A TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME

(SIWES)
HELD AT

NIGERIA LIQUEFIED NATURAL GAS LIMITED

BONNY ISLAND, RIVERS STATE,
NIGERIA.
BY

ORJI SAM, CHISOM O.E.

MOUAU/04/4092
SUBMITTED TO

DEPARTMENT OF ELECTRICAL/ELECTRONIC ENGINEERING

COLLEGE OF ENGINEERING AND ENGINEERING
TECHNOLOLGY
MICHAEL OKPARA UNIVERSITY OF AGRICULTURE, UMUDIKE,
NIGERIA.
IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE OF BACHELOR OF ENGINEERING (B.ENG) IN
ELECTRICAL/ELECRTONIC ENGINEERING

JANUARY, 2009

DEDICATION

This report is dedicated to the King Eternal, Immortal, Invincible; the Only Wise God. The
One who was and is and is to come. The Creator of the ends of the earth that faint not neither
is weary; there is no searching of His understanding. He gives power to the weak and to those
that have no might, He increases strength. From the rising of the sun, till the going down of
the same, the name of the Lord is to be praised. I love you Jesus!

ACKNOWLEDGEMENT

I must first of all thank the Love of my life, Jehovah Effizi- My God of Special Effects, the
Almighty God for His Grace, Wisdom and Safety.

I want to also say a big thanks to the Conteam of NLNG, starting from the Executive Project
Manager, Engr Tony Ogbuigwe FNSChE, for giving me this rare privilege to have my
training in this multi-cultural world class company. Special thanks also go to the Chief
Engineer/Construction Manager, Mr Jan Schouten. I must also appreciate my wonderful Line
Head, Mr Frankenmolen Rob; and my explicit supervisors Mr Salihi Dawaki and Mr Henk
Heesemans who took me to the plant through out my period of attachment and you taught me
a lot, including how to be committed to the job. Thank you all for adding to my values! To
the entire NPP team, I say you are too much! I indeed enjoyed the team spirit that exists
among you, I can never forget NPP. I will not forget to mention the DBN staff that I worked
with; Messrs Emmason, Ralph, Peter Green, Jacob Solomon, Francis, etc. Thank u all for
your efforts in making me learn.

To my parents, Sir & Lady Sam Orji, JP God bless you real good for your contributions to
my life, ur advices and all your efforts, I love u and I say a big Thank you. To My Sisters
Ngozi and Miracle, my Brother- Prosper, i love you all. I must also thank my own
Thunderbolt Family not for getting room30.com: Nnana, John, Julius, Obaino, Frauk, Justin,
Pnd, 2Thunda, Katch, Oge, Mb, Jamo-D, Chima, Phil, Benz, Owen, McDon, T&T, and my

beloved sisters: Chiluv, Jennifa, Stella, Okwy, Magi, Loveti, Uche, Aky, and others, thanks
for ur love, and also to my people in COR, JCCF, SUCF, MPNSC, I love you all and God
bless you too.

My lecturers, I want to seize this opportunity to say a very big thank you for your efforts.
To my colleagues in NPP; Samuel Amakiri, Ifeoluwalayomi Wole-Osho, Ichebadu Ejekwu,
Obubelebara Brown, Toye Adeyemo, Benjamin Ederiane, August Akpodiete, Rolian Green,
Priscilla Amachree, Muyiwa Tella and the guys from Lagos Office; Franklin Odoemena,
Emmanuel Okoro, Chioma Nwamah and Adebowale Adebiyi; I say the memories of being
with you guys will always be in my heart.

To everybody that has, in one way or the other, assisted in making my Industrial Training a
memorable one, I say thank you all and God bless you.

TABLE OF CONTENTS

Title Page

Dedication

ii

Acknowledgement

iii

Abstract

iv

Table of Contents

List of Tables

vii

List of Figures

vii

List of Abbreviations

viii

CHAPTER ONE

1.0 INTRODUCTION

1.1 Background

1.2 Aims and Objectives

1.2.1 Aims

1.2.2 Objectives

1.3 About Nigeria Liquefied Natural Gas (Nigeria LNG) Limited

1.3.1 Location

1.3.2 Organizational Structure

1.3.3 Available Facilities

1.3.4 Production Capacity

1.3.5 Staff Strength

CHAPTER TWO

10

2.0 WORK EXPERIENCE

10

2.1 Work Done

10

2.2 Experience Acquired

11

2.3 Challenges Faced

12

2.4 Solutions Proffered

13

2.5 Detailed Description of the Training Schedule

13

2.6 Tasks Performed

13

2.6.1 Valves

13

2.6.1.1 Classification of Valve

14

2.6.1.2 Globe Valve

15

2.6.1.3 Butterfly Valve

15

2.6.1.4 Gate Valve

16

2.6.1.5 Solenoid Valve

17

2.7 Fire & Gas Detection

18

2.7.1 Detection System

18

2.7.2 The Logic System

19

2.7.3 Plant Alarm Warning System

19

2.7.4 Alarm Presentation

20

2.7.5 Visual Alarm

20

2.7.6 Flammable Gas

21

2.7.7 Open Path Gas Detectors

22

2.7.8 Fire Detectors

23

2.7.9 Manual Call Point

23

2.7.10 Automatic Fire Detectors

24

2.7.11 Smoke Detectors

25

2.8 Transmitters

25

2.8.1 Masoneilian Transmitters

25

2.8.2 Flow Rate

26

2.8.3 Flow Transmitters

26

2.8.4 Vortex Flow Transmitters

27

2.8.5 Pressure Transmitters

27

2.8.6 Pressure Transmitters Used in Nlng

29

CHAPTER THREE

30

3.0 Conclusion and Recommendations

30

3.1 Conclusion

30

3.2 Recommendations

31

References

32

LIST OF FIGURES

Fig 1.2: NLNG Managing Director Division (MD) Corporate Organogram

Fig 1.3(a): NLNG Plus Project (NPP) Organogram.

Fig 1.4(b): NLNG Plus Project (NPP) Organogram.

Fig 1.1: Typical LNG Train

Fig 2:1 LNG Production

Fig 2.2: Vortex Valve

15

Fig 2.3: Butterfly Valve

16

Fig 2.4: Gate Valve

17

Fig 3.1: Point Gas Detector

22

Fig 3.2: Open Path Gas Detector

22

Fig 3.3: Manual Call Point

23

Fig 4.1: Vortex flow Transmitter

27

Fig 4.2: Hart Communicator

28

Fig.4.3: Rosemount Pressure Transmitter

29

LIST OF TABLES

ALARM PRESENTATION (Visual Alarm)

20

LIST OF ABBREVIATIONS

CCR Central Control Room.

GTS Gas Transmission System
ISB Integrated Supply base
ISBL Inside Battery Limit
LNG Liquefied Natural Gas
LPG Liquefied Petroleum Gas
NLNG Nigeria Liquefied Natural Gas
NPP NLNG Plus Project
OSBL Outside Battery Limit
PEFS Process Engineering Flow Scheme
PPE Personal Protective Equipment
FAR- Field Auxiliary Room
F & G- Fire and Gas (System)
MCP- Manual Call Point

CHAPTER ONE

1.0 INTRODUCTION.
1.1 Background
Over the years, experts have been of the opinion that there is a yearning gap between the
learning acquired by graduates of Nigerian Universities and the skills repertoire required in
the workplace. Clearly, academic learning and theoretical knowledge alone would not
usually prepare an educated person for the world of work.
Highlights of the general deterioration in the quality of graduates from Nigerian Universities
in the recent past are open secrets. Employers believe that Nigerian graduates bring sufficient
theoretical knowledge to the job but that they generally lack hands-on or practical skills that
would make them productive and efficient. Consequently, a worker must not only be
knowledgeable but must also be versatile in the application of skills required to perform
defined jobs and work. This requirement is particularly crucial for graduates of science,
engineering and technology disciplines.
The great and spectacular advances and progress recorded by developed nations are primarily
and substantially attributable to the contributions of their scientific, engineering and
technological educational communities. They are the creators of change and innovation
which drive the world today. The community constitutes one of the most precious resources
and assets of any developing nation. Consequently, the capacity of Nigerian graduates to
innovate and create determines the extent of their potential contributions to the growing of
the economy and national development. However, the expected contributions can not be
made by graduates who are lacking in practical or hands-on skills repertoire.

1.2 Aims and Objectives

1.2.1 Aims
1. To bridge the gap between university work and actual practice.
2. To enhance students contacts for later job placement.
3. To further expose students to the opportunities/potentials in their fields.

1.2.2 Objectives:
Specifically, the objectives of the Students Industrial Work Experience Scheme (SIWES) are
to:
1. Provide an avenue for students in the Nigerian Universities to acquire industrial skills and
experiences in their course of study;
2. Prepare students for the work situation they are likely to meet after graduation;
3. Expose students to work methods and techniques in handling equipment and machineries
that may not be available in the universities;
4. Provide students with an opportunity to apply their theoretical knowledge in real work
situation, thereby bridging the gap between university work and actual practice;
5. Make the transition from the university to the world of work easier, and thus, enhance
students contacts for later job placement; and
6. Enlist and strengthen employers involvement in the entire educational process of
preparing university graduates for employment in industry.

1.3 About Nigeria Liquefied Natural Gas (Nigeria LNG) Limited

Nigeria LNG Limited was incorporated on May 17, 1989 as a joint venture company, to
harness Nigeria's natural gas reserves, some of which are currently being flared. The
company purchases and liquefies Natural Gas for export to overseas markets. On 29th
November 1985; a Framework Agreement was signed following the formation of the LNG
Working Committee comprising the Nigerian Government, Shell Gas B.V, Elf and Agip. The
committee initiated the project and appointed Shell as Technical Adviser. The Nigerian
government is represented by the Nigerian National Petroleum Corporation, NNPC.

Fig 1.1: A Typical LNG Train

1.3.1 Location
The Plant Complex is at Finima, Bonny Island, Rivers State, Federal Republic of Nigeria.
The head office is in Lagos and the liaison offices are in Abuja and London

1.3.2 Organizational Structure

The company has an organizational structure as shown in the organizational organograms
(with reference indicators) below. I was actually offered placement in the NLNG Plus Project
(NPP), a department under the Managing Director Division (MD). NPP is the project
construction team of NLNG and we are in charge of adding to the existing facilities (in terms
of structures) of the company. Our duty is to build the company. We are also involved in
community support and development programmes for our host communities.

Fig 1.2: NLNG Managing Director Division (MD) Corporate Organogram

NLNG Plus Project Department (1)

Executive Project Manager
NPP
A. U. Ogbuigwe

HSE Coordinator
NPP/6
G. Stone

Project Services Coord.

NPP/4
S. Robertson

Project Interface Coord.

NPP/3
Francis Amego

PA To Exec Proj Mgr

NPP/0
N. Lawson (C)

RET Manager
T6 ISBL/OSBL

Commissioning Manager
NPP/CM
R. Verburg

Construction Manager
NPP/C
A. van Bergen

Chief Engineer
NPP/1

Lead Mech. Engr

NPP/11
B. Starink

Lead Civil Engr

NPP/12
AKL Sabry

OSBL Coord
NPP/CO
A. Uwais

Head Electrical Engr

NPP/13

Lead Instrument Engr

NPP/14
R. Frankenmolen

Head Rotating Equip Eng

NPP/15
S. Yusuf

Snr. Mech. Engr

NPP/111
T. Ikpe

Civil Engr
NPP/121
I. Brown

Snr Electrical Engr

NPP/131
W. Couch

Snr. DCS Engineer

NPP/141

Snr. Rotat Equip Engr

NPP/151
R. Hull

Mech. Engr
NPP/112
A. Ezekwe

Civil Engr
NPP/122

Electrical Engr
NPP/132

Instrument Engr
NPP/142
H. Heesemans

Rotating Equip Engr

NPP/152

Mech. Engr
NPP/113

Civil Engr
NPP/123

Electrical Engr
NPP/133

Instrument Engr
NPP/143

Rotating Equip Engr

NPP/153

Civil Engr
NPP/124
N. Mbata

QA/QC Coordinator
NPP/2

Const Mgr GTS 2/4 SC

NPP/SC

Head Quality Assurance

NPP/21
T. B. Aholu

Project Engineer
NPP/CO1

QA Engineer
NPP/211

QA Engineer
NPP/212
Y. Jegede (C)
Head Quality Control
NPP/22
A. Tayo

Quality Control Engr

NPP/221
J. Van der Meer

Instrument Engr
NPP/144
G. Kwajaffa

Wielding Engr
NPP/222
H. de Wit
Field Inspector
NPP/223
B. Alabi
Field Inspector
NPP/224

Fig 1.2(a): NLNG plus Project (NPP) Organogram.

Asst Field Inspector

NPP/225
A. Brown (C)

NLNG Plus Project Department (2)

Executive Project Manager
NPP
A. U. Ogbuigwe

Project Interface Coordinator

NPP/3
F. Amego

Project Relations Engr

NPP/31

CR Project Engr
NPP/311
G. Olanrewaju (C)

CR Field Engr
NPP/32
A. Allagoa
Lead Proj Interface Engr
NPP/32

Proj. Services Coord.

NPP/4
S. Robertson

Lead Proj/Contract Engr

NPP/41
T. Abana

Proj. Services Engr

NPP/411

Administrative Assistant
NPP/331
B. Biambo

Proj. Devt. Engr

NPP/42

Senior Cost Engr

NPP/43
A. Akpuokwe

Proj. Services Engr

NPP/412
F. Tella

Project Cost Cotroller

NPP/431
O. Ewuyemi (C)

Asst Proj. Services Engr

NPP/413
S. Adebimpe

Project Cost Controller

NPP/432

Commissioning Manager
NPP/CM
R. Verburg

Senior HSE Engr

NPP/611
A. Dauda

Environmental Engr
NPP/612

HSE Engineer
NPP/613
W. Tom-George (C)
HSE Engineer
NPP/614
F. Ezinwo (C)

Document Controller
NPP/44
E. Fubara (C)

Proj Interface Engr

NPP/322
S. Jumbo (C)
Senior Admin Office
NPP/33
J. Okubor (C)

HSE Coordinator
NPP/6
G. Stone

Asst Document Controller

NPP/441
C. Oguji (C)

Asst Document Controller

NPP/442

Asst Document Controller

NPP/443
C. Olodu (C)

Procurement Officer
NPP/335
J. Ngeneka (C)

Admin Asst
NPP/338
G. Ezekiel (C)
Logistics/Office Admin
NPP/334
E. Somiari (C)

Protocol/Liaison Officer
NPP/336
J. Aguh (C)

Protocol/Liaison Officer
NPP/333
G. Uka (C)
Administrative Assistant
NPP/337

Fig 1.4(b): NLNG Plus Project (NPP) Organogram.

See
Comm & Start Up
Team

1.3.3 Available Facilities

The first structures built are called Base Project and it has a design capacity of 5.8 million
tons per annum of LNG and can deliver 7.15 bcm per annum to customers. In addition to
LNG, the Base Project produces 6,000 barrels of condensate per day. The Base Project
consists of the following:

Two train gas liquefaction plant.

A Gas Transmission System (GTS) passing through 110 communities for the supply
of natural gas to the plant via gas network.

Two LNG storage tanks with capacity of 84,200 cubic metres each.

Two condensate storage tanks with capacity of 36,000 cubic meters each.

Four Gas Turbine Power generators with a total capacity of 160 MWatts.

LNG export jetty.

Seven LNG vessels for Cost Insurance and Freight (CIF) deliveries to the LNG
Buyers.

Residential areas covering 2.08 square km.

Materials off-loading jetty.

The next project embarked upon was called Expansion Project. The Expansion Project
includes a third liquefaction train, LPG facilities - storage and a jetty. The Expansion Project
consists of:

A third LNG train of similar design to the existing two Base Project trains.

Modification of trains 1 and 2 to process 100% associated gas.

A common fractionation plant to produce LPG.

LPG storage and loading facilities.

A third LNG storage tank.

Additional utilities and common facilities (electrical power, water, building, etc).

Two LNG vessels for CIF deliveries to the LNG buyers.

Total LNG plant capacity of the Base and Expansion Projects is 8.7 million tons per annum.
The next project was the Plus Project which includes two liquefaction trains (4th and 5th).
The two trains have a different design from the existing three in that they are cooled by air
while the first 3 trains are cooled by water. Therefore, no water cooling tower was built as
part of the Plus Project.

After the Plus Project came the Six Project divided into ISBL and OSBL. ISBL was awarded
to TSKJ. The Six Project (ISBL) provided the 6th NLNG liquefaction train. Train 6 design is
just a replica of that of Trains 4 and 5. No cooling tower was built as part of this train also
because it is air-cooled.
The on-going project is called NLNG OSBL Six Project, awarded to Entrepose Contracting
Delattre-Bezons Nigeria Limited. It is to provide additional LNG and LPG storage tanks
(LNG, Butane and Propane tanks) and another Condensate Stabilization Unit (CSU).

In addition to the aforementioned, the company also has the following associated facilities:

Water Wells and other utilities.

The Gas Transmission System (GTS) which transports gas to the plant site from the
three supply points: Soku (SPDC), Obite (EPNL) and Obrikom (NAOC).

The Gas Transmission System (GTS) Node at Rumuji/Ubeta.

The ISB (Integrated Supply Base) at Port Harcourt.

1.3.4 Production Capacity.

The existing trains have a design capacity of over 17.4 million tons per annum of LNG and
can deliver 21.45 bcm of LPG per annum to customers. In addition to LNG, the trains
produce over 18,000 barrels of condensate per annum.

Fig 2.1: LNG Production

1.3.5 Staff Strength.

The company has human asset of approximately 4,000 direct and contract staff including
secondees from the shareholder companies (i.e. Shell, Total and Agip).

CHAPTER TWO

2.0 WORK EXPERIENCE.

2.1 Work Done.
The following is a shortlist of tasks and activities carried out during the programme:

Inspection of Installation of instruments at the Condensate Stabilization Unit (CSU).

Clearing of master punch list for instruments on top of propane tank.

Inspection of Installation of valves on top of propane tank.

Inspection of Installation of Transmitters on top of propane tank

Inspection of Junction boxes on top of propane tank.

Clearing of master punch list for instruments at integration area of propane tank.

Inspection of instrument name plate, wire tags, ends cap and cable tray cover
installations.

Inspection of fire alarm systems in propane tank area

Inspection of Junction boxes at integration area of propane tank.

Inspection of valves on top of butane tank

Inspection of installations of transmitters on top of butane tank

Clearing of master punch list for instruments on top of butane tank

Clearing of master punch list for instruments at integration area of butane tank

Inspection of Junction boxes on top of butane tank

Inspection of Junction boxes at integration area of butane tank

Inspection of fire alarm system in butane tank area.

Inspection of gas and fire alarm panels and systems in butane tank area, FAR 18 and
SS 35

Inspection of slab Resistance Thermosistor Detector in propane and butane tanks

Inspection of underground cable name plates prior to backfilling at CSU

Inspection of name plates, cable tray cover and wire tags for instruments, cables and
wires at CSU and Tank areas

Continuity testing of the slab RTDs around the Propane and Butane tanks.

Inspection of air compressor and Junction boxes at the CSU

Information Security Training

Various safety trainings and inductions such as Health, Safety and Environment (HSE)
induction, Confined Space Entry induction and Nitrogen awareness training, Job
hazard analysis and Permit to work (safety) Trainings.

2.2 Experience Acquired.

The NLNG is a world class multi-cultural oil and gas company that has integrity, teamwork,
excellence and caring as her core values. The company instils this belief into the minds of her
workers and provide them with all the necessities of life for them to concentrate on their jobs
efficiently. The company has given me a world class experience as I have been exposed to
various ways of office practices, engineering management, construction site inspection, plant
operation, safety, working in accordance with procedures and specifications, division of
labour, client-contractor relationship, setting and meeting targets, human relationship,
teamwork, integrity, efficiency, productivity, observation, alertness etc. It was a great
opportunity to see some theories learnt in school being put into useful work

2.3 Challenges Faced.

The programme was quite challenging, but was seen as a process of making and a kind of
build up to greatness. NPP is the construction department of the company so; I had to face all
the rigours of construction processes. The followings are the challenges:

1. Adaptation to work place environment (gas plant and construction site) as it was
totally different from the other environment I was used to.
2. Climbing very tall heights like Butane tank and Propane tank using stairs which
initially always led to body pains.
3. Adaptation to early hour resumption time (strictly 7.00 am).
4. Adaptation to working under sun for hours.
5. The challenge of adapting to working with the inconveniency of wearing the basic
PPE (e.g. safety shoes, hard hat, goggles, hand gloves, ear plugs, etc.).
6. The need to manoeuvre oneself into little spaces in-between pipelines to confirm
installation of items that can not be seen from afar.
7. The need to cope with some offensive smell when working in certain areas of the
plant.
8. Standing firmly on the slippery storage tanks tops of about 46 meters above ground
level was also a challenge.
9. I had to wait for a period of time for the company to provide me with an identity card
that will allow me entry into the live plant area.

2.4 Solutions Proffered.

I had no choice other than to increase my proficiency through increased commitment. On

height climbing, I chose to be taking a lot of rest after work. So, I always stay indoors at
home after work. The entire members of staff of NPP also helped a lot, especially, the
cooperation I received from NPP Instrumentation Department.

2.5 Detailed Description of the Training Schedule.

For the major part of the period, I was with the NPP; I only visited the CCR and the plant
panel where the operators operate the plant with touch-screen technology to control/monitor
virtually all valves and other instruments, to store and load LNG and LPG, and to carry out
every other operation on the plant.

2.6 Tasks Performed.

2.6.1 VALVES

A valve is a control device that is used to modify the flow rate in a pipe. The modification could
be as a result of full restriction of passage to provide zero flow or no restriction to provide
maximum flow or modification between the two states. A typical valve consists of an actuator,
stem and valve body. Other additional parts include instrumentation and control devices such as
the positional (especially for control valve), and the proximity sensor, solenoid valve, pressure
regulator, etc.

The valve body provides the path through which the flow can be modified. The actuator is the
source of motion, while the stem links the actuator to the valve body in other to transmit the
motion to the closure member. The positioner, when installed is used to provide a controlled
actuation of the valve. It also tells the position of the valve. The proximitor sensors are for valve
position signal transmission.
Different types of valves from different instrument manufacturers are used in the NLNG plant.
They include the Valtek control valve, the Masoneilan, Fisher, Joucomatic , Globe etc.

2.6.2

CLASSIFICATION OF VALVES

Valves are categorized according to the design style. The style can be grouped into the following:
1. Type of stem motion- linear or rotary
2. Valve operation- air to close(ATC) or air to open (ATO)
3. Type of seat- single seat or double seat
4. Shape of closure member- gate, equal percentage and linear valve
5. Application- antisurge, relief, trip, pressure control, level control valve etc
6. Others are- solenoid valve, check valve relief valve

2.6.3

GLOBE VALVES

This is the most common linear stem motion control valve. In globe valve, the closure member is
called a plug. The plug is guided by a large diameter port. It moves within the port to provide the
flow control orifice of the valve. Some designs have cage guided plugs in which openings in the
cage provides the flow orifice.

The valve seat is the zone of contact between the moving plug and the stationary valve body. The
plug, the cage, the seat ring and associated seal are grouped and also called the trim of the valve.
When the plug closes against the seat, it closes the flow orifice thereby preventing the flow. On
the other way, if the actuator moves the plug away from the seat, the orifice opens and the fluid
flows accordingly.
Example of this type of valve used here in the plant is the Flowserve Valtek control valve as shown in
fig-----

Fig. 2.2 picture of Flowserve

Valtek Control valve

2.6.4

Fig. 2.2b Valtek control valve showing the

internals

BUTTERFLY VALVE

Another type of valve widely used in the plant is the butterfly valve. This is an example of the
rotary motion valve. They come in different sizes depending on the process pipeline they are to
be used. Like any type of valve, it could be manually or actuator driven. It also consists of the
actuator and the body components and the stem also. The body of the valve makes it different

from other valve. It has a classic wafer body design which is clamped between the pipeline flange,
and a disc closure member which is offset from the shaft

Fig. 2.3 picture of Butterfly valve

2.6.5

GATE VALVE

The Gate Valve is a type of isolation valve normally used for ON/OFF application. Its peculiarity
is the manner which it operates. The closing member is a disc, also called the gate which moves
Perpendicular to the flow stream. The disc is moved up and down when actuated by a threaded
screw stem that is rotated to effect the disc movement.

Fig. 2.4b Schematic for gate valve

Fig. 2.4 Body of a Gate valve

arrangement

The gate valve is used for ON/OFF control action because it provides a very tight shut off to
prevent any form of leakage. It is the most widely used valve in this application.
Additional sensitivity to over pressure conditions can be improved by adding an auxiliary
pressure relief valve (pilot) to the basic pressure relief valve. This combination is known as a pilot
operated pressure relief valve.
The safety valve is not different function wise to the normal relief valve. The only difference is
that the safety valve is designed to fully open or pop with only a small amount of pressure over
the rated limit.

2.6.6

SOLENOID VALVE

Solenoid valves are special types of valve. It is electrically powered unlike the conventional
pneumatically powered valves. It also has a port for pneumatic input and output. As the name
implies, it is solenoid operated. A solenoid is an electromagnet which will become magnetic
when current flows through it.

When sufficient electric current is supplied to the coil, an internal armature moves against
a spring to an extreme position this creates a clearance to either shut off or allow air flow

through the valve. Removal of the current source de-energizes the electromagnet and the
armature causes the spring to return to normal position thus blocking the flow of air.
Generally, solenoid valves are not used as stand alone valves. They are used with the
other valves (main valve) as valve control device to pressurize or vent actuator casing for
ON/OFF control valve application. It is also used in safety shutdown applications for
safeguarding systems.

2.7 FIRE AND GAS DETECTION SYSTEM

Due to the hazardous and critical nature of the LNG process, the protection of the
plant and associated facilities against any form of fire and gas hazard is given a very
high priority. An independent system is dedicated for this purpose. Negligence on the
protection of facilities against fire has cost many organizations, individuals, including
the government a great loss. The negative impact the aftermath that fire and gas
disasters bring is something not to be imagined. The experience from this section can
be applied in other organizations, government establishments and even our homes.

2.7.1 DETECTION SYSTEM

The function of the detection system is to promptly detect any hazardous condition
resulting due to fire and gas, and to also send control signals to other sub-systems for
required protective action. Appropriate flammable gas, smoke, heat, and fire detectors
are provided in strategic locations through out the plant for immediate detection of
specific hazard. Most of the detectors send signals of 4-20mA or 24volt or volt free

contact signal input to the logic system. The field signal is connected to the logic
system by means of systems cable via the MDF cabinet.

2.7.2 THE LOGIC SYSTEM

The logic system receives input signals from the detection system and carries out
functions such as:
1. Selective alarm display initiation in the control room and the plant areas.
2. Shutdown of equipment and isolation of process units as appropriate GT shutdown,
fan and damper shutdown, isolation of electrical supplies in hazardous atmosphere etc.
3. Activation of fire fighting devices as specified e.g. spray systems, Co2 systems.
The logic system is implemented by means of dedicated redundant PLCs located in
the appropriate FARs.

2 .7.3 PLANT ALARM AND WARNING SYSTEM

According to their location, gas detector will initiate alarms and trip functions. Some
could be configures to be alarm only, alarm and trip, pre-alarm and trip.
Alarm audio visual devices such as horns, beacons, Sirens etc are provided in
strategic areas through out the plant and occupied building to alert plant personnel of
imminent danger. Gas alarm is accompanied with the flashing of a blue beacon. Fire
alarm, which is louder, is accompanied with the flashing of red beacon. In the event of
any fire alarm, all personnel on sight are expected to safely terminate whatever job
they are doing and go to designated muster points. They will remain there until the all
clear alarm is sound

2.7.4 ALARM PRESENTATION

Alarms are presented in different ways in the plant. This depends on the location of
distress and also the cause of the alarm. Variation in alarm presentation helps for easy
identification of the cause. The tables below give summary of how alarms are
presented in the plant.

2.7.5 VISUAL ALARMS

Visual alarm presentation devices vary with location. However the colour codes are
still the same. In the central control room, on the fire and Gas semi graphic panel, the
alarm presentation is as follows:
Cause
Flammable gas
Fire
System fault
Others

Visual alarm
blue light
red light
white light
Red

Audible alarm
buzzer
buzzer
buzzer
buzzer

remark

Note that in the event of any of these troubles, the buzzer will continue to sound until
the operator pushes the accept button to acknowledge the alarm.
In addition, a dedicated printer is provided in the central control room for recording of the
alarms and events related to the fire and gas system.

2.7.6 FLAMABLE GAS DETECTION

The fire triangle principle upholds that fire will occur if the following constituents are
available:

1. flammable gas between its LEL and UEL

2. ignition source
3. sufficient oxygen to burn
The early detection of flammable gas leak is of vital importance in preventing explosions
or potentially hazardous conditions. Alarms for flammable gas detectors are set below the
lower explosion limit (LEL) of the gas so that it can be quickly dispersed before it
achieves the potential to cause fire.
In the NLNG processes, probable leak sources resulting in flammable gas clouds are not
limited to the seals of centrifugal process gas compressors, and pumps handling light
hydrocarbons. Gas detectors are also installed on the LNG loading Jetty, the storage tank
platform, and other gas associated facilities.

All detectors use two different wavelengths of signals, one that can be absorbed by the
gas (sample) and another one that cannot be absorbed by the gas (reference), so that
under gas free conditions both beams are affected by similar ambient changes such as
humidity or dust. Should gas be present, the sample beam is absorbed by the gas, the
reference beam remains unaffected and a differential output is obtained as a signal
warning indicating the presence of gas.
When a single IR source or emitter is housed together with the receiver, and a reflector or
mirror to send signal to the receiver, the detector is said to be a Point gas detector because
it can only analyze gas at one spot. Otherwise, it is called open path gas detector. This
eliminates the difference in the signal strength of the sample and reference sources.

Fig. 3.1 Picture of Polytron IR Point gas detector

Fig. 3.1b Schematic diagram of operation of

Polytron Infrared point gas detector

2.7.7 OPEN PATH GAS DETECTORS

These are installed around the perimeters of the LNG Process Trains, and above the
Regen Gas Coolers. The operating principle is similar to the Infra Red Point Detector.
Here the receiver is somewhat separated from the transmitter box. For the one use here,
maximum distance of separation is up to 120m away

Fig. 3.2 Picture of Polytron IR open path gas detector

Again, in the event of a hydrocarbon gas cloud passing between source and receiver, it
absorbs light proportionally equal to the concentration.

The detector transmits a 4 to 20 mA signal to the F & G system. This corresponds to a 0

to 100% of the LEL.M of the gas. The signal range is 0 to 5LEL.M. However in NLNG,
alarm is set at 1LEL.M. An audible gas alarm is triggered from the F&G system when
this setting is reached.

2.7.8 FIRE DETECTORS

The detection of fire in its earliest stage of development cannot be overemphasized if

prevention of fire outbreak and attendant explosion is to be achieved.
In NLNG, two forms of fire detection are employed namely: manual fire alarm call points
and plastic tube automatic fire detection.

2.7.9 MANUAL CALL POINT (MCP)

Manual call points are break glass actuated switches which are located through out the
plant areas along the roads, escape routes, at higher risk
locations e.g. pump floors, manifold etc, and the exits of
buildings.
Here the appropriate action is/are initiated according to
the cause and effect matrix programmed in the PLCs.

Fig. 3.3 Picture of Manual Call Point

Some manual call points especially those in buildings have capacity to be addressed. This
makes identification of distressed point easy from the fire panel in the building.
Manual call points in the plant initiate plant wide fire alarm. The alarm latches on the fire
and gas system until the glass is replaced.

2.7.10 AUTOMATIC FIRE DETECTOR

This is the major automatic fire detector system in the plant is the Fusible polyethylene
tubing. It used mostly on the equipments protected by automatic fixed water system or by
manually activated low expansion foam system. The equipments include hydrocarbon
pumps, expanders, compressors Storage tanks etc.
The fire detection works on a simple principle. Black fire retardant polyethylene tubing is
placed in close proximity to the fire prone parts of the protected equipment.

The start of the tube has a pressure regulator to fix the tube pressure to 2barg. Another
end is connected to a pressure switch which is set at 1.5barg.
In the event of fire, the tube will rupture at 100oc then the pressure switch will signal loss
of air pressure due to rupture, at 1.5barg.
The pressure switch contact (normally closed when healthy, opening on trip) are input
into the F&G system, where appropriate actions are initiated, according to the cause and
effect matrix of that unit.

Apart from the low foam system, this has only one tube arrangement, some other
equipments have a pair of fire tubes for protection. In the event of one failing, an alarm is
generated on control panel as system fault. Should both fail, then the On/Off Valve on
the fixed water system will open to spray extinguisher (if specified), fire alarms will be
initiated locally and in the control room. Fire pumps would also start automatically.

2.7.11 SMOKE DETECTION

There is no fire without a smoke is a popular saying we often hear. Smoke detection is
essential because non explosion engendered fire like burns will usually generate smoke
for some time before the actual fire comes. For this reason, appropriate smoke detectors
are placed at strategic places for its detection. Three types of smoke detector are in use
here. They include:
-Combined Optical/heat type detectors
-Very early Warning type smoke detectors
-Ionization type smoke detectors.

2.8 TRANSMITTERS

2.8.1

MASONEILIAN DIGITAL LEVEL TRANSMITTERS

The masoneilian digital transmitter used here is the MODEL 12300 type. It is a displacer type of
level instrument, with high performance easy to set instrumentation. It is a 2-wire, loop powered,
and digital displacement level transmitter with HART communication module. It has a displacer
tube which is a narrow, long, closed cylinder. This tube is half submerged in the liquid at normal
level. The mass of the displacer is sufficiently large not to float and so the displacer will sink if it
is not attached to the measurement system. The displacer tube is linked via a torque arm to a
torque tube which transmits rotary motion through its torque rod to a magnet over a Hall Effect
Sensor.

2.8.2

FLOW RATE MEASUREMENT

Flow rate of liquids and gases is very important in the process industry. Measurement of flow
indicates how much fluid is used or distributed in a process. Although flow measuring
instruments are not as common like the other process variable instruments, they are indispensable
in the process plant. Another less frequently used term is the volume flow, which is used to
describe the volume that flows per unit of time e.g. m3/s or dm3/min at a specified temperature
and pressure.
Volume flow rate, q = change in volume, m3/s
Change in time
Mass flow rate, W = q, expressed in Kg/s
Where = density of fluid
Flow instruments used in the plant include flow indicators and flow transmitters produced by
various instrument manufacturers.
Flow indicators are mainly for field indication purposes, having no control and alarming function.
The transmitters give continuous measurement in a standard 4 20mA electronic signal output
which can be transmitted to the FARs and CCR?
Flow transmitters or indicators can be installed online or inline. Inline installation requires fixing
the device on the same line as the process pipe. Online diverts the flow through another channel
for measurement.There are various principles of flow rate measurement. These include the
differential pressure flow meters, turbine flow meters, vortex-shedding flow meters, magnetic
flow meters, positive displacement sensors, ultrasonic flow meters etc. Examples are: the Khrone
and the Brook flow indicators.

2.8.3

FLOW TRANSMITTERS

Flow transmitters do not only measure the flow, it also converts the measured signal into a
standard electrical form, which is transmitted to process control stations for necessary

information and action. Some of them have on site indications. An example of the flow
transmitter used in the plant is the vortex- shedding flow transmitter.

2.8.4

VORTEX FLOW TRANSMITTERS

These flow meters take advantage of vortex shedding, which occurs when a fluid flows
past a non streamlined object (a blunt body). The flow cannot follow the shape of the
object and separates from it, forming turbulent vortices or eddies at the objects side
surfaces. As the vortices move downstream, they grow in size and are eventually shed or
detach from the object. Shedding takes place alternately at either side of the object. The
resulting pulsations are sensed by a piezoelectric crystal. The rate or frequency of vortex
formation and shedding is directly proportional to the fluid volumetric flow rate.

Fig. 4.1 picture of Vortex flow

transmitter

2.8.5

PRESSURE TRANSMITTER

In the control of modern process plant, the transmitter is indispensable and indeed the
crown of process measuring instruments.
A pressure transmitter is an instrument which measures the pressure of a process converts
it into a standard electrical signal which could be read on site and can be transmitted over
a distance to for example a receiver in the Field auxiliary room (FAR) or the control room.

A typical transmitter consists of a sensor, converter and amplifier unit. Intelligent ones
are microprocessor based and include a communication unit.
In addition to the electronic transmitters of the two-wire type there are also transmitters
that use the four-wire system. With this type two wires are used for connecting to the
external supply.
The other two wires are used for the output signal of 0 to 20 mA. With the four-wire system
it is possible to use 0 to 20 mA as the auxiliary energy required for the transmitter is not
obtained from the output signal. However, most of the transmitters used in NLNG are the
two wire type. Modern transmitters are microprocessor based and include a communication
unit. They are known as smart or intelligent transmitters because they can communicate and
be communicated to. The HART communicator is used to communicate with the device.

Fig 4.2 A pressure transmitter connected to a HART communicator

Fig. 4.2b Picture of HART communicator

2.8.6 PRESSURE TRANSMITTERS USED IN NLNG

Majority of the pressure transmitters used in NLNG are of two manufacturers. These are
the ABB transmitter and the more popular ROSEMOUNT transmitters. They all work on
the basic principle of transmitter above, and are intelligent devices HART compliant.

Fig. 4.3 pictures of different models of

Rosemount Pressure Transmitter

They work on the capacitance pressure sensor principle. The two diaphragms are filled
with silica oil. It is designed to work as a differential type, having the low (-) and the high
(+) pressure side. Rosemount transmitters are classified in ranges three (3) to nine (9).
This defines the maximal measurable range of the transmitter.
The ABB transmitter comes in both differential type and the gauge type

CHAPTER THREE

3.0 CONCLUSION AND RECOMMENDATIONS

3.1 Conclusion
I have drawn the following conclusions from my SIWES programme:
1. The SIWES programme provided a great opportunity for me to get the necessary practical
experience needed while still in school. This exposure to practical work has helped me
develop a better appreciation of what is being taught in school. In the engineering discipline,
the benefits of such practical experience are numerous. Theoretical information became real
to me as I saw, with my own eyes, the application(s) of what I had been taught. Seeing the
practical work also ensures that I will not forget what I have been taught.
2. However, the benefits of any industrial training can only be obtained if the trainee is
willing and inquisitive enough to learn. Without an inquisitive attitude, a trainee would
simply look at various works being carried out, without being able to understand or link them
with previously acquired knowledge.
3. My industrial training at NLNGs Construction Office (NPP) resulted in me, being able to
see some huge and uncommon (in this part of the world) engineering construction works and
equipments. I was also fortunate to have access to engineering codes of practice, procedures,
manuals, textbooks and drawings, which I studied to find out more about the various
activities being carried out at the construction site and plant complex.

4. The industrial training programme was very beneficial, and active participation should be
encouraged. Various engineering firms should also be willing to assist the universities in
training students by allowing the students to obtain practical experience with them.

3.2 Recommendations

I hereby make the following recommendations:

1. Having undergone my industrial training in a world class multi-cultural company like the
Nigeria LNG Limited, I discovered that six months is actually not enough time for a student
to bridge the gap existing between theory and practice of engineering and technology. It is
not enough time for students to get acquainted to professional work methods and ways of
safeguarding the work areas and workers in the industries and other organizations. I would
like to suggest that the SIWES period be increased to nine months or one year.
2. Universities should ensure that all students on industrial attachment are visited in their
work stations so as to boost students morale and help them increase their commitment
towards the programme. It will also monitor and ensure that students are receiving the right
training.
3. It was observed that each time rain falls; we would not be able to work on site due to
severe weather and construction activities would stand still. I would like to suggest again that
the National University Commission (NUC) should try and arrange the school calendar in
such a way that Engineering/Technology students will be having their own programme in the
dry season so that they will be able to utilize the whole of SIWES period for serious work.

REFERENCES

Nigeria LNG Limited, NLNG Six Project, 2006, Instruments Installation procedure,
pp 6-11.

Nigeria LNG Limited, NLNG Six Project, 2006, Continuity Testing Procedure, pp 1018.

Nigeria LNG Limited, NLNG Six Project, 2006, Punch Listing Procedure, pp 4,5, 13
& 14

Engineering Practice (DEP) Manual (Used by Companies of the Royal Dutch/Shell

Group) on Equipment, Pressure Testing equipment and Systems, pp 5-6.

Design and Engineering Practice Manual (Used by Companies of the Royal

Dutch/Shell Group), General Requirements, pp 60-62.

HRP (Human Resource Services), http://bonny.nlng.com/, 23/10/08.

Human Resources Planning, What We Do, http://dev.nlng.com/Default.htm, 23/10/08.

Manpower Planning and Resources, MD Organogram,

http://lagos.nlng.com/HR/HRR/organogram.htm, 23/10/08.

http://dev.nlng.com/hrp/HRP_2/Inhouse/Operations/Materials/general/Operator%20dic.htm, 23/10/08.