SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

SKIKDA, ALGERIA
OPERATING MANUAL VOLUME IV, SECTION 3-1:
UNIT 56 PLANT AND INSTRUMENT AIR

DOCUMENT NO: PP-AAA-PP1-145

KBR
JOB NO.: J6404

1 VAS Issue for Implementation 03-Nov-10 GRM BA

0 VAS Issue for Implementation 23-Oct-10 GRM BA KB

A JES Issue for Client Approval 18-Sep-09 VAS BA

Rev. By Description Date KBR KBR CLIENT

Chkd App App

 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

TABLE OF CONTENTS
1.0 INTRODUCTION................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running..............................................................................................................6
3.1.1 Air Compressor Package, 56-MJ01-A/B/C ...................................................................6
3.1.2 Wet Air Separator, 56-ML02.........................................................................................6
3.1.3 Air Dryer Package, 56-ML01-A/B .................................................................................6
3.1.4 Instrument Air Receiver, 56-MD02 ...............................................................................6
3.2 Typical Operating Parameters ........................................................................................7
3.3 Temporary Operation......................................................................................................7
4.0 START-UP ............................................................................................................ 8
5.0 SHUTDOWN ......................................................................................................... 9
5.1 Normal Shutdown ...........................................................................................................9
5.2 Process Upsets and Production Losses .........................................................................9
6.0 SAFETY/EMERGENCY SHUTDOWN................................................................ 10
6.1 Safety Critical Shutdown Systems ................................................................................10
6.1.1 I-5610 - Air Supply to Plant Air Header ......................................................................10
6.1.2 I-0000 - Plant ESD .....................................................................................................10
6.2 Pressure Safety Valve Summary ..................................................................................10
6.3 Fire Protection Equipment ............................................................................................10
7.0 ATTACHMENTS ................................................................................................. 11
7.1 Attachment I: Equipment List ........................................................................................12
7.2 Attachment II: Utility Consumption...............................................................................13

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

1.0 INTRODUCTION
This operating manual relates to the facilities indicated on Process Flow Diagram
PR-56-PR32-001 and P&ID’s PR-56-SYPI-001A through PR-56-SYPI-003A.
The function of the Plant Air System is to provide air at approximately 9.5 barg to
utility air stations via the plant air headers and supply the Instrument Air System
which provides dried atmospheric air to instrument air users at a normal pressure of
approximately 9 barg.

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NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

TO DISTRIBUTION

TO DISTRIBUTION
INTRUMENT AIR
PLANT AIR

Instrument Air
56-MD02

Receiver
1015
PI

T
56-ML01-A/B
Air Dryer
Package

Separator
56-ML02
Wet Air

OW
56-MJ01-A/B/C
Air Compressor
Package

Simplified Flow Diagram

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

2.0 SYSTEM DESCRIPTION

There are 3 x 100% Air Compressor Packages, 56-MJ01-A/B/C; one in operation
and two in stand-by; each rated for 3345 Nm³/h at a nominal discharge pressure of
10 barg. The compressors are motor driven oil free screw type, two stage, pulsating
free air, water cooled systems.
Compressed atmospheric air from the compressors passes through the Wet Air
Separator, 56-ML02, where any water that condenses during compression is
separated. The air is then distributed to utility stations via the plant air headers.
There are 2 x 100% Air Dryer Packages, 56-ML01-A/B; one in operation and one in
stand-by. Each dryer package is comprised of two vessels; one drying and one
regenerating. They are of the heat-less type and the air is dried to a water dew point
of -40ºC at operating pressure of approximately 9.0 barg. Each package includes
after filters to remove desiccant fines.
In each dryer package, wet compressed air enters the bottom of the package and is
directed by the switching valves to the in service dryer where dry desiccant removes
moisture from the air. The air flows up through the dryer and is directed to the outlet
of the package. Approximately, fifteen percent of the dry air is directed into the
regenerating dryer where it is depressurized to atmospheric pressure and is used to
regenerate the desiccant in the second dryer. After removing the moisture from the
desiccant, the purge air exits the dryer through a muffler to the atmosphere. After a
preset time or based on dewpoint control, the package shifts dryers. At a dryer shift,
the regenerated dryer is gradually pressurized, the switching valves sequentially
shift, and the offstream tower is depressurized.
The instrument quality air from the dryers flows to the Instrument Air Receiver,
56-MD02, before it is distributed to the users. The receiver will provide sufficient
instrument air at normal instrument air flow for 5 minutes to allow for a controlled
shutdown of the plant in the event of total air compressor failure.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Plant and
Instrument Air System. Refer to Section 3.2 for a list of typical operating variables for
this system.
3.1.1 Air Compressor Package, 56-MJ01-A/B/C
Under normal operating conditions, one Air Compressor Package, 56-MJ01-A/B
or C, will be running. In the event the pressure of the Instrument Air Header
decreases to 8.5 barg at 56-PT-1015 near the Instrument Air Receiver, 56-MD02, a
second compressor will start. The third compressor is normally left off line as a
maintenance spare.
The two cooling water systems for the operating and stand by compressor will be
continuously running. The compressor motor will be prevented from starting in the
event of low cooling water pressure.
The compressors can be started and stopped locally and from the DCS using 56-HS-
3300-A/B/C.
3.1.2 Wet Air Separator, 56-ML02
Air from the compressors passes through the Wet Air Separator, 56-ML02, where
free water is removed before being distributed to the plant air header and the dryers.
The level of water in the separator is indicated by 56-LI-1010 and displayed on the
DCS. An electronic water drain is provided on the separator drain line to
automatically drain the separator to the oily water sewer.
3.1.3 Air Dryer Package, 56-ML01-A/B
All operation of the Air Dryer Package, 56-ML01-A/B, is performed at the local
control panel and are started and stopped locally when the panels are energized.
Dryer status, discharge pressures, and dew points are indicated on the DCS.
In each Air Dryer Package, 56-ML01-A/B, wet air is directed by the switching valves
to the in service dryer. The dry air is directed to the outlet of the package with a
portion of the dry air is directed into the regenerating dryer where it is depressurized
to atmospheric pressure and is used to regenerate the desiccant. After a preset time
or based on dewpoint control, the package shifts dryers. At a dryer shift, the
regenerated dryer is gradually pressurized, the switching valves sequentially shift,
and the offstream tower is depressurized.
3.1.4 Instrument Air Receiver, 56-MD02
Pressure indicator 56-PI-1015 measures the Instrument Air Receiver, 56-MD02,
discharge pressure to the instrument air header. This pressure is the measured
variable for controllers 56-PY-1015A/B/C which turn on or off the Air Compressor
Packages, 56-MJ01-A/B/C. The receiver will provide sufficient instrument air at
normal instrument air flow for 5 minutes to allow for a controlled shutdown of the
plant in the event of total air compressor failure.
An air trap is provided on the Instrument Air Receiver, 56-MD02, drain line to
automatically drain any water collect in the receiver.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

Pressure in 56-MD02 Compressor Discharge

Pressure
Instrument Description Action Pressure [barg]
[barg]
Autostart Second
56-PT-1015 PAL 8.5* 9.3 - 8.6
Compressor
56-PT-1018
PALL 8.0* Shut Off Plant Air 8.8 - 8.1
A/B/C
56-PT-1018
PALLL 5.5* Plant Shutdown 6.3 - 5.6
A/B/C

*Set Point Pressures

Notes:
• MR/PR compressor package valves are designed for minimum instrument air
pressure of 7.0 barg, which is 7.5 barg at the receiver. If an Air Compressor
Package cannot be started by the time the receiver pressure reaches PALL, then
preparations must be made for refrigeration compressor train shutdown followed
by plant shutdown. If instrument air pressure falls below MR/PR package valve
limits, the valves may not operate properly and cause a trip of the MR/PR
compressors. A trip of the MR/PR compressors will cause a process upset but
will not directly trip Plant ESD interlock I-0000.
• All other control and on/off valves are designed for minimum instrument air
pressure of 5.0 barg, which is 5.5 barg at the receiver. If plant shutdown has not
been achieved by the time the receiver pressure reaches PALLL, the plant will be
shutdown automatically via interlock I-0000.
3.2 Typical Operating Parameters
The following table contains typical operating variables for the Plant and Instrument
Air System.

Operating Variables for the Plant and Instrument Air System

Tag No. Description Typical Value Units

56-PI-1012 Wet Air Separator Pressure 10.0 barg

Indicator

56-PI-1015 Instrument Air Receiver Pressure 9.0 barg

Indicator

3.3 Temporary Operation

Not applicable.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

4.0 START-UP
This section outlines the steps necessary to place the Plant and Instrument Air
System in service. For the purpose of this section of the operating manual, it is
assumed that the following conditions exist: utilities are in service, and system ready
for start-up.
1. Isolate Instrument Air Receiver, 56-MD02, from the Air Dryer Packages,
56-ML01-A/B, by closing package outlet isolation valves.
2. Line up Air Compressor Package, 56-MJ01-A/B/C, to discharge to atmosphere
and start-up compressor.
3. Line up system to allow air to be passed through the Wet Air Separator,
56-ML02, and the Air Dryer Package, 56-ML01-A/B, to atmosphere.
4. Slowly open the isolation valve between the air compressor discharge and the
Wet Air Separator.
5. Continue to flow air through the Air Dryer Package to atmosphere periodically
alternating which package is online.
6. Commission the dew point analyzers, switch the unit to operate on dew point
control.
7. Line up system to allow dried air to flow to the Instrument Air Receiver,
56-MD02, and instrument air header.
8. Open plant air supply valves ESDV-1042 and ESDV-1043 to allow compressed
air to flow to the plant air header for distribution.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Plant and Instrument
Air System.
During plant shutdown periods the Plant and Instrument Air System should remain in
service to continue to supply air to the headers at the regulated pressure.
A shut down of the Plant and Instrument Air System will require a complete shut
down of the facilities unless instrument air is supplied by an adequate alternate
source.
1. Isolate the supply of air to the plant air header at 56-ESDV-1042 and 56-ESDV-
1043.
2. Isolate the supply of air to the instrument air header using the ball valve at
discharge of the Instrument Air Receiver, 56-MD02.
3. Depressure instrument air header.
4. Shutdown Air Compressor Package, 56-MJ01-A/B/C.
5. Shutdown Air Dryer Package, 56-ML01-A/B.
6. Depressure system.
5.2 Process Upsets and Production Losses
In the event of a change in conditions or trips, the process may become upset and
possibly require shutdown. In the event of an emergency requiring a shutdown of
the Plant and Instrument Air System the system should be shut down as outlined
above.
1. Loss of Electrical Power
Loss of main and emergency electrical power to the Air Compressor Package,
56-MJ01-A/B/C, will result in a shutdown of the Plant and Instrument Air System.
Instrument valves required for safety have local air receivers with sufficient volume
for three strokes of the valve.
2. Loss of Cooling Water
The compressors are cooled by individual circulating cooling water systems. Loss of
cooling water to the Air Compressor Package, 56-MJ01-A/B/C, will result in trip of the
compressor package and a shutdown of the Plant and Instrument Air System.
Instrument valves required for safety have local air receivers with sufficient volume
for three strokes of the valve.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-5610 - Air Supply to Plant Air Header
The Air Supply to Plant Air Header Interlock I-5610 will trip the air supply to the plant
air header on Lo-Lo instrument air pressure by closing valves 56-ESDV-1042 and
56-ESDV-1043.
6.1.2 I-0000 - Plant ESD
The Plant ESD Interlock I-0000 will be initiated on Lo-Lo-Lo instrument air pressure.
6.2 Pressure Safety Valve Summary
The Plant and Instrument Air System Pressure Relief Valve Summary contains a
listing of all the pressure relief valves associated with this system.

Plant and Instrument Air System Pressure Relief Valve Summary

Set Pressure
Valve Number Description/Location (barg)

56-PRV-1005A/B Instrument Air Receiver/Relief to Atmosphere 10.0

56-PRV-1011A/B Wet Air Separator/Relief to Atmosphere 11.0

6.3 Fire Protection Equipment

The Plant and Instrument Air System Fire Protection Equipment Summary contains a
listing of fire protection equipment associated with this system.

Plant and Instrument Air System Fire Protection Equipment Summary

Description Quantity

CEC - Air Compressor

63-SP-006 Two Way Hydrant 6

63-SP-012 Hydrant Cabinet two Way 4

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Plant and Instrument Air
System.

Plant and Instrument Air System Equipment List

Design Design
Pressure Temp
Equipment No. Description (barg) (ºC)

56-MD02 Instrument Air Receiver 10.0 85

56-MJ01-A/B/C Air Compressor Packages 10.0

56-ML01-A/B Air Dryer Packages 10.0

56-ML02 Wet Air Separator 10.0

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-145
OPERATING MANUAL VOLUME IV, SECTION 3-1: REVISION 0
PLANT AND INSTRUMENT AIR Nov 03, 2010

7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Plant and Instrument Air
System and their expected consumption.

Plant and Instrument Air System Motor List

Available
Motor Load
Equipment No. Description (kW)

56-MJ01-A-M Air Compressor Electric Motor 600

56-MJ01-A-ML01- Fans For Cooling Water Exchanger 22

MC01-MJ1-A/B

56-MJ01-A-ML01- Electric Motor 132

MJ01-M

56-MJ01-A-ML01- Electric Motor (Standby) 132

MJ01-A-M

56-MJ01-B-M Air Compressor Electric Motor 600

56-MJ01-B-ML01- Fans For Cooling Water Exchanger 22

MC01-MJ1-A/B

56-MJ01-B-ML01- Electric Motor 132

MJ01-M

56-MJ01-B-ML01- Electric Motor (Standby) 132

MJ01-A-M

56-MJ01-C-M Air Compressor Electric Motor 600

56-MJ01-C-ML01- Fans For Cooling Water Exchanger 22

MC01-MJ1-A/B

56-MJ01-C-ML01- Electric Motor 132

MJ01-M

56-MJ01-C-ML01- Electric Motor (Standby) 132

MJ01-A-M

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