3. LNG Vaporiser Contro l Requirements The details of the vaporisation technology and hence control requirements are to be determined.

9.3.

Start-up and Restart The start-up and restart methodologies will depend on the state of the equipment and length of shutdown. Shock-cooling of equipment represents the major hazard due to the induced thermal stresses. Whenever cryogenic equipment is allowed to heat up a cool-down phase is required as part of start-up to prevent vapour locking, liquid surges and shock-cooling. Therefore, it is preferable to operate process trains at minimum turn-down rather than stop throughput. Start-up and restart should occur at minimum capacities to allow equipment temperature profiles to stabilize before increasing throughput to the required production rate. The detailed procedures for start-up and restart will depend on the technology selection. Under all scenarios it is endeavoured that vaporized LNG is sent to the pipeline as sales gas or to the BOG system for recovery. Flaring and venting as part of normal start-up and restart will not be accepted. Page 16 of 28


10. AUTOMATION, INSTRUMENTATION AND COMMUNICATIONS PHILOSOPHY 10.1. System Requirements The RU shall be equipped with a fully integrated system, the Integrated Control and Safety System (ICSS). This shall be scalable, single system architecture with integrated control and data management system. The ICSS, preferably from single manufacturer of common hardware, shall be an integrated system, comprising of the following: a. Process Control System (PCS); b. Safety Instrumented System (SIS); c. Fire and Gas System (FGS); d. Loading Arm or Cryogenic Hose Control System; e. Power Emergency Release System; f.

Compressor Control System;

It is intended to be used for control, monitoring and safeguarding the RU facilities. The system architecture proposed for the ICSS shall be defined in a Control, SIS and FGS System Architecture Block Diagram during the early stages of the detailed design phase of the project. SIS and FSG shall be SIL3 rated. Although the ICSS shall comprise of a PCS, SIS and FGS as separate stand alone systems, they shall be integrated seamlessly without duplication of functions. The ICSS architecture and hardware shall be based on conventional, latest state of the art, distributed control system with safeguarding system of a fault tolerant, TUV approved system. System architecture shall be for optimum multiple communication and multi-supplier interoperability without extensive and costly application programming. A Management Information System (MIS) highway shall be configured to provide an upper level monitoring, supervisory and data exchange functionality with other users. This network shall use TCP/IP over Ethernet bridges. The network and its Ethernet bridges shall be dual redundant. The SIS and FGS systems being a sub-system of the ICSS shall meet the requirements of COMPANY specifications for SIS and fire and gas system design.

10.1.1. Overall Instrumentation and Control Philosophy The overall philosophy shall be to use the appropriate level of technology, consistent with prevailing HSE regulations, industry best practice and codes that shall provide the required reliability to meet the project’s business targets. All existing instrument equipment (hardware and software) shall be replaced. The primary objective of this philosophy is to describe the requirements for a system which shall minimise downtime and operating costs without a negative impact upon Page 17 of 28


safety, the environment or the operation of the combined facilities. The design shall maintain simplicity in system operation; and shall facilitate diagnostics and faultfinding of operational issues or the maintenance of equipment. The system equipment shall be selected based upon well proven design, service history, reliability and integrity. All system equipment shall be standardised, wherever possible and practical, with the equipment installed on the RU. Field devices certified for use in hazardous areas shall utilise Ex ‘d’ (explosion proof) methods of protection wherever possible and practical. The general philosophy shall be to utilise Foundation Field Bus (FFB) field devices for all PCS field devices where appropriate. FFB field devices shall not be used for accommodation/utility/marine systems services and on the SIS or FGS. The use of FFB instrumentation for packaged equipment shall be dependant on each vendor’s standard.

10.1.2. Systems Interface Control data communications between elements of the ICSS shall use the ICSS vendor’s proprietary communications system, or a recognised alternative i.e. Industrial Ethernet, as approved by COMPANY. This control network shall be extended where required through OPC Gateway Units to the PCS on the RU. For control data communications with other control systems external to the ICSS, the use of OPC is preferred. Where communication interfaces are serial, they shall conform to industry standard Modbus RTU communication protocols (RS-485, RS-422 or RS232) and be standardised throughout the facility. Each high-speed communication link shall be dual redundant. ICSS control and asset management functionalities are to operate independently. Dual redundant data links are required for the PCS to interface to large sub-systems such as: 

Offloading System;



Regasification Control Systems.



Marine Systems

Fibre-optic, multi-core cable shall be utilised for the data links, as it provides faster data communications, is much more resistant to signal interference and is generally now the Vendor’s standard data transmission cable type. Unit Control Panels (UCP) for packaged equipment shall be utilised to operate major items of plant equipment; with the SIS and FGS inputs and logic in the RU SIS and FGS systems. a. UCPs for new packaged equipment shall be PLC based and use a common hardware and software as specified by COMPANY. In addition, status and alarm monitoring, shall also be provided in PCS;

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b. In the event that a vendor does not offer the above common PLC equipment, COMPANY’s approval shall be sought for the proposed PLC system; c. Local display shall be provided as part of the UCP for control, monitoring and diagnostics of the packaged equipment.

10.1.3. Contr ol Ro om and Human Machine Interf ace The main operator interface for RU process and safeguarding systems shall be at a main control console located in a CCR. The CCR shall either be combined in one room or be immediately adjacent. They shall be equipped with a number of Operator Work Stations (OWS), each with double layer flat screen to provide interfaces with both the RU process and the relevant marine/utility systems. The Console shall also contain: a. ESD manual pushbuttons, lamps, key switches etc; b. Set of critical start-up and maintenance override key-switches; c. Telecommunication workstation housing telephone handsets, PAGA access and crew radio sets; d. Closed circuit television system (CCTV) flat screens; e. 1 off large screen display (LCD or overhead projector) which shall be able to display any ICSS graphic screen; f.

1 off ICSS data historian workstation;

g. 1 off ICSS data SOE workstation; and h. PCS, SIS and FGS Engineering Work Stations (EWS) for systems diagnostics and carrying out system configurations changes shall be installed in an adjacent Instrument Equipment Room.

10.2. PCS Specifi c Design Requirements 10.2.1. PCS Arch itect ure The PCS shall be based on a standard distributed control system open architecture with industry standard high-speed data communication network. The PCS shall allow functional and geographical distribution and integration of foreign devices. The PCS shall provide an infrastructure for advanced control application, plant information network, distributed plant performance review stations, FFB field devices and plant expansions. Any OWS operating with the same database shall ensure 100% redundancy of the process control system display. These OWS shall be mounted on an ergonomically designed control console. The operating system for all OWS and EWS should be Microsoft Windows based. Interface adapters shall be provided on the workstation allowing connection to the

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Ethernet based MIS information domain. The workstation shall be able to work as server to clients in the MIS connected to Ethernet LAN. The controllers are stand alone process control and data acquisition systems and interface the field signals to the communication network via I/O termination assemblies, I/O modules, control processors and network communication modules. Interfaces to the SIS and FGS shall be carried out on a common control/SIS Highway. The requirements for this highway shall be addressed in an Emergency Shutdown System Operating Philosophy to be developed during the detailed design phase of this project.

10.2.2. Funct ional Requirements The primary objective of the PCS shall be to facilitate control and monitoring (including the production of written reports) by fast acquisition and processing of the parameters, to enhance the operator's overall knowledge of the plant conditions and operational conditions. The system is expected to monitor all points collected from various parts of the plant and present the required information on the OWS screens in suitable formats at the operator's request thereby offering a suitable operating interface. The objectives can be summarised as: a. Data acquisition and processing of inputs and displaying them on OWS for open loops, to perform control tasks to generate control signal outputs in case of closed loops, and displaying the data on OWS. It shall have self-tuning capability for the control loops; b. It shall exchange the required information with the other nodes of the data network (including OWS) to facilitate operation of control algorithms and also the functions of the operator interfaces and algorithms of the other workstations; c. It shall carry out extensive self-diagnostics and provide detail diagnostics display on the OWS. The diagnostics shall cover all elements of the ICSS, and other sub systems including power supply; d. Plant and equipment monitoring, including alarming, trending archiving events and recording; e. The PCS shall provide facilities for user application software development, system configuration changes, process and safety picture development in online and off-line modes including diagnostics; f.

It shall also have the capability for on-line modification of measurement and control parameters, without impact on the running system; and

g. Plant management information and logs. A large historical database shall be maintained for keeping the process value in suitable formats enabling the operator to print out reports on-demand.

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10.2.3. Data Com muni catio n Data communication between the system interfaces shall be at least 100-Mbps for nodes and 10-Mbps for LAN. It shall be fault tolerant and dual redundant. The medium of data transmission shall be fibre optic cables. PCS system performance shall not be impaired by the loss of a single channel in the process bus. In the event of a temporary loss of communications in the control network, all elements of the ICSS and connected UCPs shall continue to operate independently to maintain the RU’s operations. A communications watchdog shall monitor the correct operation of the control network communications, and shall initiate a critical alarm in the event that communications are lost. Selected data from PLC controlled packages shall be made available in the PCS. This shall cover data for monitoring and normal control of package equipment from the PCS and common alarms for diagnostics. This includes but not limited to: a. Detail displays; b. Graphics for process and diagnostics; c. Configuration software; d. Real time trends; e. Overview; f.

Alarm display; and

g. Critical event archiving. Data available from the intelligent motor control centre shall be made available in the PCS.

10.2.4. Tank Level Measur ing In str umentati on The buffer tank level measuring system of the RU is required to be fully redundant, based on two different tank buffer level measuring principles. At this stage, it is proposed that a guided wave radar beam shall be the principle method, with a floating sensor system as the secondary/check system. The achievement of the required level of performance associated with the buffer tank level measurement system shall be demonstrated during commissioning – with the design CONTRACTOR responsible for the production of a validation procedure which demonstrates – both empirically and in reference to the calculations results provided by the two systems installed – the measured uncertainty of the metering instrumentations. The buffer tanks shall be internally surveyed as part of detailed design modifications to accurately establish their volume. The results shall be certified by an authorised surveying company to ensure that the overall accuracy of the system is achieved. These measurements shall be used to produce capacity tables for buffer tank volume verification.

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10.3. Commun ications Philoso phy 10.3.1. Telephone System Telephone equipment shall be supplied to enable analogue extensions to be located on the RU to be connected to the PABX at the ORF. a. Telephones are to be located as a minimum in the following areas: i)

CCR/MSCR;

ii)

Instrument Equipment Room;

iii)

Restroom;

iv)

Communications/IT Server Room/Radio Equipment Room (RER).

b. The following locations shall have telephones which are certified as suitable for a hazardous area: i)

Musterpoint/Temporary Safe Refuge;

ii)

Alternative Temporary Safe Refuge.

c. An analogue line is also required for PAGA system access. 10.3.2. IT Netwo rk The network shall be implemented on CAT9 Structured cable. The telephone system shall use the same structured cable network. There shall be no differentiation between the two systems, i.e. same patch panels, numbering and outlet types.

10.3.3. Public Addr ess and General Alarm Sys tem A PAGA system shall be installed on the RU. The RU system shall distribute audio alarms, visual alarms and emergency messages, and shall be interfaced to the SIS for alarm input. The PAGA system shall also be used for general announcements. As such it shall be zoned so as not to interfere with sleeping personnel. No single failure in equipment or cables, nor any single external event, shall cause significant reduction of PAGA sound level in any area. The PAGA system shall provide microphone input stations at selected locations throughout the facility. PABX access to the PAGA system shall be available for select users. This shall be achieved using the PABX class of service restriction access. The RU FGS system shall interface with the PAGA system for the annunciation of emergency tones. The PAGA system shall also activate alert beacons, where noise limits exceed 85dBA. Page 22 of 28


10.3.4. Close Circ uit TV and Securi ty Sys tem A CCTV system with associated security functionality shall be installed on the RU. This shall not be directly connected to other CCTV and security systems installed elsewhere in the field. Colour CCTV cameras with heavy-duty pan/tilt and zoom mountings suitable for use in hazardous areas shall be installed on the deck levels. Colour television monitors with a screen diagonal dimension of a minimum 24” shall be installed in the CCR, with camera control keyboards. A LAN interface shall be provided, such that cameras may be viewed over the LAN by using software provided for installation on selected computers. The camera controller and switcher unit shall be installed in the RER. The CCTV system shall be used to maximise the visibility and safety of processing equipment during operations. It shall be equipped with “flame flicker” fire detection, leakage and motion detection functionality. This shall automatically initiate an alarm on the CCR central control console human/machine interface, but not a Facility Fire Alarm; details of this alarm initial shall be covered in the Emergency Shutdown System Operating Philosophy document to be developed during the detailed design phase of the project. The CCTV system shall be pre-programmed so that the activation of a fire or gas detector in the process areas shall automatically cause a CCTV camera covering that fire zone to focus on the area identified. An intruder alarm and security system shall be incorporated with the CCTV system; it shall automatically initiate alarms both locally in the CCR and in the CCR’s at the RU and the ORF. The system shall be interconnected to a digital video recorder to enable recording and later playback of any potential safety or security events.

10.3.5. Meteorol ogic al Sys tem The meteorological system shall provide weather recording and archiving facilities for the RU. The system shall include the ability for authorised personnel to view weather data via the RU’s LAN. The weather data shall be displayed on a graphical or numerical display capable of showing both instantaneous readings and historical readings in user selectable intervals.

10.3.6. Radio Equipm ent Roo m The RER is to contain the telecommunications and entertainment equipment. Space is also to be provided for a platform control system monitor. LAN connection outlets are to be provided in the RER.

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11. MISCELLANEOUS OPERATIONAL PHILOSOPHIES 11.1. Simultaneous Operations Simultaneous operations (such as maintenance activities beside “live” plant) are permitted on the basis that an acceptable level of protection is in place to prevent loss of control. As a minimum, two levels of protection shall be in place such that loss of any one protection measure does not result in loss of control. Common protection measures for two or more operations shall be acceptable. Function testing of the agreed protection measures shall be undertaken prior to commencing the simultaneous operations. A simultaneous operations procedure shall be developed during the detailed design phase of the project, detailing the set of simultaneous operations which are permitted and the measures which are required to prevent loss of control. This information shall become the permitted operations, which is part of the operating manual for the RU. LNG regasification during offloading of LNG from an FSU/LNGC to the RU is a normal operating mode and therefore is a permitted simultaneous operation. The protection measure in place is the loading arms ERS or cryogenic hoses. This system shall be function tested prior to loading commencing.

11.2. Materials Handling/Accessibi lity/Dropped Object Protection 11.2.1. Materials Handling Materials handling procedures shall be developed during the detailed design phase based on the results of the materials handing study. Equipment removal routes to designated laydown areas or other areas as necessary, which are easily accessible by the RU’s cranes, shall be identified.

11.2.2. Accessibility Good access shall be provided to items of equipment which require frequent (more than once per year) testing, inspection or maintenance. This shall also apply to the permanent handling/lifting devices (such as beams, pad eyes) installed for equipment removal. Scaffolding or other temporary fixtures shall be used where equipment testing, inspection or maintenance is less frequent (greater than 2-years).

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11.2.3. Impact Prot ectio n The need for dropped object protection or additional protection of “live” process equipment from dropped objects shall be studied as part of the materials handling study. Crane and mobile vehicle operations shall be minimised near to or over “live” process equipment. Dropped object protection shall not be required where infrequent heavy material movements near or over equipment are carried out when the equipment has been isolated and depressurised.

11.3. General Hous ekeepin g RU housekeeping shall be the responsibility of shift personnel. When maintenance work is carried out, the maintenance team shall leave the area clean and tidy.

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12. MAINTENANCE PHILOSOPHIES 12.1. Objectives The primary objectives of the maintenance function shall be to achieve: a. Technical integrity within COMPANY requirements; b. Optimum equipment availability with the minimum of staffing levels; c. Lowest life cycle cost; and d. Meet legislative requirements with regard to equipment inspections/testing. The RU shall be maintained so that it remains in an operable condition to the end of its design life and can be maintained in service without a major re-build or dry-docking. During the detailed design phase of the project, maintenance personnel shall be involved in order to assist in achieving the above objectives (e.g. optimum equipment availability -through careful selection and equipment arrangement). A detailed maintenance philosophy for the RU shall be developed at the detailed design stage . This shall detail the maintenance strategy to be applied to equipment and systems; either frontline, preventative, "on condition" or breakdown maintenance. The selection of the maintenance strategy shall be determined against the objectives set out above.

12.2. Servicing The optimum means of servicing equipment shall be carefully assessed against maximising RU availability. The servicing options, which shall be evaluated, are: a. Maintain/repair onsite or in the facility workshop; and b. Remove equipment and repair onshore. Consistent with the philosophy of minimum staffing, onshore repair or maintenance shall be pursued. Additionally the option of vendors providing full or part servicing of equipment shall be reviewed during the design to determine the optimum strategy.

12.3. Maintenance Management A maintenance, testing and inspection plan shall be developed by the RU CONTRACTOR. This shall outline the type of maintenance required on each item of equipment/system (routine, preventative or breakdown) against the objectives listed in section 13.1. Maintenance/testing/inspection scheduling shall be based on this plan. As part of this management process, a through-life database shall be developed to ensure continual improvement and enhanced technical integrity.

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12.4. Front lin e Maintenance Frontline maintenance, such as condition monitoring, control valve repairs, troubleshooting and repair of field instrumentation, instrument calibrations and routine equipment servicing (lube oil change, etc.) shall be carried out by production personnel.

12.5. Major Shutdowns Major planned shutdowns shall be necessary to meet required storage tanks inspections (either set by legislation including classification society rulings or technical integrity considerations) and the replacement components associated with the regasification units. Major shutdowns shall be planned to minimise the time offline by having a 24-hour working period with a maximum labour input consistent with safe and efficient practices. Major shutdowns shall be managed by using existing maintenance staff supported by additional contracted maintenance personnel and specialist vendor personnel.

12.6. Condition Monito ring, Testing and Inspection A maintenance, inspection and test plan shall be developed during the detailed design phase of the project to cover all safety and production critical equipment. This plan shall outline the requirements for the following tasks and activities: a. Condition monitoring, including monitoring strategy and monitoring data collection and processing; b.

Testing requirements as set out in vendor recommendations. Testing requirements shall also be reviewed and modified as necessary based on equipment/system historical data;

c. Alarm and trip testing of critical trips and alarms; d. Inspection requirements consistent with maintaining technical integrity and meeting legislation and COMPANY requirements.

12.7. Certification Early in the detailed design phase, the Certifying Authority shall be appointed. The work scope definition for the Certifying Authority shall be developed in consultation with the appropriate government department. An integrated approach shall be developed whereby the Certifying Authority, design and operations team work together to achieve the desired level of technical integrity.

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12.8. Spares Holdin g Spares holding for the RU shall be based on the results of a reliability, availability and maintainability study (RAM). In particular, spares shall be established for the regasification system selected. A critical spares listing shall be developed and used for setting the level of spares holding on the RU itself. The criteria for deciding on a critical spare shall be taken to be: "An item of equipment which in the event of failure shall result in an unacceptable safety risk or a significant business loss" The sparing philosophy is that the RU shall warehouse only safety or production critical equipment spares. Spares shall not be held where equipment/systems are duplicated (spared) within the RU (e.g. duty and standby pumps). Non-critical spares and consumables can be stored in a suitable supply base/warehouse located onshore. Sparing of portable fire fighting equipment on the RU shall be provided equivalent to 5% of the total of each type of device so as to provide expedient replacement. Commissioning, start-up and first year spares shall be identified during the detailed design phase and are available prior to commencement of commissioning.

12.9. Permit to Work /Work Orders All maintenance work on the LNG Facility shall be carried out under a “Permit to Work” system. Work orders shall be generated and shall be prioritised In all cases, apart from an emergency or breakdown, work orders shall be issued by the onshore maintenance support personnel.

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LNG Ship Operating Philosophy

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