Hamworthy QGII operation manual 2007

Hamworthy Gas Systems AS Project Title: QGII QFLEX The contents of this document are Hamworthy’s intellectual property and shall be treated as confidential Information This rd document shall not be shown nor given to any party without written acceptance by Hamworthy Gas Systems AS 02 13.09.2007 As-built SS BB AL 01 25.06.2007 Reissued before Gas trial SS BB AL 00 29.06.2006 Issued for Comments PS RK Rev Made Checked by by Project no: Effective Date Description Client / Client ref: HHI/SHI AL Approved by 400573 Document Title: Project Document no: QGII Operation Manual Page of 124 400573-R-HGS-69299 Hamworthy Gas Systems AS Project no: 400573 Project Doc no: 400573-R-HGS-69299 QGII Operation Manual Revision: Effective Date: 01 25.06.2007 Table of Contents Introduction 1.1 PURPOSE 1.2 CONTACT ADDRESS 1.3 REQUIRED QUALIFICATIONS OF PERSONNEL 1.4 REFERENCED DOCUMENTS AND DRAWINGS 1.5 ABBREVIATIONS AND TERMINOLOGY 1.6 SAFETY PRECAUTIONS 10 1.7 WARRANTY 10 2.1 TECHNICAL DATA 11 2.2 PROCESS CONSUMPTIONS 11 3.1 GENERAL DESCRIPTION 12 3.2 BOIL-OFF LOOP 14 Main Data 11 Technical Description 12 3.2.1 3.2.2 3.2.2.1 3.2.2.2 3.2.2.3 3.3 PRE-COOLER 15 BOG COMPRESSOR (TWO OFF) 16 BOG-Compressor lube oil system .18 Bulk head seal for BOG-compressor 19 BOG Compressor shaft seal gas system 19 3.2.3 COLD BOX 20 3.2.4 SEPARATOR 21 3.2.5 LNG PUMP SKID WITH VENT GAS HEATER 22 3.2.6 GAS ANALYSER 25 N2 R-LOOP 26 3.3.1 3.3.1.1 3.3.1.2 3.3.1.3 3.3.1.4 3.3.2 3.3.3 3.3.3.1 N2 COMPANDERS 27 N2-compander lube oil system 30 N2-compander seal gas system 30 N2-compander seal air system 30 N2 coolers .30 COLD BOX 30 N2 BOOSTER COMPRESSOR SKID WITH DRYER 31 N2 dryer .32 3.4 3.3.4 N2 RESERVOIR 33 HARDWARE LAYOUT 34 4.1 GENERAL 35 4.2 RELIQUEFACTION MODE (RELIQ MODE) 36 Operation Stages 35 4.2.1 4.2.2 RELIQ PLANT OFF 36 RELIQ PLANT STANDSTILL 36 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 4.3 4.2.3 RUNNING STANDBY 36 4.2.4 FREE FLOW 36 4.2.5 NORMAL RELIQ 36 4.2.6 VENT GAS MODE 37 4.2.7 EXCESSIVE BOG MODE 37 GCU MODE 37 4.4 4.3.1 GCU STANDSTILL 37 4.3.2 GCU MODE 37 SPECIAL OPERATING SCENARIOS 38 4.4.1 4.4.2 BOG COMPRESSOR OPERATION DURING WARMING UP OF THE CARGO TANKS 38 BOG COMPRESSOR OPERATION DURING GAS FREEING / INERTING OF THE CARGO TANKS 38 Operation procedures 39 5.1 PREPARATIONS FOR START 39 5.2 5.1.1 SELECT TANK PRESSURE CONTROL SETTINGS 39 5.1.2 SELECT LEAD EQUIPMENT 39 5.1.3 VERIFY VALVE POSITIONS 39 PLANT OPERATION FLOW CHART 39 5.3 RELIQ READY 39 5.4 RELIQ MODE START 39 5.5 RELIQ STANDBY 39 5.6 RELIQ STOP 39 5.7 GCU MODE START 39 5.8 GCU MODE STOP 39 5.9 AFTER PROCESS SHUT DOWN 39 5.9.1 5.9.2 5.9.2.1 5.9.2.2 N2 COMPANDER PROCESS SHUT DOWN 39 BOG COMPRESSOR SHUT DOWN 39 From operation with one BOG compressor running 39 From operation with two BOG compressors running 39 5.9.3 N2 BOOSTER COMPRESSOR SHUT DOWN 39 5.9.4 LNG PUMP SHUT DOWN 39 5.10 OPERATION DURING FAILURE 39 5.10.1 PRE-COOLER LIQUID SUPPLY CONTROL VALVE RL-818 (25TV103) 39 5.10.2 SEPARATOR LIQUID LEVEL CONTROL VALVE RL-823 (25LV040) 39 5.10.3 SEPARATOR PRESSURE CONTROL VALVE RG-826 (25PV030) 39 5.10.4 VENT GAS TEMPERATURE CONTROL VALVE RG-847 (25TV038) 39 5.10.5 R-LOOP LOADING CONTROL VALVE RN-848 (40PV055) 39 5.10.6 R-LOOP UNLOADING CONTROL VALVE RN-843 (40PV060) 39 5.10.7 DAMAGE TO COLD BOX 39 5.11 OTHER OPERATION FEATURES 39 5.11.1 MANUAL CAPACITY CONTROL OF BOG COMPRESSORS 39 5.11.2 MANUAL CONTROL OF BOOSTER COMPRESSORS 39 5.11.3 CHANGING BETWEEN LEAD AND LAG N2 COMPANDER 39 5.12 HANDLING OF RAPIDLY INCREASING TANK PRESSURE 39 Emergency Procedures 39 6.1 EQUIPMENT EMERGENCY SHUTDOWN 39 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 6.2 START-UP AFTER EMERGENCY SHUTDOWN 39 7.1 PREVENTIVE MAINTENANCE SCHEDULE 39 7.2 PREVENTIVE MAINTENANCE 39 7.3 7.2.1 BOG COMPRESSOR SKID 39 7.2.2 N2 COMPANDER SKID 39 7.2.3 LNG PUMP 39 7.2.4 GAS ANALYSER 39 7.2.5 N2 DRYER 39 7.2.6 N2 BOOSTER COMPRESSOR 39 FAULT SYMPTOMS & ERROR MESSAGES 39 7.4 7.3.1 PRE-COOLER 39 7.3.2 BOG COMPRESSOR 39 7.3.3 COLD BOX 39 7.3.4 SEPARATOR 39 7.3.5 LNG PUMP 39 7.3.6 VENT GAS HEATER 39 7.3.7 N2 COMPANDER 39 7.3.8 N2 BOOSTER PUMP 39 7.3.9 N2 RESERVOIR 39 7.3.10 N2 DRYER 39 7.3.11 BUTTERFLY VALVES 39 7.3.12 BALL VALVES 39 7.3.13 CONTROL VALVES 39 PURGING PROCEDURE 39 Maintenance 39 7.4.1 7.4.2 7.4.2.1 7.4.2.2 7.4.2.3 7.4.2.4 7.4.2.5 7.4.3 INTRODUCTION 39 DEPRESSURIZING AND PURGING OF N2 CYCLE 39 Depressurizing of N2 Compander no (40KX100) .39 Depressurizing of N2 Compander no (40KX200) .39 Depressurizing of N2 Booster train no (40KX104) 39 Depressurizing of N2 Booster train no (40KX204) 39 Depressurizing and purging of complete N2 Cycle .39 DEPRESSURIZING AND PURGING OF BOG CYCLE 39 7.4.3.1 Depressurizing and purging of Precooler (25VA100) and BOG Compressor no (25KX100) 39 7.4.3.2 Depressurizing and purging of BOG compressor no (25KX100) 39 7.4.3.3 Depressurizing and purging of BOG compressor no (25KX200) 39 7.4.3.4 Depressurizing and purging of complete BOG cycle 39 7.4.4 VACUUMING 39 7.4.4.1 Vacuuming of complete N2 Cycle 39 7.4.4.2 Warm purging of N2 companders 39 7.4.4.3 Vacuuming of complete BOG Cycle 39 Spare Parts 39 8.1 SPARE PARTS DELIVERED WITH THE RELIQUEFACTION SYSTEM 39 8.2 VALVE SPARES 39 FLOW METERS 39 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 8.3 DIFFERENTIAL PRESSURE TRANSMITTERS 39 8.4 PRESSURE TRANSMITTERS 39 8.5 LEVEL SWITCH 39 8.6 PRESSURE SWITCH 39 8.7 TERMOSTAT 39 8.8 TEMPERATURE SWITCH 39 8.9 POSITION SWITCH 39 8.10 MANOMETERS 39 8.11 TEMPERATURE ELEMENTS 39 10 Disposal instruction 39 Drawings and Documents 39 10.1 DRAWINGS 39 10.2 DOCUMENTS 39 10.3 SUB SUPPLIER DOCUMENTATION 39 11 12 13 14 15 Appendix A - Valves Position 39 Appendix B - BOG compressor log sheets 39 Appendix C - N2 compander log sheets 39 Appendix D - N2 booster compressor log sheets 39 Appendix E - Manual control of N2 supply 39 Introduction 39 1.1 PURPOSE OF MANUAL OPERATION 39 1.2 ERROR IN 40PV055 AND 40PV060 39 2.1 IMPORTANT GENERAL NOTES 39 2.2 INCREASING INVENTORY 39 2.3 REDUCING INVENTORY 39 2.4 2.3.1 RUNNING COMPANDER DISCHARGE PRESSURE < 36 BARG 39 2.3.2 RUNNING COMPANDER DISCHARGE PRESSURE > 36 BARG 39 SUPPLY OF NITROGEN FROM SHIP SYSTEM 39 2.5 MOVING NITROGEN FROM STANDBY COMPANDER TO RESERVOIR 39 Procedures 39 16 Appendix F - Cause & effect matrix 39 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 List of Figures Figure Plant general arrangement Boil-off loop in red, N2 loop in green 12 Figure MOSS RS reliquefaction system Boil-off loop in red, N2 loop in green 13 Figure Boil-off Loop arrangement 14 Figure Pre-cooler assembly 15 Figure BOG compressor assembly left 17 Figure BOG compressor assembly right 18 Figure Bulk head seal for BOG-compressor 19 Figure BOG compressor seal gas system 19 Figure Cold box 20 Figure 10 Cold box w/ separator 21 Figure 11 Pump bearing heater 22 Figure 12 Vent Gas Heater 22 Figure 13 Flow element w / transmitter 23 Figure 14 LNG pump skid 24 Figure 15 Gas analyser 25 Figure 16 N2 arrangement N2 loop in green 26 Figure 17 N2 compander right 28 Figure 18 N2 compander left 29 Figure 19 N2 booster compressor skid 31 Figure 20 N2 dryer 32 Figure 21 Dew point transmitter 32 Figure 22 N2 reservoir 33 Figure 23 DACS Hardware Layout 34 Figure 24 Overview of the different operating modes 35 Figure 25 Reliq BOGC GMS 39 Figure 26 Reliq Booster comp main 39 Figure 27 Reliq.plant main 39 Figure 28 Plant operation flow chart 39 Figure 29 Reliq booster comp main 39 Figure 30 Reliq plant main 39 Figure 31 Reliq Plant Main 39 Figure 32 Reliq Booster Comp Main 39 Figure 33.Reliq plant Main 39 Figure 34 Reliq Plant Main 39 Figure 35 Oil level indicator 39 Figure 36 Pressure drop across filter & refill of oil 39 Figure 37 Oil pressure to el motor 39 Figure 38 DGV 39 Figure 39 Condensate & drain 39 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 Figure 40 Oil level indicator 39 Figure 41 Refill of oil 39 Figure 42 Pressure drop across filter 39 Figure 43 IGV 39 Figure 44 Heating cable 39 Figure 45 Gas analyser instrument panel 39 Figure 46 Gas analyser 39 Figure 47 N2 dryer 39 Figure 48 Oil level, filling and filter 39 Figure 49 Pressure and temperature 39 Figure 50 Drain of demister 39 Figure 51 Oil separators 39 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 Introduction The User Manual contains the basic information that is necessary in order to operate the plant in a safe and secure manner 1.1 Purpose The purpose of this User Manual is to inform the operator on how the plant is designed, its function, technical data, operation, maintaining, faultfinding and any dangers or hazards that may arise/occur during operation The operator must adhere to all instructions and recommendations from this User Manual including corresponding User Manuals from sub-suppliers It is therefore imperative that the User Manual is ready available to all plant operators 1.2 Contact address Address Hamworthy Gas Systems AS Solbraaveien 10, NO-1383 Asker Postal Addr.: PO box 144, NO-1371 Asker Norway Telephone +47 815 48500 Telephone 24 hrs +47 6610 9660 Telefax +47 815 48520 Email gasspares@hamworthy.com Internet http://www.hamworthy.com/contact/officesearch.asp 1.3 Required qualifications of personnel Only qualified personnel are allowed to operate the plant Qualified personnel shall fulfil the following: • General training and experience • Specific training on the LNG reliquefaction plant • Familiar with basic work safety and accident prevention regulations, • Read and familiarised themselves with this user manual and accompanying documentation The user manual is designed to provide qualified personnel with information for the day-to-day operations and maintenance tasks on the delivered equipment 1.4 Referenced documents and drawings All documents and drawings referred to in this document are listed in chapter 10 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 1.5 Abbreviations and terminology The following abbreviations and terminology are used throughout this document: ASV Anti Surge Valve Bar a Absolute Pressure In Bar Bar g Gauge Pressure In Bar BOG Boil-Off Gas BOR Boil-Off Rate CCR Cargo Control Room Cryogenic Low Temperature Cooling DACS Distributed Alarm And Control System DGV Diffusor Guide Vanes ESD Emergency Shutdown EMR Electrical Motor Room GCU Gas Combustion Unit HD High Duty HGS Hamworthy Gas Systems IGV Inlet Guide Vane Laden Voyage Loaded With Gas Lag Standby LBOG Liquefied Boil-Off Gas (Condensate) LNG Liquefied Natural Gas MCC Motor Control Room N2 Nitrogen N2 compander N2-Compressor/Expander Unit PFD Process Flow Diagram PSV Pressure Safety Valve RS Reliquefaction System R-loop Reliquefaction Loop Page of 124 400573 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 1.6 Safety precautions In this user manual the following symbols are used: Disregard of directions in cautions can result in damage to equipment CAUTION NOTE Text set off in this manner brings attention to additional information or specific instructions 1.7 Warranty Warranty or liability claims in connection with personal injuries or damage to equipment or the plant not apply if the injury or damage is due to one of the following: • Faulty use or operation of the plant • Faulty installation, commissioning, operation or maintenance of the plant • Continuous operation of the plant after a fault has been identified • Information in this User Manual concerning transportation, storage, installation, commissioning, and maintenance has not been followed • Changes made to the plant without Hamworthy Gas Systems AS approval • Insufficient condition monitoring of wear parts • Repair work has not been done according to supplier’s specifications and requirements • Non-genuine spare parts have been used • Unqualified personnel operating, maintaining, using or installing the plant • If the LNG reliquefaction plant is operated outside its operating limits Page 10 of 124 Hamworthy Gas Systems AS Project no: 400573 Project Doc no: 400573-R-HGS-69299 QGII Operation Manual Revision: 01 Effective Date: 25.06.2007 11 Appendix A - Valves Position Refer to document 400573-P-HGS-59764 “QGII QFLEX / OSG, P&ID – Moss RS reliquefaction plant” when reading this appendix NOTE All instrument block and bleed valves shall be open All instrument root valves shall be open Valve tag no Valve position Open Valve tag no Closed Valve position Open N2 Booster compressor: Closed N2 Reservoir: RN-821 Open RN-601 Closed RN-822 Open RN-602 Closed RN-827 Open RN-828 Open RN-850 Open RN-831 Open RN-863 Open RN-832 Open RN-873 Open RN-842 Open RN-874 Open RN-845 Open RN-846 Open RN-849 Open Cold box and separator: Page 110 of 124 Hamworthy Gas Systems AS Project no: Project Doc no: 400573-R-HGS-69299 QGII Operation Manual Valve tag no Valve position Open 400573 Revision: 01 Effective Date: 25.06.2007 Valve tag no Closed Valve position Open N2 Compander no as lead Closed N2 Compander no as lead RC-805 Open RC-805 Closed RC-806 Open RC-806 Closed RC-809 Open RC-809 Closed RC-810 Open RC-810 Closed RN-803 Open RN-803 Open RN-804 Open RN-804 Open RN-807 Open RN-807 Closed RN-808 Open RN-808 Closed RN-817 Open RN-817 Closed RN-818 Open RN-818 Closed RN-876 Open RN-876 Open RN-878 Open RN-878 Open RN-881 Open RN-881 Closed RC-801 Closed RC-801 Closed RC-802 Closed RC-802 Closed RC-807 Closed RC-807 Open RC-808 Closed RC-808 Open RC-811 Closed RC-811 Open RC-812 Closed RC-812 Open RN-805 Closed RN-805 Open RN-806 Closed RN-806 Open RN-809 Closed RN-809 Open RN-810 Closed RN-810 Open RN-811 Closed RN-882 Open RN-812 Closed RN-819 Closed RN-819 Open RN-820 Closed RN-820 Open Page 111 of 124 Hamworthy Gas Systems AS Project no: Project Doc no: 400573-R-HGS-69299 QGII Operation Manual Valve tag no Valve position Open 400573 Revision: 01 Effective Date: 25.06.2007 Valve tag no Closed Valve position Open BOG Compressor: Closed Pre-cooler and LNG pump RG-822 Open RG-842 Open RG-804 Open RG-843 Open RG-816 Open RG-844 Open RG-821 Open RG-845 Open RG-803 Open RG-848 Open RG-815 Open RG-849 Open RG-851 Open RG-817 Closed RL-803* Open RG-818 Closed RL-804 Open RG-805 Closed RL-809* Open RG-806 Closed RL-810 RG-812 Closed RL-813 Open Open RG-811 Closed Open RG-819 Closed RL-817 RL-819 RG-820 Closed RL-822 Open RG-807 Closed RL-824 Open RG-808 Closed RL-811* Closed RG-813 Closed RL-812 Closed RG-814 Closed RI-849 Closed RI-809 Closed RL-827 Closed RI-869 Closed RL-829 Closed RG-823 Closed Page 112 of 124 Open Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 12 Appendix B - BOG compressor log sheets Serial no 14Machine type GT026T2K2 Measuring point: Unit oil temp before gear box oil pressure before gear box vibration stage vibration stage axial position bull gear bearing temp stage bearing temp stage motor winding temp U motor winding temp V motor winding temp W motor power motor cooling medium Suction temp stage Suction temp stage Suction pressure stage Suction pressure stage position DGV stage position DGV srage seal gas inlet pres stage and mass flow bulk head seal inlet pressure pressure difference across oil filter bearing oil temp electric driver bearing oil press electric driver °C bar µm µm mm °C °C °C °C °C kW °C °C °C bar (g) bar (g) % % Tag no Date bar (g) kg/h bar (g) bar (g) °C bar (g) Page 113 of 124 Date Date Date Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 13 Appendix C - N2 compander log sheets Serial no 14Machine type: GT032N3D0/ETG150MS Measuring point: Unit oil temp before gear box °C oil pressure before gear box bar vibration stage µm vibration stage µm vibration stage µm vibration stage (expander) µm axial position bull gear mm Bearing temp stage °C Bearing temp stage °C Bearing temp stage °C Bearing temp Stage (esp.) °C Bearing temp BG rad DE °C Bearing temp BG rad NDE °C motor winding temp U °C motor winding temp V °C motor winding temp W °C motor power kW Suction temp stage °C Suction temp stage °C Suction temp stage discharge temp downstream after cooler °C Suction pressure stage bar (g) Tag no Date °C discharge pressure stage bar (g) inlet pressure expander bar (g) outlet pressure expander bar (g) seal gas pressure expander bar (g) ∆P seal gas stage bar (g) ∆P seal gas stage bar (g) ∆P seal gas stage bar (g) leak gas pressure stage1 - bar (g) leak gas pressure expander bar (g) nozzle position expander % pressure diff across oil filter bar (g) Bearing oil temp electric driver °C Bearing oil temp electric driver °C Page 114 of 124 Date Date Date Hamworthy Gas Systems AS Project no: 400573 Project Doc no: 400573-R-HGS-69299 QGII Operation Manual Revision: 01 Effective Date: 25.06.2007 14 Appendix D - N2 booster compressor log sheets Serial no.: Machine type : 5217 SP1 Date Time Hours Run Stage Temp Page 115 of 124 Stage Pr (barg) Sign Remarks Hamworthy Gas Systems AS Project no: QGII Operation Manual Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 15 Appendix E - Manual control of N2 supply Table of Contents Introduction 1.1 PURPOSE OF MANUAL OPERATION 1.2 ERROR IN 40PV055 AND 40PV060 2.1 GENERAL NOTES 2.2 INCREASING INVENTORY 2.3 REDUCING INVENTORY 2.4 SUPPLY OF NITROGEN FROM SHIP SYSTEM 2.5 MOVING NITROGEN FROM STANDBY COMPANDER TO RESERVOIR Procedures Page 116 of 124 400573 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 Introduction 1.1 Purpose of manual operation This appenix describes manual operation of booster compressor skids 40KX104/204 The booster compressors normally operate automatically, serving the following main tasks: • Removing inventory from the running loop if the nitrogen reservoir pressure has reached N2compressor discharge pressure • Moving nitrogen from standby compander to N2-reservoir under certain conditions • Topping up the reservoir from the ship’s N2-supply In case of an unforseen error in the inventory control system, these and other operations can be performed manually by the operator Errors that can be temporarily rectified by manual operation of the booster skids include malfunction of the nitrogen reservoir control valves 40PV055 (and 40PV060), see next section 1.2 Error in 40PV055 and 40PV060 In the event of malfunction of 40PV055, the booster compressors should be operated in manual mode for increasing the nitrogen content of the running R-loop; i.e inventory control Procedures for such operation are included in this appendix, see next chapter If 40PV060 fails, the control system will automaticallly pulse the bypass valve RN-865 instead Error in this control valve is therefore handled by the system automatically, requiring no further operator intervention 40PV060 should be repaired as soon as possible If, by some reason, the bypass valve should fail as well, the procedure in chapter 2.3 can be followed, reducing the inventory Connecting the running loop with the N2-reservoir by means of manual opening on/off valves is not recommended The cold box can be damaged if the inventory is adjusted too rapidly When adjusting the inventory, the operator should pay attention to the rate of change of the N2 cold box inlet temperature, 40TE120/220, and in particular to any rate of change alarms In case of error in 40PV055 the inventory should be increased untill the compander bypass valve 40TV120/220, or 40PV060, starts opening The system will then perform minor adjustments of the refrigeration duty by modulating the bypass valve Procedures 2.1 Important general notes The compressors must be set in manual mode (in accordance with the standard method for the ship control system) While in manual mode, all HH or LL settings as provided in the cause and effect diagram will be active, protecting the compressor against damage None of the automatic start permissives will be active, and manual operation requires checking out these prior to starting the compressor This will generally prevent start-up against closed valves etc The operator should thus pay close attention to the start permissives as listed for the various operations Important: Valves RN-875 and RN-877 must always be set back into automatic mode when manual operation is finished Page 117 of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 The valves RN-801 and RN-802 can be used for alligning the reservoir pressure with the standby compander pressure 2.2 Increasing inventory Valve settings prior to start-up of booster compressor: The column marked “Positions KX104” refers to operation of booster compressor KX104 Valve Positions KX104 Positions KX204 Description RN- 801 Closed Closed To compander suction RN- 802 Closed Closed To compander suction RN- 825 Closed RN- 826 RN- 833 RN- 834 RN- 835 RN- 836 RN- 837 Closed RN- 838 Closed RN- 839 RN- 840 RN- 841 N2 supply KX104 Closed Closed N2 supply KX204 KX104 suction Closed Open KX204 suction From KX104 disch to compander suction Open From KX204 disch to compander suction Closed Nitrogen vent From KX104 disch to N2-reservoir Closed Open From KX204 disch to N2-reservoir From reservoir to KX104 suction Open From reservoir to KX204 suction Settings when 40KX100 is the running compander RN- 875 N/A N/A From KX100 HP disch to reserv/booster suct RN- 877 N/A N/A From KX200 HP disch to reserv/booster suct Settings when 40KX200 is the running compander RN- 875 N/A N/A From KX100 HP disch to reserv/booster suct RN- 877 N/A N/A From KX200 HP disch to reserv/booster suct Compressor start sequence Item Action KX104 KX204 Start Compressor Compressor Page 118 of 124 Note Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 Compressor stop sequence Item Action KX104 KX204 Stop Compressor Compressor Close RN-835 RN-836 Note Booster disch 2.3 Reducing inventory 2.3.1 Running compander discharge pressure < 36 barg The following procedure can be used for reduction of the inventory if the discharge pressure of the running compander (40TE120/220) is less than 36 barg If the discharge pressure is above 36 barg, follow the procedure under the next section, 2.3.2 Valve settings prior to start-up of booster compressor: The column marked “Positions KX104” refers to operation of booster compressor KX104 Valve Positions KX104 Positions KX204 Description RN- 801 Closed Closed To compander suction RN- 802 Closed Closed To compander suction RN- 825 Closed RN- 826 RN- 833 RN- 834 RN- 835 RN- 836 RN- 837 Closed RN- 838 Open RN- 839 RN- 840 RN- 841 N2 supply KX104 Closed Open N2 supply KX204 KX104 suction Open Closed KX204 suction From KX104 disch to compander suction Closed From KX204 disch to compander suction Closed Nitrogen vent From KX104 disch to N2-reservoir Open Closed From KX204 disch to N2-reservoir From reservoir to KX104 suction Closed From reservoir to KX204 suction Settings when 40KX100 is the running compander RN- 875 Open Open From KX100 HP disch to reserv/booster suct RN- 877 Closed Closed From KX200 HP disch to reserv/booster suct Settings when 40KX200 is the running compander RN- 875 Closed Closed From KX100 HP disch to reserv/booster suct Page 119 of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual RN- 877 Open Open 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 From KX200 HP disch to reserv/booster suct Compressor start sequence Item Action KX104 KX204 Start Compressor Compressor Note Compressor stop sequence Item Action KX104 KX204 Stop Compressor Compressor Close RN-833 RN-834 Note Booster suction 2.3.2 Running compander discharge pressure > 36 barg This procedure can be used for reducing running compander inventory if the compander discharge pressure is higher than 36 barg As the max differential pressure of the booster compressor suction reduction valve is 36 bar, this procedure reduces the inventory from the suction side of the running compander If 40PV060 is in operation, it should be used for initial reduction of inventory The following procedure assumes that both 40PV060 and the bypass valve RN-865 is out of operation Step 1: Allign standby compressor pressure with running compander suction pressure If 40KX100 is the running compressor: Open standby compander recycle valve, 40FV213 Open RN-802 untill 40TE203 is approximately equal with 40TE103 Close RN-802 If the stby compander alligns with the N2-reservoir before alligning with running compander, close RN-802, and open RN-806 in short intervals Inventory is now transferred from the suction side of the running compander to the stby compander Make sure to reduce inventory slowly in order to protect the cold box Continue until 40TE203 is alligned with 40TE103 Open RN-806 If running compander discharge pressure is still above 36 barg, continue with step 2, otherwise, close RN-806 and follow the procedure in the previous section 2.3.1 If 40KX200 is the running compressor: Open standby compander recycle valve, 40FV113 Open RN-801 untill 40TE103 is approximately equal with 40TE203 Close RN-801 If the stby compander alligns with the N2-reservoir before alligning with running compander, close RN-801, and open RN-805 in short intervals Inventory is now transferred from the suction side of the running compander to the stby compander Make sure to reduce inventory slowly in order to protect the cold box Continue until 40TE103 is alligned with 40TE203 Open RN-805 Page 120 of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 If running compander discharge pressure is still above 36 barg, continue with step 2, otherwise close RN-805 and follow the procedure in the previous section 2.3.1 Step 2: Further reduce inventory using booster compressor Follow procedure 2.5 in order to reduce inventory of stby compander Since running compander is connected with the standby compander, running compander inventory will also be reduced When the preferred running compander inventory has been reached, close RN-805/RN-806 2.4 Supply of nitrogen from ship system Valve settings prior to start-up of booster compressor: The column marked “Positions KX104” refers to operation of booster compressor KX104 Valve Positions KX104 Positions KX204 Description RN- 801 Closed Closed To compander suction RN- 802 Closed Closed To compander suction RN- 825 Open RN- 826 RN- 833 RN- 834 RN- 835 RN- 836 RN- 837 Closed RN- 838 Open RN- 839 RN- 840 RN- 841 N2 supply KX104 Open Closed N2 supply KX204 KX104 suction Closed Closed KX204 suction From KX104 disch to compander suction Closed From KX204 disch to compander suction Closed Nitrogen vent From KX104 disch to N2-reservoir Open Closed From KX204 disch to N2-reservoir From reservoir to KX104 suction Closed From reservoir to KX204 suction Settings when 40KX100 is the running compander RN- 875 N/A From KX100 HP disch to reserv/booster suct N/A RN- 877 N/A From KX200 HP disch to reserv/booster suct N/A Settings when 40KX200 is the running compander RN- 875 From KX100 HP disch to reserv/booster suct N/A N/A RN- 877 From KX200 HP disch to reserv/booster suct N/A N/A Compressor start sequence Page 121 of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual Item Action KX104 KX204 Start Compressor Compressor 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 Note Compressor stop sequence Item Action KX104 KX204 Stop Compressor Compressor Close RN-825 RN-826 Note N2 supply 2.5 Moving nitrogen from standby compander to reservoir Valve settings prior to start-up of booster compressor: The column marked “Positions KX104” refers to operation of booster compressor KX104 Valve Positions KX104 Positions KX204 Description RN- 801 Closed Closed To compander suction RN- 802 Closed Closed To compander suction RN- 825 Closed RN- 826 RN- 833 RN- 834 RN- 835 RN- 836 RN- 837 Closed RN- 838 Open RN- 839 RN- 840 RN- 841 N2 supply KX104 Closed Open N2 supply KX204 KX104 suction Open Closed KX204 suction From KX104 disch to compander suction Closed From KX204 disch to compander suction Closed Nitrogen vent From KX104 disch to N2-reservoir Open Closed From KX204 disch to N2-reservoir From reservoir to KX104 suction Closed From reservoir to KX204 suction Settings when 40KX100 is the running compander RN- 875 Closed Closed From KX100 HP disch to reserv/booster suct RN- 877 Opem Open From KX200 HP disch to reserv/booster suct Settings when 40KX200 is the running compander RN- 875 Open Open From KX100 HP disch to reserv/booster suct RN- 877 Closed Closed From KX200 HP disch to reserv/booster suct Page 122 of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06.2007 Compressor start sequence Item Action KX104 KX204 Start Compressor Compressor Note Compressor stop sequence Item Action KX104 KX204 Stop Compressor Compressor Close RN-833 RN-834 Booster suction Close RN-875/RN-877 RN-875/RN-877 Stby compander discharge Page 123 of 124 Note Hamworthy Gas Systems AS Project no: QGII Operation Manual 16 Revision: 01 Effective Date: 25.06.2007 Appendix F - Cause & effect matrix Cause and effect matrix HGS-40438 Page 124 of 124 400573 Project Doc no: 400573-R-HGS-69299 ... 39 Page of 124 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06 .2007 Introduction The User Manual contains... 400573 Hamworthy Gas Systems AS Project no: QGII Operation Manual 400573 Project Doc no: 400573-R-HGS-69299 Revision: 01 Effective Date: 25.06 .2007 1.6 Safety precautions In this user manual. .. Technical Manual for more details Page 15 of 124 Hamworthy Gas Systems AS Project no: 400573 Project Doc no: 400573-R-HGS-69299 QGII Operation Manual Revision: 01 Effective Date: 25.06 .2007 3.2.2