SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

SKIKDA, ALGERIA
OPERATING MANUAL VOLUME 1, SECTION 3-9:
UNIT 15 BOG RECYCLE COMPRESSOR

DOCUMENT NO: PP-AAA-PP1-113

KBR
JOB NO.: J6404

1 KM Re- Issued for Implementation 2-Aug-13 SS RM

0 JDS Issued for Implementation 23-Nov-10 MDL BA AB

B JDS Issued for Client Approval 9-Sep-10 MDL BA -

A ACG Issued for Client Approval 13-Nov-09 VAS BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 3
2.0 SYSTEM DESCRIPTION ...................................................................................... 5
3.0 OPERATIONS....................................................................................................... 6
3.1 Normal Running ................................................................................................................6
3.1.1 BOG Recycle Compressors 15-MJ06-A/B/C .................................................................6
3.1.2 BOG Recycle Compressor Aftercooler 15-MC17...........................................................6
3.1.3 Other BOG Recycle Gas Users......................................................................................6
3.2 Typical Operating Parameters ..........................................................................................7
4.0 START-UP ............................................................................................................ 8
5.0 SHUTDOWN ......................................................................................................... 9
5.1 Normal Shutdown .............................................................................................................9
5.2 Process Upsets and Production Loss ...............................................................................9
6.0 SAFETY/EMERGENCY SHUTDOWN ................................................................ 11
6.1 Safety Critical Shutdown Systems ..................................................................................11
6.1.1 I-1500 - Liquefaction, Unit 15 ESD ...............................................................................11
6.1.2 I-1515 - Boil Off Gas Header Vacuum Break ...............................................................11
6.1.3 I-1560 BOG Recycle Compressors Trip.......................................................................11
6.1.4 I-1562/64/66 - 15-MJ06-A/B/C BOG Recycle Compressor Trip ..................................11
6.1.5 I-1593 - 15-MJ06 BOG Recycle Compressor Area Depressurizing.............................11
6.2 Pressure Safety Valve Summary ....................................................................................12
6.3 Fire Protection Equipment ..............................................................................................12
7.0 ATTACHMENTS ................................................................................................. 13
7.1 Attachment I: Equipment List ..........................................................................................14
7.2 Attachment II: Utility Consumption .................................................................................15

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

1.0 INTRODUCTION
This operating manual relates to the facilities indicated on Process Flow Diagram
PR-15-PR32-004 and P&ID’s PR-15-SYPI-001 through PR-15-SYPI-001C and
PR-15-SYPI-014 through PR-15-SYPI-016.
Boil-off Gas (BOG) Recycle System is located in Unit 15. This system receives
excess boil-off gas from the Boil-off Gas System in Unit 71 and vapors from the
Demethanizer Overhead Heater, 07-MC22. Boil-off gas is compressed by BOG
Recycle Compressors, 15-MJ06-A/B/C, and passes through the BOG Recycle
Compressor Aftercooler, 15-MC17.
BOG from the BOG Recycle Compressor Aftercooler, 15-MC17 flows to the main
feed gas line upstream of the Feed Gas/HP Propane Cooler, 15-MC01, for recovery.
Compressed BOG recycle also supplies vacuum protection for the storage system,
purge gas to the flare systems, and feed to the Defrost Gas Heater, 15-ML01.
The primary source of defrost gas is dry feed gas. The defrost system does not rely
on BOG as a source.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

15-PIC
1315

BOIL-OFF GAS FROM

71-MC01-A/B/C

DEMETHANIZER 15-MJ06-A/B/C
OVERHEAD BOG Recycle
Compressor

15-MC17 TO 15-MC01
BOG Recycle
Compressor Aftercooler

15-ESDV-1185

TO 15-ML01

FEED GAS 15-PIC

FROM 01-IC03 1197
15-XV-1186

TO 65-MB08/MB09

15-PIC
3136

TO 65-MD09-A/B

15-PIC
1010

VACUUM
PROTECTION

Simplified Sketch of BOG Recycle Compressor System

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

2.0 SYSTEM DESCRIPTION

Excess boil-off gas from the Boil-off Gas Compressors, 71-MJ05-A/B/C, in LNG Storage and
Loading Unit, Unit 71, combines with the vapors from the Demethanizer Overhead Heater,
07-MC22. This combined boil-off gas has a total normal flow rate of 27,172 kg/hr during one
tanker loading mode and enters the BOG Recycle Compressors, 15-MJ06-A/B/C, at 28.74
barg. The boil-off gas is compressed to 62.90 barg and its temperature increases to 101°C
at the compressor discharge. Compressed boil-off gas is cooled in the BOG Recycle
Compressor Aftercooler, 15-MC17, air cooler to 39°C.
Downstream of BOG Recycle Compressor Aftercooler, 15-MC17, boil-off gas flows into the
main feed gas line coming from Mercury Removal System feeding the Feed Gas/HP
Propane Cooler, 15-MC01.
Compressed BOG recycle is also the primary supply of vacuum protection for the storage
system, purge gas to the flare systems for seal gas backup and feed to the Defrost Gas
Heater. If the BOG recycle pressure is too low, feed gas from 01-IC03 is utilized as the
secondary source
BOG recycle compressor supplies backup gas to the Defrost Gas Heater, 15-ML01, if the
primary source of defrost gas from the Mercury Removal system is interrupted.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

3.0 OPERATIONS
3.1 Normal Running
3.1.1 BOG Recycle Compressors 15-MJ06-A/B/C
BOG Recycle Compressors, 15-MJ06-A/B/C, are motor-driven reciprocating type
compressors. The compressors are started and stopped manually by the operator from the
DCS with hand switches 15-HS-6130A/B/C or from the local panel. There are three different
design cases for the BOG Recycle Compressors, 15-MJ06-A/B/C.
The first design case is “one tanker loading operation” which is the normal operating mode
for the BOG Recycle Compressors, 15-MJ06-A/B/C. During the normal operations only one
of the compressors, 15-MJ06-A, 15-MJ06-B or 15-MJ06-C, is operated. Each compressor
has enough capacity to keep up with the normal flow at 27,172 kg/hr during one tanker
loading stage.
The second design case is “two tanker loading operation” on which the system operates at
the maximum capacity. The rate of BOG increases to the 39,367 kg/hr and two of the
compressors are placed in operation as the third one remains in standby mode.
The third and last design case is “Holding operation”. During the holding operation, BOG
Recycle Compressor system keeps one of the compressors running while no tanker is
loaded. The BOG flow rate for the holding design case is 16,853 kg/hr.
Pressure controller, 15-PIC-1315 adjusts the minimum recycle flow to compressor inlet by
controlling the pressure on the suction line and it also adjusts the compressor
loading/unloading valves. Refer to the following Nuovo Pignone Documents and Control
Narrative for more details of the BOG Recycle Compressor 15-MJ06-A/B/C control system.
MJ010-SOP5694370 Control System Functional Description
MJ010-SOP5694337 Start-Stop Sequence
MJ010-SOP5694399 Functional Logic Diagram
IC-15-I35-001 Control and Safety Function Narrative: Unit 15 – Liquefaction
3.1.2 BOG Recycle Compressor Aftercooler 15-MC17
BOG Recycle Compressor Aftercooler, 15-MC17, is a fin-fan type cooler consists of 1 bay
and 1 bundle and shares 3 fixed speed fans with Helium Rich Stream Compressor
Discharge Cooler, 15-MC13. Boil-off gas from the BOG Recycle Compressors, 15-MJ06-
A/B/C, flows to BOG Recycle Compressor Aftercooler, 15-MC17, at 101°C and is cooled to
39°C
The fans are started and stopped by the operator from the DCS or local switches.
3.1.3 Other BOG Recycle Gas Users
The vacuum protection to the boil off gas header is controlled by 15-PIC-1010 which
regulates the flow of recycle gas.
The assist gas to the flame front generators and liquid flares is controlled by 15-PIC-1197
which regulates the flow of recycle gas.
The dry gas to the Cold/Heavy Liquid Blow Cases 65-MD09-A/B is controlled by 15-PIC-
3136 which regulates the flow of recycle gas.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

3.2 Typical Operating Parameters

The following table contains typical operating variables for the BOG Recycle Compressor
System.

Operating Variables for the BOG Recycle Compressor System

Tag No. Description Typical Value Units

15-PIC-1010 BOG Header Pressure Controller 17 barg

15-PIC-1197 Assist Gas Pressure Controller 6.5 barg

15-PIC-1315 15-MJ06-A/B/C Suction Pressure 30.1 barg

Controller

15-PIC-3136 Dry Gas to 65-MD09-A/B Pressure 6.8 barg

Controller

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

4.0 START-UP
This section outlines the steps necessary to place the BOG Recycle Compressor System in
service under normal operating conditions of “one tanker loading operation”. For the purpose
of this section of the operating manual, it is assumed that the following conditions exist:
utilities are in service, oil system is in service, Unit 71 Storage and Demethanizer Systems
are in service, downstream units are ready for feed gas, and system is purged and ready for
start-up.
1. Confirm isolation valve 15-ESDV-1314 upstream of BOG Recycle Compressor, 15-
MJ06-A/B/C, from Unit 71 is closed.
2. Confirm isolation valve 07-ESDV-1217 upstream of BOG Recycle Compressor, 15-
MJ06-A/B/C, from Demethanizer Overhead Heater, 07-MC22, is closed.
3. Confirm isolation valve 15-ESDV-1330 downstream of BOG Recycle Compressor
Aftercooler, 15-MC17, is closed.
4. Place minimum recycle flow controller 15-PV-1315 in manual and open.
5. Verify boil-off gas is lined up from BOG Compressor Aftercooler, 71-MC01-A/B/C, to
the BOG Recycle Compressor, 15-MJ06-A/B/C, closed feed isolation valve 15-ESDV-
1314 with this system gas going to fuel.
6. Open valve 15-ESDV-1314 with hand switch 15-HS-1314.
7. Line up Demethanizer overheads from Demethanizer Overhead Heater, 07-MC22, to
isolation valve 07-ESDV-1217.
8. Open valve 07-ESDV-1217 with hand switch 07-HS-1217.
9. Monitor the pressure on the suction line of BOG Recycle Compressor, 15-MJ06-
A/B/C.
10. Open 15-ESDV-1330 at the BOG Recycle Compressor Aftercooler, 15-MC17,
discharge to send flow of the recycle gas to dry feed gas line upstream of the Feed
Gas/HP Propane Cooler 15-MC01.
11. Start BOG Recycle Compressor Aftercooler, 15-MC17, fan.
12. When all start permissives are met, start a recycle compressor.
13. Allow the compressor suction pressure to increase to normal.
14. Place suction pressure controller 15-PIC-1315 in automatic mode. 15-PIC-1315
manipulates the compressor loading valves (through the compressor control system)
and the gas circulation valve 15-PV-1315 to maintain correct suction pressure of the
compressor.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the BOG Recycle Compressor
System.
1. Notify operators in Unit 07 and Unit 71 that you are going to shutdown the BOG
Recycle Compressor 15-MJ06 A/B/C; therefore, gas flow from Demethanizer
overhead in Unit 07 will be stopped and BOG from Unit 71 will be discontinued.
2. Notify operators in Units that receive the compressor discharge flow of the shutdown.
3. Close 15-ESDV-1330 from BOG Recycle Compressor Aftercooler, 15-MC17,
discharge.
4. Close boil-off gas isolation valve 15-ESDV-1314 upstream of BOG Recycle
Compressor, 15-MJ06-A/B/C.
5. Close Demethanizer overhead vapor isolation valve 07-ESDV-1217 upstream of BOG
Recycle Compressor, 15-MJ06-A/B/C.
6. Stop BOG Recycle Compressor 15-MJ06-A/B/C with handswitch 15-HS-6130A/B/C.
7. Once the stop signal has been activated, the Control logic will:
• Stop the Compressor
• Alarm/SD Annunciator Light comes on
• Start the Compressor Auxiliary Lube Oil Pump for post lubricating.
• After a time delay of 300 seconds the Compressor Lube Oil pump stops.
8. Stop BOG Recycle Compressor Aftercooler, 15-MC17, fans.
5.2 Process Upsets and Production Loss
In the event of an emergency requiring a shutdown of the BOG Recycle Compressor System
the system should be shut down as outlined above. In the event of causes and actions listed
below only process upsets or production loss may occur and not necessarily require the
BOG Recycle Compressors to be shutdown.
1. Loss of Electrical Power
Loss of electrical power to the BOG Recycle Compressor, 15-MJ06A/B/C, will cause the
BOG Recycle Compressor System to shut down. Boil off gas with flow to the fuel system and
Demethanizer overhead will be diverted to the cold flare.
Loss of power to the BOG Recycle Compressor Aftercooler, 15-MC17, fans will result in a
reduction of cooling in the aftercooler. The reduction of cooling will not necessarily trip the
BOG Recycle Compressor, 15-MJ06A/B/C, but compressor temperature should be
monitored to avoid a high temperature trip.
2. Loss of Instrument Air
Loss of instrument air will cause control valves to fail to their safe position. Consequences of
the loss of instrument air for the major control and isolation valves are given below:
• Valves 07-ESDV-1217, 15-ESDV-1314, 15-ESDV-1330, 15-ESDV-1185 will fail close
3. Loss of Boil Off Gas
In the event of loss of boil-off gas, the BOG Recycle Compressor, 15-MJ06A/B/C, can
remain on full recycle until the conditions are stabilized and the boil-off gas flow is re-
established. It may be necessary to shut down the compressor if the interruption is lengthy.
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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

4. Loss of Demethanizer Overhead

In the event of loss of feed gas from the Demethanizer Overhead Heater, 07-MC22, the
BOG Recycle Compressor, 15-MJ06A/B/C, can remain in operation with boil off gas from
Unit 71 or on full recycle.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
6.1.1 I-1500 - Liquefaction, Unit 15 ESD
The Liquefaction Unit ESD Interlock I-1500 is activated by the Plant ESD Interlock I-0000.
The Liquefaction Unit ESD takes action in the BOG Recycle Compressor System by closing
boil-off gas to BOG Recycle Compressor, 15-MJ06-A/B/C, valves 15-ESDV-1314 and 07-
ESDV-1217; tripping BOG Recycle Compressor Aftercooler, 15-MC17; and tripping
interlocks I-1515, I-1560, I-1562, I-1564, I-1566.
6.1.2 I-1515 - Boil Off Gas Header Vacuum Break
The Boil Off Gas Header Vacuum Break Interlock I-1515 opens feed gas valve to supply
secondary source of gas for vacuum relief, purge gas, or backup seal gas on low dry gas
pressure or Liquefaction Unit ESD Interlock I-1500. The interlock opens the wet gas to
recycle gas header valve 15-XV-1186, and closes the dry gas valve 15-ESDV-1185.
The reset hand switch 15-HS-1184 (located in the DCS) opens 15-ESDV-1185 and closes
15-XV-1186, the recycle gas pressure returns to normal operating pressure.
6.1.3 I-1560 BOG Recycle Compressors Trip
BOG Recycle Compressors Trip I-1560 closes 15-ESDV-1330 on Liquefaction Unit ESD
Interlock I-1500 or on 71-MJ05A/B/C BOG Compressor Trip Interlock I-7195.
BOG Recycle Compressors Trip I-1560 closes 07-ESDV-1217 which shuts off Demethanizer
overhead to 15-MJ06-A/B/C (but does not trip the compressors) is initiated by high-high level
07-LT-1344A/B/C of the Demethanizer Reflux Drum 07-MD10 or New Train/Fractionation
shutdown Interlock I-0000.
6.1.4 I-1562/64/66 - 15-MJ06-A/B/C BOG Recycle Compressor Trip
The BOG Recycle Compressor Trip Interlocks I-1562/64/66 trip the BOG Recycle
Compressors, 15-MJ06-A/B/C, on low-low lube oil pressure 15-PT-6127A/B/C, low-low
suction pressure 15-PT-6101A/B/C, high-high discharge pressure 15-PT-6113A/B/C, high-
high discharge temperature 15-TT-6107&9A/B/C, mechanical and machine trips,
Liquefaction Unit ESD Interlock I-1500 or on 71-MJ05A/B/C BOG Compressor Trip Interlock
I-7195.
The BOG Recycle Compressor Trip Interlocks I-1562/64/66 will also trip the compressor lube
oil heater on high-high oil temperature 15-TSHH-6128A/B/C.
6.1.5 I-1593 - 15-MJ06 BOG Recycle Compressor Area Depressurizing
Depressurizing interlock I-1593 is initiated manually with hand switch 15-HZ-1339 which will
open the valve 15-HIC-1331 to depressurize BOG Recycle Compressor system to the cold
flare system.

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

6.2 Pressure Safety Valve Summary

The BOG Recycle Compressor System Pressure Relief Valve Summary contains a listing of
all the pressure relief valves associated with this system.

BOG Recycle Compressor System Pressure Relief Valve Summary

Set Pressure
Valve Number Description/Location (barg)

Vacuum Protection to BOG Header/Relief To

15-PRV-1061A/B 22.00
Warm Flare Header

15-PRV-1198A/B Assist Gas/Relief to Warm Flare Header 11.00

15-MJ06-A BOG Recycle Compressor/Relief To

15-PRV-6195A 75.00
Cold Flare Header

15-MJ06-B BOG Recycle Compressor/Relief To

15-PRV-6195B 75.00
Cold Flare Header

15-MJ06-C BOG Recycle Compressor/Relief To

15-PRV-6195C 75.00
Cold Flare Header

6.3 Fire Protection Equipment

The BOG Recycle Compressor System Fire Protection Equipment Summary is included in
below listing of Liquefaction Unit Fire Protection Equipment

BOG Recycle Compressor System Fire Protection Equipment Summary

Description Quantity

Liquefaction Area

63-SP-005 Fire Blanket 1

63-SP-008 Fire Water Monitor (Grade) 3

63-SP-010 Live Hose Reel 2

63-SP-011 Hydrant Cabinet 4-Way 2

63-SP-024 Firewater Monitor Mounted on Four Way Hydrant 3

63-SP-050 Fire Water Monitor (Elevated) 2

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

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-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

7.1 Attachment I: Equipment List

The following is a list of equipment associated with the BOG Recycle Compressor System.

BOG Recycle Compressor System Equipment List

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

15-MC17 BOG Recycle Compressor Aftercooler 75 190/-12

15-MJ06-A/B/C BOG Recycle Compressor Rated Capacity

28,013 kg/hr (one
tanker loading)
27,414 kg/hr (two
tankers loading)
29,144 kg/hr
(holding)

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 NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-113
OPERATING MANUAL VOLUME 1, SECTION 3-9: REVISION 1
BOG RECYCLE COMPRESSOR 2-Aug-2013

7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the BOG Recycle Compressor System and
their expected consumption.

BOG Recycle Compressor System Motor List

Available
Motor Load
Equipment No. Description (kW)

15-MC17-MJ01 thru 03 BOG Recycle Compressor Aftercooler 30

Fan/Motor

15-MJ06-A/B/C-M BOG Recycle Compressor Motor 1210

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