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COMPANY : PT. PERTAMINA (PERSERO)


CONTRACTOR : PT. Bangun Bejana Baja
PROJECT TITTLE : Pekerjaan Jasa Pembangunan Tangki Timbun LPG, Piping dan
Instrument Di Depot Dumai Kap. 2 x 3000 MT
LOCATION : Dumai - Riau, INDONESIA
CONTRACT NO. : 004/R10000/2018-S3

0 05-Marc-2019 Issued For Approval ML AN AZS

DIBUAT DIPERIKSA DISETUJUI DIPERIKSA DISETUJUI


OLEH OLEH OLEH OLEH OLEH
REV. TGL URAIAN
PT PERTAMINA
PT BANGUN BEJANA BAJA
(PERSERO)
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REVISION SHEET

No. Rev. Date Description

0 05/03/19 Issued For Approval


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TABLE OF CONTENTS
1.0 GENERAL
1.1 Introduction ......................................................................................................... 4
1.2 Location ............................................................................................................... 4
1.3 Scope ................................................................................................................... 5
1.4 References .......................................................................................................... 5
1.5 Definitions ............................................................................................................ 5
2.0 PRESSURIZED LPG TERMINAL FACILITY AND SUPPORTING FACILITIES ....6
3.0 OPERATING AND CONTROL PHILOSOPHy ...................................................... 6
3.1 LPG Receiving (Unloading) System ..................................................................... 6
3.2 LPG Storage Tank System ................................................................................... 8
3.3 LPG Truck Loading System .................................................................................. 9
3.4 Utility Air and Instrument Air System .................................................................... 10
4.0 SAFEGUARD PHILOSOPHy ................................................................................ 11
5.0 EMERGENCY POWER FAILURE ........................................................................ 12
5.1 Diesel Engine Generator ....................................................................................... 12
5.2 Uninterruptible Power Supply (UPS) System ...............................................12
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1.0 GENERAL
1.1 Introduction
PT. PERTAMINA (Persero) Direktorat Pemasaran dan Niaga intends to build Pressurized LPG
Terminal at Dumai, Riau. The purpose of the construction of Pressurized LPG Terminal at
Dumai, Riau is in line with the government's program to reduce fuel (BBM) subsidies by
diverting use of kerosene for households to LPG. The LPG needs in the future will continue to
increase meanwhile the availability of LPG receiving facilities, LPG storage terminal facilities,
and LPG distribution are still not sufficient, so it needs to build new LPG receiving facilities, new
LPG storage terminal facilities, and new LPG distribution to anticipate future needs in order to
avoid the crisis availability of LPG for the customers. The project shall consist of pressurized
LPG storage (spherical) tanks with capacity 2 x 3000 MT, 3 (three) LPG truck filling pumps,
pipeline construction for vapour and liquid LPG, and 1 (one) LPG marine loading arm (MLA).
The project shall also executes for supporting facility such as seawater pump system, fire water
system for fire fighting/cooling, instrument air compressor, and other facilities such as power
supply, electrical, instrumentation, TAS (Terminal Automation System), control room, etc.

1.2 Location
Pressurized LPG terminal Dumai will be located within the area PT Patra Niaga, Aspalt plant
Terminal of Dumai Riau.
The location map of PT Patra Niaga, Aspalt plant Terminal of Dumai Riau. is shown in figure
1.2.1 below.

Figure 1.2.1
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1.3 Scope
• The objective of this document is to define the operation, control and safeguarding philosophy for
LPG unloading system and distribution system and other utility facilities.
.
1.4 References

DMI-BD-10-011-A4 Basic Engineering Design Data (BEDD)


DMI-PFD-10-001-A3 Process Flow Diagram LPG Storage System
DMI-PFD-10-002-A3 Heat & Material Balance LPG Storage System
DMI-UFD-10-002-A3 Utility Flow Diagram (UFD) IA/UA System
DMI-PID-10-001-A3 P & I Diagram Legend & Symbols
DMI-PID-10-002-A3 P & I Diagram LPG Unloading System
DMI-PID-10-003-A3 P & I Diagram LPG Custody Meter System
DMI-PID-10-004-A3 P & I Diagram LPG Pressurized Storage System
DMI-PID-10-005-A3 P & I Diagram LPG Truck Filling Pump
DMI-PID-10-006-A3 P & I Diagram Truck Filling (Filling Shed)
DMI-PID-10-007-A3 P & I Diagram Instrument Air & Utility Air System
DMI-PID-10-008-A3 P & I Diagram Instrument Air Distribution System
DMI-PID-10-015-A3 P & I Diagram Diesel Engine Generator System

1.5 Definitions
The definition contained in the contents of this procedure and other procedures are as follows:

PTM : PT. Pertamina (Persero) Directorate of Marketing and Commerce as the


owners and users of the facility or equipment.

MIGAS : The Representatives of the Indonesian government which is responsible for the
issuing of licenses and permits operation of oil and gas.

Third Party : A third party inspector to be appointed by Pertamina to inspect the works of
Contractor.

QA / QC : Quality Assurance / Quality Control.

Issuer : The person / party who develop and release the document and
correspondence.

Project Documents : All documents which are prepared, revised, and issued for accelerating the
project execution, such as correspondence, drawings, specifications,
requisitions, purchase orders, and Vendor Prints, etc
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SITE : the right-of-way and places provided by the Employer where the construction
works are to be executed and any other places as may be specifically designated
in the Contract as forming part of the Site.

2.0 PRESSURIZED LPG TERMINAL FACILITY AND SUPPORTING FACILITIES


The new pressurized LPG facility and supporting facilities within the project of Pressurized
LPG Terminal at Dumai Riau consist of the following items:

1. Receiving (unloading) system facility :


a. 1 (one) package unit Marine Loading Arm (MLA) with capacity of 350 MT/hr including vapor line.
The type of MLA is pygyback system and completed with Emergency Release System (ERS) and
Quick Connect/Disconnect Coupling (QCDC).
b. LPG Unloading Metering Package interfacing to Terminal Automation System (TAS).
c. Odorizer System Package.

2. 2 (two) units the Pressurized LPG Storage Tank, sphere type, with capacity 3000 MT each. The LPG
Storage Tank shall be equipped with Automatic Tank Gauging (ATG) and magnetic level gauge
interfacing to Terminal Automation System (TAS).

3. Motor Operated Valves (MOV) which interfaces to Terminal Automation System (TAS).

4. 3 (three) units LPG Truck Filling Pumps with Variable Speed Drive (VSD) motor type in order to
control the speed of pump depending on LPG flow demand in LPG Loading Arm system to the
Distribution Truck.

5. 3 (three) LPG Loading Arm Systems with capacity 50 MT/hr within modern Filling Shed Facility to
feed LPG into the Distribution Truck interfacing to Terminal Automation System (TAS).

6. 3 (three) LPG Metering Systems installed at each upstream of Loading Arm System and interfacing
to Terminal Automation System (TAS).

7. Instrumentations and piping associated to the equipments.

8. Electricity back-up use Diesel Engine Generator set with automatically load operation (Ioadshedding
& sinkronizer).

9. Un-interruptible Power Supply (UPS) is utilized back-up autonomy of 2 (two) hours.

Pressurized LPG Terminal at Dumai Riau is designed to be able to operate for 20 years, with working
hours 7 x 24 hours per week.
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3.0 OPERATING AND CONTROL PHILOSOPHY


3.1 LPG Receiving (Unloading) System
LPG Receiving (Unloading) System is for receiving LPG from LPG tanker ship to be distributed to
LPG Storage Tanks (200-T-01/02). The LPG Receiving (Unloading) System consists of the
following equipments :
1. Marine Loading Arm Package (100-MLA-01) with capacity 350 MT/hr
2. Jetty LPG Metering Package (100-M-02)
3. Vapor LPG Metering Package (FQR/I 200B)
4. Odorizer System Package (100-D-01)

The tanker unloading process is controlled by Deck Officer in the Cargo Control Room (CCR) and
done in concert with Control Room of Dumai Riau. The system used to control cargo operation is
typically a combination of mechanical, hydraulic, and electronic automated system to provide the
cargo personnel with the ability to fully monitor operation and gives adequate warnings when the
LPG storage tanks (200-T-01/02) are full or the pumps system of the ship are not operating
correctly. The Quick Connect Disconnect Coupling (QCDC) of Marine Loading Arm (100-MLA-01) is
quickly and easily connected and clamped to LPG tanker on the ship to the appropriate
flange/nozzle by hydraulically operation. There are 3 (three) hydraulic drives i.e. 2 (two) drives for
in-board and out-board arm movement and 1 (drive) for rotation movement. Movements of the
hydraulic loading arm can be electrically effectuated by push-buttons on either operator panel
console or remote control pendant boX/wireless set or manually hydraulic operation by directly
mounting levers to the valve block adjacent to the loading arm stand post (manual hydraulic
operation ). Once 100-MLA-01 is well-connected and ready to LPG unloading process, LPG is
pumped from the ship's tanker to LPG Storage Tank (200-T-01/02) via Jetty LPG Metering System
(100-M-02). This Jetty LPG Metering System (100-M-02) will control the inlet flow of LPG coming to
Terminal Dumai Riau which interfaces to Terminal Automation System (TAS) to record the data.
Before coming to Jetty LPG Metering System (100-M-02), LPG is injected by odorant in Odorizer
System Package (100-D-01). This chemical gives odor to LPG for pre-detection when LPG either
liquid or gas form is present to the environment and prevent an explosion from a build-up of LPG
vapour. Marine Loading Arm (100-MLA-01) is completed with Emergency Release Coupling (ERG)
interfacing to Emergency Release system (ERS). During emergencies, the Emergency Release
Coupling (ERG), which includes fast acting and hydraulically actuated ball valves, will stop LPG
flow before the Marine Loading Arm (100-MLA-01) are automatically de-coupled from the ship.
Marine Loading Arm (MLA-001) is equipped with alarm and system to monitor the arm's position
and provide warning when the maximum operating envelope area (area over limit) is reached due
to tidal fluctuation, wind, wave, and changes in the ship's vessel draught as it is unloaded. An
Integrated Position Management System (IPMS) is used to display the actual position of the Marine
Loading Arm (100-MLA-01) within its defined operating envelope area and it ensures the interface
in the Control Room. The first step alarm is an audible and visual alert that lets the operator know
that the first boundary in the operating envelope area has been reached. The LPG flow transfer
system from the tanker to LPG Storage Tank (200-T-01/02) is automatically activated to stop and
close the actuated ball valves on each side of Emergency Release Coupling (ERC) preventing any
spillage of LPG from the piping ends. Then the arm is ready to be disconnected. The second step
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alarm is an audible and visual alarm which alerts the operator that Emergency Release Coupling
(ERC) is open and the arm disconnects from the ship's tanker. Marine Loading Arm (100-MLA-01)
is connected with temperature element to control temperature of liquid LPG flowing through MLA.
Temperature shall be higher than 0°C because the pipe is designed for receiving LPG mixed; if
temperature less than 0°C then Shut Down Valve will closed and unloading process can't be
running. Marine Loading Arm (100-MLA-01) is also completed with arm for piggy back vapor return
line. This kind of arm is functioned to minimize the escape of LPG vapor to atmosphere by returning
the vapor to the tanker whilst the unloading process is running. During LPG unloading process,
vapor LPG is flowing back to the ship's tanker from LPG Storage Tank (200-T-01/02) via Vapor
LPG Metering System (100-M-02). This Vapor LPG Metering System (M-300) will control the outlet
flow of LPG from Terminal Dumai Riau which interfaces to Terminal Automation System (TAS) to
record the data.

3.2 LPG Storage Tank System


The 2 (two) of LPG Storage Tanks (200-T-01/02), with capacity 3000 MT each, receive LPG from
the ship's tanker via Marine Loading Arm (100-MLA-01). Each of LPG Storage Tank (200-T-01/02)
is equipped with Motor Operated Valves (MOVs) in inlet and outlet of the storage tank and Level
Control in order to manage filling process. The following table 3.2.1 is the list of MOV and Level
Control associated on each LPG storage tank.

Table 3.2.1 List of MOV and Level Control on LPG Storage Tank

Motor Operated Valve


Equipment Level Control
MOV
200-T-01 200-MOV-01-1 (Inlet) 200-LlT-01-3
200-MOV-01-2 (Outlet)
200-T-02 200-MOV-02-1 (Inlet) 200-LlT-02-3
200-MOV-02-2 (Outlet)

During LPG filling process from ship's tanker to LPG storage tank, when the one of the LPG storage
tank has achieved High Level, the inlet MOV will automatically close. Once the inlet MOV of the full
LPG storage tank is closed, the inlet MOV of another empty LPG storage tank is open to start the
LPG filling process. Otherwise, when the one of LPG storage tank has been reached Low Level due
to pumping process to LPG Loading Arm (LH-01A/02A/03A) by LPG Truck Filling Pumps (P-
01/02/03) the outlet MOV will automatically close. But, before the outlet MOV of that nearly empty
LPG storage tank is closed, the outlet MOV of another full LPG storage tank must be firstly and
automatically opened. The whole of filling process and emptying process of LPG from LPG Storage
Tank (200-T-01/02) as the above description, are automatically worked by Automatic Tank Gauging
(ATG) and Terminal Automation System (TAS). Automatic Tank Gauging (ATG) System is
custodian level measuring which is compensated by pressure transmitter and temperature
transmitter for metering accuracy. 200-PIT-01-1 and 200-TIT-01-1/2 for LPG Storage Tank 200-T-01
and 200-PIT-02-1 and 200-TIT-02-1/2 for LPG Storage Tank 200-T-02, respectively. 200-MOV-01-4
and 200-MOV-02-4 installed at outlet vapour LPG line are opened only at loading time. 200-MOV-
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01-4 and 200-MOV-02-4 open to stabilize/balance the pressure in the LPG Storage Tank (200-T-
01/02). The LPG vapor from LPG Storage Tank (200-T-01/02) is released to the vapor arm built-in
with Marine Loading Arm (100-MLA-01). LPG Storage Tank (200-T-01/02) is associated with water
spray system installed around the storage tank outside. When Temperature Transmitter (200-TIT-
01-1 / 200-TIT-02-1) indicates that temperature of LPG Storage Tank (200-T-01/02) is slightly
above the operating temperature, then deluge valves of water spray system (500-DV-01-1/2 and
500-DV-02-1/2) will open to cool down the LPG Storage Tank (200-T-01/02) until the operating
temperature of the storage tank is achieved. This process will keep LPG within the storage tank in
liquid form condition. LPG Storage Tank (200-T-01/02) has a back-up overpressure protection by
pressure safety valve (200-PSV-01-1 and 200-PSV-01-2) for LPG Storage Tank (200-T-01) and
pressure safety valve (200-PSV-02-1 and 200-PSV-02-2) for LPG Storage Tank (200-T-02).

3.3 LPG Truck Loading System


LPG Truck Loading System is a system for distributing LPG from LPG Storage Tank (200-T-01/02)
to LPG loading trucks. LPG Truck Loading System consists of the following items:
1. LPG Truck Filling Pumps (P-01/02/03)
2. LPG Metering Packages (300-M-01/02/03)
3. LPG Truck Loading Arms (300-LH-M-01A/02A02A)
4. LPG Truck Vapor Arm (300-LH-M-01B/02B02B)
5. LPG Truck Weight Bridge (W-01/02)
LPG distribution from LPG Storage Tank (200-T-01/02) to the LPG Filling Shed is done
by LPG Truck Filling Pumps (P-01/02/03) with configuration 3 (two) operations. The type of LPG
Truck Filling Pumps (P-01/02/03) is centrifugal pump.
The motor drives of those pumps are equipped with Variable Speed Drive (VSD) to control the
rotating speed of the pump. The LPG flow rate control to LPG Truck Loading Arms (300-LH-M-
01A/02A02A) within LPG Filling Shed is managed by the electrical motor speed of LPG Truck
Filling Pumps (P-01/02/03) via Variable Speed Drive (VSD), the running management of LPG Truck
Filling Pumps (P-01/02/03) which run parallel or single (staging - de-staging), and start/stop
controlling. All of those are carried out by Terminal Automation System (TAS).
The speed controlling of LPG Truck Filling Pumps (P-01/02/03) via Variable Speed
Drive (VSD) is triggered by signal inputs from Total Flow Controller (300-FY-300) via
300-FI-300 and Pressure Transmitter (300-PIT-314) to control the speed of motor's VSD. Total Flow
Controller (300-FY-300) gets data informationfrom LPG Metering Packages (300-M-01/02/03)
installed at each of LPG Truck Loading Arms (-LH-M-01A/02A02A). If there is an excess of LPG
liquid during LPG loading into the LPG distribution trucks from LPG Truck Filling Pumps (P-
1/02/03), then the excess of LPG liquid will recycled to LPG Storage Tank (200-T-01/02). The LPG
return flow is controlled by pressure control valve (PCV-314) which is triggered by pressure
indicator transmitter (300-PIT-314) via pressure indicator controller (PIC-314). LPG Truck Vapor
Arm (300-LH-M-01B/02B02B) is also attached with Truck Loading Arms (300-LH-M-01A/02A02A)
within the Filling Shed. Whenever LPG loading process is carried out to the truck, LPG Truck Vapor
Arm (300-LH-M-01B/02B02B) is also connected to the truck. The release vapor from the truck is
returned to LPG Storage Tank (200-T-01/02). LPG Truck Loading Arms (300-LH-M-01A/02A02A) is
completed with Quick Coupling and Safety Break-away Coupling.
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LPG Truck Loading System is completed by 2 (two) LPG Truck Weight Bridge (W-01/02) with
capacity 60 MT.

3.4 Utility Air and Instrument Air System


Utility and instrument air system supplies air for instrument and plant needs to run the facilities
related to Pressurized LPG Terminal project at Dumai Riau.
The utility and instrument air system consists of :
1. Air Compressor Package (400-K-01/02)
2. Utility Air Receiver (400-V-01)
3. Instrument Air Receiver (400-V-02)
The air compressors (K-01/02) are non-oily free screw type air compressor with motor driver. The 2
(two) unit compressors are installed in running configuration 2 x 100%. The discharged compressed
air is directed into Utility Air Receiver (V-01) and Instrument Air Receiver (V-02). The operation of
Air Compressor (K-01/02) is controlled by load-unload arrangement system of compressor which is
controlled by Pressure transmitter (PIT-02) via pressure controller (PIC-02) installed at outlet of
Instrument Air Receiver (V-02). When the pressure controller (PIC-02) indicates Low Pressure
meaning that the end users usage for instrument air and utility air exceed than the flow capacity of
the running air compressor, then the stand-by air compressor will run. When the pressure controller
(PIC-02) indicates High Pressure meaning that the end users usage for instrument air and utility air
is less than the flow capacity of the running air compressors, then the stand-by air compressor will
stop. Air Compressor Package (K-01/02) is provided with stand alone control system which is part
of package vendor scope. The Utility Air Receiver (V-01) is also a basic water knock-out (KO) drum
to separate water from compressed air. Utility air is directed to utility air distribution system for being
supplied to the compressor station. Utility air supply points shall be located in all suitable locations
to allow for maintenance usage around the station. The water level is controlled by automatic drain
trap. When the liquid fulfil the trap, the trap will automatically opened to draw the liquid into open
ditch. The air from Air Compressor is dried by Air Dryer which is compatible in Air Compressor
Package (K-01/02) prior to being flowed to Instrument Air Receiver (V-02). The Air Dryer will absorb
moisture from compressed air. Air Dryer is also attached with Pre-Filter at upstream of Air Dryer
and After Filter at downstream of Air Dryer. The Air Dryer Unit is heatless regeneration type. The
dried instrument air enters the Instrument Air Receiver (V-02). Instrument air is directed to
instrument air distribution system for being supplied to the terminal facility. Instrument air supply
points shall be located in terminal facility and in suitable locations where instrument air supply is
needed around the terminal facility. Operation of Instrument Air System is all automatic with its own
dedicated local control panel. However, all operating parameters can be communicated and
monitored from Control Room via serial link communication. The control philosophy for Instrument
Air System shall be detailed by Vendor during detailed design.

4.0 SAFEGUARD PHILOSOPHY


The process safeguarding system or Safety Control System (SCS) is a separated system dedicated to
manage or regulate shutdown in Pressurized LPG Terminal at Dumai Riau during emergency condition.
Safety Control System must ensure that suitable protection is provided against the maximum pressure
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(and other parameters) that can generate the worst credible malfunction. Safety Shutdown Level
Facility shutdown in Pressurized LPG Terminal at Dumai Riau consist of :

1. Emergency Shutdown (ESD), automatically triggered from fire detection and manual push button for
ESD. After receiving ESD signal, ESD system will take over control to protect equipment from
damage. ESD location is in the Control Room.
2. Process Shutdown (PSD), automatically triggered from upset conditions of each type of LPG delivery
system.
3. Bay Shutdown (Bay SD), manual switch installed in each bay and triggered from upset conditions of
that bay.
Safety Control System (SCS) shall be designed for fail safe so that it can perform the safe shutdown
operation. Safety Control System (SCS) shall be separated from Process Control System (PCS).
The following table 4.1 is the list of SDV for Pressurized LPG Terminal Dumai riau.

Table 4.1 List of SDV for Pressurized LPG Terminal Dumai

Equipment Shudown Valve (SDV) InstallationPosition


100-MLA-01 100-SVD-101 Liquid LPG outlet line
100-SDV-103 Vapor LPG inlet line
M-200 100-SDV-102 Downstream of control valve 100-PCV-200
200-T-01 200-SDV-01-1 Liquid LPG inlet line
200-SDV-01-2 Liquid LPG outlet line
200-T-02 200-SDV-02-1 Liquid LPG inlet line
200-SDV-02-2 Liquid LPG outlet line
P-01/02/03 300-SDV-300 Liquid LPG discharge of pump

The table for safety shutdown system will be developed in CAUSE & EFFECT Diagram document no.
DMI-LST-10-001-A3.

5.0 EMERGENCY POWER FAILURE


5.1 Diesel Engine Generator
Electricity power for Pressurized LPG Terminal at Dumai Riau is supplied from PLN and 2 (two)
Diesel Engine Generator for backup.
Generator switching shall use Automatic Transfer Switch (ATS). When power from PLN is start to
voltage drop, the "stand-by" Diesel Engine Generator (DEG-01) which is ready to start will be in
auto-synchronizing mode. Once it has been synchronized, the "stand-by" Diesel Engine Generator
(DEG-01) will become "on-duty" DEG. After power from PLN is already exist, it will be in
synchronizing mode. Once it has been synchronized, the "on-duty" Diesel Engine Generator (DEG-
01) will stop automatically. CONTRACTOR/Vendoe shall provide a complete operating manual
document for these switching operation procedures.

5.2 Uninterruptible Power Supply (UPS) System


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An Uninterruptible Power Supply (UPS), also uninterruptible power source, UPS or battery/flywheel
backup is an electrical apparatus that provides emergency power to a load when the input power
source, typically mains power, fails. The UPS shall have sufficient capacity to supply the loads for a
minimum of 2 (two) hours.

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