1- LNG Rundown, Storage and Loading Unit-71
LNG product is pumped from the process trains to the LNG storage tanks (PACKAGE II) via the product rundown and loading line. LNG product is pumped to a LNG carrier via loading lines when a LNG carrier is ready to receive LNG for transport. Vapor is generated by natural heat leak into the tank and lines, and energy added by machinery, vapor displaced by inlet liquid, and vapor flashed at inlet of the rundown/circulation and ship return vapor. The BOG is collected and transported to the fuel system.
Three full containment type refrigerated storage tanks are provided, each with a working capacity of 140,000 m3. All three storage tanks are equipped with four submerged loading cryogenic pumps. Each pump with a capacity of 1,770 m3/hr is mounted inside a pump column supported from the concrete roof of the storage tank
2- Refrigerant Storage Unit-72
The refrigerant Storage Unit consists of ethane and propane storage bullets, vaporizers and charge pumps. This unit provides offsite storage of propane and ethane refrigerant to charge the refrigeration systems in the process trains when the normal make-up from the Fractionation Unit is either unavailable or insufficient.
This storage shall be common for process trains and is intended primarily to supply start-up refrigerant for the mixed refrigerant circuits in refrigeration Units.
The normal liquid storage of one ethane (330 m3) bullet and one propane bullet (330 m3 each) provides sufficient capacity needed for one LNG process train demand during start-up.
Nitrogen, methane, and ethane refrigerants are normally supplied from within the LNG process train. Liquid ethane and propane refrigerants are produced in the Fractionation Unit. The propane refrigerant is normally make-up from the refrigerant storage after vaporization. The ethane refrigerant is stored at a pressure sufficient to prevent any boil off from the bullet in normal operation.
3- Condensate Rundown Unit-73
The condensate produced in the Fractionation Units will be combined and routed to the Stabilization Unit constructed by others and mixed with the stabilized condensate from that Unit. The condensate from the Fractionation Units is metered.
4- Flare System Unit-74
Waste hydrocarbon vapors and liquid streams generated in the LNG facilities during various operating conditions shall be safely disposed in the gas flare systems and the liquid disposal systems. The hydrocarbon vapors shall be burned in the elevated flares and the liquids are stored in a slop oil tank after evaporating lighter hydrocarbon components. The sour water is treated in the sour water degasser and then transferred to the oil contaminated sewer for further treatment.
The facility of the LNG plant shall be equipped with flare headers to collect the following hydrocarbon vapor and liquid streams:
• Wet gas
• Dry gas
• Wet liquid
• Dry liquid
• Wet sour liquid
• LP gas
• LP sour gas
The wet gas and wet liquid headers shall be connected to wet gas flare Knock out (K.O.) drum. Wet gas from wet gas flare K.O. drum shall be routed to wet gas flare. Hydrocarbon liquid shall be routed to slop oil storage drum and sour liquids to LP sour gas K.O. drum. The dry gas and dry liquid headers shall be connected to dry gas flare K.O. drum. The dry gas from dry gas flare K.O. drum shall be routed to dry gas flare and liquid into wet gas flare K.O. drum. The sour liquid header and LP sour gas headers shall be connected to LP sour gas K.O. drum. LP sour gas from LP sour gas K.O. drum shall be routed to wet gas flare.
Sour liquid from LP sour gas K.O. drum shall be pumped by LP sour liquid pump to sour water surge drum. Where required, the K.O. drums shall be provided with sparger to vaporize light hydrocarbon liquids using defrost gas.
5- Fire Protection System Unit-75
The fire protection systems for the facilities shall be suitable for the anticipated hazards in the plant, such as gas release, liquid release and fire.
The design and engineering of the fire fighting systems shall be based on a single fire risk philosophy, i.e., there will be only one fire at a time anywhere in LNG process areas or the other areas, such as LNG storage tank area and LNG jetty area.
5.1 Fire water Supply System
(1) Fire water sources
For fresh firewater storage, two fresh fire water tanks, each having a capacity for supplying the maximum anticipated water demand for a period of not less than 2 hours, shall be provided.
(2) Fire water main system
The fire water main system shall be provided as a grid and form a loop around the process blocks. Fire mains shall also be looped around the storage tank area, and arranged such that mains are routed outside of tank dikes.
(3) Fire water pumps
The following fire water pump systems shall be provided to supply fire water to the facilities.
• Fresh water fire pumps (two diesel engine driven and one electric motor driven) to supply fresh water to all facilities.
• Sea water fire pumps at the sea water intake facility as a back up to the fresh fire water system.
• Two diesel engine driven pumps as sea water fire pumps.
• Two electric motor driven fresh fire water jockey pumps to continuously maintain the fire main pressure.
5.2 Fire Protection Systems and Equipment
(1) Outdoor fire protection
(a) Fire water hydrant
Fire hydrants shall be spaced not more than 60 m around the process areas, and not more than 90 m in other areas, such as utility, building and off-site areas. At least 3 hydrants shall be located on the LNG jetty head. 2 international ship shore connections shall be located at the LNG jetty and LPG jetty.
(b) Hose Boxes
A fire hose box shall be provided for every three hydrants
(c) Water monitor
Fixed water monitors at grade, portable wheeled water monitors and remotely operated water monitors shall be used in the process area, and LNG/LPG jetty areas.
(d) Live hose reel
Live hose reels shall be located under main pipe racks in the LNG process and utility areas every 30 m, where equipment is handling flammable gases.
(e) Fixed water spray system
Fixed water spray systems shall be provided for fire control and cooling for hazardous equipment, such as compressors handling flammable gases, BOG compressors, platform on LNG/LPG tanks and LNG/LPG jetty area.
(f) Automatic high expansion foam system
The high expansion foam systems shall be provided in the process area, LNG tank and LNG jetty areas.
(g) Carbon dioxide fixed extinguishing system
In control rooms and substations, fixed gas-extinguishing systems, such as CO2 or FM 200, will not be installed due to the hazards they may present to the operators. Instead, smoke detectors shall be provided in every room, under elevated floors and above suspended ceilings where there are cable runs. Upon detection of a fire, portable or wheeled type CO2 extinguishers shall be used to extinguish the fire.
Fixed CO2 extinguishing systems shall only be provided for the enclosures of MR compressor gas turbines, propane compressor gas turbines and main gas turbines.
(h) Portable Fire Extinguishers
BC 9 kg portable extinguishes and BC 50 kg portable extinguishers shall be provided at appropriate locations in the facility.
(2) Indoor fire protection
(a) Automatic water sprinkler systems
Water sprinkler systems shall be provided in the canteen, laboratory, maintenance work shop, and warehouse.
(b) Indoor hydrant
The indoor hydrants shall be provided in buildings as required.
(c) Dry chemical fixed system
Dry chemical fixed system shall be provided for kitchen hoods in the Canteen.
(d) Portable fire extinguisher
5 kg CO2 extinguishers, 20 kg CO2 extinguishers and ABC 9 kg extinguishers shall be provided at appropriate locations in the buildings.
(3) Mobile fire fighting equipment
The following equipment shall be provided
• Fire trucks
• Ambulance
• Fire brigade equipment
(4) Fire training ground
An area suitable for training of fire fighters for fire shall be provided. Miscellaneous training equipment shall also be provided.
(5) Fire alarm and gas detection system
Automatic fire and gas detection devices shall be installed throughout the plant to monitor hazardous conditions and events.
In addition, manual call points shall be located throughout the plant. The system shall consist of:
• Flammable gas detector
• Toxic (H2S) gas detector
• UV/IR flame detector
• Spill detector
• Manual alarm call point
• Smoke detector
• Heat detector
• F&G panel
• Building /Local panel
• Gas receiving panel
Fire alarm and gas detection system (F&G System) shall be integrated with the Process DCS for monitoring and with the PA system for audible alarms.
5.3 Personnel protection
Safety shower/eye washer units and air breathing apparatus shall be provided at appropriate locations in the plant.
6- Sulfur Solidification, Storage and Loading Unit-76
The molten sulfur storage and Solidification Unit receives molten sulfur from the two Sulfur Recovery Units via steam jacketed rundown pipeline into the liquid sulfur storage tank. The rundown pipeline and sulfur storage tank shall be sized for rundown rate and 4 days production rate of the two Sulfur Recovery Units.
The unit consists of a sulfur storage tank, sulfur pit, liquid sulfur pump, packaged Sulfur Solidification Unit, conveyors, solid sulfur storage and ship loader. The molten sulfur shall be solidified in the form of granules in the granulating drum and transferred to the solid sulfur storage by conveyors. During ship loading, granulated sulfur from the storage is transferred to the ship loader by conveyors.
7- Effluent Treatment System Unit-77
A segregated drainage system shall be provided to separate waste water from non-contaminated and contaminated sources. Contaminated sources are further segregated according to the contaminants to allow the treatment of waste water to meet effluent quality standards.
The segregated drainage systems are
• Non-contaminated sewer
• Chemical contaminated sewer
• Oil water sewer
• Sanitary sewer
• Sour water header
The non-contaminated sewer system shall collect surface water run-off, including rain water from unpaved area, and parking lot and roof drainage. These effluents are considered clean and, therefore, discharged into the open ditch drainage system.
The chemical contaminated sewer system shall be located in the process and utility areas to collect all chemically contaminated wastewater, as well as the boiler blowdown water.
Potentially oil contaminated wastewater shall be collected in the oily water sewer system.
Sour water contaminated with H2S is collected in the sour flare K.O. drum and transferred to the sour water degasser via the sour water storage drum for H2S stripping. The sour gas is sent to the flare system and treated water to the oil contaminated water system for further treatment.
Wastewater generated from the facility shall be treated to meet the effluent quality standards. Treated water is used as irrigation water.
Solid wastes shall be segregated into non-hazardous and hazardous streams for proper disposal. Recommended disposal methods are based on USEPA’s (US Environmental Protection Agency"s) RCRA (Resource Conservation and Recovery Act) requirements.
8- Irrigation Water System Unit-78
The irrigation water system is provided to maximize the use of treated effluent waste water for the landscaping areas within the facility. The system consists of a storage tank, pumps, a sprinkler system and a truck filling station with filling points.
9- LPG Rundown, Storage and Loading
Propane and butane products from the process trains are routed to the propane and butane tanks via rundown and loading lines. The LPG products from the trains are cooled by the product refrigeration/BOG recovery facility. The product refrigeration/BOG recovery facility has two objectives:
• To cool liquid LPG products into storage tanks and
• To liquefy BOG generated by heat leak.
Propane and butane products are separately pumped to a LPG carrier via separate loading lines when a LPG carrier is ready to receive LPG for transport. Vapor is generated by natural heat leak into the tank and lines, energy added by machinery, vapor displaced by inlet liquid, and vapor flashed at inlet of the rundown/circulation line and ship return vapor. The BOG is condensed and routed to the storage tanks.
Two full containment type refrigerated storage tanks are provided for propane and butane respectively, each with a working capacity of 30,000 m3. The two storage tanks are equipped with three submerged loading pumps. Each pump, with a capacity of 1,000 m3/h, is mounted inside a pump column supported from the concrete roof of the storage tank.
10- Description of General Facilities and Buildings
The Administration and Maintenance area consists of the administration complex and the maintenance and warehouse area.
The administration complex includes the administration building, mosque, canteen, training center, fire station, clinic, main entrance gate house, and covered car park.
The maintenance and warehouse area includes the maintenance workshop, maintenance office, warehouse, and covered store yard.
