OPERATING MANUAL

FUEL GAS SYSTEM

Section : 03.10.00 Date:01/06/06

Objective
The objective of the fuel gas system is to superheat fuel gas to meet the specification for turbines, heaters and
flares. A minimum of 7 C° above dew point specification is required. Also the high-pressure fuel gas has to be
regulated to meet turbine intake pressure @ 1400kpag, This is the high Pressure supply header. The low-pressure
supply header is regulating the fuel gas pressure @ 600kpag to meet the requirements for the fired heaters and
flare pilots.

Supply Of Fuel Gas

There are three sources of fuel gas: Gas/Gas exchanger E-602, old fuel gas module, new fuel gas module.
During normal operation the primary source of fuel gas will be via a 6 inch line from the gas/gas exchanger E-
602 (shell side), with the gas plant running on normal parameters, this gas is dry and has a low dew point (-
29°C). During start up, or any other plant up-sets, two alternative gas feed lines are provided:

1) From V-601 inlet separator. When using this mode of operation, special care has to be taken as this gas is
untreated and may be saturated with water and condensate.
2) From E-602 shell side via a 4" line to the old fuel gas skid (normally open on standby).

Backup Fuel Gas Supply

Normally the fuel gas is taken from downstream of PV-1602 for all Gas plant users and both fuel gas units are
offline. But old fuel gas system on standby, Normal set point of PIC 619-1 should be selected just below normal
fuel gas supply pressure such that PV 619-1 is normally closed but will open automatically to maintain fuel gas
supply as required.

Fuel Gas Consumers

The fuel gas system treats a gas stream prior to transmission to the downstream users. The system controls the
temperature and pressure of the gas and filters contaminants and liquids from the process.

The fuel gas consumers are

K-201 A/B/C/D & K-202 Export gas compressors
K-203 A/B/C Refrigeration compressors
G-201G/202G Power turbines
H-683 A/B Hot oil fired heaters
Fuel gas to purge system.
Blanket gas, pilot burners.
Fuel gas to GSA/GSB gas compressors.
Fuel gas to CPF power turbines.
Fuel gas to water injection pumps.
In addition fuel gas is supplied to the Omar power plant via a separate system. See (Operation of Fuel Gas to
Omar Power Plant.

Main Fuel Gas Letdown

Dry gas from the gas/gas exchanger E-602 is supplied to GSA&GSB (ring main) after the pressure is reduced to
250 psi (=17.24 bar) by PCV 602-2. FI 621-1 indicates total fuel gas usage by the gas plant and the GSA/GSB
ring main. Figure not used currently due inst. problem. The 4" standby line to the old fuel gas is downstream of
PCV 602-2.

HAZARDS
High noise area, ear protection to be worn.
Noise
Use NORM precautions when measurements show figures above the
standard level.
NORM
Updated by: Amer Numan Any black dust accumulated
Approved
in the
by:bottom
OGP/1 of the vessel could auto ignite.
Checked by: Abdul Wahab Vessels should be washed out if black
Approved dust is present.
by: OGP
Pyrophoric Iron
IMPORTANT
Page 1 of 5 NOTICES
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 OPERATING MANUAL

FUEL GAS SYSTEM

Section : 03.10.00 Date:01/06/06

Old Fuel Gas Module

Fuel Gas Heater E-618

Fuel gas system is provided with a fuel gas heater E-618, but, as the incoming gas
temperature from the inlet separator or from down stream of E-602 is always above the
dew point temperature., the purpose of this unit becomes unnecessary , the heater has
been switched off since the plant started up . The following is a unit description which is
designed to used in case the incoming gas temperature is below 14 C (hydrate
temperature. At 30 bar)
The fuel gas is heated up in the fuel gas heater to create a constant fuel gas temperature (TIC-618-1 set @ 35
°C) before the gas pressure is reduced. This will ensure relatively constant supply condition of fuel gas to all
users all year round, regardless the incoming gas flow or the ambient temperature. TIC-618-1 controls the load to
the electric heating element and receives a signal from the transmitter located at the high-pressure header
downstream of the filter separators. TAH 618-1 and TAL 618-1 are installed to enunciate possible malfunctions
of the heater. High/high sheath temperature TAHH 618-1A will shut down the heater. This is to protect the heater
from overheating. A high/high fuel gas outlet temperature (TAHH 618-1B or TAHH 618-1C) protects against the
over heating of fuel gas.

The corresponding sensor elements for the process shutdown switches are located at the outlet of the heater. It is
possible to drain the heater through a 1½" drain line to the hot closed drain. The heater control panel is purged
with instrument air to get ride of possible explosive mixtures. Low cabinet Pressure initiates PALL 618-1.

Setting and actions of the heater

TSL 618 -5 °C Trips Low temperature alarm.
TSH 618-1 65°C Trips High temperature alarm.
TSHH 618-1B 115 °C Gas outlet temperature. Trips heater.
TSHH 618-1A 643 °C Heater sheath temperature. Trips heater.
TIC 618-1 35°C Normal heater control setting.

A low/low gas flow will also trip the heater and protect it from overheating. FAL 619-1 and FALL 619-1 will
enunciate low or low/low gas flow. During start up or whenever there is too little fuel gas off take, gas can be
flared through the manual depressurising line, to be able to send sufficient gas flow through the heater. By doing
so it is possible to reset the FALL 619-1 and the heater can be started up.

High Pressure Fuel Gas Letdown PV 619-1:

To control the fuel gas pressure from the heater outlet to the filter separators and the high-pressure header
PIC619-1 (set @ 1400 kpa) is installed. Under normal conditions the pressure controller should be able to
maintain 1400 kpa in the high-pressure header. Change in this pressure can indicate stop/start of any solar
turbine, PIC 619-1 control valve failure, fuel gas leak, closing of SDV 618-1, plugged filter separator V-621A/B,
or any possible -left open- drain or depressurising line.

Setting and actions of the high pressure fuel gas

Updated by: Amer Numan Approved by: OGP/1
Checked by: Abdul Wahab Approved by: OGP

Page 2 of 5
 OPERATING MANUAL

FUEL GAS SYSTEM

Section : 03.10.00 Date:01/06/06
PIC 619-1 1400 kpa Controls high-pressure header.
PSHH 619-1 1800 kpa Trips high/high alarm and PSD.
PSH 619-1 1550 kpa Trips high alarm.
PSLL 619-1 850 kpa Trips low/low alarm and PSD.
PSL 619-1 1100 kpa Trips Low alarm.

Fuel Gas Filter Separator V 621 A/B:

After being let down in pressure, the fuel gas is fed into either one of the two filter separators, which are placed
in parallel. The objective is to remove liquid droplets and particles. Each filter separator has two stages. Fuel gas
flows into the top stage, where it coalesces liquid droplets, which drain automatically by means of LV 621 A/B-2
this is on/off control. This top stage is provided with a level glass to be able to see the level of the liquid in the
top stage. It is also provided with a LSHH, LAHH, PDAH, an incoming PI, and a differential pressure indicator.
If the filter elements become dirty, this will show on the DP indicator, this is a indication to change out the filter
elements. Filtered fuel gas will flow via a vane to the lower stage of the filter separator where liquid will be
removed. This liquid compartment has a LIC 621-A/B1 to maintain a liquid level. It is also provided with LSH,
LSHH, and LSLL. If LSHH is initiated it will cause a PSD, because this creates the risk of slugging liquid to the
users, which is not a desired situation especially for solars and fired heaters. It is good operational practice to
have one filter in service while the second is on stand-by, which means the stand-by filter can be used
immediately, whenever it is desired.

Filter Change Over

1. Make sure that the other filter is ready to be placed on line.
2. Check if all instrument lines are open, all level gauges operational, and all corresponding alarms on the
Panel in order.
3. Make sure that the drain lines are opened in order to drain the liquid via LIC.
4. Purge the filter to flare by opening the vent valve and slowly opening the inlet valve.
5. When filled with gas close the vent valve and let the filter pressurise, and check for any possible leaks.
When there are no leaks observed, slowly open the outlet valve. By doing this both filters are running in
parallel.
6. Slowly close the incoming valve of the filter, which is to be taken out of service, observe the pressures, and
DP of the filter which has just been put into service, if this is working without any abnormalities, the
procedure can be continued.
7. Close the outlet valve of the filter to be taken out of service and depressurise to flare.
8. Once the filter is fully depressurised it can be opened for inspection of its filter elements, or any other
maintenance, prior to inspection of the filter, the depressurising line to the flare should be closed again to
prevent the intake of air into the flare line.
Note: do not back flow the filter separator, A high velocity flow inside of the element will rupture the filters and
cause channelling.

Filter Alarm Settings

PDSH 621 A-1 70 kpa High DP alarm
PDSH 621 B-1 70 kpa High DP alarm

Fuel Gas Low Pressure Letdown

PIC 619-2 controls the low-pressure fuel gas @ 600 kpa, by reducing it from 1400 kpa from the high-pressure
fuel gas header. High and low-pressure alarms and a PALL are fitted to indicate possible process abnormalities.
These abnormalities can be any malfunction on PV 619-2, a possible leak in the low-pressure system or a
shutdown has already occurred. After PV 619-2 low-pressure fuel gas will supply the low-pressure users such as
the hot oil heaters and purge gas. The purge gas regulators are set @ 50 kpa.
PIC 619-2 600 kpa. LP header
PSH 619-2 800 kpa High pressure alarm
PSL 619-2 200 kpa Low pressure alarm
PSLL 619-2 100 kpa Low/low pressure alarm
PCV 619-1A ...1H 50 kpa purge gas regulators
PCV 619-2A …2G 50 kpa purge gas regulators

Updated by: Amer Numan Approved by: OGP/1

Checked by: Abdul Wahab Approved by: OGP

Page 3 of 5
 OPERATING MANUAL

FUEL GAS SYSTEM

Section : 03.10.00 Date:01/06/06
Note: The main concern of the fuel gas system is to prevent liquids in the system. Therefor special care has to be
taken after a shutdown or when running in "wet gas mode" by using inlet separator gas. In this situation drain
regularly at low points in the lines and monitor the fuel gas scrubber well. Drain liquid where ever possible.

New Fuel Gas Module

The objective of the second fuel gas system is to produce a reliable good quality supply of fuel gas (15
MMSCFD). The source of gas is the outlet of the inlet separator V-601. The added benefit is that this fuel gas
module can be brought on line to reduce the load on the Chiller E-603, because the fuel gas will be taken from
upstream of the Chiller and hydrocarbon liquids can be recovered to the process from this unit.

Gas from-601 will be first cooled in the tube side of the Gas/Gas Exchanger E-1620. Lean MEG injection, 50
kg/hr, (=flow indication 0.06 M3/HR) onto the tube plate will prevent hydrate formation in the exchanger. The
gas then flows via a Joule- Thompson valve, PV-1620, into the Fuel Gas Separator, V-1621. The PV-1620 also
has MEG injection (=flow indication 0.1 M3/HR). The Separator is a 3-phase vessel to separate gas, condensate
and rich MEG. The rich MEG is controlled by an interface controller LIC- 1621-1, to the rich MEG return
header. The condensate will be pumped via P-1619 into F-604. In the event of a failure (or low capacity) of the
pump, it will flow under level control LIC-1621-2 to the closed drain header.
The gas flows to the shell side of E-1620, where it is superheated (cooling down the incoming gas). It then flows
off the skid through the dry gas filter, F-1622, to the existing fuel gas header.

The unit has a gas inlet NV-1620-1 that will operate on USD. A depressurising valve is fitted to enable the unit to
be blown down (NV-1620-2) activated from the DCS system. (HS 1620-3 must be selected open in order to blow
down this unit. It does not open automatically on an ESD).

Start Up Procedure
1. Ensure that the unit PSV and blow down manual valves are lined up.
2. Open manual isolating valves on the fuel gas outlet from F-1622, condensate outlet from V-1621, glycol
outlet from V-1621, glycol injection, and condensate discharge from P- 1619.
3. Lower the Setpoint of PIC-1620 so that the valve is closed (via the DCS) or (close on manual).
4. Reset the unit from DCS system.
5. Open NV-1620-1 (gas inlet shutdown valve)
6. Open the 2" bypass block valve upstream NV-1620-1. Pressurise slowly the unit, using the globe valve of
the 2" bypass.
7. Open the 6" block valve upstream of NV-1620-1 and close 2" by-pass valve.
8. Open up glycol supply to E-1620 (= flow 0.06 M3/HR) and glycol supply to PV-1620 ( = flow 0.1 M3/HR)
9. To change over from old unit, increase slowly the Setpoint of PIC-1620 and lower the setpoint of PIC-619-
1. Keep on doing this till the unit delivers the required amount of fuel-gas and PIC-619 1 output is 100%
CLOSED. Flow rate can be monitored on FI- 1601.
Note: PIC-619-1 Output; 0% is fully open and 100% is fully closed (different from PIC-1602 and PIC-1620).

During Operation
1. In case of non-availability of P-1619 during low temperature operation (TI 1621 below
0C°) the bypass can be cracked open to allow some MEG to flow with the cold condensate to
discourage freezing of the closed drain header.
2. In case of failure of this module when it is online, an automatic 100% backup fuel gas supply is available
from PV-1602 (the normal main supply), which lets down gas from the outlet of E-602 into the fuel gas
system. This valve has a downstream PSV to protect the fuel gas system from over pressure. All controls are
via the DCS system.

Check Stable Operating Parameters Reached

Check interface levels in separator V-1621. Using LG-1621-1 and LT-1621-1. At start-up it is possible that LSL
on LT-1621-1 activated due to low level, closes NV-1621. When the level comes up it will auto reset, and LV-
1621-1 will control the level.
1. Check condensate level in separator V-1621. This is maintained automatic by P-1619. This pump has a local
manual variable output. To adjust the output of the pump, you can change the stroke of the pump by the
hand wheels on the pump.
Note: The pitch of both cylinders must be the same at all times. Before turning the hand wheels, loosen the stop,
and after changing put the stop back on.
Updated by: Amer Numan Approved by: OGP/1
Checked by: Abdul Wahab Approved by: OGP

Page 4 of 5
 OPERATING MANUAL

FUEL GAS SYSTEM

Section : 03.10.00 Date:01/06/06

2. Check the differential pressure filter F-1622. It is possible that there are still liquids in the dry gas, due to
sudden unstable conditions. Blow down a little to check.
3. Check the operating temperature of V-1621. There is no constant low temperature in the unit. But gas
temperature should be 30°C lower than the gas supply temperature from V-601. This is important to
maintain a dew point, and no condensation can occur due to ambient temperature.
4. Check operating pressure. Also the pressure of the first back-up supply PIC-619-1 should be slightly below
the fuel gas supply pressure (13.5 bar), 2nd back up supply pressure PIC 1602 should be 13.0 bar. In case
something happens the back-up system will immediately take over.
5. Check the differential pressure across E-1620. This should not be higher than 20 kpa. Higher DP could
indicate hydrate formation due to insufficient glycol injection.
6. Check glycol flow to E-1620 and PV-1620. E-1620 flow rate should be 0.06 M3/HR and PV-1620 flow rate
0.1 M3/HR. This is to prevent hydrates and to dry the fuel gas.

Trips and Settings

PSHH 1620 1600kpag Causes USD.
LSHH 1621 457mm Causes USD.
LIC 1621-1 31% Control LV-1621-1 (glycol)
LIC 1621-2 65% Control LV-1621-2 (condensate)
LSLL 1621 0mm Close NV-1619 and S/D P-1619.
Pump 1619 30% level Stop condensate pump.
50% level Start condensate pump.

Fuel Gas to Omar Power Plant

The fuel gas to power plant can come from three sources:
1) Slug-catcher.
2) V-601 (inlet separator).
3) E-602 (gas/gas exchanger) shell side.

Operation of Fuel Gas to Omar Power Plant

The control scheme is configured so that the primary source of fuel gas will be E-602 in order to maximise
hydrocarbon liquids in gas plant. In the event of a plant upset the source will change automatically so that
minimise disturbances occurs to the gas plant process. Group 19 (DCS) displays the controls for the power plant
fuel gas. TIC 605-1 cascades its output to FIC 36001. TIC 605-1 indicates the dew point of the gas in E-603. The
set point is varied according to the operator. Should the gas temperature rise to above the set point then a signal
is sent to FIC 36001, which starts closing the valve (Note: reverse acting valve). At the same time this causes the
pressure to fall in the power plant feed pipeline. This is sensed by PIC 36001, which then opens to supply gas
from V-601 (it maintains its own set point).

In the event of a PSD or an ESD, NV 1601 (located beside sluge catcher panel ) closes and NV 1808
opens to provide gas from the slug-catcher to the power plant. Check that this has occurred following an PSD or
ESD) , BDV601-2 is installed to depressure to flare header pipe section between NV1601
and both PV36001 and FV 36001 in case of ESD.

The operator may change the source of the power plant fuel gas at any time (especially during summer to reduce
the load on the refrigeration system). To change the fuel gas to power plant to come from V-601 put TIC605-1 in
manual and slowly close the output (reverse acting) FV 36001 will close causing the gas pressure to
drop below the set point. PIC 36001 will open automatically.

To change to the slug-catcher call up the fuel gas graphic select HS 1601, place the cursor at the desired valve
"open" command and press ”enter”, one valve will close and the other will open.

Updated by: Amer Numan Approved by: OGP/1

Checked by: Abdul Wahab Approved by: OGP

Page 5 of 5
 OPERATING MANUAL

FUEL GAS SYSTEM

Section : 03.10.00 Date:01/06/06

SALES GAS
DRY FUEL GAS
TO EXPORT 30 BAR WET FUEL GAS
TO E-602
COMPRESSORS

V-601
FCV-36001 PCV-36001 PCV-601.3
PROCESS GAS FROM V-601 E-603
E-602

FROM V-605

CHECK VALVE FQI-621-1

CHECK VALVE CHECK VALVE New Fuel Gas Skid

PV-602-2
NV-1620-1 GLYCOL INJECTION
GSA AND CFP
FUEL GAS
SDV-602-4
PIC-1602 14.1 bar E-1620

TO FLARE
SDV-602-3 PT-1602
FROM V-601
GLYCOL INJECTION
GSB FUEL GAS
F-1622
PV-1620
E-618
OFF= CLOSE NV-1601
30 BARg
HS OPEN NV-1808 V-1621
PV-619 ON = OPEN NV-1601
SDV-618-1 CLOSE NV-1808
OLD FUEL GAS UNIT NV-1601

FROM
NV-1620-2
SLUGCATCHER
NV-1808 CCR DCS
FUEL GAS HEATER HS Blow Down P-1619 HS
(hand switch)
TO NV-1621-1
FUEL GAS FUEL GAS OMAR POWER To Cold
PLANT Flare Header
FILTER SEPARATOR FILTER SEPARATOR
LV-1621-2

RICH GLYCOL NV-1619

TO MEG UNIT
LV-1621-1 To Wet Closed
Drain header
Condensate to F-604

V-621-A V-621-B
LV-621B-1
SDV-G-201 SDV-G-202 SDV-K203C SDV-K203B SDV-K203A SDV-K202 SDV-K201A SDV-K201B SDV-K201C SDV-K201D
LV-621A-1
FT-1601-3

14.1 BAR
FT-619-1 H.P.FUEL GAS HEADER 14.1 BAR

To Closed Drain
Header
SDV-619-1 L.P.FUEL GAS HEADER 6 BAR
PT-619-1
PV-619-2
6 BAR

MAIN HOT OIL FLARE LINE INTO GROUND

OGP FUEL GAS SYSTEM FLARE
PILOT
HEATERS PURGE AT
OMN/SHL INLET

Updated by: Amer Numan Approved by: OGP/1

Checked by: Abdul Wahab Approved by: OGP

Page 6 of 5